Case CX800 Tier III Crawler Excavator Operator's Manual 87538934 - PDF DOWNLOAD

CX800 TIER III CRAWLER EXCAVATOR OPERATOR’S MANUAL Part Number: 87538934

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

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

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

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

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

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

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

●

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

●

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

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.

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Background color is YELLOW

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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.

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Reads and understands ALL Safety Decals on the machine.

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Clears the area of other persons.

●

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

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

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2006 Case Corporation All Rights Reserved CASE and IH are registered trademarks of Case Corporation

Bur 87538934 NA Issued June 2006

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-3 1-4 1-6

CHAPTER 2 SAFETY AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Instrument/controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Function Cancellation Lever and Safety Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Operator’s Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Right-Hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Left-hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Systems Display And Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Anti-theft Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Arm and Upper Structure Swing Control Left-Hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Boom and Bucket Control Right-hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Optional Control Pattern Arm and Upper Structure Swing Left-Hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Optional Control Pattern Boom And Bucket Right-hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Travel Control Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Automatic Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Rear Window And Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Towing Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Load Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Load Holding Control Valves (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Auxiliary Hydraulic Valves (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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Run-in Period Of A New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Before Operating The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Lifting Loads With The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operating The Machine In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Operating The Machine On Sloping Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Operating The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Towing The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Counterweight Removal Device (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Auxiliary Hydraulics (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Safety Before You Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fluids And Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lubrication/filters/fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Lubrication And Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Hardware Torque Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Replacing A Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Boom/Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 General Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 General Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Overall Dimensions and Weight of Main Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 CHAPTER 9 INDEX

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NOTES

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

BD06E025

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

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

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

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

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

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

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

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

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

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

Always keep this manual in the operator’s compartment (in the seat back, behind the operator’s seat). Make sure it is always complete and in good condition. If you wish to obtain additional manuals, or manuals in another language, consult your CASE Dealer.

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

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CHAPTER 1 - GENERAL INFORMATION

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

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

NOTE: The identification plate on your machine may differ slightly in appearance, but plate location is the same.

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤ Engine serial number

➤ Transmission and serial number

➤ BS06D307

Attachment serial number

Figure 3

➤

Figure 2

CP98N006

PRODUCT IDENTIFICATION NUMBER (P.I.N.) LOCATION

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS 1

2

3

4 5 6

7

8 9

11 15

14

13

12

11

10

16 8

21 17 20

19

18

Figure 4

CS01B541

1-4

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87538934NA

CHAPTER 1 - GENERAL INFORMATION

The CX800 is an all hydraulic machine. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upper structure frame. The upper structure frame supports the attachment, the engine, the hydraulics and cab. When the operator works the controls, the engine-driven variable flow pump delivers hydraulic fluid under pressure to the control valves. The control valves distribute the hydraulic fluid to the various cylinders and hydraulic motors employed. A cooling system and oil cooler keep the fluid temperature at normal working temperature.

Key to main components 1. Fuel Tank 2. Engine compartment 3. Swing reduction units 4. Hydraulic reservoir 5. Boom 6. Boom cylinders 7. Cab 8. Hand holds 9. Counterweight 10. Travel reduction gears 11. Steps 12. Upper rollers 13. Lower rollers 14. Idler 15. Arm 16. Arm cylinder 17. Bucket cylinder 18. Bucket 19. Undercarriage 20. Track 21. Upper structure

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CHAPTER 1 - GENERAL INFORMATION

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

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

6

1

4

6

3

5

5

2 Figure 5

CS99A820

1. FRONT 2. REAR

1-6

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

5. TRAVEL REDUCTION GEARS 6. IDLERS

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87538934NA

CHAPTER 2 - SAFETY AND DECALS

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

Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Or Explosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ductile Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6 2-6 2-6 2-7 2-7 2-7 2-7 2-8 2-8 2-8

OPERATOR PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions To This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

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CHAPTER 2 - SAFETY AND DECALS

NOTES

2-2

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CHAPTER 2 - SAFETY AND DECALS

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

M171C

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

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

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

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

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CD00E001

Figure 1

OPERATOR’S MANUAL LOCATION AND STORAGE

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

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

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

2-3

CHAPTER 2 - SAFETY AND DECALS

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

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

• • • •

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

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

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

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

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

Figure 2

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

2-4

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CHAPTER 2 - SAFETY AND DECALS

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

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW. Prohibition symbols such as

and

STOP

if used are RED.

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

1

2

Figure 3

CS97M019

1. WORKING AREA 2. SAFETY AREA

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CHAPTER 2 - SAFETY AND DECALS

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

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

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

PERSONAL SAFETY

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

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

• Know and use the protective equipment that is to

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

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

• Before you drive or operate in an area with high

• Certain protective equipment should be replaced

• Contact with high voltage lines, underground

lines or cables, tell the power or utility company what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines or cables.

You must know the safe working distance from the high voltage power equipment and must know any federal, state/provincial or local safety codes or regulations that apply to the job site.

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

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

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

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

•

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

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

•

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

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

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

who

has

the

GENERAL

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

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

• Do not permit riders on the machine.

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

• Remove all loose objects stored in the machine.

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

• Do not use the machine as a manlift.

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

• Operate the machine controls from the operator’s seat only. Always fasten the seat belt.

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CHAPTER 2 - SAFETY AND DECALS

• Remove the starter key when leaving the machine

PROPER ENTRY AND EXIT

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

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

parked or unattended.

OPERATING PRECAUTIONS

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

• If a failure that causes loss of control such as

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

Sound the horn before starting.

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

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

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

• Understand the machine limitations and keep the

furthermost contact point to view operation danger area from the work site personnel view and angle.

This is the safety area necessary for the machine to operate at the maximum range of the tool plus 6 feet (2 meters).

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

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

• Start and operate the machine only from the

machine under control.

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

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

• Carry loads in recommended positions for maximum stability.

• Do not bypass the machine’s interlock system.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and

The interlock system must be repaired if it malfunctions.

• Know and understand the job site traffic flow

• Use jumper cables only in the recommended

patterns, and obey signalmen, road signs and flagmen.

operator’s station.

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

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

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

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

• Before leaving the operator’s station, lower the

counterweighting.

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

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

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

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

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CHAPTER 2 - SAFETY AND DECALS

• Use proper transport devices when roading the

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

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

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

• Stay away from hazardous areas such as ditches,

• Use the approved attachment point when using

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

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

• Be alert and always know the location of all

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

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

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

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

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

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

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

• Contact

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

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

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

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

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

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

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

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

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• Use extreme caution when removing radiator

MAINTENANCE PRECAUTIONS

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

caps, drain plugs, grease fittings or pressure taps.

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

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

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

• Towing this machine is not recommended.

• Observe the proper maintenance procedures.

• Whenever servicing or replacing hardened pins,

Figure 4

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

• Before you service the machine, put a Do Not

• Keep the brakes and steering systems in good

321-4614

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

• Wear protective glasses and other required safety

operating condition.

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

FUEL HANDLING PRECAUTIONS

equipment when servicing or repairing the machine.

• Do not smoke or permit open flames while fueling

• Wear gloves to protect hands when handling

• Never remove the fuel cap or refuel gasoline

cable.

or near fueling operations.

electrical system. Know the consequences of disconnecting any electronic or computer devices.

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

• Avoid lubrication or mechanical adjustments with

• To avoid spilling fuel, maintain control of the fuel

• Disconnect the battery before working on the

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

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

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

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

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filler nozzle when filling the tank.

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

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

2-9

CHAPTER 2 - SAFETY AND DECALS BURN PREVENTION WARNING: BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

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

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

HAZARDOUS CHEMICAL PRECAUTIONS

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

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

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

• Before you service this machine and before you dispose of the old fluids and lubricants, always be environmentally responsible. DO NOT put oil or fluids on the ground or into containers that can leak.

2-10

• Check with your local environmental or recycling center or your dealer for correct disposal information.

TRANSPORTING PRECAUTIONS

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

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

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

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

2. Lower the attached equipment to the ground.

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

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

This decreases the temperature of the engine parts evenly.

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

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

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

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

This will prevent the tracks from freezing to the ground.

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

DUCTILE IRON

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

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SEAT BELT PRECAUTIONS SPECIFIC PRECAUTIONS TO THIS MACHINE

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

2

• No work should be performed when machine tracks are in the transport position. The transport position is to be used only when transporting the machine. The upper structure should always be aligned with the tracks during transport.

3

1 Figure 5

CD00E032

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

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

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

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

4. The seat belt will automatically retract.

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

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SAFETY DECALS WARNING: Injury or death can result if you cannot read a safety decal or if a safety decal is missing. Replace any missing or damaged safety decals and keep all safety decals clean. See your dealer for new safety decals.

SC002

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

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

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

See your dealer for new decals.

Figure 6

KHP1525

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CHAPTER 2 - SAFETY AND DECALS

1

Figure 7

BD02D152

1

Figure 8

KHP1537-00

This decal is located inside the cab right rear window.

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CHAPTER 2 - SAFETY AND DECALS

2

3

Figure 9

BD02D152

3

2

Figure 11

CS00F530

This decal shows the function of the left-hand and right-hand control levers. See “Left-hand control l eve r ” a n d “ R i g h t - h a n d c o n t r o l l eve r ” i n t h e “Controls/Instruments/Accessories” Section. This decal is inside the cab on the right window.

KHP1531

Figure 10

This decal advises to engage the function cancellation lever when leaving the cab for any reason. The decal is located inside the cab on the right window.

2-14

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CHAPTER 2 - SAFETY AND DECALS

4

Figure 12

16148A1

STANDARD PEDALS WITH SINGLE PEDAL TRAVEL P9290008A

Figure 13

4

KHP1533-00

Figure 14

This decal warns of the hazard associated with rotating parts and components.

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CHAPTER 2 - SAFETY AND DECALS

5 5

Figure 15

383972A1

This decal instructs the operator to use diesel fuel only.

Figure 16

KHP1013

6 6

P9290004

Figure 17 Figure 18

KHP1542-00

This decal states cautions when removing the hydraulic tank cap, the hydraulic pressure should be first relieved.

See “Releasing pressure” in the hydraulic system.

2-16

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CHAPTER 2 - SAFETY AND DECALS

7 7

Figure 19

P929006A

KHP1534-0

Figure 20

This decal warns of hot fluid under pressure hazards when removing the radiator cap.

8 8

Figure 21

BD01E065

KHP1536

Figure 22

This decal warns of hazards associated with servicing batteries or jump starting.

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CHAPTER 2 - SAFETY AND DECALS

Figure 24

BD02D097

This decal warns the operator of slippery surfaces.

KHP1013

Figure 23

This decal warns of a falling hood if not properly locked.

2-18

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CHAPTER 2 - SAFETY AND DECALS This decal warns of danger and to keep clear of swing upper structure to prevent serious bodily injury.

Figure 25

BS00M141

Figure 26

1P2240

This decal warns of the danger of standing too close to a machine that becomes electrified.

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CHAPTER 2 - SAFETY AND DECALS

BS00M134

Figure 27

This decal warns the operator that grease may be under heavy spring pressure. Pressure must be released before disassembly.

2-20

Figure 28

KHP1015-00

This decal reminds the operator proper procedures for checking the hydraulic oil level.

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CHAPTER 2 - SAFETY AND DECALS

Figure 29

KHP1360

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

9

Figure 30

KHP1538

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

9

Figure 31

P*92900200A

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

Figure 32

BI97D059

START THE ENGINE

COME TO ME

Wave hands back and forth (palms inward)

2-22

STOP THE ENGINE

Figure 33

BP97D022

Figure 34

BI97D025

BP97D023

FIGURE 35

MOVE AWAY FROM ME

Wave hands back and forth (palms outward).

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Figure 36

BP97D030

GO THIS FAR

ALL STOP AND HOLD

Figure 37

BI97D029

BI97D021

STOP

Move both hands back and forth.

BI97D028

FIGURE 38

RAISE LOAD OR TOOL

Issued 06-06

FIGURE 40

EMERGENCY STOP

Move one hand back and forth

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Figure 39

BP97D060

Bur

BI97D027

FIGURE 41

LOWER LOAD OR TOOL

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CHAPTER 2 - SAFETY AND DECALS

Figure 42

BI97D020

RAISE LOAD OR TOOL SLOWLY

LOWER LOAD OR TOOL SLOWLY

Figure 43

BI97D034

Figure 45

BI97D026

BI97D033

FIGURE 46

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

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

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

BP97D057

BI97D055

FIGURE 44

RAISE BOOM

2-24

FIGURE 47

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CHAPTER 2 - SAFETY AND DECALS

BI97D041

FIGURE 48

BI97D032

RETRACT ARM

EXTEND ARM

BI97D054

FIGURE 49

FILL TOOL

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FIGURE 50

BI97D031

FIGURE 51

EMPTY TOOL

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NOTES

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 STEPS AND ACCESS HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 FUNCTION CANCELLATION LEVER AND SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 OPERATOR’S COMPARTMENT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 RIGHT-HAND CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 LEFT-HAND CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 SYSTEMS DISPLAY AND CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 ANTI-THEFT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 ARM AND UPPER STRUCTURE SWING CONTROL LEFT-HAND CONTROL LEVER . . . . . . . . . . . . . . . . . 3-23 BOOM AND BUCKET CONTROL RIGHT-HAND CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 OPTIONAL CONTROL PATTERN ARM AND UPPER STRUCTURE SWING LEFT-HAND CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 OPTIONAL CONTROL PATTERN BOOM AND BUCKET RIGHT-HAND CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 TRAVEL CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 CAB FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 AUTOMATIC TEMPERATURE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 LOWER FRONT WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 REAR WINDOW AND EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 TOWING HOLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 LOAD LIFTING EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 LOAD HOLDING CONTROL VALVES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 AUXILIARY HYDRAULIC VALVES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

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NOTES

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INSTRUMENT/CONTROLS

1 3 Figure 1

CD00E002

CD00E004

Figure 3

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

WARNING: Be careful not to catch your hand or anything in the door when closing it.

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

2

Figure 2

CD00E003

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

STEPS AND ACCESS HANDLES

Figure 4

CS01B542

To get on or off of the machine use the steps and hand holds.

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

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

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 leaving the machine or upper structure, always face the machine and use the steps and access handles.

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FUNCTION CANCELLATION LEVER AND SAFETY BAR

2

2

1

1

Figure 5

CD00E005

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

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

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

CD00E006

Figure 6

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

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

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

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OPERATOR’S COMPARTMENT CONTROLS WARNING: Before starting the engine, make sure that you are fully aware of the location of and the function of each control. Incorrect operation of the controls can cause serious injuries.

1

2

3

4

5

6 17

16

7

8

15 9

14 10 13

11 12 Figure 7

CS00E501

3-6

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 1. Systems display and control panel 2. Cab interior lighting 3. Right-hand control arm tilt adjustment lever 4. Operator’s seat 5. Rear window opening system 6. Air vents 7. Left-hand control arm tilt adjustment and function cancellation lever 8. Function cancellation lever 9. Left-hand control arm 10. Left-hand control lever, arm and upper structure swing controls, horn 11. Safety bar 12. Foot rest 13. Left-hand travel control pedal and lever 14. Right-hand travel control pedal and lever 15. Single pedal travel pedal 16. Right-hand control arm 17. Right-hand control lever, boom and bucket controls, engine idle

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RIGHT-HAND CONTROL ARM 1. CONTROL ARM TILT ADJUSTMENT LEVER - This lever enables the operator to tilt the angle of the control arm to suit his convenience. Raise the lever 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 shut-down) and “ACC” (accessory current supply). See “Starting the engine” in the “Operating Instructions” Section.

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

NOTE: The starter switch 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 allows engine speed to be increased or lowered. 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. See “Heating and ventilation or air conditioning controls”.

5. ENGINE IDLE SPEED SELECTOR - This control makes it possible to select automatic engine idle speed manually or automatically, without having to return to the engine throttle button. To select idle speed manually, press and release the control for the engine automatically to go into idle speed; 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”.

3-8

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5

3

2 1

4

Figure 8

CS00E502

RIGHT-HAND CONTROL ARM

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

4 3

1 5

2

6 7 8

Figure 9

BS00K047

LEFT-HAND CONTROL ARM

3-10

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

LEFT-HAND CONTROL ARM 1. CONTROL ARM TILT ADJUSTMENT AND FUNCTION CANCELLATION LEVER - This lever makes it possible for the operator to adjust the tilt angle of the control arm to suit his convenience. 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 makes it possible for the operator to cancel the machine 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 operate the horn, press the tip of the left-hand control lever.

IMPORTANT: Always sound the horn before operating the machine.

5. ASHTRAY - Pull the ashtray upwards to empty it 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 upper structure swing function. A message is displayed in the “ON” position. See “Systems display and control panel) and priority is given to boom raising. In the “OFF” position, boom raising and upper structure swing function are normal.

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

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

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.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

SYSTEMS DISPLAY AND CONTROL PANEL 6 4

5

2

1

3

Figure 10

BD00J056

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.

NOTE: Wipe the display panel with a soft, dry cloth. Do not use water or solvents.

1. TRAVEL SPEED SELECTOR - This is a push button for changing from high speed to low speed and low to high. A confirmation message appears on the indicator (4).

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

Low speed (I), 0 to 2.9 km/hr (0 to 1.8 mph) Select this speed to travel on slopes, rough ground or soft terrain.

High speed (II), 0 to 4.3 km/hr (0 to 2.6 mph) Select this speed to travel on hard, flat ground in good terrain conditions.

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

NOTE: When the hydraulic system is overloaded and the machine is in 2nd speed, the machine automatically 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 push button allows one of three working modes to be selected. “S” (standard) mode for ordinary duties; “H” (heavy) mode for hard work or when there is an increase in work load and “L” (lift) mode for precision work requiring lower operating speed. Confirmation of the mode selected is displayed on the indicator (5).

NOTE: The selector will not function when “Auto” mode (3) is selected.

NOTE: When starting the engine, “S” (standard) mode is automatically selected.

3. AUTOMATIC WORKING MODE SELECTOR - This button when pushed, makes it possible to obtain automatic selection of the working mode which will ensure the best savings in fuel consumption. The confirmation (Auto) will be displayed on the indicator (5). Press the button again to come out of “Auto” mode, “H” (heavy) mode will then automatically be selected.

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4. TRAVEL SPEED INDICATOR - This indicator displays a sign showing the travel speed selected with Button 1.

Slow speed, (I), 0 to 2.9 km/hr (1.8 mph). High speed, (II), 0 to 4.3 km/hr (2.6 mph).

5. WORKING MODE INDICATOR - This indicator shows the initial of the working mode selected by the button (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” (lifting) mode.

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

NOTE: When starting the engine and also when coming out of “Auto” mode, “S” (standard) mode is automatically selected.

6. ENGINE IDLE SPEED INDICATOR - This indicator displays the type of engine idle speed selected with the control on the right-hand control lever. See “Right-hand control lever” (item 5).

• “ON”: automatic selection.

• “OFF”: manual selection.

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7

8

9 Figure 11

CD00E008

7. ENGINE COOLANT TEMPERATURE INDICATOR - Temperature changes are reflected by an increase or decrease in the number of luminous horizontal bars. Zone “C” indicates that the engine coolant temperature is low. If the luminous 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 - Temperature changes are reflected by an increase or decrease in the number of luminous horizontal bars. Zone “C” indicates that the hydraulic fluid temperature is low. If the luminous horizontal bars reach zone “H”, the audible alarm device sounds and the message “Over Heat” is displayed (see item 10). Idle the engine, and allow the machine to cool down. Remove the starter switch key and find the cause of the problem.

9. FUEL LEVEL INDICATOR - The quantity of fuel is represented by the number of luminous horizontal bars.

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).

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

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10 Figure 12

CD00E009

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

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

ENG. PRE HEAT - This message shows that the engine needs preheating and that the “glow plug” is functioning. The length of time this message remains is dependent on the coolant temperature. As soon as the engine reaches starting temperature, the audible alarm device will sound.

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

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

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.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

10 Figure 13

CD00E009

(10) MESSAGE DISPLAY SCREEN

LOW COOLANT - This message shows that the engine coolant level is low. The audible alarm device also sounds. 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 the “Lubrication/Filters/Fluids” Section.

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

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

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

The audible alarm device also sounds. Reduce engine speed. If the temperature does not drop, shut 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 also sounds.

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

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

ENGINE AIR FILTER - The message shows there is a restriction in the engine air filter. The audible alarm will sound. Air has been restricted and requires immediate service. Shut down the engine, and remove the starter switch key. See the “Lubrication and Maintenance” Section 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 9) under “Left-hand control arm”.

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

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11

13 12

14

Figure 14

BD00J057

11. AUDIBLE ALARM DEVICE CUT-OUT CONTROL, DISPLAY LAMP AND INDICATOR TEST- Press this control to turn off the audible alarm device. If the audible alarm device 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. UPPER STRUCTURE SWING LOCKING SWITCH - This switch is used to lock the swing function. When the switch is pressed, the upper structure swing function will be locked and the “Upper structure 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.

13. EMERGENCY SHUT DOWN SWITCH - This switch is used to shut down the engine in a case of emergency or if it is not possible to stop the engine using the starter switch 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.

14. WORKING LIGHTS - This switch is used to operate the working lights. Press the switch to turn the indicator lamp and the working lights on. Press the switch once more to turn them off.

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3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS

15 17

18

16 Figure 15

BCD00E011

15. WINDSHIELD WIPER SWITCH - This switch has three positions: “Off”, “Intermittent” and “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 for the function to cease.

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 down the switch to operate the windshield wiper and windshield washer. Release the switch for the function to cease.

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

17. ATTACHMENT CUSHION CONTROL SWITCH (boom and arm) - This switch makes it possible to select one of two different types of attachment operation. When the lamp in 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 control (with the lamp off) is automatically selected.

18. FREE SWING BUTTON -This button has two positions, ON and OFF. When the engine is started, Free Swing is OFF. Push and release the button for the ON position (indicator lamp illuminates). Free Swing allows the upper structure to coast to a stop. This feature is useful when lifting loads to allow the upper structure to center over the load and prevent the load from swinging when raised.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

19

20 Figure 16

CD00E011

19. HOURMETER -The hourmeter displays the total time that the engine has been operated, in hours and tenths of an hour. It also enables service operations to be scheduled (see the “Servicing Intervals” Section).

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

20. TRIP CONTROL (specific number of hours) - This control enables the operator to record a specific number of operating hours. Press the control for the hourmeter to read zero and for the message “Trip” 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 reading, press the control and release it immediately. To cancel the specific number of hours display, press the control for about 2 seconds and the specific number of hours reading will return to zero.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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 has to activate the system for it to be operational.

Once this operation has been performed, a special access code has to be entered each time you start the engine.

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

SETTING THE CODE 1. Place the starter switch key in “ON” position.

3

Figure 19

CD00E077

Figure 17

CD00E077

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

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

4. To finish entering the code, place the starter switch key in “OFF” position.

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

2

Using the anti-theft device

1

CD00E078

Figure 18

2. To enter the code (e.g. 1234) press button (1) the same number of times as the digit selected (e.g. once), then press button (2) to proceed to the second digit. Press the button (1) same number of times as the second digit (e.g. twice) and then press button (2) to proceed to the third digit.

Repeat the procedure for the third and fourth digits.

3-20

The anti-theft device has to be actuated 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 to start the engine you will have to enter the access code.

You are not obliged to activate the anti-theft device. If you so wish, when shutting down the engine, simply place the starter switch key in the “OFF” position, and it will not be necessary to enter the access code to start the engine.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ENTERING THE ACCESS CODE If the anti-theft device was activated the last time the engine was shut down, then it will be necessary to enter the access code before being able start it again.

3

1. Place the starter switch key in the “ON” position.

CD00E078

Figure 22

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

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.

Figure 20

CD00E077

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

2

1 CD00E079

Figure 21

CD00E078

2. To enter the code (e.g. 1234), press button (1) the same number of times as the digit selected (e.g once) then press button (2) to proceed to the second digit. Press the button (1) same number of times as the second digit (e.g. twice) and then press button (2) to proceed to the third digit.

Repeat the procedure for the third and fourth digits.

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Figure 23

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 3.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

ARM AND UPPER STRUCTURE SWING CONTROL LEFT-HAND CONTROL LEVER 1 9

4

3

2 SWING LEFT

ARM OUT

3

1 SWING RIGHT

ARM IN

2

4 Figure 24

BC00J123

1.Arm out

3.Swing left

2.Arm in

4.Swing right

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

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

BOOM AND BUCKET CONTROL RIGHT-HAND CONTROL LEVER 5 9

7

8

6 BUCKET CLOSE

BOOM DOWN

7

5 BOOM UP

BUCKET OPEN

6

8 Figure 25

BC00J122

5.Boom down

7.Bucket close (retracts)

6.Boom up

8.Bucket open (extends)

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPTIONAL CONTROL PATTERN ARM AND UPPER STRUCTURE SWING LEFT-HAND CONTROL LEVER 1 9

4

3

2 BOOM DOWN

SWING LEFT

3

1 BOOM UP

SWING RIGHT

4

2

Figure 26

BC00J125

1.Boom down

3.Swing left

2.Boom up

4.Swing right

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

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPTIONAL CONTROL PATTERN BOOM AND BUCKET RIGHT-HAND CONTROL LEVER

5 9

7

8

6 ARM OUT

5

BUCKET CLOSE

7

ARM IN

6

BUCKET OPEN

8

Figure 27

BC00J124

5.Arm out

7.Bucket close (retracts)

6.Arm in

8.Bucket open (extends)

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

TRAVEL CONTROL LEVERS AND PEDALS

Figure 28

BD00M485

Figure 29

BD00M485

TRAVEL CONTROL LEVERS

TRAVEL CONTROL PEDALS

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

IMPORTANT: Travel speed either forwards or in reverse depends on the position of the travel speed selector. See “Systems display panel” (item 1).

IMPORTANT: The movements of the machine are shown in the “Control functions” decal. See “Decals” in the “Safety/Decals/Hand signal” Section.

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

FOOT RESTS

BD00M485

ATTACHMENT OPTION CONTROL

Figure 30

FOOTREST

Figure 32

CD00E005A

HYDRAULIC OPTION CONTROL

SINGLE PEDAL TRAVEL

BD00M485

Figure 31

THIS PEDAL IS FOR SINGLE PEDAL TRAVEL

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB FEATURES CIGARETTE LIGHTER

CAB LIGHT

RD00K032

Figure 33

CD00E013

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

COAT HANGER

Figure 36

The cigarette lighter (24 volt) is to the right at the rear of the cab.

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

FUSE BOX

BD00E059

Figure 34

CD00E013

This hook is on the right-hand cab upright.

AUXILIARY POWER SUPPLY (OPTIONAL)

Figure 37

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 the “Electrical system” Section.

CAB DOOR SLIDING WINDOWS

Figure 35

RD00K032

Optional 12 Volt, 10 amp auxiliary power supply.

RD00K032

Figure 38

When the locks are released, the windows can be opened and closed to the left/right as required.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ROOF HATCH

CD00E015

SUN SHIELD

Figure 39

To open the roof hatch, turn the handle and push the hatch upwards. To close the roof hatch, pull the handle.

Figure 42

CD00E018

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

STORAGE COMPARTMENT

IMPORTANT: Since roof hatch closing is assisted by two gas struts, simply follow through the closing movement without “forcing” the strut.

STORAGE TRAYS

Figure 43

CD00E017

L o c a t e d b e h i n d t h e o p e r a t o r ’s s e a t , t h i s compartment is used, among other things, for storing the machine’s technical documentation.

BD00J048

Figure 40

CAB RADIO COMPARTMENT

CD00E032

Figure 41

BD00J048

Figure 44

A 24 volt radio is located on the rear right-hand side of the operator’s seat. A CD player, or similar electronic device, can be mounted below the radio in the pre-cut space provided.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

6

3

9

7

2 4 8

1

5

Figure 45

CD00E033

1. On/Off

6. Air recycling

2. Automatic

7. Air flow direction control

3. Air conditioning

8. Windshield defroster

4. Fan Speed

9. Display screen

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

ON/OFF

FAN SPEED

9

4 1 Figure 46

CD00E048

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

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

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CD00E048

Figure 47

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR FLOW DIRECTION

TEMPERATURE

9

9 7

5 Figure 48

CD00E049

Figure 50

CD00E050

These push buttons (5) allow the temperature to be adjusted within an 18° to 32° C (64° to 89° F) range.

To increase the temperature, press the right-hand button. To lower the temperature, press the left-hand button. The temperature reading will appear on the display screen (9).

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

- Via the top front air vent.

- Via the top front and rear air vents.

- Via the top and lower rear air vents.

- Via the lower rear and wind shield air vents.

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

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

AIR RECYCLING

6

WINDSHIELD DEFROSTER

9

9

CD00E050

Figure 49

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

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

8 Figure 51

CD00E050

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

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR CONDITIONING

MANUAL

IMPORTANT: When using the air conditioning, it is essential for all the operator’s compartment windows, the windshield and the cab door to be kept closed.

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

6

3

9

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

AUTOMATIC

7

5 9

CD00E49

2

4 Figure 53

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).

5

TEMPERATURE AND LIGHT SENSOR

1 Figure 52

CD00E049

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

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

CD00E051

Figure 54

The temperature and light sensor 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.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR VENTS

CD00E052

Figure 55

CD00E017

Figure 56

The air vents are located to the front and rear of the operator’s compar tment, 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.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

8

7

9

4 3

1

5

2 6

Figure 57

BD00J066

SUSPENSION ADJUSTMENT

AIR SUSPENSION ADJUSTMENT (OPTIONAL)

1

Figure 58

CD00F010

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

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CD00F010

Figure 59

Pull the lever forward to obtain softer suspension.

Push the lever backward to obtain firmer suspension

3-33

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BACK ANGLE ADJUSTMENT

FORE/AFT ADJUSTMENT

2 4

Figure 60

CD00F010

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

SEAT POSITION ADJUSTMENT

Figure 62

CD00F010

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

WARNING: Before tilting the seat back forward, it is essential for the arm rests to be in raised position to prevent them from contacting the control levers.

LUMBAR SUPPORT ADJUSTMENT

3

CD00F010

Figure 61

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

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

5 Figure 63

CD00E030

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.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT AND CONTROL ARM ASSEMBLY FORE AND AFT ADJUSTMENT

HEADREST ADJUSTMENT

8 6

Figure 66

CD00E031

Figure 64

CD00F010

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

ARMREST ANGLE 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.

SEAT BELT

9

7 Figure 65

CD00E031

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

CD00E032

Figure 67

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).

IMPORTANT: Inspect the seat belt. Make certain there is no damage, that the mounting screws are correctly tightened. If any damage is visible, replace the seat belt and/or 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.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

OPENING

Figure 70

CD003047 CD00E039

Figure 68

Push to the rear until the wind shield engages.

Pull the right-hand latch back into the hold slot, as indicated by arrow.

Figure 71

CD00E019

Engage the right-hand latch in the cab upright.

BD01K040

Figure 69

Pull the release lever and hold the upper and lower handles while raising the windshield.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CLOSING

CD00E047

CD00E019

Hold both handles and carefully lower the wind shield. Make sure the window is completely down and latched at the top.

Figure 72

CD00E023

CD00E019

Release the right-hand latch.

CD00E020

Figure 73

Use the lever to release the windshield.

Figure 74

Make sure the top of the windshield is correctly latched.

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

Figure 75

CD00E021

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

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CD00E022

Figure 76

Place the window in the storage position provided to the left of the operator’s seat and then lock it in place using the storage clips.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

REAR WINDOW AND EMERGENCY EXIT OPENING

2

1 Figure 79

CD00E026 CD00E24

Figure 77

Pull the handle upwards.

To open the window completely, release the pin (2) from the locking studs (1).

NOTE: The window can not be fastened in this position.

CD00E025

Figure 78

Push back the handle to open the window for ventilation.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CLOSING

1

2

CD00E024

Figure 80

CD00E026

Figure 81

Fold the handle back into position.

Press the locking studs (1), bring the pin (2) into its housing and then release the studs.

Figure 82

KHP1360-00

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE DOORS Use the outside handles to open the doors. To hold the doors, open, remove the struts from their storage position and install them in the holes provided. When closing, put the struts back into storage position.

WARNING: Always install the struts when doors are open.

RIGHT-HAND DOORS

LEFT-HAND DOORS

CD01N017

Figure 83

The starter switch key will lock and unlock the side doors.

The left hand doors give access to the air filter, the batteries, and certain hydraulic components.

Figure 85

CD01K054

The right hand door gives access to a number of hydraulic components (pump, filters, etc.), the s e l f - d e t a c h i n g c o u n t e r we ig h t c o n t r o l b ox ( i f equipped), as well as the hydraulic reservoir gauge.

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

WARNING: Never leave tools or other objects behind the side doors.

CD01N018

Figure 84

To open the right side of the LH door, remove the two retaining bolts.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS REAR VIEW MIRRORS

FRONT STORAGE BOX

Figure 86

CD01K053A

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

CD00E036

Figure 88

Rear view mirrors are located on both the cab and the upper structure. Before undertaking any travel, make sure the rear view mirrors are clean and properly adjusted.

Figure 87

CD01K053B

Use the handle to release the toggles, open the storage box and tilt the cover completely upward. To close, raise the door slightly, pull back the support strut and lower the cover.

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

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

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3-41

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FUEL TANK Use the starter switch key to lock the cap.

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

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

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

CD01K024B

WARNING: Never refill the fuel tank when the engine is running. Never smoke during refuelling.

Figure 89

The fuel tank capacity is 900 liters (237 gal).

NOTE: Clean around the fuel cap before refuelling, and do not remove the screen located in the filler orifice.

See “Fuel tank filter” in the “Maintenance/Adjustments” Section.

Figure 90

CT05L002

The fuel tank is equipped with a maximum level gauge.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

ENGINE HOOD Opening

CLOSING

Figure 91

CD01K058

To open the hood, pull the handle to release the toggles. Raise the hood completely until the strut locks into position.

Figure 93

BD01K059

Raise the hood slightly, pull the strut back and then lower the hood and close it.

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

NOTE: To lock the hood, lock the front fastener with the starter switch key.

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

Lower Panels

Figure 92

BD01K057

The rod must be locked into the slot as shown.

CT05L003

Figure 94

These panels are located under the upper structure f r a m e a n d g i ve a c c e s s t o c e r t a i n m a c h i n e components.

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB PROTECTION (FOPS)

WINDSHIELD WASHER RESERVOIR

CT05L004

Figure 95

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

Figure 96

CT04D008A

It is essential that the cab protection is used when work takes place in areas where there is a danger of falling stones or debris. If the machine was not originally equipped with this protection, see your CASE Dealer for its installation.

Remove the cap to fill the reservoir.

The reservoir can be lifted out of its support.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

TOWING HOLES WARNING: Towing is always carried out at the risk of the user. The manufacturer’s warranty does not apply to any incidents or accidents which may occur during towing.

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

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

Figure 97

CD00E069

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

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

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

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

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

Figure 98

BD00J053

WARNING: Never weld hooks or lugs on the bucket for load handling operations. The only attachment point which may be used is the bucket lifting eye.

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LOAD HOLDING CONTROL VALVES (OPTIONAL)

AUXILIARY HYDRAULIC SELECTOR BLOCKS (OPTIONAL)

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

Figure 100

CT06D008

CT06D007

Figure 99

The role of the load holding valve is to stop the attachment from dropping due to valve spool leakage in neutral position or in the event of a line or hose breaking. In the latter event, the holding valve also ensures that the attachment may be lowered gently to the ground. See “Load handling” in the “Operating Instructions” Section.

These blocks, located on the upper structure at the bottom of the boom make it possible to select the correct hydraulic circuit for an auxiliary attachment to be used. Never alter the main relief valve setting unless you first consult your CASE Dealer, as you could damage the machine.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

WARNING: Cylinder mounted load holding control devices are pilot operated devices.

The operator MUST return the control lever to the neutral position to prevent the attachment and load from falling in the event a hydraulic hose or line fails.

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AUXILIARY HYDRAULIC VALVES (OPTIONAL)

Figure 101

A24690

Located on the end of the arm, these two valves are used to ensure oil supply to auxiliary attachment such as a hydraulic hammer. These valves have two positions.

CD00E055

Figure 104

1. Using a hexagonal wrench, place the supply valves in “O” position (open).

CD00E057

Figure 105

2. Remove the snap ring.

Figure 102

CD00E056

Position “S” (closed): In this position, there is no supply of oil to the tool.

CD00E058

Figure 103

RD00K032

Figure 106

3. Remove the locking plate, and then reinstall it, turning it a quarter of a turn so that the notch is over the locking pin. Install the snap ring.

Position “O” (open): In this position, oil is supplied to the tool.

The valves can be locked in open position “O”.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS C O U N T E RW E I G H T (OPTIONAL)

R E M OVA L

DEVICE

COUNTERWEIGHT REMOVAL DEVICE CIRCUIT SUPPLY VALVE (OPTIONAL)

1 2 3

CD01D035

Figure 107

1. ON/OFF 2. RAISE/LOWER 3. UP/DOWN

Figure 108

CD01D036

This valve is used to supply or shut off the flow of oil to the self-detaching counterweight circuit.

See “Self-detaching counterweight” in the “Operating Instructions” Section.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Anti-vandal Guard (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 MACHINE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 LIFTING LOADS WITH THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 OPERATING THE MACHINE IN WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 OPERATING THE MACHINE ON SLOPING GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 OPERATING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 COUNTERWEIGHT REMOVAL DEVICE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 AUXILIARY HYDRAULICS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

By Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 On A Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

RUN-IN PERIOD OF A NEW MACHINE ENGINE OPERATION During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following: 1. Operate the machine with normal loads for the first eight hours. Do not work the engine hard up to stall speeds 2. Keep the engine at normal operating temperature.

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

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

SB055

BEFORE OPERATING THE MACHINE WARNING: Do not attempt to operate this machine unless you have first read and perfectly understand the safety messages and instructions appearing in this manual.

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

• Check the level of all fluids (engine oil, hydraulic

• Check that no tools or other items have been left

fluid and coolant), and make sure that the fluids and lubricants are suitable for prevailing conditions. See “Fluids and Lubricants” in the “Lubrication/Filters/Fluids” Section and “Operating the machine in cold weather”.

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

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

• Inspect the machine, look for any signs of wear,

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

• Make sure no one is on or under the machine. The

damage, leakage and check the hoses. Tighten or replace as necessary. See the “Maintenance/ Adjustments” Section.

• Make sure no one is standing in the machine

• Check the track assemblies. See “Tracks” in the

• Find out about current safety measures in use on

“Maintenance/Adjustments” Section.

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

• Clean the steps and hand holds. Grease, oil, mud

operator must be alone on the machine. working area. the work site.

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

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

• When operating the machine, be sure to do the

• Clean or replace any decals which are illegible.

• When starting the engine, be sure to use the

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

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

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

• Remove any obstructions which hinder visibility.

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

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following: correct procedure for the prevailing weather conditions. See “Starting the engine”.

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

See “Service intervals”.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

• Keep all parts of the machine a minimum of 15 feet (4.57 m) away from the power source.

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

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

• Modify your driving to suit the type of work and working conditions. See “Operating Instructions”.

• Do not allow anyone to stand in the machine working area. Stop all operations until everyone has moved away.

• Operate all controls gradually to ensure smooth machine operation.

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

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

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

• See “Towing the machine” when it is necessary to tow the machine.

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

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

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

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

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

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

consideration.

See

• See “Parking the machine” when you have to park the machine OPERATING INSTRUCTIONS

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

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

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

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

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

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

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

• The following operations are likely to damage the machine. 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.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

• When climbing up a slope, place the bucket about 250 mm (10 inches) above the ground. When traveling 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 upper structure on slopes of 15° in the direction of travel or 10° at right angles to the direction of travel.

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

ENGINE OPERATION WALK-AROUND INSPECTION Do the following items each day before you start the engine.

1. Check for leaks under the machine.

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

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

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

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

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

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

STARTING THE ENGINE NOTE: If the weather is cold, if the machine has not been run for several weeks, or if the engine oil filter has been replaced, see Priming the Turbocharger Lines with Oil in this manual.

1. Adjust the seat and fasten your seat belt. Make sure you can push the pedals completely down with your back against the seat cushion.

2. Make sure the parking brakes are engaged by pulling both levers all the way back.

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

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

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

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

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

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

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

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

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

2. Lower the attachment to the ground.

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

3. Place the Direction Control Levers in NEUTRAL.

5. Check all instruments are operating correctly.

5. Run the engine at low idle speed for a few minutes if the engine has been working with a heavy load. This decreases the temperature of the engine parts evenly.

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

7. Unlock the upper structure swing function.

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

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

4. Engage the parking levers by pulling them all the way back to the engaged position.

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

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

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

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

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

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

SA044

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand holds and steps, and get on or off the machine slowly.

SA038

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CHAPTER 4 - OPERATING INSTRUCTIONS ANTI-VANDAL GUARD (OPTIONAL)

1

Figure 1

A23919

1. Release the two storage clamps and remove the guard from the top of the cab.

2. Remove the two bolts from the front of the cab.

Install the anti-vandal guard and install the two bolts.

2

BD00M214

Figure 4

IMPORTANT: Place the four bolts that hold the lower section in place into the bosses BEFORE taking this section topside.

5. Place the lower section onto the upper guards u s i n g t h e fo u r b o l t s s h ow n a n d t h e s l o t s provided.

2

Figure 2

BD00M212

3. Use the four bolts on the lower section to install it on the bottom of the front cab as shown.

BD00M215

Figure 5

6. Vandal guards in storage position.

5

Figure 3

BD00M213

4. To secure the vandal guards on the top of the cab, first attach the upper covers using the bolts and slots provided. The two longest bolts, which secure the upper guards, (shown) will be used to secure the lower section to the top.

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

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

WARNING: This engine is equipped with a glow plug; use of a starting fluid can cause explosion, personal injury or property damage.

CD00E005

Figure 6

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

Figure 8

CD00E005

4. Sound the horn on the left-hand control lever to give war ning of your intention to star t the machine.

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

Figure 9

CD00E060

CD00E060

Figure 7

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

4-8

5. Turn the starter switch key to “ON” position. Do NOT turn the key to start without reading the “Systems display and control panel” to make certain the engine is ready to start.

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Figure 10

CD00E061

6. As soon as the audible alarm device sounds, the message will disappear, turn the key to the “START” position. Release the key as soon as the engine starts to run.

Figure 12

8. Run the engine until the “Auto warm up” message disappears from the systems display panel. See “Systems display and control panel” (item 10) in the “Controls Instruments Accessories” Section.

Figure 11

CD00E060

7. If the engine stops, wait about a minute and recommence the operation. 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.

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CD00E006

Figure 13

9. Lower the function cancellation lever (safety bar out).

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

4-9

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

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

Engine Automatic Warm-up

Hydraulic Oil Warm-up

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

Turn the engine throttle button to half-open position.

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

Engine Manual Warm-up With the engine throttle button a quarter open, start the engine, and allow it to run approximately for 5 to 1 0 m i n u t e s. W h e n t h e c o o l a n t t e m p e r a t u r e increases, carry out the hydraulic fluid warm-up procedure.

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

Continue the extending and retracting procedure until the temperature rises. See “Systems display and control panel” in the “Controls/Instruments/ Accessories” Section.

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

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

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

• Let the engine run at idle speed until the engine

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

and hydraulic oil reaches normal operating temperature.

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

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

2. There is no abnormal noise or vibration.

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

4-10

Check the systems display and control panel regularly.

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

• • • •

Sudden increase or decrease in engine speed.

Abnormal noise.

Black smoke at the exhaust.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN COLD WEATHER

OPERATING THE MACHINE IN HOT WEATHER

Cold weather conditions cause special problems.

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

Follow the recommendations made below:

Batteries and Electrical System

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.

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

3. Test the radiator cap before hot weather starts.

Replace the cap as required.

Fuel

6. Check the dust valve in the air cleaner frequently when operating in extremely dusty conditions.

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.

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

5. Check the condition of the fan drive belt.

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

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

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

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE

CD00E010

Figure 14

1. Press the upper structure swing locking switch on the control panel.

Figure 16

CD00E080

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

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

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

CD00E060

Figure 15

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

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

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

4-12

Figure 17

CD00E010

In the event of an emergency, or if it is not possible to stop the engine using the contact key switch, press the emergency shut-down switch on the control panel. The switch must be reset after use to shut down engine or engine will not restart.

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION OPERATING INSTRUCTIONS WARNING: Follow the operating instructions listed 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

• If earth or mud stays stuck inside the bucket,

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.

operate the bucket through it’s full range of travel several times so as to loosen the earth or the mud.

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

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

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

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

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

• Do not work close to a live overhead electric cable without first making sure that the following minimum distances are respected:

• Keep all parts of the machine a minimum of 15 ft (4.57 m) away from the power source.

• 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.

• 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.

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

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

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

• Always use caution when operating on a slope.

Try to keep the upper structure over the tracks.

Never swing the upper structure on a slope of 15 degrees or more in the same direction of travel.

Do not swing the upper structure at a right angle on a slope of 10 degrees or more.

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

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

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

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

4. Check all instruments are operating correctly.

5. Sound the horn.

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

7. Unlock the upper structure swing function.

8. Try out all the controls in a safe, open area with all other people clear of the machine.

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CHAPTER 4 - 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 upper structure. If the upper structure is turned 180° in relation to the undercarriage, travel control functions 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 following travel configurations described are with the travel reduction gears to the rear of the upper structure.

Traveling In A Straight Line (Forward)

GCS98M546

Traveling In A Straight Line (In Reverse)

Figure 18

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

BS00M167

Press the single travel pedal forward.

4-14

Figure 19

Figure 20

CS98M547

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

Figure 21

BS00M168

Press the single travel pedal rearward.

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

Turning To The Left (In Reverse)

Figure 22

CS98M548

CS98M549

Figure 24

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

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

Turning To The Right (Forward)

Turning To The Right (In Reverse)

Figure 23

CS98M551

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

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CS98M550

Figure 25

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

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS Turning On The Spot, To The Right

CS98M552

Gradual Turn On The Move

Figure 26

Figure 28

CS98M545

Press the left-hand pedal (or push the left-hand lever) forwards and at the same time press the right-hand pedal (or push the right-hand lever) rearwards.

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

Turning On The Spot, To The Left

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

CS98M553

Figure 27

Press the right-hand pedal (or push the right-hand lever) forwards and at the same time press the le ft- hand pe dal (or pu sh the left-ha nd lever) rearwards.

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CHAPTER 4 - OPERATING INSTRUCTIONS

LIFTING LOADS WITH THE MACHINE WARNING: This machine is not a crane. Use extreme caution when lifting loads. You or others in the area can be injured or killed if you do not follow the instructions that follow.

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

L Mode: Lifting capacities are increased in the L (Light/Lifting Mode). It is recommended that you use this mode when you lift loads. See the lifting chart in the cab of your machine. See the lifting capacity charts in this manual.

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

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

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

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

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.

Figure 29

BD00J053

FREE SWING CONTROL

LIFTING POINT - ATTACH RIGGING HERE

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

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

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

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

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

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

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

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

• Be careful to balance the load correctly.

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Figure 30

BD00J057

FREE SWING CONTROL

This button has two positions, ON and OFF. When the engine is started, Free Swing is OFF. Push and release the button for the ON position (indicator lamp illuminates). Free Swing allows the upper structure to coast to a stop. This feature is useful when lifting loads to allow the upper structure to center over the load and prevent the load from swinging when raised.

• Do not perform any work functions with the track in the transport position. The transport position is to be used only for machine transport. Keep the upper structure aligned with the track when in the transport position.

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CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN WATER

Figure 31

CS99A825

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

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

IMPORTANT: Do not operate in a fast flowing stream.

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

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

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.

• Use extreme caution on hillside operations.

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

EXCAVATING METHOD

PDH0493M

Figure 32

PDH0494M

Figure 33

CORRECT

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WRONG

WRONG

The bucket will dig in and cause a stall.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

PARKING THE MACHINE 1. Position the machine on flat, level ground, away from soft ground excavations and badly shored cavities.

2. Place the upper structure frame in line with the undercarriage with travel reduction gears at rear of upper structure. Retract the attachment and lower it to the ground.

Figure 36

CD00E060

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

CD00E010

Figure 34

3. Use the upper structure swing locking switch on the systems display and control panel and make sure the locking indicator lamp lights up on the display panel.

Figure 37

CD00E005

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

CD00E060

Figure 35

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

5. If desired, activate the anti-theft device. See “Anti-theft Device” in this manual.

Figure 38

CD00E002

WARNING: Never jump down from the machine. When leaving from the operator’s compartment, or from the upper structure, always face the machine, and use the steps and hand holds.

4-20

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

TOWING THE MACHINE Before attempting to tow the machine, consult your CASE Dealer.

Wherever possible, carry out any repairs at the site.

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

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

WARNING: The operator must be the only person on the machine when towing. Make sure that no other people are on the machine or within its working range.

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

CD00E111

Figure 39

CD00E060

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

Figure 41

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

Figure 40

CD00E006

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

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CHAPTER 4 - OPERATING INSTRUCTIONS SETTING THE TRACKS IN TRANSPORT POSITION WARNING: Narrow track gauge or transport position must not be used for any purpose other than transporting the machine.

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

1

Figure 42

CD01D140

1. Position the machine on firm, level ground. Keep people clear of the area when raising and slinging the machine.

2. Place the upper structure at right angles to the under carriage and lay the bucket flat on the ground.

Figure 45

CS01D570

5. Make certain all persons are clear of the machine. Start the engine.

6. Rest the attachment on the ground for support and use it to raise the track slowly so that it slides towards the inside of the undercarriage.

3. Remove the shields (1).

2

Figure 46

CS01D571

Figure 43

CD01D141

7. If the track does not slide freely press it up against a block to push it inwards.

8. Lower the track to the ground. Stop the engine.

9. Install 12 of the pieces of mounting hardware and tighten to a torque between 2550 to 2943 Nm (1880 to 2169 ft lbs).

2

10. Repeat Steps 3 to 6 for the other track.

WARNING: Turn the engine off performing any work on the track.

CD01D143

before

Figure 44

4. Remove the 24 pieces of mounting hardware (2).

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CHAPTER 4 - OPERATING INSTRUCTIONS SETTING THE TRACKS IN WORKING POSITION 1. Position the machine on firm, level ground. Keep people clear of the area when raising and slinging the machine.

2. Take the shields and spare pieces of mounting hardware out of the front storage box.

3. Place the upper structure at right angles to the undercarriage and lay the bucket flat on the ground.

CD01D141

Figure 47

CD01D142

4. Remove the 12 pieces of mounting hardware.

5. Protect the sling points.

CD01D143

Figure 49

8. Install the 24 pieces of mounting hardware and tighten to a torque between 2550 to 2943 Nm (1880 to 2169 ft lbs).

9. Repeat Steps 2 to 7 for the other track.

2

1

Figure 48

CS01D573

6. Sling as indicated above and then use the attachment to raise the track from the ground.

For safety, block the frame (2).

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

CD01D140

Figure 50

10. Install the shields.

WARNING: Turn the engine off performing any work on the track.

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before

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CHAPTER 4 - OPERATING INSTRUCTIONS

COUNTERWEIGHT REMOVAL DEVICE (OPTIONAL) IMPORTANT: When handling the counterweight:

• The machine must be on flat, hard, level ground.

Keep people clear of the work area.

1

• The upper structure must be in line with the

2

undercarriage with the travel reduction gears to the rear.

• The arm and bucket attachment must be retracted

3

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 inward position.

REMOVAL NOTE: Counterweight moving distance is 1.50 m maximum and 0.67 m minimum (59 inch maximum and 26 inch minimum), measured from the tracks.

Figure 53

CD01D035

5. Place the control box switch (1) in “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 in).

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.

10. Place switch (1) in “OFF” position.

BS02B048

Figure 51

1. Make certain there is nothing under the counterweight.

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 bolts holding the counterweight on the upper side.

Close the hood.

Figure 54

CD01D036

11. Close the supply valve.

12. Install the lower panel.

WARNING: DO NOT remain within the counterweight handling area under any circumstances.

CD01D036

Figure 52

4. Open the supply valve.

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CHAPTER 4 - OPERATING INSTRUCTIONS INSTALLATION 1. Position the machine and the counterweight on flat, hard, level ground.

2. Bring the machine to within 0.67 m (26 in) of the counterweight. Lower the cylinder and cable assembly to the ground.

Figure 55

VF01D036

3. Open the supply valve.

1 2 3 Figure 56

CD01D035

4. Place the control box switch (1) in “ON” position.

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

6. Fasten the hitching system to the counterweight.

7. Tilt the switch (3) towards “TOP” position, and bring the handling arm up against the rear upper structure plate.

8. Tilt switch (2) to “LOWER” position to engage the assembly.

9. 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.

The bolts should be tightened to a torque of 2256 Nm (1663 ft lbs).

11. Place switch (1) in the “OFF” position. Close the supply valve.

12. Install the lower panel.

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CHAPTER 4 - OPERATING INSTRUCTIONS

AUXILIARY HYDRAULICS (OPTIONAL) Your machine has two types of auxiliary hydraulic circuits. One circuit is for single flow equipment, such as hydraulic breakers. The second circuit is for single flow or double flow continuous flow equipment, or double flow equipment such as concrete crushers. Consult your CASE Dealer for instructions on how to select the correct pressure for the optional attachment.

NOTE: See the Breaker and Crusher Valve and Switch Settings decal inside the right rear cab window.

Hydraulic Breaker Configuration

Figure 59

BD01B374

Figure 57

A24690

1. Using a hexagonal wrench, place the supply valves in “O” (open) position. See “Auxiliary Hydraulic Valves” in the “Controls/Instruments/ Accessories” Section.

DOUBLE FLOW EQUIPMENT SWITCH

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

1

Figure 60

CD00E006

CD00E070

Figure 58

2. Remove the screw (1), place the flow selector valve in position (B) and then install the screw (1).

4-26

4. Use the hand control to operate the hydraulic breaker.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS Double Flow Concrete Crusher Configuration

Figure 61

CD00E082

5. When removing the hydraulic breaker, place the supply valves in “S” position (closed), and plug the orifices.

1. Using a hexagonal wrench, place the supply valves in “O” (open) position. See “Auxiliary Hydraulic Valves” in the “Controls Instruments Accessories” Section.

Figure 62

BD01B374

1

DOUBLE FLOW EQUIPMENT SWITCH

6. Tilt the control to the central position.

Figure 63

A24690

CD00E071

Figure 64

2. Make sure the selector blocks (1) and (2) are positioned as shown.

BD01B374

Figure 65

3. Tilt the control on the left-hand arm to the right for hammer operation.

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CHAPTER 4 - OPERATING INSTRUCTIONS

CD00E006

Figure 66

4. Use the hand control to operate the concrete crusher.

CD00E082

Figure 68

BD01B3741

6. Tilt the control to the central position.

Figure 67

5. When removing the concrete crusher place the supply valves in “S” position (closed) and plug the orifices.

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CHAPTER 4 - OPERATING INSTRUCTIONS Single Flow Concrete Crusher And Bucket Configuration

Figure 69

A24690

1. For the concrete crusher, use a hexagonal wrench to place the supply valves in O (open) position. See “Auxiliary Hydraulic Valves” in the “Controls/Instruments/Accessories” Section.

CD00E012

CD00E082

Figure 70

CD00E071

2. The flow selector block (1) should be in the C position.

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Figure 71

3. Use the hand control to operate the concrete crusher.

Figure 72

4. When removing the concrete crusher, place the supply valves in the “S” position (closed) and plug the orifices.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE

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

ON A TRAILER WARNING: 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: Attachment must be removed from machine prior to transporting. Keep upper structure of machine in alignment with track (lower structure).

WARNING: The counterweight MUST BE removed 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. The attachment must be removed from machine prior to transporting. Cap any hoses to prevent dust and contamination from entering any circuits. Keep upper structure of machine in alignment with track (lower structure).

Loading

CT02C196

Figure 73

1. Place a block behind the trailer wheels. Install the trailer side extensions (if fitted). Keep non-authorized personnel clear of the machine and trailer.

Figure 75

BD00K073

3. Select the automatic engine idle function, so position “ON” appears on the display screen.

v

Figure 76

BD00K073 CD00E010

Figure 74

4. Select slow travel speed.

2. Make sure the upper structure swing lock has not been applied.

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CHAPTER 4 - OPERATING INSTRUCTIONS Unloading 1. Keep non-authorized personnel clear of the machine and trailer.

2. Remove the blocks and fastening chains.

3. Start the engine.

4. Unlock the upper structure swing function.

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

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

Figure 77

CS001D582

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

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

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

6. Carefully move the machine to the front of the trailer, and swing the upper str ucture 180 degrees.

7. Lock the upper structure swing function.

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

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

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

Figure 78

CS99B518

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

IMPORTANT: Measure the distance between the ground and the highest point of the machine. You must know the overall height to assure safe and legal transport. See “Machine overall dimensions” in the “Specifications” Section.

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

Releasing Pressure In The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding Air From The Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding air from the hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir/Transmission Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7 5-7 5-7 5-7 5-7 5-7 5-7

LUBRICATION/FILTERS/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Daily/Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 10 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 100 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

GENERAL SAFETY BEFORE YOU SERVICE SERVICING INSTRUCTIONS WARNING: Before you begin any service or repair work you must know and understand how to relieve hydraulic pressure properly. Always have bucket and/or attachments down in safe positions.

General Information Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on firm, level ground, away from any obstacles with the bucket or attachment on the ground. Unless otherwise specified, all maintenance operations should be carried out with:

• • • • • • •

the engine stopped the parking brake engaged the key removed from the starter switch a Do Not Operate tag placed on the key switch all circuits cooled down before starting work all hydraulic pressure released with any accumulator pressure released for the appropriate circuit

• all non-authorized personnel clear of the machine operating area Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

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

When carrying out service work on the machine, place a Do Not Operate or warning tag on the instrument panel or key switch. Never climb down from the operator's compartment leaving the engine running.

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

Consult your Case Dealer.

The service intervals in this chapter refer to normal operating conditions. During the first operation period of a new machine or rebuilt component and under particularly severe conditions the service intervals should be carried out more frequently.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life. Use genuine Case replacement filters and oil for maximum service intervals.

IMPORTANT: Oils and fluids must be disposed of properly. Be aware of environmental issues.

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.

CE-NA000

WARNING: Before attempting any service procedures on the machine, it is your responsibility to know how many accumulators are on the machine and how to properly release pressure of each. Not releasing pressure properly can cause death or serious injury.

M959

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.

CE-NA000

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1. Park the machine on firm, level ground, lower the attachment to the ground and stop the engine.

Figure 4

CD00E080

5. Unscrew the hydraulic reservoir protective cap and remove it.

CD00E060

breather

Figure 1

2. Keep all non-authorized personnel clear of the machine. Turn the starter switch key to the “ON” position.

Figure 5

CD01N035

6. Press the button on top of the breather to release any residual pressure.

CD00E006

Figure 2

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

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

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 (104° F).

CD00E11

Figure 3

4. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the starter key to the OFF position.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

WARNING: Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap, and press the button on the breather to release all pressure in the system. Failure to observe these instructions can cause injury. See “Releasing pressure in the hydraulic system”.

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.

BLEEDING AIR FROM THE HYDRAULIC COMPONENTS

Hydraulic swing motors

Hydraulic pump

CT05L045

Figure 6

CT05L044

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.

Figure 7

Keep all non-authorized personnel clear of the machine.Start and run the engine at low idle speed.

Loosen the unions on the top of the swing motors to release any air.

Retighten the unions as soon as the fluid flows out of the ports.

After the warm up procedure is completed, move each control slowly several times to remove any air in the system.

Swing the upper structure evenly left to right two complete turns or more.

Bleed the second bleed plug hole at the same time.

Stop the engine, and wait five minutes.

Attachment cylinders

Check the oil level in the hydraulic reservoir, and add oil as required. Be certain there are no air bubbles in the hydraulic reservoir.

Keep all non-authorized personnel clear of the machine. 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 the end of stroke.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

ENGINE HOURMETER Service your machine at the intervals and locations g i ve n i n t h e L u b r i c a t i o n / M a i n t e n a n c e Q u i ck Reference Chart. When you service your machine, use only high quality lubricants.

Figure 9

CD00E073 A27274

Figure 8

Ask your dealer about our lubr icant analysis program, Systemgard®. Through this service, your lubricants are tested in an independent laboratory.

You simply remove a sample of lubricant from your machine and send the sample to the independent System gard ® lab orator y. After the sam ple is processed, the laboratory will report back to you and g u i d e yo u w i t h m a i n t e n a n c e r e q u i r e m e n t s .

Systemgard can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of equipment.

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the remaining numbers to the left display hours. Use the engine hourmeter along with the Lubrication/Maintenance Chart to service your machine at the correct time periods.

Engine hours are displayed with the key switch off or with the engine running.

The normal engine oil change interval is every 500 hours of operation. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended that you use the Systemgard® Lubricant Analysis program. See your dealer.

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change .................................................................................................... 52 Liters (13.7 gal.)

Specifications ...................................................................................................................... CASE AKCELA No. 1 FUEL TANK Capacity ..............................................................................................................................900 Liters (237.7 gal.)

COOLING SYSTEM Capacity ................................................................................................................................108 Liters (28.5 gal.)

Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDRAULIC RESERVOIR/TRANSMISSION REFILL Total system capacity ...........................................................................................................720 Liters (190.2 gal.)

Reservoir capacity..................................................................................................................310 Liters (81.8 gal.)

Specifications ........................................................................................................................Case Hy-Tran® Ultra TRAVEL REDUCTION GEARS Capacity - (per reduction gear) ...............................................................................................13.8 Liters (3.6 gal.)

Specifications ................................................................................................................................. Case 135 H EP SWING REDUCTION GEARS Capacity (per reduction gear)....................................................................................................4.7 Liters (1.2 gal.)

Specifications ............................................................................................................................... Case 135 H EP

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION/FILTERS/FLUIDS Lubricants must have the correct properties for each application.

IMPORTANT: The conditions for the use of individual fluids and lubricants must be respected.

HYDRAULIC FLUID

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)

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.

GREASE

Temperate climates

“Extreme Pressure” multipurpose grease with lithium soap and molybdenum disulphide.

-20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

CASE/AKCELA: MOLY GREASE 251H EP-M (NLGI 2)

CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2)

Hot climates

“Extreme Pressure” multipurpose grease with lithium soap and calcium.

0° C to +50° C

CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)

CASE/AKCELA: AW HYDRAULIC FLUID 68 HV

“Extreme Pressure” multipurpose grease with lithium soap.

( M S 1 2 1 6 . I S O VG 6 8 . D I N 5 1 5 2 4 PA RT 3 CATEGORY HVLP) Cold climates -25° C to +20° C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE LUBRICATION ENGINE OIL SELECTION API Service CI-4 Engine Oil is recommended for use in your Case Engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions.

If Case oil is not available, use only oil meeting API engine oil standards.

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

BD97F136

Figure 10

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below -5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear. See the chart below for the correct oil for ambient temperatures.

OIL VISCOSITY/TEMPERATURE RANGES

Figure 11

BC02N250

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS OIL CHANGE AND FILTER REPLACEMENT INTERVALS WITH HYDRAULIC ATTACHMENTS (OPTIONAL) Hydraulic Fluid When using the hydraulic attachments, hydraulic fluid deteriorates more quickly than during ordinary digging. The hydraulic fluid must be checked more frequently. In addition, when replacing the filters, also check the condition of the hydraulic fluid.

• Using the graph below, replace all of the hydraulic filters on the machine and change the hydraulic fluid, depending on the operation frequency of the hydraulic attachment.

• If the attachment is operated for a short period of time and the hourmeter exceeds 100 hours during that period, replace both auxiliary return filter and the hydraulic reservoir return filter every 100 hours of operation.

• Check the hoses, tubes, plugs, connectors and fittings each day for oil leaks. Also check the mounting bolts and nuts for looseness. Repair, replace, or tighten as required.

1

4

3

2 Figure 12

CS01B509

1.

2.

3.

4.

PERCENTAGE OF USE INTERVALS IN HOURS HYDRAULIC FLUID REPLACEMENT HYDRAULIC FILTER REPLACEMENT

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

As Required (AR)

Every 10 hours

6-15

Fan and air conditioning drive belt

5-42

Air filter

5-17

Fuel tank filter

6-3

Clean track

6-6

Steel track shoe bolt torque

AR

5-14

Engine oil level

10

drain

grease

replace AR

AR

AR

AR

AR

AR

5-15

Coolant level

10

5-16

Hydraulic reservoir level

10

5-15

Radiator and oil cooler

10

5-16

Fan/alternator belt tension

10

5-17

Fuel pre-filter purge

10

5-17

Bleed fuel filters

10

Every 50 hours 5-18 5-19

Attachment

50

Drain fuel tank sediment

50

5-19

Hydraulic system lines

5-20

Pilot filter

Run-in

5-21

Return filter

Run-in

5-22

Air conditioning

50 50 50 50

50

6-6

Track shoe bolt torque

Run-in

50

6-7

Bolt and nut torque

Run-in

50

7-3 Every 100 hours 5-24

Battery check

50

Hydraulic breaker return filter

5-25

Idler wheel and rollers

5-25

Drain hydraulic reservoir sediment

5-26

Fuel prefilter

5-27

Radiator and oil cooler - hoses & clamps

Every 250 hours 5-28

100 250 250 250 250

Swing reduction gear

Run-in

250

5-29

Travel reduction gears

Run-in

250

6-6

Track shoe bolt torque

250

6-7

Bolt and nut torque

250

6-8

Fan/alternator belt tension

250

7-5

Battery electrolyte level

250

Every 500 hours 5-30

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check

page

Service points

Intervals in hours

clean

Service intervals

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

Machine Grease Points

500

5-30

Turntable bearing

500

5-30

Turntable teeth

5-31

Engine oil

500

5-31

Engine oil filters

500

5-33

Fuel filter

500

500

5-33

Priming pump screen

6-8

Fan and Alternator Belt Tension

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500

5-11

Every 1000 hours

Every 4000 hours

Every 5000 hours

Attachment

1000

5-36

Self-detaching counterweight (optional)

1000

5-37

Draining and filling cooling system

5-39

Hydraulic fluid condition

5-39

Reservoir breather filter

5-40

Inlet Filter

5-41

Swing reduction gear

5-42

Travel reduction gears

5-43

Primary air filter element

5-43

Secondary air filter element Tappet clearances

drain

grease

replace

5-35

See your Case Dealer

Every 2000 hours

check

page

Service points

Intervals in hours

clean

Service intervals

INITIAL NEW MACHINE

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

1000 1000 1000 1000 1000 1000 1000 1000 1000

Alternator

1000

Starter motor

1000

5-45

Pilot filter

2000

5-46

Return filter

2000

5-47

Ultra Clean filter

2000

5-48

Swing reduction gear

See your Case Dealer

Fuel hoses

4000

Main pump output hydraulic hoses

4000

Boom/bucket cylinder hydraulic hoses

4000

5-49

Replacing inlet filter

5000

5-50

Hydraulic fluid

5000

5-51

Air conditioning (See your Case Dealer)

5000

2000

NOTE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message Service Due will appear on the screen by way of a reminder that service work is due. See “Systems display and control panel” in the “Controls/Instruments/Accessories” Section.

5-12

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DAILY/PERIODIC INSPECTION Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

General

• • • •

Check for signs of leaking oil or water.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator’s compartment, decals and warning labels).

Check for any signs of deterioration.

Engine

• • • • • • •

Check the oil level, and change the oil if necessary.

Check the coolant level.

Check the radiator for signs of clogging or deterioration of air flow.

Check the radiator fan belt tension.

Check the air filter for cleanliness and/or restrictions.

Check the components for signs of leaking oil or water.

Check the condition of all lines and tubes.

Upper structure

• • • • • • • •

Check the fuel tank level.

Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the components for signs of leaking oil or water.

Check the condition of all lines.

Make sure there are no electrical short circuits.

Check the battery connections are properly tightened.

Adjust the rear view mirrors.

Undercarriage

• Check the pad and pad hardware.

• Check the condition of the track chain assembly.

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

Attachment

• • • •

Check the cylinders are not leaking oil.

Check the condition of all lines and tubes.

Check the condition of the bucket teeth.

Check the attachment for any damage or deterioration.

After Starting The Engine

• • • • • •

Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check that the hydraulic components are not making strange noises.

Check the components for signs of leaking oil or water.

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

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

Check that the upper structure swing brake functions correctly.

IMPORTANT: If any defect is found, repair it immediately prior to using the machine or contact your dealer.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE OIL LEVEL Engine Service Specifications Oil Type. . . . . . . . . . . . . . . . . . . . . . . . . . CASE No. 1 Oil Capacity . . . . . . . . . . . . . . . . 52 Liters (13.7 gal.)

Check the engine oil level before you start the engine each day or before the start of each 10 hour shift.

Always check the oil level with the engine stopped and when the machine is on level ground. If the oil pressure message displays and/or the audible alarm device sounds, shut the engine down, and find the cause of the problem.

Figure 15

CS98M579

Add oil if necessary, and replace the fill cap.

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

1

Figure 13

CD01N025

1. ENGINE OIL DIPSTICK

Push the engine oil level dipstick completely down, and pull out before you check the oil level.

A

B CS98M579

Figure 14

If the oil level is below the ADD mark (A), add oil to raise the oil level up to the FULL mark (B).

5-14

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

Radiator And Oil Cooler

CHECK COOLANT LEVEL

Check the radiator and oil cooler before you start the engine each day or before the start of each 10 hour shift.

Service Specifications System capacity . . . . . . . . . . . . 108 litres (28.5 gal.)

Coolant . . . . . . 50% Water and 50% Ethylene Glycol Check the coolant level before you start the engine each day or before the start of each 10 hour shift.

Always check the coolant level with the engine stopped and when the machine is on level ground. If the low coolant or overheat message displays and/or the audible alarm device sounds, shut the engine down, and find the cause of the problem.

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.

CT06D006

Figure 17

CD01N018

Figure 18

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 l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Consult your CASE Dealer for suitable coolant solution.

Check for leakage on and around the radiator and oil cooler components every ten hours.

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

1 2

CS98N547

Figure 16

CD01D040

On firm, level ground, before using the machine, (while the engine is still cold), the level in the coolant reservoir should be between the “FULL” (1) and “LOW” (2) marks.

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Figure 19

Once every week or every day in case of extremely dusty conditions, complete a dust removal procedure for the cooling system. Use the fan reverse as needed.

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE HYDRAULIC FLUID RESERVOIR LEVEL Service Specifications Reservoir capacity . . . . . . . . . . . 310 litres (81.9 gal.)

Total system capacity . . . . . . . . 720 litres (190 gal.)

Type of oil . . . . . . . . Case Hy-Tran Ultra® (MS 1209) Check the hydraulic fluid reservoir level before you start the engine each day or before the start of each 10 hour shift. Always check the levels with the engine stopped and when the machine is on level ground.

IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components”.

2. The oil should be in the middle of the indicator.

Add more oil if necessary.

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.

IMPORTANT: If metal filings are discovered in replaced 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 (104° F).

WARNING: Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap and press the button on the breather to release all pressure in the system.

Failure to observe these instructions can cause injury. See “Releasing pressure in the hydraulic system”.

Figure 21

CD01D041

FAN AND ALTERNATOR DRIVE BELT Visually check the fan and alternator drive belt before you start the engine each day or before the start of each 10 hour shift.

Check the hydraulic fluid level in the reservoir

Figure 22

CT05L058

Check if there are any signs of wear or damage to the pulleys or the belt. Check carefully to ensure that the belt is correctly positioned in the pulley grooves.

If the belt is stretched, cracked or frayed, it must be replaced.

CS98N547

Figure 20

1. Keep all non-authorized personnel clear of the machine. Start and position the machine on firm, level ground, and place the attachment in the position shown. Stop the engine, and remove the starter switch key.

5-16

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE FUEL PREFILTER BLEEDING Check and drain the fuel prefilter before you start the engine each day or before the start of a 10 hour shift.

CT05L035

Figure 26

2. Loosen the drain plug and drain the water and dirty fuel. After draining, retighten the bleed screw.

Figure 23

CT05L031

1. Place a receptacle of a suitable capacity under the prefilter. Loosen the drain plug and drain the water and dirty fuel.

3. Repeat the process for the second filter.

FUEL TANK SCREEN

CD01K039A

Figure 24

CT05L032

2. After draining, close the drain plug. Check for any signs of leakage.

Figure 27

The fuel tank screen is located in the fuel tank orifice.

Clean the tank screen periodically. To clean, remove cap and filter. Clean the screen in diesel oil.

FUEL FILTER BLEEDING Bleed the fuel filter before you start the engine each day or before the start of each 10 hour shift.

Figure 25

CT05L034

1. Place a container with a suitable capacity under the filters.

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Issued 06-06

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5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE Grease the attachment grease points at 50 hour intervals or sooner if conditions require.

If linkage is not fitted with genuine CASE parts, grease every ten hours.

ATTACHMENT GREASE POINTS Service Specifications Type . . . . . . . . . . . . . . . . . . . . . . . . EP NLGI grade 2 (for temperate and hot climates) -20° C to +60° C (-4° to 160° F) Type. . . . . . . . . . . . . . . . . . . . . . . . . . . EP NLGI grade 0 (for cold climates) -40° C to +20° C (-40° to 68° F)

BD00J052

Figure 28

Bucket linkage . . . . . . . . . . . . . . . . . . . . (6 locations) Bucket cylinder bottom pin . . . . . . . . . . . . (1) location

5-18

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Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE DRAINING WATER AND SEDIMENT FROM FUEL TANK Service Specifications Fuel tank capacity . . . . . . . . . . 900 litres (237.7 gal.)

Type of fuel . . . . . . . . . . . . . . . . . . . . . . No. 2 Diesel Drain water and contaminants from the fuel tank every 50 hours of machine operation.

CHECK HYDRAULIC LINES Check hydraulic system lines every 50 hours to make certain there are no leaks from the hydraulic system hoses, pipes, plugs, connections and fittings. Check to be cer tain all nuts and screws are correctly tightened. Repair, replace or tighten components concerned.

WARNING: Before carrying out any service work on the hydraulic system. it is necessary to allow it to cool (the temperature should not be more than 40°C (104° F).

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.

Figure 29

CT05L030

1. Have a container ready to collect the drained contaminants.

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.

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WARNING: Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap and press the button on the breather to release all pressure in the system.

Failure to observe these instructions can cause injury. See “Releasing pressure in the hydraulic system”.

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE REPLACING THE PILOT FILTER Replace the pilot filter in the hydraulic system when the machine is new and the hour meter registers 50 hours. This will be during the initial run-in period. The next filter replacement will occur at 2000 hours or more often if conditions require.

1 2 3

4

Figure 31

C198M156 CT05L042

Figure 30

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system.”

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

3. Remove the old filter (3) and O-ring (2) 4. Clean the filter body (4) in cleaning solvent and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid and install the filter on the head (1) 6. Install the filter body (4) and tighten with a wrench. Do not overtighten.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

5-20

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Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE RETURN FILTER REPLACEMENT

1

Replace the return filter in the hydraulic system when the machine is new and the hour meter registers 50 hours. This will be during the initial run-in period. The next filter replacement will occur at 2000 hours or more often if conditions require.

2

3 4

5

CS01D526A

Figure 33

3. Remove the cover (1) and O-ring (2).

4. Take out the spring (3), valve (4) and return filter (5).

Figure 32

CT05L040

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system.”

2. Clean the top of the hydraulic reservoir and the return filter covers.

5. Install a new filter. Clean the spring (3) and valve (4) and assemble them.

6. Check O-ring (2) and replace it if worn or damaged.

7. Install the cover (1).

8. Check the level of the hydraulic fluid and add more fl uid, if necessar y. See “Filling the reservoir”.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

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5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE AIR CONDITIONING

Cleaning The Air Intake Filter

Check the components of the air conditioning system ev e r y 5 0 h o u r s o f m a c h i n e o p e r a t i o n . A i r conditioning systems need servicing at regular intervals. Make sure these intervals are followed 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 should be repaired immediately.

2

1

WARNING: Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

Figure 34

CD02A023

NOTE: Operate the air conditioning system at least once a week, if only for a short time. See the “Controls/Instruments/Accessories” Section.

1. Remove the screws (2) and sealing cover (1) in the battery compartment.

Inspection

4

In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below before starting work.

3

Condenser If the condenser is dirty, it will not dissipate heat properly. Clean the condenser with water.

IMPORTANT: Never use water under pressure to clean the condenser.

Lines

Figure 35

CD0E139

2. Remove the screws (3) and open the panel (4).

Make a visual check of the lines, and make sure there is no accumulation of dust, grease, etc.

5

Figure 36

CD00E140

IMPORTANT: Always use a safety type air gun, and protect your face before using compressed air.

3. Remove the filter and clean it with compressed air. Replace the filter if it is damaged.

4. Install the filter in its housing with the seal (5) on the inside.

5. Close the panel (4) and install the screws (3).

6. Install the sealing cover (1) and the screws.

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Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE Cleaning The Air Recycling Filter

A

1

B

C

2

CS00E555

Figure 37

CD00E142

1. The air recycling filter is located underneath the fuse box (1). Remove the access panel and take out the filter (2).

IMPORTANT: Always use a safety type air gun, and protect your face before using compressed air.

2. Clean the filter (2) with compressed air. Replace the filter if it is damaged.

Figure 39

2. This check should be made approximately one minute after turning on the air conditioning.

A. Few bubbles observed. Transparent at first, then whitish. “Normal”.

B. Many bubbles. Check all connections and see your CASE Dealer.

C. No bubbles visible. Check all connections and see your CASE Dealer.

3. Install the filter and the access panel.

Checking The Circuit Charge Level

Figure 38

CD00E149

1. Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

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5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE HYDRAULIC BREAKER FILTER (OPTIONAL) When using a hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinar y digging. Replace the hydraulic breaker return filter when the machine hour meter registers 100 hours.

1

7 2

3

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system”.

4

IMPORTANT: You MUST use the option control switches to release all pressure in the hydraulic breaker circuit.

WARNING: Use the option control switches to release all pressure in the hydraulic breaker circuit to avoid unexpected release of hydraulic fluid and possible injury.

5

6 Figure 41

CS98M622

7

3. Remove the four screws (1) on top of the case and remove the cover (2), indicator and O-ring (3) assembly.

4. Change the filter (5) with a new filter.

5. Discard the used O-rings.

Figure 40

6. Insert new O-rings (3) and (4) and install the assembly.

2. This filter is equipped with an indicator (7). When the filter is restricted, the filter must be changed.

7. Tighten the retaining screws (1) for the cover (2).

CT06D013

8. Install the drain plug (6).

9. Start the engine and run it at low speed. Operate the hydraulic breaker and check that there are no leaks.

5-24

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Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE CHECK TRACK ROLLERS AND IDLER WHEELS Check for oil leakage of track rollers and idler wheels when the machine hour meter registers 250 hours.

The upper and lower rollers and idler wheels use a permanent floating sealing mechanism. The service life will normally last until overhaul, but it is important to check visually from time to time for any oil leakage.

If oil leakage is found, component replacement is necessary. See your CASE Dealer.

DRAIN HYDRAULIC RESERVOIR SEDIMENT Drain the hydraulic reservoir when the machine hour meter registers 250 hours or more often if conditions so require.

Figure 42

CT05L041

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. Add hydraulic oil, if necessary.

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5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE REPLACE THE FUEL PREFILTER

2

Replace the fuel prefilter when the machine hour meter registers 250 hours or more often if conditions so require.

2

1

3

Figure 45

CT05L031

6. Check the condition of the filtering element seal, replace if necessary. Reinstall the assembly on the filter head by rotating the prefilter until the seal is in contact with the filter head, then tighten an extra half turn by hand. Retighten the plug (2).

Figure 43

CT05L031

1. Place a receptacle of a suitable capacity under the prefilter.

7. Bleed the system.

2. Loosen the bleed plug (1) and the plug (2) then allow the prefilter to drain.

3. Clean around the prefilter body (3). Remove the prefilter using the filter wrench provided with the machine.

3 4

1 CT05L032

Figure 44

4. 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.

5. Clean the sediment bowl. Check the condition of its seal and replace if the seal is damaged. Apply a thin coat of oil on the new seal, then install the sediment bowl on a new filter element (3), tightening by hand. Retighten the bleed plug (1).

NOTE: Only the filter element must be replaced, not the sediment bowl.

5-26

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE RADIATORS AND OIL COOLERS Clean the radiator and oil cooler when the machine hour meter registers 250 hours. Periodically remove dust when conditions require.

CT05L057

Figure 48

4. Remove the wing nuts, then the protective grilles.

Figure 46

CT06D006

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

2. Open the rear left hand side door and block it with the supporting strut.

IMPORTANT: Always use a safety type air gun and protect your face when using compressed air, water jet, or cleaning chemicals.

5. Clean the radiators and the oil coolers:

• Dry dust: use compressed air.

• Mud: use a water jet.

• Greasy dust: use perchlorethylene.

IMPORTANT: Do not use trichlorethylene.

6. Install the protective grilles, then install the wing nuts.

Hoses and Clamps

Figure 47

CT06D014

3. Use the handle and raise the top flap completely until the strut locks in position.

CT05L027

Figure 49

Check all radiator hoses, connections, and clamps when the machine hour meter registers 250 hours.

Make certain there are no leaks and/or damaged components.

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5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE SWING REDUCTION GEAR

Draining And Refilling

Perform an oil change after the first 250 hours of operation during run-in. Check swing reduction gear oil level every 250 hours thereafter.

Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 4.7 litres (1.2 gal.) (per reduction gear) Oil type . . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (2).

1

3

2 Figure 52

CT06D009 CT05L052

Figure 50

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine, and remove the starter switch key.

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (3). Allow the oil to drain.

NOTE: Oil will take 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.

3

CP98N043

Figure 51

2. Remove the dipstick (2). The oil should come up to the hatched area. Add oil if necessary through the filler hole (1).

Figure 53

CD01K025

3. Install the dipstick.

4. Install the drain plug (3).

4. Repeat the procedure for the second reduction gear.

5. Add oil through the filler holes (2) until the level is correct.

6. Install the dipstick (1) and the filler plugs (2).

7. Wait ten minutes, and check the oil level again.

Add more oil, if necessary.

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Issued 06-06

Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE TRAVEL REDUCTION GEARS Change the oil after the first 250 hours of operation of the run-in period. Check the oil every 250 hours there after.

Service Specifications Oil capacity (per reduction gear) .13.8 litres (3.6 gal.)

Oil type . . . . . . . . . . . . . . . . . . . . . . .Case 135 H EP Checking Travel Reduction Gear Oil Level

Draining And Refilling Travel Reduction Gear Oil 1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

2. Move the machine so that plug (1) is in the lowest possible position.

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

4. Place a receptacle of a suitable capacity under the travel reduction gear, and remove plugs (1) and (2) and (3).

3

5. Allow the oil to drain.

2

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

6. Install plug (1), fill with oil through the orifice (3) until oil comes up to the bottom edge of orifice (2).

1 Figure 54

CD01B014

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

2. Move the machine so that plug (1) is in the lowest possible position.

7. Install plugs (2) and (3). Repeat the procedure for the other travel reduction gear.

8. Travel slowly with the machine, and make sure there are no leaks.

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 lower edge of the orifice. If necessary, remove the plug (3) and add oil until the level comes up to the bottom edge of orifice (2).

5. Install the plugs (2) and (3).

6. Repeat for the other travel reduction gear.

7. Travel slowly with the machine, and make sure there are no leaks.

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5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE MACHINE GREASE POINTS Grease the following grease points when the hour meter registers 500 hours or more often if conditions require.

Service Specifications EP NLGI grade 2 ..................................................(for temperate and hot climates) -20° C to +60° C (-4° to 160° F) EP NLGI grade 0 ........................................................................ (for cold climates) -40° C to +20° C (-40° to 68° F) Greasing The Turntable Teeth

2 1 1

CS98N551

Figure 55

Figure 58

CT05L017

1. Every 500 hours, remove the inspection cover (1), and visually check the condition of the gear surface for any damage.

1. TURNTABLE GREASE POINT 2. TURNTABLE TEETH GREASE POINT

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

1

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

CD01N019

Figure 56

2

Turntable . . . . . . . . . . . . . . . . . . . . . . . . (3 locations)

2 Figure 59

CD001K028

4. If the presence of water is detected: A. Remove the protective panel from the lower, central area.

B. Remove the plug (2).

C. Discharge the water or cloudy grease.

D. Install plug (2).

CD010034

Figure 57

E. Insert new grease through the port, and install the cover (1).

Turntable teeth . . . . . . . . . . . . . . . . . . . . . (1 location) 5-30

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE OIL CHANGE AND FILTER REPLACEMENT Service Specifications Capacity. . . . . . . . . . . . . . . . . . . . .52 liters (13.7 gal) Oil type . . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Change the engine oil more frequently than every 500 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures). If the oil pressure message displays and/or the audible alarm device sounds, shut the engine down, and find the cause of the problem.

4. Screw the end of the extension drain hose provided with the machine onto the engine check valve. Place the other end in the container and allow the oil to flow out.

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

Return the extension drain hose to the front storage compartment.

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter key. Oil will be easier to change if it is still warm (not hot).

Before draining the oil, have a container that will hold the required oil quantity.

CT06D012

Figure 62

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

2

Figure 60

CT05L024

2. Raise and lock the engine hood. Open the access hatch, and remove the oil filler cap (2).

PH08325

Figure 63

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 seals.

Figure 61

CD01N029

3. Remove the protective cap from the engine housing drain valve.

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5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE

2

CT05L024

Figure 64

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

10. Run the engine for a few minutes, and make certain 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.

5-32

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Issued 06-06

Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE CLEANING THE PRIMING PUMP SCREEN

REPLACING FUEL FILTER ELEMENT Replace the fuel filter element when the engine hour meter registers 500 hours or more often if conditions so require.

1

1

Figure 67

CT05L036

Figure 65

CT05L0E4

The priming pump screen is located in the socket head screw (1). Remove the screen, and clean with compressed air. Rinse in clean fuel.

1. Place a container with a suitable capacity under the filters.

FUEL SYSTEM AIR BLEEDING

2. Loosen the bleed plug (1)

It is necessary to bleed the fuel system when:

• The fuel prefilter has been changed.

• The fuel filters have been replaced.

• Parts of the fuel system have been removed for servicing or repair work

• The tank has been completely emptied.

• The machine has been in storage.

2

1 Figure 66

CT05L035

1

3. Loosen the bleed screw (2) and allow the filter to drain.

4. Clean around the filter body then remove it, using the wrench provided with the machine.

5. Replace the filter element with a new element.

Check condition of the body seal and change, 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 using the key. Tightening torque should be 29.4 Nm (21.7 ft. lb.).

CT05L034

Figure 68

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

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

7. Retighten the bleed plug (1) 8. Repeat the procedure for the second filter.

9. Bleed the system.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE

1 3 2

Figure 69

CT05L036

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

Figure 72

CT05L037

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).

2

Figure 70

CS98M578

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

3

4 Figure 73

CT05L036

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). Retighten the bleed screw (4).

8. Once the bleed screws (1), (4) and the pistons (3) have been retightened, operate the priming p u m p ( 2 ) a g a i n u n t i l a r e s i s t a n c e i s fe l t .

Retighten the priming pump knob (2).

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

3

WARNING: Carefully wipe off any fuel spills.

Fuel spills can cause a fire.

CT05L034

Figure 71

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

5-34

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Bur

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE ATTACHMENT GREASE POINTS Grease the following machine points when the machine hour meter registers 1000 hours or more frequently if conditions so require.

Service Specifications: EP NLGI grade 2 Grease .....................................(for temperate and hot climates) -20° C to +60° C (-4° to 160° F) EP NLGI grade 0 Grease .................................................................... (for cold climates) -40° C to +20° C (-40° to 68° F)

1 3 1

2

3 4 Figure 74

CS98N551

2

1

CT05L013

CD01N024

Boom bottom pin . . . . . . . . . . . . . . . . . . (2 locations) Boom cylinder top in . . . . . . . . . . . . . . . (2 locations) Bucket cylinder bottom pin . . . . . . . . . . . (1 location)

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Issued 06-06

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CT06D007

Figure 75

Boom bottom pin . . . . . . . . . . . . . . . . . . (2 locations)

5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Greasing Self-detaching Counterweight System (Optional)

3

CT06D010

Figure 76

Boom/bucket linkage . . . . . . . . . . . . . . . . (1 location) Bucket cylinder top pin . . . . . . . . . . . . . . . (1 location) Bucket cylinder bottom pin . . . . . . . . . . . . (1 location)

Figure 78

CD01D038

Cylinder top pins . . . . . . . . . . . . . . . . . . (3 locations) Handling arm . . . . . . . . . . . . . . . . . . . . . (2 locations)

4

CD01C165

Figure 77

Connecting rod linkages . . . . . . . . . . . . . (4 locations) IMPORTANT: If the linkage points on the machine are not equipped with original parts, these points must be lubricated every 50 hours.

5-36

Figure 79

CT06D010

Cylinder bottom pins . . . . . . . . . . . . . . . (3 locations)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE DRAINING AND FILLING THE COOLING SYSTEM

Draining

Service Specifications System capacity . . . . . . . . . . . . .108 litres (28.5 gal) Type . . . . . . . . . 50% water and 50% Ethylene Glycol Drain the engine coolant when the hour meter registers 1000 hours, flush the system, and refill with new coolant. If the low coolant or overheat message displays and/or the audible alarm device sounds, shut the engine down, and find the cause of the problem.

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, turn the cap to the first notch and wait until there is no more pressure. Then, remove the cap.

CT05L026

Figure 80

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

WARNING: Check and service the cooling system according to manufacturer’s instructions.

Coolant solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

CT05L027

Figure 81

2. Open the radiator drain valve.

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

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

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

CT05LL028

Figure 82

3. Open the drain plug located on the engine block.

Allow the radiator to completely empty.

NOTE: Have a receptacle of a suitable capacity ready.

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5-37

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Flushing

Filling

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

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

3. Keep all non-authorized personnel clear of the machine. Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80°C (176° F).

4. Drain the system once more.

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

Figure 83

CT05L026

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

Figure 84

CT05L029

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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE HYDRAULIC FLUID Service Specifications System capacity . . . . . . . . . . . . 720 liters (190.2 gal) Type . . . . . . . . . . . . . . .MS-1209, Case Hy-Tran Ultra

REPLACING THE HYDRAULIC RESERVOIR BREATHER FILTER Replace the hydraulic reservoir breather filter when the machine hour meter register 1000 hours or more often if conditions so require.

IMPORTANT: Every 1000 operating hours, it is important to have the hydraulic fluid analyzed. See your CASE Dealer.

Check the machine hydraulic fluid. If any metal particles are found in the fluid or any old filters, see your CASE Dealer.

IMPORTANT: After changing the hydraulic fluid it is necessary to bleed all air from the hydraulic components.

WARNING: Before carrying out any service work on the hydraulic system, it is necessary to allow the hydraulic system to cool (the temperature should not be more than 40° C (104° F).

3

WARNING: Hydraulic fluid or grease injected into the skin can cause severe injury or death. Keep the hands and body away from any pressurized leak. Use cardboard or paper to check for leaks. If fluid is injected into your skin, see a physician 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.

Figure 85

CT05L038

1 4

5 7

6 2

CS00E528A

Figure 86

1. Release all pressure from the hydraulic system.

See Releasing Pressure in the Hydraulic System, page 5-4 in this section.

2. Remove the cap (1) then press the button (2) to release all pressure from the hydraulic reservoir.

3. Remove the nut (3), the seal (4), and the cover (5) from the breather.

4. Remove and discard the used filter (6).

5. Install a new filter element, making certain the seal (7) is facing upwards.

6. Install the assembly.

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5-39

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE CLEANING AND REPLACING THE INLET FILTER Clean the inlet filter when the hourmeter registers 1000 hours or more often if conditions require.

Figure 87

CT05L040

1. Release all pressure in the hydraulic system.

See Releasing Pressure In The Hydraulic System.

2. Clean the top of the hydraulic reservoir, and clean the inlet filter cover.

1

2 3

CTS01D526A

Figure 88

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 for any damage. If there is any damage on the surface, replace the filter with a new one.

5. To install filter, install a new O-ring 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 fluid, if necessary.

5-40

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE SWING REDUCTION GEAR

Draining And Refilling

Drain and bleed swing reduction gear oil when the machine hourmeter registers 1000 hours or more often if conditions require.

Service Specifications Oil capacity . . . . . . . . . . . . . . . . . .4.7 litres (1.2 gal.) (per reduction gear) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine, and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (2).

1

3

2 Figure 91

CT06D009

Figure 89

CT05L052

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine, and remove the starter switch key.

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (3). Allow the oil to drain.

NOTE: Oil will take 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.

3

Figure 90

CP98N043

2. Remove the dipstick (2). The oil should come up to the hatched area. Add oil, if necessary through the filler hole (1).

CD01K025

Figure 92

3. Install the dipstick.

4. Install the drain plug (3).

4. Repeat the procedure for the second reduction gear.

5. Add oil through the filler holes (2) until the level is correct.

6. Install the dipstick (1) and the filler plugs (2).

7. Wait ten minutes and check the oil level again.

Add more oil, if necessary.

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5-41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Refilling

TRAVEL REDUCTION GEARS Drain and refill the oil in the travel reduction gears when the machine hourmeter registers 1000 hours or more often if conditions require.

6. Install plug (1), fill with oil through the orifice (3) until oil comes up to the bottom edge of orifice (2).

Service Specifications Oil capacity (per reduction gear) 13.8 litres (3.6 gal.)

Oil type . . . . . . . . . . . . . . See “Fluids and lubricants”

7. Install plugs (2) and (3). Repeat the procedure for the other travel reduction gear.

Draining

8. Travel slowly with the machine, and make sure there are no leaks.

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

3

2

1 CD01B014

Figure 93

2. Move the machine so that plug (1) is in the lowest possible position.

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

4. Place a receptacle of a suitable capacity under the travel reduction gear, and remove plugs (1) and (2) and (3).

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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE PRIMARY AIR FILTER Replace the primary element every 1000 hours. The secondary element should be replaced at the same time. Do not clean the secondary element. It must be replaced. Replacing the air filter elements may be requi red mo r e f r eq u e nt l y i n ex tr e m el y d u sty conditions.

If the air restriction message displays and/or the audible alarm device sounds, shut the engine off and find the cause of the problem.

Removing The Elements CD00E116

Figure 96

3. Remove the wing nut in order to remove the s e c o n d a r y e l e m e n t c o v e r. R e p l a c e t h e secondary element with a new element.

IMPORTANT: Do not clean the secondary element. It must be changed, not cleaned.

Installing the Element

Figure 94

CT05L047

1. Release the fasteners and remove the cover.

CD00E116

Figure 97

1. Install the new secondary element, and tighten the cover wingnut.

Figure 95

CT05L48

2. Remove the wing nut, and take out the primary element.

CT05L48

Figure 98

2. Install the primary element, and tighten the wingnut.

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5-43

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

CT05L047

3. Install the air filter cover, then fasten.

5-44

Figure 99

Figure 100

CT05L047

4. Check that the dust ejector under the prefilter cover is working correctly.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE REPLACING THE PILOT FILTER Replace the pilot filter in the hydraulic system when the machine hour meter registers 2000 hours or more often if conditions require.

1 2 3

4

Figure 101

CT05L042

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system.”

C198M156

Figure 102

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

3. Remove the old filter (3) and O-ring (2) 4. Clean the filter body (4) in cleaning solvent, and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid, and install the filter on the head (1).

6. Install the filter body (4), and tighten with a wrench. Do not overtighten.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

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5-45

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE RETURN FILTER REPLACEMENT

1

Replace the return filter in the hydraulic system when the machine hour meter registers 2000 hours or more often if conditions require.

2

3 4

5

Figure 104

CS01D526A

3. Remove the cover (1) and O-ring (2).

CT05L040

Figure 103

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system.”

2. Clean the top of the hydraulic reservoir and the return filter covers.

4. Take out the spring (3), valve (4) and return filter (5).

5. Install a new filter. Clean the spring (3) and valve (4) and assemble them.

6. Check O-ring (2) and replace it if worn or damaged.

7. Install the cover (1).

8. Check the level of the hydraulic fluid and add more fl uid, if necessar y. See “Filling the reservoir”.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE ULTRA CLEAN FILTER REPLACEMENT Replace the ultra clean filter in the hydraulic system when the machine hour meter registers 2000 hours or more often if conditions require.

7

1

2

4 3

8

5 6

Figure 105

CT05L043

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system.”

2. Clean the top of the filter with solvent. Close the supply valve (8).

3. Remove the four cover bolts (1), and remove the cover (2), O-ring (3) and 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).

CS02A544

Figure 106

7. Install the spring (4), new O-ring (3) and cover (2). Open the supply valve (8).

8. Keep all non-authorized personnel clear of the machine. Start the engine and run at idle speed.

9. Loosen the vent plug (7) on top of the cover.

When air free hydraulic fluid (without bubbles) comes out of the vent hole, tighten the vent plug (7). Clean all fluid from the filter body.

10. Check the level of the hydraulic fluid, and add more fl uid, if necessar y. See “Filling the reservoir”.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

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5-47

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE GREASE THE SWING REDUCTION GEAR Grease the swing reduction gear when the machine hour meter registers 2000 hours or more often if conditions require.

1 2

Figure 107

CT06D009

1. Remove the lower panel, remove the air bleed plug (1) and fill with grease via the greasing point (2). Grease should come out of the air bleed plug (1) hole.

2. Install the plug (1) IMPORTANT: When filling with grease, the inner seal will be damaged if the air bleed plug (1) is not removed.

1 2

CT06D017

Figure 108

3. Repeat the procedure on the second reduction gear.

4. Install the lower panel.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE REPLACING THE INLET FILTER Replace the inlet filter in the hydraulic system when the machine hour meter registers 5000 hours or more often if conditions require.

1

2

3

CTS01D526A

Figure 110

3. Remove the cover (1), O-ring (2) and spring on the top of the inlet filter rod assembly.

Figure 109

CT05L040

1. Release all pressure in the hydraulic system.

See Releasing Pressure In The Hydraulic System.

2. Clean the top of the hydraulic reservoir, and clean the return filter covers.

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4. Remove the inlet filter (3).

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.

5-49

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE REPLACING THE HYDRAULIC FLUID Drain and refill the hydraulic system when the machine hour meter registers 5000 hours or more often if conditions require.

Figure 112

CD01K081

4. Remove the drain plug to remove the remaining fluid from the reservoir.

Figure 111

CD01N035

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.

WARNING: Before carrying out any service work on the hydraulic system, it is necessary to allow it to cool (the temperature should not be more than 40° C (104° F).

5. Replace the inlet filter and the return filter. See “Cleaning and replacement of the Inlet filter” and “Return filter replacement”.

6. Install the reservoir drain plug.

7. Put new hydraulic fluid into the reservoir. See “Filling the reservoir”.

8. Install the reservoir cover plate and seal.

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. Keep all non-authorized personnel clear of the machine. Start and run the engine with no load for approximately five minutes.

10. Move each control slowly several times to remove any air in the system.

11. Swing the upper structure evenly left to right two complete turns or more.

12. Move the machine to firm, level ground, and then stop the engine.

13. Check the oil level in the hydraulic reservoir and add oil, as required. Make sure there are no air bubbles in the hydraulic reservoir.

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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE AIR CONDITIONING FILTERS Replace the air intake and air recycling filters of the air conditioning system when the machine hour m e t e r r e g is t e r s 5 0 0 0 h o u r s o r m o r e o f t e n i f conditions require.

Replacing the Air Intake and Air Recycling Filters

5

Figure 115

CD00E140

2

3. Remove the filter, and replace with new filter.

1

4. Install the filter in its housing with the seal (5) on the inside.

2

5. Close the panel (4), and install the screws (3).

6. Install the sealing cover (1) and the screws (2).

Figure 113

CT06D015

1. Remove the screws (2) and sealing cover (1) in the rear of the cab.

Replacing The Air Recycling Filter

1

3

1

2

Figure 114

CD00E139

2. Remove screws (3) and open the panel (4).

CD0E142

Figure 116

1. The air recycling filter is located underneath the fuse box (1). Remove the access panel, and take out the filter (2).

2. Replace with a new filter, and reinstall the access panel.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 HARDWARE TORQUE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 FAN AND ALTERNATOR DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 INSPECTING AND CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 WELDING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 FIRE EXTINGUISHER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 CHECKING FOR CYLINDER LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 REPLACING A BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Teeth and tooth tip wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Periodic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting up after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6-18 6-18 6-18 6-18

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-2

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS IMPORTANT: If tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after working.

CLEANING

.

When the machine has been working in mud, a reduction in temperature can cause the mud to solidify .

CS01D529

Figure 3

5. Operate the travel control lever for the raised track forwards and then in reverse, to remove the mud.

Figure 1

CS01D529

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground.

6. Lower the track and repeat Steps 1 to 4 for the other track.

2. Position the upper structure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground. .

Figure 2

CD00E075

3. Turn the engine throttle button to maximum speed position.

4. Use the travel speed selector to select high speed.

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6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING TRACK TENSION 1. Keep all non-authorized personnel clear of the machine. Move the machine to fir m, level ground.

2. Clean the tracks. .

CS01D529

Figure 4

3. Position the upper structure at right angles to the undercarriage. Use the attachment to press on the ground, and lower the boom until the track is raised off the ground.

4. Use the travel control lever to operate the raised track in reverse for a few moments.

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

PEO7531

Figure 5

6. Measure the sag of the track at the center between the base of the undercarriage and the pad. The value should be 460 to 480 mm (18.1 to 18.9 in).

7. Adjust tension, if necessary and then lower the raised track to the ground.

8. Repeat Steps 3 to 7 for the other track.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS To Reduce Tension

ADJUSTING TRACK TENSION Make any necessary track adjustments after the track tension has been checked.

.

To Increase Tension .

Figure 8

CD01D119

WARNING: Never unscrew the grease fitting adaptor completely to speed up the flow of grease. The grease in the cylinder is under high pressure.

Figure 6

CD01D118

1. With the track in raised position, clean the grease fitting adaptor, and connect the grease pump hose to the grease fitting.

1. With the track in raised position, loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder.

.

.

Figure 7

PE07531

2. Connect the grease pump. Inject grease to obtain the right amount of track tension. The value should be 18.1 to 18.9 in (460 to 480 mm).

3. Remove the grease pump, clean the grease fitting, and then lower the raised track to the ground.

4. Repeat Steps 1 to 3 for the other track.

PE07531

Figure 9

2. When the correct track tension is obtained, tighten the adaptor. The value should be 18.1 to 18.9 in (460 to 480 mm).

3. Clean the grease adaptor and fitting.

4. Lower the raised track, and repeat Steps 1 to 3 for the other track.

5. If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regular ly, and replace it, if necessary.

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6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK SHOE BOLT TORQUE Check track shoe bolt torque every 250 hours.

1

3

4

2

CS00E504

Figure 10

PE08316

Figure 11

Tighten the track shoe bolts to a torque of: 1588 to 1869 Nm (1171to 1379 ft lbs).

Tighten the bolts in the order shown above.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

HARDWARE TORQUE INSPECTION At the end of each working day, check all mounting nuts and screws for tightness and tighten, if necessary. Make sure no hardware items are missing. Replace them, if necessary. Torque all bolts according to table after the first 50 hours during the run-in period and every 250 hours thereafter.

TORQUE SPECIFICATIONS PER COMPONENT Component

Bolt Size

Torque (Ft.Lbs)

Torque (Nm)

Travel reduction gear (*)

M27

963 - 1125

1307 - 1526

Drive sprocket (*)

M24

963 - 1125

1307 - 1526

Idler (*)

M16

196 - 230

267 - 312

Upper roller (*)

M20

384 - 448

521 - 608

Lower roller (*)

M27

963 - 1125

1307 - 15269

Chain guide (*)

M27

963 - 1125

1307 - 15269

Track shoe

M27

1171 - 1379

1588 - 1869

Counterweight

M42

1301 - 1881

2256 - 2550

Turntable bearing

M30

1328 - 15491

1800 - 2100

Undercarriage side members

M36

1881 - 2170

2550 - 2942

Swing reduction gear (*)

M24

663 - 774

900-1050

Engine (*)

M24

665 - 774

902 1049

Engine mounts (*)

M14

128 - 149

173 - 202

Radiator

M20

384 - 448

520 - 608

Hydraulic pump (*)

M12

80 - 94

109 - 127

Hydraulic reservoir (*)

M20

347 - 419

471 - 568

Fuel tank (*)

M20

347 - 419

471 - 568

Control valve (*)

M20

253 - 289

343 - 392

Hydraulic swivel(*)

M16

197 - 230

267 - 312

Cab

M16

58 - 59

78-80

Battery

M10

15 -

20 - 29

* Use Loctite 262, or the equivalent, on bolts.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

108 to 132

12 to 15

5/16 inch

204 to 252

23 to 28

3/8 inch

420 to 504

48 to 57

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

7/16 inch

70 to 84

95 to 114

1/2 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

NOTE: Use thick nuts with Grade 8 bolts.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Grade 10.9 Bolts, Nuts, and Studs

Grade 8.8 Bolts, Nuts, and Studs

10.9

8.8

Size

PoundInches

Newton metres

M4

24 to 36

3 to 4

M5

60 to 72

7 to 8

M6

96 to 108

11 to 12

M8

228 to 276

26 to 31

M10

456 to 540

52 to 61

M12

66 to 79

90 to 107

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Size

PoundInches

Newton metres

M4

36 to 48

4 to 5

M5

84 to 96

9 to 11

M6

132 to 156

15 to 18

M8

324 to 384

37 to 43

M10

54 to 64

73 to 87

M12

93 to 112

125 to 150

M14

149 to 179

200 to 245

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

M24

780 to 940

1050 to 1275

M30

1470 to 1770

2000 to 2400

M36

2580 to 3090

3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

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6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FAN AND ALTERNATOR DRIVE BELT Visually check the fan and alternator drive belt daily.

Check the belt tension every 500 hours.

Tension Adjustment

Checking Tension

1

2

1

Figure 14

CS99A852

CT05L058

Figure 12

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.

To adjust tension, loosen the mounting bolts (1). Use the adjustment screws (2) to move the alternator outwards until belt tension is correct. Retighten the pulley attachment to a torque of 147 Nm (108 ft lbs).

Tighten the alternator mounting bolt.

Replacing Drive Belt

1

2

1

Figure 15

CS99A852 CS98M560

Figure 13

With the engine off, and the star ter switch key removed, press the center of the belt, exerting a pressure of about 10 kg (20 lbs). The belt deflection should be about 6 to 8 mm (.2 to .3 in).

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.

6-10

1. Remove the mounting bolts (1). Use the adjustment screws (2) to push the alternator inwards.

2. Remove the worn belt.

3. Install a new belt.

4. Tighten the mounting bolts (1).

5. Run the engine for about an hour, and then check the belt tension again.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

INSPECTING AND CLEANING THE MACHINE

FIRE EXTINGUISHER (OPTIONAL)

Inspect and clean the machine periodically or whenever oil or grease has been spilled on the machine. Clean off with steam or a high pressure water jet. Use personal protection equipment when cleaning the machine.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear. Look for any leaks and check the condition of all pipes and hoses.

CS98M573

WELDING ON THE MACHINE Whenever carrying out a welding operation on the undercarr iage or upper str ucture carr iage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed. Never connect the welding apparatus to the undercarriage when welding on the upper structure (or vice-versa). Never connect the welding apparatus ground to a component of the hydraulic system.

Figure 16

It is recommended a fire extinguisher be kept on the machine for emergencies. The fire extinguisher can be kept in the front storage box.

Service Specifications

• Every month: Inspect the extinguisher and check for any signs of damage or leakage.

• Every six months: Have the chemical removed and have the fire extinguisher refilled by an approved organization.

• Every year: Have the fire extinguisher inspected by an approved organization.

WARNING: Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer.

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6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHECKING FOR CYLINDER LEAKAGE

3. Extend the cylinder rod.

A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

4. Carry out the leak test by applying a piece of paper to the rod.

1. Wipe the cylinder rod and bearing off.

2. Operate normally for five or ten minutes.

Rod appearance Dry Slightly oily Oily

Test

Conclusion

Slight traces of oil when a piece of paper is wiped over 20 cm (8 in) of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

Consult your CASE Dealer

PLASTIC AND RESIN PARTS When cleaning plastic parts such as the instrument console or the control arms, do not use gasoline, kerosene, paint solvents, etc. Use soap and water and a clean cloth only.

The use of gasoline, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts

6-12

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

REPLACING A BUCKET Removal

Installation

1. Keep all non-authorized personnel clear of the machine. Position the bucket flat on firm, level ground. Operate the attachment controls so that the arm/bucket linkage pin is not held in place by the weight of the arm.

1. Make sure the bucket is in a stable position.

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

CD00E099

Figure 20

2. Install the linkage seals on the arm bushing shoulders. Change them if necessary.

Figure 17

CD00E096

3. Remove the retaining rings and pins.

Figure 18

CD00E097

4. Remove the bucket pins.

3. Keep all non-authorized personnel clear of the machine. Start the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine, and remove the starter switch key.

CD00E100

Figure 21

4. Install the arm/bucket linkage pin, and then install the retaining pin and ring.

5. Start the engine and bring the bucket connecting rod into its housing. Stop the engine, and remove the starter switch key.

WARNING: Do not use fingers or hand to align holes for pin. Serious injury could result.

Figure 19

CD0E099

5. Start the engine, disengage the attachment from the bucket, and retain the linkage seals for reuse.

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6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Shimming the Bucket

1

J 2 CD00E096

Figure 22

6. Install the connecting rod/bucket linkage pin, and then install the retaining pin and ring.

7. Push the seals back into their housing.

8. Adjust the arm/bucket shimming.

9. Grease the linkages.

Figure 23

CD00E121

Side play adjustment 1. Place the bucket firm on level, firm ground.

2. Check the play (J) between the arm and the bucket ear.

3. If the play (J) exceeds 2 mm (.07 in), remove the four screws, the cap (1) and the shims (2).

4. Use the shims (2) as a feeler gauge to determine the number of shims necessary to take up the play (J).

5. Install the necessary number of shims.

6. Install the cap (1) and the four screws.

NOTE: When the screws in the cap (1) are tightened, the inner bushing moves toward the arm and takes up the play.

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap (1) has an orifice on its inside surface. When installing the cap (1), make certain the lug is inside this orifice.

6-14

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CHAPTER 6 - MAINTENANCE AND 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 by interchanging them regularly.

NOTE: Do not wait for teeth or tooth tips to be completely worn through before changing them.

IMPORTANT: Never try to work with a missing tooth tip or a tooth tip which is worn through. The adaptor could be seriously damaged.

Replacing a tooth on the bucket

Figure 24

CD01D128

REMOVAL 1. Keep all non-authorized personnel clear of the machine. Position the bucket a few inches above the ground. Stop the engine and remove the starter switch key.

2. Use a drift to remove the locking pin from its housing by striking it with a hammer until it is ejected.

3. Remove the worn tooth tip, turning it to the left.

INSTALLATION 1. Clean the mating surface on the adaptor.

2. Install a new tooth tip up to the stop, turning it to the right and holding it in this position.

3. Place the locking pin in position and strike it until it is flush with the tooth tip.

IMPORTANT: Make sure that the latch has been installed with the correct orientation.

NOTE: When replacing a tooth tip, it is advisable to replace the locking pin at the same time.

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6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions.

SA048

Lubrication Of The Air Conditioning Compressor Seals

Checking The Air Conditioning Circuit Charge Level

Operate the air conditioning once every 250 hours to lub r icat e th e co m pr ess or s ea ls. Tu r n th e a ir conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a cover over the air conditioning condenser. This will allow the refrigerant and lubricants in the system to be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, use care when cleaning the condenser.

Inspection In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below prior to starting work.

Figure 25

CD0E149

1. Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

A

Cleanliness of the Condenser

B

C

If the condenser is dirty, it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

Check the Air Conditioning Lines Make a visual check of lines and make certain there is no accumulation of dust, grease, etc.

Figure 26

CS00E555

2. This check should be made approximately one minute after turning on the air conditioning.

A. Few bubbles observed. Transparent at first, then whitish. “Normal”.

B. Many bubbles. Check all connections and see your CASE Dealer.

C. No bubbles visible. Check all connections and see your CASE Dealer.

6-16

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Air Conditioning Drive Belt

Figure 27

CT02D235

3. Check the air conditioning connectors to make certain they are not dusty or dirty.

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CD01D131

Figure 28

With engine off, exert pressure of approximately 10 kg (22 lb force) on the center of the air conditioning drive belt. The amount of deflection should be between 5 to 7 mm (.2 to .3 in). Adjust the tension of the belt if necessary.

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

STORAGE 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 firm, 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 arm cylinder rod as far 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.

NOTE: When the machine resumes service, the film will disappear automatically.

1. 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.

2. While the engine is still warm, drain the oil sump, fill with anti-corrosive oil, and replace the engine oil filter.

3. When the engine is cold, clean the outer parts of the engine with diesel fuel.

4. Remove the injectors and inject some engine oil through the injector holes. (This operation can be performed using a syringe, after moving each piston to bottom dead center.

5. Clean or replace the air filter element.

6. Drain the cooling system, leave the drain valves open, and do not tighten the radiator cap.

1. The battery charge and battery electrolyte level.

Recharge the batteries if required.

2. The grease on the cylinder rods and/or perform attachment functions monthly.

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 paint work. Apply a coat of anti-rust treatment where necessary.

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.

7. Grease the cylinder rods.

12. Unplug the air filter inlet and the exhaust pipe.

8. Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries safely in a cool and dry location, where the temperature will be higher than 0° C. (32° F).

13. Remove the “Do not operate” tag and start the engine, following the starting up procedure. Keep unauthorized personnel clear of the machine.

9. Paint any areas where the paint shows signs of deterioration.

10. Plug the air filter inlet and the exhaust pipe.

11. Remove the starter switch key and place a “Do Not Operate” label on the right-hand control arm.

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

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

WARNING: Avoid running the engine in a confined place. Make certain there is adequate ventilation at all times.

12. Lock the hoods and the cab door.

6-18

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-3 7-4 7-4 7-4

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Additional Fuse Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of the instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of the instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7 7-7 7-7 7-7

ACCESSORY OUTLETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

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CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

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

SAFETY_ID_1C02

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

SB034

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

SAFETY_ID_1C02

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

SAFETY_ID_1C02

SA033

WARNING: Connecting jump start (booster battery) cables incorrectly or short- circuiting battery terminals can cause an accident.

Connect auxiliary starting cables as per the following instructions.

SAFETY_ID_1C02

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7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE

BATTERY FLUID LEVEL

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the can.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

In extreme heat conditions check battery fluid every 250 hours.

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

7-4

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CHAPTER 7 - ELECTRICAL CHECKING BATTERY ELECTROLYTE LEVEL

Figure 1

CD01D132

To gain access to the batteries, open the left-hand side door.

Remove the cell caps and check the level in each batteries cell. The level should be between 10 and 15 mm (.3 to .5 in) above the plates. Add distilled water if necessary, then install the cell caps.

IMPORTANT: When adding distilled water at temperatures below 0° C (32° F), the batteries must be charged or the engine run for two hours approximately in order to ensure that the distilled water and the electrolyte are properly mixed.

NOTE: Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

REPLACING A BATTERY

CD0E094

Figure 2

Remove the terminal protection caps, disconnect cables (negative terminals) and then cables (positive terminals). Remove the anti-sulfate pellets.

Remove the two screws, the washers and metal sheet. Remove the old battery.

Install the new battery and put the metal sheet, washers and screws back in place.

Clean the cables and battery terminals, and coat them with grease.

Install new anti-sulfate pellets, reconnect positive cable ends to positive ter minals first and then negative cable ends to negative terminals. Install the terminal protection caps.

CONNECTING BOOSTER BATTERIES WARNING: Before carrying out any service work on electrical system components, turn the starter switch key to the “OFF” position. When disconnecting batteries, always disconnect the negative (-) cable first.

When reconnecting batteries, always connect the negative (-) cable last.

WARNING: Connecting battery booster cables incorrectly or short-circuiting batteries terminals can cause an accident. Connect booster starting cables as per the following instructions.

WARNING: Hydrogen gas may be present above the discharged battery. Do not make the negative connection directly to the discharged battery, as this may ignite the hydrogen gas.

Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts).

1. Turn off the ignition and all accessories on the machine(s). Remove the battery terminal covers.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

2. Connect one end of the positive (+) cable to the positive (+) terminal on the booster battery.

Connect the other end of the positive (+) cable to the positive (+) ter minal of the discharged battery.

5. Start the engine.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

7. Install the terminal covers.

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6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

7-5

CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS IMPORTANT: Before proceeding to replace a fuse, turn the starter switch key to “OFF”.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

CD0E059

Figure 3

To gain access to the fuses, open the panel at the rear of the operator’s compartment, and remove the cover.

Figure 4

A23955

A notice on the cover gives the function and amperage of each fuse.

NOTE: To remove or install a fuse, use the notch in the upper right-hand corner of the cover.

NOTE: Two spare fuses (10 amp and 20 amp) can be found on the inside of the fuse box cover.

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CHAPTER 7 - ELECTRICAL FUSES

1

11

2

12

3

13

4

14

5

15

6

16

7

17

8

18

9

19

10

20 Figure 5

CS01B545

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Memory, cab light, radio ................................................................................................................................ 10 A Starter switch ................................................................................................................................................ 10 A Air conditioning, heater ................................................................................................................................. 20 A Air conditioning compressor............................................................................................................................ 5 A Working lights................................................................................................................................................ 15 A Not used........................................................................................................................................................ 15 A 12 Volt converter ........................................................................................................................................... 10 A Windshield wiper/washer .............................................................................................................................. 15 A Horn, self detaching counterweight (optional)............................................................................................... 10 A Cigarette lighter, operator’s seat ................................................................................................................... 15 A Engine electronic box.................................................................................................................................... 20 A Electronic box control...................................................................................................................................... 5 A Electronic box power ..................................................................................................................................... 20 A Rotating beacon (optional) ............................................................................................................................ 10 A Hydraulic control cancellation ....................................................................................................................... 10 A Fuel filler pump.............................................................................................................................................. 20 A Fuel supply pump.......................................................................................................................................... 30 A Air conditioning condenser fan...................................................................................................................... 10 A Engine preheating ......................................................................................................................................... 30 A Optional......................................................................................................................................................... 20 A

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7-7

CHAPTER 7 - ELECTRICAL REPLACING A BULB CAB LIGHT

CD00E123

Working Light

Figure 6

1. Remove the cover.

Figure 7

CD00E124

1. Remove the four mounting screws.

2. Remove the bulb, and install a bulb of the same wattage (10 W).

3. Install the lens.

Figure 8

CD00E125

2. Tilt the working light, and disconnect the plug.

Figure 9

CD00E126

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.

7-8

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CHAPTER 7 - ELECTRICAL Upper Structure Work Light

CD00E130

Figure 10

CD01K 53A

1. Raise the front storage box cover until the support strut locks.

Figure 13

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

5. Install the clip and the working light assembly.

6. Install the working light and plug (upper structure working light).

7. Install the top plate. Close the front box.

Figure 11

CT05L067

2. Remove the top plate from compartment. Disconnect the plug.

the

light

Figure 12

CD00E129

3. Remove the four screws, and tilt the working light assembly.

4. Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

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CHAPTER 7 - ELECTRICAL

NOTES

7-10

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 BOOM/ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 UPPER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 OVERALL DIMENSIONS AND WEIGHT OF MAIN MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 8-14

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CHAPTER 8 - SPECIFICATIONS

NOTES

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CHAPTER 8 - SPECIFICATIONS

ENGINE SPECIFICATIONS NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

Model.............................................................................................................................................................. 6WG1X Manufacturer....................................................................................................................................................... Isuzu Turbocharged......................................................................................................................................................... yes Number of cylinders...................................................................................................................................................6 Bore/stroke .................................................................................................................. 5.79 x 6.07 in (147 x 154 mm) Displacement.............................................................................................................................. 958 cu in (15700 cc) SAE net horsepower - rated ........................................................................................ 495 hp (369 kW) @ 1800 rpm Maximum torque.................................................................................................. 1659 lb ft (2250 Nm) @ 1500 RPM Fuel Injection ...................................................................................................................................................... direct Battery start ................................................................................................................. 2 12/24 volt batteries, 140 A/h Cooling .................................................................................................................................................. water-cooled Oil capacity ...........................................................................................................................................13.7 gal (52 L)

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CHAPTER 8 - SPECIFICATIONS

HYDRAULIC SYSTEM Main pumps Variable displacement - axial piston Quantity ..................................................................................................................................................................... 2 Maximum capacity................................................................................................................... 132.1 gpm (500 L/mn) Pilot pump Fixed displacement - gear type Quantity ..................................................................................................................................................................... 1 Maximum capacity........................................................................................................................... 7.1 gpm (27 L/m) Relief pressure ................................................................................................................................638 psi (4.4 MPa) Swing Motor ........................................................................................................ Fixed displacement, axial piston design Speed..........................................................................................................................................................7.6 rpm Brake ...............................................................................Spring applied hydraulically released with cushion relief Tail swing radius ................................................................................................................................ 14 ft (4.30 m) Tilting oil cooler with ventilation from engine.

High pressure multispiral hoses Self-lubricating hydraulic swivel Hydraulic reservoir capacity ..................................................................................................................82 gal (310 L) Total hydraulic system capacity ...........................................................................................................190 gal (720 L)

CONTROL VALVE Four control valve sections for left-hand travel, boom, bucket and arm acceleration Five control valve sections for right-hand travel, swing, arm, auxiliary attachment and boom acceleration

SWING Swing Motor ........................................................................................................ Fixed displacement, axial piston design Speed..................................................................................................................................................... .0-7.6 rpm Brake ...............................................................................Spring applied hydraulically released with cushion relief Tail swing radius ................................................................................................................................ 14 ft (4.30 m) Pump................................................................................................................................... Fixed flow, piston-type Brake ................................................................................................................................................Automatic disc

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CHAPTER 8 - SPECIFICATIONS

TRAVEL Motor .................................................................................................. Two speed hydraulic motors with axial pistons Final Drive ..........................................................................................................................Planetary reduction gears Travel control valve .............................................................................. Dual stage relief and counter-balance design Travel speed Low speed ...................................................................................................................0 to 1.8 mph (0 to 2.9 km/h) High speed ..................................................................................................................0 to 2.7 mph (0 to 4.3 km/h) Gradeability ......................................................................................................................................................70%

MACHINE WEIGHTS With 3.66m (12 ft) arm, 27 ft 7 in boom, 29.5 in (750 mm) track shoes, 6614 lb (3000 kg) bucket, 175 lb (79 kg) operator, full fuel tank, and standard equipment .......................................................................175210 lb (79474 kg) Boom (Reach) total weight ............................................................................................................21253 lb (9640 kg) 18 ft - 5 in arm (5.62 m) .................................................................................................................10273 lb (4660 kg) 14 ft 7 in arm (4.44 m) .....................................................................................................................9145 lb (4148 kg) 12 ft 0 in arm (3.66 m) .......................................................................................................................8378 lb (380 kg) Boom (Mass Excavation) total weight............................................................................................20018 lb (9080 kg) 9ft 9 in arm (2.98 Mass Excavation) ................................................................................................8799 lb (3991 kg)

SAFETY DEVICES Control for lowering attachments in case of engine failure.

Controls are disabled by lifting the function cancellation lever or the left-hand control arm.

Engine emergency shut-down, anti-theft protection.

Safety glass, horn, Inertia reel type safety belt Safety valves with overload indicator.............................................................................................................. optional Fire extinguisher ............................................................................................................................................. optional

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CHAPTER 8 - SPECIFICATIONS

OPERATOR’S COMPARTMENT High comfort seat with armrests, inertia reel type safety belt, multiple adjustments and head rest.

Hydraulically assisted controls.

Attachment and swing .........................................................................................................................2 control levers Travel ...................................................................................................................................................... 2 foot pedals Automatic speed change.

Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation/air conditioning, cab lighting, cigarette lighter, sun shield.

Working lights: On upper structure (1 light) ....................................................................................................................24 V, 70 W On attachment (2 lights).........................................................................................................................24 V, 70 W On cab (2 lights).....................................................................................................................................24 V, 70 W

CAB Removable, with sound proofing, mounted on flexible Isomount® climate control system Front window safety glass Windshield wiper/washer Foldaway windscreen.

Rear window emergency exit.

Sun shield.

Sliding windows on door.

24 V radio with precut space for CD player.

Anti-theft device Roof hatch.

Windshield protection grille............................................................................................................................. optional Cab guard....................................................................................................................................................... optional Falling Object Protection (FOPS) ................................................................................................................... optional

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CHAPTER 8 - SPECIFICATIONS

BOOM/ARMS Boom Reach ............................................................................................................................................27 ft 7 in (8.4 m) Boom with arm cylinder and plumbing ......................................................................................17725 lb (8040 kg) Hoist cylinders (2) ................................................................................................................ 1764 lb (800 kg) each Total weight ...............................................................................................................................21253 lb (9640 kg) Boom Mass Excavator Reach ..........................................................................................................................................23 ft 9 in (7.25 m) Boom with arm cylinder and plumbing ......................................................................................16491 lb (7480 kg) Hoist cylinders (2) .............................................................................................................. 1764 lb (3800 kg) each Total weight ...............................................................................................................................20018 lb (9080 kg) Arms 18 ft 5 in (5.62 m)

12 ft 0 in (3.766 m)

14 ft 7 in (4.44 m)

9 ft 9 in (2.98 m)

UNDERCARRIAGE Track Shoes .........................................................................................................29.5 in (750 mm) 2-bar, 51 per side Track length ...................................................................................................................................20 ft 10 in (6.36 m) Track gauge ...................................................................................................................................11 ft 11 in (3.64 m) Type ........................................................................................................................................ Sealed and lubed track Guards....................................................................................................................................Full length track guards Track Drive...................................................................................2-speed hydrostatic, straight tracking travel priority Parking Brake ............................................................................................................................................... Disc type

UPPER STRUCTURE Control ....................................................................................................................................................... Free swing Hammer adaptable, no reinforcing required, swing brake

ELECTRICAL System............................................................................................................................................ Electronic Monitor Voltage..................................................................................................................................24 volts negative ground Alternator ........................................................................................................................................................50 amp Batteries (2) .....................................................................................................................................140 Ah (5 hr rate)

BUCKETS

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Application

Width

SAE Heaped Capacity

Heavy Duty

42 in - 84 in (1.06 m - 2.13)

2.53 cubic yd - 5.91 cubic yd (1.93 cubic m - 4.52 cubic m)

Extreme Duty

45 in - 84 in (1.14 m - 2.13 m)

2.47 cubic yd - 5.30 cubic yd (1.89 cubic m - 4.05 cub m)

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GENERAL DIMENSIONS

Figure 1

BS06E106A/BS06E106B

CX 800 - BOOM LENGTH 23 FT 9 IN (7.25 M) MASS EXCAVATION 9 FT 9 IN (2.98 M) ARM (A) Overall height...............................................................................................................................16 ft 7 in (5.0 m) (B) Top hand rail height ...................................................................................................................12 ft 5 in (3.79 m) (C) Overall Length .........................................................................................................................43 ft 4 in (13.21 m) (D) Without attachment....................................................................................................................24 ft 6 in (7.46 m) (E) Width of upper structure ..........................................................................................................13 ft 11 in (4.25 m) (F) Upper structure ground clearance ...............................................................................................5 ft 3 in (1.59 m) (G) Tail swing radius ........................................................................................................................14 ft 1 in (4.30 m) (H) Track overall length ..................................................................................................................20 ft 10 in (6.36 m) (I) Center to center (idler to sprocket)..............................................................................................16 ft 8 in (5.07 m) (J) Track gauge - extended ..............................................................................................................11 ft 4 in (3.45 m) (K) Track shoe width .........................................................................................................................29.5 in (750 mm) (L) Track overall width 29.5 in (750 mm) width shoes .....................................................................................................14 ft 4 in (4.36 m) 29.5 in (750 mm) width side frames retracted .............................................................................12 ft 3 in (3.74 m) (M) Minimum ground clearance .......................................................................................................2 ft 11 in (0.89 m) Working weight *........................................................................................................................ 175405 lb (79562 kg) Ground pressure................................................................................................................................13.7 psi (94 bar) * With 29.5 in (750 mm) track shoe; 7623 lb (3450 kg) bucket; 165 lb (75 kg) operator, full fuel and standard equipment 8-8

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PERFORMANCE SPECIFICATIONS

Figure 2

B95D1205

CX 800 Boom Length 23 ft 9 in (7.25 m) - 9 ft 9 in (2.98 m) Arm (A) Maximum dig radius.................................................................................................................40 ft 5 in (12.31 m) (B) Dig radius at ground line ..........................................................................................................39 ft 4 in (11.99 m) (C) Maximum dig depth ...................................................................................................................23 ft 1 in (7.03 m) (D) Dig depth - 8 ft 0 in (2.44 m) level bottom..................................................................................22 ft 7 in (6.88 m) (E) Dump height ............................................................................................................................25 ft 11 in (7.89 m) (F) Overall reach height .................................................................................................................38 ft 7 in (11.76 m) (G) Bucket rotation.............................................................................................................................................. 167 ° (h) Vertical straight wall dig depth..................................................................................................13 ft 11 in (4.25 m) (J) Minimum swing radius ................................................................................................................17 ft 8 in (5.39 m) Arm digging force Standard..................................................................................................................................... 71264 lb (317 kN) Power Boost .............................................................................................................................. 78009 lb (347 kN) Bucket digging force Standard..................................................................................................................................... 96668 lb (430 kN) Power Boost ............................................................................................................................. 105660 lb (470 kN)

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GENERAL DIMENSIONS

BS06E103A/BS06E103B

CX 800 BOOM LENGTH 27 FT 7 IN (8.40 M) 18 ft 5 in (5.62 m) Arm (A) Overall height.............................................................................................................................20 ft 4 in (6.20 m) (B) Cab height .................................................................................................................................12 ft 5 in (3.79 m) (C) Overall Length .........................................................................................................................45 ft 8 in (13.92 m) (D) Without attachment....................................................................................................................24 ft 6 in (7.46 m) (E) Width of upper structure ..........................................................................................................13 ft 11 in (4.25 m) (F) Upper structure ground clearance ...............................................................................................5 ft 3 in (1.59 m) (G) Tail swing radius ........................................................................................................................14 ft 1 in (4.30 m) (H) Track overall length ..................................................................................................................20 ft 10 in (6.36 m) (I) Center to center (idler to sprocket)..............................................................................................16 ft 8 in (5.07 m) (J) Track gauge - extended ..............................................................................................................11 ft 4 in (3.45 m) (K) Track shoe width .........................................................................................................................29.5 in (750 mm) (L) Track overall width 29.5 in (750 mm) width shoes .....................................................................................................14 ft 4 in (4.36 m) 29.5 in (750 mm) width side frames retracted .............................................................................12 ft 3 in (3.74 m) (M) Minimum ground clearance .......................................................................................................2 ft 11 in (0.89 m) Working weight *........................................................................................................................ 177106 lb (80334 kg) Ground pressure................................................................................................................................13.8 psi (95 bar) * With 29.5 in (750 mm) track shoe; 6614 lb (3000 kg) bucket; 165 lb (75 kg) operator, full fuel and standard equipment 8-10

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CHAPTER 8 - SPECIFICATIONS CX 800 BOOM LENGTH 27 FT 79 IN (8.40 M) MASS EXCAVATION 14 ft 7 in (4.44 m) Arm (A) Overall height.............................................................................................................................16 ft 5 in (5.00 m) (B) Cab height .................................................................................................................................12 ft 5 in (3.79 m) (C) Overall Length .......................................................................................................................46 ft 11 in (14.32 m) (D) Without attachment....................................................................................................................24 ft 6 in (7.46 m) (E) Width of upper structure ..........................................................................................................13 ft 11 in (4.25 m) (F) Upper structure ground clearance ...............................................................................................5 ft 3 in (1.59 m) (G) Tail swing radius ........................................................................................................................14 ft 1 in (4.30 m) (H) Track overall length ..................................................................................................................20 ft 10 in (6.36 m) (I) Center to center (idler to sprocket)..............................................................................................16 ft 8 in (5.07 m) (J) Track gauge - extended ..............................................................................................................11 ft 4 in (3.45 m) (K) Track shoe width .........................................................................................................................29.5 in (750 mm) (L) Track overall width 29.5 in (750 mm) width shoes .....................................................................................................14 ft 4 in (4.36 m) 29.5 in (750 mm) width side frames retracted .............................................................................12 ft 3 in (3.74 m) (M) Minimum ground clearance .......................................................................................................2 ft 11 in (0.89 m) Working weight *........................................................................................................................175997 lb (79822 kg) Ground pressure................................................................................................................................13.7 psi (94 bar) * With 29.5 in (750 mm) track shoe; 6614 lb (3000 kg) bucket; 165 lb (75 kg) operator, full fuel and standard equipment

12 ft 0 in (3.66 m) Arm (A) Overall height.............................................................................................................................15 ft 9 in (4.80 m) (B) Cab height .................................................................................................................................12 ft 5 in (3.79 m) (C) Overall Length .........................................................................................................................47 ft 1 in (14.36 m) (D) Without attachment....................................................................................................................24 ft 6 in (7.46 m) (E) Width of upper structure ..........................................................................................................13 ft 11 in (4.25 m) (F) Upper structure ground clearance ...............................................................................................5 ft 3 in (1.59 m) (G) Tail swing radius ........................................................................................................................14 ft 1 in (4.30 m) (H) Track overall length ..................................................................................................................20 ft 10 in (6.36 m) (I) Center to center (idler to sprocket)..............................................................................................16 ft 8 in (5.07 m) (J) Track gauge - extended ..............................................................................................................11 ft 4 in (3.45 m) (K) Track shoe width .........................................................................................................................29.5 in (750 mm) (L) Track overall width 29.5 in (750 mm) width shoes .....................................................................................................14 ft 4 in (4.36 m) 29.5 in (750 mm) width side frames retracted .............................................................................12 ft 3 in (3.74 m) (M) Minimum ground clearance .......................................................................................................2 ft 11 in (0.89 m) Working weight *........................................................................................................................175210 lb (79474 kg) Ground pressure.................................................................................................................................13.7 psi (94 bar * With 29.5 in (750 mm) track shoe; 6614 lb (3000 kg) bucket; 165 lb (75 kg) operator, full fuel and standard equipment 87538934 NA

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PERFORMANCE SPECIFICATIONS

Figure 3

BS06E104

Boom Length 27 ft 7 in (8.40 m) - 18 ft 5in (5.62 m) Arm (A) Maximum dig radius...............................................................................................................52 ft 10 in (16.11 m) (B) Dig radius at ground line..........................................................................................................52 ft 1 in (15.86 m) (C) Maximum dig depth .................................................................................................................35 ft 0 in (10.66 m) (D) Dig depth - 8 ft 0 in (2.44m) level bottom.................................................................................34 ft 8 in (10.56 m) (E) Dump height ............................................................................................................................33 ft 4 in (10.17 m) (F) Overall reach height ...............................................................................................................46 ft 11 in (14.30 m) (G) Bucket rotation.............................................................................................................................................. 167 ° (h) Vertical straight wall dig depth..................................................................................................29 ft 11 in (9.11 m) (J) Minimum swing radius ................................................................................................................20 ft 4 in (6.21 m) Arm digging force Standard..................................................................................................................................... 43842 lb (195 kN) Power Boost .............................................................................................................................. 48113 lb (214 kN) Bucket digging force Standard..................................................................................................................................... 74187 lb (330 kN) Power Boost ............................................................................................................................... 81156 lb (361 kN)

8-12

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CHAPTER 8 - SPECIFICATIONS Boom Length 27 ft 7 in (8.40 m) - 14 ft 7 in (4.44 m) Arm (A) Maximum dig radius.................................................................................................................49 ft 0 in (14.94 m) (B) Dig radius at ground line ..........................................................................................................48 ft 2 in (14.68 m) (C) Maximum dig depth ...................................................................................................................31 ft 1 in (9.47 m) (D) Dig depth - 8 ft 0 in (2.44m) level bottom...................................................................................30 ft 9 in (9.36 m) (E) Dump height ..............................................................................................................................31 ft 2 in (9.51 m) (F) Overall reach height .................................................................................................................44 ft 7 in (13.60 m) (G) Bucket rotation.............................................................................................................................................. 167 ° (h) Vertical straight wall dig depth....................................................................................................25 ft 5 in (7.75 m) (J) Minimum swing radius ................................................................................................................20 ft 1 in (6.13 m) Arm digging force Standard..................................................................................................................................... 52156 lb (232 kN) Power Boost .............................................................................................................................. 56877 lb (253 kN) Bucket digging force Standard..................................................................................................................................... 74187 lb (330 kN) Power Boost ............................................................................................................................... 81156 lb (361 kN)

Boom Length 27 ft 7 in (8.40 m) - 12 ft 0 in (3.66 m) Arm (A) Maximum dig radius.................................................................................................................46 ft 4 in (14.12 m) (B) Dig radius at ground line ..........................................................................................................45 ft 5 in (13.84 m) (C) Maximum dig depth ...................................................................................................................28 ft 6 in (8.69 m) (D) Dig depth - 8 ft 0 in (2.44m) level bottom...................................................................................28 ft 1 in (8.57 m) (E) Dump height ..............................................................................................................................29 ft 3 in (8.92 m) (F) Overall reach height .................................................................................................................42 ft 4 in (12.91 m) (G) Bucket rotation.............................................................................................................................................. 167 ° (h) Vertical straight wall dig depth....................................................................................................21 ft 3 in (6.44 m) (J) Minimum swing radius ................................................................................................................20 ft 7 in (6.27 m) Arm digging force Standard..................................................................................................................................... 61598 lb (274 kN) Power Boost .............................................................................................................................. 67443 lb (300 kN) Bucket digging force Standard..................................................................................................................................... 74187 lb (330 kN) Power Boost ............................................................................................................................... 81156 lb (361 kN)

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CHAPTER 8 - SPECIFICATIONS

OVERALL DIMENSIONS AND WEIGHT OF MAIN MACHINE COMPONENTS

1

2

3

4 5 6

Figure 4

CS010574B

a (length)

b (height)

c (width)

Approximate weight

(1)

19.2 ft (5.84 m)

9.68 ft (2.95 m)

11.4 ft (3.48 m)

55556 lb (25200 kg)

(2)

11.38 ft (3.47 m)

4.56 ft (1.39 m)

2.72 ft (0.83 m)

27558 lb (12500 kg)

(3) (each)

20.87 ft (6.36 m)

4.92 ft (1.50 m)

2.13 ft (0.65 m)

27337 lb (12400 kg)

(3) (each)

20.87 ft (6.36 m)

4.92 ft (1.50 m)

2.46 ft (0.75 m)

28219 lb (12800 kg)

(3) (each)

20.87 ft (6.36 m)

4.92 ft (1.50 m)

2.95 ft (0.90 m)

29542 lb (13400 kg)

(4) (7.25 m boom)

25.75 ft (7.85 m)

8.40 ft (2.56 m)

4.82 ft (1.47 m)

17461 lb (7920 kg)

(4) (8.40 m boom)

28.70 ft (8.75 m)

7.55 ft (2.31 m)

4.82 ft (1.47 m)

18298 lb (8300 kg)

(5) (both)

9.61 ft (2.93 m)

-

3.28 ft (1.00 m)

3527 lb (1600 kg)

(6) (3.00 m)

14.37 ft (4.38 m)

4.92 ft (1.50 m)

2.43 ft (0.74 m)

9370 lb (4250 kg)

(6) (standard 3.60 m)

17.06 ft (5.20 m)

4.59 ft (1.40 m)

2.43 ft (0.74 m)

9039 lb (4100 kg)

(Cab protection)

7.55 ft (2.30 m)

6.23 ft (1.90 m)

3.44 ft (1.05 m)

705 lb (320 kg)

(Walkways and access handles)

-

-

-

368 lb (167 kg)

NOTE: For dimensions and weights of buckets, refer to “Backhoe buckets”.

8-14

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CHAPTER 8 - SPECIFICATIONS CX800 LIFT CAPACITIES - BOOM LENGTH 27 FT 7 IN (8.40 M) 18.5 FT (5.62 M) ARM LIFT CAPACITIES Calculated using a 5709 lb (2590 kg) bucket, 27668 lb (12561 kg) counterweight operating in Light mode Load (lift point) height

15 ft (4.57 m) END SIDE

10 ft (3.05 m) END SIDE

20 ft (6.105 m) END SIDE

25 ft (7.62 m) END SIDE

30 ft (9.145 m) END SIDE

+40 ft (12.19 m) +35 ft (10.67 m) +30 ft (9.14 m) +25 ft (7.62 m) +20 ft (6.10 m) +15 ft (4.57 m)

26850 lb* 12179 kg

26850 lb* 12179 kg

+10 ft (3.05 m)

32750 lb* 14855 kg

32750 lb* 14855 kg

40400 lb* 18325 kg

40400 lb* 18325 kg

36000 lb* 16329 kg

36000 lb* 16329 kg

30100 lb* 13653 kg

30100 lb* 13653 kg

+5 ft (1.52 m)

69400 lb* 31479 kg

69400 lb* 31479 kg

52850 lb* 23972 kg

52850 lb* 23972 kg

41850 lb* 18983 kg

40600 lb* 18416 kg

33550 lb* 15218 kg

30250 lb 13721 kg

Ground line

48300 lb 21909 kg

48300 lb* 21909 kg

61500 lb* 27896 kg

53850 lb 24426 kg

46200 lb* 20956 kg

38050 lb 17259 kg

36550 lb* 16579 kg

28450 lb 12905 kg

-5 ft (-1.52 m)

30450 lb* 13812 kg

30450 lb* 13812 kg

48850 lb 22158 kg

48850 lb* 22158 kg

63700 lb* 28894 kg

51200 lb 23224 kg

48500 lb* 21999 kg

36150 lb 16397 kg

38500 lb* 17463 kg

27100 lb 12292 kg

-10 ft (-3.05 m)

37600 lb* 17055 kg

37600 lb 17055 kg

55950 lb* 25378 kg

55950 lb* 25378 kg

63500 lb* 28803 kg

50200 lb 22770 kg

48850 lb* 22158 kg

35050 lb 15898 kg

39100 lb* 17735 kg

26200 lb 11884 kg

-15 ft (-4.57 m)

56750 lb* 25741 kg

46250 lb* 20979 kg

64950 lb* 29461 kg

64950 lb* 29461 kg

61700 lb* 27987 kg

50250 lb 22793 kg

47900 lb* 21727 kg

34750 lb 15762 kg

38400 lb* 17418 kg

25900 lb 11748 kg

-20 ft (-6.10 m)

53187 lb* 24125 kg

56750 lb* 25741 kg

77000 lb* 34927 kg

77000 lb* 34927 kg

57800 lb* 26218 kg

50900 lb 23088kg

45200 lb* 20502 kg

35050 lb 15898 kg

36150 lb* 16397 kg

26050 lb 11816 kg

-25 ft (-7.62 m)

78150 lb* 35448 kg

78150 lb* 35448 kg

66650 lb 30232 kg

66650 lb* 30232 kg

50750 lb* 23020kg

50300 lb* 22816kg

38700 lb* 18008 kg

35900 lb 16284 kg

31150 lb* 14129 kg

26750 lb 12134 kg

50650 lb* 22974 kg

50650 lb* 22974 kg

38900 lb* 17645kg

38900 lb* 17645g

29550 lb* 13404 kg

29550 lb 13404 kg

19800 lb* 8981 kg

19800 lb* 8981 kg

-30 ft (-9.14 m)

Load (lift point) height

35 ft (10.67 m) END SIDE

40 ft (12.19 m) END SIDE

45 ft (13.72 m) END SIDE

MAXIMUM REACH @ END SIDE

+40 ft (12.19 m)

41 ft 9 in (12.73 m)

8000 lb* 3629 kg

8000 lb* 12.73 kg

+35 ft (10.67 m)

45 ft 3 in (13.79 m)

7300 lb* 3311 kg

7300 lb* 3311 kg

47 ft 10 in (14.58 m)

6900 lb* 3130 kg

6900 lb* 3130 kg

+30 ft (9.14 m)

15500 lb* 7031 kg

15500 lb* 7031 kg

+25 ft (7.62 m)

18250 lb* 8278 kg

18250 lb* 8278 kg

9300 lb* 4218 kg

9300 lb* 4218 kg

49 ft 8 in (15.14 m)

6750 lb* 3062 kg

6750 lb* 3062 kg

+20 ft (6.10 m)

22300 lb* 10115 kg

22300 lb* 10115 kg

20700 lb* 9389 kg

20400 lb* 9253 kg

15100 lb* 6849 kg

15100 lb* 6849 kg

50 ft 11 in (15.52 m)

6700 lb* 3039 kg

6700 lb* 3039 kg

+15 ft (4.57 m)

24200 lb* 10977 kg

24200 lb* 10977 kg

22350 lb* 10138kg

19800 lb 8981 kg

18100 lb* 8210 kg

15250 lb 6917 kg

51 ft 6 in (15.70 m)

6850 lb* 3107 kg

6850 lb* 3107 kg

+10 ft (3.05 m)

26300 lb* 11929 kg

24450 lb 11090 kg

23650 lb* 10727 kg

18900 lb 8573 kg

20450 lb* 9276 kg

14700 lb 6668kg

51 ft 7 in (15.72 m)

7100 lb* 3221 kg

7100 lb* 3221 kg

+5 ft (1.52 m)

28300 lb* 12837 kg

23150 lb 10501 kg

24900 lb* 11294 kg

18000lb 8165 kg

22100 lb* 10024 kg

14150lb 6418 kg

51 ft 1 in (15.57 m)

7550 lb* 3425 kg

7550 lb* 3425 kg

Ground line

30350 lb* 13767 kg

21950 lb 9956 kg

26000 lb* 11793 kg

17200 lb 7802 kg

22800 lb* 10342 kg

13600 lb 6169 kg

50 ft 0 in (15.24 m)

8200 lb* 3719 kg

8200 lb* 3719 kg

-5 ft (-1.52 m)

31700 lb* 14379 kg

20950 lb 9503 kg

26850 lb* 12179 kg

16550 lb 7507 kg

22850 lb 10365 kg

13250 lb 6010 kg

48 ft 4 in (14.73 m)

9150 lb* 4150 kg

9150 lb* 4150 kg

-10 ft (-3.05 m)

32100 lb* 14560 kg

20350 lb 9231 kg

26850 lb* 12179 kg

16150 lb 7326 kg

18150 lb* 8233 kg

13100 lb 5942 kg

45 ft 11 in (14.00 m)

10500 lb* 4763 kg

10500 lb* 4763 kg

-15 ft (-4.57 m)

31400 lb* 14243 kg

20100 lb 9117 kg

25650 lb* 11635 kg

16050 lb 7280 kg

42 ft 8 in (13.00 m)

12450 lb* 5647 kg

12450 lb* 5647 kg

-20 ft (-6.10 m)

28950 lb* 13131 kg

20300 9208 kg

20350 lb* 9231 kg

16500 lb 7484 kg

38 ft 4 in (11.68 m)

15600 lb* 7076 kg

15600 lb* 7076 kg

-25 ft (-7.62 m)

22900 lb* 10387 kg

31100 lb 9571 kg

-30 ft (-9.14 m)

• Lift capacities do not exceed 75% of the minimum tipping load or 87% of the hydraulic lift capacity. Capacities that are marked with an asterisk are hydraulic limited 87538934 NA

Issued 06-06

Bur

8-15

CHAPTER 8 - SPECIFICATIONS LIFT CAPACITIES - BOOM LENGTH 27 FT 7 IN (8.40 M) 14 FT 7 IN (4.44 M) ARM LIFT CAPACITIES Calculated using a 6616 lb (3001 kg) bucket, 27668 lb (12561 kg) counterweight operating in Light mode Load (lift point) height

10 ft (3.05 m) END SIDE

15 ft (4.57 m) END SIDE

20 ft (6.105 m) END SIDE

25 ft (7.62 m) END SIDE

30 ft (9.145 m) END SIDE

+40 ft (12.19 m) +35 ft (10.67 m) +30 ft (9.14 m) +25 ft (7.62 m) +20 ft (6.10 m) +15 ft (4.57 m)

27587 lb* 12513 kg

27587 lb* 12513 kg

35487 lb* 16097 kg

35487 lb* 16097 kg

30287 lb* 13738 kg

30287 lb* 13738 kg

+10 ft (3.05 m)

72187 lb* 32743 kg

72187 lb* 32743 kg

53687 lb* 24352 kg

53687 lb* 24352 kg

40887 lb* 18546 kg

40887 lb* 18546 kg

33137 lb* 15031 kg

30716 lb* 13933 kg

+5 ft (1.52 m)

44987 lb* 20406 kg

44987 lb* 20406 kg

59987 lb* 27210 kg

54916 lb 24910 kg

45737 lb* 20746 kg

38886 lb 17629 kg

36237 lb* 16437 kg

29016 lb 13162 kg

Ground line

23187 lb* 10517 kg

23187 lb* 10517 kg

43787 lb* 19861 kg

43787 lb* 19861 kg

63337 lb* 28729 kg

51916 lb 23549 kg

48587 lb* 22039 kg

36766 lb 16677 kg

38437 lb* 17435 kg

27566 lb 12504 kg

-5 ft (-1.52 m)

34837 lb* 15802 kg

34837 lb* 15802 kg

51287 lb* 23263 kg

51287 lb* 23263 kg

63987 lb* 29024 kg

50616 lb 22959 kg

49237 lb* 22333 kg

35466 lb 16087 kg

39337 lb* 17843 kg

26616 lb 12073 kg

-10 ft (-3.05 m)

42487 lb* 19272 kg

42487 lb* 19272 kg

59887 lb* 27164 kg

59887 lb* 27164 kg

62537 lb* 28366 kg

50566 lb 22936 kg

48537 lb* 22016 kg

35066 lb 15906 kg

38937 lb* 17661 kg

26116 lb 11846 kg

-15 ft (-4.57 m)

53187 lb* 24125 kg

53187 lb* 24125 kg

76437lb* 34671 kg

76437lb* 34671 kg

59087 lb* 26801 kg

51116 lb 23186 kg

46337 lb* 21018 kg

35216 lb 15974kg

37137 lb* 16845 kg

26166 lb 11869 kg

-20 ft (-6.10 m)

70137 lb* 31814 kg

70137 lb* 31814 kg

68687 lb* 31156 kg

68687 lb* 31156 kg

52837lb* 23966 kg

51066 lb 23163 kg

41637 lb* 18886 kg

35916 lb 16291 kg

32837 lb* 14895 kg

26716 lb 12118 kg

54337 lb* 24647 kg

54337 lb* 24647 kg

42387 lb* 19226 kg

42387 lb* 19226 kg

32787 lb* 14872 kg

32787 lb* 14872 kg

22937 lb* 10404 kg

22937 lb* 10404 kg

-25 ft (-7.62 m)

Load (lift point) height

35 ft (10.67 m) END SIDE

40 ft (12.19 m) END SIDE

45 ft (13.72 m) END SIDE

MAXIMUM REACH @ END SIDE

+40 ft (12.19 m)

36 ft 9 in (11.20 m)

8887 lb* 4031 kg

8887 lb* 4031 kg

+35 ft (10.67 m)

40 ft 8 in (12.40 m)

8037 lb* 3645 kg

8037 lb* 3645 kg

43ft 7 in (13.28 m)

7587lb* 3441 kg

7587lb* 3441 kg

+30 ft (9.14 m)

19837 lb* 8998 kg

19837 lb* 8998 kg

+25 ft (7.62 m)

23787 lb* 10790

23787 lb* 10790

14637 lb* 6639 kg

14637 lb* 6639 kg

45 ft 8 in (13.92 m)

7387 lb* 3351 kg

7387 lb* 3351 kg

+20 ft (6.10 m)

25237 lb* 11447 kg

24916 lb 11302 kg

21287 lb* 9656 kg

19466 lb* 8830 kg

47 ft 0 in (14.33 m)

7337 lb* 3328 kg

7337 lb* 3328 kg

+15 ft (4.57 m)

26887 lb* 12196 kg

24616 lb 11166 kg

24037 lb* 10903 kg

18866 lb 8558 kg

47 ft 8 in (14.53 m)

7487 lb* 3396 kg

7487 lb* 3396 kg

+10 ft (3.05 m)

28687 lb* 13012 kg

23416 lb 10621 kg

25587 lb* 11606 kg

18116 lb 8217kg

11187 lb* 5074 kg

11187 lb* 5074 kg

47 ft 9 in (14.55 m)

7837 lb* 3555 kg

7837 lb* 3555 kg

+5 ft (1.52 m)

30287 lb* 13738 kg

22266 lb 10100 kg

26437 lb* 11992 kg

17416 lb 7900kg

12737 lb* 5777 kg

12737 lb* 5777 kg

47 ft 2 in (14.38 m)

8387 lb* 3804 kg

8387 lb* 3804 kg

Ground line

31737 lb* 14396 kg

21316 lb 9669 kg

27037 lb* 12264 kg

16766 lb 7605 kg

46 ft 0 in (14.02 m)

9187 lb* 4167 kg

9187 lb* 4167 kg

-5 ft (-1.52 m)

32366 lb* 14681 kg

20616 lb 9351 kg

27137 lb* 12309 kg

16366 lb 7424 kg

44 ft 2 in (13.46 m)

10387 lb* 4711 kg

10387 lb* 4711 kg

-10 ft (-3.05 m)

31887 lb* 14464 kg

20316 lb 9215 kg

26037 lb* 11810 kg

16266lb 7378 kg

41 ft 6 in (12.65 m)

12087 lb* 5483 kg

12087 lb* 5483 kg

-15 ft (-4.57 m)

29837 lb* 13534 kg

20416 9261 kg

37 ft 9 in (11.51 m)

14737 lb* 6685 kg

14737 lb* 6685 kg

-20 ft (-6.10 m)

24237 lb* 10994 kg

21116 lb 9578 kg

-25 ft (-7.62 m)

• Lift capacities do not exceed 75% of the minimum tipping load or 87% of the hydraulic lift capacity. Capacities that are marked with an asterisk are hydraulic limited

8-16

87538934 NA

Issued 06-06

Bur

CHAPTER 8 - SPECIFICATIONS LIFT CAPACITIES - BOOM LENGTH 27 FT 7 IN (8.40 M) 12 FT 0 IN (3.66 M) ARM LIFT CAPACITIES Calculated using a 6616 lb (3001 kg) bucket, 27668 lb (12561 kg) counterweight operating in Light mode Load (lift point) height

15 ft (4.57 m) END SIDE

10 ft (3.05 m) END SIDE

20 ft (6.105 m) END SIDE

25 ft (7.62 m) END SIDE

30 ft (9.145 m) END SIDE

+35 ft (10.67 m) +30 ft (9.14 m) +25 ft (7.62 m)

28248 lb* 12813 kg

28248 lb* 12813 kg

+20 ft (6.10 m)

30248 lb* 13720 kg

30248 lb* 13720 kg

66048 lb 29959 kg

+15 ft (4.57 m)

66048 lb 29959 kg

+10 ft (3.05 m)

48648 lb* 22066 kg

48648 lb* 22066 kg

36698 lb* 17553 kg

36698 lb* 17553 kg

32748 lb* 14854 kg

31898 lb* 14469 kg

55448 lb* 25151 kg

55448 lb* 25151 kg

43998 lb* 19957 kg

40549 lb* 18392 kg

35298 lb* 16011 kg

30199 lb* 13698 kg

+5 ft (1.52 m)

37498 lb* 17009 kg

37498 lb* 17009 kg

60998 lb* 27668 kg

53299 lb 24176 kg

47948 lb* 21749 kg

38049 lb 17259 kg

37898 lb* 17190 kg

28599 lb 12972 kg

Ground line

44048 lb* 19980 kg

44048 lb* 19980 kg

63898 lb* 28984 kg

51049 lb 23155 kg

49548 lb* 22475 kg

36299 lb 16465 kg

39448 lb* 17893 kg

27399 lb 12428 kg

-5 ft (-1.52 m)

42648 lb* 19345 kg

42648 lb* 19345 kg

52598 lb* 23858 kg

56198 lb* 25491 kg

63598 lb* 28848 kg

50599 lb 22951 kg

49348 lb* 22384 kg

35399 lb 16056 kg

39648 lb* 17984 kg

26649 lb 12088 kg

-10 ft (-3.05 m)

48948 lb* 22203 kg

48948 lb* 22203 kg

69198 lb* 31388 kg

69198 lb* 31388 kg

61148 lb* 27736 kg

50899 lb 23087 kg

48048 lb* 21749 kg

35349 lb 16034 kg

38698 lb* 17553 kg

26399 lb 11974 kg

-15 ft (-4.57 m)

64798 lb* 29392 kg

64798 lb* 29392 kg

72748 lb* 32998 kg

72748 lb* 32998 kg

56398 lb* 25582 kg

51548 lb 23382 kg

44698 lb* 20275 kg

35799 lb 16238 kg

35798 lb* 16238 kg

26699 lb 12110 kg

-20 ft (-6.10 m)

80048 lb* 36309 kg

80048 lb* 36309 kg

61248 lb* 27782 kg

61248 lb* 27782 kg

48298 lb* 21908kg

48298 lb 21908 kg

38248 lb* 17349 kg

36399 lb 16510 kg

29248 lb* 13267 kg

27499 lb 12473 kg

34848 lb* 15807 kg

34848 lb* 15807 kg

25448 lb* 11543 kg

25448 lb* 11543 kg

-25 ft (-7.62 m)

Load (lift point) height

35 ft (10.67 m) END SIDE

40 ft (12.19 m) END SIDE

45 ft (13.72 m) END SIDE

MAXIMUM REACH @ END SIDE

+35 ft (10.67 m)

37 ft 5 in (11.40 m)

13698 lb* 6213 kg

13698 lb* 6213 kg

+30 ft (9.14 m)

40 ft 7 in (12.37 m)

13148 lb* 5964 kg

13148 lb* 5964 kg

42 ft 10 in (13.06 m)

12948 lb* 5873 kg

12948 lb* 5873 kg

+25 ft (7.62 m)

26048 lb* 11815 kg

25749 lb 11679 kg

+20 ft (6.10 m)

27584 lb* 12496 kg

25299 lb 11475 kg

17798 lb* 8073 kg

17798 lb* 8073 kg

44 ft 3 in (13.49 m)

13048 lb* 5919 kg

13048 lb* 5919 kg

+15 ft (4.57 m)

28948 lb* 13131 kg

24249 lb 10999 kg

25698 lb* 11657 kg

18649 lb 8459 kg

45 ft 0 in (13.72 m)

13348 lb* 6055 kg

13348 lb* 6055 kg

+10 ft (3.05 m)

30448 lb* 13811 kg

23149 lb 10500 kg

26748 lb* 12133 kg

18049 lb 8187kg

45 ft 0 in (13.72 m)

13948 lb* 6327 kg

13948 lb* 6327 kg

+5 ft (1.52 m)

31698 lb* 14378 kg

22149 lb 10046 kg

27448 lb* 12450 kg

17449 lb 7915 kg

44 ft 6 in (13.56 m)

14848 lb* 6735 kg

14149 lb* 6418 kg

Ground line

32648 lb* 14809 kg

21349 lb 9684 kg

27698 lb* 12564 kg

16649 lb 7688 kg

43 ft 3 in (13.18 m)

16148 lb* 7325 kg

14799 lb* 6712 kg

-5 ft (-1.52 m)

32698 lb* 14832 kg

20799 lb 9434 kg

27098lb* 12292 kg

16699 lb 7574 kg

41 ft 2 in (12.55 m)

18048 lb* 8187 kg

16149 lb* 7325 kg

-10 ft (-3.05 m)

31887 lb* 14832 kg

20699 lb 9389 kg

38 ft 3 in (11.66 m)

20898 lb* 9479 kg

18599 lb* 8436 kg

-15 ft (-4.57 m)

31498 lb* 14287 kg

22099 lb 9570 kg

-20 ft (-6.10 m)

27798 lb* 12609 kg

-25 ft (-7.62 m)

• Lift capacities do not exceed 75% of the minimum tipping load or 87% of the hydraulic lift capacity. Capacities that are marked with an asterisk are hydraulic limited.

87538934 NA

Issued 06-06

Bur

8-17

CHAPTER 8 - SPECIFICATIONS LIFT CAPACITIES - BOOM LENGTH 23 FT 9 IN (7.25 M) 9 FT 9 IN (2.98 M) ARM LIFT CAPACITIES Calculated using a 7623 lb (3450 kg) bucket, 27668 lb (12561 kg) counterweight operating in Light mode Load (lift point) height

10 ft (3.05 m) END SIDE

15 ft (4.57 m) END SIDE

20 ft (6.105 m) END SIDE

25 ft (7.62 m) END SIDE

30 ft (9.145 m) END SIDE

+30 ft (9.14 m) +25 ft (7.62 m) +20 ft (6.10 m)

38750 lb* 17577 kg

38750 lb* 17577 kg

34900 lb* 15830 kg

30400 lb 13789 kg

+15 ft (4.57 m)

71000 lb 32205 kg

71000 lb 32205 kg

52050 lb* 23609 kg

52050 lb* 23609 kg

42400 lb* 19232 kg

40000 lb* 18144 kg

36750 lb* 16670 kg

29150 lb* 13222 kg

+10 ft (3.05 m)

84550 lb* 38351 kg

84550 lb* 38351 kg

56950 lb* 25832 kg

53500 lb* 24267 kg

43200 lb* 20956 kg

37500 lb* 17010 kg

38700 lb* 17554 kg

27750 lb* 12587 kg

+5 ft (1.52 m)

68450 lb* 31048 kg

68450 lb* 31048 kg

63600 lb* 28848kg

50150 lb 22748 kg

49100 lb* 22271 kg

35450 lb 16080 kg

40250 lb* 18257 kg

26550 lb 12043 kg

Ground line

77700 lb* 35244 kg

77700 lb* 35244 kg

64950 lb* 29461 kg

48250 lb 21886 kg

50250 lb* 22793 kg

34100 lb 15468 kg

40600 lb* 18416 kg

25700 lb 11657 kg

38950 lb* 17667 kg

25400 lb 11521 kg

-5 ft (-1.52 m)

59100 lb* 26807 kg

59100 lb* 26807 kg

83300 lb* 37784 kg

78050 lb 35403 kg

62950 lb* 28554 kg

47600 lb 21591 kg

49050 lb* 22249 kg

33500 lb 15195 kg

-10 ft (-3.05 m)

84400 lb* 38283 kg

84400 lb* 38283 kg

73900 lb* 33520 kg

73900 lb* 33520 kg

57200 lb* 25945 kg

47950 lb 21750 kg

44600 lb* 20230 kg

33750 lb 15309 kg

58960 lb* 26744 kg

58960 lb* 26744 kg

43200 lb* 20956 kg

46200 lb 20956 kg

-15 ft (-4.57 m)

Load (lift point) height

35 ft (10.67 m) END SIDE

40 ft (12.19 m) END SIDE

45 ft (13.72 m) END SIDE

MAXIMUM REACH @ END SIDE

+30 ft (9.14 m)

26 ft 4 in 8.03 m

26500 lb* 12020 kg

26500 lb* 12020 kg

+25 ft (7.62 m)

29 ft 8 in 9.04 m

26200 lb* 11884 kg

26200 lb* 11884 kg

+20 ft (6.10 m)

31 ft 11 in 9.73 m

26900 lb* 12202 kg

26900 lb* 12202 kg

+15 ft (4.57 m)

33 ft 3 in 10.13 m

28500 lb* 12927 kg

24100 lb* 10932 kg

+10 ft (3.05 m)

33 ft 9 in 10.29 m

31200 lb* 16080 kg

22550 lb 10229 kg

+5 ft (1.52 m)

33 ft 6 in 110.21 m

31200 lb* 14152 kg

22100 lb* 10024 kg

Ground line

32 ft 6 in 9.91 m

36750 lb* 16670 kg

22650 lb* 10274 kg

-5 ft (-1.52 m)

30 ft 8 in 9.35 m

37600 lb* 17055 kg

24600 lb* 11158 kg

-10 ft (-3.05 m)

27 ft 9 in 8.46 m

38550 lb* 17486 kg

28900 lb* 13109 kg

-15 ft (-4.57 m)

23 ft 5 in 7.14 m

38050 lb* 17259 kg

38050 lb* 17259 kg

• Lift capacities do not exceed 75% of the minimum tipping load or 87% of the hydraulic lift capacity. Capacities that are marked with an asterisk are hydraulic limited

8-18

87538934 NA

Issued 06-06

Bur

CHAPTER 9 - INDEX

Chapter 9

INDEX A Air Conditioning Compressor ................................................... 6-16 Condenser ..................................................... 6-16 Air conditioning .................................................. 5-22 Air filter .............................................................. 5-43 Air recycling ....................................................... 3-30 Anti-Theft Device ............................................... 3-20 Anti-Vandal guard ................................................ 4-7 Ashtray .............................................................. 3-11 Attachment cushion control switch .................... 3-18 Attachment failure .............................................. 4-21 Audible warning device cut-out control .............. 3-17 Automatic working mode selector ...................... 3-12 Auxiliary hydraulic circuits ................................. 4-26

B Battery Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operation Safety ...................................... 2-6 Bleeding ............................................................... 5-5 Bucket specifications ........................................... 8-7

C Cab light ................................................... 3-26, 3-27 Cab Service ....................................................... 6-16 Cigarette lighter ................................................. 3-27 Coat hanger hook .............................................. 3-27 Control arm tilt adjustment and function cancellation lever ............................................................ 3-11 Control arm tilt adjustment lever .......................... 3-8 Cooling system .................................................. 5-37 Counterweight control and supply valve ............ 3-48

Engine idle speed indicator ................................3-13 Engine idle speed selector ...................................3-8 Engine Lubrication ................................................5-9 Engine Oil Selection .........................................5-9 Engine Oil Level .................................................5-14 Engine Oil Selection .............................................5-9 Engine Operation ......................................... 4-3, 4-5 Engine Speed ..................................................4-5 Parking the Machine and Stopping the Engine 4-6 Starting the Engine ..........................................4-5 Engine Service Engine Oil Level .............................................5-14 Oil Change and Filter Replacement ...............5-31 Engine Speed .......................................................4-5 Engine starting procedure ....................................4-8 Engine stopping procedure ................................4-12 Engine throttle button ...........................................3-8

F Fan and alternator drive belt ..............................5-16 Filter Engine ............................................................5-31 Fluid and Lubricants .............................................5-7 Fluids and lubricants ............................................5-8 Footrest ..............................................................3-26 Free swing button ...............................................3-18 Front storage box ...............................................3-41 Fuel Handling Precautions ...................................2-9 Fuel level indicator .............................................3-14 Fuel system ........................................................5-19 Fuel tank .............................................................3-42 Function cancellation lever .................................3-11 Fuse box .............................................................3-27

G General Information ..............................................1-1 General Safety .....................................................5-3

D

H

Daily inspection ................................................. 5-13

Hardware torque inspection .................................6-7 Hazardous Chemical Precautions ......................2-10 Horn ....................................................................3-11 Hourmeter ..........................................................3-19 Hourmeter, Engine ...............................................5-6 Hydraulic fluid temperature indicator ..................3-14 Hydraulic hammer service intervals ...................5-10

E Electrical System ................................................. 7-3 Emergency shut down switch ............................ 3-17 Engine Hourmeter ....................................................... 5-6 Specifications .................................................. 8-3 Engine coolant temperature indicator ................ 3-14 87538934 NA

Issued 06-06

Bur

9-1

CHAPTER 9 - INDEX

I Identification Numbers Engine ............................................................. 1-3 Product Identification Number (P.I.N.) ............ 1-3 Inspecting and cleaning the machine ................ 6-11 Instructions, General Safety ................................ 5-3 Instrument Panel ................................................. 3-3

Releasing Hydraulic System Pressure .................5-4 Replacing a tooth on the backhoe bucket ..........6-15 Right-hand control arm .........................................3-8 Rotating beacon ....................................... 3-18, 4-17 Run-In Period of a New Machine Track Shoe Bolts ..............................................4-3

S L Lifting loads ....................................................... 4-17 Load holding control device ............................... 3-46 Lower panels ..................................................... 3-43 Lowering the attachment in the event machine failure 4-21 Lubrication/Filters/Fluids ...................................... 5-8 Engine Lubrication .......................................... 5-9 Fluid and Lubricants ........................................ 5-7

M Machine operation ............................................... 4-3 Machine Operation Safety ................................... 2-6 Machine overall dimensions ................................ 8-8 Machine travel ................................................... 4-14 Maintenance Precautions .................................... 2-9 Maintenance, 10 Hour ............ 5-14, 5-15, 5-16, 5-17 Message display screen .................................... 3-15

O Oil Change Engine ........................................................... 5-31 Oil Viscosity/Temperature Ranges ...................... 5-9 Operating in water ............................................. 4-18 Operating Instructions ......................................... 4-5 Operating Precautions ......................................... 2-7 Operating the backhoe bucket ........................... 4-19 Operating the machine in cold weather ............. 4-11 Operating the machine in hot weather ............... 4-11 Operator’s seat .................................................. 3-33 Owner, To The ..................................................... 1-1

P Parking the Machine and Stopping the Engine ... 4-6 Parking The Machine Safety ............................. 2-10 Personal Safety ................................................... 2-6 Plastic and Resin Parts ....................................... 5-6

Q Quick coupler locking/unlocking control ............ 3-27

R

Safety bar ...........................................................3-11 Safety Decals .....................................................2-12 Safety Instructions, General .................................5-3 Safety, Battery ......................................................7-3 Safety, Decals, and Hand Signals Personal Safety ................................................2-6 Safety Rules .....................................................2-3 Utility Safety .....................................................2-4 Safety/Decals/Hand Signals Before Operation ..............................................2-6 Machine Operation ...........................................2-6 Parking The Machine .....................................2-10 Safety Decals .................................................2-12 Seat belt .............................................................3-35 Self-detaching counterweight circuit supply valve .....

3-48 Self-detaching counterweight control box ..........3-48 Setting the tracks in transport position ...............4-22 Setting the tracks in working position .................4-23 Sides of the machine Right-hand, left-hand, front, and rear ...............1-6 Specifications Engine Specifications .......................................8-3 Starter switch ........................................................3-8 Starting and Stopping Precautions .......................2-7 Starting the Engine ...............................................4-5 Starting the engine ...............................................4-8 Storage tray ........................................................3-28 Sun shield ...........................................................3-28 Swing reduction gear ..........................................5-28

T Teeth and tooth tip wear limits ...........................6-15 Temperature control system ...............................3-29 To the Owner ........................................................1-1 Tool supply valve ................................................3-47 Towing the machine ...........................................4-21 Track Shoe Bolts ..................................................4-3 Travel control levers and pedals ........................3-26 Travel speed indicator ........................................3-13 Travel speed selector .........................................3-12 Trip control .........................................................3-19

Radiators and oil coolers ................................... 5-27 Rear window emergency exit ............................ 3-38 9-2

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CHAPTER 9 - INDEX

U Upperstructure swing locking switch ................. 3-17 Utility Safety Rules Message ............................... 2-4

W Walk-Around Inspecion ....................................... 4-5 Weights - Operating ............................................. 8-5 Windshield washer switch ................................. 3-18 Windshield wiper switch .................................... 3-18 Working lights .................................................... 3-17 Working mode indicator ..................................... 3-13 Working mode selector ...................................... 3-12

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Issued 06-06

Bur

9-3

CHAPTER 9 - INDEX

9-4

87538934 NA

Issued 06-06

Bur