Case CX700 Tier III Crawler Excavator Operator's Manual 87364242 - PDF DOWNLOAD

OPERATOR’S MANUAL

CRAWLER EXCAVATOR CX700 TIER III

87364242 NA

Issued 01-2006

OPERATORS MANUAL HYDRAULIC EXCAVATOR

CX700 TIER III

Bur • Issued 01-2006 Printed in U.S.A. • Book/Form Number 87364242 NA Copyright © 2006. CNH America, LLC. All Rights Reserved.

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

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01-2006

CX700 TIER III

87364242

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

CX700 TIER III HYDRAULIC EXCAVATOR OPERATOR’S MANUAL Part Number: 87364242

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

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

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

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

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

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

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

●

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

●

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

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

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

Is instructed in safe and proper use of the machine.

●

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

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

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

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

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2006 CNH America LLC All Rights Reserved CASE and IH are registered trademarks of CNH America LLC

Bur 87364242NA Issued January, 2006

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

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

TABLE OF CONTENTS SECTION 1 - TO THE OWNER .................................................................................................................. 1-1 CX700 hydraulic crawler excavator .......................................................................................................... 1-1 Official documents .................................................................................................................................... 1-2 Right, left, front and rear of the machine .................................................................................................. 1-3 SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS .................................................. 2-1 Type, serial number and year of manufacture of the machine ................................................................. 2-1 Description of the main components ........................................................................................................ 2-3 SECTION 3 - SAFETY/DECALS/HAND SIGNALS .................................................................................... 3-1 Safety instructions .................................................................................................................................... 3-1 Before using the machine ........................................................................................................................ 3-2 Operating the machine ............................................................................................................................. 3-3 Safety area ............................................................................................................................................... 3-5 Parking the machine ................................................................................................................................ 3-5 Maintenance and adjustments ................................................................................................................. 3-6 Preventing fires or explosions .................................................................................................................. 3-7 Prevention of burns .................................................................................................................................. 3-7 Decals ...................................................................................................................................................... 3-8 Hand signals .......................................................................................................................................... 3-16 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 Left-hand control arm ............................................................................................................................... 4-5 Systems display and function control panel ............................................................................................. 4-6 Heating and ventilation or air conditioning controls ................................................................................ 4-13 Function cancellation lever and safety bar ............................................................................................. 4-18 Dipper and upperstructure swing left-hand control lever ........................................................................ 4-19 Boom and bucket right-hand control lever ............................................................................................. 4-20 Travel control levers and pedals ............................................................................................................ 4-20 Option pedal ........................................................................................................................................... 4-20 Footrest .................................................................................................................................................. 4-21 Cab light ................................................................................................................................................. 4-21 Coat hanger hook ................................................................................................................................... 4-21 Cigarette lighter ...................................................................................................................................... 4-22 12 volt auxiliary socket ........................................................................................................................... 4-22 Fuse box ................................................................................................................................................ 4-22 Roof hatch .............................................................................................................................................. 4-23 Cab door sliding windows ...................................................................................................................... 4-23 Storage tray ............................................................................................................................................ 4-23 Storage compartment ............................................................................................................................. 4-23

TABLE OF CONTENTS Controls/Instruments/Accessories (continued) Sun shield ...............................................................................................................................................4-24 Cab radio compartment ..........................................................................................................................4-24 Operator's seat .......................................................................................................................................4-25 Windshield ..............................................................................................................................................4-29 Lower front window .................................................................................................................................4-30 Rear window and emergency exit ..........................................................................................................4-31 Fuel tank .................................................................................................................................................4-32 Rear view mirrors ...................................................................................................................................4-33 Front storage box ...................................................................................................................................4-34 Side doors ..............................................................................................................................................4-35 Engine hood ...........................................................................................................................................4-36 Lower panels ..........................................................................................................................................4-36 Windshield washer reservoir ..................................................................................................................4-37 Cab protection (F.O.P.S.) .......................................................................................................................4-37 Load handling eye ..................................................................................................................................4-38 Rotary light cable ....................................................................................................................................4-38 Safety valves ..........................................................................................................................................4-39 Optional tool flow selector blocks ...........................................................................................................4-39 Optional tool supply valves .....................................................................................................................4-40 Self-detaching counterweight controls ....................................................................................................4-40 Fuel tank filling 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 Anti-theft device ........................................................................................................................................5-4 Starting the engine ...................................................................................................................................5-6 Bringing the machine up to operating temperature ..................................................................................5-8 Engine operation ......................................................................................................................................5-9 Stopping the engine ................................................................................................................................5-10 Operating the machine in cold weather ..................................................................................................5-11 Operating the machine in hot weather ....................................................................................................5-12 Machine operation ..................................................................................................................................5-13 Machine travel ........................................................................................................................................5-14 Handling the machine .............................................................................................................................5-17 Load handling .........................................................................................................................................5-17 Load handling limits ................................................................................................................................5-19 Operating the machine in water ..............................................................................................................5-19 Operating the machine on sloping ground ..............................................................................................5-20 Operating the backhoe bucket ................................................................................................................5-20

TABLE OF CONTENTS Operating instructions (continued) Parking the machine .............................................................................................................................. 5-21 Radiator and oil-cooler dust removal switch ........................................................................................... 5-23 Auxiliary hydraulic circuits ...................................................................................................................... 5-24 Lowering the attachment in the event of a machine failure .................................................................... 5-29 Setting the tracks in transport position ................................................................................................... 5-30 Setting the tracks in working position ..................................................................................................... 5-31 Self-detaching counterweight ................................................................................................................. 5-33 Transporting the machine ...................................................................................................................... 5-35 SECTION 6 - SERVICING INTERVALS ..................................................................................................... 6-1 Servicing instructions ............................................................................................................................... 6-1 Hourmeter ................................................................................................................................................ 6-2 Daily inspections ...................................................................................................................................... 6-2 Intervals .................................................................................................................................................... 6-4 SECTION 7 - LUBRICATION/FILTERS/FLUIDS ........................................................................................ 7-1 Fluids and Lubricants ............................................................................................................................... 7-1 Environment ............................................................................................................................................. 7-3 Fluid and lubricant capacities and specifications ..................................................................................... 7-4 Grease points ........................................................................................................................................... 7-5 Levels ..................................................................................................................................................... 7-11 Engine .................................................................................................................................................... 7-13 Cooling system ....................................................................................................................................... 7-16 Fuel system ............................................................................................................................................ 7-19 Releasing pressure in the hydraulic system ........................................................................................... 7-26 Hydraulic system .................................................................................................................................... 7-28 Air filter ................................................................................................................................................... 7-39 Swing reduction gears ............................................................................................................................ 7-43 Travel reduction gears ........................................................................................................................... 7-45 SECTION 8 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 8-1 Tracks ...................................................................................................................................................... 8-1 Track rollers and idler wheels .................................................................................................................. 8-5 Radiators and oil coolers .......................................................................................................................... 8-5 Fan and alternator drive belt .................................................................................................................... 8-7 Adjustment of engine valve rocker clearances ......................................................................................... 8-8 Fuel tank filter ........................................................................................................................................... 8-8 Fire extinguisher ....................................................................................................................................... 8-9 Welding on the machine ........................................................................................................................... 8-9 Inspecting and cleaning the machine ..................................................................................................... 8-10 Checking for cylinder leakage ................................................................................................................ 8-10 Plastic and resin parts ............................................................................................................................ 8-10 Teeth and tooth tip wear limits ............................................................................................................... 8-11

TABLE OF CONTENTS Maintenance/Adjustments (continued) Replacing a tooth on the backhoe bucket ..............................................................................................8-11 Replacing a backhoe bucket ..................................................................................................................8-12 Shimming the backhoe bucket ...............................................................................................................8-13 Air conditioning .......................................................................................................................................8-14 Engine troubleshooting ...........................................................................................................................8-18 Hardware torque inspection ....................................................................................................................8-20 SECTION 9 - ELECTRICAL SYSTEM ........................................................................................................ 9-1 Fuses ........................................................................................................................................................9-1 Batteries ...................................................................................................................................................9-3 Alternator ..................................................................................................................................................9-6 Starter motor .............................................................................................................................................9-6 Replacing a bulb .......................................................................................................................................9-7 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 Transport ................................................................................................................................................11-3 Weights ...................................................................................................................................................11-4 Standard attachment ..............................................................................................................................11-4 Short attachment ....................................................................................................................................11-4 Backhoe buckets ....................................................................................................................................11-4 Machine overall dimensions ...................................................................................................................11-5 Overall dimensions and weight of the main machine components .........................................................11-7 Working range ........................................................................................................................................11-8 SECTION 12 - ALPHABETICAL INDEX ................................................................................................... 12-1

SECTION 1

4

TO THE OWNER CX700 HYDRAULIC CRAWLER EXCAVATOR

CT05L000

1 Dealer's Stamp

1-1

SECTION 1 - TO THE OWNER

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. See "Official documents".

However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

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

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

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

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

OFFICIAL DOCUMENTS

Do not use this machine for any application or purpose other than those described in this manual.

If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your CASE Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine's technical specifications and with prevailing safety requirements.

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

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

Before permitting a new operator on this machine, make sure: 1. That the operator necessary training on machine correctly and training centres or organization.

has received the how to operate the safely in one of our from an approved

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

1-2

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

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

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

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

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

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

FRONT REAR RH SIDE LH SIDE TRAVEL MOTORS IDLER WHEELS

A F

F

D

C

E

E

B CS99A820A

2

1-3

SECTION 1 - TO THE OWNER

NOTES

1-4

SECTION 2

4

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

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

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

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

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

1

2

3

CT04A171A

1 ENGINE Make and type ......................... ISUZU AH-6WG1X Serial number .......................................................... .................................................................................

CT04D014B

2

2-1

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

Swing reduction gears .............................................

(Right) ......................................................................

(Left).........................................................................

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

(Right) ......................................................................

(Left).........................................................................

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

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

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

2-2

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS DESCRIPTION OF THE MAIN COMPONENTS The CX700 is an all hydraulic machine. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven 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.

11

15

12 10

16

6

7 4

8

5

19

17 9

13 21

14

20

22

18

23

1 2

3

CT05J001A

3 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Backhoe bucket Connecting rod Backhoe bucket yokes Backhoe bucket cylinder Dipper Dipper cylinder Boom Boom cylinders Cab/Operator's compartment Swing reduction gears Fuel tank Hydraulic reservoir

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Batteries Air filter Engine compartment Counterweight Turntable bearing Tracks Travel reduction gears Lower rollers Upper rollers Tension shock absorbers Idler wheels

2-3

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS

NOTES

2-4

SECTION 3

20

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

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

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

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

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

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

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

CD00E001

1

3-1

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

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

2.

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

3.

4.

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.

5.

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

6.

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

7.

Remove any obstructions which hinder visibility.

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

8.

Make sure the windshield wiper works correctly.

9.

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

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

3-2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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.

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

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

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

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

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

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

15. To access or exit the operator’s compartment, the LH control arm must be in the raised position. Never forget this basic requirement.

3-3

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

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

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

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

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

21. Before tilting the operator’s seat back forward, it is mandatory to raise the armrests to avoid any accidental operation of the hand controls.

3-4

PREVENTION OF RISKS DUE TO VIBRATION 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.

2.

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

3.

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

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 seat complies with the ISO 7096, 2000 standard, EM 3 or EM 4 class (according to the model).

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

1.

Working area.

2.

Safety area.

2

1 CS97M019

2

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

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

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

4. Be absolutely sure to raise the function cancellation lever (safety bar in inward position) before leaving the operator’s compartment.

5. Lock the cab door.

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

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

3-5

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 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.

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.

3.

Release pressure completely in the hydraulic system before disconnecting the hydraulic piping. Hydraulic oil escaping under pressure can cause serious injury.

11. The pressure in the track tension cylinders is high. Follow the procedure described in this manual carefully for increasing or reducing track tension.

4.

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

5.

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

6.

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

7.

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

12. When carrying out a welding operation on the undercarriage or upperstructure carriage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires and connect the welding apparatus earth cable to the component on which the welding operation is to be performed.

Never connect the welding apparatus to the undercarriage when welding on the upperstructure (or vice-versa). Never connect the welding apparatus earth to a component of the hydraulic system.

1. Park the machine on flat, level ground.

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

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

4. Lock the tracks to prevent any machine movement.

8.

9.

3-6

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.

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.

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

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

15. Periodically inspect the fastening of the main components, as part of the machine maintenance programme: counterweight, turntable bearing and operator's compartment.

In the event of problems, contact your CASE Dealer.

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

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

SECTION 3 - SAFETY/DECALS/HAND SIGNALS PREVENTING FIRES OR EXPLOSIONS

PREVENTION OF BURNS

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.

1.

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.

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

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

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

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

2.

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

3.

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

Ensure adequate ventilation when charging batteries or when using in a confined place.

Always protect your eyes when working near the battery.

4.

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. Before removing the cap, let the system cool down and then turn the cap to its first notch, waiting until all pressure is released.

Then remove the cap.

5.

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

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.

3-7

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DECALS

!

WARNING

!

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

!

WARNING

!

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

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

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

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.

4 3

5 6

2

1

7

CT05K001B

3

3-8

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

8

9

10

11

12

18

10 13

14

20 21

22 19

CT05J002

16 17 15 4

Illustration of decals OPERATOR’S MANUAL Part number: 168099A1

1

This decal shows that it is essential to read the operator's manual before operating the machine.

CS96D164

5

3-9

SECTION 3 - SAFETY/DECALS/HAND SIGNALS TOOL INTERFERENCE Part number: KHP10500

2

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

CT05K003

6 FUNCTION CANCELLATION Part number: KHP1818

3

This decal shows that it is mandatory to raise the lever before leaving the operator’s compartment.

KHP1818-00 CT05K004A

7 FUNCTION OF THE CONTROL LEVERS Part number: KHP1506

4

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

CS00F530

8 POCKET FOR MAXIMUM HANDLING LIMITS TABLE

5 Part number: G4647501 This pocket is provided for the table showing maximum handling limits corresponding to the attachment installed on the machine. See "Load handling limits" in section 5.

3-10

SECTION 3 - SAFETY/DECALS/HAND SIGNALS EMERGENCY EXIT Part number: KHP1360

6

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

CS00F531

9 FUNCTION OF THE LEVERS AND PEDALS Part number: KHP1498 (standard) 169357A1 (with right-hand option) KHP1510 (with left-hand option) KHP1511 (with right and left-hand options)

7

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

CS00E529

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

8

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

CS95M062

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

9

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

CS95M063

12 3-11

SECTION 3 - SAFETY/DECALS/HAND SIGNALS SLINGING POINTS Part number: H7947565

10

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

PDE0768

13 FUEL TANK Part number: 168102A1

11

This decal shows the location of the fuel tank.

CS96D165

14 HYDRAULIC RESERVOIR Part number: 168104A1

12

This decal shows the location of the hydraulic reservoir.

CS96D166

15 EXHAUST Part number: 168112A1

13

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

CS96C040

16 3-12

SECTION 3 - SAFETY/DECALS/HAND SIGNALS STARTING THE ENGINE Part number: 168110A1

14

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

CS96D163

17 FAN BELT Part number: 168111A1

15

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

18 ENGINE HOOD Part number: 168109A1

16

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

CS98B169

19 RADIATOR Part number: 168101A1

17

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

20 3-13

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 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.

18

CT05L042

21 BATTERY Part number: 383772A1

19

Located on the batteries, this decal indicates the risks as well as the precautions to be taken when handling the batteries.

383772A1

22 FILLING PUMP

20

Part number: L2651565 This decal shows that this manual should be consulted to fill the fuel tank using the filling pump.

See "Fuel tank filling pump" in section 4.

PDF0357

23

3-14

SECTION 3 - SAFETY/DECALS/HAND SIGNALS OPERATOR’S MANUAL (optional) Part number: 168099A1

21

This decal shows that you must refer to the operator’s manual in order to operate the selfdetaching counterweight system correctly.

CS96D164

24 NOISE LEVEL

22

Part number: KHP1768 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 stage 2.

CS02G515

25

3-15

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

START THE ENGINE

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

PDE0002A

26

PDE0003A

SHUT DOWN THE ENGINE

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

PDE0002

27 PDE0003

29

3-16

SECTION 3 - SAFETY/DECALS/HAND SIGNALS EMERGENCY STOP

GO THIS FAR

Wave hands back and forth.

PDE0004A

30 ALL STOP AND HOLD

PDE0005

33 RAISE LOAD OR TOOL

PDE0004

31 STOP

PDE0006A

34 LOWER LOAD OR TOOL

Wave one hand back and forth.

PDE0005A

PDE0006

32

35

3-17

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

SLOWLY RAISE THE LOAD OR TOOL

To stop movement, stop moving hand and clench fist.

PDE0007A

36 SLOWLY LOWER THE LOAD OR TOOL

PDE0008

39 RAISE TOOL

PDE0007

37 TURN MACHINE LEFT (swing load left)

PDE0009A

To stop movement, stop moving hand and clench fist.

PDE0008A

PDE0009

38

3-18

40 LOWER TOOL

41

SECTION 3 - SAFETY/DECALS/HAND SIGNALS EXTEND DIPPER

LIFT BOOM

PDE0010A

PDE0011

42

45 FILL TOOL

LOWER BOOM

PDE0010

PDE0012A

43

46 EMPTY TOOL

RETRACT DIPPER

PDE0011A

PDE0012

44

47

3-19

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

NOTES

3-20

SECTION 4

44

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

1 CD00E002

1

2

CD00E003

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

CD00E004

3

!

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

4-1

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

1

2

CD01K023A

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

!

WARNING

!

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

!

WARNING

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

1 2

!

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

!

1

CD01K022A

5

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

!

WARNING

!

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

14

12

13

1

10

15

11 16

17

9

3 2

8 5

7 6

4

CS00E501A

6 1.

2.

3.

4.

5.

6.

7.

8.

9.

Operator's seat LH control arm Function cancellation lever Safety bar Left-hand control lever, dipper and upperstructure swing controls, horn Footrest Left-hand travel control pedal and lever Right-hand travel control pedal and lever Option pedal

10. RH control arm 11. Right-hand control lever, boom and bucket controls, engine idle 12. Right-hand control arm tilt adjustment lever 13. Systems display and control panel 14. Cab light 15. Rear window opening system 16. Air vents 17. Left-hand control arm tilt adjustment and function cancellation lever

4-3

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND CONTROL ARM 3

5 CS00E502A

2

4

1 7

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

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

IMPORTANT: When the starter switch key is in "ON" (contact) position, the code must be entered if the anti-theft device has been programmed. The message "Password" will be displayed. See "Antitheft protection" in section 5.

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

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 5).

4-4

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

5. ENGINE IDLE SPEED SELECTOR This control provides manual or automatic engine idle without operating the throttle button. To select idle speed manually, press and release the control.

The engine will then automatically go into idle speed and the message "Eng. Idling" will appear on the systems display panel. When the control is pressed and released once more the engine will revert to its original speed and the message on the systems display panel will disappear. To select idle speed automatically, press the control for about 3 seconds until the audible alarm device sounds, then release the control. The message "Eng. Idling" will appear on the systems display panel. In this position, if no further operations are carried out, the engine will go into idle speed after 5 seconds. (It is possible to increase this lapse of time. See your CASE Dealer).

If any controls are then used (control levers, pedals) the engine will revert to its original speed. To cancel automatic selection, press the control for about 3 seconds. In each of these configurations, a confirmation message appears on the systems display panel. See items 6 and 10 under "Systems display and control panel".

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LEFT-HAND CONTROL ARM 7

9

2

8

6

5

3

1

4

CS00E503B

8 1. CONTROL ARM TILT ADJUSTMENT AND FUNCTION CANCELLATION LEVER This lever is used to adjust the control arm tilt to suit the operator. Raise the lever to the right and hold it in this position. tilt the control arm to the required position and then release the lever. This lever also makes it possible to raise the control arm completely, so as to cancel all machine functions.

2. FUNCTION CANCELLATION LEVER This lever is used to cancel the functions without having to raise the control arm. It is also used to operate the safety bar (3). See "Function cancellation lever and safety bar".

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

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

IMPORTANT: Always sound the horn before operating the machine.

6. BOOM RAISING PRIORITY SWITCH This is a two-position switch which can be used during loading operations to ensure faster boom raising compared to the upperstructure swing function. A message is displayed in the "ON" position. See "Systems display and control panel" (item 10) and priority is given to boom raising. In the "OFF" position, boom raising and upperstructure swing function are as normal.

NOTE: The "OFF" position is automatically selected each time the engine is started.

7. FAN ROTATION REVERSAL SWITCH This is a pulse switch used to clear the radiator and the oil-cooler of the accumulation of dust that can obstruct the fins. See "Radiator and oil-cooler dust removal switch" in section 5.

8. OPTION CONTROL (if equipped) This three-position control is used to control optional accessories such as hydraulic hammer, grab, shears, etc. Place the control in one of the three positions depending on the accessory being used.

See "Hydraulic hammer or high flow circuits" in section 5.

9.

HEAVY LIFT CONTROL (if equipped)

5. ASHTRAY Pull the ashtray upwards to empty it.

4-5

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

5

6

1

2

3

CD00E007A

!

WARNING

!

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

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

Do not use solvents.

1. TRAVEL SPEED SELECTOR This key is used to change from high speed (II) to low speed (I). Confirmation of the mode selected is displayed on the indicator (4).

!

WARNING

!

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

Low speed (I) (0 to 3 kph), select this speed to travel on slopes, rough ground or soft terrain.

High speed (II) (0 to 4.1 kph), select this speed to travel on hard, flat ground in good terrain conditions.

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

4-6

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

2. WORKING MODE SELECTOR This key is used to select three working modes. "S" (standard) mode for ordinary duties. "H" (heavy) mode for difficult work or if the load increases. "L" (light) mode for precision work where the machine movement speed is slowed. Confirmation of the mode selected is displayed on the indicator (5).

NOTE: When starting the engine, "Auto" mode is automatically selected.

3. AUTOMATIC WORKING MODE SELECTOR This key is used for automatic selection of the working mode which provides the best fuel economy. The confirmation (Auto) will be displayed on the indicator (5). Press the button again to come out of "Auto" mode.

4. TRAVEL SPEED INDICATOR This indicator displays the sign corresponding to the speed selected by the key (1). Slow speed (I), 0 to 3 kph; high speed (II), 0 to 4.1 kph.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 5. WORKING MODE INDICATOR This indicator displays the initial of the working mode selected by the key (2).

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

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

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

"Auto" will be displayed to confirm that "Auto" has been selected with button (3).

NOTE: When starting the engine, "Auto" mode is automatically selected.

6. IDLE INDICATOR This indicator displays the type of idle selected by the control on the right-hand control lever. See item 5 under "Right-hand control arm".

"ON": automatic idle.

"OFF": manual idle.

4-7

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

7 8

9

CD00E008A

10 7. ENGINE COOLANT TEMPERATURE INDICATOR The degree of temperature is defined by the increase or the decrease in the number of horizontal lighted segments. Zone "C" indicates that the engine coolant temperature is low. If the lighted horizontal bars reach zone "H", the audible alarm device sounds and the message "Over Heat" is displayed (see item 10). Stop the engine, remove the starter switch key and find the cause of the problem.

8. HYDRAULIC FLUID TEMPERATURE INDICATOR The degree of temperature is defined by the increase or the decrease in the number of horizontal lighted segments. Zone "C" indicates that the hydraulic fluid temperature is low. If the lighted horizontal bars reach zone "H", the audible alarm device sounds and the message "Over Heat" is displayed (see item 10). Stop the engine, remove the starter switch key and find the cause of the problem.

4-8

9. FUEL LEVEL INDICATOR The quantity of fuel is defined by the number of horizontal lighted segments. Zone "F" shows that the fuel tank is full. If the horizontal bars reach zone "E" the audible alarm device sounds and the message "Low Fuel" is displayed (see item 10). 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.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 10. MESSAGE DISPLAY SCREEN This screen displays information symbols and messages which will vary depending on the use to which the machine is put. The symbols and messages are listed below along with their explanations.

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

10 CD00E009

11 ENG. PRE HEAT This message shows that it is necessary to warm up the engine. When the engine has reached its working temperature, the message will disappear.

AUTO WARM-UP. This message shows that engine temperature is automatically rising to working temperature.

It disappears once the engine has reached operating temperature or when the throttle control button or a control lever is operated. See item 3 under "Right-hand control arm".

ENG. IDLING This message shows that the engine idle speed selector has been operated and that the engine is running at idle speed. See item 5 under "Right-hand control arm".

POWER UP This message shows that maximum power has been selected automatically for the attachment.

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

NOTE: To delete the "SERVICE DUE" message, press the audible alarm device cut-out control (11) for 20 seconds.

LOW FUEL This message shows that the level of fuel in the fuel tank is low and that fuel must be added. The audible alarm device also sounds. Use suitable fuel, see "Fluids and lubricants" in section 7.

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

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

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

OVER HEAT This message shows that the temperature of the engine coolant or the hydraulic fluid is too high. The audible alarm device will sound. Reduce engine speed. If the temperature does not drop, shut down the engine, remove the starter switch key and find the cause of the problem.

ALTERNATOR This message shows that the alternator is defective. The audible alarm device will sound.

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

4-9

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BOOM PRIORITY This message shows that the boom raising priority switch has been pressed. As a result, the boom disposes of maximum flow from the hydraulic pump and this increases boom operating speed. See item 5 under "Left-hand control arm".

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

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

NOTE: To stop the audible alarm device, press the control (item 11).

11

12

13

14

CD00E010

12 11. AUDIBLE WARNING DEVICE CUT-OUT CONTROL Press the control to stop the audible warning. If the audible alarm device still sounds, immediately read the message appearing on the systems display panel screen (10). When the audible alarm device is not working, this control also has another function. Press the control to test the lamps and indicators on the systems display panel for correct operation.

12. UPPERSTRUCTURE SWING LOCKING CONTROL This control is used to lock the swing function. When the switch is pressed, the upperstructure swing function will be locked and the "Upperstructure swing lock" lamp comes on. Press the switch once more to unlock the swing function. The swing function becomes operational and the lamp goes out.

IMPORTANT: When travelling or when the upperstructure swing is not needed, always lock the swing (with the lamp lighted).

4-10

13. EMERGENCY SHUT DOWN SWITCH This control enables the engine to be shut down in emergency or when it is not possible to shut it down by means of the starter key. When this switch is pressed, the engine stops, the audible alarm device sounds and the indicator lamp in the switch comes on. To start the engine again, press the switch once more and then turn the starter switch key to start the engine.

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

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

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

17 18

15

16

CD00E010

13 15 WINDSHIELD WIPER SWITCH This switch has three positions: "Off", "Intermittent", "Continuous". Press the switch for intermittent operation, the lower lamp comes on. Press the switch again to obtain continuous operation, the upper lamp comes on. Press the switch once more to stop the wiper.

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

16. 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.

17. CONTROL SWITCH FOR STOPPING THE ATTACHMENT CUSHION FUNCTION (boom and dipper) This control is used to select one of two modes for stopping the movement of the attachment. When the lamp on the switch is not on, attachment functions will be cushioned and come to a smooth halt. If the lamp is on, attachment functions will come to a sharp halt.

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

18. ROTARY LIGHT CONTROL This control is used to turn the rotary light on or off.

Press the switch once and the rotating light and the indicator lamp in the switch will light up. When the switch is pressed again, the rotary light goes out.

4-11

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 19. HOURMETER The hourmeter displays engine operation hours and tenths of an hour (6 minutes) and enables maintenance intervals to be calculated. See section 6.

19

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

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

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

4-12

20

CD00E011

14

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

6

3

9

7

2

4 8

1

5

CD00E033

15 1.

ON/OFF

6.

Air recycling

2.

Automatic

7.

Air flow direction

3.

Air conditioning

8.

Windshield defroster

4.

Ventilation

9.

Display screen

5.

Temperature

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

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

1

CD00E048

16

4-13

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Ventilation These push buttons (4) enable the air flow to be increased or reduced. To increase the flow of air, press the top button. To decrease the flow of air, press the lower button. The segments on the display screen (9) will increase or decrease depending on the flow selected.

9

4 CD00E048

17

Temperature 9

These push buttons (5) allow the temperature to be raised or lowered within an 18 to 32°C range. To increase the temperature, press the right-hand button.

To lower the temperature, press the left-hand button.

The temperature reading will appear on the display screen (9).

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

5 CD00E049

18 Air recycling

6

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

9

(A) Internal air circulated.

(B) External air circulation.

A

B

CD00E050A

19

4-14

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

9

7

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

CD00E050

20 (A) Upper front distribution.

(B) Upper rear distribution.

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

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

A

B

C

D

CD00E050B

21

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

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

9 8

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

CD00E050

22

4-15

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Air conditioning IMPORTANT: When using the air conditioning, it is essential for all the operator’s compartment windows, the windshield and the cab door to be kept closed. The air vents must be kept in open position.

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

Manual

6

This button (3) is used to turn the air conditioning on and off. When the air conditioning is running, confirmation is given on the display screen (9). Manual adjustments can be made using controls (4), (5), (6) and (7).

9

7

3

5

4

CD00E049

23 Automatic

9

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

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

2

5

1

CD00E049

24 To obtain hot or cold air quickly:

2

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

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

5

5A

CD00E049

25

4-16

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Temperature probe The temperature probe is behind the operator’s seat and should never be obstructed or covered.

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

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

CD00E051

26

Air vents The air vents are located to the front and rear of the operator’s compartment, as well as under the operator’s seat and allow the circulation and direction of air to be controlled. The air vents are opened and controlled manually.

CD00E052

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

CD00E017

28

4-17

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUNCTION CANCELLATION LEVER AND SAFETY BAR The safety bar (1) is designed to prevent the operator from leaving the operator’s compartment without first having lowered this bar.

2

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

When the lever (2) is in raised position, the safety bar (1) is in inward position in the control arm and the attachment, travel and swing functions can not be operated.

1

CD00E005

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

!

WARNING

2

!

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

NOTE: It is also possible to cancel all controls by completely raising the left-hand control arm. See "Lefthand control arm" (item 1).

1

CD00E006

30

4-18

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIPPER AND UPPERSTRUCTURE SWING LEFT-HAND 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 two 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 CS98M565

31 1.

2.

3.

4.

The dipper extends.

The dipper retracts.

The upperstructure turns to the left.

The upperstructure turns to the right.

4

3

2

1 CS98N547

32

4-19

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BOOM AND BUCKET RIGHT-HAND CONTROL LEVER

5

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

7

8

6 CS98M564

33 5.

6.

7.

8.

The boom lowers.

The boom raises.

The bucket retracts (filling).

The bucket extends (dumping).

6

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

5 8

7

CS98N547

34

TRAVEL CONTROL LEVERS AND PEDALS To move the machine, see "Machine travel" in section 5.

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

See "Systems display panel" (item 1).

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

CD00E012

35

OPTION PEDAL (if equipped) This pedal is used for optional accessories such as hydraulic hammer, if equipped, etc. See "Hydraulic hammer or high flow hydraulic circuits" in section 5.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

CD00E012

36 4-20

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FOOTREST

CD00E012

37

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

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

CD00E013

38

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

CD00E013

39

4-21

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CIGARETTE LIGHTER The cigarette lighter (24 volt) is located to the right at the rear of the cab.

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

!

WARNING

!

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

CD00E014A

40

IMPORTANT: Never put any thing other than the cigarette lighter into its housing.

12 VOLT AUXILIARY SOCKET A 12 volt supply socket is located at the rear of the cab on the right-hand side.

CD00E014A

41

FUSE BOX To gain access to the fuses, open the hatch to the left behind the operator’s seat and then remove the fuse box cover. To replace a fuse, see "Fuses" in section 9.

CD00E059

42

4-22

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ROOF HATCH To open the roof hatch, turn the handle and push the hatch upwards. To close the roof hatch, pull the handle.

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

CD00E015

43

CAB DOOR SLIDING WINDOWS When the locks are released, the windows can be opened and closed to the left or right as required.

CD00E016

44

STORAGE TRAY

CD00E014A

45

STORAGE COMPARTMENT Located behind the operator’s seat, this compartment is used, among other things, for storing the machine’s technical documentation and conformity certificates.

CD00E017

46 4-23

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SUN SHIELD The sun shield is fixed to the windshield and can easily be positioned as required.

CD00E018

47

CAB RADIO COMPARTMENT This pre-fitted compartment is located on the rear righthand side of the operator’s seat and is designed for a 12 volt cab radio.

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

CD00E014A

48

4-24

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

8

9

7

4 3 1

5

6 2 CD00E027

49 1.

2.

3.

4.

5.

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

6.

7.

8.

9.

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

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

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

4-25

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SUSPENSION ADJUSTMENT Pull the lever (1) forward to obtain softer suspension. Push the lever (1) backward to obtain harder suspension.

1

CD00E028

50 FORE/AFT ADJUSTMENT Hold the control (2) in the raised position, slide the seat to the required position and then release the control.

2

CD00E029

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

3

CD00E029

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

!

WARNING

!

4

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

CD00E029

53 4-26

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

CD00E030

54 SEAT AND CONTROL ARM ASSEMBLY FORE AND AFT ADJUSTMENT Pull the lever (6) upwards, and slide the seat and control arm assembly to the desired position, then release the lever.

6

CD00E029

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

7 CD00E031

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

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

8

CD00E031

57 4-27

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SEAT BELT Sit comfortably in the 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 if you fasten it correctly and wear it at all times. The safety belt should not be too loose. It should not be twisted or caught in the seat.

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

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

4-28

9

!

CD01D032

58

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD

!

WARNING

!

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

OPENING 1.

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

2

1 CD00E023

59 2.

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

3

CD00E047

60 3.

Engage the RH latch (4) in the cab pillar.

4 CD00E019

61

4-29

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CLOSING 1. Unlock the right-hand latch (4).

2.

Operate the lever (5) to release the windshield.

3.

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

4.

Make sure the top of the windshield is correctly latched.

5 CD00E020

62

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

1.

Push the right-hand and left-hand latches and remove the window.

CD00E021

63 2.

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

CD00E022

64

4-30

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES REAR WINDOW AND EMERGENCY EXIT OPENING 1.

Pull the handle (1) upwards.

1

CD00E024

65 2.

Push back the handle (1) to open the window partially.

1

CD00E025

66 3.

To open the window completely, operate the locking studs (2) and simultaneously release the pin (3).

NOTE: The window cannot be held on its own.

2

3

CD00E026

67 CLOSING 1.

Press the locking studs (2), bring the pin (3) into its housing and then release the studs.

2.

Fold the handle (1) back into position.

4-31

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUEL TANK The fuel tank capacity is 900 litres.

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

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

CD01K024B

68

!

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

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

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

The fuel tank is equipped with a max level gauge.

CT05L002

69

4-32

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

CAB

CD00E035A

70 UPPERSTRUCTURE

CD01K027A

71

4-33

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT STORAGE BOX This is to the front right of the upperstructure. It is used for storing emergency parts.

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

Use the handle to release the toggles, open the storage box and tilt the cover completely upward.

CD01K053A

72 To close, raise the door slightly, pull back the support strut and tilt the cover downwards.

NOTE: To lock the storage box cover, secure the left toggle using the starter switch key.

!

WARNING

!

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

CD01K053B

73

4-34

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE DOORS RIGHT-HAND DOOR The RH door gives access to a number of hydraulic components (pump, filters etc.) as well as the hydraulic reservoir gauge.

CD01K054B

74 LEFT-HAND DOORS The LH doors are mainly for obtaining access to the batteries, air filter, radiators, oil coolers, etc.

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

CD01K055C

75

!

WARNING

!

Always install the struts when the doors are open.

Use the starter switch key to lock the front side doors.

NOTE: The rear door is locked using two screws.

!

WARNING

!

Never leave tools or other objects behind the side doors.

!

WARNING

CD01K055D

76

!

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

4-35

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE HOOD OPENING The hood is opened by releasing the toggles.

Raise the hood completely until the strut locks automatically in position.

Use the starter switch key to open and lock the LH toggle.

!

WARNING

!

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

CD01K058A

77 CLOSING Raise the hood slightly, move the support strut back and tilt the hood downwards.

!

WARNING

!

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

CD01K059A

78

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

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

!

WARNING

!

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

CT05L003

79

4-36

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD WASHER RESERVOIR This reservoir, located in the compartment behind the cab, is equipped with an electric pump which is operated from the control panel. See item 16 under "Systems display and control panel".

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

Remove the cap to add windshield washing fluid.

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

The reservoir can be lifted out of its support.

CT05L004

80

CAB PROTECTION (F.O.P.S.) It is essential that the cab protection is used when work takes place in areas where stones or debris may fall. If the machine was not originally equipped with this protection, see your CASE Dealer for its installation.

CT04D008A

81

4-37

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOAD HANDLING EYE To handle a load, it is imperative for all slings and chains be attached to the connecting rod eye.

See "Load handling" in section 5.

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

See "Load handling limits" in section 5.

!

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

CD01C165

82

!

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

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

CD01D028A

83

4-38

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

On boom cylinders

CD01D029A

84

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

CT05L005

85

OPTIONAL TOOL FLOW SELECTOR BLOCKS (optional) These blocks, located on the upperstructure at the bottom of the boom, make it possible to select the correct hydraulic circuit for the optional tool to be mounted.

See "Hydraulic hammer or high flow circuits" in section 5.

1

IMPORTANT: Never alter the main relief valve (1) setting unless you first consult your CASE Dealer, otherwise you could damage the machine.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

CD01K061A

86

4-39

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPTIONAL TOOL SUPPLY VALVES (optional) Located on the end of the dipper, these two valves are used to ensure oil supply to optional tools, for example, hydraulic breakers, etc. These valves have two positions, open/closed.

CD01K042B

87

SELF-DETACHING COUNTERWEIGHT CONTROLS (optional) Located in the rear RH compartment.

(1): Control box (2): Supply valve See "Self-detaching counterweight" in section 5.

1

2 CT05L006

88

4-40

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUEL TANK FILLING PUMP

!

WARNING

!

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

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

1.

Park the machine on flat, horizontal ground, stop the engine and set the starter switch key to the "ON" position (contact).

2.

Take the inlet compartment.

pipe

out

of

the

storage

CT05L007

89 3.

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

4.

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

1

PDF0361

90

4-41

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 5.

Remove the fuel tank filler cap.

!

WARNING

!

It is essential that the cap is removed before filling.

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

CD01K024B

91 6.

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

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

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

CT05L008

92 7.

Turn the switch located on the pump to the "ON" position (start). The tank is filled.

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

8.

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

9.

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

10. Refit the fuel tank filler cap.

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

4-42

CT05L009

93

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES NOTE: The pump is equipped with a 20 amp fuse.

CT05L010

94

4-43

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

NOTES

4-44

SECTION 5

40

OPERATING INSTRUCTIONS BEFORE USING THE MACHINE

!

WARNING

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

The operator must be alone on the machine.

!

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 hydraulic fluid and coolant) and make sure the fluids and lubricants are suitable prevailing conditions. See "Fluids lubricants" in section 7 and "Operating machine in cold weather".

oil, that for and the

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.

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

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

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

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

10. Remove any obstructions which hinder visibility.

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

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

5-1

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

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

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

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

2.

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

3.

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

4.

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

5.

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

6.

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

7.

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

8.

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

9.

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

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

5-2

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

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

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

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

15. 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.

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

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

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

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

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

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

22. 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.

Check all instruments frequently.

Check the oil levels and coolant solution level frequently.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule: After the first 50 hours Replace the pilot circuit filter and the return filter.

See "Hydraulic system" in section 7.

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.

After the first 250 hours Change the oil in the travel reduction gears. See "Travel reduction gears" in section 7.

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

5-3

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

Your CASE Dealer can do this for you.

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

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

Recording the code 1.

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

2.

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

CD00E077

1 3.

To record the code (example: 1234), press the number of times which correspond to the first figure (example: 1 time) on key (1) then press key (2) to move to the second figure. Press the number of times which correspond to the second figure (example: 2 times) on key (1) then press key (2) to move to the third figure. Repeat the procedure for the third and fourth digits.

4.

Once all four digits have been entered, press button (3) for the code to be recorded in the system. The audible alarm device will sound.

5.

To finish recording the code, turn the starter switch key to the "OFF" position.

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

5-4

2

3

1 CD00E078

2

SECTION 5 - OPERATING INSTRUCTIONS Using the anti-theft device The anti-theft device has to be activated when you are shutting down the engine. Turn the starter switch from "ON" to "OFF", "ON" to "OFF" for about 2 seconds at a time until the audible alarm device sounds. The anti-theft device is now operational and before being able start the engine you will have to enter the access code.

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

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

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

1.

Place the starter switch key in the "ON" position.

2.

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

3.

To enter your code (example: 1234), press the number of times which correspond to the first figure (example: 1 time) on key (1) then press key (2) to move to the second figure. Press the number of times which correspond to the second figure (example: 2 times) on key (1) then press key (2) to move to the third figure. Repeat the procedure for the third and fourth digits.

4.

Once all four digits have been entered, press button (3). The audible alarm device will sound.

2

3

1 CD00E077

3

If the access code has been entered correctly, the message "Password" will disappear from the display screen and it will be possible to start the engine.

If the code entered was incorrect or different from that recorded in the machine, the message "ERROR" will appear, the audible alarm device will sound and it will be necessary to start all over again.

Place the starter switch key in the "OFF" position and repeat Steps 1 to 4.

NOTE: If the anti-theft device was activated the last time the engine was turned off, it will still be possible to start the machine without the access code, or with the wrong code, but the engine will run at idle speed, it will be impossible to accelerate and the upperstructure rotation function will be cancelled.

CD00E079

4

5-5

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

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

1.

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

2.

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

CD00E005

5 3.

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

4.

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

5.

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

1

2

CD00E060

6 In cold weather, the message "Eng. pre heat" appears on the systems display panel. See "Control and function display console" (item 10) in section 4.

6.

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

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

CD00E061

7

5-6

SECTION 5 - OPERATING INSTRUCTIONS 7.

Run the engine until the "Auto warm up" message disappears from the systems display panel. See "Control and function display console" (item 10) in section 4.

8.

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

CD00E006

8 9.

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

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

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

Starting this engine takes about 1 second before stabilisation is reached.

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 sometimes difficult to start.

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

CD00E006

9

5-7

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

After starting the engine and before using the machine, allow the hydraulic fluid to reach a temperature of 20°C, as indicated by the appearance of the first segment on the hydraulic fluid temperature indicator. See "Control and function display console" (Item 8) in section 4.

ENGINE AUTOMATIC WARM-UP

HYDRAULIC FLUID WARM-UP

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

Turn the engine throttle button to half-open position.

Operate the bucket control slowly until the bucket is completely closed. Operate the dipper retracting control slowly until the dipper is completely retracted and hold the control in this position for 30 seconds.

During this time the temperature of the hydraulic fluid will increase.

MANUAL ENGINE WARM-UP

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

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

Continue the dipper extending and retracting procedure until the temperature rises. See item 8 under "Control and function display console" in section 4.

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

5-8

SECTION 5 - OPERATING INSTRUCTIONS ENGINE OPERATION When the engine has started and before beginning work, the following procedure must be observed: - Let the engine idle for about five minutes until it has warmed up.

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

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

- There is no abnormal noise or vibration.

- There are no oil, fuel or water leaks.

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

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

Check the systems display and console regularly.

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

- Abnormal noise.

- Black smoke at the exhaust.

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

5-9

SECTION 5 - OPERATING INSTRUCTIONS STOPPING THE ENGINE 1.

Press the upperstructure swing locking switch on the console.

CD00E010

10 2.

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

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

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

3.

1

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

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

2

CD00E060

11

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

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

CD00E062

12

5-10

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

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

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

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

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

5-11

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

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

2.

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

3.

Test the radiator cap before hot weather starts.

Replace the cap as required.

4.

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

5.

Check the condition of the fan drive belt.

6.

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

7.

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

5-12

SECTION 5 - OPERATING INSTRUCTIONS MACHINE OPERATION OPERATING INSTRUCTIONS

!

WARNING

!

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

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

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

2) Excavation using the machine’s travel force.

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

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

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

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

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

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

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

More than 57 000 volts: 5 metres.

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

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

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

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

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

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

- Avoid turning the machine on steep slopes.

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

OPERATION 1.

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

2.

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

3.

Sound the horn.

4.

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

5.

Check all indicator lamps and gauges are operating correctly.

6.

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

7.

Unlock the upperstructure swing function.

8.

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

5-13

SECTION 5 - OPERATING INSTRUCTIONS MACHINE TRAVEL

!

WARNING

!

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

IMPORTANT: Before undertaking any travel, raise the attachment.

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

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

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

CS98M546

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

CS98M547

14

5-14

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 5-15

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

5-16

SECTION 5 - OPERATING INSTRUCTIONS HANDLING THE MACHINE Never handle the machine without contacting your CASE Dealer beforehand. Your CASE Dealer will provide you with the correct procedure to be followed to ensure the operation is carried out in perfect safety.

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

See "Weight" in section 11.

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

!

WARNING

!

The machine must be handled very slowly and horizontally.

!

WARNING

!

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

LOAD HANDLING

!

WARNING

!

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

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

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.

- Use the load fixing point (load handling eye) located on the bucket control rod, (see "Load handling eye", in section 4). 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".

5-17

SECTION 5 - OPERATING INSTRUCTIONS - Place the overload indicator switch on the left-hand control arm in "ON" (running) position. This is mandatory. See "LH control arm" (Item 6) in section 4.

- Select the "L" (light) work mode. See "Control and function display console" (Item 2) in section 4.

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

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

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

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

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

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

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

- Be sure all travel is undertaken in 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.

5-18

SECTION 5 - OPERATING INSTRUCTIONS LOAD HANDLING LIMITS 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.

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

OPERATING THE MACHINE IN WATER 1.

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

2.

Only the undercarriage must be below water level. The maximum water level must not be higher than the height of the tracks (1.12 m).

CS00E556

22

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

3.

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

IMPORTANT: Do not operate in a fast flowing stream.

CT05J004

23

5-19

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE ON SLOPING GROUND

!

WARNING

!

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

- During hillside operations, be extra careful.

- Make sure that the low speed travel is selected.

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

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

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

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

EXCAVATING METHOD

PDH0493M

24

1

2

3

PDH0494M

25 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

5-20

SECTION 5 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1.

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

2.

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

3.

Use the upperstructure swing locking switch on the systems display and console and make sure the locking indicator lamp lights up on the display panel.

CD00E010

26 4.

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

5.

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

CD00E060

27 6.

Stop the engine, remove the starter switch key.

CD00E080

28

5-21

SECTION 5 - OPERATING INSTRUCTIONS 7.

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

CD00E005

29 8.

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.

5-22

CD00E002

30

SECTION 5 - OPERATING INSTRUCTIONS RADIATOR AND OIL-COOLER DUST REMOVAL SWITCH It is recommended to perform this operation once every week or every day in dusty atmospheres.

1.

Open the engine hood.

2.

Turn the ignition key to the "ON" position (ignition).

3.

Make sure that the engine idle speed indicator is in the "OFF" position.

CD00E009

31 4.

Press and release the fan rotation reversal switch on the LH control arm.

5.

Start the engine, the fan rotates in the reverse direction and the audible alarm sounds.

CT05L001

32 6.

The fan speed can be adjusted by rotating the engine throttle volume.

NOTE: For safety, no control can be activated during dust removal.

NOTE: For relatively long dust removal, it is recommended to also open the rear LH door.

7.

To stop dust removal, simply stop the engine using the starter switch key ("OFF" position).

8.

Close the engine hood and the rear LH door.

IMPORTANT: Do not perform dust removal for more than three hours at a time.

NOTE: This control is inactive under normal operating conditions of the machine.

CD00E060

33

5-23

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

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

HYDRAULIC BREAKER OR HIGH FLOW HYDRAULIC CIRCUITS (optional) Your machine has two types of auxiliary hydraulic circuit. One circuit is for single flow equipment, such as hydraulic breakers. The second type of circuit is intended for use with one flow or two flows with continuous flow or for use with two flows such as demolition concrete crushers, etc.

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

Hydraulic breaker configuration 1.

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

CD01K042B

34

2

1

CD01K061A

35

5-24

SECTION 5 - OPERATING INSTRUCTIONS 2.

Move the selector blocks (1) and (2) to position them as shown.

1

2

CS01K612/613

36 3.

Tilt the control (3) on the left-hand arm to the right for hydraulic breaker operation.

3

CD00E072

37 4.

Use the control pedal to operate the hydraulic breaker.

NOTE: In normal working position (digging) the selector block (2) must be in vertical position and the control (3) in central position.

CD00E012

38

5-25

SECTION 5 - OPERATING INSTRUCTIONS Double flow concrete crusher configuration 1.

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

CD01K042B

39

1

2

CD01K061A

40 2.

Move the selector blocks (1) and (2) to position them as shown.

1

2

CS01K614/615

41

5-26

SECTION 5 - OPERATING INSTRUCTIONS 3.

Tilt the control (3) on the left-hand arm to the left for concrete crusher operation.

3

CD00E072

42 4.

Use the control pedal to operate the concrete crusher.

NOTE: In normal working position, control (3) should be in central position.

CD00E012

43 Single flow concrete crusher and backhoe bucket configuration 1.

For the concrete crusher, make the connection and then open the supply valves, using a hexagonal wrench.

CD01K042B

44

5-27

SECTION 5 - OPERATING INSTRUCTIONS 2.

The selector block (1) does not require adjustment.

1 CD01K064

45 3.

Make sure the selector block (2) is positioned as shown.

2

CS01K615

46 4.

Make sure the control on the left-hand arm is in central position.

CD00E072

47 5.

Use the control pedal to operate the concrete crusher.

CD00E012

48 5-28

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.

CD00E060

49 2.

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

CD00E006

50 3.

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

CD00E111

51

5-29

SECTION 5 - OPERATING INSTRUCTIONS SETTING THE TRACKS IN TRANSPORT POSITION IMPORTANT: Narrow track gauge or transport position must in no event be used for any purpose other than transporting the machine.

IMPORTANT: Do not allow anybody to stand within the machine working area.

1.

Place the upperstructure at right angles to the undercarriage and lay the bucket flat on the ground.

2.

Remove the 24 pieces of mounting hardware (2).

2

CD01D141

52

2

CD01D143

53 3.

Press the attachment down on the ground for support and use it to raise the track slowly so that it slides by itself towards the inside of the undercarriage until coming to the stop.

CT05J005

54

5-30

SECTION 5 - OPERATING INSTRUCTIONS 4.

If the track does not slide, insert a block (about 50x50 mm) under the track on the outer side.

Slowly lower the boom until the track slowly slides until coming to the stop.

CT05J006

55 5.

Install 12 pieces of retaining hardware tightened to a torque of between 2550 to 2943 Nm.

6.

Slowly lower the track to the ground. Repeat Steps 3 to 5 for the other track.

7.

Store the unused pieces of retaining hardware in the front tool box.

CD01D142

56

SETTING THE TRACKS IN WORKING POSITION 1.

Remove the spare pieces of retaining hardware from the front tool box.

2.

Place the upperstructure at right angles to the undercarriage and lay the bucket flat on the ground.

3.

Remove the 12 pieces of mounting hardware.

4.

Protect the sling points.

CD01D142

57

5-31

SECTION 5 - OPERATING INSTRUCTIONS 5.

Sling as indicated in the diagram opposite and then use the attachment to raise the track from the ground.

6.

Use a hand winch (1) to slide the track into position.

1 CT05J007

58 7.

Install the 24 pieces of retaining hardware tightened to a torque of between 2550 to 2943 Nm.

8.

Remove the hand winch (1) and slowly lower the track to the ground.

CD01D141

59

CD01D143

60 9.

Repeat Steps 2 to 8 for the other track.

5-32

SECTION 5 - OPERATING INSTRUCTIONS SELF-DETACHING COUNTERWEIGHT (optional) IMPORTANT: When handling the counterweight: - The machine must be on flat, hard, level ground.

- The upperstructure must be in line with the undercarriage with the travel reduction gears to the rear.

- The dipper and bucket must be retracted as far as possible and then lowered to the ground.

- Engine speed must be at low idle.

- The function cancellation lever must be in raised position (with the safety bar in retracted position).

!

WARNING

!

It is strictly forbidden to be present in the counterweight handling area.

REMOVAL NOTE: The counterweight clearance is about 0.63 m from the upperstructure frame.

1.

Make sure there counterweight.

is

nothing

under

the

2.

Remove the lower panel (under the engine) and then remove the two bolts holding the counterweight on the inside.

3.

Open the engine hood and remove the two pieces of retaining hardware holding the counterweight on the upper side. Close the engine hood.

0.63 m CT05J008

61 4.

Open the supply valve located in the rear RH compartment.

See "Self-detaching counterweight controls" in section 4.

S O

CT05L011

62

5-33

SECTION 5 - OPERATING INSTRUCTIONS 5.

Place the control box switch (1) in the "ON" position.

NOTE: Engine speed will automatically rise to 1700 rpm.

6.

Tilt the switch (2) towards "RAISE" position in order to raise the counterweight 180 mm.

7.

Tilt the switch (3) towards "BOTTOM" position.

Lower the counterweight to the ground.

8.

Remove the counterweight retaining pins.

9.

Tilt switches (2) and (3) to return to normal position.

1 2 3 CD01D035

63

10. Place switch (1) in the "OFF" position.

11. Close the supply valve.

12. Install the lower panel.

INSTALLATION 1.

Place the machine and the counterweight on flat, hard, level ground.

2.

Bring the machine to about 0.63 m from the counterweight and lower the attachment to the ground.

3.

Open the supply valve.

O S

CT05L012

64 4.

Place the control box switch (1) in "ON" position.

5.

Tilt switches (2) and (3) to lower the hitching system.

6.

Fasten the counterweight.

7.

Tilt the switch (3) towards "TOP" position and bring the handling arm up against the rear upperstructure plate.

8.

Tilt switch (2) to the "LOWER" position to engage the assembly.

9.

hitching

system

to

Open the engine hood and install the two upper counterweight bolts. Close the hood.

10. Remove the lower panel (under the engine) and then install the two lower counterweight bolts.

NOTE: The retaining hardware must be tightened to a torque of 2256 to 2550 Nm. 11. Place switch (1) in the "OFF" position. Close the supply valve.

12. Install the lower cover plate.

5-34

1

the

2 3 CD01D035

65

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE REMOVING THE ATTACHMENT FROM THE MACHINE The use of lifting systems is necessary for removal and installation of the machine attachment. See your CASE Dealer.

See "Overall dimensions and weight of the main machine components'" in section 11 to find out the weight and dimensions of the attachment installed on the machine.

!

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.

5-35

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORT POSITION OF THE MACHINE

A

CS01D574A

66 When transporting the machine and to reduce the overall height, it is recommended that the lubrication hose is disconnected from the dipper cylinder head and the dipper cylinder is blocked, then its head is disconnected and retracted; this will give a height of 3.70 m.

!

WARNING

!

In this configuration, great care must be taken when moving the attachment (swinging of the dipper), it is strictly forbidden to park in the working range of the attachment.

NOTE: The approximate weight of the machine in this configuration is 70 tons.

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 undertaking any travel without the attachment or transporting the machine without the attachment.

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.

5-36

SECTION 5 - OPERATING INSTRUCTIONS LOADING 1.

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

CT02C196

67 2.

Make sure the upperstructure swing lock has not been applied.

CD00E010

68 3.

Select the automatic engine idle function, so position "ON" appears on the display screen.

CD00E150

69

5-37

SECTION 5 - OPERATING INSTRUCTIONS 4.

Select low travel speed.

CD00E150

70 5.

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.

6.

Move the machine right to the front of the trailer, swing the upperstructure.

7.

Lock the upperstructure swing function.

8.

Stop the engine, remove the starter switch key, raise the function cancellation lever (with the safety bar inward).

9.

CS01D582A

71

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

10. Fold the rear view mirrors inwards. Retract the radio aerial.

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

12. Measure the distance between the ground and the highest point of the machine. You must know the overall height.

CS01D583A

72

5-38

SECTION 5 - OPERATING INSTRUCTIONS UNLOADING 1.

Remove the blocks and fastening chains.

2.

Start the engine.

3.

Unlock the upperstructure swing function.

4.

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

5.

Select low travel speed and slowly move off the trailer.

6.

Turn the rear view mirrors and the radio aerial back to the correct position.

IMPORTANT: If the attachment has been removed, all air must be bled from the hydraulic system once the attachment has been reinstalled and a check must be made that the machine is working properly.

Do not forget to check the oil level.

5-39

SECTION 5 - OPERATING INSTRUCTIONS

NOTES

5-40

SECTION 6

6

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

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits. Wear suitable clothing and remember to use the necessary safety equipment.

!

WARNING

!

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

!

WARNING

!

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

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

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

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

4. Lock the tracks to prevent any machine movement.

!

WARNING

!

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

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

Remove lower panels as necessary for the time required for 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.

CD00E073

1

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

- Check that the hydraulic oil is clean.

- Check signs of leaking oil or water.

- Check that all screws and nuts are correctly tightened. dust

- Check the fuel tank level.

- Check the hydraulic reservoir level.

GENERAL REMARKS

- Wipe off any compartment etc.).

UPPERSTRUCTURE

(engine,

operator's

- 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.

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

- Check the condition of all lines.

- Make sure there are no electrical short circuits.

- Check the battery connections are properly tightened.

- Adjust the rear view mirrors.

UNDERCARRIAGE - Check the pad hardware.

- Check the condition of the tracks.

- Check that the upper and lower track rollers and the idler wheels are not leaking oil.

ATTACHMENT - Check the cylinders are not leaking oil.

- Check the condition of all lines.

- Check the condition of the bucket teeth.

6-2

SECTION 6 - SERVICING INTERVALS AFTER STARTING THE ENGINE - Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

- Check for abnormal noise on the hydraulic components.

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

- Check the audible alarm devices, working lights and windshield wipers.

- Check that all circuits (travel, swing and tool) are functioning correctly.

- Check that the upperstructure swing brake functions correctly.

IMPORTANT: If the slightest defect is found, repair it immediately before using the machine or see your CASE Dealer.

6-3

SECTION 6 - SERVICING INTERVALS

6-4

DRAIN BLEED

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

INTERVALS

7-13

Engine oil level

1

10

7-16

Coolant level

1

10

7-19

Fuel pre-filter purge

1

10

7-19

Bleeding the fuel filters

2

10

7-28

Hydraulic reservoir level

1

8-5

Radiators and oil coolers

-

8-7

Fan/alternator belt tension

1

7-6

Bucket linkages

2

7-19

Drain fuel tank sediment

1

7-28

Hydraulic system lines

-

8-14

Air conditioning (optional)

1

9-3

Battery change

2

7-28

Hydraulic breaker return filter

1

100

7-19

Fuel pre-filter filter element

1

250

7-16

Tightening of clamps, radiator hoses

-

7-28

Drain hydraulic reservoir sediment

1

7-39

Primary air filter element

1

7-43

Swing reduction gears

2

250

1000 (H)

7-45

Travel reduction gears

2

250

1000 (H)

8-1

Pad screw torque

-

250 (D)

10 250 (M)

10 10/500 50 50 50

50

5000

50 (E) 50

250 (A) 250 250 (B)

1000 (C)

250 (B)

8-5

Idler wheel and rollers

-

250

8-20

Screw and nut tightening torque

-

250 (D)

9-3

Batteries electrolyte level

2

250

7-5

Turntable bearing

3

500 500

7-5

Turntable bearing teeth

1

7-13

Engine oil

1

7-13

Engine oil filters

2

500

7-19

Filtering element of fuel filters

2

500

7-19

Priming pump screen

1

7-6

Attachment (except bucket linkages) (NOTE 3)

14

1000

7-10

Self detaching counterweight (optional)

8

1000

7-16

Cooling system

1

7-28

Hydraulic fluid condition

-

7-28

Hydraulic reservoir breather

1

8-8

Tappet clearances

-

1000 (O)

9-6

Alternator

1

1000 (O)

9-6

Starter motor

1

1000 (O)

7-28

Inlet filter

1

500

500

1000 (J) 1000 1000

1000

5000

7-28

Pilot filter

1

2000 (F)

7-28

Return filters (NOTE 1)

2

2000 (F)

7-28

Ultra Clean filters (NOTE 1)

2

2000

7-39

Secondary air filter element

1

2000 (G)

7-19

Fuel hoses

-

4000 (N)

7-28

Main pump output hydraulic hoses

-

4000 (N)

7-28

Boom, dipper and bucket cylinder hydraulic hoses

-

4000 (N)

7-28

Hydraulic fluid (NOTE 2)

1

5000

4-39

Safety valves

3

8-1

Tracks

2

(K)

8-8

Fuel tank filter

1

(K)

8-9

Fire extinguisher

1

8-10

Machine inspection

1

8-10

Cylinders

-

DRAIN BLEED

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

SECTION 6 - SERVICING INTERVALS

(I) (K) (L) (K)

(K) (P)

6-5

SECTION 6 - SERVICING INTERVALS (A) Or every six months.

(B) Or when the message "AIR FILTER" is shown on the message display screen.

(C) Or after cleaning 6 times.

(D) Check after the first 50 hours during the run-in period.

(E) Have this checked by a specialist every 6 months.

(F) Replace after the first 50 hours during the run-in period.

(G) Or when the green mark disappears from the indicator.

(H) Drain after the first 250 hours during the run-in period.

(I) Have this checked by your CASE Dealer every 6 months.

(J) Or every two years or twice a year (autumn/spring) if antifreeze is used.

(K) Periodically.

(L) Check once a month and have it checked every 6 months by a specialist.

(M) Remove dust every week or every day in dusty atmosphere.

(N) Or every 2 years, whichever comes first.

(O) Ask your CASE Dealer to check this.

(P) Check for leakage.

NOTE 1: If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 1000 hours.

NOTE 2: If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 2000 hours.

NOTE 3: If all these linkage points are not equipped with genuine parts, these points must be greased every 50 hours.

NOTE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message "Service due" will appear on the screen by way of a reminder that service work is due. (It is possible to increase this lapse of time. See your CASE Dealer). See "Control and function display console" (Item 10) in section 4.

6-6

SECTION 7

46

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.

HYDRAULIC FLUID CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature.

Temperate climates -20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates 0° C to +50° C CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)

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 CASE/AKCELA: MOLY GREASE 251H EP-M (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.

CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium.

CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.

Hydraulic breakers (optional) CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Cold climates -25° C to +20° C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30° C to +40° C This yellow-coloured fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the circuit completely before refilling with this fluid.

CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

7-1

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE OIL 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 E5. API CH-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 Use fuel which is to ASTM (American Society for Testing and Materials) 975 standard.

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), a mixture of fuels No. 1-D and No. 2-D is approved as a temporary measure. 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 even minute dust particles, have the correct 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 IMPORTANT: Using any other fuel will reduce the operating performance of the engine.

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. CASE 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. In all cases, for your engine, never 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 any diesel fuel, ask the supplier if this fuel has been mixed with engine oil.

IMPORTANT: For correct 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.

ANTI-FREEZE/ANTI-CORROSION 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) 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.

ENVIRONMENT 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.

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

7-3

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ENGINE Type of oil ........................................................................................................................... "No. 1 ENGINE OIL" Capacity (with filter change).................................................................................................................... 52 litres COOLING SYSTEM System capacity.................................................................................................................................... 112 litres FUEL SYSTEM Reservoir capacity ................................................................................................................................ 900 litres HYDRAULIC SYSTEM Type of fluid ..............................................................................................."HYDRAULIC EXCAVATOR FLUID" Total system capacity ........................................................................................................................... 650 litres Reservoir capacity ................................................................................................................................ 310 litres TRAVEL REDUCTION GEARS Type of oil .............................................................................................. "GEAR 135H EP" extreme pressure oil Capacity (per reduction gear) ................................................................................................................. 30 litres SWING REDUCTION GEARS Type of oil .............................................................................................. "GEAR 135H EP" extreme pressure oil Capacity (per reduction gear) ................................................................................................................. 27 litres

7-4

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASE POINTS Type of grease.......................................................................................................... See "Fluids and lubricants" NOTE: The numbers within brackets mentioned on the right of the description indicate the number of lubrication points.

NOTE: After lubrication, refit the protective and indicating plastic caps to the grease fittings.

MACHINE

2 1

CS01D517A

3 Every 500 hours Turntable ............................................................. (3)

1

CT05L016

4 Turntable teeth .................................................... (1) See "Greasing the turntable teeth".

2

CT05L017

5 7-5

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ATTACHMENT

4

2

4

2 3

4 CS01D517A

1

5 6

Every 50 hours Bucket linkages....................................................(2)

1

CD01C165

7

7-6

SECTION 7 - LUBRICATION/FILTERS/FLUIDS IMPORTANT: If the following linkage points are not equipped with original parts, these points must be lubricated every 50 hours.

Every 1000 hours Boom bottom pin ................................................. (2) Boom cylinder top pin .......................................... (2) Dipper cylinder bottom pin................................... (1)

2

CT05L013

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

3

CT05L014

9 Boom/dipper linkage............................................ (1) Dipper cylinder top pin......................................... (1) Bucket cylinder bottom pin .................................. (1)

4

CT05L015

10

7-7

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Yoke/connecting rod linkages ..............................(4)

5

CD01C165

11

7-8

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE TURNTABLE TEETH Every 500 hours 1.

Remove the inspection cover (1) and visually check the condition of the gear surface and for any damage.

2.

If the gear surface is not well greased, add grease.

3.

If the grease is white due to moisture content, etc. replace it with new grease.

1

CT05L017

12 4.

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

- Remove the protective panel from the lower central area.

- Remove plug (2).

- Discharge the water or contaminated grease.

- Install plug (2).

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

2

CD01K028

13

7-9

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE SELF-DETACHING COUNTERWEIGHT SYSTEM (optional) Every 1000 hours Cylinder top pins ..................................................(3) Handling arm........................................................(2)

CD01D038

14 Cylinder bottom pins ............................................(3)

CD01D039

15

7-10

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVELS Type of fluids and lubricants..................................................................................... See "Fluids and lubricants" NOTE: The numbers within brackets mentioned on the right of the description indicate the number of levels.

Every 10 hours Engine oil............................................................. (1)

CT05L018

16 Coolant solution expansion reservoir .................. (1)

CT05L019 CT02C288

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

CT05L020

18

7-11

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Batteries...............................................................(2)

CT05L021

19 Travel reduction gears .........................................(2)

CD01K026

20 Swing reduction gears .........................................(2)

CT05L022

21

7-12

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check ............................................................................................. Every 10 hours or every day Oil change ................................................................................................................................. Every 500 hours Oil filters replacement................................................................................................................ Every 500 hours Oil type ..................................................................................................................... See "Fluids and lubricants" Oil capacity ............................................................................................................................................. 52 litres LEVEL 1.

Park the machine on flat, horizontal ground.

Stop the engine, remove the starter switch key.

2.

When the engine has been stopped for fifteen minutes, raise and lock the engine hood, remove the dipstick, wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

CT05L018

22 3.

If the level is situated between the marks (A) and (B) on the dipstick, the level is correct.

4.

If the oil level is at mark (A) (min) or below, open the access hatch then remove the filling plug and add oil up to mark (B) (max) of the dipstick.

A

NOTE: The level should not be higher than the mark (B) (maximum on the dipstick).

B CT05L023

23 5.

Install the plug, close the access panel.

CT05L024

24

7-13

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE OIL CHANGE AND OIL FILTER REPLACEMENT NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

Use the extension drain hose from the front boot.

1.

Place the machine on flat and level ground.

Stop the engine, remove the starter switch key then open the hatch under the engine.

2.

Raise and lock the engine hood, open the access hatch then remove the filling cap.

CT05L024

25 3.

Remove the protective cap from the engine housing drain valve.

4.

Screw the end of the extension drain hose onto the engine check valve, place the other end in a container of suitable capacity and allow the oil to flow out.

5.

Remove the extension drain hose and install the protective cap on the housing check valve.

Place the extension drain hose in the front storage compartment.

CT05L033

26 6.

Clean the area around the filter and remove it, using a filter wrench.

CT05L025

27

7-14

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 7.

Coat the seal of each new filter with a fine film of oil.

8.

Install the new filters. Turn the filters until the seals come into contact with the filter head then tighten an extra half turn by hand.

IMPORTANT: Do not use a filter wrench to tighten the filters. Excessive tightening can damage the filters and the seals.

PH08325

28 9.

Fill the engine with new engine oil. Install the filling plug, close the access hatch.

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.

CT05L024

29

7-15

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.................................................................................................................................... 112 litres

!

WARNING

!

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap, allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

!

!

WARNING

Check and service the cooling system according to the instructions given in this manual.

COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage. Do not use non-approved anti-rust additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

LEVEL The level of coolant solution should be checked when the engine is cold.

On flat, level ground, before using the machine (while the engine is still cold), the level in the expansion reservoir should be between the "Full" (1) and "Low" (2) marks. If not, see "Filling".

1 2 CT05L019

30

7-16

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING 1.

Using the starter switch key open the access hatch then remove the radiator cap.

!

WARNING

!

Do not remove the radiator cap when the engine is hot. The system is still under pressure and you could be scalded.

CT05L026

31 2.

Open the radiator drain valve.

CT05L027

32 3.

Open the drain plug located on the engine block.

NOTE: Have a receptacle of a suitable capacity ready.

CT05L028

33

7-17

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RINSING 1.

Close the drain valve once the radiator is completely empty. Close the plug on the engine block.

2.

Fill the system with clean water. Install the radiator cap.

3.

Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80°C.

4.

Drain the system once more.

5.

Repeat Steps 1 to 4 until the water drained is clear.

FILLING 1.

Fill with coolant solution via the radiator until it overflows, install the radiator cap then lock the access hatch.

CT05L026

34 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.

CT05L029

35

7-18

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Fuel reservoir bleeding ........................................................................................ Every 50 hours or every week Filter bleeding ......................................................................................................... Every 10 hours or every day Fuel pre-filter draining............................................................................................. Every 10 hours or every day Change the pre-filter element ....................................................................................................Every 250 hours Replacing the filtering element of the filters............................................................................... Every 500 hours Cleaning the priming pump screen............................................................................................ Every 500 hours Replacing the fuel hoses .............................................................................. Every 2 years or every 4000 hours (whichever comes first) Fuel tank capacity................................................................................................................................. 900 litres Type of fuel............................................................................................................... See "Fluids and lubricants"

!

WARNING

!

Completely wipe off any spilt fuel after changing a filter element or bleeding the system.

DRAINING THE FUEL TANK 1.

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.

CT05L030

36

7-19

SECTION 7 - LUBRICATION/FILTERS/FLUIDS PRE-FILTER BLEEDING 1.

Place a receptacle of a suitable capacity under the pre-filter.

2.

Loosen the drain plug and drain the water and the dirty fuel.

CT05L031

37 3.

After draining, close the drain plug.

4.

Check for any signs of leak.

CT05L032

38 CHANGING THE PRE-FILTER ELEMENT 1.

Place a receptacle of a suitable capacity under the pre-filter.

2.

Loosen the bleed plug (1) and the plug (2) then let the pre-filter drain.

3.

Clean around the pre-filter body (3) then remove it using the filter wrench provided with the machine.

2

3

1

CT05L031

39

7-20

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 4.

5.

Clean the area around the sediment bowl (4) then remove the bowl from the filtering element by loosening it using the wrench provided with the machine.

3

Clean the sediment bowl, check the state of its seal, replace it if necessary, apply a thin coat of oil on the seal then install the sediment bowl on a new filter (3) element, tightening it by hand.

Retighten the bleed plug (1).

4 1

IMPORTANT: Only the filtering element must be replaced, not the sediment bowl.

CT05L032

40 6.

7.

Check the state of the filtering element seal, replace it if necessary, reinstall the assembly on the filter head by rotating the pre-filter until the seal is in contact with the filter head then tighten an extra half turn by hand. Retighten the plug (2).

2

Bleed the system.

CT05L031

41

7-21

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FILTER BLEEDING 1.

Place a container with a suitable capacity under the filters.

CT05L034

42 2.

Loosen the drain plug and drain the water and the dirty fuel.

3.

After draining, retighten the bleed screw.

4.

Proceed in the same manner for the second filter

CT05L035

43 REPLACING THE FILTERING ELEMENT ON THE FILTERS 1.

Place a container with a suitable capacity under the filters.

2.

Loosen the bleed plug (1).

1

CT05L034

44

7-22

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Loosen the bleed screw (2) then let the filter drain.

4.

Clean around the filter body (3) then remove it using the wrench provided with the machine.

5.

Replace the filtering element with a new one.

Check the condition of the body seal, change it if necessary, apply a thin coat of oil on the seal then replace the body by rotating it until it is in contact with the filter head.

6.

Tighten the body (3) using the key, the tightening torque must be 29.4 Nm.

7.

Check the state of the bleed screw (2), change it if required. Retighten the bleed screw (2) to a torque of 1.5 to 2.5 Nm.

8.

Retighten the bleed plug (1).

9.

Proceed in the same manner for the second filter

3

2 CT05L035

45

10. Bleed the system CLEANING THE PRIMING PUMP SCREEN IMPORTANT: Always protect your face before using compressed air.

The screen is placed in the socket-head screw (1).

Remove the screen, clean it with compressed air then rinse it in fuel.

1

CT05L036

46

7-23

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM AIR BLEED It is necessary to bleed the fuel system when: -

The tank has been completely emptied.

The fuel pre-filter has been changed.

The fuel filters have been replaced.

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.

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

2.

Loosen the bleed screws (1) on the fuel filters.

1 1

CT05L034

47 3.

Loosen the fuel pump priming pump knob (2) on the engine.

2

CT05L036

48 4.

Move the handle of the priming pump (2) up and down until no bubbles come out of the air bleed screws (1).

CS98M578

49

7-24

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 5.

Turn the fuel filter priming pump (3) pistons to the left so as to release the springs.

3

3

CT05L034

50 6.

Operate the priming pumps (3) until the fuel flows from the bleed screw (1) without air bubbles, then retighten the bleed screws (1) and retighten the priming pump pistons (3).

1

3

CT05L037

51 7.

Loosen the bleed screw (4) on the fuel pump.

Move the handle of the priming pump (2) up and down until no bubbles come out of the air bleed screws (4) then retighten the bleed screw (4).

8.

Once the bleed screws (1), (4) and the pistons (3) have been retightened, operate the priming pump (2) again until a certain resistance is felt, then retighten the priming pump knob (2).

9.

2 4

Carefully wipe off any spilt fuel. Start the engine and check for possible leakage.

!

WARNING

!

Carefully wipe off any spilt fuel. It could cause a fire.

CT05L036

52

7-25

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1.

Place the machine on flat, level ground, lower the attachment to the ground and stop the engine.

2.

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

CD00E060

53 3.

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

CD00E006

54 4.

Operate the control levers from right to left and front to rear a dozen times approximately.

5.

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

CD00E111

55

7-26

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 6.

Remove the hydraulic reservoir protective cap by unscrewing it.

breather

CT05L038

56 7.

Press the button on top of the breather to release any residual pressure. Install the protective cap.

CT05L039

57

7-27

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 Change the hydraulic breaker return circuit filter (optional) ...................................................... Every 100 hours Draining water and sediment from the hydraulic reservoir........................................................ Every 250 hours Check the condition of the hydraulic fluid ............................................................................... Every 1000 hours Change the pilot filter .............................................................................................................. Every 2000 hours (after the first 50 hours during the run-in period) Change the reservoir breather filter ........................................................................................ Every 1000 hours Clean the inlet filter ................................................................................................................. Every 1000 hours Replace the return filters......................................................................................................... Every 2000 hours (after the first 50 hours during the run-in period) Replace the Ultra Clean filters ................................................................................................ Every 2000 hours Change the main pump outlet hoses ............................................................Every 2 years or every 4000 hours (whichever comes first) Change the boom, dipper and bucket cylinder hoses...................................Every 2 years or every 4000 hours (whichever comes first) Change the inlet filter .............................................................................................................. Every 5000 hours Change the hydraulic fluid ...................................................................................................... Every 5000 hours Reservoir capacity ................................................................................................................................ 310 litres Total system capacity ........................................................................................................................... 650 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 filters......................................................................................................... Every 1000 hours (after the first 50 hours during the run-in period) Replace the Ultra Clean filters ................................................................................................ Every 1000 hours Change the hydraulic fluid ...................................................................................................... Every 2000 hours NOTE: If the machine is new or if a major component has been overhauled or changed in the hydraulic system, change the pilot filter and return filter after 50 hours of operation. After that, change these filters at the stipulated interval.

IMPORTANT: Every 1000 operating hours, it is necessary to have the hydraulic fluid analysed. See your CASE Dealer.

IMPORTANT: After changing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See "Bleeding air from the hydraulic components".

IMPORTANT: If metal particles are found in the old filters, see your CASE Dealer.

!

WARNING

!

Before carrying out any service work on the hydraulic system it is necessary to allow it to cool down (the temperature should not be more than 40°C).

7-28

!

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".

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVEL IN THE RESERVOIR 1.

Place the machine on flat, level ground and place the attachment in the position shown.

Stop the engine and remove the starter switch key.

CS01D517B

58 2.

The oil should be in the middle of the indicator.

Add more oil if necessary. See "Filling the reservoir".

CT05L020

59 FILLING THE RESERVOIR 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the cover plate and the area around the plate. Remove the cover plate and add hydraulic fluid to the reservoir as required.

3.

Replace the cover plate seal if required and install the cover plate.

CT05L040

60

7-29

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RESERVOIR SEDIMENT REMOVAL 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Position a drain pan under the drain plug. Open the access hatch.

3.

Loosen the bleed screw on the bottom of the reservoir a few turns and drain the sediment and water accumulated at the bottom of the reservoir.

4.

After draining, tighten the bleed screw. Close the access hatch.

5.

Add hydraulic oil if necessary. See "Filling the reservoir".

CT05L041

61 PILOT FILTER REPLACEMENT Release all pressure in the hydraulic system. See "Releasing pressure in the hydraulic system".

CT05L042

62 Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

Remove the old filter (3) and O-ring (2).

1

Clean the filter body (4) in solvent and wipe dry with a cloth.

2

Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid and install the filter on the head (1).

3

Install the filter body (4) and tighten with a wrench.

Do not overtighten.

4 CS98M619

63

7-30

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING AND REPLACEMENT OF THE INLET FILTER 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

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

CT05L040

64 3.

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

4.

Remove the inlet filter (3) 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 (3), spring and rod assembly.

6.

Install the cover (1).

7.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

NOTE: Install a new inlet filter every 5000 hours of operation or when the hydraulic fluid is changed.

1

2

3 CS01D526A

65

7-31

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RETURN FILTER REPLACEMENT 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the top of the hydraulic reservoir and clean the return filter covers.

CT05L040

66 3.

Remove the cover (1) and O-ring (2).

4.

Take out the spring (3), valve (4) and filter (5).

5.

Install a new filter. Clean the spring (3) and valve (4) and install them.

6.

Check O-ring (2) and change it if worn or damaged.

7.

Install the cover (1).

8.

Repeat Steps 3 to 6 for the second filter.

9.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

1 3

2

4 5

CS01D526A

67

7-32

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ULTRA CLEAN FILTER REPLACEMENT 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the top of the filters with solvent. Close the supply valve (8).

8

CT05L043

68 3.

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

4.

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

5.

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

6.

Carefully install a new filter element (6) in the body (5).

7.

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

8.

Repeat Steps 3 to 7 for the second filter. Open the supply valve (8).

9.

Start the engine and run it at low speed.

7

1

2

3 4 5

6

CS02A544

69

10. Loosen the vent plugs (7) on top of the covers.

When hydraulic fluid without bubbles comes out of the vent holes, tighten the vent plugs (7).

Clean all fluid from the filter bodies.

11. Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

7-33

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE RESERVOIR BREATHER FILTER

CT05L038

70 1.

Remove the cap (1) then press the button (2) to release all pressure from the hydraulic reservoir.

2.

Remove the nut (3), the seal (4) and the cover (5) from the breather.

3.

Remove and discard the used filter (6).

4.

Install a new element, making sure the seal (7) is facing upwards.

5.

Install the assembly in the reverse order.

3

1 4

5 6

7 2 CS00E528A

71

7-34

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE HYDRAULIC FLUID 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Remove the reservoir cover plate.

3.

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

CT05L040

72 4.

Place a drain pan under the reservoir drain plug. Open the access hatch then remove the drain plug to remove the remaining fluid from the reservoir.

5.

Change 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. Close the access hatch.

7.

Fill the reservoir with new hydraulic fluid. See "Filling the reservoir".

8.

Install the reservoir cover plate and seal.

CT05L041

73

IMPORTANT: Before you start the engine, it is very important that you bleed air from all the hydraulic components. See "Bleeding air from the hydraulic components".

9.

Start and run the engine with no load for approximately five minutes.

10. Move each control several times to remove any air in the system.

11. Swing the upperstructure evenly left to right two complete turns or more.

12. Place the machine in position and then stop the engine.

13. Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

7-35

SECTION 7 - LUBRICATION/FILTERS/FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS IMPORTANT: After bleeding air from the components, stop the engine for five minutes and check there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Hydraulic pump Clean around the air bleed plug. Loosen the air bleed plug, remove the plug if the fluid does not flow.

Fill the pump with hydraulic fluid through this port, until the fluid comes up to the edge of the port.

Install and tighten the air bleed plug.

Start the engine and run it at low speed. Loosen the air bleed plug on the pump. Tighten the plug when air free fluid comes out of the bleed plug hole. Clean the area completely.

Bleed the second bleed plug hole at the same time.

CT05L044

74 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.

Hydraulic swing motors Start and run the engine at low idle speed. Loosen the unions on the top of the swing motors to release any air.

Retighten the unions as soon as the fluid spills out of the ports.

After the warm up procedure is completed, move each control slowly several times to remove any air in the system.

Swing the upperstructure evenly left to right two complete turns or more.

Stop the engine and wait five minutes.

Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

7-36

CT05L045

75

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE HYDRAULIC FLUID AND FILTERS WHEN A HYDRAULIC BREAKER (optional) IS USED Hydraulic fluid - When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinary digging. Check the hydraulic fluid level more frequently. In addition, when changing the filters, also check the condition of the hydraulic fluid.

- Using the following graph as a reference, determine the intervals for changing the hydraulic fluid and filters, depending on the frequency of use of the hydraulic breaker.

- When changing filters, change the return filter for the hydraulic breaker also.

With standard hydraulic fluid

1 4

3

2 CS99A860A

76 With biodegradable fluid

1

4

3

2 CS01N581

77 (1) Percentage of use (2) Interval in hours

(3) Changing the hydraulic fluid (4) Changing the hydraulic filters

7-37

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Return filter 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

IMPORTANT: It is mandatory to use the option control pedal to release all pressure in the hydraulic breaker circuit.

2.

This filter is equipped with an indicator (7).

When the filter is restricted, the filter must be changed.

CT05L046

78 3.

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

4.

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

5.

Change the filter (5) with a new filter.

6.

Discard the used O-rings.

7.

Insert new O-rings (3) and (4) and install the assembly.

8.

Tighten the retaining screws (1) for the cover (2).

9.

Install the drain plug (6).

1

7 2

3

4

5

10. Start the engine and run it at low speed.

Operate the hydraulic breaker and check that there are no leaks.

6 CS98M622

79 CHECKING THE HYDRAULIC SYSTEM PIPING Make sure there are no leaks from the hydraulic system hoses, pipes, plugs, connections and fittings and check that all nuts and screws are correctly tightened. In the event of problems, repair, change or tighten the component(s) concerned.

7-38

SECTION 7 - LUBRICATION/FILTERS/FLUIDS AIR FILTER INSPECTION Be sure to carry out regular checks on the air filter, intake manifold, seals and hoses. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be changed before they are worn.

SERVICE SPECIFICATIONS Inspect and clean the primary element...................................................................................... Every 250 hours or when the "AIR FILTER" message is displayed on the message display screen Change the primary element ...................................................................................................Every 1000 hours or after cleaning 6 times Change the secondary element...............................................................................................Every 2000 hours or when the green mark disappears from the indicator IMPORTANT: The primary element can be cleaned.

The secondary element cannot be cleaned and must be changed.

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

REMOVING THE ELEMENTS 1.

Release the fasteners and remove the cover.

CT05L047

80 2.

Remove the wing nut and take out the primary element.

CT05L048

81

7-39

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Check the indicator if the green point no longer appears, the secondary element should be replaced.

CT05L050

82 4.

Remove the retainer pin and the indicator and take out the secondary element if it has to be replaced.

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

CT05L049

83 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.

PE08311

84

7-40

SECTION 7 - LUBRICATION/FILTERS/FLUIDS NOTE: Do not use compressed air if there is oil or soot in the element.

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

IMPORTANT: Allow the element to dry completely before installing it. It is advisable to keep a spare, clean element ready for installation on the air filter while the cleaned element is drying.

PDE0088A

85 INSPECTING THE ELEMENT Check the element for damage by placing an inspection lamp inside the element.

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

PDE0378

86 INSTALLING THE ELEMENTS 1.

Install (if necessary) a secondary element and a new indicator, then the retainer pin.

NOTE: The tightening torque of the indicator must be 13 Nm maximum.

CT05L049

87

7-41

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 2.

Install the primary element and tighten the wing nut.

CT05L048

88 3.

Install the cover then fasten it.

CT05L047

89 4.

Check that the dust ejector under the airprefilter cover is working correctly.

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

CT05L051

90

7-42

SECTION 7 - LUBRICATION/FILTERS/FLUIDS SWING REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check ...........................................................................................................................Every 250 hours Oil change ...............................................................................................................................Every 1000 hours (after the first 250 hours during the run-in period) Oil capacity (per reduction gear) ............................................................................................................ 27 litres Oil type ..................................................................................................................... See "Fluids and lubricants"

!

WARNING

!

Wait till all components have cooled down before carrying out any operation.

1.

Park the machine on flat, horizontal ground.

Stop the engine and remove the starter switch key.

LEVEL

1

2 CT05L052

91 1.

Remove the dipstick (2). The oil should come up to the hatched area. If necessary, add more oil through the filler hole (1).

2.

Install the dipstick.

3.

Proceed in the same manner for the second reduction gear.

CP98N043

92

7-43

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING 1.

Park the machine on flat, horizontal ground.

Stop the engine and remove the starter switch key.

2.

Remove the dipstick (2) and the filler plug (1) from each reduction gear.

1

2 CT05L052

93 3.

4.

Place a receptacle of a suitable capacity under the upperstructure and remove the drain plugs (3).

3

Allow the oil to drain.

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

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

5.

Install the drain plugs (3).

6.

Add oil through the filler holes (1) until the level is correct.

7.

Install the dipsticks (2) and the filler plugs (1).

8.

Wait ten minutes and then use the dipsticks (2) to check the oil level again. If necessary, add more oil through the filler holes (1).

7-44

CT05L053

94

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) ............................................................................................................ 30 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.

Remove the plug (2) and check the oil level.

The level must come up to the bottom edge of the port (2). If required, top up through this port (2) until oil comes up to the bottom edge of the port.

5.

Install plug (2).

6.

Repeat Steps 2 to 5 for the other travel reduction gear.

7.

2

1 CD01K026

95

Travel slowly with the machine and make sure there are no leaks.

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 and remove the two plugs (1) and (2).

5.

Allow the oil to drain.

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

6.

Install the plug (1), fill with oil through the port (2) until oil comes up to the bottom edge of port, then install plug (2).

7.

Repeat Steps 2 to 6 for the other travel reduction gear.

8.

Travel slowly with the machine and make sure there are no leaks.

7-45

SECTION 7 - LUBRICATION/FILTERS/FLUIDS

NOTES

7-46

SECTION 8

37

MAINTENANCE/ADJUSTMENTS TRACKS MAINTENANCE SPECIFICATIONS Clean .................................................................. Periodically and when the machine has been working in mud Check tension....................................................................................................................................Periodically Check steel pad screw torques .................................................................................................Every 250 hours (after the first 50 hours during the run-in period) IMPORTANT: If the tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after work.

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

1.

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

2.

Turn the engine throttle button to maximum speed position.

CD00E060A

1 3.

Use the travel speed selector to select high speed.

CD00E075

2

8-1

SECTION 8 - MAINTENANCE/ADJUSTMENTS 4.

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

5.

Repeat Steps 1 to 4 for the other track.

CD00E147

3 CHECKING THE TENSION 1.

Park the machine on flat, horizontal ground.

2.

Clean the tracks.

3.

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

4.

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

5.

Stop the engine and remove the starter switch key.

6.

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

The value must be between: 410 mm and 430 mm.

7.

Adjust the tension if necessary and then lower the raised track to the ground.

8.

Repeat Steps 3 to 7 for the other track.

PE07531

4

8-2

SECTION 8 - MAINTENANCE/ADJUSTMENTS ADJUSTING THE TENSION NOTE: This operation is to be carried out after the tension has been checked.

To increase tension 1.

With the track raised, clean the grease fitting adaptor and the grease fitting.

2.

Connect the grease pump. Inject grease to obtain the right amount of track sag.

The value must be between: 410 mm and 430 mm.

3.

Remove the grease pump and clean the grease fitting.

4.

Repeat Steps 1 to 3 for the other track.

CT05L054

5 To reduce tension 1.

With the track in raised position, slowly loosen the grease fitting adaptor by about three turns to allow grease to flow out of the cylinder.

!

WARNING

!

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

2.

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

The value must be between: 410 mm and 430 mm.

3.

Clean the grease adaptor and fitting and then lower the raised track to the ground.

4.

Repeat Steps 1 to 3 for the other track.

CD01D119

6

IMPORTANT: If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regularly and replace it if necessary.

8-3

SECTION 8 - MAINTENANCE/ADJUSTMENTS TIGHTENING TORQUE OF THE TRACK PAD SCREWS IMPORTANT: Regularly check the tightening of the screws. Do not use the machine with the track pad screws loose, the screws may come off and damage the track.

The tightening torque of the screws should be between: 1765 to 2157 Nm.

PE08316

7 IMPORTANT: Follow the prescribed order.

1 4

3 2

CS00E504

8

8-4

SECTION 8 - MAINTENANCE/ADJUSTMENTS TRACK ROLLERS AND IDLER WHEELS MAINTENANCE SPECIFICATION Check ........................................................................................................................................ Every 250 hours The upper and lower rollers and idler wheels use a permanent floating seal type sealing mechanism. The service life normally lasts until overhaul, but check visually from time to time before work for oil leakage. If oil leakage is found, component replacement is necessary. See your CASE Dealer.

RADIATORS AND OIL COOLERS MAINTENANCE SPECIFICATIONS Check for leakage................................................................................................... Every 10 hours or every day Dust removal .................................................................................................................................... Every week (or every day in dusty atmosphere) Clean ......................................................................................................................................... Every 250 hours CLEANING 1.

Stop the engine and remove the starter switch key.

2.

Open the rear LH side door and block it with the supporting strut.

CT05L055

9 3.

Raise the top flap completely until the strut locks in position.

CT05L056

10

8-5

SECTION 8 - MAINTENANCE/ADJUSTMENTS 4.

Remove the wing nuts, then the protective grilles.

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

5.

Clean the radiators and the oil coolers: - Dry dust: use compressed air.

- Mud: use a water jet.

- Greasy dust: use perchlorethylene.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

6.

Install the protective grilles, then install the wing nuts.

!

WARNING

CT05L057

11

!

Before travelling, make sure that the rear LH side door and the top flap are securely fastened in place.

DUST REMOVAL Once every week or every day in case of an extremely dusty atmosphere, carry out a complete dust removal procedure for the cooling chamber.

See "Radiator and oil-cooler dust removal switch" in section 5.

CT05L001

12

8-6

SECTION 8 - MAINTENANCE/ADJUSTMENTS FAN AND ALTERNATOR DRIVE BELT MAINTENANCE SPECIFICATIONS Visual check ........................................................................................................... Every 10 hours or every day Check belt tension .....................................................................................................................Every 500 hours CHECKING THE TENSION IMPORTANT: If the engine runs with the belt slack, the belt can slip in its housing and cause the engine to overheat or the battery to receive insufficient charge.

CT05L058

13 With engine shut down and the starter switch key removed, use your finger to exert a pressure of about 10 kg at the centre of the belt. The tension slack should be between about 6 and 8 mm.

NOTE: Check if there are any signs of wear damage to the pulleys or the belt. Check carefully to ensure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

CS98M560

14 ADJUSTING THE TENSION Loosen the retaining screw (3) and the pulley attachment (4). Use the adjustment screws (1) and (2) to move the alternator and the pulley outwards until belt tension is correct. Retighten the pulley attachment (4) to a torque of 147 Nm. Tighten the alternator mounting bolt (3).

3

1

4

IMPORTANT: Check once again the tension of the belt after tightening the attachments.

2 CT05L059

15

8-7

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING THE BELT If the belt breaks, the battery load indicator lights up on the instrument panel. Shut down the engine, remove the starter switch key and change the belt.

Loosen the retaining screw (3) and the pulley attachment (4). Use the adjustment screws (1) and (2) to push the alternator and the pulley inwards.

3

Remove the warn belt.

1

4

Install a new belt.

Adjust the belt tension, see "Tension adjustment".

Run the engine for about an hour and then check the belt tension again.

2 CT05L059

16

ADJUSTMENT OF ENGINE VALVE ROCKER CLEARANCES MAINTENANCE SPECIFICATION Check...................................................................................................................................... Every 1000 hours NOTE: Ask your CASE Dealer to check this.

FUEL TANK FILTER MAINTENANCE SPECIFICATION Clean filter......................................................................................................................................... Periodically Remove the filter and clean it in diesel oil.

NOTE: To refill the fuel tank, see "Fluids and lubricants" in section 7.

CD01K039A

17

8-8

SECTION 8 - MAINTENANCE/ADJUSTMENTS FIRE EXTINGUISHER (not supplied) It is strongly recommended to have a fire extinguisher available and to keep it in the front boot.

MAINTENANCE SPECIFICATION Every month: Examine the fire extinguisher and make sure it is not damaged.

Every six months: Have an approved specialist empty and refill the powder in the fire extinguisher.

Every year:

CS98M573

Have an approved specialist examine the fire extinguisher.

18

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.

8-9

SECTION 8 - MAINTENANCE/ADJUSTMENTS 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 FOR CYLINDER LEAKAGE A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1.

Wipe clean the rod and bearing on the cylinder to be cleaned.

2.

Operate normally for five or ten minutes.

3.

Extend the cylinder rod.

4.

Carry out the leak test.

ROD APPEARANCE Dry Slightly greasy Oily

TEST

CONCLUSION

Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time the cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

See your CASE Dealer

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

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

8-10

SECTION 8 - MAINTENANCE/ADJUSTMENTS TEETH AND TOOTH TIP WEAR LIMITS The degree to which teeth or tooth tips are worn can be assessed visually.

It is possible to extend the life of teeth or tooth tips which are wearing unevenly, in a non-symmetrical fashion.

Interchange over the teeth regularly.

NOTE: Do not wait for teeth or tooth tips to be completely worn through before changing them.

IMPORTANT: Never try to work with a missing tooth tip or a tooth tip which is worn through. The adaptor could be seriously damaged.

CD01D128

19

REPLACING A TOOTH ON THE BACKHOE BUCKET 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.

CD01D128

20 INSTALLATION 1.

Clean the mating surface on the adaptor.

2.

Install a new tooth tip up to the stop, turning it to the right and holding it in this position.

3.

Place the locking pin in position and strike it until it is flush with the tooth tip.

IMPORTANT: Make sure that the latch has been installed with the correct orientation.

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

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 retaining hardware from the shafts.

4.

Remove the bucket pins.

CT02D211

5.

21

Start the engine, disengage the attachment from the bucket and save the linkage seals for re-use.

CT02D212

22

8-12

SECTION 8 - MAINTENANCE/ADJUSTMENTS INSTALLATION 1.

Make sure the bucket is in a stable position.

2.

Install the linkage seals on the dipper bushing shoulders. Change them if necessary.

3.

Start the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine and remove the starter switch key.

4.

Install the dipper/bucket connecting pin, then install the connecting pin stop.

5.

Start the engine. Bring the bucket rod into its housing, stop the engine and remove the starter switch key.

6.

Install the connecting rod/bucket connecting pin then install the connecting pin stop.

7.

Push the seals back into their housings.

8.

Adjust the dipper/bucket shimming.

"Shimming the backhoe bucket".

9.

Grease the linkage pins.

CT02D212

23

See

SHIMMING THE BACKHOE BUCKET SIDE PLAY ADJUSTMENT 1.

Place the bucket flat on flat, horizontal ground.

2.

Check the play (J) between the dipper and the bucket ear.

3.

If the play (J) exceeds 2 mm, remove the four screws, the cap (1) and the shims (2).

4.

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

5.

Install the necessary number of shims.

6.

Install the cap (1) and the four screws.

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

1

J 2 CD00E121

24

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap (1) has an orifice on its inside surface. When installing the cap (1), make sure the lug is inside this orifice.

8-13

SECTION 8 - MAINTENANCE/ADJUSTMENTS AIR CONDITIONING MAINTENANCE SPECIFICATION Clean the intake filter .................................................................................................................. Every 50 hours Clean the air recycling filter......................................................................................................... Every 50 hours Replace the filters ................................................................................................................... Every 5000 hours Have checked by a specialist......................................................................................................Every 6 months The components of the air conditioning system need servicing at regular intervals. Make sure these intervals are respected, in order to ensure the air conditioning functions correctly and with maximum effectiveness. The air conditioning system contains gas which is subject to strict legislation. Any defect in the system must be fixed rapidly.

!

WARNING

!

Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

NOTE: Operate the air conditioning system at least once a week, if only for a short time. See "Heating, ventilation or air-conditioning control" in section 4.

INSPECTION In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below before starting work.

CLEANLINESS OF THE CONDENSER If the condenser is dirty it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

CHECKING THE BELT TENSION Use your finger to exert pressure of around 10 kg on the centre of the drive belt. The tension slack should be between about 5 and 7 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.

CT05L060

25

8-14

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR INTAKE AND AIR RECYCLING FILTERS 1.

Remove the screws (2) and sealing cover (1) in the rear of the cab.

2 1

2 CT05L061

26 2.

Remove the screws (3) and open the panel (4).

3 4

CD00E139

27 3.

Remove the filter and clean it with compressed air. Replace the filter if it is damaged.

IMPORTANT: Always protect your face before using compressed air.

4.

Install the filter in its housing with the seal (5) on the inside.

5.

Close the panel (4) and install the screws (3).

6.

Install the sealing cover (1) and the screws (2).

5

CD00E140

28

8-15

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR RECYCLING FILTER 1.

The air recycling filter is located underneath the fuse box (1). Remove the access panel and take out the filter (2).

2.

Clean the filter (2) with compressed air. Replace the filter if it is damaged.

1

IMPORTANT: Always protect your face before using compressed air.

3.

Install the filter and the access panel.

2 CD00E142

29 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.

CT05L062

30 2.

This check should be made approximately one minute after turning on the air conditioning.

A

(A) Very few bubbles observed, then transparent at first, then whitish: "Normal".

B

C

(B) The bubbles are numerous: check the unions and consult your CASE Dealer.

(C) No bubbles are visible: check the unions and consult your CASE Dealer.

CS00E555

31

8-16

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

Check if the hydraulic line and air-conditioning hose connectors are dirty or dusty.

CT02D235

32

8-17

SECTION 8 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING NOTE: This section shows how to easily diagnose problems relating to the engine and describes the solutions to be adopted. If you are unable to determine the cause of the failure, or if the latter is difficult to rectify, contact your CASE Distributor.

PROBLEM

Engine does not start.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run)

Check starter switch

Defective rotation of starter (starter rotates slowly)

Discharged batteries, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Incomplete air bleeding of fuel system

Completely bleed air

Engine too cold (cold weather)

Preheat the intake air or warm up the coolant

No fuel in fuel tank

Refill

Poor fuel quality

Inspect and replace as necessary

Fuel filter clogged

Clean or replace

Possible seizure in engine Low compression

See your CASE Dealer

Defective fuel injection pump Engine stops during operation.

Incorrect oil pressure.

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

Defective oil pressure switch 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 Low compression

8-18

See your CASE Dealer

See your CASE Dealer

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 Low compression

Excessive fuel consumption.

See your CASE Dealer

Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Incorrect spray from fuel injection nozzle Incorrect fuel injection timing

See your CASE Dealer

Low compression

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

Engine overheating (water temperature is too high).

Excessive oil

Drain oil to proper level

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage

Retighten and replace parts if necessary

Worn cylinder piston ring

See your CASE Dealer

Poor fuel quality

Replace

Damage inside muffler

Replace

Low coolant

Refill

Coolant leakage

Repair

Worn or damaged belt

Replace

Incorrect mixture of anti-freeze solution

Replace

Defective radiator Broken fan Defective thermostat

See your CASE Dealer

Defective water pump Defective water temperature gauge

Defective battery charge.

Incorrect belt tension

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Defective alternator

See your CASE Dealer

8-19

SECTION 8 - MAINTENANCE/ADJUSTMENTS HARDWARE TORQUE INSPECTION MAINTENANCE SPECIFICATION Check........................................................................................................................................ Every 250 hours (after the first 50 hours during the run-in period) At the end of each working day, check all mounting nuts and screws for tightness and tighten if necessary. Make sure no hardware items are missing. Replace them, if necessary.

TORQUE SPECIFICATIONS PER COMPONENT Screw (Ø)

Wrench (mm)

Torque setting (Nm)

Travel reduction gear (*)

M24

41

901-1052

Drive sprocket (*)

M24

41

901-1052

Undercarriage side members

M36

55

2550-2942

Upper roller (*)

M30

46

1781-2078

Lower roller (*)

M30

46

1781-2078

Chain guide (*)

M30

46

1668-1962

Track pad

M27

30

1765-2157

Counterweight

M42

65

2256-2550

Turntable (upperstructure) (*)

M30

46

1460-1700

Swing reduction gear (*)

M24

36

900-1050

Engine (*)

M24

36

902-1049

Engine mounts (*)

M14

22

173-202

Radiator

M20

30

392-490

Hydraulic pump (*)

M12

19

Hydraulic reservoir (*)

M20

30

471-258

Fuel tank (*)

M20

30

471-258

Control valve (*)

M20

30

343-392

Hydraulic swivel (*)

M16

24

267-312

Cab

M16

24

78-80

Batteries

M10

17

20-29

Component

NOTE: Use Loctite 262, or the equivalent, on screws marked (*).

8-20

109-127

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.

CD00E059

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 or install a fuse, use the notch in the upper right-hand corner of the cover.

NOTE: Two spare fuses (10 amp and 20 amp) are to be found on the inside of the cover.

A23955

2

9-1

SECTION 9 - ELECTRICAL SYSTEM FUSE FUNCTIONS (1) Memory, cab light, car radio ........................10 A (2) Starter switch key ........................................20 A (3) Air conditioning, heater................................20 A (4) Air conditioning compressor ..........................5 A (5) Working lights ..............................................15 A (6) Not used ......................................................15 A (7) DC rectifier...................................................10 A (8) Windshield wiper/washer.............................15 A (9) Horn, self-detaching counterweight (optional)...............................15 A (10) Cigarette lighter, operator’s seat ...............15 A (11) Engine electronic box ................................20 A (12) Electronic box control ..................................5 A (13) Electronic box power .................................20 A (14) Rotating beacon (not supplied)..................10 A (15) Hydraulic control cancellation....................10 A (16) Fuel filler pump .........................................20 A (17) Fuel supply pump ......................................30 A (18) Air conditioning condenser fan ..................10 A (19) Engine pre-heating ....................................30 A (20) Optional .....................................................20 A

1

11

10A

20A

20A

5A

20A

20A

5A

10A

5

15A

10A

15

6

15A

20A

16

7

10A

30A

17

8

15A

10A

18

15A

30A

15A

20A

2 3 4

9 10

12 13 14

19 20

CS00E505B

3

9-2

SECTION 9 - ELECTRICAL SYSTEM BATTERIES MAINTENANCE SPECIFICATION Checking the charge state...........................................................................................................Every 50 hours Electrolyte level check ............................................................................................................... Every 250 hours NOTE: When starting the machine with booster batteries, see "Connecting booster batteries".

!

WARNING

!

Before starting any operation on the components of the electrical circuit, put the starter switch key in the "Off" (shut down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.

!

WARNING

!

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

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

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

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

!

WARNING

!

A spark or a naked light can cause the hydrogen in a battery to explode. To prevent explosion, proceed as follows: - When disconnecting battery cables, always disconnect the negative cable (-) first.

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

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

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

!

WARNING

!

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

9-3

SECTION 9 - ELECTRICAL SYSTEM To gain access to the batteries, open the left-hand side door.

CHECKING THE ELECTROLYTE LEVEL 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.

CP99A022

4

CHANGING A BATTERY 1.

Remove the terminal protection caps, disconnect cables (negative terminals) and then cables (positive terminals). Remove the antisulphate pellets.

2.

Remove the two screws, the washers and metal sheet and then remove the old battery.

3.

Install the new battery and put the metal sheet, washers and screws back in place.

4.

Clean the cables and battery terminals and coat them with grease.

5.

Install new anti-sulphate pellets, reconnect positive cable ends to positive terminals and then negative cable ends to negative terminals.

Install the terminal protection caps.

!

WARNING

!

Do not invert battery terminals. Connect positive cable ends to positive terminals (+) and negative cable ends to negative terminals (-).

!

WARNING

!

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

!

WARNING

!

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

9-4

CT05L063

5

SECTION 9 - ELECTRICAL SYSTEM CONNECTING BOOSTER BATTERIES

!

WARNING

!

Connecting auxiliary cables wrongly or shortcircuiting batteries terminals can cause an accident.

Connect auxiliary starting cables as per the following instructions.

Make sure that the booster battery voltage corresponds to the voltage system of the machine (24 volts).

1.

Remove the terminal sleeves.

2.

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

3.

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

4.

Start the engine.

5.

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

6.

Install the terminal sleeves.

9-5

SECTION 9 - ELECTRICAL SYSTEM ALTERNATOR MAINTENANCE SPECIFICATION Check...................................................................................................................................... Every 1000 hours

!

WARNING

!

Whenever carrying out a welding operation on the machine (authorised by the manufacturer and in accordance with his instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires.

IMPORTANT: Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

Ask your CASE Dealer to check the alternator.

NOTE: Make sure that the terminal protectors are correctly installed.

CT05L064

6

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.

CT05L065

7

9-6

SECTION 9 - ELECTRICAL SYSTEM REPLACING A BULB OPERATOR’S COMPARTMENT LIGHTING 1.

Remove the cover.

2.

Remove the bulb and install a bulb of the same wattage (10 W).

3.

Install the lens.

CD00E123

8 ATTACHMENT LIGHTS

CT05L066

9 1.

Remove the 4 retaining screws.

CD00E124

10

9-7

SECTION 9 - ELECTRICAL SYSTEM 2.

Tilt the working light and disconnect the plug.

CD00E125

11 3.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

4.

Install the clip and reconnect the plug.

5.

Put the working light back into position and install the mounting screws.

CD00E126

12 UPPERSTRUCTURE AND CAB HEADLIGHTS 1.

Raise the front storage box cover until the support strut is locked.

CD01K053A

13

9-8

SECTION 9 - ELECTRICAL SYSTEM 2.

Remove the compartment.

top

3.

Disconnect the plug.

plate

from

the

light

CT05L067

14 4.

Remove the four screws and tilt the headlight.

CD00E129

15 5.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

6.

Install the clip, put the headlamp back in position and install the screws and the plug.

7.

Install the top plate. Close the front box.

CD00E130

16

9-9

SECTION 9 - ELECTRICAL SYSTEM

NOTES

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.

Clean the machine.

2.

Retract the dipper cylinder rod as for as possible and lower the boom until the attachment is resting on the ground.

3.

Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your CASE Dealer.

1.

The battery charge and recharge the batteries if required.

2.

The grease on the cylinder rods.

3.

The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

4.

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

5.

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

NOTE: When the machine resumes service, the film will disappear automatically.

4.

Drain the fuel tank and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

5.

While the engine is still warm, drain the oil sump, fill with anti-corrosive oil and replace the engine oil filter.

6.

When the engine is cold, clean the outer parts of the engine with diesel fuel.

7.

Clean or replace the air filter element.

8.

Drain the cooling system, leave the drain valves open and do not tighten the radiator cap.

9.

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.

10. Paint any areas where the paintwork is not good.

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

12. Remove the starter switch key and place a "Do not operate" label on the right-hand control arm and then raise the function cancellation lever (safety bar in inward position).

13. Lock the hoods and the cab door.

10-1

SECTION 10 - STORAGE STARTING UP AFTER STORAGE 1.

Close the drain valves and fill the cooling system.

2.

Drain the fuel reservoir and top up with suitable fuel, see "Fluids and Lubricants" in section 7.

3.

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

4.

Replace the filtering element of the fuel filters.

5.

Install the batteries.

6.

Grease the machine thoroughly.

7.

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

8.

Check the condition of the air conditioning drive belt and replace it if necessary.

9.

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

10. Check the travel reduction gears and swing reduction gear oil level and add more oil if necessary.

11. Clean the cylinder rods.

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

13. Remove the "Do not operate" tag and start the engine, following the starting up procedure.

14. 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

!

Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly or an electrical appliance from starting up.

!

WARNING

!

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

10-2

SECTION 11

10

SPECIFICATIONS ENGINE Latest "common rail" engine, in conformity with the European requirements applicable to low smoke emission, in accordance with directive 97/69/EC 3A. Make and type ...................................................................................................................... ISUZU AH-6WG1X Common rail, turbo, intermediate cooler, fuel cooler..................................................................................... yes Electronically ......................................................................................................................... controlled injection Number of cylinders........................................................................................................................................... 6 Bore/stroke ............................................................................................................................ 147 mm x 154 mm Displacement.....................................................................................................................................15 700 cm3 Cooling ........................................................................................................................................... water-cooled Battery starting .................................................................................................... 2 12/24 volt batteries, 140 A/h WORKING CONDITIONS Speed ................................................................................................................................................... 1800 rpm Power EEC 80/1269 ....................................................................................................................345 kW/462 hp Engine oil capacity......................................................................................................................................... 52 l Fuel tank capacity........................................................................................................................................ 900 l Fuel filler pump.

Engine/pump assembly mounted on flexible mountings.

Filtration in dusty conditions.

Electronically controlled governor.

HYDRAULIC SYSTEM Variable flow piston-type double pump.

Max main pump output (at 2030 rpm) .............................................................................................2 x 440 l/min Fixed flow pump (pilot circuit).

Max flow ................................................................................................................................................. 27 l/min Working pressure.

Attachment/power boost................................................................................................................... 320/350 bar Tilting oil cooler with ventilation from engine.

High pressure multispiral hoses minimum safety factor ................................. 2 to 4 times the working pressure Self-lubricating hydraulic swivel.

Hydraulic reservoir capacity ........................................................................................................................ 310 l Total hydraulic system capacity................................................................................................................... 650 l CONTROL VALVE Four control valve sections for right-hand travel, boom/bucket and dipper acceleration.

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

Boom/dipper load holding valves.

11-1

SECTION 11 - SPECIFICATIONS SWING Fixed flow, piston-type pump.

Automatic disk brake.

Upperstructure swing speed ................................................................................................................... 6.5 rpm TRAVEL Two speed hydraulic motors with axial pistons.

Planetary reduction gears.

Low speed.......................................................................................................................................... 0 to 3 km/h High speed...................................................................................................................................... 0 to 4.1 km/h Gradeability.................................................................................................................................................. 70% STANDARD ATTACHMENT (Boom 7.70 m) Crowd force....................................................................................................................................... 31 700 daN Break-out force (with 3.00 m dipper)................................................................................................. 26 700 daN Break-out force (with 3.55 m dipper)................................................................................................. 24 500 daN Break-out force (with 4.10 m dipper)................................................................................................. 22 100 daN Break-out force (with 5.00 m dipper)................................................................................................. 19 200 daN SHORT ATTACHMENT (Boom 6.60 m) Crowd force....................................................................................................................................... 36 500 daN Break-out force (with 3.00 m dipper)................................................................................................. 25 900 daN

UNDERCARRIAGE "X" configuration chassis with (mechanically) variable track gauge.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks ................................................................................. Track pads of: 650 mm, 750 mm and 900 mm Ground pressure (with 650 mm track pads)........................................................................................... 1.03 bar

SAFETY DEVICES Control for lowering attachments in case of engine failure.

Controls are disabled by lifting the function cancellation lever or the left-hand control arm.

Engine emergency shut-down, anti-theft protection.

Safety glass, horn.

Safety valves with overload indicator...................................................................................................... optional Inertia reel type safety belt.

Fire extinguisher ..................................................................................................................................... optional

11-2

SECTION 11 - SPECIFICATIONS OPERATOR’S COMPARTMENT Deluxe seat with armrests, inertia type safety belt, multi-position adjustment and headrest (vibration level III/ ISO 7096, 2000 Class EM 3 or EM 4 depending on the model).

Hydraulically assisted controls.

Attachment and swing .................................................................................................................2 control levers Travel.............................................................................................................................................. 2 foot pedals Speed programmer, also provides automatic speed change.

Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation/air conditioning, cab lights, cigarette lighter, sun shield.

Working lights: One on upperstructure................................................................................................................ 24 V, 70 W Two on attachment .................................................................................................................... 24 V, 70 W Two on cab ................................................................................................................................ 24 V, 70 W

NOISE LEVELS Guaranteed by the manufacturer.

In accordance with European directive 2000/14/EC stage 2.

Inside the operator’s compartment ....................................................................................................77 decibels Outside the operator's compartment (Lwa) .....................................................................................108 decibels

VIBRATION LEVEL INSIDE THE CAB Upper members............................................................................................................level lower than 2.5 m/s2 Body .............................................................................................................................level lower than 0.5 m/s2

CAB Removable, sound proof, mounted on flexible mountings.

Foldaway windscreen.

Rear window emergency exit.

Sun shield.

Sliding windows on door.

Prefitted for radio installation.

Roof hatch.

Windshield protection grid (optional).

Cab protection (optional).

TRANSPORT The width of the track gauge for transport can be reduced to 3.30 m (with 650 mm track pads).

This machine may be equipped (optionally) with a self-detaching counterweight. A system consisting of 3 hydraulic control cylinders allows quick removal, without requiring any special handling equipment.

11-3

SECTION 11 - SPECIFICATIONS WEIGHTS STANDARD ATTACHMENT With 7.70 m boom, 3.55 m dipper, 2780 l backhoe bucket (general purpose), 650 mm track pads, operator and full fuel tank ............................................................................... 69 390 kg SHORT ATTACHMENT With 6.60 m boom, 3.00 m dipper, 2870 l backhoe bucket (very heavy duty), 650 mm track pads, operator and full fuel tank ............................................................................... 69 600 kg COUNTERWEIGHT Weight.................................................................................................................................................. 10 500 kg Self detaching counterweight................................................................................................................(optional)

STANDARD ATTACHMENT Boom, length.............................................................................................................................................7.70 m Dipper, length............................................................................................................................................3.00 m Dipper, length............................................................................................................................................3.55 m Dipper, length............................................................................................................................................4.10 m Dipper, length............................................................................................................................................5.00 m

SHORT ATTACHMENT Boom, length.............................................................................................................................................6.60 m Dipper, length............................................................................................................................................3.00 m

BACKHOE BUCKETS GENERAL PURPOSE SAE capacity Width

1700 l

2125 l

2780 l

3225 l

3665 l

3885 l

2710 kg

3002 kg

3372 kg

3649 kg

3886 kg

1700 l

2780 l

3665 l

3885 l

4105 l

4016 kg

HEAVY DUTY SAE capacity

1100 mm 1600 mm 2000 mm 2100 mm 2200 mm

Weight

2779 kg

3476 kg

4024 kg

4154 kg

4272 kg

1740 l

2185 l

2870 l

3330 l

3790 l

VERY HEAVY DUTY SAE capacity Width Weight

4250 l

1100 mm 1300 mm 1600 mm 1800 mm 2000 mm 2200 mm 3150 kg

QUARRY SAE capacity

3300 l

Width

1800 mm

Weight

4299 kg

11-4

4550 l

1100 mm 1300 mm 1600 mm 1800 mm 2000 mm 2100 mm 2200 mm 2400 mm

Weight

Width

4105 l

3457 kg

3911 kg

4214 kg

4576 kg

4884 kg

4134 kg

4507 kg

SECTION 11 - SPECIFICATIONS MACHINE OVERALL DIMENSIONS STANDARD ATTACHMENT (7.70 m boom)

CS01B548A

1 Dippers 3.00 m 3.55 m 4.10 m 5.00 m (A)......................................................................4.37 m .................. 4.30 m ................ 4.47 m ................. 5.16 m (B)......................................................................3.79 m .................. 3.79 m ................ 3.79 m ................. 3.79 m (C)....................................................................13.25 m ................ 13.29 m .............. 13.30 m ............... 13.17 m (D)......................................................................6.91 m .................. 6.91 m ................ 6.91 m ................. 6.91 m (E)......................................................................3.99 m .................. 3.99 m ................ 3.99 m ................. 3.99 m (F) ......................................................................1.51 m .................. 1.51 m ................ 1.51 m ................. 1.51 m (G) .....................................................................4.00 m .................. 4.00 m ................ 4.00 m ................. 4.00 m (H)......................................................................5.88 m .................. 5.88 m ................ 5.88 m ................. 5.88 m (I) .......................................................................4.70 m .................. 4.70 m ................ 4.70 m ................. 4.70 m (J)* .....................................................................3.25 m .................. 3.25 m ................ 3.25 m ................. 3.25 m (J)**....................................................................2.74 m .................. 2.74 m ................ 2.74 m ................. 2.74 m (K) (standard pads)............................................0.65 m .................. 0.65 m ................ 0.65 m ................. 0.65 m (L)* (with 650 mm pads) ....................................3.90 m .................. 3.90 m ................ 3.90 m ................. 3.90 m (L)** (with 650 mm pads)...................................3.39 m .................. 3.39 m ................ 3.39 m ................. 3.39 m (L)* (with 750 mm pads) ....................................4.00 m .................. 4.00 m ................ 4.00 m ................. 4.00 m (L)** (with 750 mm pads)...................................3.49 m .................. 3.49 m ................ 3.49 m ................. 3.49 m (L)* (with 900 mm pads) ....................................4.15 m .................. 4.15 m ................ 4.15 m ................. 4.15 m (L)** (with 900 mm pads)...................................3.64 m .................. 3.64 m ................ 3.64 m ................. 3.64 m (M) .....................................................................0.83 m .................. 0.83 m ................ 0.83 m ................. 0.83 m NOTE: * (working position) ** (transport position)

11-5

SECTION 11 - SPECIFICATIONS SHORT ATTACHMENT (6.60 m boom)

CS01B547A

2 Dipper 3.00 m (A) .............................................................................................................................................................4.76 m (B) .............................................................................................................................................................3.79 m (C) ...........................................................................................................................................................12.11 m (D) .............................................................................................................................................................6.91 m (E) .............................................................................................................................................................3.99 m (F) .............................................................................................................................................................1.51 m (G).............................................................................................................................................................4.00 m (H) .............................................................................................................................................................5.88 m (I)...............................................................................................................................................................4.70 m (J)* ............................................................................................................................................................3.25 m (J)** ...........................................................................................................................................................2.74 m (K) (standard track pads) ..........................................................................................................................0.65 m (L)* (with 650 mm pads)............................................................................................................................3.90 m (L)** (with 650 mm pads) ..........................................................................................................................3.39 m (L)* (with 750 mm pads)............................................................................................................................4.00 m (L)** (with 750 mm pads) ..........................................................................................................................3.49 m (L)* (with 900 mm pads)............................................................................................................................4.15 m (L)** (with 900 mm pads) ..........................................................................................................................3.64 m (M).............................................................................................................................................................0.83 m NOTE: * (working position) ** (transport position)

11-6

SECTION 11 - SPECIFICATIONS OVERALL DIMENSIONS AND WEIGHT OF THE MAIN MACHINE COMPONENTS STANDARD ATTACHMENT (7.70 m boom)

1 2

3

4

5 6 CS01D574B

3 a (length)

b (height)

c (width)

Approximate weight

(1)

5.57 m

2.92 m

3.55 m

22 500 kg

(2)

3.39 m

1.39 m

0.77 m

10 500 kg

(3) (each)

5.88 m

1.35 m

0.90 m

10 900 kg

(4)

8.04 m

1.92 m

1.28 m

6600 kg

(5) (both)

2.76 m

-

0.85 m

1400 kg

(6)

4.95 m

1.38 m

0.87 m

3430 kg

NOTE: For dimensions and weights of buckets, refer to "Backhoe buckets".

11-7

SECTION 11 - SPECIFICATIONS WORKING RANGE STANDARD ATTACHMENT (7.70 m boom)

CS01B550A

4 Dippers 3.00 m 3.55 m 4.10 m 5.00 m (A) (Maximum digging range) ........................... 12.90 m. ...............13.20 m. ..............13.70 m ...............14.60 m (B) (Maximum digging depth at ground level) .......................................... 12.60 m. ...............12.90 m. ..............13.40 m ...............14.30 m (C) (Maximum digging depth) ............................. 7.87 m. .................8.40 m. ................8.97 m .................9.85 m (D) (Maximum digging depth over a length of 2.44 m)................................ 7.72 m. .................8.27 m. ................8.85 m .................9.75 m (E) (Maximum dump height)............................... 8.33 m. .................8.02 m. ................8.16 m .................8.71 m (F) (Maximum working height).......................... 12.40 m. ...............11.92 m. ..............12.04 m ...............12.70 m (G) (Minimum attachment swing radius) ............. 5.86 m. .................5.81 m. ................5.68 m .................5.70 m (H) (Maximum digging depth on a vertical face .......................................... 6.85 m. .................6.87 m. ................7.36 m .................8.63 m (I) (Maximum length of flat-bottomed trench)...... 2.44 m. .................2.44 m. ................2.44 m .................2.44 m

11-8

SECTION 11 - SPECIFICATIONS SHORT ATTACHMENT (6.60 m boom)

CS01B549A

5 Dipper 3.00 m (A) (Maximum digging depth)................................................................................................... ............... 11.75 m (B) (Maximum digging depth at ground level) ........................................................................... ............... 11.46 m (C) (Maximum digging depth)................................................................................................... ................. 7.18 m (D) (Maximum digging depth over a length of 2.44 m) .............................................................. ................. 7.04 m (E) (Maximum dump height) .................................................................................................... ................. 7.04 m (F) (Maximum working height) ................................................................................................. ............... 11.13 m (G) (Minimum attachment swing radius) ................................................................................... ................. 5.21 m (H) (Maximum digging depth on a vertical face......................................................................... ................. 5.10 m (I) (Maximum length of flat-bottomed trench) ........................................................................... ................. 2.44 m

11-9

SECTION 11 - SPECIFICATIONS

NOTES

11-10

SECTION 12 ALPHABETICAL INDEX 12 volt auxiliary socket ..................................... 4-22 A Adjustment of engine valve rocker clearances ... 8-8 Air conditioning ................................................. 8-14 Air filter ............................................................. 7-39 Alternator ............................................................ 9-6 Anti-theft device.................................................. 5-4 Arm angle adjustment lever................................ 4-4 Ashtray ............................................................... 4-5 Audible warning device cut-out control............. 4-10 Automatic working mode selector....................... 4-6 Auxiliary hydraulic circuits ................................ 5-24 B Backhoe buckets .............................................. 11-4 Batteries ............................................................. 9-3 Before using the machine................................... 5-1 Boom and bucket right-hand control lever........ 4-20 Boom raising priority switch................................ 4-5 Bringing the machine up to operating temperature .................................... 5-8 C Cab ................................................................... 11-3 Cab door............................................................. 4-1 Cab door sliding windows................................. 4-23 Cab light ........................................................... 4-21 Cab protection (F.O.P.S.) ................................. 4-37 Cab radio compartment .................................... 4-24 Checking for cylinder leakage .......................... 8-10 Cigarette lighter ................................................ 4-22 Coat hanger hook ............................................. 4-21 Control arm tilt adjustment and function cancellation lever .............................. 4-5 Control switch for stopping the attachment cushion function ........................ 4-11 Controls/Instruments/Accessories ...................... 4-1 Cooling system ................................................. 7-16 D Daily inspections................................................. 6-2 Decals................................................................. 3-8 Dipper and upperstructure swing left-hand control lever................................... 4-19

E Electrical system ................................................. 9-1 Emergency shut down switch ........................... 4-10 Engine......................................................7-13, 11-1 Engine coolant temperature indicator ................. 4-8 Engine hood...................................................... 4-36 Engine idle speed selector.................................. 4-4 Engine operation................................................. 5-9 Engine throttle button.......................................... 4-4 Engine troubleshooting ..................................... 8-18 Environment........................................................ 7-3 F Fan and alternator drive belt ............................... 8-7 Fan rotation reversal switch ................................ 4-5 Fire extinguisher ................................................. 8-9 Fluid and lubricant capacities and specifications .......................... 7-4 Fluids and lubricants ........................................... 7-1 Footrest............................................................. 4-21 Front storage box.............................................. 4-34 Fuel level indicator .............................................. 4-8 Fuel system....................................................... 7-19 Fuel tank ........................................................... 4-32 Fuel tank filling pump ........................................ 4-41 Fuel tank filter ..................................................... 8-8 Function cancellation lever ................................. 4-5 Function cancellation lever and safety bar........ 4-18 Fuse box ........................................................... 4-22 Fuses .................................................................. 9-1 G Grease points ..................................................... 7-5 Greasing the self-detaching counterweight system................................... 7-10 Greasing the turntable teeth ............................... 7-9 H Hand signals ..................................................... 3-16 Handling the machine ....................................... 5-17 Hardware torque inspection .............................. 8-20 Heating and ventilation or air-conditioning controls................................ 4-13 Heavy lift control ................................................. 4-5 Horn .................................................................... 4-5 Hourmeter ..................................................4-12, 6-2

12-1

SECTION 12 - ALPHABETICAL INDEX H

P

Hydraulic breaker or high flow hydraulic circuits ........................................... 5-24 Hydraulic fluid temperature indicator .................. 4-8 Hydraulic system......................................7-28, 11-1

Parking the machine ......................................... 5-21 Plastic and resin parts ...................................... 8-10 Position of the operator’s compartment controls and accessories ................................ 4-3

I

R

Identification numbers/Machine components...... 2-1 Idle indicator........................................................ 4-7 Inspecting and cleaning the machine................ 8-10 Intervals .............................................................. 6-4

Radiator and oil-cooler dust removal switch ..... 5-23 Radiators and oil coolers .................................... 8-5 Rear view mirrors.............................................. 4-33 Rear window and emergency exit..................... 4-31 Releasing pressure in the hydraulic system ..... 7-26 Replacing a backhoe bucket............................. 8-12 Replacing a bulb ................................................. 9-7 Replacing a tooth on the backhoe bucket......... 8-11 Right, left, front and rear of the machine ............ 1-3 Right-hand control arm ....................................... 4-4 Roof hatch ........................................................ 4-23 Rotary light cable .............................................. 4-38 Rotary light control............................................ 4-11 Run-in period ...................................................... 5-3

L Left-hand control arm.......................................... 4-5 Levels................................................................ 7-11 Load handling ................................................... 5-17 Load handling eye............................................. 4-38 Load handling limits .......................................... 5-19 Lower front window ........................................... 4-30 Lower panels..................................................... 4-36 Lowering the attachment in the event of a machine failure ...................................... 5-29 Lubrication/Filters/Fluids ..................................... 7-1 M Machine operation ............................................ 5-13 Machine overall dimensions.............................. 11-5 Machine travel................................................... 5-14 Maintenance/Adjustments................................... 8-1 Message display screen ..................................... 4-9 N Noise levels....................................................... 11-3 O Operating instructions ......................................... 5-1 Operating the backhoe bucket .......................... 5-20 Operating the machine........................................ 5-2 Operating the machine in cold weather ............ 5-11 Operating the machine in hot weather .............. 5-12 Operating the machine in water ........................ 5-19 Operating the machine on sloping ground ........ 5-20 Operator's seat ................................................. 4-25 Operator’s compartment ................................... 11-3 Option control...................................................... 4-5 Option pedal...................................................... 4-20 Optional tool flow selector blocks...................... 4-39 Optional tool supply valves ............................... 4-40

12-2

S Safety bar ........................................................... 4-5 Safety devices .................................................. 11-2 Safety instructions .............................................. 3-1 Safety valves .................................................... 4-39 Safety/Decals/Hand signals ................................ 3-1 Self-detaching counterweight ........................... 5-33 Self-detaching counterweight controls .............. 4-40 Servicing instructions .......................................... 6-1 Servicing intervals............................................... 6-1 Setting the tracks in transport position.............. 5-30 Setting the tracks in working position ............... 5-31 Shimming the backhoe bucket.......................... 8-13 Short attachment .............................................. 11-4 Side doors......................................................... 4-35 Specifications.................................................... 11-1 Standard attachment ........................................ 11-4 Starter motor ....................................................... 9-6 Starter switch ...................................................... 4-4 Starting the engine.............................................. 5-6 Steps and access handles.................................. 4-2 Stopping the engine.......................................... 5-10 Storage ............................................................. 10-1 Storage compartment ....................................... 4-23 Storage tray ...................................................... 4-23 Storing the machine.......................................... 10-1

SECTION 12 - ALPHABETICAL INDEX S Sun shield......................................................... 4-24 Swing reduction gears ...................................... 7-43 Systems display and function control panel ....... 4-6 T Teeth and tooth tip wear limits.......................... 8-11 To the owner....................................................... 1-1 Track rollers and idler wheels............................. 8-5 Tracks................................................................. 8-1 Transport .......................................................... 11-3 Transporting the machine................................. 5-35 Travel control levers and pedals....................... 4-20 Travel reduction gears...................................... 7-45 Travel speed indicator ........................................ 4-6 Travel speed selector ......................................... 4-6 "Trip" control ..................................................... 4-12 Type, serial number and year of manufacture of the machine........................... 2-1 U Undercarriage................................................... 11-2 Upperstructure swing locking control................ 4-10 V Vibration level inside the cab............................ 11-3 W Weight .............................................................. 11-4 Welding on the machine ..................................... 8-9 Windshield ........................................................ 4-29 Windshield washer reservoir ............................ 4-37 Windshield washer switch ................................ 4-11 Windshield wiper switch ................................... 4-11 Working lights switch ........................................ 4-10 Working mode indicator...................................... 4-7 Working mode selector....................................... 4-6 Working range .................................................. 11-8

12-3