Case CX800B Crawler Excavator Operator's Manual 47462359 - PDF DOWNLOAD

CX800B Crawler excavator

Operator's Manual Print No. Lep 47462359 3rd edition English 12/2012 - Original Instructions Replaces Lep 84403235

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

if used, are RED.

WARNING MPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: x Is instructed in safe and proper use of the machine. x Reads and understands the Manual(s) pertaining to the machine. x Reads and understands ALL Safety Decals on the machine. x Clears the area of other persons. x Learns and practises safe use of machine controls in a safe, clear area before operating this machine on a job site.

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

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

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

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

Reproduction or translation, even partial, is prohibited without written authorization from CNH France Company Lep 47462359 EN Copyright 2012 CNH France

OPERATOR’S MANUAL CX800B

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

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

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TABLE OF CONTENTS SECTION 1 - TO THE OWNER .................................................................................................................. 1-1 CX800B hydraulic crawler excavator ....................................................................................................... 1-1 Official documents .................................................................................................................................... 1-3 Right, left, front and rear of the machine .................................................................................................. 1-3 SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS .................................................. 2-1 Type, serial number and year of manufacture of the machine ................................................................. 2-1 Description of the main components ........................................................................................................ 2-3 SECTION 3 - SAFETY/DECALS/HAND SIGNALS .................................................................................... 3-1 Safety instructions .................................................................................................................................... 3-1 Before using the machine ........................................................................................................................ 3-2 Operating the machine ............................................................................................................................. 3-3 Cab protection (F.O.P.S.) ......................................................................................................................... 3-4 Preventing risks caused by vibrations ...................................................................................................... 3-4 Safety area ............................................................................................................................................... 3-5 Parking the machine ................................................................................................................................ 3-5 Using an implement other than a bucket .................................................................................................. 3-5 Implement operation and maintenance .................................................................................................... 3-5 Maintenance and adjustments ................................................................................................................. 3-6 Prevention of burns .................................................................................................................................. 3-7 Preventing fires or explosions .................................................................................................................. 3-7 Decals ...................................................................................................................................................... 3-8 Hand signals .......................................................................................................................................... 3-19 SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 4-1 Cab door .................................................................................................................................................. 4-1 Steps and access handles ....................................................................................................................... 4-2 Position of the operator’s compartment controls and accessories ........................................................... 4-3 Right-hand control arm ............................................................................................................................. 4-4 Front RH console ..................................................................................................................................... 4-6 Left-hand control arm ............................................................................................................................... 4-7 RH console ............................................................................................................................................... 4-9 Systems display and function control panel ........................................................................................... 4-10 Function and message display screen ................................................................................................... 4-12 Heating and ventilation or air conditioning controls ................................................................................ 4-15 Function cancellation lever and safety bar ............................................................................................. 4-19 Dipper and upperstructure swing left-hand control lever ........................................................................ 4-20 Boom and bucket right-hand control lever ............................................................................................. 4-20 Travel control levers and pedals ............................................................................................................ 4-21 Option pedals ......................................................................................................................................... 4-21 Low flow hydraulic circuit control pedal .................................................................................................. 4-21 Adjustment and locking the option pedals .............................................................................................. 4-22 Footrest .................................................................................................................................................. 4-23 Cab light ................................................................................................................................................. 4-23

TABLE OF CONTENTS Controls/Instruments/Accessories (continued) Coat hanger hook ...................................................................................................................................4-23 Fuse box .................................................................................................................................................4-24 Roof curtain ............................................................................................................................................4-24 Roof hatch ..............................................................................................................................................4-24 Cab door sliding windows .......................................................................................................................4-25 Sun shield ...............................................................................................................................................4-25 Magazine rack ........................................................................................................................................4-25 Refrigerated compartment ......................................................................................................................4-25 Storage compartment .............................................................................................................................4-26 Cup holder ..............................................................................................................................................4-26 Operator's seat .......................................................................................................................................4-27 Windshield ..............................................................................................................................................4-31 Lower front window .................................................................................................................................4-32 Rear window (emergency exit) ...............................................................................................................4-32 Fuel tank .................................................................................................................................................4-33 Rear view mirrors ...................................................................................................................................4-34 Front storage box ...................................................................................................................................4-35 Side doors ..............................................................................................................................................4-36 Battery master switch ..............................................................................................................................4-37 Engine hood ...........................................................................................................................................4-38 Lower panels ..........................................................................................................................................4-38 Windshield washer reservoir ..................................................................................................................4-39 Cab protection (F.O.P.S.) .......................................................................................................................4-39 Load handling eye ..................................................................................................................................4-40 Rotary light cable ....................................................................................................................................4-40 Safety valves ..........................................................................................................................................4-41 Optional tool flow selector blocks ...........................................................................................................4-41 Optional tool supply valves .....................................................................................................................4-42 Self-detaching counterweight controls ....................................................................................................4-42 Fuel tank filling pump ..............................................................................................................................4-43 SECTION 5 - OPERATING INSTRUCTIONS ............................................................................................. 5-1 Before using the machine .........................................................................................................................5-1 Operating the machine .............................................................................................................................5-2 Run-in period ............................................................................................................................................5-3 Anti-theft device ........................................................................................................................................5-4 Starting the engine ...................................................................................................................................5-7 Bringing the machine up to operating temperature ..................................................................................5-9 Engine operation ....................................................................................................................................5-10 Stopping the engine ................................................................................................................................5-11 Operating the machine in cold weather ..................................................................................................5-12 Operating the machine in hot weather ....................................................................................................5-12 Machine operation ..................................................................................................................................5-13

TABLE OF CONTENTS Operating instructions (continued) Machine travel ........................................................................................................................................ 5-14 Handling the machine ............................................................................................................................ 5-17 Load handling ......................................................................................................................................... 5-18 Operating the machine in water ............................................................................................................. 5-19 Operating the machine on sloping ground ............................................................................................. 5-20 Operating the backhoe bucket ............................................................................................................... 5-21 Parking the machine .............................................................................................................................. 5-22 Radiators and oil-coolers dust removal .................................................................................................. 5-24 Auxiliary hydraulic circuits ...................................................................................................................... 5-25 Lowering the attachment in the event of a machine failure .................................................................... 5-33 Setting the undercarriage into the transport position ............................................................................. 5-34 Setting the undercarriage into the working position ............................................................................... 5-35 Removal and installation of the counterweight ....................................................................................... 5-37 Self-detaching counterweight ................................................................................................................. 5-39 Transporting the machine ...................................................................................................................... 5-42 SECTION 6 - SERVICING INTERVALS ..................................................................................................... 6-1 Servicing instructions ............................................................................................................................... 6-1 Hourmeter ................................................................................................................................................ 6-2 Daily inspections ...................................................................................................................................... 6-2 Intervals .................................................................................................................................................... 6-4 SECTION 7 - LUBRICATION/FILTERS/FLUIDS ........................................................................................ 7-1 Fluids and lubricants ................................................................................................................................ 7-1 Environment ............................................................................................................................................. 7-4 Fluid and lubricant capacities and specifications ..................................................................................... 7-4 Grease points ........................................................................................................................................... 7-5 Levels ..................................................................................................................................................... 7-12 Engine .................................................................................................................................................... 7-14 Cooling system ....................................................................................................................................... 7-17 Fuel system ............................................................................................................................................ 7-21 Releasing pressure in the hydraulic system ........................................................................................... 7-27 Hydraulic system .................................................................................................................................... 7-29 Air filter ................................................................................................................................................... 7-39 Swing reduction gears ............................................................................................................................ 7-43 Travel reduction gears ........................................................................................................................... 7-45 SECTION 8 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 8-1 Tracks ...................................................................................................................................................... 8-1 Track rollers and idler wheels .................................................................................................................. 8-5 Radiators and oil coolers .......................................................................................................................... 8-5 Fan and alternator drive belts .................................................................................................................. 8-7 Adjustment of engine valve rocker clearances ......................................................................................... 8-8 Fuel tank filter ........................................................................................................................................... 8-8

TABLE OF CONTENTS Maintenance/Adjustments (continued) Cab protection (F.O.P.S.) .........................................................................................................................8-9 Fire extinguisher .......................................................................................................................................8-9 Welding on the machine .........................................................................................................................8-10 Inspecting and cleaning the machine .....................................................................................................8-10 Checking the machine settings ...............................................................................................................8-10 Checking for cylinder leakage ................................................................................................................8-11 Plastic and resin parts ............................................................................................................................8-11 Tooth tip wear limits ................................................................................................................................8-12 Replacing a tooth tip ...............................................................................................................................8-12 Replacing a backhoe bucket ..................................................................................................................8-13 Shimming the backhoe bucket ...............................................................................................................8-14 Air conditioning .......................................................................................................................................8-15 Engine troubleshooting ...........................................................................................................................8-19 Hardware torque inspection ....................................................................................................................8-21 SECTION 9 - ELECTRICAL SYSTEM ........................................................................................................ 9-1 Fuses ........................................................................................................................................................9-1 Batteries ...................................................................................................................................................9-3 Alternator ..................................................................................................................................................9-6 Starter motor .............................................................................................................................................9-6 Replacing a bulb .......................................................................................................................................9-7 SECTION 10 - STORAGE ......................................................................................................................... 10-1 Storing the machine ................................................................................................................................10-1 SECTION 11 - SPECIFICATIONS ............................................................................................................. 11-1 Engine ....................................................................................................................................................11-1 Hydraulic system ....................................................................................................................................11-1 Undercarriage .........................................................................................................................................11-2 Safety devices ........................................................................................................................................11-2 Operator's compartment .........................................................................................................................11-3 Noise levels ............................................................................................................................................11-3 Vibration level inside the cab ..................................................................................................................11-3 Cab .........................................................................................................................................................11-4 Transport ................................................................................................................................................11-4 Weights ...................................................................................................................................................11-4 Standard attachment ..............................................................................................................................11-4 Short attachment ....................................................................................................................................11-4 Backhoe buckets ....................................................................................................................................11-5 Machine overall dimensions ...................................................................................................................11-6 Overall dimensions and weight of the main machine components .........................................................11-8 Working range ........................................................................................................................................11-9 SECTION 12 - ALPHABETICAL INDEX ................................................................................................... 12-1

SECTION 1

6

TO THE OWNER CX800B HYDRAULIC CRAWLER EXCAVATOR

CT08D003

1 Dealer's Stamp

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

1-1

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

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

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

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

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

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

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

Consult your CASE Dealer.

1-2

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

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

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

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

Make sure it is always complete and in good condition.

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

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

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

A F

F

D

C

E

E

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

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

FRONT REAR RH SIDE LH SIDE TRAVEL MOTORS IDLER WHEELS

B CT08D001A

2

OFFICIAL DOCUMENTS A "EC" certificate of conformity: IMPORTANT: An original of this "CE" certificate is supplied with each machine and must be kept carefully by the owner.

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

1-3

SECTION 1 - TO THE OWNER “EC” DECLARATION OF CONFORMITY

1

2

3

4 5 EC

3

1-4

SECTION 1 - TO THE OWNER "EC" DECLARATION OF CONFORMITY On page 1-4 is provided copy of the "EC" Declaration of Conformity (EC Declaration of Conformity).

The EC Declaration of Conformity is the manufacturer's declaration about equipment compliance to relevant EU provisions.

Please keep the original document in a safe place. Local authorities may require you to show this document in order to assure compliance of your equipment.

Translation of this declaration in your own country language is provided on the reverse page of the original document. For your better and easier understanding of the document hereafter you'll find some explanatory notes.

1.

Under section 1.2 are listed those options or variants which have safety related functions. Some of them are standard provided, like FOPS or ROPS (please refer to pages 2-2, 3-4 and 4-38 for other detail). Others, like object handling kit required to lift loose objects, are available upon customer request.

2.

Under point 2 are listed all information required by EU "Outdoor Noise" Directive 2000/14/EC. Please refer your own original EC Declaration of Conformity for specific equipment information. Other information about equipment guaranteed sound power level (LwA) can be found on pages 3-17 and 11-3. On the same page are indicated information about operators station noise level (LpA) which is not matter of above mentioned EU Directive and therefore not indicated on it.

3.

Generic serial number for this equipment type. Sequence of letters and numbers may vary depending on equipment configuration.

4.

EC Declaration of Conformity serial number. Please make reference to this number when requiring information or support to CASE about EC Declaration of Conformity.

5.

Signature of a person authorised to sign the document on behalf of the company.

1-5

SECTION 1 - TO THE OWNER

NOTES

1-6

SECTION 2

4

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

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

MACHINE (1) Type / Model and Category...................................... ...................................... (Hydraulic Excavator) CX800B (2) Serial number...........................................................

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

(4) Indication that the weight shown on the manufacturer's plate is a value using the heaviest configuration and that it does not always correspond to the transport configuration.

(& 5 HSUHVHQWDW YH

1

2 RGH

&;

+\ GUDX OLF( [ FDYDW RU

%

QWLILFDWL RQ1XPE HU3,1

3

<HDURIPDQXIDFWX H 0 D[ LPXP ZHLJKW

4

1 RPLQDOSRZHU , 62

.53

CT09F001

1 ENGINE Make and type ................. ISUZU AH-6WG1XYSS-02 Serial number................................................................. ........................................................................................

CT04D014B

2

2-1

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

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

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

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

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

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

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

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

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

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

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

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

CD09C001

3

2-2

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS DESCRIPTION OF THE MAIN COMPONENTS The CX800B is an all hydraulic excavator. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven pump delivers hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various cylinders and hydraulic motors employed. A cooling system maintains the hydraulic fluid at normal operating temperature.

11

15

12 10

16

6

7 8

19

17 9 13

5 4

14

20 21 22 18

23

1 2

3

CT08D002

4 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

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

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

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

2-3

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS

NOTES

2-4

SECTION 3

22

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

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

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

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

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

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

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

CT06M020

1

3-1

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

2.

3.

4.

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

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

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

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

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

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

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

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

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

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

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

5.

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

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

6.

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

7.

Remove any obstructions which hinder visibility.

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

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

8.

Make sure the windshield wiper works correctly.

9.

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

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

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

3-2

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

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

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

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

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

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

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

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

OPERATING THE MACHINE 1.

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

7.

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

8.

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

9.

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

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

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

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

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

13. Stop the engine, remove the starter switch key, wait one minute minimum and place the key of the battery master switch in "O" (Off) position when the machine is not in use, even for short periods of time.

2.

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

3.

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

4.

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

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

5.

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

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

Never forget this basic requirement.

6.

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

More than 57 000 volts: 5 metres.

3-3

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

PREVENTING RISKS CAUSED BY VIBRATIONS

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

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

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

1.

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

2.

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

3.

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

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

4.

Make sure that the operator's seat and is adjustment controls are in good condition and then adjust the seat to suit the operator's size and weight. The operator's seat complies with the ISO 7096, 2000 standard, EM 6 class class (seat coefficient < 0.7).

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

1.

Operate all controls gradually to ensure smooth machine operation.

2.

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

3.

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

4.

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

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

22. Never turn the key of the battery master switch in "O" (Off) position when engine is running, the electrical systems can be damage.

23. When the engine is stopped, always wait one minute minimum before to place the key of the battery master switch in "O" (Off) position, otherwise the computer program of the hydraulic will not exit successfuly.

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

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

2.

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

3.

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

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

3-4

During work:

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

1.

Working area.

2.

Safety area.

2

1 CS97M019

2

PARKING THE MACHINE When parking the machine, proceed as follows:

USING AN IMPLEMENT OTHER THAN A BUCKET

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

When using a special implement (hydraulic breaker, cutter-crusher etc.), refer to the operator's manual provided with the implement.

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

IMPLEMENT OPERATION AND MAINTENANCE

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

For the implement (cutter-crusher, hydraulic breaker) operation and maintenance, refer to the operator's manual provided with the implement.

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

5. Lock the cab door.

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

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

8. Place the key of the battery master switch in "O" (Off) position.

3-5

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

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

2.

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

3.

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

Hydraulic oil escaping under pressure can cause serious injury.

4.

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

5.

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

6.

7.

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

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

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

3. Stop the engine and remove the starter switch key, wait one minute minimum and place the key of the battery master switch in "O" (Off) position.

4. Lock the tracks to prevent any machine movement.

8.

9.

3-6

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

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

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

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

11. Coolant solution is toxic.

Avoid contact with skin, eyes and clothing.

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

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

EYES: rinse thoroughly with water and seek medical advice.

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

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

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

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

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

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

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

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

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 18. The accumulator is charged with nitrogen under high pressure. Do not weld or allow flames to come near to the accumulator.

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

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

Do not touch the controller or the injector.

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

PREVENTING FIRES OR EXPLOSIONS 1.

Engine fuel can cause an explosion or a fire.

- Never refuel when the engine is running.

- Never smoke while refuelling.

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

2.

Always use a non-inflammable solvent for cleaning parts.

3.

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

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

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

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

4.

Before performing maintenance for the electrical systems or electric welding, always place the key of the battery master switch in "O" (Off) position or disconnect the negative (-) terminal of the batteries, in order to cut off the electrical circuit.

5.

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

6.

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

7.

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

8.

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

9.

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

PREVENTION OF BURNS 1.

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

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

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

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

2.

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

3.

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

4.

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

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

5.

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

3-7

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DECALS

!

WARNING

!

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

!

WARNING

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

!

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

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

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

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

2

1

7 6

3

KHP11600-00

KHP12540-00

4 5

KHP11370-00

KHP12151-00

ACTIVATE

24V

:A FUNCTION

AUX.CONTROL

ACTIVATE :B FUNCTION

KHP1484-00

KHP11590 00 KHP11590-00

CT06K001

3

3-8

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

24 8 27

27

9

10 10

14

12 18 13

11

22 23

21 25

26

20

15 16 17 19 CT08D005

4 ILLUSTRATION OF DECALS TABLE OF SAFETY PRECAUTIONS Part number: KHP12151

1

CT06K003

A

F

B

E

C

D 5

3-9

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

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

A

CT05K003

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

B

CT06K004

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

C

CT06K005

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

D

CS96D164

9 3-10

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

E

CT06K006

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

F

CT06K007

11 FUNCTION OF THE CONTROL LEVERS Part number: KHP11370

2

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

KHP11370-00

CT06K008

12 WINDSHIELD LOCKING Part number: KHP12540

3

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

CT06K009

13 3-11

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

4

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

CS00E529

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

5

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

24V

KHP11590-00

CT06K010

15 EMERGENCY EXIT Part number: KHP11600

6

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

KHP11600-00

CT06K011

16 POCKET FOR MAXIMUM HANDLING LIMITS TABLE

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

3-12

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

8

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

CS95M062

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

9

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

CS95M063

18 SLINGING POINTS Part number: H7947565

10

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

PDE0768

19 FUEL TANK Part number: KHP11700

11

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

CT06B013

20 3-13

SECTION 3 - SAFETY/DECALS/HAND SIGNALS HYDRAULIC RESERVOIR Part number: 168104A1

12

This decal shows the location of the hydraulic reservoir.

CS96D166

21 EXHAUST Part number: 168112A1

13

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

CS96C040

22 STARTING THE ENGINE Part number: 168110A1

14

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

CS96D163

23 FAN BELT Part number: 168111A1

15

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

CS96C038

24 3-14

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

16

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

CS98B169

25 RADIATOR Part number: 168101A1

17

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

CS96C179

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

18

CT05L042A

27 BATTERIES Part number: KHP12240

19

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

CT06K014

KHP12240-00

28 3-15

SECTION 3 - SAFETY/DECALS/HAND SIGNALS ENGINE HOOD Part number: KHP12230

20

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

KHP12230-A

CT06K012

29 RISK OF FALLING Part number: KHP12220

21

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

KHP12220-00

CT06K013

30 FILLING PUMP Part number: L2651565

22

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

PDF0357

31 SERVICING TABLE Part number: KUP10341 This decal shows the servicing points and intervals.

23 10h

1 2 3 4 5 6 7 8 9

50h

1 10

250h

8 11 12 13 14 15

500h

3 9 16 17 18

1000h

2 13 14 15 19

2000h

10 11 12 20 21

: CHECK : CLEAN : CHANGE INITIALLY : LUBRICATE CHANGE

6

18

15

10

17 3 9 13

21

8

12

11

19

5

20

11

4

2 x4

7 x2 x3

2 16

14 x3 1

4000h

6

5000h

5 20

x3

2

KUP10340-00

KUP10340

32 3-16

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

24

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

CS96D164

33 COMMON RAIL FUEL SYSTEM Part number: KHP13160

25

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

CT07G043

34 NOISE LEVEL Part number: KHP1768

26

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

CS02G515

35

3-17

SECTION 3 - SAFETY/DECALS/HAND SIGNALS TIE-DOWN POINT Part number: KHP15200

27

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

CT08K003

36 BATTERIES This decal is on the batteries and draws attention to the risks and precautions to be taken when handling batteries.

CT10B001

37

3-18

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

START THE ENGINE

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

PDE0002A

38

PDE0003A

SHUT DOWN THE ENGINE

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

PDE0002

39 PDE0003

41

3-19

SECTION 3 - SAFETY/DECALS/HAND SIGNALS EMERGENCY STOP

GO THIS FAR

Wave hands back and forth.

PDE0004A

42

PDE0005

ALL STOP AND HOLD

45 RAISE LOAD OR TOOL

PDE0004

43

PDE0006A

STOP

46 LOWER LOAD OR TOOL

Wave one hand back and forth.

PDE0005A

PDE0006

44

3-20

47

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

SLOWLY RAISE THE LOAD OR TOOL

To stop movement, stop moving hand and clench fist.

PDE0007A

48

PDE0008

SLOWLY LOWER THE LOAD OR TOOL

51 RAISE TOOL

PDE0007

49

PDE0009A

TURN MACHINE LEFT (swing load left)

52

To stop movement, stop moving hand and clench fist.

PDE0008A

LOWER TOOL

PDE0009

50

53

3-21

SECTION 3 - SAFETY/DECALS/HAND SIGNALS LIFT BOOM

EXTEND DIPPER

PDE0010A

PDE0011

54 LOWER BOOM

57 FILL TOOL

PDE0010

PDE0012A

55 RETRACT DIPPER

EMPTY TOOL

PDE0011A

PDE0012

56

3-22

58

59

SECTION 4

46

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

1

CT06K017

1

2

CT06K018

2 The door can be latched in completely open position.

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

!

WARNING

!

3

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

!

WARNING

!

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

See "Function cancellation lever and safety bar".

!

WARNING

CT06K019

3

!

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

4-1

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STEPS AND ACCESS HANDLES To get in or out of the machine use the steps (2), the tracks, the walkways (3) and the access handles (1).

!

WARNING

1

!

1

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

!

WARNING

!

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

!

WARNING

1

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

2

3

!

2 CT08D004

4

!

WARNING

!

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

4-2

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

!

WARNING

!

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

1 14

11

13 12 10 15

7 9

3

8

2

16 4

7 6

5

CT06K016

5 1.

2.

3.

4.

5.

6.

7.

8.

9.

Operator's seat LH control arm Function cancellation lever Safety bar Dipper and upperstructure swing left-hand control lever Footrest or option pedal Travel control levers and pedals Footrest or option pedal Front RH console

10.

11.

12.

13.

14.

15.

16.

RH control arm Boom and bucket right-hand control lever Right-hand control arm tilt adjustment lever RH console Air vents Storage compartment Left-hand control arm tilt adjustment and function cancellation lever

4-3

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

6

1 7

5

3 4 8 7

2

CT06K022

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

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

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

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

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

4-4

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

3. ENGINE IDLE SPEED SELECTOR This control enables automatic engine idle without operating the throttle button. To select idle speed, press and release the control for the engine automatically to go into idle speed; the "Engine idling" icon will appear on the systems display panel. When the control is pressed and released once more the engine will revert to its original speed and the icon on the systems display panel will disappear.

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

!

WARNING

!

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

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

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

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

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

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

4-5

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

TEMPERATURE PROBE

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

1

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

2.

CLOCK

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

Every time the "M" key is pressed, the minutes display is incremented by one unit (00 to 59).

Pressing the "M" key continuously resets the clock.

3.

2 H

M

3 3

AIR VENTS

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

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

4.

STORAGE TRAY

5.

CIGARETTE LIGHTER SOCKET (24 Volts)

4 or

ELECTRICAL

5

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

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

!

WARNING

!

If the cigarette lighter does not move outwards 30 seconds after pressing it in, pull it out manually, since otherwise the electrical circuit could be damaged; consult your CASE Dealer Once the cigarette lighter has been removed from its socket, the latter can be used as a 24 volts electrical socket.

!

WARNING

!

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

4-6

CT06K023

7

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

2

6

4

8 5

3 1

6

7

CT06K024A

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

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

!

WARNING

!

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

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

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

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

IMPORTANT: Always sound the horn before operating the machine.

5. ASHTRAY Pull the ashtray upwards to empty it.

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

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

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

4-7

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

9

10

CT06K024A

9 9. EMERGENCY SHUT DOWN SWITCH This control enables the engine to be shut down in emergency or when it is not possible to shut it down by means of the starter key. Press on the front of the control, the engine stops, the audible warning device sounds, the control indicator lamp comes on and the message "ENGINE STOP" is displayed, see "Message display". To start the engine again, press on the back of the control once more and then turn the starter switch key to start the engine.

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

4-8

10. 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. During this operation, the "FAN REVERSING" message is displayed, see "Message display" and see "Radiators and oil coolers dust removal" in section 5.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES RH CONSOLE

1

3

3

2

4

CT06K022

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

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

See "Auxiliary hydraulic systems" in section 5.

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

!

WARNING

!

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

4-9

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

1

A H SP !4567

n/min

TRIP

2

ODO

12345.6 1/10H

AUTO

n n/min

C

H

C

H

E

TRIP

F

3 CT06K026

!

WARNING

!

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

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

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

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

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

Do not use solvents.

Low speed (I) (0 to 2.9 km/h), select this speed to travel on slopes, rough ground or soft terrain.

High speed (II) (0 to 4.2 km/h), select this speed to travel on hard, flat ground in good terrain conditions.

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

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

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

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

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

4-10

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

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

6

n/min

A H SP !4567

8

TRIP

2

ODO

12345.6 1/10H

AUTO

TRIP

n n/min

C

H

C

H

E

F

7

4

5

9

CT06K026

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4-11

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

n/min

1

C

4

5

6

A H SP !4567

H

C

CT06K027

H

8

2

E

F

3

2 13

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

Zone "C" indicates that the engine coolant temperature is low. If the luminous bars reach zone "H", the audible alarm device sounds and the message "OVER HEAT" is displayed (see "Message display"). Stop the engine, remove the starter switch key and find the cause of the problem.

2. HYDRAULIC FLUID TEMPERATURE INDICATOR The degree of temperature is defined by the increase or the decrease in the number of lighted segments.

Zone "C" indicates that the hydraulic fluid temperature is low. If the luminous bars reach zone "H", the audible alarm device sounds and the message "OVER HEAT" is displayed (see "Message display"). Stop the engine, remove the starter switch key and find the cause of the problem.

3. FUEL LEVEL INDICATOR The quantity of fuel is defined by the number of lighted segments. Zone "F" shows that the fuel tank is full. If the luminous bars reach zone "E", the audible alarm device sounds and the message "LOW FUEL" is displayed (see "Message display").

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

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

4-12

4. WORKING MODE INDICATOR This indicator displays the initial working mode and the engine speed selected by the engine acceleration button and the working mode selector. See item 2 under "Right-hand control arm".

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

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

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

8. ACCESSORIES ICONS (if equipped)

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

Hydraulic breaker

Cutter crusher

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

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

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

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

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

A H SP

LOW COOLANT

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

IMPORTANT: If a message persists after servicing.

Consult your CASE dealer.

CT06K028

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

14

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

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

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

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

4-13

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

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

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

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

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

ALTERNATOR This message shows that the alternator is defective or that the belts are broken. The audible alarm device will sound. Shut down the engine, remove the starter switch key and check the alternator. Consult your CASE Dealer or replace the belts, see "Fan and alternator drive belts" in section 8.

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

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

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

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

4-14

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

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

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

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

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

FAN REVERSING This message shows that the fan rotation reversal switch is activated. The audible alarm device will sound. It is necessary to stop the engine to cancel this function. See "Left-hand control arm" (item 10).

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

6

9

R/F

3 A/C

AUTO

7 MODE

AUTO

2

TEMP

ON

DEF

8

OFF

1

4

5

CS06K016

15 1.

ON/OFF

6.

Air recycling

2.

Automatic

7.

Air flow direction

3.

Air conditioning

8.

Windshield defroster

4.

Ventilation

9.

Display screen

5.

Temperature

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

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

A/C

AUTO

AUTO TEMP

ON OFF

1 CS06K016

16

4-15

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES VENTILATION

9

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

A/C

AUTO

AUTO TEMP

ON OFF

4 CS06K016

17 TEMPERATURE

9

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

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

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

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

AUTO A TEMP

O

5

CS06K016

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

(A) Internal air circulated.

(B) External air enters.

9

6 A R/F

B

AUTO

MODE TEMP

DEF

CS06K017

19

4-16

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

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).

7

9

R/F

AUTO

MODE TEMP

DEF

CS06K016

20 (A) Upper front distribution.

(B) Upper rear distribution.

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

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

A

B

C

D

CD00E050B

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

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

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

R/F

AUTO

MODE TEMP

DEF

9 8 CS06K016

22

4-17

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

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

Manual

6

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

9

3

AUTO E

A TEMP

O

7

4

5

CS06K016

23 Automatic

9

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

2

A/C

AUTO

AUTO

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

TEMP

ON OFF

5

1

CS06K016

24 To obtain hot or cold air quickly:

2

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

A/C

AUTO

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

AUTO TEMP

ON OFF

5

5A

CS06K016

25

4-18

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

The lever (2) operates the safety bar (1) and cancels the functioning of the control levers and pedals. When the lever (2) is in central position, the safety bar (1) is in inward position in the control arm and the attachment, travel and swing functions cannot be operated.

2

1

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

CT06K029

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

!

WARNING

2

!

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

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

1 CT06K030

27

4-19

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

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

In the intermediate position two movements can be obtained simultaneously.

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

1

2

4

CT06K031

28 1.

2.

3.

4.

The dipper extends.

The dipper retracts.

The upperstructure turns to the left.

The upperstructure turns to the right.

4

3

2

1

CT08D006

29

BOOM AND BUCKET RIGHT-HAND CONTROL LEVER

5

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

8 7

6 CT06K032

30 5.

6.

7.

8.

The boom lowers.

The boom raises.

The bucket retracts (filling).

The bucket extends (dumping).

6

5 7

8 CT08D006

31 4-20

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

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

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

CT06K033

32

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

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

CT06K033

33

LOW FLOW HYDRAULIC CIRCUIT CONTROL PEDAL (if equipped)

1

This pedal is used to direct the clamshell.

1.

2.

The clamshell turns to the right.

The clamshell turns to the left.

!

WARNING

!

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

2 CT07B002

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

34

4-21

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

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

1

CT06K070

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

1

CT06K071

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

!

WARNING

!

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

1

CT06K072

37

4-22

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FOOTREST

CT06M005

38

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

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

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

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

CT06K034

39

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

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

CT06K035

40

4-23

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

CT06K036

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

CT06K037

42

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

CT06K038

43

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

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

CT06K039

44 4-24

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

CT06K044

45

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

CT06K051

46

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

CT06K040

47

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

CT06K042

48 4-25

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

CT06K041

49 Located behind the operator’s seat.

These compartments are used to store various objects.

CT06K040

50

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

CT06K043

51

4-26

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

8

9

7

7 3 5

4 1 2 6

CT06M007

52 1.

2.

3.

4.

5.

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

6.

7.

8.

9.

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

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

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

4-27

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES COMBINED HEIGHT AND WEIGHT ADJUSTMENT Lower the handle (1) to decrease the rigidity of the suspension. Raise the lever (1) backward to obtain harder suspension. The indicator (2) must be green when the operator is sitting on the seat.

2

1

CT06K046

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

3

CT06K046

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

!

WARNING

!

4

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

CT06M008

55 LUMBAR SUPPORT ADJUSTMENT Use the inflation bulb (5) to inflate the lumbar support.

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

5

CT06K046

56 4-28

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

6

CT06M008

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

7

CT06K047

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

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

8

CT06K050

59

4-29

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

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

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

9

!

WARNING

!

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

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

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

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

4-30

CT06K048

60

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD

!

WARNING

!

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

OPENING 1.

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

3

2 1 CT06K051

61 2.

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

CT06K052

62 CLOSING 1.

Use the lever (2) to release the windshield.

2.

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

3.

3

Make sure the top of the windshield is correctly latched.

2 CT06K052

63

4-31

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

1.

Remove the window from its housing by sliding it upwards.

CT06K053

64 2.

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

CD00E022

65

REAR WINDOW (EMERGENCY EXIT)

!

WARNING

!

2

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

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

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

To install the window, consult your CASE Dealer.

4-32

1

CT06K054

66

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

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

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

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

See "Fuel tank filter" in section 8.

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

CD01K024B

67

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

!

WARNING

!

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

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

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

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

CT05L002

68

4-33

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

CAB

CT07K055

69 UPPERSTRUCTURE

CD01K027B

70

4-34

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

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

To open, release the toggles then open the storage box and tilt the cover completely upward.

CD01K053A

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

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

!

WARNING

!

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

CD01K053B

72

4-35

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

RIGHT-HAND DOOR The RH door gives access to a number of hydraulic components (pump, filters etc.) as well as the hydraulic reservoir gauge.

CT06D005

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

CD01K055E

74

!

WARNING

!

Always install the struts when the doors are open.

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

NOTE: The rear door is locked using two screws.

!

WARNING

!

Never leave tools or other objects behind the side doors.

CD01K055D

75

!

WARNING

!

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

4-36

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES BATTERY MASTER SWITCH Located near the batteries, open the left-hand door.

76 When the key of the battery master switch is in "I" (On) position, all electrical circuits are connected.

When the key of the battery master switch is in "O" (Off) position, all electrical circuits are disconnected.

IMPORTANT: Never turn the key of the battery master switch in "O" (Off) position when engine is running, the electrical systems can be damage.

IMPORTANT: When the engine is stopped, always wait one minute minimum before to place the key of the battery master switch in "O" (Off) position, otherwise the computer program of the hydraulic will not exit successfully.

NOTE: When the key of the battery master switch is in "O" (Off) position, the stations stored on the radio presets and the time set for clock will be all cleared.

NOTE: The key can be remove from the battery master switch.

77

4-37

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

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

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

!

WARNING

!

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

CT06D016

78 CLOSING Raise the hood slightly, pull the support strut back then lower the hood. Lock the toggles.

!

WARNING

!

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

CD01K059A

79

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

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

!

WARNING

!

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

CT05L003

80

4-38

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

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

Remove the cap to add windshield washing fluid.

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

The reservoir can be lifted out of its support.

CT05L004A

81

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

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

CT04D008B

82

4-39

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

See "Load handling" in section 5.

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

See "Load handling limits chart" in section 5.

!

WARNING

!

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

!

WARNING

CD01C165

83

!

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

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

CD01D028

84

4-40

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SAFETY VALVES (optional) SERVICE SPECIFICATIONS Check by your CASE Dealer ...................................................................................................... Every 6 months The role of the safety valve is to stop the attachment from dropping due to valve spool leakage in neutral position or in the event of a line or hose accidentally breaking. In the latter event, they also ensure that the attachment may be lowered gently to the ground.

ON BOOM CYLINDERS

CT06D007

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

CT05L005

86

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

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

1

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

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

CD01K061A

87

4-41

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

CD01K042B

88

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

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

1

2 CT05L006

89

4-42

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

!

WARNING

!

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

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

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

1.

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

2.

Take the inlet pipe out of the storage compartment.

CT05L007

90 3.

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

4.

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

1

PDF0361

91

4-43

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 5.

Remove the fuel tank filler cap.

!

WARNING

!

It is essential that the cap is removed before filling.

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

CD01K024B

92 6.

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

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

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

CT05L008

93 7.

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

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

8.

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

9.

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

CT05L009

10. Refit the fuel tank filler cap.

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

4-44

94

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

CT05L010

95

4-45

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

NOTES

4-46

SECTION 5

46

OPERATING INSTRUCTIONS BEFORE USING THE MACHINE

!

WARNING

!

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

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

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

2.

Carry out the daily maintenance operations.

See section 6.

3.

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

4.

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

5.

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

6.

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

7.

Clean or replace any decals which are illegible.

See "Decals" in section 3.

8.

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

9.

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

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

The operator must be alone on the machine.

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

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

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

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

10. Remove any obstructions which hinder visibility.

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

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

5-1

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

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

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

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

2.

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

3.

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

4.

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

5.

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

6.

7.

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

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

8.

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

9.

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

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

5-2

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

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

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

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

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

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

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

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

19. In the event of an 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. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

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

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

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

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

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

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

Check all instruments frequently.

Check the oil levels and coolant solution level frequently.

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

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

(If equipped) Check the cab protective structure.

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

AFTER THE FIRST 250 HOURS Replace the pilot circuit filter and the return filter.

See "Hydraulic system" in section 7.

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

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

5-3

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

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

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

- The audible alarm device will sound.

- The engine stops if the machine is handled.

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

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

RECORDING THE CODE 1.

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

2.

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

?

?

?

?

CT06K075

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

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

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

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

1

3

TRIP

2

123 AUTO

T

n n/min

F

5

4

2

CT06K026

2

5-4

SECTION 5 - OPERATING INSTRUCTIONS 4.

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

The screen returns to its normal display.

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

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

A H SP

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

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

C

H

C

H

E

F

CT06K076

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

1.

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

2.

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

3.

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

TRIP

2

123 AUTO

T

n n/min

F

5 CT06K026

4

5-5

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

A H SP

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

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

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

5-6

C

H

C

H

E

F

CT06K077

5

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

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

1.

Place the key on the battery master switch in "I" (On) position.

2.

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

3.

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

CT06K029

6 4.

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

5.

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

6.

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

2 1

1

2

CT06M021

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

7.

A H SP

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

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

CT06K078A

8

5-7

SECTION 5 - OPERATING INSTRUCTIONS 8.

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

9.

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

CT06K080

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

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

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

Starting this engine takes about 1 second before stabilisation.

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

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

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

5-8

CT06K030

10

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

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

ENGINE AUTOMATIC WARM-UP

HYDRAULIC FLUID WARM-UP

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

Turn the engine throttle button to half-open position.

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

MANUAL ENGINE WARM-UP

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

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

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

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

5-9

SECTION 5 - OPERATING INSTRUCTIONS ENGINE OPERATION

!

WARNING

!

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

!

WARNING

!

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

Do not touch the controller or the injector.

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

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

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

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

- There is no abnormal noise or vibration.

- There are no oil, fuel or water leaks.

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

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

Check the systems display and console regularly.

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

- Abnormal noise.

- Black smoke at the exhaust.

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

5-10

SECTION 5 - OPERATING INSTRUCTIONS STOPPING THE ENGINE 1.

Lower the attachment until it is resting on the ground.

2.

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

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

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

3.

1

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

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

4.

2

CT06M012

11

Place the key of the battery master switch in "O" (Off) position.

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

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

See "LH control arm" (item 9) in section 4.

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

CT06K024A

12

5-11

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

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

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

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

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

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

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

2.

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

3.

Test the radiator cap before hot weather starts.

Replace the cap as required.

4.

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

5.

Check the condition of the fan drive belt.

6.

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

7.

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

5-12

SECTION 5 - OPERATING INSTRUCTIONS MACHINE OPERATION OPERATING INSTRUCTIONS

!

WARNING

!

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

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

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

2) Excavation using the machine’s travel force.

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

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

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

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

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

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

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

More than 57 000 volts: 5 metres.

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

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

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

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

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

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

- Avoid turning the machine on steep slopes.

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

OPERATION 1.

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

2.

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

3.

Sound the horn.

4.

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

5.

Check all indicator lamps and gauges are operating correctly.

6.

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

7.

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

5-13

SECTION 5 - OPERATING INSTRUCTIONS MACHINE TRAVEL

!

WARNING

!

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

IMPORTANT: Before undertaking any travel, raise the attachment.

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

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

CT08D007

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

CS98M546

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

CS98M547

15

5-14

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

CS98M548

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

CS98M551

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

CS98M549

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

CS98M550

19 5-15

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

CS98M552

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

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

CS98M553

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

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

CS98M545

22

5-16

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

30°~ 40°

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

See "Weight" in section 11.

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

CT08D009

23

!

WARNING

!

60°

The machine must be handled very slowly and horizontally.

!

WARNING

!

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

!

WARNING

!

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

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

!

WARNING

=

=

CT08D010

24

!

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

!

WARNING

!

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

5-17

SECTION 5 - OPERATING INSTRUCTIONS LOAD HANDLING

!

WARNING

!

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

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

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

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

- Use the load fixing point (load handling eye) located on the bucket control rod (see "Load handling limits charts").

It is forbidden to weld hooks or lugs on the bottom plate of buckets.

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

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

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

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

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

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

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

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

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

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

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

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

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

NOTE: Load handling on CASE machines is in conformity with standard EN 474-1 and standard EN 474-5 relative to directive 2006/42/EC.

5-18

SECTION 5 - OPERATING INSTRUCTIONS LOAD HANDLING LIMITS CHARTS The load handling chart (located in the cab) shows the different permitted loads which can be lifted, depending on the reach and the type of attachment on the machine.

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

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

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

CS00E556

25

OPERATING THE MACHINE IN WATER 1.

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

2.

Only the undercarriage must be below water level. The maximum water level must not be higher than the height of the tracks (1.20 m).

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

3.

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

IMPORTANT: Do not operate in a fast flowing stream.

CT08D008

26

5-19

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE ON SLOPING GROUND

!

WARNING

!

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

!

WARNING

!

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

- During hillside operations, be extra careful.

- Make sure that the low speed travel is selected.

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

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

5-20

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE BACKHOE BUCKET FILLING Fill the backhoe bucket by manoeuvring the dipper. Keep the bottom of the backhoe bucket parallel to the cut.

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

EXCAVATING METHOD

PDH0493M

27

1

2

3

PDH0494M

28 1.

2.

3.

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

5-21

SECTION 5 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1.

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

2.

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

3.

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

4.

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

CT06M021

29 5.

Stop the engine, remove the starter switch key.

CT06M022

30 6.

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

CT06K029

31

5-22

SECTION 5 - OPERATING INSTRUCTIONS 7.

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

8.

Place the key of the battery master switch in "O" (Off) position.

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

!

WARNING

!

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

CT06K017

32

5-23

SECTION 5 - OPERATING INSTRUCTIONS RADIATORS AND OIL-COOLERS DUST REMOVAL It is recommended to perform this operation every day for 3 to 5 minutes.

1.

Open the engine hood.

2.

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

3.

Make sure that the engine automatic idle function is not selected (indicator lamp off).

TRIP

2

123 AUTO

n n/min

F

CT06K026

33 4.

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

5.

Start the engine, the fan rotates in the reverse direction, the "FAN REVERSING" message is displayed on the screen (see "Message display" in section 4) and the audible alarm sounds.

CT06K024A

34 6.

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

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

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

7.

To stop dust removal, set the engine to low idle then stop it using the starter switch key ("OFF" position).

8.

Close the engine hood and the rear LH door.

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

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

5-24

CT06M021

35

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

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

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

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

Hydraulic breaker or single flow hydraulic circuit configuration 1.

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

CD01K042B

36

2

1

CD01K061A

37

5-25

SECTION 5 - OPERATING INSTRUCTIONS 2.

Move the selector blocks (1) and (2) located on the upperstructure to position them as shown opposite.

1

2

CS01K612/613

38 3.

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

4.

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

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

5.

2

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

1 CT06K083

39 6.

The icon of the accessory associated to each type of flow appears on the screen.

A H SP

1

CT06K086

40 7.

Unlock the pedal and engage the locking pin.

CT06K071

41 5-26

SECTION 5 - OPERATING INSTRUCTIONS 8.

Use the control pedal to operate the hydraulic breaker.

CT06K033

42 9.

During operation the flow is displayed on the screen.

A H SP

1

481

CT07K010C

43

5-27

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

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

CD01K042B

44

2

1

CD01K061A

45 2.

Move the selector blocks (1) and (2) located on the upperstructure to position them as shown opposite.

1

2

CS01K614/615

46

5-28

SECTION 5 - OPERATING INSTRUCTIONS 3.

Toggle the switch (1) located on the RH console upwards, corresponding to the cutter crusher.

4.

Toggle upwards the switch (2) to the "ON" position corresponding to a double flow hydraulic circuit.

1

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

5.

2

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

CT06K083

47 6.

The icon of the accessory associated to each type of flow appears on the screen.

A H SP

3

CT06K087

48 7.

Unlock the pedal.

CT06K070

49 8.

Use the control pedal to operate the cutter crusher.

CT06K033

50 5-29

SECTION 5 - OPERATING INSTRUCTIONS 9.

During operation the flow is displayed on the screen.

A H SP

3

386 703

CT07K009C

51

5-30

SECTION 5 - OPERATING INSTRUCTIONS AUXILIARY HYDRAULIC CIRCUIT FLOW PATTERNS The values of the flow patterns 1, 2 and 3 shown below correspond to the initial values. They can be identified by the number on the screen.

NOTE: The number of setting patterns is 3 maximum.

Values

1 flow (l/min)

2 flows (l/min)

A

493

987

1

481

975

B

436

929

2

391

884

C

346

839

D

300

794

E

255

749

3

210

703

F

165

658

G

120

613

NOTE: The values A to G are the possible programmable values.

Changing the flow patterns

!

WARNING

!

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

1.

Operate the switch (1) located on the RH console to display the flow pattern to be changed.

1 CT06K083

52

5-31

SECTION 5 - OPERATING INSTRUCTIONS 2.

The recorded value can be identified by the number shown on the screen. (e.g.: 2 = value 2 in the table).

3.

Hold the switch (1) pressed for 3 seconds, the changing flow rate screen (2) appears.

A H SP

2

391 884 2 CT07K008D

53 4.

Operate the windshield wiper switch (1) to show the previous pattern.

Operate the auto idling switch (2) to show the following pattern.

5.

Operate the travel speed switch (3) to record.

1

2

AUTO

n n/min

E

CT06K026

F

3

2 54

5-32

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

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

CT06M021

55 2.

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

CT06K030

56 3.

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

CT06K082

57

5-33

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

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

1.

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

2.

Remove the 24 pieces of mounting hardware (2).

2

CD01D141

58

2

CD01D143

59 3.

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

!

WARNING

!

Only raise the track as little as necessary. Raising it too much can cause the machine to tip over.

CT05J005A

60

5-34

SECTION 5 - OPERATING INSTRUCTIONS 4.

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

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

CT05J006A

61 5.

Install 12 pieces of retaining hardware tightened to a torque of between 2550 to 2942 Nm.

6.

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

7.

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

CD01D142

62

SETTING THE UNDERCARRIAGE INTO THE WORKING POSITION 1.

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

2.

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

3.

Remove the 12 pieces of mounting hardware.

4.

Protect the sling points.

CD01D142

63

5-35

SECTION 5 - OPERATING INSTRUCTIONS 5.

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

!

WARNING

!

Only raise the track as little as necessary. Raising it too much can cause the machine to tip over.

6.

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

1 CT05J007A

64 7.

Install the 24 pieces of retaining hardware tightened to a torque of between 2550 to 2942 Nm.

8.

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

CD01D141

65

CD01D143

66 9.

Repeat Steps 2 to 8 for the other track.

5-36

SECTION 5 - OPERATING INSTRUCTIONS REMOVAL AND INSTALLATION OF THE COUNTERWEIGHT

!

WARNING

!

Never stand under the counterweight during removal and installation operations.

!

WARNING

!

Use slings and cables that are in good condition and that can bear the load to be lifted. Slinging and handling operations must be entrusted to qualified personnel.

REMOVAL 1.

Park the machine on a firm, level surface with the upperstructure frame in line with the undercarriage.

2.

Stop the engine and remove the starter switch key.

3.

Given that it is forbidden to stand under the counterweight, it is essential that you take the necessary precautions to prevent personnel from entering this area.

4.

Check the lifting device and make sure that it is in good condition, suitable for lifting the load to be handled and fitted with safety type hooks that will not accidentally open (the counterweight weighs 12 500 kg).

5.

Fasten the lifting device securely to the counterweight according to the instructions shown (vertical lifting or at a 60° angle).

CS06K009A

67 Vertical lifting

CS06K010

68

5-37

SECTION 5 - OPERATING INSTRUCTIONS 60° angle lifting 6.

Keep the cables permanently taut with the lifting device.

CS06K011A

69 7.

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

CT08H002

70 8.

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

IMPORTANT: Never stand under the counterweight when the screws have been removed.

9.

Lift the counterweight. Carefully remove it from the machine and place it on the ground.

CT08H003

71 INSTALLATION 1.

Install the counterweight in the reverse order to that of removal.

2.

Tighten the four screws uniformly to a torque of 2256 to 2550 Nm. Close the engine hood then install the lower panel.

5-38

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

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

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

- Engine speed must be at low idle.

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

!

WARNING

!

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

REMOVAL NOTE: The counterweight clearance is about 0.67 m from the upperstructure frame.

1.

Make sure 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 pieces of retaining hardware holding the counterweight on the upper side. Close the engine hood.

0.67 m CT05J008A

72 4.

Open the supply valve located in the rear RH compartment. See "Self-detaching counterweight controls" in section 4.

S O

CT05L011

73

5-39

SECTION 5 - OPERATING INSTRUCTIONS 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.

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

Lower the counterweight to the ground.

8.

Remove the counterweight retaining pins.

9.

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

1 2 3 CD01D035

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

74

11. Close the supply valve.

12. Install the lower panel.

O S

CT05L012

75

5-40

SECTION 5 - OPERATING INSTRUCTIONS INSTALLATION 1.

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

2.

Bring the machine to about 0.67 m from the counterweight and lower the attachment to the ground.

3.

Open the supply valve.

S O

CT05L011

76 4.

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

5.

Tilt switches (2) and (3) to lower the 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 upperstructure plate.

8.

9.

1 2

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

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

3 CD01D035

77

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

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

12. Install the lower cover plate.

O S

CT05L012

78

5-41

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE REMOVING THE ATTACHMENT FROM THE MACHINE NOTE: Set the undercarriage into the transport position. See "Setting the undercarriage into the transport position".

IMPORTANT: For transporting the machine, the attachment and counterweight must be removed, see "Removal and installation of the counterweight" or, if equipped, "Self-detaching counterweight".

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

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

!

WARNING

!

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

!

WARNING

!

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

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

!

WARNING

!

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

5-42

!

WARNING

!

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

!

WARNING

!

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

SECTION 5 - OPERATING INSTRUCTIONS

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

ON A TRAILER

!

WARNING

!

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

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

LOADING 1.

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

CT02C196

79 2.

Select the automatic engine idle function.

567

2

AUTO

n n/min

H

E

F

CT06K026

80

5-43

SECTION 5 - OPERATING INSTRUCTIONS 3.

Select low travel speed, indicator lamp off.

!4567

2

AUTO

n n/min

H

E

F

CT06K026

81 4.

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

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

5.

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

6.

Stop the engine, remove the starter switch key, place the function cancellation lever in the central position (with the safety bar inward).

7.

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

8.

Fold the rear view mirrors inwards.

9.

Place the key of the battery master switch in "O" (Off) position.

CS01D582B

82

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

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

CS01D583B

83

5-44

SECTION 5 - OPERATING INSTRUCTIONS UNLOADING 1.

Remove the blocks and fastening chains.

2.

Place the key of the battery master switch in "I" (On) position.

3.

Start the engine.

4.

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

5.

Select low travel speed to move off the trailer.

6.

Turn the rear view mirrors back to their correct position.

7.

Install the attachment and the counterweight.

8.

It is mandatory to set the undercarriage back into the working position. See "Setting the undercarriage into the working position".

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

5-45

SECTION 5 - OPERATING INSTRUCTIONS

NOTES

5-46

SECTION 6

6

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

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

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

!

WARNING

!

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

!

WARNING

!

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

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

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

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

4. Lock the tracks to prevent any machine movement.

!

WARNING

!

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

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

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

!

WARNING

!

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

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

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

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

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

6-1

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

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

TRIP

ODO

12345.6

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

1/10H

AUTO

n n/min

TRIP

CT06K026

1

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

GENERAL REMARKS - Check signs of leaking oil or water.

- Check that all screws and nuts are correctly tightened.

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

- Check for any signs of damage.

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

- Check the coolant level.

- Check the radiator for signs of clogging or deterioration.

- Check the radiator fan belt tension.

- Check the air filter is clean and not restricted.

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

- Check the condition of all lines.

UPPERSTRUCTURE - Check the fuel tank level.

- Check the hydraulic reservoir level.

- Check that the hydraulic oil is clean.

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

- Check the condition of all lines.

- Make sure there are no electrical short circuits.

- Check the battery connections are properly tightened.

- Adjust the rear view mirrors.

UNDERCARRIAGE - Check the pad hardware.

- Check the condition of the tracks.

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

ATTACHMENT - Check the cylinders are not leaking oil.

- Check the condition of all lines.

- Check the condition of the bucket teeth.

6-2

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

- Check for abnormal noise on the hydraulic components.

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

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

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

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

6-3

SECTION 6 - SERVICING INTERVALS

6-4

7-14

Engine oil level

7-17 7-21

DRAIN BLEED

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

INTERVALS

1

10 (A)

Coolant level

1

10 (A)

Drain fuel tank sediment

1

10 (A)

7-21

Bleeding the fuel filters

2

10 (A)

7-29

Hydraulic reservoir level

1

8-5

Radiators and oil coolers dust removal

-

8-7

Fan/alternator belt tension

1

7-7

Bucket linkages

2

7-29

Hydraulic system lines

-

8-15

Air conditioning (optional)

1

7-21

Fuel pre-filter filter element

1

7-17

Tightening of clamps, radiator hoses

-

10 (A) 10 (B)

10 (A) 10 (A) 250 50 (C) 50

50

2000

(D)

250 250 (E)

7-29

Drain hydraulic reservoir sediment

1

7-39

Primary air filter element

1

250

7-43

Swing reduction gears

2

250

1000 (H)

7-45

Travel reduction gears

2

250

1000 (H)

8-1

Pad screw torque

-

250 (J)

8-5

Radiators and oil coolers

-

250 (F)

1000 (G)

250 (F)

250

8-5

Idler wheel and rollers

-

250

8-9

Cab protection (optional)

1

250 (J)

8-21

Screw and nut tightening torque

-

250 (J)

9-3

Battery charge

2

250

9-3

Batteries electrolyte level

2

250

7-5

Turntable bearing

3

500 500

7-9

Turntable bearing teeth

1

7-14

Engine oil

1

7-14

Engine oil filters

2

500

7-21

Filtering element of fuel filters

2

500

7-21

Priming pump screen

1

500

500

7-7

Attachment (except bucket linkages)

14

1000 (K)

7-11

Self detaching counterweight (optional)

8

1000

7-17

Cooling system

1

7-29

Hydraulic fluid condition (*)

-

7-29

Hydraulic reservoir breather

1

1000

7-39

Secondary air filter element

1

1000

8-8

Tappet clearances

-

1000 (M)

9-6

Alternator

1

1000 (M)

9-6

Starter motor

1

1000 (M)

1000 (L) 1000

Inlet filter (*)

1

7-29

Pilot filter (*)

1

2000 (N)

7-29

Return circuit filters (*)

2

2000 (N) (P)

7-21

Fuel hoses

-

4000 (Q)

7-29

Main pump output hydraulic hoses

-

4000 (Q)

7-29

Boom, dipper and bucket cylinder hydraulic hoses

-

4000 (Q)

7-29

Hydraulic fluid (*)

1

5000 (R)

4-41

Safety valves

3

7-21

Fuel pre-filter purge

1

7-29

High pressure line filters

2

(W)

8-1

Tracks

2

(T)

8-8

Fuel tank filter

1

(T)

8-9

Fire extinguisher

1

8-10

Machine inspection

1

8-10

Machine settings

-

(V)

8-11

Cylinder sealing

-

(T)

DRAIN BLEED

5000

7-29

GREASE

2000

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

SECTION 6 - SERVICING INTERVALS

(V) (S) (T) (U) (T)

(T)

(A) Or every day.

(B) Remove dust every day for 3 to 5 minutes.

(C) If all these linkage points are not equipped with genuine parts, these points must be greased every 10 hours.

(D) To be checked every 6 months by a specialist.

(E) Or every 6 months.

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

(G) Or after cleaning 6 times.

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

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

(K) If all these linkage points are not equipped with genuine parts, these points must be greased every 50 hours.

(L) Every two years or twice a year (autumn/spring) if antifreeze is used.

(M) Ask your CASE Dealer to check this.

(N) Replace after the first 250 hours during the run-in period.

(P) If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 1000 hours and after the first 50 hours during the run-in period.

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

(R) If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 2000 hours.

6-5

SECTION 6 - SERVICING INTERVALS (S) When the float reaches the level line (A).

(T) Periodically.

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

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

(W) In the event of hydraulic pump malfunction.

NOTE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message "SERVICE DUE" will appear on the screen (see "Message display in section 4) by way of a reminder that service work is due.

(It is possible to increase this lapse of time. Consult your CASE Dealer). (*) IMPORTANT: If the machine is equipped with a hydraulic breaker, it is imperative that the servicing intervals are reduced, see "Replacing the hydraulic filters and fluid when a hydraulic breaker is used" in section 7.

6-6

SECTION 7

46

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

!

WARNING

!

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

TRANSMISSION COMPONENT OIL Extreme pressure oil used for enclosed transmission components.

CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316.

ZF TE-ML 05A) GREASE

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

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

Temperate climates -20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates 0°C to +50°C CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates -25°C to +20°C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C This yellow-coloured fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the circuit completely before refilling with this fluid.

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

7-1

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE OIL The CASE/AKCELA "No. 1 ENGINE OIL" is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

1 OIL RANGE

1 2 2 3 3

CT02M001

2 (1) With mineral base (2) With semi-synthetic base (3) With synthetic base

7-2

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL The fuel used must comply with the Tier 3 emission control regulations.

Use grade No. 2-D fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather (below -7°C), it is provisionally approved to use a mixture of fuels No. 1-D and No. 2-D. Consult your fuel supplier or your CASE Dealer.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

Conditions applicable to diesel fuel The diesel fuel used must: -

be free from dust particles, even minute ones, have the proper viscosity, have a high cetane number, present great fluidity at low temperatures, have low sulphur content, have very little residual carbon.

Recommendations applicable to diesel fuel - JIS (Japanese Industrial Standard): No. 2 - DIN (Deutsche Industrie Normen): DIN 51601 - SAE (Society of Automotive Engineers) according to SAE-J-313C: No. 2-D - BS (British Standard) according to BS/2869-1970: Class A-1 - EN 590 - or fuel corresponding to these standards and stipulated in your country.

Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the fuel supply system and the engine. The CASE company disowns any responsibility concerning this kind of damage, which is not covered by the guarantee. To avoid any damage to the engine fuel supply system, you are recommended to take the following safety messages into account: - Certain fuel suppliers mix used engine oil with diesel fuel.

Certain manufacturers of large engines allow them to do this. However, for your engine, do not use diesel fuel contaminated by engine oil. In addition to damaging the engine, this fuel can actually adversely affect the correct purification of exhaust gases. Before using diesel fuel, ask the supplier to confirm that it meets the above specifications.

IMPORTANT: For a proper use of fuel additives consult your supplier or your CASE Dealer. Do not inject fuel oil or gasoline, both fuels can damage the engine.

IMPORTANT: In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.

Fuel storage Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

IMPORTANT: It you use fuel which has a sulphur content of more than 2500 ppm, use API grade CF-4 or JASO grade DH-1 engine oil. However, if these specifications cannot be met, it is imperative that the engine servicing intervals are reduced to 250 hours (oil change, filters etc.). Every 3000 hours, the injectors and EGR (Exhaust Gas Recirculation) circuit parts must be checked and replaced by your CASE Dealer.

IMPORTANT: Use of any other fuel can cause serious breakdown and will cancel the guarantee.

7-3

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ANTI-FREEZE/ANTI-CORROSION

ENVIRONMENT

Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)

Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

For areas where the temperature goes down to -38°C, mix 50/50 with water.

IMPORTANT: Do not mix products of a different origin or brand.

The same product must be used when topping up the system.

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

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ENGINE Type of oil ........................................................................................................................................"No. 1 ENGINE OIL" Capacity (with filters change) ............................................................................................................................. 52 litres COOLING SYSTEM System capacity................................................................................................................................................ 108 litres FUEL SYSTEM Reservoir capacity ............................................................................................................................................ 900 litres HYDRAULIC SYSTEM Type of fluid ........................................................................................................... "HYDRAULIC EXCAVATOR FLUID" Total system capacity........................................................................................................................................ 720 litres Reservoir capacity ............................................................................................................................................ 310 litres TRAVEL REDUCTION GEARS Type of oil .........................................................................................................."GEAR 135H EP" extreme pressure oil Capacity (per reduction gear).......................................................................................................................... 13.8 litres SWING REDUCTION GEARS Type of oil .........................................................................................................."GEAR 135H EP" extreme pressure oil Capacity (per reduction gear)............................................................................................................................ 4.7 litres Type of grease................................................................................................................................ "GREASE 251H EP" Capacity (per reduction gear)............................................................................................................................... 1.2 kg TURNTABLE TEETH Type of grease................................................................................................................................ "GREASE 251H EP" Capacity ................................................................................................................................................................. 57 kg

7-4

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

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

MACHINE

C

B A

CT06B015

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

A

CT05L016

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

B

CT05L017

5 7-5

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 2000 hours Swing reduction gears ............................................ (2)

C

See "Greasing the swing reduction gears".

CT06D009

6

C

CT06D017

7

7-6

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ATTACHMENT

B D

B

C

D CT06B015

A

D

E 8

IMPORTANT: If the following linkage points are not equipped with original parts, these points must be lubricated every 10 hours.

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

A

CD01C165

9

7-7

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

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

B

CT05L013

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

C

CT06D007

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

D

CT06D010

12

7-8

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 1000 hours Yoke/connecting rod linkages................................... (4)

E

CD01C165

13 GREASING THE TURNTABLE TEETH Grease capacity...................................................................................................................................................... 57 kg Type of grease ..................................................................................................................... See "Fluids and lubricants" Every 500 hours 1.

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

2.

If the gear surface is not well greased, add grease.

3.

If the grease is white due to moisture content, etc. replace it with new grease.

1

CT05L017

14 4.

If the presence of water is detected, remove the plug (2) and drain off the water.

- Remove the protective panel from the lower central area.

- Remove plug (2).

- Discharge the water or contaminated grease.

- Install plug (2).

- Insert new grease through the port and install the inspection cover (1).

2

CD01K028

15

7-9

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE SWING REDUCTION GEARS Grease capacity (per reduction gear) ................................................................................................................... 1.2 kg Type of grease...................................................................................................................... See "Fluids and lubricants" Every 2000 hours 5.

Remove the lower panel, remove the air bleed plug (1) and refill with grease through the grease point (2). A certain amount of grease should run out from the air bleed plug (1).

6.

Install plug (1).

1

IMPORTANT: When greasing, if the air bleed plug (1) is not removed, the inner seal will be damaged.

CT06D009

2 16

7.

Proceed in the same manner for the second reduction gear.

8.

Install the lower panel.

1

2 CT06D017

17

7-10

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE SELF-DETACHING COUNTERWEIGHT SYSTEM (optional) Every 1000 hours Cylinder top pins ....................................................... (3) Handling arm ............................................................ (2)

CD01D038

18 Cylinder bottom pins................................................. (3)

CD01D039

19

7-11

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVELS Type of fluids and lubricants......................................................................................See "Fluids and lubricants" NOTE: The numbers within brackets mentioned on the right of the description indicate the number of levels.

Every 10 hours Engine oil................................................................... (1)

CT05L018

20 Coolant solution expansion reservoir ....................... (1)

CT05L019 CT02C288

21 Hydraulic reservoir.................................................... (1)

CT05L020

22

7-12

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Batteries.................................................................... (2)

CT05L021

23 Travel reduction gears .............................................. (2)

CT06D018

24 Swing reduction gears.............................................. (2)

CT06D011

25

7-13

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check......................................................................................................... Every 10 hours or every day Oil change ............................................................................................................................................. Every 500 hours Oil filters replacement ........................................................................................................................... Every 500 hours Oil type ................................................................................................................................. See "Fluids and lubricants" Oil capacity.......................................................................................................................................................... 52 litres LEVEL 1.

Park the machine on flat, horizontal ground. Stop the engine, remove the starter switch key.

2.

When the engine has been stopped for fifteen minutes, raise and lock the engine hood, remove the dipstick, wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

CT05L018

26 3.

If the level is situated between the marks (A) and (B) on the dipstick, the level is correct..

4.

If the oil level is at mark (A) (min) or below.

A

B CT05L023

27 5.

If the oil level is at mark (A) (min) or below, open the access hatch then remove the filling plug and add oil up to mark (B) (max) of the dipstick. Install the plug, close the access hatch.

NOTE: The level should not be higher than the mark (B) (maximum on the dipstick).

CT05L024

28

7-14

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING, CHANGING THE OIL FILTERS AND FILLING NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

Use the extension drain hose from the front boot.

1.

Park the machine on flat, horizontal ground. Shut down the engine, remove the starter switch key then open the hatch under the engine.

2.

Raise and lock the engine hood, open the access hatch then remove the filling cap.

CT05L024

29 3.

Remove the protective cap from the engine housing drain valve.

4.

Screw the end of the extension drain hose onto the engine check valve, place the other end in a container of suitable capacity and allow the oil to flow out.

5.

Remove the extension drain hose and install the protective cap on the housing check valve. Place the extension drain hose in the front storage compartment.

CT05L033

30 6.

Clean the area around the filters and remove them using a filter wrench.

CT06D012

31

7-15

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 7.

Coat the seal of each new filter with a fine film of oil.

8.

Install the new filters. Turn the filters until the seals come into contact with the filter head then tighten an extra half turn by hand.

IMPORTANT: Do not use a filter wrench to tighten the filters. Excessive tightening can damage the filters and the seals.

PH08325

32 9.

Fill the engine with new engine oil. Install the filling plug, close the access hatch.

10. Run the engine for a few minutes and check that there are no leaks. Check the level again and top up if necessary.

IMPORTANT: Always wait fifteen minutes to allow the oil to return to the sump before checking the oil level.

CT05L024

33

7-16

SECTION 7 - LUBRICATION/FILTERS/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Expansion reservoir level check........................................................................................ Every 10 hours or every day Checking the tightening of clamps, of radiator hoses............................................Every 250 hours or every 6 months Draining the system (long duration) ........................................................................ Every 1000 hours or every 2 years Draining the system (with anti-freeze) (spring and autumn) ...................................................................... Twice a year System capacity.................................................................................................................................................108 litres

!

WARNING

!

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap, allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

!

WARNING

!

!

!

WARNING

Coolant solution is toxic.

Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL: rinse thoroughly with water and remove soiled clothes.

INTERNAL: do not induce vomiting. Rinse the mouth out with water. Seek medical advice.

EYES: rinse thoroughly with water and seek medical advice.

Check and service the cooling system according to the instructions given in this manual.

COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage.

Do not use non-approved anti-rust additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your CASE Dealer who will supply you with the suitable coolant.

LEVEL The level of coolant solution should be checked when the engine is cold.

On flat, level ground, before using the machine (while the engine is still cold), the level in the expansion reservoir should be between the "Full" (1) and "Low" (2) marks. If not, see "Filling".

1 2 CT05L019

34

7-17

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING 1.

Using the starter switch key open the access hatch then remove the radiator cap.

!

WARNING

!

Do not remove the radiator cap when the engine is hot. The system is still under pressure and you could be scalded.

CT05L026

35 2.

Open the radiator drain valve.

CT05L027

36 3.

Open the drain plug located on the engine block.

NOTE: Have a receptacle of a suitable capacity ready.

CT05L028

37

7-18

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RINSING 1.

Close the drain valve once the radiator is completely empty. Close the plug on the engine block.

2.

Fill the system with clean water. Install the radiator cap.

3.

Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80°C.

4.

Stop the engine and remove the starter switch key.

5.

Drain the system once more.

6.

Repeat Steps 1 to 5 until the water drained is clear.

FILLING 1.

Loosen the bleed screws (1) of the EGR (Exhaust Gas Recirculation) cooler.

1

1

CT08D011

38 2.

Fill via the radiator with coolant solution until overflowing through the EGR cooler bleed screws (1).

3.

Tighten the EGR cooler bleed screw (1). The tightening torque must be 27.5 ± 3 Nm.

4.

Fill the radiator completely with coolant solution then install the radiator cap and lock the access hatch.

CT05L026

39

7-19

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 5.

Fill the expansion reservoir to the "Full" mark and install the cap.

IMPORTANT: Use the correct coolant solution.

6.

Run the engine at idle speed for about five minutes. Add coolant solution if the level in the expansion reservoir drops.

IMPORTANT: Do not fill the expansion reservoir above the "Full" mark.

CT05L029

40

7-20

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Fuel tank bleeding ............................................................................................................. Every 10 hours or every day Filter bleeding..................................................................................................................... Every 10 hours or every day Pre-filter bleeding...................................................................................................When the float reaches the level (A) Replacing the pre-filter element ........................................................................................................... Every 250 hours Replacing the filter element of the filters.............................................................................................. Every 500 hours Cleaning the priming pump screen ...................................................................................................... Every 500 hours Replacing the fuel hoses ......................................................................................... Every 2 years or every 4000 hours (whichever comes first) Fuel tank capacity..............................................................................................................................................900 litres Type of fuel........................................................................................................................... See "Fluids and lubricants"

!

WARNING

!

Take all necessary precautions during the following operations; no foreign matter must enter the fuel system.

!

WARNING

!

Completely wipe off any spilt fuel after changing a filter element or bleeding the system.

DRAINING THE FUEL TANK 1.

Place a receptacle of a suitable capacity under the drain plug.

2.

Open the drain valve located at the bottom of the tank and drain the accumulated sediment and water.

3.

After draining, close the drain valve.

CT05L030

41

7-21

SECTION 7 - LUBRICATION/FILTERS/FLUIDS PRE-FILTER BLEEDING When the float reaches the level line (A): 1.

Place a receptacle of a suitable capacity under the pre-filter.

2.

Loosen the drain plug (1) and the bleed screw (2) then drain the water and sediment.

2

1 CT05L031A

42 3.

When the float (3) settles on the bottom, tighten the drain plug (1) to a torque of between 1.5 and 2.5 Nm, then tighten the bleed screw (2) to a torque of between 8 and 12 Nm.

A 3

IMPORTANT: Overtightening can damage the seal.

4.

Check for any signs of leak.

1

NOTE: In cold weather, the water can freeze on the top part of the bowl. Bleed after the ice has melted.

CT05L032A

43

7-22

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE PRE-FILTER ELEMENT

!

WARNING

!

If a fuel filter other than a genuine CASE filter is used, the guarantee will not be applied to a fault caused by the use of a wrong filter.

1.

Close the valve on the supply line then place a receptacle of a suitable capacity under the pre-filter.

CT05L032B

44 2.

Remove the drain plug (1), loosen the bleed screw (2) then let the pre-filter drain.

3.

Clean around the pre-filter body (3) then remove it using the filter wrench provided with the machine.

4.

Replace the drain plug (1) seal then install the drain plug (1) on the pre-filter body (3); the tightening torque must be between 8 and 12 Nm.

5.

Install the new filter element. Replace the filter body seal with a new seal, fill the filter body with clean fuel then install the body, turning it until it is in contact with the pre-filter head.

2

3 1 CT05L031A

6.

Tighten the body (3) using the wrench, the tightening torque must be between 28 Nm and 32 Nm.

45

IMPORTANT: Overtightening can damage the seals.

IMPORTANT: Never re-use the seals of the filter body (3) or the drain plug (1); they must always be replaced with new seals.

7.

Open the valve on the supply line.

8.

Bleed the system. See "Fuel system air bleed".

7-23

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FILTER BLEEDING Proceed in the same manner as for the pre-filter.

See "Pre-filter bleeding".

Proceed in the same manner for the second filter.

CT05L034A

46 REPLACING THE FILTER ELEMENT ON THE FILTERS

!

WARNING

!

If a fuel filter other than a genuine CASE filter is used, the guarantee will not be applied to a fault caused by the use of a wrong filter.

Proceed in the same manner as for the pre-filter but do not fill the filter body with fuel. See "Changing the pre-filter element".

IMPORTANT: Do not fill the filter body with fuel before installing.

Proceed in the same manner for the second filter.

CT05L034A

47

7-24

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING THE PRIMING PUMP SCREEN IMPORTANT: Always protect your face before using compressed air.

The screen is placed in the socket-head screw (1).

Remove the screen, clean it with compressed air then rinse it in fuel.

1

CT05L036

48 FUEL SYSTEM AIR BLEED It is necessary to bleed the fuel system when: -

The tank has been completely emptied.

The fuel pre-filter has been changed.

The fuel filters have been replaced.

Parts of the fuel system have been removed for servicing or repair work.

- The machine has been in storage for a fairly long period.

1.

Turn the starter switch key to the "ON" position.

!

WARNING

!

Do not leave the starter switch key in the "ON" position for more than five minutes unless bleeding has been performed. It may damage the fuel supply pump.

2.

Loosen the bleed screw (1) on the fuel filter (2).

3.

Turn the priming pump piston (3) of the fuel filter (2) to the left in order to release the spring.

1

3 1 2

5 4 CT05L034A

49

7-25

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 4.

Operate the priming pump (3) until the fuel flows from the bleed screw (1) without air bubbles then retighten the bleed screw (1) to a torque of between 8 and 12 Nm.

1

IMPORTANT: When bleeding the system, always begin and end with the fuel filter (2).

5.

2

Proceed in the same manner for the second filter (4) and tighten the priming pump piston (5).

3

CT05L037A

50 6.

Loosen the fuel pump priming pump knob (6) on the engine.

6

CT05L036

51 7.

Operate the priming pump (6) until the fuel flows from the bleed screw (7) without air bubbles, then retighten the bleed screw (7) to a torque of between 8 and 12 Nm and retighten the priming pump piston (6).

6

IMPORTANT: Overtightening can damage the seal.

7

NOTE: When replacing the filter elements of the fuel filters and pre-filter, steps 6 and 7 are not necessary.

8.

Completely wipe off any spilt fuel. Start the engine and check for possible leakage.

!

WARNING

!

Completely wipe off any spilt fuel. It could cause a fire.

7-26

CT05L036

52

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1.

Place the machine on flat, level ground, lower the attachment to the ground and stop the engine.

2.

Turn the starter switch key to the "ON" position.

CT06M021

53 3.

Push the function cancellation lever forward (safety bar in outward position).

CT06K030

54 4.

Operate the control levers from right to left and front to rear a dozen times approximately.

5.

Turn the starter switch key to the "OFF" position (shut down).

CT06K082

55

7-27

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 6.

Remove the hydraulic reservoir protective cap by unscrewing it.

breather

CT05L038

56 7.

Press the button on top of the breather to release any residual pressure. Install the protective cap.

CT05L039

57

7-28

SECTION 7 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Check the hydraulic reservoir fluid level............................................................................. Every 10 hours or each day Check the lines ........................................................................................................................................Every 50 hours Draining water and sediment from the hydraulic reservoir.................................................................. Every 250 hours Check the condition of the hydraulic fluid........................................................................................... Every 1000 hours Change the reservoir breather filter element ..................................................................................... Every 1000 hours Change the pilot filter.......................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Clean the inlet filter ............................................................................................................................. Every 2000 hours Change the return filters..................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Change the main pump outlet hoses...................................................................... Every 2 years or every 4000 hours (whichever comes first) Change the boom, dipper and bucket cylinder hoses ............................................ Every 2 years or every 4000 hours (whichever comes first) Change the inlet filter.......................................................................................................................... Every 5000 hours Change the hydraulic fluid .................................................................................................................. Every 5000 hours Cleaning of the high pressure line filters.................................................... In the event of hydraulic pump malfunction Reservoir capacity .............................................................................................................................................310 litres Total system capacity ........................................................................................................................................720 litres Oil type ................................................................................................................................. See "Fluids and lubricants" IMPORTANT: If biodegradable fluid is used, it is essential to reduce the following servicing intervals to the number of hours shown: Change the return filters..................................................................................................................... Every 1000 hours (after the first 50 hours during the run-in period) Change the hydraulic fluid .................................................................................................................. Every 2000 hours NOTE: If the machine is new or if a major component has been overhauled or changed in the hydraulic system, change the pilot filter and return filter after 50 hours of operation. After that, change these filters at the stipulated interval.

IMPORTANT: Every 1000 operating hours, it is necessary to have the hydraulic fluid analysed. Consult your CASE Dealer.

IMPORTANT: After changing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See "Bleeding air from the hydraulic components".

IMPORTANT: If metal particles are found in the old filters, consult your CASE Dealer.

!

WARNING

!

Before carrying out any service work on the hydraulic system it is necessary to allow it to cool down (the temperature should not be more than 40°C).

!

WARNING

!

Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak.

Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

!

WARNING

!

Before carrying out any operation on the hydraulic filters or the hydraulic system, the pressure must be released from the system. Failure to observe this instruction can cause injury. See "Releasing pressure in the hydraulic system".

7-29

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVEL IN THE RESERVOIR 1.

Place the machine on flat, level ground and place the attachment in the position shown. Stop the engine and remove the starter switch key.

CS01D517B

58 2.

The oil should be in the middle of the indicator.

Add more oil if necessary. See "Filling the reservoir".

CT05L020

59 FILLING THE RESERVOIR 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the cover plate and the area around the plate. Remove the cover plate and add hydraulic fluid to the reservoir as required.

3.

Replace the cover plate seal if required and install the cover plate.

!

WARNING

!

Make sure that no contaminant (water, sand etc.) enters the reservoir during filling.

CT05L040

60

7-30

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RESERVOIR SEDIMENT REMOVAL 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Place a receptacle of a suitable capacity under the drain plug. Open the access hatch.

3.

Loosen the drain plug on the bottom of the reservoir by a few turns and drain the sediment and water accumulated at the bottom of the reservoir.

4.

After draining, tighten the drain plug. Close the access hatch.

5.

Add hydraulic oil if necessary. See "Filling the reservoir".

CT05L041

61 PILOT FILTER REPLACEMENT Release all pressure in the hydraulic system. See "Releasing pressure in the hydraulic system".

Use a wrench to unscrew the filter and remove it.

Coat the seal of the new filter with a fine film of oil.

Install the new filter. Turn the filter until the seal comes into contact with the filter head then tighten an extra third of a turn by hand.

CT05L042A

62

7-31

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING AND REPLACEMENT OF THE INLET FILTER 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the top of the hydraulic reservoir and clean the inlet filter cover.

CT05L040

63 3.

Remove the cover (1), O-ring (2) and spring on the top of the inlet filter rod assembly.

4.

Remove the inlet filter (3) and clean with solvent.

Dry it completely and check it for any damage. If there is any damage on the surface, replace it with a new one.

5.

Install a new O-ring (2) and install the inlet filter (3), spring and rod assembly.

6.

Install the cover (1).

7.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

NOTE: Install a new inlet filter every 5000 hours of operation or when the hydraulic fluid is changed.

7-32

1

2

3 CS01D526B

64

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RETURN FILTER REPLACEMENT 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the top of the hydraulic reservoir and clean the return filter covers.

CT05L040

65 3.

Remove the cover (1) and O-ring (2).

4.

Take out the spring (3), valve (4) and filter (5).

5.

Install a new filter. Clean the spring (3) and valve (4) and install them.

6.

Check O-ring (2) and change it if worn or damaged.

7.

Install the cover (1).

8.

Repeat Steps 3 to 6 for the second filter.

9.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

1 3

2

4 5

CS01D526B

66

7-33

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE RESERVOIR BREATHER FILTER ELEMENT

CT05L038

67 1.

Remove the cap (1) then press the button (2) to release all pressure from the hydraulic reservoir.

2.

Remove the nut (3), the seal (4) and the cover (5) from the breather.

3.

Remove and discard the used filter element (6).

5

4.

Install a new element (6), making sure the seal (7) is facing upwards.

7

5.

Install the assembly in the reverse order.

3

1 4 6

2 CS00E528A

68

7-34

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE HYDRAULIC FLUID 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Remove the reservoir cover plate.

3.

Using a pump, remove the fluid from the hydraulic reservoir. Have a container with a suitable capacity ready.

CT05L040

69 4.

Place a receptacle of a suitable capacity under the reservoir drain plug. Open the access hatch then remove the drain plug to remove the remaining fluid from the reservoir.

5.

Change the inlet filter and the return filter. See "Cleaning and replacement of the inlet filter" and "Return filter replacement".

6.

Install the reservoir drain plug. Close the access hatch.

7.

Fill the reservoir with new hydraulic fluid. See "Filling the reservoir".

8.

Replace the cover plate seal if required and install the cover plate on the reservoir.

CT05L041

70

IMPORTANT: Before you start the engine, it is very important that you bleed air from all the hydraulic components. See "Bleeding air from the hydraulic components".

9.

Start and run the engine with no load for approximately five minutes.

10. Move each control several times to remove any air in the system.

11. Swing the upperstructure evenly left to right two complete turns or more.

12. Place the machine in position and then stop the engine.

13. Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

7-35

SECTION 7 - LUBRICATION/FILTERS/FLUIDS HIGH PRESSURE LINE FILTERS It may be necessary to clean the two filters in the event of pump malfunction.

1

1

CT06D005

71 1.

Release all pressure in the hydraulic system. See "Releasing pressure in the hydraulic system".

2.

Place a container with a suitable capacity under the filters.

3.

Remove the hoses (1).

4.

Remove the covers (2) and then clean the filters (3).

5.

Replace the seals and backup rings (4).

6.

Reassemble and check there are no leaks.

2

4

3

CS01D546

72

7-36

SECTION 7 - LUBRICATION/FILTERS/FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS IMPORTANT: After bleeding air from the components, stop the engine for five minutes and check there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Hydraulic pump Using a solvent, clean the periphery of the air bleed plug. Loosen the air bleed plug, remove the plug if the fluid does not flow.

Fill the pump with 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 idle speed. Loosen the air bleed plug on the pump. Tighten the plug when air free fluid comes out of the bleed plug hole. Clean the area completely.

CT05L044

Bleed the second bleed plug hole at the same time.

73

Attachment cylinders Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing them to end of stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to end of stroke.

Swing reduction gears Start and run the engine at low idle speed. Loosen the unions on the top of the swing motors to release any air.

Retighten the unions as soon as the fluid spills out of the ports.

After the warm up procedure is completed, move each control slowly several times to remove any air in the system.

Swing the upperstructure evenly left to right two complete turns or more.

Stop the engine and wait five minutes.

CT05L045

74

Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

7-37

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE FILTERS AND HYDRAULIC FLUID WHEN A HYDRAULIC BREAKER IS USED (optional) Hydraulic fluid - When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinary digging. Check the hydraulic fluid level more frequently.

In addition, when changing the filters, also check the condition of the hydraulic fluid.

- Using the following table as a reference, determine the intervals for changing the hydraulic fluid and filters, depending on the frequency of use of the hydraulic breaker.

Percentage of use Interval in hours

100% 10

100

40% 600

10

(3)

(1)

300

20% 1500

10

(3)

(1)

600

10% 3000

10

(3)

(1)

800

Page

Service points

7-29

Hydraulic fluid

7-29

Return circuit filter

(3)

7-29

Inlet filter

(2)

7-29

Pilot filter

(3)

(3)

(3)

(3)

7-29

Hydraulic fluid condition

200 h

300 h

600 h

800 h

(1)

(3) (3)

(1) Check the level (2) Clean or replace CHECKING THE HYDRAULIC SYSTEM PIPING Make sure there are no leaks from the hydraulic system hoses, pipes, plugs, connections and fittings and check that all nuts and screws are correctly tightened.

In the event of problems, repair, change or tighten the component(s) concerned.

7-38

(2)

(3) (3)

(3) Replace

(2)

4000

(3) (3)

(3)

(2)

(3)

SECTION 7 - LUBRICATION/FILTERS/FLUIDS AIR FILTER INSPECTION Be sure to carry out regular checks on the air filter, intake manifold, seals and hoses. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be changed before they are worn.

SERVICE SPECIFICATIONS Inspect and clean the primary element................................................................................................ Every 250 hours or when the message "AIR FILTER" is shown on the message display screen Change the primary element.............................................................................................................. Every 1000 hours or after cleaning 6 times Change the secondary element......................................................................................................... Every 1000 hours IMPORTANT: The primary element can be cleaned.

The secondary element cannot be cleaned and must be changed.

IMPORTANT: Observe the air filter service intervals shown above. Clean filters mean longer engine life.

REMOVING THE ELEMENTS 1.

Release the fasteners and remove the cover.

CT05L047

75 2.

Remove the wing nut and take out the primary element.

CT05L048

76

7-39

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Remove the wing nut and take out the secondary element if it has to be replaced.

IMPORTANT: The secondary element must be changed, not cleaned.

CT05L049

77 CLEANING THE PRIMARY ELEMENT IMPORTANT: Always protect your face before using compressed air.

If the primary element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least 3 cm from the inside wall of the element. Cleaning is completed once no more dust comes out of the primary element.

IMPORTANT: Compressed air pressure should not exceed 7 bar.

PE08311

78 NOTE: Do not use compressed air if there is oil or soot in the element.

If the cartridge is greasy: Clean it in water with a suitable detergent (consult your CASE Dealer). Instructions for using the detergent are printed on the packaging.

IMPORTANT: Allow the element to dry completely before installing it. It is advisable to keep a spare, clean element ready for installation on the air filter while the cleaned element is drying.

PDE0088A

79

7-40

SECTION 7 - LUBRICATION/FILTERS/FLUIDS INSPECTING THE ELEMENT Check the element for damage by placing an inspection lamp inside the element.

IMPORTANT: Change the element if light can be seen through a hole, however small.

PDE0378A

80 INSTALLING THE ELEMENTS 1.

Install a secondary element (if necessary) and tighten the wing nut.

CT05L049

81 2.

Install the primary element and tighten the wing nut.

CT05L048

82

7-41

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Install the cover and close the fasteners.

CT05L047

83 4.

Check that the dust ejector under the air-prefilter cover is working correctly.

IMPORTANT: If exhaust smoke is abnormal after cleaning, the air filter primary element must be changed.

CT05L051

84

7-42

SECTION 7 - LUBRICATION/FILTERS/FLUIDS SWING REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check ....................................................................................................................................... Every 250 hours Oil change........................................................................................................................................... Every 1000 hours (after the first 250 hours during the run-in period) Grease ................................................................................................................................................ Every 2000 hours Oil capacity (per reduction gear) ........................................................................................................................4.7 litres Oil type ................................................................................................................................. See "Fluids and lubricants"

!

WARNING

!

Wait till all components have cooled down before carrying out any operation.

1.

Park the machine on flat, horizontal ground. Stop the engine and remove the starter switch key.

LEVEL

1

2 CT05L052

85 1.

Remove the dipstick (2). The oil should come up to the hatched area. If necessary, add more oil through the filler hole (1).

2.

Install the dipstick.

3.

Proceed in the same manner for the second reduction gear.

CP98N043

86

7-43

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING 1.

Park the machine on flat, horizontal ground. Stop the engine and remove the starter switch key.

2.

Remove the dipstick (2) and the filler plug (1) from each reduction gear.

1

2 CT05L052

87 3.

Place a receptacle of a suitable capacity under the upperstructure, remove the lower panel and remove the drain plugs (3).

4.

Allow the oil to drain.

3

NOTE: The oil takes a relatively long time to drain.

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, consult your CASE Dealer.

CT06D009

88 5.

Install the drain plugs (3) and the lower panel.

6.

Add oil through the filler holes (1) until the level is correct.

7.

Install the dipsticks (2) and the filler plugs (1).

8.

Wait ten minutes and then use the dipsticks (2) to check the oil level again. If necessary, add more oil through the filler holes (1).

3

NOTE: When greasing the swing reduction gears, see "Greasing the swing reduction gears".

CT06D017

89

7-44

SECTION 7 - LUBRICATION/FILTERS/FLUIDS TRAVEL REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check ....................................................................................................................................... Every 250 hours Oil change........................................................................................................................................... Every 1000 hours (after the first 250 hours of operation) Oil capacity (per reduction gear) ......................................................................................................................13.8 litres Oil type ................................................................................................................................. See "Fluids and lubricants" LEVEL 1.

Park the machine on flat, horizontal ground.

2.

Move the machine so that plug (1) is in the lowest possible position.

3.

Stop the engine and remove the starter switch key.

4.

Remove the plug (2) and check the oil level. The level must come up to the bottom edge of the port (2). If necessary, remove the plug (3) and top up through this port (3) until oil comes up to the bottom edge of the port (2).

5.

Install the plugs (2) and (3).

6.

Repeat Steps 2 to 5 for the other travel reduction gear.

7.

3

2

1 CT06D018

90

Travel slowly with the machine and make sure there are no leaks.

DRAINING AND REFILLING 1.

Park the machine on flat, horizontal ground.

2.

Move the machine so that plug (1) is in the lowest possible position.

3.

Shut down the engine and remove the starter switch key.

4.

Place a receptacle of a suitable capacity under the travel reduction gear and remove the three plugs (1), (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, consult your CASE Dealer.

6.

Install the plug (1), fill with oil through the port (3) until oil comes up to the bottom edge of port (2), then install the plugs (2) and (3).

7.

Repeat Steps 2 to 6 for the other travel reduction gear.

8.

Travel slowly with the machine and make sure there are no leaks.

7-45

SECTION 7 - LUBRICATION/FILTERS/FLUIDS

NOTES

7-46

SECTION 8

37

MAINTENANCE/ADJUSTMENTS TRACKS MAINTENANCE SPECIFICATIONS Clean............................................................................. Periodically and when the machine has been working in mud Check tension ................................................................................................................................................Periodically Check steel pad screw torques ............................................................................................................ Every 250 hours (after the first 50 hours during the run-in period) IMPORTANT: If the tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after work.

CLEANING When the machine has been working in mud, a reduction in temperature can cause the mud to solidify.

1.

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground. Then place a block beneath the undercarriage to relieve the attachment.

!

WARNING

!

Only raise the track as little as necessary. Raising it too much can cause the machine to tip over.

2.

Turn the engine throttle button to maximum speed position.

CT06M031

1

8-1

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

Use the travel speed selector to select high speed.

2

AUTO

n n/min

E

F

CT06K026

2 4.

Operate the travel control lever for the raised track forwards and then in reverse, to remove the mud.

5.

With the track raised, check the track tension.

6.

Repeat Steps 1 to 5 for the other track.

CT06M017

3 CHECKING THE TENSION 1.

If the track is not yet raised, put the machine into the required position by proceeding in the same manner as for cleaning. See "Cleaning".

2.

Use the travel control lever to operate the raised track in reverse for a few moments.

3.

Stop the engine and remove the starter switch key.

4.

Measure the sag of the track at the center between the base of the undercarriage and the pad.

The value must be between: 410 mm and 430 mm.

1.

Adjust the tension if necessary, remove the chock from beneath the undercarriage then lower the raised track to the ground.

2.

Repeat Steps 1 to 5 for the other track.

PE07531

4

8-2

SECTION 8 - MAINTENANCE/ADJUSTMENTS ADJUSTING THE TENSION NOTE: This operation is to be carried out after the tension has been checked.

To increase tension 1.

Clean the grease fitting adaptor and the grease fitting.

2.

Connect the grease pump. Inject grease to obtain the right amount of track sag.

The value must be between: 410 mm and 430 mm.

3.

Remove the grease pump and clean the grease fitting.

4.

Repeat Steps 1 to 3 for the other track.

CD01D118

5 To reduce tension 1.

Loosen the grease fitting adaptor slowly about three turns to allow grease to flow out of the cylinder.

!

WARNING

!

Never unscrew the grease fitting adaptor completely to speed up the flow of grease. The grease in the cylinder is under high pressure.

2.

As soon as the right track sag is obtained, tighten the adaptor.

The value must be between: 410 mm and 430 mm.

3.

Clean the grease adaptor and fitting and then lower the raised track to the ground.

4.

Repeat Steps 1 to 3 for the other track.

CD01D119

6

IMPORTANT: If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regularly and replace it if necessary.

8-3

SECTION 8 - MAINTENANCE/ADJUSTMENTS TIGHTENING TORQUE OF THE TRACK PAD SCREWS IMPORTANT: Regularly check the tightening of the screws. Do not use the machine with the track pad screws loose, the screws may come off and damage the track.

The tightening torque of the screws should be between: 1588 to 1869 Nm.

PE08316

7 IMPORTANT: Follow the prescribed order.

1 4

3 2

CS00E504

8

8-4

SECTION 8 - MAINTENANCE/ADJUSTMENTS TRACK ROLLERS AND IDLER WHEELS MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours The upper and lower rollers and idler wheels use a permanent floating seal type sealing mechanism. The service life normally lasts until overhaul, but check visually from time to time before work for oil leakage. If oil leakage is found, component replacement is necessary. Consult your CASE Dealer.

CT08D002

9

RADIATORS AND OIL COOLERS MAINTENANCE SPECIFICATIONS Check for leakage.............................................................................................................. Every 10 hours or every day Dust removal...................................................................................................................... Every 10 hours or every day Clean..................................................................................................................................................... Every 250 hours CLEANING 1.

Stop the engine and remove the starter switch key.

2.

Open the rear LH side door and block it with the supporting strut.

CT05L055

10

8-5

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

Raise the top flap completely until the strut locks in position.

CT06D014

11 4.

Remove the wing nuts and remove the protection grids.

IMPORTANT: Always protect your face before using compressed air.

5.

Clean the radiators and the oil coolers: - Dry dust: use compressed air.

- Mud: use a water jet.

- Greasy dust: use perchlorethylene.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

6.

Install the protection grids and install the wing nuts.

!

WARNING

CT05L057

12

!

Before travelling, make sure that the rear LH side door and the top flap are securely fastened in place.

DUST REMOVAL Every day for 3 to 5 minutes, carry out a complete dust removal procedure for the cooling chamber. See "Radiator and oil-cooler dust removal switch" in section 5.

CT06K024A

13

8-6

SECTION 8 - MAINTENANCE/ADJUSTMENTS FAN AND ALTERNATOR DRIVE BELTS MAINTENANCE SPECIFICATIONS Visual check....................................................................................................................... Every 10 hours or every day Check belts tension .............................................................................................................................. Every 250 hours CHECKING THE TENSION IMPORTANT: If the engine runs with the belts slack, the belts can slip in their housing and cause the engine to overheat or the battery to receive insufficient charge.

CT05L058

14 With engine shut down and the starter switch key removed, use your finger to exert a pressure of about 10 kg at the centre of the belts. The tension slack should be between about 6 and 8 mm.

NOTE: Check if there are any signs of wear damage to the pulleys or the belts. Check carefully to ensure that the belts are correctly positioned in the pulley grooves. If the belts are stretched, cracked or frayed, they must all be replaced.

CS98M560

15 ADJUSTING THE TENSION Loosen the retaining screw (3) and the pulley attachment (4). Use the adjustment screws (1) and (2) to move the alternator and the pulley outwards until belts tension is correct. Retighten the pulley attachment (4) to a torque of 147 Nm. Tighten the alternator mounting bolt (3).

3 1 4

IMPORTANT: Check once again the tension of the belts after tightening the attachments.

2 CT05L059

16

8-7

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING THE BELTS If the belts break, the "ALTERNATOR" message is displayed on the message display screen. Shut down the engine, remove the starter switch key and change the belts.

Loosen the retaining screw (3) and the pulley attachment (4). Use the adjustment screws (1) and (2) to push the alternator and the pulley inwards.

3 1

Remove the worn belts.

4

Install a new belts.

Adjust the belts tension, see "Tension adjustment"..

Run the engine for about an hour and then check the belts tension again.

2 CT05L059

17

ADJUSTMENT OF ENGINE VALVE ROCKER CLEARANCES MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours NOTE: Ask your CASE Dealer to check this.

FUEL TANK FILTER MAINTENANCE SPECIFICATION Clean filter ......................................................................................................................................................Periodically Remove the filter and clean it in diesel oil.

NOTE: Use suitable fuel to refill the fuel tank, see "Fluids and lubricants" in section 7.

CD01K039A

18

8-8

SECTION 8 - MAINTENANCE/ADJUSTMENTS CAB PROTECTION (F.O.P.S.) (optional) MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours (after the first 50 hours of operation) MAINTENANCE AND CHECKS Check the retaining hardware, if necessary retighten the screws.

Check the absence of cracks, rust or holes in the protective structure and the components that constitute it.

Ageing, bad weather and accidents can cause damage. If you have even the slightest doubt regarding the condition of the structure, consult your CASE Dealer.

If the protective structure has suffered any accident, it is necessary to replace the damaged components of the structure in order to restore the initial protection, consult your CASE Dealer.

CT04D008B

19

FIRE EXTINGUISHER (not supplied) It is strongly recommended to have a fire extinguisher available and to keep it in the front boot.

MAINTENANCE SPECIFICATION Every month: Examine the fire extinguisher and make sure it is not damaged.

Every six months: Have an approved specialist empty the powder and refill the fire extinguisher.

Every year: Have an approved specialist examine the fire extinguisher.

CS98M573

20

8-9

SECTION 8 - MAINTENANCE/ADJUSTMENTS WELDING ON THE MACHINE Whenever carrying out a welding operation on the undercarriage or upperstructure carriage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires and connect the welding apparatus earth cable to the component on which the welding operation is to be performed. Never connect the welding apparatus to the undercarriage when welding on the upperstructure (or vice-versa).

Never connect the welding apparatus earth to a component of the hydraulic system.

!

WARNING

!

Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer.

INSPECTING AND CLEANING THE MACHINE MAINTENANCE SPECIFICATIONS Inspect and clean...........................................................................................................................................Periodically Or whenever oil or grease has been spilt on the machine. Clean off with steam or a high pressure water jet.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear. Look for any leaks and check the condition of all pipes and hoses.

CHECKING THE MACHINE SETTINGS MAINTENANCE SPECIFICATION Check by your CASE Dealer ................................................................................................................. Every 6 months

8-10

SECTION 8 - MAINTENANCE/ADJUSTMENTS CHECKING FOR CYLINDER LEAKAGE A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1.

Wipe clean the rod and bearing on the cylinder to be cleaned.

2.

Operate normally for five or ten minutes.

3.

Extend the cylinder rod.

4.

Carry out the leak test.

ROD APPEARANCE Dry Slightly greasy Oily

TEST

CONCLUSION

Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time the cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

Consult your CASE Dealer

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

8-11

SECTION 8 - MAINTENANCE/ADJUSTMENTS TOOTH TIP WEAR LIMITS The degree to which a tooth tip can be worn can be assessed visually.

It is possible to extend the life of a tooth tip which is wearing unevenly, in a non-symmetrical fashion.

Interchange and turn over the teeth regularly.

NOTE: Do not wait for tooth tips to be completely worn through before changing them.

IMPORTANT: Never try to work with a missing tooth tip or a tooth tip which is worn through. The adaptor nose could be seriously damaged.

CD01D128A

21

REPLACING A TOOTH TIP REMOVAL 1.

Place the bucket a few centimetres above the ground. Stop the engine and remove the starter switch key.

2.

Use a drift to remove the locking pin from its housing by striking it with a hammer until it is ejected.

3.

Remove the worn tooth tip, turning it to the left.

CD01D128A

22 INSTALLATION 1.

Clean the mating surface on the adaptor.

2.

Install a new tooth tip turning it to the right up to the stop and holding it in this position.

3.

Place the locking pin in position and strike it until it is flush with the tooth tip.

NOTE: When replacing a tooth tip, it is advisable to replace the locking pin at the same time.

8-12

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING A BACKHOE BUCKET REMOVAL 1.

Place the bucket flat on flat, horizontal ground.

Operate the attachment controls so that the dipper/bucket linkage pin is not gripped by the weight of the dipper.

2.

Stop the engine and remove the starter switch key.

3.

Remove the pins hardware.

CT09F004

23 4.

Remove the bucket pins.

5.

Start the engine, disengage the attachment from the bucket and save the linkage seals for re-use.

CT09F005

24 INSTALLATION 1.

Make sure the bucket is in a stable position.

2.

Start the engine. Bring the dipper into its housing.

Stop the engine and remove the starter switch key.

3.

Install the linkage seals between the dipper and the bucket. Change them if necessary.

8-13

SECTION 8 - MAINTENANCE/ADJUSTMENTS 4.

Install the dipper/bucket linkage pin and its hardware.

5.

Start the engine. Bring the bucket rod into its housing, stop the engine and remove the starter switch key.

6.

Install the linkage seals between the rod and the bucket. Change them if necessary.

7.

Install the rod/bucket linkage pin and its hardware.

8.

(If equipped) Adjust the dipper/bucket shimming.

See "Shimming the backhoe bucket".

9.

Grease the linkage pins.

CT09F004

25

SHIMMING THE BACKHOE BUCKET (if equipped) This mechanism is used to adjust the play between the dipper and the bucket in order to eliminate the play caused by wear. Check and adjust the play regularly.

SIDE PLAY ADJUSTMENT 1.

Place the bucket flat on flat, horizontal ground and stop the engine.

2.

Check the play (J) between the dipper and the bucket ear.

3.

If the play (J) exceeds 2 mm, remove the four screws, the cap (1) and the shims (2).

4.

Use the shims (2) as a feeler gauge to determine the number of shims necessary to take up the play (J).

5.

Install the necessary number of shims.

6.

Install the cap (1) and the four screws.

NOTE: When the screws in the cap (1) are tightened, the inner bushing moves towards the dipper and takes up the play.

IMPORTANT: It is recommended to maintain a play of about 1.2 mm. If the play is insufficient, it may cause wear by friction or seizing.

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap (1) has an orifice on its inside surface. When installing the cap (1), make sure the lug is inside this orifice.

8-14

1

J 2 CD00E121

26

SECTION 8 - MAINTENANCE/ADJUSTMENTS AIR CONDITIONING MAINTENANCE SPECIFICATION Clean the intake filter ...............................................................................................................................Every 50 hours Clean the air recycling filter .....................................................................................................................Every 50 hours Replace the filters ............................................................................................................................... Every 2000 hours Have checked by a specialist .................................................................................................................Every 6 months The components of the air conditioning system need servicing at regular intervals. Make sure these intervals are respected, in order to ensure the air conditioning functions correctly and with maximum effectiveness. The air conditioning system contains gas which is subject to strict legislation. Any defect in the system must be fixed rapidly.

!

WARNING

!

Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

NOTE: Operate the air conditioning system at least once a week, if only for a short time. See "Heating, ventilation or air-conditioning control" in section 4.

INSPECTION In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below before starting work.

CLEANLINESS OF THE CONDENSER If the condenser is dirty it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

CHECKING THE BELT TENSION Use your finger to exert pressure of around 10 kg on the centre of the drive belt. The tension slack should be between about 5 and 7 mm. If necessary, adjust the belt tension.

CHECKING THE LINES Make a visual check of the lines and make sure there are no accumulations of dust, grease, etc.

CT05L060

27

8-15

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR INTAKE AND AIR RECYCLING FILTERS 1.

Remove the screws (2) and sealing cover (1) in the rear of the cab.

2 1

2 CT05L061

28 2.

Remove the screws (3) and open the panel (4).

3 4

CD00E139

29 3.

Remove the filter and clean it with compressed air.

Replace the filter if it is damaged.

IMPORTANT: Always protect your face before using compressed air.

4.

Install the filter in its housing with the seal (5) on the inside.

5.

Close the panel (4) and install the screws (3).

6.

Install the sealing cover (1) and the screws (2).

5

CD00E140

30

8-16

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR RECYCLING FILTER 1.

To access the filter, open the panel located behind the operator’s seat.

CT06K036

31 2.

Remove the filter and clean it with compressed air.

Replace the filter if it is damaged.

IMPORTANT: Always protect your face before using compressed air.

3.

Install the filter in its housing by following the direction of installation then close the panel.

CT06K113

32 CHECKING THE CHARGE STATE OF THE SYSTEM 1.

Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

CT05L062

33

8-17

SECTION 8 - MAINTENANCE/ADJUSTMENTS 2.

This check should be made approximately one minute after turning on the air conditioning.

A

(A) Very few bubbles observed, then transparent at first, then whitish: "Normal".

(B) The bubbles are numerous: check the unions and consult your CASE Dealer.

B

(C) No bubbles are visible: check the unions and consult your CASE Dealer.

C CT07K015

34 3.

Check if the hydraulic line and air-conditioning hose connectors are dirty or dusty and clean them if necessary.

CT02D235

35

8-18

SECTION 8 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING NOTE: This section shows how to easily diagnose problems relating to the engine and describes the solutions to be adopted. If you are unable to determine the cause of the failure, or if the latter is difficult to rectify, consult your CASE Dealer.

PROBLEM

Engine does not start.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run) or battery master switch in "O" (Off) position

Check starter switch/Place the battery master switch in "I" (On) position

Defective rotation of starter (starter rotates slowly)

Discharged batteries, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Incomplete air bleeding of fuel system

Completely bleed air

Engine too cold (cold weather)

Preheat the intake air or warm up the coolant

No fuel in fuel tank

Refill

Poor fuel quality

Inspect and replace as necessary

Fuel filter clogged

Clean or replace

Possible seizure in engine Low compression

Consult your CASE Dealer

Defective fuel injection pump Engine stops during operation.

No fuel in fuel tank

Refill

Fuel filter clogged

Clean or replace

Air in the fuel system

Retighten fuel in line connections

Low oil

Refill

Oil filter clogged

Replace oil filter

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage from connections

Tighten connections

Incorrect oil pressure.

Defective oil pressure switch Consult your CASE Dealer Incorrect functioning of oil pump

Exhaust from engine is white or blue.

Excessive oil

Disassemble and clean/replace parts

Excessively low oil viscosity

Replace with oil that has correct viscosity

Excessive cooling by radiator

Adjust

Incorrect fuel injection timing Consult your CASE Dealer Low compression

8-19

SECTION 8 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Exhaust from engine is black or dark grey.

POSSIBLE CAUSE

SOLUTION

Incorrect fuel

Replace with correct fuel

Incorrect valve clearance

Adjust

Insufficient air intake (air filter clogged)

Clean or replace the air filter

Defective fuel injection pump Consult your CASE Dealer Low compression Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Excessive fuel consumption.

Incorrect spray from fuel injection nozzle Consult your CASE Dealer Incorrect fuel injection timing Low compression Excessive oil

Drain oil to proper level

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage

Retighten and replace parts if necessary

Worn cylinder piston ring

Consult your CASE Dealer

Poor fuel quality

Replace

Damage inside muffler

Replace

Low coolant

Refill

Coolant leakage

Repair

Worn or damaged belt

Replace

Incorrect mixture of anti-freeze solution

Replace

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

Engine overheating (coolant temperature is too high).

Defective radiator Broken fan Defective thermostat

Consult your CASE Dealer

Defective water pump Defective water temperature gauge

Defective battery charge.

Incorrect belt tension

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Consult your CASE Dealer Defective alternator

8-20

SECTION 8 - MAINTENANCE/ADJUSTMENTS HARDWARE TORQUE INSPECTION MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours (after the first 50 hours during the run-in period) At the end of each working day, check all mounting nuts and screws for tightness and tighten if necessary.

Make sure no hardware items are missing. Replace them, if necessary.

TORQUE SPECIFICATIONS PER COMPONENT Screw (Ø)

Wrench (mm)

Torque setting (Nm)

Travel reduction gear (*)

M27

41

1307-1526

Drive sprocket (*)

M27

41

1307-1526

Undercarriage side members

M36

55

2550-2942

Upper roller (*)

M20

30

521-608

Lower roller (*)

M27

41

1307-1526

Chain guide (*)

M27

41

1307-1526

Track pad

M27

30

1588-1869

Counterweight

M42

65

2256-2550

Turntable (upperstructure) (*)

M30

46

1800-2100

Swing reduction gear (*)

M24

36

900-1050

Engine (*)

M24

36

902-1049

Engine mounts (*)

M14

22

173-202

Radiator

M20

30

392-490

Hydraulic pump (*)

M12

19

Hydraulic reservoir (*)

M20

30

471-568

Fuel tank (*)

M20

30

471-568

Control valve (*)

M20

30

471-568

Hydraulic swivel (*)

M16

24

267-312

Cab

M16

24

142-172

Batteries

M10

17

20-29

Component

109-127

NOTE: Use Loctite 262, or the equivalent, on screws marked (*).

8-21

SECTION 8 - MAINTENANCE/ADJUSTMENTS

NOTES

8-22

SECTION 9

10

ELECTRICAL SYSTEM FUSES IMPORTANT: Before changing fuses or relays, turn the starter switch key to the "Shut down" position, wait one minute minimum and place the key of the battery master switch in "O" (Off) position.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

To access the fuse box, open the panel located behind the operator’s seat.

CT06K036

1 To access the fuses, remove the cover of the box.

CT06K037

2 A notice on the cover gives the function and amperage of each fuse.

NOTE: To remove or install a fuse, use the notch in the upper right-hand corner of the cover.

NOTE: Two spare fuses (10 Amp and 20 Amp) are to be found on the inside of the cover.

A23955

3

9-1

SECTION 9 - ELECTRICAL SYSTEM FUSE FUNCTIONS (1) Memory, cab lighting, cab radio ....................... 10 A (2) Engine pre-heating........................................... 30 A (3) Optional............................................................. 10 A (4) Air conditioning, heater....................................... 5 A (5) Air conditioning condenser fan......................... 15 A (6) Air conditioning compressor............................... 5 A (7) Solenoid............................................................ 10 A (8) Windshield wiper/washer ................................. 15 A (9) Horn, self-detaching counterweight (optional)................................... 10 A (10) Working lights (boom and upperstructure) .... 15 A (11) Fuel filler pump............................................... 20 A (12) Clock............................................................... 10 A (13) Cigarette lighter, operator’s seat .................... 15 A (14) DC rectifier...................................................... 10 A (15) Rotating beacon (not supplied)...................... 10 A (16) Not used ......................................................... 15 A (17) Fuel supply pump........................................... 10 A (18) Not used ......................................................... 15 A (19) Hydraulic control cancellation ........................ 10 A (20) Working lights on cab..................................... 15 A

1

10A

20A

11

2

30A

10A

12

10A

15A

4

5A

10A

14

5

15A

10A

15

6

5A

15A

16

10A

10A

15A

15A

10A

10A

15A

15A

3

7 8 9 10

13

17 18 19 20

CT06K073

4

9-2

SECTION 9 - ELECTRICAL SYSTEM BATTERIES MAINTENANCE SPECIFICATION Checking the charge state.................................................................................................................... Every 250 hours Electrolyte level check .......................................................................................................................... Every 250 hours NOTE: When starting the machine with booster batteries, see "Connecting booster batteries".

!

WARNING

!

Before any operation on the components of the electrical circuit, put the starter switch key in the "Off" (shut down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.

!

WARNING

!

The electrolyte in the batteries can cause serious burns. Batteries contain sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL: rinse thoroughly with water and remove soiled clothes.

INTERNAL: do not induce vomiting. Rinse the mouth out with water. Seek medical advice.

EYES: rinse thoroughly with water for 15 minutes and seek medical advice.

!

WARNING

!

A spark or a naked light can cause the hydrogen in a battery to explode. To prevent explosion, proceed as follows: - When disconnecting battery cables, always disconnect the negative cable (-) first.

- When connecting battery cables, always connect the negative cable (-) last.

- Never short-circuit the battery terminals with metal objects.

- Do not weld, grind or smoke near the batteries.

!

WARNING

!

Batteries give off explosive gases. Keep all naked flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

9-3

SECTION 9 - ELECTRICAL SYSTEM To gain access to the batteries, open the left-hand side door.

CHECKING THE CHARGE STATE OF A MAINTENANCE-FREE BATTERY The charge indicator on the battery shows the state of charge of the battery.

If the colour is: Green; the charge is correct.

Black; insufficient charge. Recharge the battery until the indicator turns green.

Transparent (colourless); replace the battery as soon as possible.

CT07A047

5 CHECKING THE ELECTROLYTE LEVEL OF A MAINTENANCE-TYPE BATTERY Remove the cell caps and check the level in each batteries cell. The level should be between 10 and 15 mm above the plates. Add distilled water if necessary, then install the cell caps.

IMPORTANT: When adding distilled water at temperatures below 0°C, the batteries must be charged or the engine run for two hours approximately in order to ensure that the distilled water and the electrolyte are properly mixed.

NOTE: Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

CP99A022

6 CHANGING A BATTERY 1.

Place the key of the battery master switch in "O" (Off) position.

2.

Remove the terminal protection caps, disconnect cables (negative terminals) and then cables (positive terminals). Remove the anti-sulphate pellets.

3.

Remove the two screws, the washers and metal sheet and then remove the old battery.

4.

Install the new battery and put the metal sheet, washers and the two screws back in place.

5.

Clean the cables and battery terminals and coat them with grease.

6.

Install new anti-sulphate pellets, reconnect positive cable ends to positive terminals and then negative cable ends to negative terminals. Install the terminal protection caps.

7.

9-4

Place the key of the battery master switch in "I" (On) position.

CT05L063

7

SECTION 9 - ELECTRICAL SYSTEM

!

WARNING

!

Do not invert battery terminals. Connect positive cable ends to positive terminals (+) and negative cable ends to negative terminals (-).

!

WARNING

!

Always store batteries in a safe place, out of the reach of children.

!

WARNING

!

Never touch battery terminals with the hands as electrolysis can take place within the human body and damage vital organs.

CONNECTING BOOSTER BATTERIES

!

WARNING

!

Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

Make sure that the booster battery voltage corresponds to the voltage system of the machine (24 volts).

1.

Place the key of the battery master switch in "O" (Off) position.

2.

Remove the terminal sleeves.

3.

Connect the positive (+) cable to the positive (+) terminal on the first machine battery.

4.

Connect the negative (-) cable to the negative (-) terminal on the second machine battery.

5.

Place the key of the battery master switch in "I" (On) position and start the engine.

6.

Remove the booster battery negative (-) cable and then the positive (+) cable.

7.

Install the terminal sleeves.

9-5

SECTION 9 - ELECTRICAL SYSTEM ALTERNATOR MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours

!

WARNING

!

Whenever carrying out a welding operation on the machine (authorised by the manufacturer and in accordance with his instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires.

IMPORTANT: Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

Ask your CASE Dealer to check the alternator.

NOTE: Make sure that the terminal protectors are correctly installed.

CT05L064

8

STARTER MOTOR MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours Ask your CASE Dealer to check the starter motor.

NOTE: Make sure that the terminal protectors are correctly installed.

CT05L065

9

9-6

SECTION 9 - ELECTRICAL SYSTEM REPLACING A BULB OPERATOR’S COMPARTMENT LIGHTING 1.

Remove the cover.

2.

Remove the bulb and install a bulb of the same wattage (10 W).

3.

Install the cover.

CT06M039

10 ATTACHMENT LIGHTS

CT05L066

11 1.

Remove the 4 retaining screws.

CD00E124

12

9-7

SECTION 9 - ELECTRICAL SYSTEM 2.

Tilt the working light and disconnect the plug.

CD00E125

13 3.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

4.

Install the clip and reconnect the plug.

5.

Put the working light back into position and install the mounting screws.

CD00E126

14 UPPERSTRUCTURE AND CAB HEADLIGHTS 1.

Raise the front storage box cover until the support strut is locked.

CD01K053A

15

9-8

SECTION 9 - ELECTRICAL SYSTEM 2.

Remove the top plate from the light compartment.

3.

Disconnect the plug.

CT05L067

16 4.

Remove the four screws and tilt the headlight.

CD00E129

17 5.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

6.

Install the clip, put the headlamp back in position and install the screws and the plug.

7.

Install the top plate. Close the front box.

CD00E130

18

9-9

SECTION 9 - ELECTRICAL SYSTEM

NOTES

9-10

SECTION 10

2

STORAGE STORING THE MACHINE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building or, if not possible, outside and covered with a tarpaulin. Before storing the machine, carry out the following operations:

Every month, check:

1.

2.

3.

4.

1.

The battery charge and recharge the batteries if required.

2.

The levels and top up if necessary.

Clean the machine.

3.

Make sure that the machine has no damaged or missing parts. Replace them if necessary.

The condition of all lines, connectors and clamps (rust). Grease if necessary.

4.

The condition of the paintwork. Apply a coat of anti-rust treatment where necessary.

5.

Unplug the air filter inlet and the exhaust pipe.

6.

Run the engine at low speed following the starting up procedure and operate the attachment, swing and travel controls.

Retract the cylinder rods as for as possible and lower the boom until the attachment is resting on the ground.

Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. Consult your CASE Dealer.

!

WARNING

!

NOTE: When the machine resumes service, the film will disappear automatically.

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times..

5.

7.

The grease on the cylinder rods.

8.

Plug the air filter inlet and the exhaust pipe.

While the engine is still warm, drain the oil sump, replace the oil filters and fill with the stipulated oil.

Check the oil level and add more if necessary.

6.

Clean or replace the air filter element.

7.

Check the level of coolant solution. If the machine is within 100 hours of the next scheduled coolant change, change the coolant now.

8.

Place the key of the battery master switch in "O" (Off) position.

9.

Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries safely in a cool and dry location, where the temperature is higher than 0 °C or disconnect the cable from the negative (-) terminal.

10. Paint any areas where the paintwork is not good.

11. Plug the air filter inlet and the exhaust pipe.

12. Remove the starter switch key and place a "Do not operate" label on the right-hand control arm and then place the function cancellation lever in the central position (safety bar in inward position).

13. Lock the hoods, side doors and the cab door.

10-1

SECTION 10 - STORAGE STARTING UP AFTER STORAGE 1.

Bleed the fuel tank, pre-filter and fuel filters, replace the filter elements if necessary.

2.

Fill the fuel tank with suitable fuel, see "Fluids and Lubricants" in section 7.

3.

Check if the key of the battery master switch is in "O" (Off) position.

4.

Install the batteries or reconnect the cable to the negative (-) terminal.

5.

Grease the machine thoroughly.

6.

Check the condition of the fan drive belts and replace if necessary.

7.

Check the condition of the air conditioning drive belt and replace it if necessary.

8.

Check the level of the cooling system and add more coolant if necessary.

9.

Check the hydraulic fluid level and add more fluid if necessary.

10. Check the travel and swing reduction gears oil level and add more oil if necessary.

11. Clean the cylinder rods.

12. Unplug the air filter inlet and the exhaust pipe.

13. Place the key of the battery master switch in "I" (On) position.

!

WARNING

!

Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly.

14. Remove the "Do not operate" tag and start the engine, following the starting up procedure.

15. Check all the indicators and lamps carefully.

!

WARNING

!

Check the machine for leaks or for any parts that are broken, defective or missing.

!

WARNING

!

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

10-2

SECTION 11

10

SPECIFICATIONS ENGINE Latest "common rail" engine, in conformity with the European requirements applicable to low fumes emission, in accordance with the directive 97/68/EC. Make and type .....................................................................................................................ISUZU AH-6WG1XYSS-02 Common rail, turbo, intermediate cooler, fuel cooler.................................................................................................yes Injection...................................................................................................................................... electronically controlled Number of cylinders....................................................................................................................................................... 6 Bore/stroke.........................................................................................................................................147 mm x 154 mm Displacement ................................................................................................................................................ 15 700 cm3 Cooling................................................................................................................................................................by water Battery starting ......................................................................................................... 2 12 volt batteries, 140 A/h WORKING CONDITIONS Speed................................................................................................................................................................1800 rpm EEC 80/1269 power ............................................................................................................................... 397 kW/532 hp Engine oil capacity ................................................................................................................................................... 52 l Fuel tank capacity................................................................................................................................................... 900 l Fuel filler pump.

Engine/pump assembly mounted on flexible mountings.

Filtration in dusty conditions.

Electronically controlled governor.

HYDRAULIC SYSTEM Variable flow piston-type double pump.

Max main pump output (at 1800 rpm) .............................................................................................2 x 500 l/min Fixed flow pump (pilot circuit).

Max. flow ................................................................................................................................................. 27 l/min Working pressure.

Attachment/power boost ................................................................................................................... 320/350 bar Tilting oil cooler with ventilation from engine.

High pressure multispiral hoses minimum safety factor.................................... 2 to 4 times the working pressure Self-lubricating hydraulic swivel.

Hydraulic reservoir capacity......................................................................................................................... 310 l Total hydraulic system capacity ............................................................................................................................ 720 l CONTROL VALVE Four control valve sections for right-hand travel, boom/bucket and dipper acceleration.

Five control valve sections for left-hand travel, swing, dipper, auxiliary attachment and boom acceleration.

Boom/dipper load holding valves.

11-1

SECTION 11 - SPECIFICATIONS SWING Fixed flow, piston-type pump.

Automatic disk brake.

Upperstructure swing speed................................................................................................................................6.4 rpm TRAVEL Two speed hydraulic motors with axial pistons.

Planetary reduction gears.

Low speed...................................................................................................................................................0 to 2.9 km/h High speed..................................................................................................................................................0 to 4.2 km/h Gradeability ...............................................................................................................................................................70% Pull force........................................................................................................................................................ 56 500 daN STANDARD ATTACHMENT (8.40 m boom) Crowd force................................................................................................................................................... 36 100 daN Break-out force (with 3.66 m dipper)............................................................................................................ 30 000 daN Break-out force (with 4.44 m dipper)............................................................................................................ 25 300 daN Break-out force (with 5.62 m dipper)............................................................................................................ 21 400 daN SHORT ATTACHMENT (7.25 m boom) Crowd force................................................................................................................................................... 47 000 daN Break-out force (with 2.98 m dipper)............................................................................................................ 34 700 daN

UNDERCARRIAGE "X" configuration chassis with (mechanically) variable track gauge.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks...........................................................................................Track pads of: 650 mm, 750 mm and 900 mm Ground pressure (with 650 mm track pads) ......................................................................................................1.12 bar

SAFETY DEVICES Control for lowering attachments in case of engine failure.

Controls are disabled by lifting the function cancellation lever or the left-hand control arm.

Engine emergency shut-down, anti-theft protection.

Safety glass, horn.

Safety valves with overload indicator ................................................................................................................. optional Inertia reel type safety belt.

Battery master switch.

Fire extinguisher.................................................................................................................................................. optional

11-2

SECTION 11 - SPECIFICATIONS OPERATOR'S COMPARTMENT Deluxe seat with armrests, inertia type safety belt, multi-position adjustment and headrest (vibration level III/ISO 7096, 2000 Class EM 6) class (seat coefficient < 0.7).

Hydraulically assisted controls.

Attachment and swing .............................................................................................................................2 control levers Travel ...............................................................................................................................................2 foot pedals Speed programmer, also provides automatic speed change.

Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation/air conditioning, cab lights, cigarette lighter, sun shield.

Working lights: One on upperstructure.................................................................................................................24 V, 70 W Two on attachment...................................................................................................................... 24 V, 70 W Two on cab.................................................................................................................................. 24 V, 70 W

NOISE LEVELS Guaranteed by the manufacturer.

Outside the operator's compartment (Lwa).

Sound power level 108 dB (A) in accordance with the 2000/14/EC directive.

Inside the operator's compartment (Lpa).

Sound power level 77 dB (A) in accordance with the ISO 6396/2008 standard: Weighted sound pressure level at the cab measured with the cab door and windows closed and with the heating/ventilation system fan at maximum speed.

VIBRATION LEVEL INSIDE THE CAB The vibration level to which the operator's hand-arm system is exposed is less than 2.5 m/s2 The vibration level to which the operator's whole body is exposed is less than 0.5 m/s2 These results are obtained using an acceleration gauge with the machine in digging mode with a standard bucket.

NOTE: The vibration levels vary with the working conditions and the type of terrain. They are not therefore representative for the different conditions of use corresponding to the normal operating conditions defined in this manual.

Consequently, these values cannot be used to determine the operator's exposure to vibrations as per the European Directive 2002/44/EC. Rather, it is recommended that you measure the vibration levels in real working conditions. If this is not possible, use the table below. This table is an extract from the information sheet ISO/TR 25398:2006. (ISO/TR/25398; Earthmoving machinery - Guidelines for assessment of exposure to whole-body vibration of ride-on machines - Use of harmonized data measured by international institutes, organizations and manufacturers).

Average Working conditions

1.4*a

1.4*aw,

w,eqx

eqy

2

2

Standard deviation aw,eqz [m/s2]

1.4*Sx [m/s2]

1.4*Sy [m/s2]

Sz [m/s2]

[m/s ]

[m/s ]

Digging

0.44

0.27

0.30

0.24

0.16

0.17

Hydraulic breaker

0.53

0.31

0.55

0.30

0.18

0.28

Mine

0.65

0.42

0.61

0.21

0.15

0.32

Combined movements

0.48

0.32

0.79

0.19

0.20

0.23

11-3

SECTION 11 - SPECIFICATIONS CAB Removable, sound proof, mounted on flexible mountings.

Foldaway windscreen.

Rear window emergency exit.

Sun shield.

Sliding windows on door.

Prefitted for radio installation.

Roof hatch.

Windshield protection grid (optional).

Cab protection (optional).

TRANSPORT Reduction of the width of the undercarriage to 3.74 m (with 650 mm track pads).

This machine may be equipped (optionally) with a self-detaching counterweight. A system consisting of 3 hydraulic control cylinders allows quick removal, without requiring any special handling equipment.

WEIGHTS STANDARD ATTACHMENT With 8.40 m boom, 3.66 m dipper, 3300 l backhoe bucket (general purpose), 650 mm track pads, operator and full fuel tank ......................................................................................................................... 80 300 kg SHORT ATTACHMENT With 7.25 m boom, 2.98 m dipper, 3900 l backhoe bucket (very heavy duty), 650 mm track pads, operator and full fuel tank ......................................................................................................................... 80 400 kg COUNTERWEIGHT Weight.............................................................................................................................................................. 12 500 kg Self detaching counterweight ...........................................................................................................................(optional)

STANDARD ATTACHMENT Boom, length ........................................................................................................................................................8.40 m Dipper, length........................................................................................................................................................3.66 m Dipper, length........................................................................................................................................................4.44 m Dipper, length........................................................................................................................................................5.62 m

SHORT ATTACHMENT Boom, length ........................................................................................................................................................7.25 m Dipper, length........................................................................................................................................................2.98 m

11-4

SECTION 11 - SPECIFICATIONS BACKHOE BUCKETS GENERAL PURPOSE SAE capacity

2400 l

2780 l

3300 l

3700 l

4100 l

5000 l

Width

1300 mm

1450 mm

1650 mm

1800 mm

1900 mm

2300 mm

Weight

2960 kg

3110 kg

3400 kg

3540 kg

3640 kg

4120 kg

HEAVY DUTY and VERY HEAVY DUTY SAE capacity

2550 l

2960 l

3900 l

4210 l

5330 l

Width

1300 mm

1450 mm

1800 mm

1900 mm

2300 mm

Weight

3570 kg

3740 kg

4290 kg

4410 kg

5020 kg

QUARRY SAE capacity

4100 l

Width

1800 mm

Weight

4500 kg

11-5

SECTION 11 - SPECIFICATIONS MACHINE OVERALL DIMENSIONS STANDARD ATTACHMENT (8.40 m boom)

CS01B548B

1 Dippers 3.66 m 4.44 m 5.62 m (A) ....................................................................................................4.81 m ................5.00 m .................6.30 m (B) ....................................................................................................3.88 m ................3.88 m .................3.88 m (C) ..................................................................................................14.36 m ..............14.32 m ...............13.83 m (D) ....................................................................................................7.46 m ................7.46 m .................7.46 m (E) ....................................................................................................4.25 m ................4.25 m .................4.25 m (F) ....................................................................................................1.59 m ................1.59 m .................1.59 m (G)....................................................................................................4.28 m ................4.28 m .................4.28 m (H) ....................................................................................................6.36 m ................6.36 m .................6.36 m (I)......................................................................................................5.07 m ................5.07 m .................5.07 m (J)* ...................................................................................................3.45 m ................3.45 m .................3.45 m (J)** ..................................................................................................2.83 m ................2.83 m .................2.83 m (K) (standard pads) ..........................................................................0.65 m ................0.65 m .................0.65 m (L)* (with 650 mm pads)...................................................................4.36 m ................4.36 m .................4.36 m (L)** (with 650 mm pads) .................................................................3.74 m ................3.74 m .................3.74 m (L)* (with 750 mm pads)...................................................................4.46 m ................4.46 m .................4.46 m (L)** (with 750 mm pads) .................................................................3.84 m ................3.84 m .................3.84 m (L)* (with 900 mm pads)...................................................................4.61 m ................4.61 m .................4.61 m (L)** (with 900 mm pads) .................................................................3.99 m ................3.99 m .................3.99 m (M)....................................................................................................0.89 m ................0.89 m .................0.89 m * (working position) ** (transport position)

11-6

SECTION 11 - SPECIFICATIONS SHORT ATTACHMENT (7.25 m boom)

CS01B547B

2 Dipper 2.98 m (A).......................................................................................................................................................................... 5.00 m (B).......................................................................................................................................................................... 3.88 m (C)........................................................................................................................................................................ 13.23 m (D).......................................................................................................................................................................... 7.46 m (E).......................................................................................................................................................................... 4.25 m (F).......................................................................................................................................................................... 1.59 m (G) ......................................................................................................................................................................... 4.28 m (H).......................................................................................................................................................................... 6.36 m (I) ........................................................................................................................................................................... 5.07 m (J)*......................................................................................................................................................................... 3.45 m (J)**........................................................................................................................................................................ 2.83 m (K) (standard pads)............................................................................................................................................... 0.65 m (L)* (with 650 mm pads) ....................................................................................................................................... 4.36 m (L)** (with 650 mm pads)...................................................................................................................................... 3.74 m (L)* (with 750 mm pads) ....................................................................................................................................... 4.46 m (L)** (with 750 mm pads)...................................................................................................................................... 3.84 m (L)* (with 900 mm pads) ....................................................................................................................................... 4.61 m (L)** (with 900 mm pads)...................................................................................................................................... 3.99 m (M) ......................................................................................................................................................................... 0.89 m * (working position) ** (transport position)

11-7

SECTION 11 - SPECIFICATIONS OVERALL DIMENSIONS AND WEIGHT OF THE MAIN MACHINE COMPONENTS 1 2

3

4

5 6 CT08H001

3 a (length)

b (height)

c (width)

Approximate weight

(1)

5.88 m

2.96 m

3.48 m

25 300 kg

(2)

3.47 m

1.39 m

0.83 m

12 500 kg

(3) (each)

6.36 m

1.50 m

0.65 m

12 500 kg

(3) (each)

6.36 m

1.50 m

0.75 m

12 900 kg

(3) (each)

6.36 m

1.50 m

0.90 m

13 600 kg

(4) (7.25 m boom)

7.85 m

2.56 m

1.47 m

7920 kg

(4) (8.40 m boom)

8.75 m

2.31 m

1.47 m

8300 kg

(5) (both)

2.93 m

-

1.00 m

1610 kg

(6) (2.98 m)

4.38 m

1.50 m

0.74 m

4250 kg

(6) (standard 3.66 m)

5.20 m

1.40 m

0.74 m

4100 kg

(Cab protection)

2.30 m

1.90 m

1.05 m

230 kg

(Walkways and access handles)

-

-

-

111 kg

NOTE: For dimensions and weights of buckets, refer to "Backhoe buckets".

11-8

SECTION 11 - SPECIFICATIONS WORKING RANGE STANDARD ATTACHMENT (8.40 m boom)

CS01B550C

4 Dippers 3.66 m 4.44 m 5.62 m (A) (Maximum digging reach).......................................................... 14.12 m .............. 14.94 m ............... 16.11 m (B) (Maximum digging reach at ground level)................................... 13.84 m .............. 14.68 m ............... 15.86 m (C) (Maximum digging depth)............................................................ 8.69 m ................ 9.47 m ............... 10.66 m (D) (Maximum digging depth over a length of 2.44 m)........................ 8.57 m ................ 9.36 m ............... 10.56 m (E) (Maximum dump height) ............................................................. 8.92 m ................ 9.51 m ............... 10.17 m (F) (Maximum working height) ........................................................ 12.91 m .............. 13.60 m ............... 14.30 m (G) (Minimum attachment swing radius) ............................................ 6.27 m ................ 6.13 m ................. 6.21 m (H) (Maximum digging depth on a vertical face)................................. 6.44 m ................ 7.75 m ................. 9.11 m (I) (Maximum length of flat-bottomed trench) .................................... 2.44 m ................ 2.44 m ................. 2.44 m

11-9

SECTION 11 - SPECIFICATIONS SHORT ATTACHMENT (7.25 m boom)

CS01B549C

5 Dipper 2.98 m (A) (Maximum digging reach) ..................................................................................................................12.31 m (B) (Maximum digging reach at ground level) ............................................................................................11.99 m (C) (Maximum digging depth) .....................................................................................................................7.03 m (D) (Maximum digging depth over a length of 2.44 m) .................................................................................6.88 m (E) (Maximum dump height).......................................................................................................................7.89 m (F) (Maximum working height)..................................................................................................................11.76 m (G) (Maximum digging depth on a vertical face) ..........................................................................................4.25 m (H) (Maximum length of flat-bottomed trench) .............................................................................................2.44 m

11-10

SECTION 12 ALPHABETICAL INDEX A

D

Accessories icons .............................................. 4-13 Adjustment and locking the option pedals........... 4-22 Adjustment of engine valve rocker clearances ...... 8-8 Air conditioning .................................................. 8-15 Air filter .............................................................. 7-39 Air vents .............................................................. 4-6 Alternator............................................................. 9-6 Anti-theft device ................................................... 5-4 Anti-theft protection indicator .............................. 4-12 Arm angle adjustment lever........................... 4-4, 4-7 Ashtray................................................................ 4-7 Automatic engine idle speed selector ................. 4-11 Auxiliary 12 volts socket ....................................... 4-9 Auxiliary hydraulic circuit flow patterns................ 5-31 Auxiliary hydraulic circuits .................................. 5-25

Dipper and upperstructure swing left-hand control lever........................... 4-20

B Backhoe buckets ............................................... 11-5 Batteries .............................................................. 9-3 Battery master switch......................................... 4-37 Before using the machine.............................. 3-2, 5-1 Boom and bucket right-hand control lever........... 4-20 Bringing the machine up to operating temperature............................. 5-9 C Cab ................................................................... 11-4 Cab door ............................................................. 4-1 Cab door sliding windows................................... 4-25 Cab light ............................................................ 4-23 Cab protection (F.O.P.S.)..................... 3-4, 4-39, 8-9 Cab radio compartment........................................ 4-5 Car radio mute control.......................................... 4-7 Checking for cylinder leakage ............................ 8-11 Checking the machine settings........................... 8-10 Cigarette lighter or electrical socket (24 Volts)....... 4-6 Clock ................................................................... 4-6 Coat hanger hook .............................................. 4-23 Controls/Instruments/Accessories ........................ 4-1 Cooling system .................................................. 7-17 Cup holder......................................................... 4-26 D Daily inspections.................................................. 6-2 Decals ................................................................. 3-8 Description of the main components..................... 2-3

E “EC” Declaration of conformity.............................. 1-4 Electrical system .................................................. 9-1 Emergency shut down switch ............................... 4-8 Engine ......................................................7-14, 11-1 Engine acceleration button and working mode selector .............................. 4-4 Engine coolant temperature indicator.................. 4-12 Engine hood ...................................................... 4-38 Engine idle speed selector.................................... 4-4 Engine operation................................................ 5-10 Engine troubleshooting....................................... 8-19 Environment ........................................................ 7-4 Error code indicator ............................................ 4-12 F Fan and alternator drive belts ............................... 8-7 Fan rotation reversal switch .................................. 4-8 Fire extinguisher................................................... 8-9 Fluid and lubricant capacities and specifications ... 7-4 Fluids and lubricants ............................................ 7-1 Footrest ............................................................. 4-23 Front RH console ................................................. 4-6 Front storage box ............................................... 4-35 Fuel level indicator ............................................. 4-12 Fuel system ....................................................... 7-21 Fuel tank............................................................ 4-33 Fuel tank filling pump ......................................... 4-43 Fuel tank filter ...................................................... 8-8 Function and message display screen .......4-10, 4-12 Function cancellation lever and lifting the control arm ................................. 4-7 Function cancellation lever and safety bar........... 4-19 Fuse box............................................................ 4-24 Fuses .................................................................. 9-1 G Grease points ...................................................... 7-5 Greasing the self-detaching counterweight system .................................... 7-11 Greasing the swing reduction gears.................... 7-10 Greasing the turntable teeth ................................. 7-9

12-1

SECTION 12 - ALPHABETICAL INDEX H

O

Hand signals ...................................................... 3-19 Handling the machine......................................... 5-17 Hardware torque inspection................................ 8-21 Heating and ventilation or air-conditioning controls ............................. 4-15 Horn .................................................................... 4-7 Horn volume control ........................................... 4-10 Hourmeter...................................................4-11, 6-2 Hydraulic breaker or high flow hydraulic circuits.............................. 5-25 Hydraulic fluid temperature indicator ................... 4-12 Hydraulic system.......................................7-29, 11-1

Operating the machine ..................................3-3, 5-2 Operating the machine in cold weather ............... 5-12 Operating the machine in hot weather ................ 5-12 Operating the machine in water .......................... 5-19 Operating the machine on sloping ground........... 5-20 Operator's compartment..................................... 11-3 Operator's seat .................................................. 4-27 Option control ........................................4-5, 4-7, 4-9 Option pedals..................................................... 4-21 Optional tool flow selector blocks........................ 4-41 Optional tool supply valves ................................. 4-42 Overall dimensions and weight of the main machine components .................... 11-8 Overload indicator switch ..................................... 4-5

I Identification numbers/Machine components......... 2-1 Implement operation and maintenance ................. 3-5 Inspecting and cleaning the machine .................. 8-10 Intervals ............................................................... 6-4 L Left-hand control arm ........................................... 4-7 Levels ................................................................ 7-12 Load handling .................................................... 5-18 Load handling eye.............................................. 4-40 Low flow hydraulic circuit control pedal ............... 4-21 Lower front window ............................................ 4-32 Lower panels ..................................................... 4-38 Lowering the attachment in the event of a machine failure......................... 5-33 Lubrication/Filters/Fluids....................................... 7-1 M Machine operation.............................................. 5-13 Machine overall dimensions ............................... 11-6 Machine travel.................................................... 5-14 Magazine rack ................................................... 4-25 Maintenance and adjustments.............................. 3-6 Maintenance/Adjustments .................................... 8-1 Message display ................................................ 4-13 N Noise levels ....................................................... 11-3 O Official documents................................................ 1-3 Operating icons.................................................. 4-13 Operating instructions........................................... 5-1 Operating the backhoe bucket ............................ 5-21 12-2

P Parking the machine ...................................3-5, 5-22 Plastic and resin parts ........................................ 8-11 Position of the operator’s compartment controls and accessories.................................. 4-3 Preventing fires or explosions............................... 3-7 Preventing risks caused by vibrations ................... 3-4 Prevention of burns .............................................. 3-7 R Radiators and oil coolers ...................................... 8-5 Radiators and oil-coolers dust removal ............... 5-24 Rear view mirrors............................................... 4-34 Rear window (emergency exit) ........................... 4-32 Refrigerated compartment.................................. 4-25 Releasing pressure in the hydraulic system ........ 7-27 Removal and installation of the counterweight .... 5-37 Replacing a backhoe bucket............................... 8-13 Replacing a bulb .................................................. 9-7 Replacing a tooth tip........................................... 8-12 RH console .......................................................... 4-9 Right, left, front and rear of the machine ............... 1-3 Right-hand control arm......................................... 4-4 Roof curtain ....................................................... 4-24 Roof hatch ......................................................... 4-24 Rotary light cable ............................................... 4-40 Rotary light control ............................................... 4-4 Run-in period ....................................................... 5-3 S Safety area .......................................................... 3-5 Safety bar ............................................................ 4-7 Safety devices ................................................... 11-2

SECTION 12 - ALPHABETICAL INDEX S

V

Safety instructions................................................ 3-1 Safety valves ..................................................... 4-41 Safety/Decals/Hand signals ................................. 3-1 Self-detaching counterweight ............................. 5-39 Self-detaching counterweight controls ................ 4-42 Servicing instructions ........................................... 6-1 Servicing intervals................................................ 6-1 Setting the undercarriage into the transport position............................... 5-34 Setting the undercarriage into the working position ................................ 5-35 Shimming the backhoe bucket ........................... 8-14 Short attachment ............................................... 11-4 Side doors ......................................................... 4-36 Specifications .................................................... 11-1 Standard attachment.......................................... 11-4 Starter motor........................................................ 9-6 Starter switch....................................................... 4-4 Starting the engine............................................... 5-7 Steps and access handles ................................... 4-2 Stopping the engine ........................................... 5-11 Storage ............................................................. 10-1 Storage compartment ........................................ 4-26 Storage tray.................................................. 4-6, 4-9 Storing the machine ........................................... 10-1 Sun shield.......................................................... 4-25 Swing reduction gears........................................ 7-43 Systems display and function control panel.............................. 4-9, 4-10

Vibration level inside the cab .............................. 11-3 W Weights ............................................................. 11-4 Welding on the machine..................................... 8-10 Windshield ......................................................... 4-31 Windshield washer reservoir............................... 4-39 Windshield washer switch .................................. 4-11 Windshield wiper switch ..................................... 4-11 Working lights switch.......................................... 4-11 Working mode indicator...................................... 4-12 Working range ................................................... 11-9

T Temperature probe .............................................. 4-6 To the owner ....................................................... 1-1 Tooth tip wear limits ........................................... 8-12 Track rollers and idler wheels ............................... 8-5 Tracks ................................................................. 8-1 Transport........................................................... 11-4 Transporting the machine................................... 5-42 Travel control levers and pedals......................... 4-21 Travel reduction gears ....................................... 7-45 Travel speed selector......................................... 4-10 Trip control ........................................................ 4-11 Type, serial number and year of manufacture of the machine......................... 2-1 U Undercarriage.................................................... 11-2 Using an implement other than a bucket............... 3-5 12-3

SECTION 12 - ALPHABETICAL INDEX

NOTES

12-4

CASE TECHNICAL MANUALS You can obtain manuals on the operation, maintenance and repair of your machine from your CASE Dealer. To ensure quick and efficient service, consult your CASE Dealer for assistance in ordering the correct manuals for your machine.

Your CASE Dealer can deal with orders for operator’s manuals, parts catalogues and service manuals.

Always give the type and serial number of your machine so that your CASE Dealer can supply you with the right manuals for your machine.

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