CASE CX 135 SR Excavator OPERATOR’S MANUAL PDF DOWNLOAD

CX135SR Excavator

OPERATOR’S MANUAL

Part number 84425059 English January 2011 Replaces part number 84290497

CX135SR EXCAVATOR OPERATOR’S MANUAL

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

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

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

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

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

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

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

●

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

●

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

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

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

Is instructed in safe and proper use of the machine.

●

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

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

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

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

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2011 CNH America LLC All Rights Reserved Case is a registered trademark of CNH America LLC

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operator’s Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Function Cancellation Lever and Safety Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Anti-theft Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Automatic Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Travel Control Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Run-in Period Of A New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Before Operating The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Checking Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Safety Before You Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fluids And Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lubrication And Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 I

Replacing A Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Hardware Torque Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Monobloc Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 9 INDEX

II

8-1 8-3 8-4 8-4 8-4 8-4 8-4 8-5 8-5 8-5 8-5 8-5 8-6

CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

GRAPHIC3A

CX135SR HYDRAULIC EXCAVATOR

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

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

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

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

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

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

Do not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely. All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permit.

The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the service that is given to the machine. Ensure that you have complete and current information from you dealer before you start any machine operation.

1-1

CHAPTER 1 - GENERAL INFORMATION Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is complete and in good condition. If you wish to obtain additional copies, or copies in languages other than that of the country of use, consult your authorized dealer.

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

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

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

• That the operator has the necessary permits and licenses to operate this machine.

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

1-2

CHAPTER 1 - GENERAL INFORMATION

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.

6

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

1

4

6

3

5

5

2 Figure 2

CS99A820

1. FRONT 2. REAR

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

5. TRAVEL REDUCTION GEARS 6. IDLER

1-3

CHAPTER 1 - GENERAL INFORMATION

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

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

Machine ➤

CNH America LLC

Machine Model and Type

Racine, WI 53404 U.S.A

➤ Made in Japan

Product Identification Number: P.I.N. Type

➤ Year of Build

Component Serial Numbers ➤ Engine Serial Number

➤ KHP10690-00

Transmission and Serial Number 30016E

➤ ROPS Cab or Canopy Serial Number

➤ Attachment Serial Number

➤

Figure 3

3-0172E

MACHINE IDENTIFICATION PLATE

1-4

Figure 4

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

1-0122E BD02H141

Figure 5

1. Bucket

9. Cab

17. Turn table bearing

2. Bucket link

10. Swing unit

18. Track shoe

3. Arm link

11. Fuel tank

19. Travel unit

4. Bucket cylinder

12. Hydraulic oil tank

20. Lower roller

5. Arm

13. Battery

21. Upper roller

6. Arm cylinder

14. Air cleaner

22. Track tension unit

7. Boom

15. Engine and radiator

23. Take up roller

8. Boom cylinder

16. Counterweight

24. Blade 1-5

CHAPTER 1 - GENERAL INFORMATION

NOTES

1-6

CHAPTER 2 - SAFETY AND DECALS

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

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

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

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

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..... ..... ..... .....

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

STARTING AND STOPPING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Ductile Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Specific Precautions To This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Cab Interior Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Exterior Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

2-25 2-25 2-25 2-25 2-25 2-25 2-26 2-26 2-26 2-26 2-26 2-26 2-27 2-27 2-27 2-27 2-27 2-27 2-28 2-28 2-28 2-28 2-28 2-28

2-1

CHAPTER 2 - SAFETY AND DECALS

NOTES

2-2

CHAPTER 2 - SAFETY AND DECALS

SAFETY RULES WARNING This safety alert symbol indicates important safety message s in th is ma nual. W hen you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

M171C

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

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

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

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

Pocket

0-0137E

Figure 1

OPERATOR’S MANUAL LOCATION AND STORAGE

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

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

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

The safety information contained in this publication does not replace safety codes, insurance needs, federal, state, or local laws. Make certain that your machine has the correct equipment according to these rules or laws.

2-3

CHAPTER 2 - SAFETY AND DECALS

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

.

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

• • • •

Electrical Power Line Gas Line Water Line Communication Television

Line

- Telephone

or

Cable

B e f or e b e g in n in g a ny t r e n ch i n g, o r o t he r construction work it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

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

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

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

RH99G001

Figure 2

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

2-4

CHAPTER 2 - SAFETY AND DECALS

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

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate method in order to avoid the hazard.

Background color is YELLOW. Prohibition symbols such as

and

STOP

if used are RED.

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

1

2 CS97M019

Figure 3

1. WORKING AREA 2. SAFETY AREA

2-5

CHAPTER 2 - SAFETY AND DECALS

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

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

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

PERSONAL SAFETY

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

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

• Know and use the protective equipment that is to

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

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

• Before you drive or operate in an area with high

• Certain protective equipment should be replaced

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

• Electrical cables, gas pipes, water pipes, sewers,

or other underground objects can cause injury or death. Learn the location of underground hazards before you operate your machine in a new area.

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

• Inspect the seat belt mounting bolts on a daily

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

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

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

who

has

the

GENERAL

• It is the responsibility of the operator to read and

understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform

• Operate the machine controls from the operator’s

maintenance work if you have not had appropriate training and have read and fully understand the instructions and warnings in this manual.

• If this machine rolls over, you can be injured or

• Do not permit riders on the machine.

• Make sure that all protective guards, canopies,

basis to insure their integrity.

seat only. Always fasten the seat belt and keep it securely fastened when operating the machine.

killed. You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches,

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

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

2-6

doors, etc. are in place and secure.

• Remove all loose objects stored in the machine.

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

• Do not use the machine as a manlift.

CHAPTER 2 - SAFETY AND DECALS PROPER ENTRY AND EXIT

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

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

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

OPERATING PRECAUTIONS

• Check steering and other machine control devices

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

• If a failure that causes loss of control such as

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

Sound the horn before starting.

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

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

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

• Understand the machine limitations and keep the

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

• Check that the parking device is applied, place the

ground drive controls in neutral and check that the auxiliary controls or switches are in neutral or off positions.

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

• Start and operate the machine only from the operator’s station.

• Do not bypass the machine’s interlock system.

The interlock system must be repaired if it malfunctions.

• Use battery booster cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

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

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

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

• Before leaving the operator’s station, lower the

machine under control.

• Operate and drive the machine with care and at

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow

patterns, and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may

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

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

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

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

2-7

CHAPTER 2 - SAFETY AND DECALS

• Use proper transport devices when roading the

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

• Use the approved attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

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

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

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

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

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

• Contact

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

• Before you drive or operate in an area with high

voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

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

If a part of the machine touches high voltage power:

1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

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

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

2-8

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

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

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

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

• Stay away from hazardous areas such as ditches,

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

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

• Develop fluid and smooth operating techniques

and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

CHAPTER 2 - SAFETY AND DECALS

• Use extreme caution when removing radiator

MAINTENANCE PRECAUTIONS

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

caps, drain plugs, grease fittings or pressure taps.

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

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

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

• Towing this machine is not recommended.

• Observe the proper maintenance procedures.

• Whenever servicing or replacing hardened pins,

Figure 4

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

• Before you service the machine, put a Do Not

• Keep the brakes and steering systems in good

321-4614

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

• Wear protective glasses and other required safety equipment when machine.

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

operating condition.

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

FUEL HANDLING PRECAUTIONS

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

• Never remove the fuel cap or refuel gasoline

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

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

• Avoid lubrication or mechanical adjustments with

• To avoid spilling fuel, maintain control of the fuel

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

• Securely block the machine or any component

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

filler nozzle when filling the tank.

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

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

• Tighten the fuel tank cap securely. Should the fuel

• To prevent unexpected movement, securely block

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

• Never make repairs on pressurized components,

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating

working elements when repairing or changing working tool parts such as cutting edges. fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

season.

2-9

CHAPTER 2 - SAFETY AND DECALS HAZARDOUS CHEMICAL PRECAUTIONS

BURN PREVENTION

• If you are exposed to or come in contact with

WARNING B ATTE R Y A C ID C AU S ES S EVE R E BU R NS .

Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Failure to comply could result in death or serious injury.

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

M144B

• Material Safety Data Sheets (MSDS) provide

information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS information is available from your dealer.

• Before you service the machine, check the MSDS

for each fluid, lubricant, etc., used in your machine. This information indicates what the risks are and how to service the machine safely.

• Before you service this machine and before you

WARNING BATTERIES PRODUCE EXPLOSIVE G ASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Failure to comply could result in death or serious injury.

M422A

• When the battery electrolyte is frozen, the battery

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

• Hot coolant can spray out if the radiator cap is

removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

2-10

hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc. used with your machine can be hazardous.

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

TRANSPORTING PRECAUTIONS

• Know the rules, laws, and safety equipment that

may be necessary for transporting this machine on a road or highway.

FIRE EXTINGUISHER It is r eco mmen de d th at a fire exting uishe r b e maintained on the machine when it is in operation to aid in event of a fire. Be sure that the extinguisher is properly maintained and be familiar with its proper use. See your local authorized dealer for fur ther information.

CHAPTER 2 - SAFETY AND DECALS PARKING THE MACHINE 1. When the work day is finished, make sure the machine is parked on level ground.

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

DUCTILE IRON

• Before you weld, cut or drill holes in a part on this

machine, make sure the part is not cast ductile iron. See your dealer if you do not know if a part is cast ductile iron.

2. Lower the attached equipment to the ground.

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

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

This decreases the temperature of the engine parts evenly.

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

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

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

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

This will prevent the tracks from freezing to the ground.

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

2-11

CHAPTER 2 - SAFETY AND DECALS

SEAT BELT PRECAUTIONS SPECIFIC PRECAUTIONS TO THIS MACHINE

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

• The transport position is to be used only when

2

transporting the machine. The upper structure should be aligned with the tracks during transport.

Track idlers should be to the front and travel reduction gears to the rear.

1 3 Figure 5

DC04D529

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

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

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

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

4. The seat belt will automatically retract.

WARNING Before starting the engine make certain seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained.

Never wear a seat belt loosely or with slack in the be lt syste m. Never wea r the be lt in a twisted condition or pinched between the seat structural members. Failure to comply could result in death or serious injury.

M422A

2-12

CHAPTER 2 - SAFETY AND DECALS

DECALS Safety decals are placed on your machine as a guide for your safety. Walk around the machine, and note the content and location of these decals before operating your machine.

WARNING An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply could result in death or serious injury.

CE-NA000

WARNING Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part. Failure to comply could result in death or serious injury.

CE-NA000

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 for the machine, consult your authorized dealer.

Figure 6

384270A1A

This symbol instructs you to refer the Operator’s M a n u a l fo r f u r t h e r i n fo r m a t i o n r e g a r d i n g maintenance, operational guidelines, etc.

BC00G075

Figure 7

This symbol instructs you to refer to the Service Manual. If you doubt your ability to perform service operations, contact your authorized dealer.

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

• DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED.

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

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

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

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW Prohibition symbols such as

and

STOP

if used are RED.

2-13

CHAPTER 2 - SAFETY AND DECALS CAB INTERIOR DECALS

11 5

4 8

6

13

12

1

3

7

9

2

A

0-0149E

2-14

10

Figure 8

CHAPTER 2 - SAFETY AND DECALS

1

ELECTROCUTION HAZARD. CONTACT WITH EXCAVATOR OR GROUND MAY CAUSE DEATH OR BODILY INJURY. KEEP ALL PARTS OF MACHINE AND LOAD AT LEAST 15 FEET (4.57M) AWAY FROM ALL ELECTRICAL POWER LINES OR SUCH DISTANCE AS SPECIFIED

BY LOCAL SAFETY CODES.

IMPROPER EXCAVATOR OPERATION AND MAINTENANCE CAN CAUSE INJURY OR DEATH. READ AND STUDY THE OPERATORÕS MANUAL AND ALL SAFETY MESSAGES. LEARN AND PRACTICE SAFE USE OF CONTROLS. ALWAYS OPERATE PROPERLY. INSPECT AND MAINTAIN EXCAVATOR DAILY.

Attachment interference.

Machine damage may result.

Do not allow the attachment, load or other devices to contact the cab or machine.

KHP1537-00

Figure 9

WARNING1

Decal Number: KHP1537-00 This decal is located inside the cab on the right window. This decal advises:

• Warns against electrocution hazard • reading the operator’s manual • attachment interference with cab Voltage

Safe Distance

6,600 V or less

2 m (6.6 ft) or more

22,000 V or less

3 m (9.8 ft) or more

66,000 V or less

4 m (13.1 ft) or more

154,000 V or less

5 m (16.4 ft) or more

187,000 V or less

6 m (19.7 ft) or more

275,000 V or less

7 m (23.0 ft) or more

500,000 V or less

11 m (36.1 ft) or more

2-15

CHAPTER 2 - SAFETY AND DECALS

4

2

OPEN POSITION

CAUTION MAINTAIN THE LOCK PIN IN THE OPEN POSITION WHEN OPENING THE WINDOW. KHP1802-00

KHP12170

Figure 12

Decal Number: KHP1802-00 This decal cautions the operator to lock the front window in the open position with provided lock pin. It is located on the front windshield.

5 0-153E

Figure 10

Decal Number: KHP1782-00 This decal is located on the side glass inside the operator’s compartment. Always raise the safety cancellation lever before leaving the cab.

3

KHP12170

Figure 13

Decal Number: KHP1540-00 A n i n fo r m a t i o n a l d e c a l lo c a t e d o n t h e f r o n t windshield instructing to only use mild detergent and a soft cloth to clean the operator compar tment windows.

0-153E

0 0154E Figure 11

Decal Number: KHP1822-00 This decal cautions the operator to lock the front window after removing or replacing to insure it will remain in a safe position. It on the left side of the operator’s compartment.

2-16

CHAPTER 2 - SAFETY AND DECALS

8

6

CONTROL FUNCTIONS ON THIS MACHINE ARE INTERCHANGABLE ONLY AN AUTHORIZED DEALER REPRESENTATIVE IS ALLOWED TO MODIFY THE CONTROL PATTERN WHEN A MODIFICATION HAS BEEN MADE THE REPRESENTATIVE MUST CHANGE THE DECAL TO MATCH THE NEW CONTROL PATTERN

Decal Number: KHP1247-00

FAILURE TO CHANGE THE DECAL COULD RESULT IN DEATH OR SERIOUS INJURY 162140A1

Figure 14

0-0157E

Figure 16

KHP11590

This decal is located on the rear window glass in the operator’s compartment. It shows the alternative emergency exit, as well as the use of the emergency hammer used to break the compar tment window glass.

Decal Number: KHP1050 The decal warns of control function modification. Any modification of the control pattern must be made by an authorized dealer and the pattern decal must match the machine control pattern. The decal is located on the right side window of the operator’s compartment.

9

24V

7

KHP11590-00 Figure 17

KHP11590

Decal Number: KHP1804-00

LONG ARM EQUIPPED BUCKET MAY HIT OPERATOR'S CAB WHEN PLACING ARM CYLINDER IN TRANSPORT PIN POSITION. DO NOT DIG WITH THE ARM CYLINDER IN THE TRANSPORT PIN POSITION. REFER TO OPERATOR'S MANUAL FOR INSTRUCTIONS.

This decal is located to the right of the operator’s seat. The decal indicates the voltage rating of the lighter socket. Do not use equipment of any other voltage. Twelve volt rated equipment will incur damage.

KHP1539-00

KHP11590

10

12V

Figure 15

Decal Number: KHP1539-00 This decal is located on the right side window glass in the operator’s compartment. It cautions against operating the machine with the long arm in the pin tran sp or t p o sitio n . The bucke t may str ike th e machine.

KHP1803-00 1-0033

KHP11590

Figure 18

Decal Number: KHP1803-00 This decal is located to the left rear of the operator’s seat near the 12V power source. Use only 12V equipment in the power source.

2-17

CHAPTER 2 - SAFETY AND DECALS

11

12

Figure 20

KPH1587

Decal Number: KHP1587-00 Loca te d on the r igh t sid e win dow gla ss in th e operator’s compar tment, this decal indicates the machine is equipped with a control pattern selector. .

13

KHP12300

Figure 19

Decal Number: KHP12300-00 The decal is located on the right side window glass in the operator’s compartment. The control pattern decal indicates the pattern of the controller. Make cer tain the actual patter n and the decal in the machine match.

Interference between blade and boom can occur during deep digging.

KHP1316-00

0-0133E

0-0133E Figure 21

Decal Number: KHP1316-00 This decal is located on the right side window glass in the Operator’s compartment. It cautions against striking the blade and boom against the dozer blade, if equipped.

2-18

CHAPTER 2 - SAFETY AND DECALS EXTERIOR DECALS

22

15

14

16

15

17 14 21

20 26 25

27 24

22 28

23

18 0-0159E

19 0-0159E Figure 22

2-19

CHAPTER 2 - SAFETY AND DECALS

14

KHP1014

15

Figure 23

RAP0144

Figure 24

Decal Number: KHP1014-00

Decal Number: KHP1532-00

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

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

2-20

CHAPTER 2 - SAFETY AND DECALS

16

18

Figure 27

KHP1533 KHP1636

Figure 25

Decal Number: KHP1536-00 Located in the batter y compar tment, this decal advises using safe battery procedures and being aware of explosive danger.

Decal Number: KHP1533-00 Inside the engine compartment, this decal warns of the ha za rd associated with rotating p ar ts an d components.

19 17

BS00M13

Figure 263

Decal Number: KHP0210-00 Located on the right front of the upper structure, this decals warns against coming in contact with power lines.

KHP1534

Figure 28

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

2-21

CHAPTER 2 - SAFETY AND DECALS

20

KHP1542

22

Figure 29

KPH1535

Figure 31

Decal Number: KHP1542-00

Decal Number: KHP1535-00

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

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

23 21

KPH1011

Figure 32

Decal Number: KHP1011-00 KPH11681

Figure 30

Decal Number: KHP11681-00 This decal instructs the operator to use recommended diesel fuel only. It is located near the fill port of the fuel tank.

2-22

This decal warns the operator of slippery surfaces.

The decal is located on the rear upper structure.

CHAPTER 2 - SAFETY AND DECALS

24

KPH1010

26

Figure 33

Decal Number: KHP1010-00 Instructs operator to lock engine hood in place when opening. It is located inside the engine compartment near the holding strut.

KPH10713

Figure 35

Decal Number: KHP1013-00 This decal cautions against starting the machine from anywhere other than the operator’s seat to prevent unexpected articulation. It is located on the upper structure.

25

27

KPH12210

Figure 34

Decal Number: KHP12210-00 This decal warns against standing or climbing on the rear of the machine. It is located on the rear upper structure.

KPH0700

Figure 36

Decal Number: KHP0700-00 This decal states the importance of using correct booster/jumper battery procedures. It is located in the battery compartment.

2-23

CHAPTER 2 - SAFETY AND DECALS This decal warns against standing or climbing on the rear of the machine. It is located on the rear upper structure.

25

DO NOT OPEN HIGH PRESSURE FUEL SYSTEM WITH ENGINE RUNNING ENGINE OPERATION CAUSES HIGH FUEL PRESSURE. HIGH PRESSURE FUEL SPRAY CAN CAUSE SERIOUS INJURY DEATH.

KPH12210

Figure 37

Decal Number: KHP13150-00

23

KPH10351

Figure 38

Decal Number: KHP10351-00 This is an informational decal stating maintenance intervals and locations. It is located on the inside cover of the tool box (right front of machine).

2-24

CHAPTER 2 - SAFETY AND DECALS

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

MOVE LOAD IN HORIZONTALLY

The following is a compilation of the Hand Signals to be used when a flagman is required for Excavator O p er at io n . All p e r so n ne l as so c ia t ed with th e operation of the excavator should know these signals and their meaning before attempting to operate this machine.

RAISE LOAD VERTICALLY

DC04E040

Figure 41

Face Machine Operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 39

Face Machine Operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

LOWER LOAD VERTICALLY

DC04E041

Figure 42

Face Machine Operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

RAISE BOOM

DC04E039

Figure 40

Face Machine Operator, extend right arm down, point index finger down and move hand in small circular motion.

DC04E042

Figure 43

Face Mac hine O pe rator, exte nd r ig ht a r m o ut horizontally from shoulder, make a fist with thumb up.

2-25

CHAPTER 2 - SAFETY AND DECALS ARM IN

LOWER BOOM

DC04E043

Figure 44

DC04E046

Figure 47

Fa ce Mac hine O pe ra tor, exte nd r ig ht a r m o ut horizontally from shoulder, make a fist with thumb down.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

SWING LEFT

ARM OUT

DC04E044

Figure 45

DC04E047

Figure 48

Fa ce Mac hine O pe ra tor, exte nd r ig ht a r m o ut horizontally from shoulder, make a fist with index finger pointing in swing direction.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other.

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 46

Fa c e M a c h in e O p e r a t o r, ex t e n d l e ft a r m o u t horizontally from shoulder, make a fist with index finger pointing in swing direction.

2-26

DC04E048

Figure 49

Face Machine Operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion.

CHAPTER 2 - SAFETY AND DECALS CLOSE BUCKET (BUCKET IN OR DIG)

COUNTER ROTATE RIGHT

DC04E049

Figure 50

DC04E052

Figure 53

Face Machine Operator, place left hand on top of hard hat, bend right arm at elbow to the left, make a fist with right hand with index finger pointing out and rotate hand in a forward circular motion.

Face Machine Operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion.

TRAVEL FORWARD.

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 51

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion TRAVEL REVERSE

DC04E051

DC04E053

Figure 54

Face Machine Operator, hold left hand in, open and stationary, hold right hand in, make fist with index finger pointing toward left hand and move right hand in small forward circular motion.

TURN LEFT

Figure 52

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion.

DC04E054

Figure 55

Face Machine Operator, raise right forearm up, make fist with right hand and hold stationary, bend left arm in, make fist with left hand and rotate left fist in a small reverse circular motion.

2-27

CHAPTER 2 - SAFETY AND DECALS STOP

TURN RIGHT

DE04E055

Figure 56

DC04E058

Figure 59

Face Machine Operator, raise left forearm up, make fist with left hand and hold stationary, bend right hand arm in, make fist with right hand and rotate right fist in a small forward circular motion.

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

MOVE THIS MUCH

EMERGENCY STOP

DC04E056

Figure 57

Face Machine Operator, raise both forearms up, hands open and facing each other, move hands in laterally indicating how far to go.

MOVE SLOWLY

DC04E059

Figure 60

Fa ce Ma c h in e O p e r a to r, ra is e b o t h a r ms o u t horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

STOP ENGINE

DC04E057

Figure 58

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise Load Slowly is illustrated).

2-28

DC04E060

Figure 61

Face Machine Operator, right arm at side, draw left thumb or index finger across throat.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS CAB DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 STEPS AND ACCESS HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Forward and Backward Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Back Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Lumbar Support Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat And Control Arm Assembly Fore And Aft Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Armrest Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Headrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 FUNCTION CANCELLATION LEVER AND SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right Hand Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

3-11 3-12 3-13 3-14 3-15 3-16 3-17

CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 ANTI-THEFT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 AUTOMATIC TEMPERATURE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

3-22 3-23 3-23 3-23 3-23 3-24 3-24 3-25

TRAVEL CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CAB FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Side Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Left-hand Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

3-33 3-35 3-36 3-36 3-36 3-38 3-40 3-40 3-41 3-42

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB DOORS

1 Door Release Lever Figure 1

1-0116E

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

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

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

WARNING Do not leave the door ajar. Secure it in a latched position. Failure to comply could result in death or serious injury.

M422B

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

STEPS AND ACCESS HANDLES

2 2 2

2

1

RIGHT

1

Figure 2

LEFT

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

WARNING To provide secure hand and foot mobility, preventing slipping and possible injury, always face the machine when mounting and dismounting. Failure to comply could result in death or serious injury.

CE-NA000

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

CE-NA000

WARNING To get in or out of the cab or on to the upper structure, it is imperative that the upper structure frame is in line with the under carriage. Failure to comply could result in injury or death.

CE-NA000

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

CE-NA000

3-4

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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 death or serious injuries.

CE-NA000

Air vent Operetor's seat

Monitor&switch panel Blade lever (Blade spec.)

Right control lever (with idle switch) Left control lever (with horn switch)

Air vent

Defroster Switch panel Trevel lever

Air conditioner switch Foot rest

Trevel pedal Foot rest

1-0123E

Lock bar

1-0123E Figure 3

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Left travel lever&pedal

Foot rest

Right travel lever&pedal

Foot rest

Lock bar

Right control lever (with idel switch)

Left control lever (with horn switch)

Air conditioner switch

ON/OFF

Blade lever (Blade spec.)

Switch panel

A/C

Monitor&switch panel Throttle volume

Start switch Cigarette ligter Seat belt

Radio

12V power socket

Air vent

1-0124E 1-0123E4

3-6

Figure 4

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR'S SEAT In order to operate the machine correctly and with maximum efficiency and comfort, adjust the seat to suit the weight and size of the operator.

4 4

3 3 8 8

11 7 7

2 2

1-0108E Figure 5

1-108E

FORWARD AND BACKWARD ADJUSTMENTS

SUSPENSION ADJUSTMENT

2

1 1-0108F

Figure 6

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

1-108F

Figure 7

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

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS LUMBAR SUPPORT ADJUSTMENT

SEAT POSITION ADJUSTMENT

5

3

Figure 8

1-0108F

Figure 10

1-0108F

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

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

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

SEAT AND CONTROL ARM ASSEMBLY FORE AND AFT ADJUSTMENT

SEAT BACK ANGLE ADJUSTMENT

4

6 1-0108F

Figure 9

1-0108F

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

WARNING Always wear seat belt while sitting in operator seat.

Always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure. Failure to comply could result in death or serious injury.

M422B

3-8

Figure 11

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

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

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FUNCTION CANCELLATION LEVER AND SAFETY BAR To make the attachment, travel, and swing functions operational, push the lever (1) down.

2

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

WARNING

1

1-0125F

Figure 12

The safety bar (1) is designed to discourage the operator from leaving the operator’s compartment without first having lowered the bar. It is located on the left hand control console (2).

WARNING: Always place the hydraulic safety lock lever in the locked (up) position before leaving the cab. Never leave the machine unattended with engine running. Failure to comply could result in death or serious injury.

M1710

The safety bar (1)cancels the functioning of the control levers and pedals. When the lever is in the raised position, the control arm and the attachment, travel and swing functions will not operate. Always raise the lever completely before leaving the cab.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND CONSOLE

1Starter Switch 2Throttle Volume 3Control lever (Right) (with Idle Switch) 4Monitor & Switch Panel

3

4

2

1 1-0067E

Figure 13

1-0067E

START ON ACC OFF

1-0069E

1-0068E 1-0068E

Figure 14

1. Starter Switch The starter switch has four positions:

Start: Engine starting position.

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

Figure 15

1-0069E

2. Throttle Control This control regulates engine RPM’s. It can be changed from low speed to high speed. If the engine RPM does not change after tur ning the throttle volume control, check the idle switch on the right hand control ever (3). Turn the idle switch to Off.

A c c e s s o r y : E n g in e in s to p p e d p o sit io n w it h accessory power on.

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

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

1-0070E 1-0070E

Figure 16

3. Engine Idle Speed Selector This control enables automatic engine idle without operating the throttle button. To select idle speed, p re s s a n d r e le a se th e c o nt r o l fo r th e e n g in e automatically to go into idle speed. When the control is pressed and released once more the engine will revert to its original speed.

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR AND SWITCH PANEL

1

4

5

6

2

7

9

8

10

3

11

12

Figure 17

1-0071E

1-0073E

1-0072E 1-0072E

13

Figure 18

1. Fuel Gauge The quantity of fuel is indicated by a needle gauge.

Refill the tank before the gauge indicates empty (E).

Use fuel from a reputable dealer. Do not wait until the fuel tank is completely empty before refilling or it will be necessary to bleed the fuel circuit.

1-0073E

Figure 19

2. Coolant Temperature Gauge Temperature of the coolant is defined by the needle indicator. C” indicates that the eng ine coolant temperature is cool. “H” (hot) indicates the engine is in an overheat condition.

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1-0074E 1-0074E

Figure 20

3. Hour Meter

1-0076E

Figure 22

5. Engine Oil Pressure

The hourmeter displays the total time that the engine has been operated in hours and tenths of an hour.

The last digit corresponds to 1/10 of an hour (6 minutes). The hour meter also enables ser vice operations to be scheduled at correct intervals (See the “Lubrication/Maintenance” Section).

If the engine oil pressure is abnormally low or the engine oil filter is blocked, the warning buzzer will sound and the engine oil pressure indicator will illuminate. Stop the engine, check oil level.

1-0077E

Figure 23

6. Low Fuel Warning 1-0075E

Figure 21

4. Overheat Warning If the overheat warning illuminates and the alarm buzzer sounds, reduce engine idle. Idle engine at low RPM until coolant temperature returns to normal. If the te mperature gauge and alarm indicate the temperature has not returned to a normal range, stop the engine, remove the key and find the cause of the problem.

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. Do not allow your machine to run out of fuel. If this occurs, the fuel system will have to be bled.

1-0078E

Figure 24

7. Battery Electrical system This message shows that there is a fault in the battery charging system. The audible alarm device also sounds.

Shut the engine off, remove the starter switch key and find the cause of the problem. See the “Electrical System” Section.

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1-0079E

Figure 25

8. Engine Electrical System

Figure 27

10. Windshield Wiper

This message indicates the engine electrical system has a shor t circuit or disconnection. Check the electric circuits and/or contact your authorized dealer.

1-0080E

1-0081E

When the switch is pressed, the wiper function toggles in an intermittent/continuous/stop cycle. The lamps above the switch will illuminate indicating if the wiper is on the intermittent or continuous cycle. Do not use the wipers when the windshield is dry or ice and snow covered. This can damage the wiper blades and/or wiper motor.

Figure 26

9. Pre-Heat Indicator This message shows that the engine needs pre-heating and it is necessary to warm up the engine. The length of time this message remains is dependent on the coolant temperature. As soon as the engine reaches starting temperature, the message will disappear.

1-0082E

Figure 28

11. Windshield Washer When the windshield wiper switch is pressed, washer flu id is sprayed and the windshield wip ers are activated. Do not use this switch if the washer fluid reservoir is empty. This can cause damage to the washer motor.

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1-0083E

Figure 29

1-0084E

Figure 30

12. Work Lamp Switch

13. Travel Mode Select Switch

Press the switch to turn work lights on. Press again to turn the lights off.

Press this switch to toggle between high and load to adjust travel speed. When the indicator light is illuminated, it indicates the travel mode is high. Do not switch back and for th between travel modes when the machine is traveling. Stop the machine before changing the travel mode: Low Speed: Use when traveling on slopes or uneven ground.

High Speed: Use when traveling on flat, level ground.

When the travel load becomes high, the machine will automatically return to low.

3-14

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEFT HAND CONTROL ARM

1Control lever (Left) (with Horn Switch) 2Gate Lock Lever 3Travel caution Switch 4Rotating beacon 5Emargency Stop Switch 6Mode Change Switch 7Air conditioner 8Auxiliarty Switch

A/C ON/OFF

1-0125E Figure 31

1-0125E

2. Safety Bar The safety bar (1) is designed to discourage the operator from leaving the operator’s compartment without first having lowered the bar. It is located on the left hand control console (2).

The safety bar (1)cancels the functioning of the control levers and pedals. When the lever is in the raised position, the control arm and the attachment, travel and swing functions will not operate. Always raise the lever completely before leaving the cab.

3. Travel Caution Switch 1-0086E

Figure 32

1. Left Hand Control Horn Switch When the switch located on top of the left side control lever is pressed, the horn will sound.

NOTICE: Always sound the horn before operating the machine.

Radio Mute

When this switch is placed in the ON position, an alar m will so und wh en the trave l c on trols ar e actuated. In the OFF position, when the travel control are actuated, the alarm will sound for ten seconds and then stop.

4. Rotating Beacon (Optional) The switch will control the optional rotating beacon.

Press the switch in order the light the beacon. Press the switch again to turn the beacon off.

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

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

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS 5. Emergency Stop Switch This control enables the engine to be shut off in an emergency or when it is not possible to shut it down by means of the starter key. Press on the front of the control, the engine stops. 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.

%106

NOTICE: 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.

#761 1(( Figure 34

1-0126E

Travel Alarm Switch

N

The travel alarm sounds when the travel controls are actuated and the switch is in the ON position.

MODE

In the Auto Off position, when the travel controls are actuated, the alarm sounds for ten seconds. Each time travel is stopped and restarted, the alarm will sound for ten seconds.

E 1-0075E

Figure 33

6. Mode Change Switch

STOP

Change the mode from standard mode to economy mode.

N Mode: Standard mode for normal digging work E Mode: Fuel consumption saving mode 7. Climate Control C o n t r o l s t h e t e m p e r a t u r e i n t h e o p e r a t o r ’s compartment. See Air Conditioner/Climate control in this section.

8. Optional Control

3-16

1-0091E

Figure 35

Emergency Stop Switch If the engine will not stop when the key is turned OFF on the starter switch, use this switch to stop the engine. Do not use this switch to turn the engine off in everyday usage.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

6

5

5

ON/OFF

A/C

h 2

7

4

3

1 1-0092E Figure 36

1-0092E

FAN SPEED

1. On/Off 2. Air conditioning 3. Fan speed 4. Temperature 5. Vent change 6. Windshield defroster 7. Air recirculation ON/OFF

1-0095E

ON/OFF

1-0093E

Figure 38

These push buttons (3) allows the air flow to be increased or reduced. To increase the flow of air, press the top button. To decrease the flow of air, press the lower button. The bars on the display screen (9) will increase or diminish, depending on the flow selected.

Figure 37

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

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

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDSHIELD DEFROSTER

TEMPERATURE

1-0096E

1

Figure 39

These push buttons (4) allow the temperature to be raised or lowered within an 18째 to 32째C (64째 to 89째F) range. To increase the temperature, press the right-hand button. To lower the temperature, press the left-hand button.

Figure 41

1-0098E

This button (6) allows the wind shield to be defrosted.

Press the button to defrost the wind shield. To turn the defroster off, press the button once more.

AIR RECYCLING

VENT CHANGE

Figure 42

1-0099E

1-0097E

1

Figure 40

This button (5) allows different types of air flow direction to be selected.

- Via the top front air vent.

- Via the top front and rear air vents.

- Via the top and lower rear air vents.

This button (7) allows two different types of air circulation to be selected. Fresh air from the outside or recycled air from within. Each time the button is pressed, the type of circulation will be changed.

AIR CONDITIONING

To select the type of air flow direction, press the button for the type of flow desired.

A/C

1-0094E

Figure 43

Press this switch (2) to turn the air conditioner off or on. Button will illuminate when air condition is on.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO

9

6

5

1

3

8

5

7

Turn the knob clockwise. A click sound will indicate the power is on. Volume is increased as the knob is turned clockwise once power is on.

2. Tone Control Turning the knob counter clockwise will decrease high sound interference and correct tone.

3. Display Statio n selectio n an d/or clock time will b e displayed. Station is displayed as radio is tuned.

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

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

5. Auto Store Memory This two fu nction bu tton is u sed to p re set m em or y scan . T he radi o wi ll rece ive a pre-programmed station for a few seconds and then scan to another pre-programmed station.

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

1-0051 Figure 44

1-0051

1. Power Switch/Volume Control

4

6. Preset Stations AM and FM band station can be preset for each of the six keys. See “Presetting Stations.�

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

8. Band Select Us e th is butto n to s elec t eith er AM o r FM stations.

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

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

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS Presetting Radio Stations

Setting the Radio Clock

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

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

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

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

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

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

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

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

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

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

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOZER BLADE CONTROL LEVER

TRAVEL CONTROL LEVERS

22 Raise

1 ①

Blade lever

3 ③

4 ④

11 Lower

② 2 10100E

1.

2.

3.

4.

1 0100E Figure 45

TRAVEL LEVER FORWARD TRAVEL LEVER REVERSE TRAVEL LEVER LEFT TRAVEL LEVER RIGHT

Figure 46

10100E

1. Push the dozer lever forward and the blade will lower.

2. Move the lever backward and the blade will raise.

Push both levers forward to move the machine forward in a straight line. Pull levers back to reverse in a straight line.

Move the left travel lever to make a right turn.

Move the right travel lever to make a left turn.

TRAVEL PEDALS Push the top of the pedal for FORWARD travel. Push the bottom of the pedal for REVERSE. Both tracks will move at the same speed. Press the left pedal to make a right turn. Press the right pedal to make a left turn.

40 ~ 50 mm Travel unit

1-010

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

See “Systems display panel”.

10100E

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

Ask your CASE Dealer for advice on optional tools.

Figure 47

Use caution when operating in order not to strike the attachments together.

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATION LEVERS The left hand operator control lever is located at the top front of the LH operator console. Its purpose is to allow the operator to control operations of the swing and arm. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has four basic operational functions.

• • • • • Figure 48

10103E

Boom, arm, bucket, and swing operations can be con trolle d ind iv id ually or s imultane ou sly. Th e operation speed will vary according to the operation lever stroke. When the lever is released, the lever will automatically return to neutral.

FORWARD - Variable speed ARM out.

BACKWARD - Variable speed ARM in.

LEFT - Variable speed left SWING. RIGHT - Variable speed right SWING. CENTER - Neutral position.

Right Hand (RH) Operator Control Lever (ISO/SAE Pattern)

Left Hand (LH) Operator Control Lever (ISO/SAE Pattern)

DC04D563

Figure 49

DC04D562

WARNING WARNING: Hydraulic controls are designed for and set to ISO operating pattern. Changing the control pattern will effect the operation of the machine controls. Failure to comply could result in death or serious injury.

M1716

3-22

Figure 50

The right hand operator control lever is located at the top front of the RH operator console. Its purpose is to allow the operator to control operations of the boom and bucket. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has four basic operational functions.

• • • • •

FORWARD - Variable Speed BOOM down.

BACKWARD - Variable speed BOOM up.

LEFT - Variable speed BUCKET in (Digging).

RIGHT - Variable speed BUCKET out (Dump).

CENTER - Neutral position.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB FEATURES CAB LIGHT

DOOR LOCK

ON

OFF

1-0117

Door Release Lever

1-0117E

Figure 51

1-0116E

Use the key switch key to lock or unlock cab door.

Insert key into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door.

The cab door can be latched in an open position by opening door until it is locked in place by the door latch located on the cab.

Release door latch by pushing release lever down to release door from latch.

Figure 52

The light is located on the operator compartment roof. The light can be turned on and off with the light switch.

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

ROOF HATCH (Optional)

Hinged Roof Panel

WARNING To provide secure hand and foot mobility, preventing slipping and possible injury, always face the machine when mounting and dismounting.

Failure to comply could result in death or serious injury.

R131B CD00E015

WARNING WARNING: Before undertaking any travel you must close and secure the side doors. Failure to comply could result in death or serious injury.

M1716

Figure 53

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

NOTICE: The roof panel may be cleaned with a clean, damp cloth. Use care when cleaning, as panel could be scratched or may cloud.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS LOWER WINDOW

OPENING AND CLOSING WINDSHIELD

Front

11 1-0111E

LOWER FRONT WINDOW

Figure 54

1-0111E

1. LOCK LEVER

1. Move the lock lever to the right on the front window to release the lock.

1 Figure 0114E 56

1-0114

1. After locking upper front window in place, lower window can be removed.

Rear

Lock

22 -A Recessed area

22 -B Front 1-0112E Figure 55

BS06J092

Figure 57

1-0115

2. Release the lock pins at sides of window.

3. This will allow the window to be removed. Store the window in the storage area in the rear left of the cab.

1. LOCK LEVER 2. CENTER HANDLE 3. WINDSHIELD STORED IN CEILING POSITION

2. Hold the lower handle and the upper handle, and lift the window up.

4. Align sides and recessed area and lock the window into place.

3. Make certain the window locks into place at auto lock (2-A). Use the lock pin (2-B) to secure.

Wiper Contact Point

WARNING A falling window can cause injury to you or others.

Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in death or serious injury.

M1709

1-0110E 1-0110

Figure 58

Do not touch connection on upper exterior of cab.

Wiper contact is housed here and can be damaged by incorrect hand contact.

3-24

CHAPTER 4 - OPERATING INSTRUCTIONS

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

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bringing The Machine Up To Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHECKING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating The Machine In Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating The Machine In Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 4-8 . . . . . 4-9 . . . . . 4-9 . . . . 4-10

MACHINE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Loads With The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Coupler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operating The Machine In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Towing The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11 4-14 4-15 4-16 4-19 4-20 4-21 4-22

TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

By Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 On A Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

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

2. Keep the engine at normal operating temperature.

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

4. Additionally, follow the guidelines for scheduled maintenance in Section 5 - Lubrication and Maintenance.

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

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

SB055

BEFORE OPERATING THE MACHINE WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Operator’s and repair manuals can be obtained from your dealer.

SB055

Before operating this machine:

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

fluid and coolant) and make sure that the fluids and lubricants are suitable for prevailing conditions. See “Fluids and Lubricants” in the “Lubrication/Filters/Fluids” Section and “Operating the Machine in Cold Weather”.

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

• Inspect the machine. Look for any signs of wear,

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

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

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

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

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

• Clean or replace any decals which are illegible.

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

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

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

• Remove any obstructions which hinder visibility.

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

• Check that no tools or other items have been left

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

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

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

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

MACHINE OPERATION

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in death or serious injury.

M422B

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

• When starting the engine, be sure to use the

• Operate all controls gradually to ensure smooth WARNING Allow machine to cool. Release hydraulic pressure before servicing any hydraulic component. Hydraulic fluid is under extreme pressure and can cause severe injury. Failure to comply could result in death or serious injury machine operation.

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

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

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

correct procedure for the prevailing weather conditions. See “Starting the Engine”.

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

• Regularly consult the hourmeter to insure that all

• Whenever load handling operations are to be

servicing operations are carried out punctually.

See “Service Intervals”.

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

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

tow the machine.

carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation. See “Load Handling”.

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

• Avoid running the engine in a confined space. If

• Locate the position of any underground pipes or

there is no alternative, proper ventilation must be provided at all times.

• Do not work near overhead high-voltage electric

• Dust, smoke or mist can reduce visibility and

conduits before starting work.

lines without checking beforehand that all necessary measures have been taken to respect the minimum safety distances:

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

• When working on a public highway, use standard

traffic signs and take into consideration the working range of the upper structure and its attachments. Local or national regulations stipulate the number, type and location of reflector strips.

• Never operate the working or travel controls

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

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

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

4-4

cause an accident. Reduce speed or come to a complete halt until visibility has improved.

• In the event of an operating problem or failure,

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

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

consideration.

See

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

OPERATING INSTRUCTIONS

• Watch carefully and make sure you are aware of

places where other people are working in your work area. Keep all other people away from the machine. Serious injury can result if these instructions are not followed.

CHAPTER 4 - OPERATING INSTRUCTIONS

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

• Modify your driving to suit working conditions

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

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

• When traveling at right angles to the slope, move

1. Excavation using the weight of the machine as a force of impact.

2. Excavation using the machine’s travel force.

• If earth or mud stays stuck inside the bucket,

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

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

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

• When using the upper structure swing, never

• Holes, obstacles, debris and other danger risks in

• When climbing up a slope, place the attachment

the working area can cause serious injury. Inspect and note all possible risks before driving the machine in a new working area.

• When operating the control levers, a whistling

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

• The following operations are likely to damage the machine. Do not perform:

change the direction of swing too suddenly.

about 250 mm (10 inches) above the ground.

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

• Avoid turning the machine on steep slopes.

• Never swing the upper structure on slopes of 15°

in the direction of travel or 10° at right angles to the direction of travel.

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

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

1. Check for leaks under the machine.

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

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

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

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

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

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

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

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

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

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

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

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

5. Turn the key switch to the ON position. Monitor th e d isp l ay p a n e l fo r g a u g e a n d m a c h in e functions.

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

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

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

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

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE SPEED Do not run the engine at idle speed for long periods.

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

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

4-6

CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

5. Check all instruments are operating correctly.

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

7. Unlock the upper structure swing function.

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

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

2. Lower the attachment to the ground.

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

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

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

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

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

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

Failure to comply could result in death or serious injury.

M422B

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

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

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

Failure to comply could result in death or serious injury.

SA044

WARNING Jumping on or off the machine can cause an injury.

Always face the machine, use the hand holds and steps, and get on or off the machine slowly. Failure to comply could result in death or serious injury.

SA038

4-7

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

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

WARNING This engine is equipped with a glow plug heater; use of a starting fluid can cause explosion, personal injury or property damage. Failure to comply could result in death or serious injury.

SB055

1. Sit correctly in the operator’s seat with the seat belt properly fastened.

Starter swtch

1

ON ACC OFF 2 DC04D529

2-0057E

Figure 1

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

Figure 2

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

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

5. If the engine does not start, wait one or two minutes before trying to start the engine again.

NOTICE: 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.

6. Perform warm-up operations with both the engine and hydraulic controls.

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

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

4-8

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

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

Engine Automatic Warm-up On ce the en gin e ha s star ted , the war ming-u p process begins automatically. At first, engine speed is he ld a t a p r e de te r min e d , lo w leve l. A s th e temperature increases, engine speed increases in proportion. It is possible to interrupt the warming-up process at any time, simply by manually changing engine speed or by operating one of the control levers. Warming-up takes approximately 5 to 10 minutes depending on the ambient temperature.

Follow monitor prompts.

Engine Manual Warm-up

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

Hydraulic Oil Warm-up Turn the engine throttle button to half-open position.

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

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

The e ng ine sh o uld b e r u n at full sp ee d wh e n operating conditions permit.

• Let the engine run at idle speed until the engine

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

• Move the engine throttle button to the maximum

Ch e ck the sy ste ms d isp lay a n d con tro l p an e l regularly.

• Once normal operating temperature has been

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

and hydraulic temperature.

oil reaches normal

operating

speed position.

reached, check the following :

1. The exhaust smoke is normal.

2. There is no abnormal noise or vibration.

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

• • • •

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.

4-9

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

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

Batteries and Electrical System Batter ies should b e fully ch arged fo r o ptimum cranking capabilities. A fully charged battery at 17° C (0° F) has only 40 percent of the normal star ting power. When the temperature decreases to -29° C (-20° F), the battery has only 18 percent of the power remaining.

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

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

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

Hydraulic Fluid The viscosity must co rre spond to the a mb ient temperature conditions. See “Fluids and Lubricants” in the “Lubrication/Filters/Fluids” Section.

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

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

Engine Preheat Check the message display screen. The engine preheat indicator will show that the engine needs preheating and that the glow plugs are functioning.

Th e l e n g t h o f t im e th is m e s s a g e r e m a i n s i s dependent on the coolant temperature. As soon as the engine reaches starting temperature, the audible alarm will sound.

4-10

OPERATING THE MACHINE IN HOT WEATHER During hot weather: 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. Have the radiator cap tested before hot weather starts. Replace the cap as required.

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

5. Check the condition of the fan drive belt.

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

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

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE

STOP

Low 2-0059E

2-00

Figure 3

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

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

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

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

1-0091E

Figure 4

In the event of an emergency In the event of an emergency or if it is not possible to stop the engine using the switch key, press the emergency disconnect switch The switch must be reset after use or engine will not restart.

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

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE TRAVEL WARNING In the normal travel position, the operator’s compartment is above the idler wheels and the travel reduction gears are to the rear of the upper structure. If the upper structure is turned 180° in relation to the undercarriage, lever functions are reversed. Failure to comply could result in death or serious injury.

SB055

Before undertaking any travel, raise the attachment.

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

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

Turning To The Left (Forward)

Traveling In A Straight Line (Forward)

GCS98M546

Figure 5

CS98M548

Figure 7

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

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

Traveling In A Straight Line (In Reverse)

Turning To The Right (Forward)

CS98M547

Figure 6

Press the two ped als (or push the two levers) rearward at the same time.

4-12

CS98M551

Figure 8

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

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

Turning To The Left (In Reverse)

CS98M549

Figure 9

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

CS98M552

Figure 11

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

Turning To The Right (In Reverse) Turning On The Spot, To The Left

CS98M550

Figure 10

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

CS98M553

Figure 12

Press the right-hand pedal (or push the right-hand lever) forward and at th e same time p re ss the left-hand pedal (or pull the left-hand lever) rearward.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS Travel Mode Select Switch

Gradual Turn On The Move

CS98M545

Figure 13

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

2-0071E

Figure 14

Coming To A Stop

Press this switch to toggle between high and load to adjust travel speed. When the indicator light is illuminated, it indicates the travel mode is high. Do not switch back and for th between travel modes when the machine is traveling. Stop the machine before changing the travel mode:

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

Low Speed: Use when traveling on slopes or uneven ground.

High Speed: Use when traveling on flat, level ground.

When the travel load becomes high, the machine will automatically return to low.

Choose speeds according to travel conditions. When traveling on rough, uneven ground, reduce travel speed. Avoid making rapid pivot or spins turns.

RUBBER TRACK When the machine is equipped with rubber track, use caution when driving on gravel, water, ice, or snow and when loading or unloading the machine.

Rubber track is best used on paved roads. Rubber track will wear quickly on rough, uneven ground.

Steer may be difficult on some surfaces.

4-14

Do not use track when temperatures are outside the range of -13째 F to 131째F (-25째 to 55째 C). Do not drive through hot surfaces, (hot asphalt, burning material) with rubber track.

When storing, try to prevent storage in direct sunlight or where oil and moisture accumulate. Do Not allow oil to remain on rubber track. Oil will deteriorate the rubber.

CHAPTER 4 - OPERATING INSTRUCTIONS BLADE OPERATION

SWING OPERATION

Blade Operation Lever

Up

Down

Be careful of interference 2-0084E

Figure 15

Do not allow anyone or any machine within the swing radius. Swing will continue due to inertia even after the swing lever is returned to neutral.

Do not use this machine except for its intended purpose. Be careful not to strike the cab or blade with the bucket attachment.

When transporting with a long arm machine, swing the upper structure 180°. This will allow the bucket to be positioned on the opposite end of the machine from the blade and prevent damage to both blade and bucket.

2-0083E

2-0083E Figure 16

The blade is designed for light duty work, such as pushing soft dirt or mud.

Do not push down hard on the blade, as it may cause dame to the blade.

Do not side load with the blade.

If using the blade to support the front of the machine during operation, ensure the blade is level and is firmly supported over the full length of the blade.

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING LOADS WITH THE MACHINE

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

SB055

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

Lifting capacities: See the lifting chart in the cab of your machine.

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

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

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

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

• If this excavator is to be used to lift loads, for

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

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

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

• Do not exceed either the radius or the height

restrictions shown on the lift capacity charts posted in the cab or in this manual.

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

• Be careful to balance the load correctly.

• It is extremely dangerous if the load lifted begins

• Know and understand each signal from the signal

• When the load is raised, keep all persons away

person before you start.

4-16

to swing. The upper structure should be centered over the load to help prevent dangerous swinging.

• Always move the load slowly. Do not move the load over the top of persons. Keep all persons away from the load. until the load is placed on blocks or on the ground.

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER

Figure 17

CS99A825

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

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

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

IMPORTANT: Do not operate in a fast flowing stream.

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

OPERATING THE MACHINE ON SLOPING GROUND\

WARNING Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc. modify terrain conditions. It is up to you to decide if the machine can be used in safety. Failure to comply could result in death or serious injury.

SB055

• Use extreme caution on hillside operations.

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

• When digging on a slope, avoid swinging the

upper structure towards the bottom of the slope with the bucket full. Always keep the travel reduction gears pointing down towards the bottom of the slope.

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

4-17

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

EXCAVATING METHOD

PDH0493M

Figure 18

PDH0494M

Figure 19

CORRECT

4-18

WRONG

WRONG

The bucket will dig in and cause a stall.

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

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

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

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

WARNING Jumping on or off the machine can cause an injury.

Always face the machine, use the hand holds and steps, and get on or off the machine slowly. Failure to comply could result in death or serious injury.

SA038

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

Low Figure 20

2-0059E

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

Starter switch ON ACC OFF 2-0060E

Figure 21

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

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

4-19

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

Wherever possible, carry out any repairs at the site. The machine must be towed very slowly, over a short distance, and only if it is unavoidable.

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

SB055

WARNING The operator must be the only person on the machine when towing. Make sure that nobody else is on the machine or within its working range. Failure to comply could result in death or serious injury.

USING THE MACHINE TO TOW

TOWING THE MACHINE

2-0073E 2-0073E

Figure 22

When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be brake d, a tow bar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake. Avoid towing over long distances.Use the approved drawbar and / or attachment point when using the machine for towing.

If a cable or chain is used, make certain it is of sufficient strength. Keep people away from the tow line.

Attach tow straps or cable to the lower frame. To prevent damage to the machine and tow material, use padding on sharp edges.

4-20

2-0074E 2-0074E

Figure 23

Do not tow objects over four tons.

Attach cable or straps of sufficient strength to the towing ring on the lover frame. Position the towing strap or cable in line with the lower frame. Tow slowly at low speeds.

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE

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

ON A TRAILER

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

SB055

WARNING It is mandatory to remove the counterweight before undertaking any travel without the attachment or transporting the machine without the attachment. Consult your CASE Dealer. Failure to comply could result in death or serious injury.

SB055

Follow all safety rules and regulations before transporting the machine. Make certain both trailer and machine are fitted with the right safety equipment. Load binders should be of sufficient capacity and in good condition.

Loading

Machine with Attachment

PDH0248 CD95M248

Figure 24

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

Install the trailer side extensions (if fitted).

Figure 25

2. Select low travel speed, the indicator lamp to the lef t of t ravel s peed s elec t or wi ll not b e illuminated.

2 0086E Figure 26

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

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

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

4-21

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

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

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

2-008 PDH0250

Figure 27

When the machine is completely and safely on the traile r, swing th e u pp er str uctu re to b rin g th e attachment toward the ramp end. Bring the machine itself to the front of the trailer. Use blocks and chains to fasten the machine and attachment to the trailer.

Lower all antennas, fold or remove mirrors, lock all doors on cab and compartments.

CS99B518

Machine without Attachment

Figure 30

Use blocks and chains to fasten the machine to the trailer. Load binders should be in good condition and of sufficient capacity and strength NOTICE: Measure the distance between the ground and the highest point of the machine. You must know the overall height. See “Machine Overall Dimensions” in the “Specifications” Section.

Unloading 1. Keep all unauthorized personnel clear of the area.

Remove the blocks and fastening chains.

CD00E150

Figure 28

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

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

2. Fasten your seat belt and start the engine.

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

4. Unlock the upper structure swing function.

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

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

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

8. When the attachment has been installed, all air must be removed from the hydraulic circuit and th e m a ch in e s h o u ld b e t e s te d fo r c o r r e ct operation. Check the hydraulic fluid level.

CD00E150

Figure 29

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

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORT POSITION FOR LONG REACH ARM If the machine is equipped with a 2.85 m (9 ft. 4 inch) arm, the hooking point on the head of the arm cylinder must be placed in the transport position prior to transporting the machine. DO NOT use the machine for any other operation with the arm in the transport position.

Figure 31

CT02C200

1. Extend the attachment and place the bucket on the ground.

2. Stop the engine, and remove the starter switch key.

Figure 33

CT02C201

NOTICE: In this configuration, the working range of the attachment will allow the tool to interfere or strike the machine. Use care when positioning the machine for transport.

3. Use a suitable lifting device to support the arm cylinder.

4. Remove the retaining hardware from the shaft, and drive the shaft out.

5. Start the engine, retract the arm cylinder rod to bring the cylinder head to the transport position.

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

Figure 34

CT02C203

NOTICE: After transporting the machine, the arm cylinder must be returned to working position. DO NOT attempt to use the machine with the arm in the transport position, not only is there a possibility of machine interference, but the arm is not structurally conformed to carry bucket weight when digging.

Figure 32

CT02C201

7. Install the shaft and its retaining hardware.

Lubricate the linkage.

WARNING When arm is in the transport position, there is the possibility of interference with the machine and/or operator’s compartment. Use care when moving the machine with the arm in the transport position.

Failure to comply could result in death or injury.

WARNING When the machine is placed on the trailer, travel and steering controls may be reversed. Do not move the machine without determining travel/upper structure direction. Failure to comply could result in death or injury.

SA038

SA038

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE Preparation For Storage

Periodical Checks

The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building. If a building is not available, park the machine in a dry area on planks and use wheel chocks, front and rear. Cover the machine with a water proof covering. Before s to r i n g t h e m a c h i n e , c a r r y o u t th e fo l lo w in g operations:

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

B. The grease on the cylinder rods.

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

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

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

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

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

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

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

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

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

7. Place a Do Not Operate tag on the key switch or steering wheel.

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

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

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

4. Change the fuel filter.

5. Install the batteries.

6. Lubricate the machine thoroughly.

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

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

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

10. Clean the cylinder rods.

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

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

WARNING Check the machine for leaks or for any parts that are broken, defective, or missing. Failure to comply could result in death or serious injury.

CE-NA000

4-24

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8 5-8 5-8 5-9

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Daily/Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 MACHINE AND ATTACHMENT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15 5-18 5-23 5-24 5-30 5-40 5-43 5-45

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

GENERAL SAFETY BEFORE YOU SERVICE WARNING

WARNING

Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

Before you begin any service or repair work you must know and understand how to relieve hydraulic pressure properly. Always have tools and attachments down in safe positions. Failure to comply could result in death or serious injury.

M1087

M110B.

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

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

CE-NA000

Comply promptly with maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on firm, level ground, aw ay fr o m a ny o b s ta c l e s w it h th e b u c ke t o r attachment on the ground. Keep all unauthorized personnel clear of the area. Un less othe rw ise specified, all maintenance operations should be carried out with:

• • • • • • •

the engine stopped the parking brake engaged the key removed from the starter switch a Do Not Operate tag placed on the key switch

.

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

Failure to comply could result in death or serious injury.

M959

all circuits cooled down before starting work all hydraulic pressure released any accumulator pressure released for the appropriate circuit

• all non-authorized personnel clear of the machine operating area

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

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

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

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

Any modification to th is machine without pr ior authorization could cause serious injury. Do not ma ke a ny mod ifications without autho rization.

Consult your Case Dealer.

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

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

5-3

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

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Lower the attachment to the ground, and stop the engine.

WARNING Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

WARNING START

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

ON ACC

M1502

OFF

WARNING

1

Figure 1

1-0068E

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

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

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

1 Ԙ

3-0001 3-0001E

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

Figure 2

breather

6. Press the button (1) on top of the breather to release any residual pressure.

5-4

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS

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

CE-NA000

WARNING Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap, and press the button on the breather to release all pressure in the system. Failure to observe these instructions can cause injury. See “Releasing Pressure in the Hydraulic System�. Failure to comply could result in death or serious injury.

CE-NA000

NOTICE: After bleeding air from the components, stop the engine for five minutes and check to make certain there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Attachment Cylinders

BLEEDING AIR FROM THE HYDRAULIC COMPONENTS

Keep all non-authorized personnel clear of the area.

Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing the cylinders to the end of the stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to the end of stroke.

Hydraulic Pump

2

1 3-0158E

3 3-0158E

Figure 3

1. AIR BLEED PLUG 2. TO ENGINE 3. OUTER SIDE

Keep all unauthorized personnel clear of the area.

Clean around the air bleed plug. Loosen the air bleed plug, remove the plug if the fluid does not flow.

Start the engine and run it at idle speed. Loosen the air bleed plug (1) on the pump. Tighten the plug when air free fluid comes out of the bleed plug hole. Clean the area completely.

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SYSTEMGARD® LUBRICATION ANALYSIS PROGRAM As k you r d e a le r a b o u t o u r lu b r ic a nt a n a lys is program, Systemgard ®. Through this service, your lubricants are tested in an independent laboratory.

You simply remove a sample of lubricant from your machine and send the sample to the independent Sy s te m g a r d ® l a b o ra t o r y. A ft e r t h e sa m p le is processed, the laboratory will report back to you and g u i d e yo u w i t h m a i n t e n a n c e r e q u i r e m e n t s .

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

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

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

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

5-6

ENGINE HOURMETER Service your machine at the intervals and locations g i v e n i n t h e Q u i c k R e fe r e n c e L u b r i c a t i o n Maintenance Chart. When you service your machine, use only high quality lubricants.

1-0074E

1 0074EFigure 4

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

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

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change ................................................................................................. 18.2 Qts. (17.2 Liters) Specifications ...................................................................................................................... CASE AKCELA No. 1 FUEL TANK Capacity ................................................................................................................................43.6 gal. (165 Liters) COOLING SYSTEM Capacity .............................................................................................................................. 14.8 Qts. (14.0 Liters) Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDRAULIC RESERVOIR/TRANSMISSION REFILL Total system capacity .............................................................................................................34.3 gal. (130 Liters) Reservoir capacity....................................................................................................................21.4 gal. (81 Liters) Specifications ................................................................................................................................ Hy-Tran® Ultra TRAVEL REDUCTION GEARS Capacity - (per reduction gear) ................................................................................................ 2.2 Qts. (2.1 Liters) Specifications ................................................................................................................................. Case 135 H EP SWING REDUCTION GEARS Capacity (per reduction gear).................................................................................................... 3.17 Qts. (3 Liters) Specifications ............................................................................................................................... Case 135 H EP TURN TABLE TEETH Specifications ...............................................................................................................................EP Grease No. 2

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE LUBRICATION ENGINE OIL SELECTION API Service CI-4 Engine Oil is recommended for use in your Case Engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions.

If Case oil is not available, use only oil meeting API engine oil standards.

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTICE: Use of an engine oil pan heater or an engine coolant heater may be required when operating in Winter or Arctic conditions.

NOTICE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below -5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear. See the chart below for the correct oil for ambient temperatures.

NOTICE: Do not put performance additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

OIL VISCOSITY/TEMPERATURE RANGES

BC02N250

5-8

Figure 5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. Adhere to machine lubrication intervals specified by the manufacturer.

TRANSMISSION COMPONENT OIL

HYDRAULIC FLUID

CASE/AKCELA: GEAR 135H EP

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

(SAE 80W-90. API GL 5 . MIL-L-2105 D. MAT 3506 ZF TE-ML 05A)

Temperate Climates

CASE/AKCELA: MAT 3550 MOLY GREASE 251H EP-M (NLGI 2)

-20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MAT 3509 ISO VG 46. DIN 51524 PART 2 HV) Hot Climates

Extreme pressure oil used for enclosed transmission components.

GREASE

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

C A S E /A K C E L A : M AT 3 5 5 0 M U LT IP U R P O S E GREASE 251H EP (NLGI 2)

CASE/AKCELA: AW HYDRAULIC FLUID 68 HV

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

( M AT 3 5 0 8 I S O VG 6 8 . D I N 5 1 5 2 4 PA RT 3 CATEGORY HVLP)

CASE/AKCELA: MAT 3550 PREMIUM GREASE EP2 (NLGI 2)

Cold Climates

“Extreme Pressure” multipurpose grease with lithium soap.

0° C to +50° C

-25° C to +20° C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MAT 3508 ISO VG 32. DIN 51524 PART 2)

Hydraulic Breakers C AS E/ A K C E L A : M AT 3 5 5 0 MU LTI P UR P OS E GREASE 251H EP (NLGI 2).

Biodegradable Fluid: -30° C to +40° C This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the circuit completely before refilling with this fluid.

CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MAT 3509 ISO VG 46. DIN 51524 PART 2 HV)

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Coolant Solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent le a k a g e . D o n o t u se n o n - a p p r o ve d a n t i- r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing.

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

HYDRAULIC FLUID Use hydraulic fluid specifically designed for high pressure applications. Your dealer can provide hydraulic fluid to fulfill different climate/temperature conditions.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions.

GREASE The type of grease to use depends on ambient te mpe ra tur e. U se a q ua lit y extre me p re ss ur e multipurpose No. 2 grease.

ENGINE OIL CI-4 is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions.

NOTICE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out with approved lubricants.

USE OF BIO-DEGRADABLE OILS When using Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable ba sed oil occ urs mo re rap id ly a nd caus es reduced service life.

5-10

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, flush the hydraulic system that was filled with mineral oil twice. This is a requirement before adding bio oil.

3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction of BIO OIL compared to that mineral oil.

4. For further information about recommended Bio-degradable oil, please contact local dealer.

ENVIRONMENT Before you service this machine and dispose of oil, fl u id s, a n d lu b r ic a n ts , a l way s r e m e m b e r th e environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

FUEL NOTICE: Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade No. 2 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, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

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.

In cold weather, fill the fuel tank at the end of the day's wor k in order to prevent the for mation of condensation.

FUEL STORAGE Prolong ed storage of fue l ca n lea d to th e 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.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Eng in e p er fo r man ce is e ffe cted by the use of biodiesel fue l. Th ere may be up to 12 percent reduction in power or torque depending on the blend used.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These par ticles are then tra p p ed by th e ve h icle filte rs a n d m ay ca u s e shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and prop er main te nance inter va ls whe n using any biodiesel fuel blend.

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

As Required (AR)

Every 10 hours

Every 50 hours

Every 250 hours

Every 500 hours

5-12

DRAIN

GREASE

REPLACE

CHECK

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

Intervals In Hours SERVICE INTERVALS

6-12

Fan and air conditioning drive belt

AR

5-23

Air filter

AR

AR

5-22

Fuel tank screen

AR

AR

6-3

Clean track

8-13

Steel track shoe bolt torque

AR

5-18

Engine oil level

10

5-18

Coolant level

10

5-19

Radiator and oil cooler

10

5-19

Fan/alternator belt tension

10

5-20

Hydraulic reservoir level

10

5-22

Bleed fuel prefilter

5-23

Hydraulic system lines

50

6-12

Air conditioning

50

6-5

Track shoe bolt torque

Run-in

50

8-13

Bolt and nut torque

Run-in

50

7-4

Battery check

5-24

Pilot filter

5-24

Drain hydraulic reservoir sediment

5-25

Return filter

Run-in

250

5-26

Swing reduction gear

Run-in

250

5-27

Travel reduction gears

Run-in

250

5-28

Fuel prefilter

5-29

Air Filter dust ejector

5-16

Grease attachment

8-13

Track shoe bolt torque

250

8-13

Bolt and nut torque

250

7-5

Battery electrolyte level

250

6-6

Fan/Alternator belt tension

250

6-4

Idler wheel and roller

250

5-16

Machine grease points

500

5-30

Turntable bearing

500

5-31

Engine oil

500

5-31

Engine oil filters

500

5-33

Fuel filter

500

5-34

Priming pump

AR

10

50 Run-in

250 250

250 250 250

500

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Every 1000 hours

5-35

Air filter primary and secondary

5-36

Hydraulic fluid condition

5-37

Swing gear

1000

5-38

Breather filter

1000

5-39

Travel reduction gear

DRAIN

GREASE

REPLACE

Machine arm and attachments

1000 1000 1000

1000

Tappet clearances

1000

Alternator

1000

Starter motor

1000

5-40

Inlet filter

5-41

Return filter

2000

5-42

Pilot filter

2000

5-542

Swing reduction gear

5-433

Draining and filling cooling system

Every 4000 hours

Every 5000 hours

CHECK

5-16

See your Case Dealer

Every 2000 hours

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

Intervals In Hours SERVICE INTERVALS

2000

2000 2000

Fuel hoses

See your Case Dealer

4000

Main pump output hydraulic hoses

See your Case Dealer

4000

Boom/bucket cylinder hydraulic hoses

See your Case Dealer

4000

5-45

Hydraulic fluid

5000

5-45

Replacing inlet filter

5000

RUN-IN: Maintenance items designated as run-in are for initial fluid or filter changes for a new or rebuilt machine.

Follow the regular maintenance intervals as indicated thereafter for best machine performance.

NOTICE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTICE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message Service Due will appear on the screen by way of a reminder that service work is due. See “Systems Display and Control Panel” in the “Controls/Instruments/Accessories” Section.

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DAILY/PERIODIC INSPECTION Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

General

• • • •

Check for signs of leaking oil or water.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator’s compartment, decals and warning labels).

Check for any signs of deterioration.

Engine

• • • • • • •

Check the oil level, and change the oil if necessary.

Check the coolant level.

Check the radiator for signs of clogging or deterioration of air flow.

Check the radiator fan belt tension.

Check the air filter for cleanliness and/or restrictions.

Check the components for signs of leaking oil or water.

Check the condition of all lines and tubes.

Upper Structure

• • • • • • • •

Check the fuel tank level.

Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the components for signs of leaking oil or water.

Check the condition of all lines.

Make sure there are no electrical short circuits.

Check the battery connections are properly tightened.

Adjust the rear view mirrors.

Undercarriage

• Check the pad and pad hardware.

• Check the condition of the track chain assembly.

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

Attachment

• • • •

Check the cylinders are not leaking oil.

Check the condition of all lines and tubes.

Check the condition of the bucket teeth.

Check the attachment for any damage or deterioration.

After Starting The Engine

• • • • • •

Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check that the hydraulic components are not making strange noises.

Check the components for signs of leaking oil or water.

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

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

Check that the upper structure swing brake functions correctly.

NOTICE: If any maintenance issue is found, place a Do Not Operate tag on the key switch, and repair it immediately prior to using the machine or contact your dealer.

5-14

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

MACHINE AND ATTACHMENT LUBRICATION GREASE POINTS Type of grease ................................................................................................................... See Fluids and Lubricants MAINTENANCE: EVERY 250 HOURS MAINTENANCE FOR EM SYSTEM; EVERY 1000 HOURS NOTICE: Always grease after completing work in water or if machine is operated in extremely wet conditions.

NOTICE: If using an attachment that is not an original or genuine equipment attachment from your authorized dealer, grease the mounting pins every ten hours.

FRONT ATTACHMENT PIN'S GREASING POINTS (16 POINTS) Greasing Points

Number on reference drawing

Boom greasing points

Boom foot pin (EMS)

1

3

Boom cylinder foot pin

2

2

Bucket cylinder top foot pin

3

6

Bucket cylinder to bucket linkage pin

3

6

Bucket linkage to bucket pin

3

6

Arm to bucket linkage pin

3

6

Arm to bucket pin

3

6

Bucket cylinder foot pin

4

4

Arm cylinder top pin

4

4

Boom to arm, connecting pin (EMS)

4

4

Boom cylinder top pin

5

3

Arm cylinder foot pin

5

3

Blade (every 50 hours)

6

6

55

11 22 44 3-0174E

33

66

3-0 Figure 6

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

(3 points) 1

4

1

22

(2 points) 3-0128E

3-0128E Figure 7

3-0129E

1. Boom foot pin (3 grease points)

Bucket cylinder foot pin

2. Boom cylinder foot pin (2 grease points)

Arm cylinder top pin

3 0129E Figure 9

Boom to arm connecting pin

3

(total Mono boom 4 points) (total off-set boom 3 points)

5

3-0116E 3-0116E

Figure 8

Bucket/Arm Bucket cylinder top pin

3-0130E

Bucket cylinder to bucket linkage pin

Boom cylinder top in (2 points)

Bucket linkage to bucket pin

Arm cylinder foot pin

Arm to bucket linkage pin

Figure 10

6

Arm to bucket pin

3-0128E

Blade - Lubricate every 50 hours Blade cylinder foot pin (2 points) Blade cylinder top pin (2 points) 5-16

Figure 11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Every 500 hours Turntable................................................................... (2)

CT07K031

Every 500 hours Swing ring gear........................................................ (1) Remove the inspection port cover (1). Visually check for damage and grease condition.

If gear surface is not well lubricated, add extreme pressure grease number 2. If grease is white with a high moisture content, replace with new grease. Contact your authorized dealer for ring gear repairs and grease replacement.

If water has accumulated, remove the grease discharge port cover and discharge water.

Remove the grease discharge port plug (2).

Discharge water or cloudy grease. Reinstall the discharge port plug and insert grease through the inspection port (3).

CT07K031

2

1

3

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE OIL LEVEL

CHECK COOLANT LEVEL

Perform the following procedures daily or at every ten hour shift.

Service Specifications System capacity . . . . . . . . . . . . 14.8 Qts (14. Liters)

Service Specifications Oil Type. . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Oil Capacity with filter . . . . . . . . . 18 Qts. (17.2 Liters)

Check the coolant level before you start the engine each day or before the start of each 10 hour shift.

Check the engine oil level before you start the engine each day or before the start of each 10 hour shift.

Always check the oil level with the engine stopped and with the machine on firm, level ground.

WARNING

Push the engine oil level dipstick completely down, and pull out before you check the oil level.

If the oil level is below the ADD mark, add oil to raise the oil level up to the FULL mark.

Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

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 le a k a g e . D o n o t u s e n o n - a p p r ove d a n t i- r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion, and causing damage to the cooling system and radiator.

ԙ 2

3 Ԛ 1Ԙ

3-0051E

Consult your CASE Dealer for suitable coolant solution.

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

Figure 12

CT07A079

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL 3. FAN BELT

1 Ԙ 2 ԙ

1 Ԙ 2 ԙ

CT05L023

CT07K026

Figure 13

1. CORRECT OIL LEVEL 2. DIPSTICK

The oil level should be between the marks (1) on the dipstick (2).

NOTICE: The level should not be higher than the maximum mark on the dipstick.

5-18

Figure 14

On flat, level ground, before using the machine, (while the engine is still cold), the level in the coolant reser voir should be between the “FULL” (1) and “LOW” (2) marks.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

FAN AND ALTERNATOR DRIVE BELT

RADIATOR AND OIL COOLER

Visually check the fan and alternator drive belt before you start the engine each day or before the start of each 10 hour shift.

Check the radiator and oil cooler before you start the engine each day or before the start of each 10 hour shift.

1 Ԙ

2 ԙ

3 Ԛ 3-0023

Figure 163

1. BELT 2. FAN PULLEY 3. GENERATOR PULLEY

3-0140E

Figure 15

Check for leakage on and around the radiator and oil cooler components. Check for any debris build-up around these components as well. Leaves, brush, etc. can create a fire hazard.

Check for any signs of wear or damage to the pulleys or the belt. Check carefully to insure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE HYDRAULIC FLUID RESERVOIR LEVEL Service Specifications Reservoir capacity . . . . . . . . . . . 21.4 Gal. (81 Liters) Total system capacity . . . . . . . 34.3 Gal. (130 Liters) Check the hydraulic fluid reservoir level before you start the engine each day or before the start of each 10 hour shift. Always check levels with the engine stopped and with the machine on firm, level ground.

2

1

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components”.

3-0176E

WARNING Before carrying out any service work on the hydraulic system it is necessary to allow it to cool (the temperature should not be more than 40°C (104° F).

Failure to comply could result in death or serious injury.

M646

WARNING Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap, and press the button on the breather to release all pressure in the system.

Failure to observe these instructions can cause injury. See “Releasing Pressure in the Hydraulic System”. Failure to comply could result in death or serious injury.

Check Hydraulic Fluid Level In The Reservoir

CS98N547

Figure 17

1. Keep all non-authorized personnel clear of the area. Position the machine on firm, level ground, and place the attachment on the ground. Stop the engine, and remove the starter switch key.

5-20

Figure 18

3-0176E

1. HYDRAULIC OIL FILL PORT 2. HYDRAULIC OIL SIGHT GAUGE

2. The oil should be in the middle of the indicator.

Add more oil if necessary.

WARNING Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. If injured by leaking fluid, seek medical attention immediately.

Failure to comply could result in death or serious injury.

M587A

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE Filling The Reservoir 1. Release all pressure in the hydraulic reservoir.

Se e “ Re le as in g Pre ssu re in th e H yd rau lic System.”

1 2 3 4

3-0155E

Figure 19

2. Clean the cover plate (2) and the area around the plate.

3. Remove the bolts (1), O-ring (3) and cover plate.

Add hydraulic fluid to the reservoir as required.

4. Replace the cover plate O-ring, and install the cover plate.

5. Check oil level in the sight gauge (4).

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

FUEL FILTER BLEEDING

FUEL PREFILTER BLEEDING

Bleed the fuel filter before you start the engine each day or before the start of each 10 hour shift.

Check and drain the fuel prefilter before you start the engine each day or before the start of a 10 hour shift.

1 Ԙ 8 ԟ Ԟ 7

ԙ 2

6 ԝ

Ԛ 3

Ԝ 5 ԛ 4 Figure 20

3-0135E

1. Place a receptacle of a suitable capacity under the prefilter. Loosen the air bleed plug (1) and drain plug (5). Drain the water and dirty fuel.

1 Ԙ

8ԟ Ԟ 7

Figure 22

3-0016

1.

2.

3.

4.

5.

6.

7.

8.

AIR BLEED PLUG HEAD CASE O-RING DRAIN PLUG O-RING ELEMENT PRIMING PUMP

ԙ 2

1. Place a container with a suitable capacity under the filters.

3 Ԛ

2. Loosen the air bleed plug an drain plug. Drain the water and dirty fuel. After draining, retighten the bleed screw.

3. Tighten air bleed plug to 8-12 Nm (6 - 9 ft lb).

ԛ 4

FUEL TANK SCREEN

6 ԝ 5 Ԝ 3-0014

1.

2.

3.

4.

5.

6.

7.

8.

3 0014 Figure 21

AIR BLEED PLUG HEAD CASE FLOAT DRAIN PLUG O-RING FILTER ELEMENT O-RING

2. After draining, close the drain plug. Check for any signs of leakage.

3. Tighten air bleed plug to 8-12 Nm (6 - 9 ft lb).

5-22

1 2

CD01K039A

Figure 23

The fuel tank screen (1)is located in the fuel tank filler neck (2). Clean the tank screen periodically. To clean, remove cap and filter. Clean the screen in diesel oil.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE HYDRAULIC SYSTEM LINES

BOLT AND NUT TORQUE

Check hydraulic system lines when the machine is new at the initial 50 hour run-in period.

Check all bolts and nuts w hen the hour meter registers 50 hours. For torque infor mation, see Section 6, Maintenance.

Service Specifications Reservoir capacity . . . . . . . . . . . 21.4 Gal. (81 Liters) Total system capacity . . . . . . . 34.3 Gal. (130 Liters) NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components” at the beginning of this section.

WARNING

AIR CONDITIONING Check the air conditioning for correct refrigerant level and filter replacement/cleaning if necessary. See Section 6, Maintenance.

BATTERY CHECK Check the battery fluid levels when the hour meter registers 50 hours. For additional information, See Section 7, Electrical

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

WARNING Before carrying out any service work on the hydraulic system it is necessary to allow it to cool (the temperature should not be more than 40°C (104° F).

Failure to comply could result in death or serious injury.

M646

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE DRAINING WATER AND SEDIMENT FROM THE HYDRAULIC RESERVOIR

PILOT FILTER REPLACEMENT

Drain the hydraulic reservoir when the machine hour meter registers 250 hours or more often if conditions so require.

1

1 ①

② 2 3-0033

3-0033 Figure 25

PILOT FILTER LOCATION

Replace the pilot filter when the machine hour meter registers 250 hours during the initial run-in period.

The p ilot filter will be r eplac ed a t 20 00 hou rs thereafter, or sooner if conditions so require.

2

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic s y s t e m . S e e “ R e l e a s i n g P r e s s u r e in t h e Hydraulic System.”

3-0156E 3-0156E

Figure 24

1. BREATHER 2. DRAIN PLUG

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic re ser voir. Se e “ Re le as in g Pr ess ure in th e Hydraulic System.”

2. Position a receptacle of suitable capacity under the drain plug.

3. Loosen the drain plug (2) on the bottom of the reservoir, and drain the sediment and water accumulated at the bottom of the reservoir.

4. After draining, tighten the drain plug. Add hydraulic oil if necessary.

5-24

2. Use a wrench on the bottom of the filter body (2) to unscrew and remove it.

3. Remove the old filter.

4. Clean the filter body in solvent and wipe dry with a cloth.

5. Coat the new filter with clean hydraulic fluid.

Install the new filter on the head (1).

6. Install the filter body and tighten by hand. Do not overtighten.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE RETURN FILTER REPLACEMENT (RUN-IN) Replace the hydraulic return filter when the machine is new and the hour meter registers 250 hours.

Replace the hydraulic fluid return filter when the hour meter registers ever y 2000 hours thereafter or sooner if conditions so require.

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic reser voir. Press th e bre ather cap (1). Se e “Releasing Pressure in the Hydraulic System.”

Clean the top of the hydraulic reservoir and clean the return filter cover.

2 1

3 4

A B C D

2. Remove the upper plate (2) on the hydraulic reservoir.

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

E

5

3-0160E8

3 0160E Figure 26

4. Remove the cover (1) and O-ring (3).

5. Take out the spring (C), valve (D) and return filter (E).

6. Install a new filter. Clean the spring (C) and valve (D) and assemble them.

7. Check O-ring (B), and replace it if worn or damaged.

8. Install the cover (A).

9. Check the level of the hydraulic fluid and add m o r e fl u id , if n e c e s s a r y. S e e “ Fi lli n g th e Reservoir”.

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE SWING REDUCTION GEAR (RUN-IN) Service Specifications Oil capacity . . . . . . . . . . . . . . . . . . 3.2 Qts (3 Liters) Oil type . . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP Perform an oil change after the first 250 hours of operation during run-in. Check swing reduction gear oil level every 250 hours thereafter. An oil change is also required at each 1000 hour interval thereafter.

1

DRAINING AND REFILLING SWING REDUCTION GEAR OIL 1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (3).

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (2).

4. Allow the oil to drain.

3

NOTICE: The oil takes a relatively long time to drain.

Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

5. Install the drain plug (2).

Satisfactory amount

6. Add oil through the filler holes (3) until the level is correct.

7. Install the dipstick (1) and the filler plugs (3).

8. Wait ten minutes and check the oil level again.

Add more oil, if necessary.

2

3-0163E

Figure 27

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter switch key.

2. To check the oil level, remove the dipstick (1).

The oil should come up to the hatched area. Add oil if necessary through the filler hole (2).

3. Install the dipstick.

5-26

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE TRAVEL REDUCTION GEARS (RUN-IN)

Draining And Refilling Travel Reduction Gears

Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 2.2 Qts. (2.1 Liters) (per reduction gear) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135 H EP 1. Change the travel reduction gear oil after the first 2 5 0 h o u r s o f o p e ra t io n . C h e ck th e t ra ve l reduction gear oil every 250 hours thereafter. An oil change is also required at each 1000 hour interval.

1. Park the machine on flat, level ground.

2. Move the machine so that plug (3) is in the lowest possible position.

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

4. Place a receptacle of a suitable capacity under the travel reduction gear and remove plugs (3) and (2).

5. Allow the oil to drain.

1

2

NOTICE: Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

6. Install plug (3), fill with oil through the plug hole (1) until oil comes up to the bottom edge of port (2).

7. Install plug (2) and repeat the procedure for the other travel reduction gear.

3 3-0165E

8. Travel slowly with the machine, and make certain there are no leaks.

Figure 28

2. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

3. Move the machine so that plug (3) is in the lowest possible position.

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

5. Slowly loosen the plug (1) to release any residual pressure.

6. Remove the plug (2) and check the oil level. The level must come up to the lower edge of the plug hole. If necessary, remove the plug (1) and add oil until the level comes up to the bottom edge of plug hole (2).

7. Install the plugs.

8. Repeat for the other travel reduction gear.

9. Travel slowly with the machine and make certain there are no leaks.

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE REPLACE THE FUEL PREFILTER Replace the fuel prefilter when the machine hour meter registers 250 hours or more often if conditions so require.

A

Figure 31

3-0136E

FUEL VALVE Figure 29

3-0135E

1. Place a receptacle of a suitable capacity under the prefilter. Loosen the air bleed plug (1) and drain plug (5). Drain the water and dirty fuel.

NOTICE: Only the filter element must be replaced, not the sediment bowl.

1 Ԙ

8ԟ Ԟ 7

5. Clean the sediment bowl (4). Replace seal (6) and (8). Apply a thin coat of oil on the new seal.

Install the sediment bowl on a new filter element.

6. Reinstall the assembly on the filter head by rotating the prefilter until the seal is in contact with the filter head.

ԙ 2

7. Tighten the body to a torque of 20 ft lbs to 23 ft lbs (27.5 to 31.3 Nm). Do not over tighten.

Retighten the bleed plug (1).

3 Ԛ

8. Tighten air bleed plug to 8-12 Nm (6 - 9 ft lb).

9. Bleed the system.

NOTICE: In cold weather, the water can freeze on the top part of the bowl. Bleed after ice has melted.

ԛ 4

6 ԝ 5 Ԝ 3-0014

1.

2.

3.

4.

5.

6.

7.

8.

3 0014 Figure 30

AIR BLEED PLUG HEAD CASE FLOAT DRAIN PLUG O-RING FILTER ELEMENT O-RING

2. . Close the valve on the supply line.

3. Clean around the prefilter body. Remove the prefilter, turning counterclockwise.

4. Clean the area around the sediment bowl (4), then remove the bowl from the filtering element.

5-28

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE 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 replaced before they are worn.

Dust Ejector

5

4

6. Do not clean the secondary filter. It must be replaced. Always make certain the filters fit securely in the housing before replacing the air filter housing cover.

WARNING Eye damage and dust inhalation hazard.

Compressed air can propel dirt, rust, etc. into the air. Wear eye protection and a face mask when cleaning with compressed air. Failure to comply could result in death or serious injury.

M1611

6 1

LUBRICATE ATTACHMENT When the hour meter registers 250 hours, lubricate the attachment. See the Lubricating the Machine and Attachments at the beginning of this section.

BOLT AND NUT TORQUE

2 3-0123E

1.

2.

3.

4.

5.

When the hour meter registers 250 hours, check the torque of nuts and bolts on the machine. See Section 6, Maintenance for torque information.

3 Figure 32

COVER ELEMENT DUST EJECTOR INDICATOR RESET BUTTON WINDOW SIGNAL

1. Periodically check the dust injector. Replace the primary air filter element every 1000 hours. The secondary element should be replaced at the same time. Do not clean the secondary element.

It must be replaced. Replacing the air filter elements may be required more frequently in extremely dusty conditions.

2. If the air restriction message displays and/or the audible alarm device sounds, shut the engine off and find the cause of the problem.

3. It may be necessary to change and/or clean the filter elements if conditions are particularly dusty.

Never clean the secondary element. It must always be replaced.

4. If the primary element is dry, compressed air can be used to clean the element. Blow compressed air from the inside towards the outside of the element at low pressure. hold the air nozzle at least 3 cm (1 inch) from the filter element. Do not exceed 7 bar (100 psi) with the air pressure.

5. An inspection light can be used to check the filter for pin holes or tears. If any damage is present on the filter, replace the filter.

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE Perform the following when the machine hour meter registers 500 hours or warning gauges so indicate.

SWING GEAR

MACHINE GREASE POINTS Use the following grease: EP NLGI grade 2 MAT 3550 . . . . . (for temperate and hot climates) -20° C to +60° C (-4° to 160° F) EP NLGI grade 0 MAT 3550(for cold climates) -40° C to +20° C (-40° to 68° F) TURNTABLE BEARING TEETH

2 1

3 Figure 34

3-01162E

Remove the inspection port cover (1). Visually check for damage and grease condition.

3-0116E

Figure 33

Apply extreme pressure # 2 grease to the two grease fitting of the turntable bearing. Pump the gun 5 - 10 times as each grease fitting.

If gear surface is not well lubricated, add extreme pressure grease number 2. If grease is white with a high moisture content, replace with new grease.

Contact your authorized dealer for ring gear repairs and grease replacement.

If wa ter h as a ccumulate d, remove the grea se discharge port cover and discharge water.

Remove the grease discharge port plug (2).

Discharge water or cloudy grease. Reinstall the discharge port plug and insert grease through the inspection port (3).

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

5-30

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE OIL CHANGE AND FILTER REPLACEMENT Service Specifications Oil Type . . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Oil Capacity with filter . . . . . . . . 18 Qts. (17.2 Liters) Change the engine oil more frequently than every 500 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

1. Park the machine on a flat, level area. Stop the engine, and remove the starter key. Oil will be easier to change if it is still warm (not hot). Before draining the oil, have a container that will hold the required oil quantity.

D 

F 3-0018

G  30

Figure 37

3. Remove the protective cap (D) from the engine housing drain.

ԙ 2

4. Screw the end of the extension drain hose (G) provided with the machine onto the engine check valve. Place the other end in a container of suitable capacity and allow the oil to drain.

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

Return the extension drain hose to its storage compartment.

3 Ԛ 1Ԙ

3-0051E Figure 35

3-0051E

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL 3. FAN BELT

A

B

E D 3-0138E

A. B. C. D. E.

C

3-013 Figure 36

DIPSTICK OIL FILLER CAP OIL PAN DRAIN PLUG OIL FILTER

2. Remove the oil filter cap (B).

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE

PH08325

CT07K038

Figure 3 38

6. Clean the area around the filter (E) and remove it.

Figure 39

7. To replace the filter, coat the seal of the new filter with a fine film of oil.

8. Install the new filter. Turn the filter until the seal comes into contact with the filter head, and turn an extra half turn by hand.

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

9. Fill the engine with new engine oil. Install the oil filler cap.

10. Run the engine for a few minutes, and make certain there are no leaks. Check the oil level again, and add more oil if necessary.

NOTICE: You must shorten the oil change interval if you use diesel fuel with a sulphur content of more than 0.5%.

NOTICE: Always wait fifteen minutes to allow the oil to return to the sump before checking the oil level.

5-32

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACING THE FUEL FILTER Replace the fuel filter when the hour meter registers 500 hours or more often if conditions require.

1 Ԙ 8 ԟ Ԟ 7

ԙ 2

6 ԝ

Ԛ 3

A

Ԝ 5 3-0016

1.

2.

3.

4.

5.

6.

7.

8.

Figure 41

CT06K099

ԛ 4

3. Clean the area around the filter head.

Figure 40

AIR BLEED PLUG HEAD CASE O-RING DRAIN PLUG O-RING ELEMENT PRIMING PUMP

1. Place a container with a suitable capacity under the filter. Make certain fuel cock (A) is closed.

2. Loosen the air bleed plug and drain plug. Drain the water and dirty fuel.

4. Place a receptacle of a suitable capacity under the filter and remove the filter, using a filter wrench.

5. Apply a thin coat of oil or grease on the new filter seal.

NOTICE: Do not fill the new filter with fuel before installing.

6. Install the new filter. Turn the filter until the seal comes into contact with the filter head. Tighten the body to a torque of 20 ft lbs to 23 ft lbs (27.5 to 31.3 Nm). Do not over tighten. Retighten the bleed plug (2).

Tighten air bleed plug to 8-12 Nm (6 - 9 ft lb).

7. Bleed the system.

NOTICE: If the engine does not regain full power after replacing the filter, bleed the system.

WARNING Drain fuel, using a suitable container, in a well ventilated area away from any source of flame or sparks, including any appliances with a pilot light.

Failure to comply could result in death or serious injury.

M1398.

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE BLEEDING THE SYSTEM It is necessary to bleed the fuel system when:

• The tank has been completely emptied.

• The fuel filter has been replaced.

• Parts of the fuel system have been removed for service or repair.

• The machine has been in storage.

To Bleed The System: 1. Loosen the knob of the priming pump (2).

Loosen the air bleed screw (1). Turn the starter switch key to the “ON” position. Turn the priming pump handle (2) to the left in order to release the spring.

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

5-34

3. When bubbles no longer come out, tighten the air bleed screw (1) and tighten the knob of the priming pump (2). Completely wipe off any spilled fuel. Start the engine, and check for fuel leakage.

WARNING Completely wipe off any fuel spills after replacing a filter element or bleeding the system. Failure to comply could result in death or serious injury.

M646

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Removing The Elements

REPLACING THE AIR FILTER Inspection

1. Release the fasteners and remove the cover(1).

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.

2. Remove the primary element (2).

The hoses should be replaced before they are worn.

3. Remove the secondary element (if equipped).

The secondary element should be replaced at the same time the primary element is replaced.

NOTICE: Do not clean the secondary element. It must be changed, not cleaned.

4

5

Installing The Air Filter Elements

6 4

5

1 6 1 2 CT07K041

3 3-0123E Figure 42

Replace the primary element every 1000 hours. The secondary element should be replaced at the same time. D o no t clea n th e se co nd a r y e le me n t (if equipped). It must be replaced. Replacing the air filter elements may be required more frequently in extremely dusty conditions.

If the air restriction message displays and/or the audible alarm sounds, shut the engine off and find the cause of the problem.

Observe the air filter service intervals, as clean filters mean longer engine life.

2

3

CT07K041

3-0123E Figure 43

4. Install the new secondary element (if equipped).

5. Install the new primary element (2).

6. Install the cover and fasten in place.

7. Check that the dust ejector under the filter is working correctly.

5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE HYDRAULIC SYSTEM Service Specifications Reservoir capacity ....................................................................................................................... 21.4 Gal. (81 Liters) Total system capacity ............................................................................................................... 34.3 Gal. (130 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) NOTICE: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 250 hours of operation. After that, replace these filters at the stipulated interval.

Every 1000 operating hours, it is necessary to have the hydraulic fluid analyzed. See your CASE Dealer.

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components” at the beginning of this section.

NOTICE: If metal filings are discovered in the replaced filters, see your CASE Dealer.

WARNING

WARNING

Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap and press the button on the breather to release all pressure in the system. See Releasing pressure in the Hydraulic System. Failure to comply could result in death or serious injury.

M587

5-36

B097

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE SWING REDUCTION GEAR Service Specifications Oil capacity . . . . . . . . . . . . . . . . . . .3.2 Qts (3 Liters) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP Check swing reduction gear oil level every 250 hours thereafter. An oil change is required at each 1000 hour interval thereafter.

DRAINING AND REFILLING SWING REDUCTION GEAR OIL 1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (3).

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (2).

1

4. Allow the oil to drain.

3

NOTICE: The oil takes a relatively long time to drain.

Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

5. Install the drain plug (2).

Satisfactory amount

6. Add oil through the filler holes (3) until the level is correct.

7. Install the dipstick (1) and the filler plugs (3).

8. Wait ten minutes and check the oil level again.

Add more oil, if necessary.

2

3-0163E

Figure 44

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter switch key.

2. To check the oil level, remove the dipstick (1).

The oil should come up to the hatched area. Add oil if necessary through the filler hole (2).

3. Install the dipstick.

5-37

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE RESERVOIR BREATHER REPLACEMENT Replace the hydraulic oil reservoir breather when the hourmeter registers 1000 hours and ever y 1000 hours thereafter or sooner, if conditions so require.

1 2

1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

3

2. Release all pressure in the hydraulic reservoir.

Se e “ Re le as in g Pre ssu re in th e H yd rau lic System.�

5 4

CS0E528

Figure 45

3. Press the button (1) to release pressure in the hydraulic reservoir.

4. Remove the nut (2) and the cover (3) from the breather.

5. Remove and discard the used filter (4).

6. Install a new element, making sure the seal (5) is facing upwards.

7. Install the assembly.

5-38

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

WARNING

TRAVEL REDUCTION GEARS Service Specifications Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 2.2 Qts. (2.1 Liters) (per reduction gear) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135 H EP Drain and refill the travel reduction gear oil when the hour meter registers 1000 hours or more often if conditions so require.

Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

1

2

3 3-0165E

Figure 46

1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

2. Move the machine so that plug (3) is in the lowest possible position.

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

4. Slowly loosen the plug (1) to release any residual pressure.

5. Place a receptacle of a suitable capacity under the travel reduction gear and remove plugs (3) and (2).

6. Allow the oil to drain.

NOTICE: Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

7. Install plug (3), fill with oil through the plug hole (1) until oil comes up to the bottom edge of plug hole (2).

8. Install plugs and repeat the procedure for the other travel reduction gear.

9. Travel slowly with the machine and make certain there are no leaks.

5-39

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE Perform the following when the machine hour meter registers 2000 hours or warning gauges so indicate.

HYDRAULIC SYSTEM Service Specifications Reservoir capacity ........................................................................................................................ 39 Gal. (147 Liters) Total system capacity .................................................................................................................. 66 Gal. (250 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) NOTICE: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 50 hours of operation. After that, replace these filters at the stipulated interval.

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components”.

NOTICE: If metal filings are discovered in the replaced filters, see your CASE Dealer.

CLEANING THE INLET FILTER 1. Park the machine on a firm, level surface. Keep all non-authorized personnel clear of the area.

Release all pressure in the hydraulic reservoir.

Press the button top of the breather (1). See “Releasing Pressure in the Hydraulic System.”

2 1 3

2. Clean the top of the hydraulic reservoir and the inlet filter cover.

4

A B

3. Remove the cover (2) and O-ring (3) and spring (4) on the top of the inlet filter rod assembly.

C

4. Remove the inlet filter (5) and, replace with a new filter.

D

E

5

3-0160E

3-0160E Figure 47

5. Install a new O-ring (3) and install the inlet filter (5), spring (3), and rod assembly.

6. Install the cover (2).

7. Check the level of the hydraulic fluid and add more if necessary. See “Filling the Reservoir”.

NOTICE: Install a new inlet filter when the hydraulic oil is replaced.

5-40

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE

2

RETURN FILTER REPLACEMENT Replace the hydraulic return filter when the machine is new and the hour meter registers 250 hours.

Replace the hydraulic fluid return filter when the hour meter registers ever y 2000 hours thereafter or sooner if conditions so require.

1 3 4

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic re ser voir. Se e “ Re le as in g Pr ess ure in th e Hydraulic System.” Clean the top of the hydraulic reservoir and clean the return filter cover.

A B C D

2. Remove the upper plate (2) on the hydraulic reservoir.

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

E

5

3-0160E

3-0160E Figure 48

4. Remove the cover (A) and O-ring (B).

5. Take out the spring (C), valve (D) and return filter (E).

6. Install a new filter. Clean the spring (C) and valve (D) and assemble them.

7. Check O-ring (B), and replace it if worn or damaged.

8. Install the cover (A).

9. Check the level of the hydraulic fluid and add m o r e fl u id , if n e c e s s a r y. S e e “ Fi lli n g th e Reservoir”.

5-41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS GREASE SWING REDUCTION GEAR

2000 HOUR MAINTENANCE PILOT FILTER REPLACEMENT

1

2

1 ①

② 2 3-0033

3-0033 Figure 49

PILOT FILTER LOCATION

Replace the pilot filter when the machine hour meter registers 250 hours during the initial run-in period.

Th e p ilot filter will be r eplac ed a t 20 00 hou rs thereafter, or sooner if conditions so require.

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic s y s t e m . S e e “ R e l e a s i n g P r e s s u r e in t h e Hydraulic System.”

2. Use a wrench on the bottom of the filter body (2) to unscrew and remove it.

3. Remove the old filter.

4. Clean the filter body in solvent and wipe dry with a cloth.

5. Coat the new filter with clean hydraulic fluid.

Install the new filter on the head (1).

6. Install the filter body and tighten by hand. Do not overtighten.

5-42

3-0164E

3 0164E Figure 50

Grease the swing reduction gear every 2000 hours or sooner if conditions so require.

Remove the lower panel, and remove the air bleed plug (1). Refill with grease through the grease point (2). A small amount of grease will run out from the air bleed plug. When greasing, if the air bleed plug is not removed, the inner seal will be damaged.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 4000 HOUR MAINTENANCE DRAINING AND FILLING THE COOLING SYSTEM

Draining

Service Specifications System capacity . . . . . . . . . . . 14.8 Qts. (14.0 Liters) Type . . . . . . . . . 50% water and 50% Ethylene Glycol

1

Drain the engine coolant when the hour meter registers 4000 hours, flush the system, and refill with new coolant. If the low coolant or overheat message displays and/or the audible alarm device sounds, shut the eng ine off, an d fin d the ca use o f th e problem.

2

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

3-0139E Figure 51

CT07K026

1. Using the starter switch key, open the access hatch, then remove the radiator cap (1).

2. Have a receptacle of suitable capacity ready.

Open the radiator drain valve (2).

WARNING Do not remove the radiator cap when the engine is hot. The system is still under pressure, and you could be scalded. Failure to comply could result in death or serious injury.

B097

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 le a k a g e . D o n o t u se n o n - a p p r o ve d a n t i- r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

Coolant Level The level of coolant solution should be checked when the engine is cold. Check coolant level on firm, level ground, before using the machine (while the engine is still cold). The level in the expansion reservoir should be between the “Full” (1) and “Low” (2) marks.

If not, see “Filling”.

3 Ԛ 3-0056E CT06M028

Figure 52

3. Open the drain plug located on the engine block (3) an d dra in in to a rece pta cle of su ita ble capacity. Allow the radiator to completely empty.

5-43

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 4000 HOUR MAINTENANCE Flushing 1. Close the drain valve once the radiator is completely empty. Close the plug on the engine block.

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

3. Keep all non-authorized personnel clear of the machine. Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80° C (176° F).

4. Drain the system once more.

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

5-44

Filling 1. Fill with coolant solution via the radiator (1) until it overflows, install the radiator cap, then lock the access hatch.

2. Fill the expansion reservoir to the “Full” mark and install the cap.

NOTICE: Use the correct coolant solution.

3. Run the engine at idle speed for about five minutes. Add coolant solution if the level in the expansion reservoir drops.

NOTICE: Do not fill the expansion reservoir above the “Full” mark.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE Service Specifications Reservoir capacity ........................................................................................................................ 39 Gal. (147 Liters) Total system capacity .................................................................................................................. 66 Gal. (250 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) NOTICE: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 50 hours of operation. After that, replace these filters at the stipulated interval.

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components”.

NOTICE: If metal filings are discovered in the replaced filters, see your CASE Dealer.

REPLACING THE HYDRAULIC FLUID 1. Keep all unauthorized personnel clear of the area. Release all pressure in the hydraulic reservoir. Press the breather button (1). See “Releasing Pressure in the Hydraulic System.”

1 2 3

2. Remove the reservoir cover plate (2) and O-ring (3).

3. Using a pump, remove the fluid from the hydraulic reservoir. Have a container with a suitable capacity ready.

6

4

5

3-0157E 3-0157E

Figure 53

4. Remove the drain plug (5) to remove the remaining fluid from the reservoir.

5. Replace the inlet filter (4)and return filter (6). See Cleaning and Replacement of the Inlet Filter and Return Filter in this section. Install the reservoir drain plug.

6. Put new hydraulic fluid into the reservoir. See “Filling the reservoir”. Install the reservoir cover plate and seal.

5-45

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE 7. Before you start the engine, it is very important t h a t y o u bl e e d a i r f r o m a l l t h e hy d r a u l i c c o m p o n e n t s. S e e “ B le e d in g A ir f r o m t h e Hydraulic Components�.

8. Start and run the engine with no load for approximately five minutes. Move each control slowly several times to remove any air in the system.

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

10. Place the machine in position, and then stop the engine.

11. Check the oil level in the hydraulic reservoir and add oil as required. Make sure there are no air bubbles in the hydraulic reservoir.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

WARNING Attempting to operate a machine with malfunctioning or leaking components could cause death or serious injury. You must repair or replace any items found to be malfunctioning or leaking BEFORE operating the machine. Failure to follow these instructions could cause death or serious injury.

M1588

WARNING Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, seek medical attention immediately. Failure to comply could result in death or serious injury.

5-46

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Track Shoe Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator And Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan And Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting And Cleaning The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5 6-5 6-6 6-7 6-7

REPLACING A BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 HARDWARE TORQUE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS NOTICE: If tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after working.

Cleaning

Checking Track Tension

When the machine has been working in mud, a reduction in temperature can cause the mud to solidify.

1. Park the machine on firm, level ground. Keep all non-authorized personnel clear of the area.

2. Clean the tracks.

. .

3-0167 CS01D529A

Figure 1

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm, level ground.

CS01D529

2. Position the upper structure at right angles to the undercarriage. Use the attachment to press on the ground, and lower the boom until the track is raised off the ground.

4. Use the travel control lever to operate the raised track in reverse for a few moments.

3. Use the travel speed selector to select high speed.

4. Operate the travel control lever for the raised track forwards and then in reverse, to remove the mud.

Figure 2

3. Place the upper structure at right angles to the undercarriage. Use the attachment to press on the ground, and lower the boom until the track is raised off the ground.

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

5. Repeat Steps 1 to 4 for the other track.

3-0065 PEO7531

Figure 3

6. Iron Track: Measure the sag of the track at the center between the base of the undercarriage and the pad. The value should be 9.4 to 10.2 in (240 to 260mm).

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS To Reduce Tension

.

WARNING

3

Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

M1720

3-0168E

Figure 4

7. Link Chain Track: Measure the sag of the track at the cente r be twe en th e base of th e undercarriage and the pad. The value should be 8.7 - 9.4 in (220 - 240 mm).

8. Adjust tension if necessary and then lower the raised track to the ground.

9. Repeat Steps 3 to 7 for the other track.

Make any necessary track adjustments after the track tension has been checked.

To Increase Tension .

3-0066 Figure 5

1. With the track in raised position, clean the grease fitting adaptor, and connect the grease pump hose to the grease fitting.

2. Connect the grease pump. Inject grease to obtain the right amount of track tension. The value should be 9.44 to 10.24 in (240 to 260 mm). R emove the gr ease pump, cle an th e grease fitting, and then lower the raised track to the ground.

3. Repeat Steps 1 to 3 for the other track.

6-4

2. When the correct track tension is obtained, tighten the adaptor. The value should be 9.44 to 10.24 in (240 to 260 mm).

3. Clean the grease adaptor and fitting.

4. Lower the raised track, and repeat Steps 1 to 3 for the other track.

Adjusting Tension

CT06M032

1. With the track in raised position, loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder.

5. If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting a d a pto r re g ula r ly, a n d re pla ce it, if necessary.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK SHOE BOLT TORQUE

RADIATOR AND OIL COOLER

Check track shoe bolt torque every 250 hours of machine operation.

Clean the radiator and oil cooler area every 500 hours. Check daily or at ever y 10 shift for any leakage.

1

3

4

2

Figure 6

CS00E504

Tighten in the order shown.

Tighten the track shoe bolts to a torque of: 267 Nm - 312 Nm (197 ft lbs - 230 ft lbs).

3 0140E Figure 8

3-010E

TRACK ROLLERS AND IDLER WHEELS

1. Keep all non-authorized personnel clear of the area. Stop the engine and remove the starter switch key.

2

2. Open the radiator access door and secure with the supporting strut.

3. Clean the radiator and compressed air or water.

oil

coolers

using

4. Reinstall the protective grille and wing nuts.

5. Close and secure all access doors prior to any machine travel.

3-0166E

Figure 7

Check the track rollers and idler wheels every 250 hours.

The upper and lower rollers and idler wheels use a permanent floating seal type sealing mechanism.

This configuration will normally last until overhaul, but visually check for oil leakage. If any leakage is visible, consult your authorized dealer.

WARNING Use safety type cleaning devices and wear full face protection if using pressurized water jets Failure to comply could result in death or serious injury.

M1720

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Tension Adjustment

FAN AND ALTERNATOR DRIVE BELT Check the fan and alternator drive belt tension when the hour meter registers 500 hours. Adjust or the replace the belt if necessary.

Visually check the fan and alternator drive belt daily.

3 Ԛ 1 Ԙ

Tension Check

2 ԙ

3-0024 Figure 10

3-0024

To adjust tension, loosen the mounting bolts (1). Use the adjustment screws (2) to move the alternator outwards until belt tension is correct. Retighten the pulley attachment and alternator mounting bolt.

CS98M560

Figure 9

With the engine off, and the star ter switch key removed, press the center of the belt, exerting a pressure of about 10 kg (20 lbs). The belt deflection should be about 10 to 15 mm (.4 to .6 in).

Check if there are any signs of wear damage to the pulleys or the belt. Check carefully to insure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

Replacing Drive Belt

3 Ԛ 1 Ԙ

2 ԙ 3-0024

3-0024 Figure 11

1. Remove the retaining screws (1) and (2). Use the adjustment screws (3) to push the alternator inwards.

2. Remove the worn belt.

3. Install a new belt. Adjust the belt using the screw (3).

4. Tighten the retaining screws (1) and (2).

5. Run the engine for about an hour, and then check the belt tension again.

If the engine runs with the belt slack, the belt can slip in its housing and cause the engine to overheat or the battery to receive insufficient charge.

6-6

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL TANK FILTER

INSPECTING AND CLEANING THE MACHINE

The fuel tank screen should be cleaned periodically.

In spect an d clean the machin e periodica lly or whenever oil or grease has been spilled on the machine. Clean off with steam or a high pressure water jet. Use personal protection equipment when cleaning the machine.

1

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 c o n d it i o n o f a ll p ip e s a n d h o s e s . R e p a ir a l l maintenance issues found.

2

3

Figure 12

3-0134E

1. FILTER SCREEN 2. FILL PORT 3. FUEL TANK

Remove the screen and clean it in diesel fuel.

NOTICE: To refill the fuel tank, see “Fluids and Lubricants� in the Lubrication/Filters/Fluids Section.

WARNING Do not smoke or work near any open flame when fueling or working on the fuel system. Clean up any spilled fuel. Failure to comply could result in death or serious injury.

M1398.

WELDING ON THE MACHINE Whenever carrying out a welding operation on the u nd e rca r r ia g e or u p pe r str u ctu r e ca rr ia ge a s authorized by the manufacturer and in accordance with his instr uctions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed. Never connect the welding apparatus to the undercarriage when welding on the upper structure (or vice-versa). Never connect the welding apparatus ground to a component of the hydraulic system.

NOTICE: Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF.

WARNING Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer. Failure to observe these instructions could cause injury.

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Checking For Cylinder Leakage A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

3. Extend the cylinder rod.

4. Carry out the leak test by applying a piece of paper to the rod.

1. Wipe the cylinder rod and bearing off.

2. Operate normally for five or ten minutes.

Rod appearance Dry Slightly oily Oily

Test Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

PLASTIC AND RESIN PARTS When cleaning plastic parts such as the instrument console or the control arms, do not use gasoline, kerosene, paint solvents, etc. Use soap and water and a clean cloth only.

The use of gasoline, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

FIRE EXTINGUISHER A f i re ex ti n g u i s h e r o n t h e m a c h in e i s h ig h ly re co mme nd e d. Eve r y mo nth exa min e th e f ir e extinguisher and make certain it is in good working order. Ever y six months, have the extinguisher checked by a certified supplier. Have any necessary mainten ance to th e extinguisher perfor med to maintain optimum working order.

6-8

Conclusion

Consult your CASE Dealer

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CAB PROTECTION (FALLING OBJECT PROTECTION - OPTION) An optional F.O.P. (Falling Object Protection) will protect the cab from falling objects. Check the FOPS at the 50 hour run-in period and every 250 hours thereafter.

Check the FOPS retaining hardware. Retighten and hardware as necessary. Check to make certain there are no cracks, rust, or holes that can compromise the FOPS protective features.

If the protective structure has suffered any damage due to an accident, it is necessary to replace the damaged components. Do not weld or alter the FOPS.

WARNING Yo u r m a c h i n e is e q u i p p e d w it h a n o p e ra to r Protective Structure, such as: Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS).

Th e Pr o te c ti ve St r u c tu r e is a sp e c ia l sa fe t y component of your machine.

D O N OT a tta ch a ny d ev ice to th e Pro te ctive Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

The Pro tective Str uctu re a nd interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Pro tective Stru cture. Co ntact yo ur d ea le r fo r Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: The protective structure MUST be replaced.

The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

All damaged parts MUST be replaced.

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

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING A BUCKET REMOVAL 1. Keep all non-authorized personnel clear of the area. Position the bucket flat on fir m, level ground. Operate the attachment controls so that the arm/bucket linkage pin is not held in place by the weight of the arm.

2 ԙ

1 Ԙ

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

Ԛ 3 Ԛ 3

2ԙ Ԛ 3

4ԛ

Figure 14

2-0058

Ԝ5

2-0058

7. Start the engine, disengage the attachment from the bucket and retain the linkage seals for reuse.

INSTALLATION 1. Make sure the bucket is in a stable position.

Ԙ 1 2-005 2-0057

Figure 13

3. Remove the retaining rings and pins.

4. Remove the bucket pins (2, 3, 4, 5).

5. If the pins are difficult to remove, it may be necessary to slightly change the position of the bucket.

6. Use care not to damage O-rings and seals and do not allow dirt or debris to adhere to them.

2. Install the linkage seals on the arm bushing shoulders. Change them if necessary.

3. Keep all non-authorized personnel clear of the ar ea . Sta r t th e e n gine. Exte nd th e bu cket cylinder rod to bring it into its housing. Stop the engine, and remove the starter switch key.

4. Install the arm/bucket linkage pin and then install the retaining pin and ring.

5. Start the engine, and bring the bucket connecting rod into its housing. Stop the engine, and remove the starter switch key.

6. Install the connecting arm/bucket linkage pin, and then install the retaining pin and ring.

7. Push the seals back into their housing.

8. Adjust the arm/bucket shimming.

9. Grease the linkages.

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

6-10

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Shimming the Bucket

REVERSING THE BUCKET

4

2 D

5

3

C ࠑ 2-0059 2-0059

G

Figure 15

1. Remove the bucket. Slightly raise the arm and turn the bucket 180°. Reattach bucket to arm.

Press bucket against ground to make cer tain connections are secure.

2. When bucket is turned over, it works as a shovel.

The operation of bucket levers (digging and dumping) are reversed.

1 Ԙ F

G

ԙ Ԛ

E

A

B

2-0080

1.

2.

3.

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

3-0080 Figure 16

SOCKET HEAD BOLT PLATE SHIM PLATE DUST SEAL O-RING ARM CLEARANCE STEEL BUSHING ATTACHMENT PIN BUCKET

Side Play Adjustment 1. Place the bucket firm on level, firm ground.

2. Check the play between the arm and the bucket ear.

3. If the play exceeds 2 mm (.07 in), remove the four screws, the cap and the shims.

4. Use the shims as a feeler gauge to determine the number of shims necessary to take up the play.

5. Install the necessary number of shims.

6. Install the cap (1) and the four screws.

NOTE: When the screws in the cap are tightened, the inner bushing moves toward the arm and takes up the play.

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap has an orifice on its inside surface. When installing the cap, make certain the lug is inside this orifice.

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TEETH AND TOOTH TIP WEAR LIMITS

1. Clean the mating surface on the adaptor.

The degree to which teeth or tooth tips are worn can be assessed visually.

2. Install a new tooth tip up to the stop, turning it to the right and holding it in this position.

It is possible to extend the life of teeth or tooth tips which are wearing unevenly in a non-symmetrical fashion by interchanging them regularly.

3. Place the locking pin in position, and strike it until it is flush with the tooth tip.

NOTICE: Do not wait for teeth or tooth tips to be completely worn through before changing them.

Never try to work with a missing tooth tip or a tooth tip which is worn through. The adaptor could be seriously damaged.

NOTICE: Check to make certain tooth is securely fastened.

When replacing a tooth tip, it is advisable to replace the locking pin at the same time.

Side Pin Bucket Tooth

Replacing a tooth on the bucket

A

B D

2ԙ

E

3Ԛ C

1Ԙ

ԛ 4

3-0068

Figure 17

3-0068

1.

2.

3.

4.

TOOTH BLOCK PIN RUBBER PIN ADAPTER

3-0096 Figure 19

3-0096

Using a hammer and punch, drive the lock pin (C) from the tooth (E).

INSTALLATION

D

REMOVAL 1. Keep all non-authorized personnel clear of the area. Position the bucket a few inches above the ground. Stop the engine and remove the starter switch key.

E

2. Use a drift to remove the locking pin from its housing by striking it with a hammer until it is ejected.

B

3. Remove the worn tooth tip, turning it to the left.

INSTALLATION

A 3-0097

1 Ԙ

Figure 20

1. Clean the mating surface on the adaptor.

2. Install a new tooth tip up to the stop.

A

B

3. Place the locking pin in position, and strike it until it is flush with the tooth tip.

C 3-0070

3-0070

6-12

Figure 18

NOTICE: Check to make certain tooth is securely fastened.

When replacing a tooth tip, it is advisable to replace the locking pin at the same time.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning systems and the safety precautions which must be followed. Failure to comply could result in death or serious injury.

SA048

Lubrication Of The Air Conditioning Compressor Seals Operate the air conditioning once every 250 hours to lu b r ic a te t h e c o mp re ss o r s e a ls. Tu r n t h e a ir conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a cover over the air conditioning condenser. This will allow the refrigerant and lubricants in the system to be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

NOTICE: Because the condenser fins bend easily, use care when cleaning the condenser.

Inspection In order to insure the air conditioning functions correctly, inspect the a ir conditioner using the procedure outlined below prior to starting work.

Cleanliness of the Condenser If the condenser is dirty, it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

Check the Air Conditioning Lines Make a visual check of lines and make certain there is no accumulation of dust, grease, etc.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AIR CONDITIONING DRIVE BELT

Checking The Air Conditioning Circuit Charge Level

A

C

B

3Figure 0171E 21

3-0171E

1. Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

A

CS00E555

B

C

3-0081 Figure 23

With engine off, exert pressure of approximately 10 kg (22 lb force) on the center of the air conditioning drive belt. The amount of deflection should be between 6 to 8 mm (.2 to .3 in). Adjust the tension of the belt if necessary.

Figure 22

2. This check should be made approximately one minute after turning on the air conditioning.

A. Few bubbles observed. Transparent at first, then whitish. “Normal�.

B. Many bubbles. Check all connections and see your CASE Dealer.

C. No bubbles visible. Check all connections and see your CASE Dealer.

3. Check the air conditioning connectors to make certain they are not dusty or dirty.

6-14

3-0081

3-0082

Figure 24

Visually inspect all connecting lines and hoses.

Periodically clean any debris, oil, etc.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING THE AIR INTAKE FILTER

CLEANING THE AIR RECYCLING FILTER 1. The air recycling filter should be cleaned every 5 0 h o u rs. Th e filte r is lo c at e d b e hin d th e operator’s seat. Remove the access panel and take out the filter (2).

NOTICE: Use a safety type air gun and always protect your face before using compressed air.

2. Clean the filter (1) with compressed air. Replace the filter if it is damaged.

3. Install the filter and the access panel.

1

2 3-0170E

3-0170E Figure 25

1. Clean the air intake filter every 50 hours.

NOTICE: Use a safety type air gun and always protect your face before using compressed air.

2. Remove the filter, and clean it with compressed air. Replace the filter if it is damaged.

3. Install the filter in its housing with the seal on the inside.

4. Close the panel and install the screws.

5. Install the sealing cover and the screws.

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

HARDWARE TORQUE INSPECTION At the end of each working day, check all mounting nuts and screws for tightness and tighten, if necessary. Make sure no hardware items are missing. Replace them, if necessary.

TORQUE SPECIFICATIONS PER COMPONENT

Component

Bolt Size

Torque (Ft.Lbs)

Torque (Nm)

Travel reduction gear (*)

M16

197-230

267-312

Drive sprocket (*)

M16

197-230

267-312

Idler wheel (*)

M16

197-230

267-312

Upper roller (*)

M20

384-448

521-608

Lower roller (*)

M18

274-319

371-432

Chain guide (*)

M18

295-341

400-462

Track shoe

M20

221

300 + 120°

Counterweight

M33

1373-1518

1862-2058

Turntable undercarriage

M20/M24

345-402 578-674

468-545 784-914

Turntable upper structure

M20/M24

345-402 578-674

468-545 784-914

Swing reduction gear (*)

M20/M24

398-465 578-674

539-630 784-914

Engine (*)

M16

152-202

206-247

Engine mounts (*)

M10

47-54

64-73

Radiator

M16

108-131

147-177

Hydraulic pump (*)

M10 M20

47-54 271-366

64-73 367-496

Hydraulic reservoir (*)

M16

171-204

232-276

Fuel tank (*)

M16

171-204

232-276

Control valve (*)

M16

243-266

330-360

Hydraulic swivel (*)

M12

79-139

107-188

Cab

M16

116

157

Battery

M10

15-21

20-29

NOTICE: Use Loctite 262, or the equivalent, on bolts marked (*).

6-16

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

108 to 132

12 to 15

5/16 inch

204 to 252

23 to 28

3/8 inch

420 to 504

48 to 57

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

7/16 inch

70 to 84

95 to 114

1/2 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

NOTE: Use thick nuts with Grade 8 bolts.

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-18

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Checking The Battery Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Connecting Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Replacing A Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY

WARNING

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

Failure to comply could cause death or serious injury.

84-109

WARNING Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Insure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries. Failure to comply could cause death or serious injury.

1c02

WARNING Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply could result in death or serious injury.

Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause serious injuries. Failure to comply could result in death or serious injury.

84-109

WARNING Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause serious injuries. Failure to comply could result in death or serious injury.

84-109

WARNING When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. Failure to comply could result in death or serious injury.

SAO46

84-109

WARNING

WARNING WARNING: Battery acid causes severe burns.

Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

Before any operation on the components of the electrical circuit, turn the key switch to the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last. Failure to comply could result in death or serious injury.

IC02

EYES: flush with water for 15 minutes and get prompt medical attention. Failure to comply could result in death or serious injury.

SB032

7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dir t, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the container.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

BATTERY FLUID LEVEL Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

In extreme heat conditions check battery fluid every 250 hours.

IMPORTANT: If the temperature is 0° C (32° F) or below and you have added water to the batteries, you must: Connect a battery charger to the batteries or operate the machine for approximately two hours.

This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Che ck th e ba tte ries and batter y co mpar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

7-4

CHAPTER 7 - ELECTRICAL REPLACING A BATTERY

CHECKING THE BATTERY ELECTROLYTE LEVEL

Terminal side

Electrolyte level is low

Removal

Do not add the solution above the UPPER level line.

1-0120E 1-0120E

1-0037E

Figure 1

Most new batteries require little or no maintenance.

Should it be necessary to check fluid levels, remove the cell caps and check the level in each cell. The level should be between 10 and 15 mm (.3 to .5 in) above the plates. Add distilled water if necessary, then install the cell caps.

NOTICE: When adding distilled water at temperatures below 0° C (32° F), the batteries must be charged or the engine run for two hours approximately in order to insure that the distilled water and the electrolyte are properly mixed.

NOTICE: Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

Figure 2

Remove the terminal protection caps, disconnect cables at negative terminals and then disconnect cables at positive terminals. Remove the anti-sulfate pellets from the posts.

Remove the two screws, the washers and metal sheet. Remove the old battery.

Install the new batter y and put the metal sheet, washers and screws back in place.

Clean the cables and battery terminals, and coat them with grease.

Install new anti-sulfate pellets, reconnect positive cable ends to positive ter minals first and then negative cable ends to negative terminals. Install the terminal protection caps.

7-5

CHAPTER 7 - ELECTRICAL CONNECTING BOOSTER BATTERIES

WARNING An error connecting auxiliary cables or short circuiting battery terminals can cause an accident. Make certain booster batteries and cables are connected correctly. Failure to comply could result in death or serious injury.

CE-NA000

WARNING Before carrying out any service work on electrical system components, turn the starter switch key to the “OFF� position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last. Failure to comply could result in death or serious injury.

IC02

Make sure that the voltage of the booster batteries is the same as that of the machine system.

1. Turn off the ignition and all accessories on the machine(s). Remove the battery terminal covers.

2. Connect one end of the positive (+) cable to the positive (+) ter minal on the booster battery.

Connect the other end of the positive (+) cable to th e positive (+) ter minal of th e discharge d battery.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

5. Start the engine.

6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

7. Install the terminal covers.

7-6

CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS NOTICE: Before replacing a fuse, turn the starter switch key to “OFF”.

NOTICE: Never replace a fuse with a fuse of a different amperage.

To gain access to the fuses, open the panel at the rear of the operator’s compartment, and remove the cover.

To access the fuses, remove the cover of the box.

A n o tice o n th e cove r g ive s th e fu n ct io n a n d amperage of each fuse.

NOTICE: To remove or install a fuse, use the notch in the upper right-hand corner of the cover.

NOTICE: Two spare fuses (10 amp and 20 amp) can be found on the inside of the fuse box cover.

BACK UP (RADIO)

REFUEL PUMP

10A

20A

ENGINE PRE-HEAT

CIGAR LGT KAB SEAT

30A

15A

OPTION LINE

OVER LOAD WARNING

10A

10A

AIRCON UNIT

DC-DC CONVERTER

5A

10A

AIRCON BLOWER

TRAVEL ALM BEACON

15A

10A

AIRCON COMPRESSOR

MONITOR

5A

10A

SOLENOID

FUEL FEED PUMP

10A

10A

WIPER WASHER

OPTION POW (SPARE)

15A

15A

HORN

LOCK LEVER (GATE)

10A

10A

LAMP

SERVICE TOOL

15A

10A KHR19920

1-0119E

1-0119E Figure 3

7-7

CHAPTER 7 - ELECTRICAL

NOTES

7-8

CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 MONOBLOC BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 MACHINE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

CHAPTER 8 - SPECIFICATIONS

ENGINE SPECIFICATIONS NOTICE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

SPECIFICATIONS ENGINE Latest "common rail" engine, in conformity with the European requirements applicable to low fumes emission, in accordance with the directive 97/69/EC 3A. Make and type ..................................................................................................................................... ISUZU AJ-4JJ1X Common rail, intermediate cooler, fuel cooler ...........................................................................................................Yes Injection......................................................................................................................................Electronically controlled Turbocharged..............................................................................................................................................................Yes Number of cylinders....................................................................................................................................................... 4 Bore/stroke....................................................................................................... 95.4 mm x 104.9 mm (3.76 in x 4.13 in) Displacement ................................................................................................................................. 2999 cm3 (413 cu in) Cooling....................................................................................................................................................................Water Battery starting ......................................................................................................... 2 12/24 V batteries, 72 A/h WORKING CONDITIONS Speed................................................................................................................................................................2000 rpm EEC 80/1269 power .............................................................................................................................. 70.9 kW (96 hp) Engine oil capacity ............................................................................................................................ 17.2 l (18 quarts) Fuel tank capacity .................................................................................................................................. 165 l (43.6 gal) Fuel filler pump ............................................................................................................................................. if equipped Engine/pump assembly mounted on flexible mountings.

Filtration in dusty conditions.

Electronically controlled governor.

HYDRAULIC SYSTEM Variable flow piston-type double pump.

Main pump max flow (at 2000 rpm) ..................................................................... 2 x 117 l/min (2 x 124 qts/min) Fixed flow pump (pilot circuit).

Max. flow .......................................................................................................................... 20 l/min (21.1 qts/min) Working pressure.

Attachment/power boost ........................................................................................343/363 bar (4975/5265 PSI) Oil cooler with air cooling from engine.

Self-lubricating hydraulic swivel Hydraulic reservoir capacity........................................................................................................... 81 l (85.6 qts) Total hydraulic system capacity .................................................................................................... 130 l (34.3 gal)

8-3

CHAPTER 8 - SPECIFICATIONS SWING Fixed flow, piston-type pump.

Automatic disk brake.

Upperstructure swing speed .............................................................................................................................10.0 rpm TRAVEL Two speed hydraulic motors with axial pistons Planetary reduction gears.

Low speed.................................................................................................................................. 0 to 3.1 km/h (2.0 mph) High speed................................................................................................................................. 0 to 5.0 km/h (3.1 mph) Gradeability...............................................................................................................................................................70% ATTACHMENT Digging force with 2.39 m Arm - 0.5 m3 bucket (7.8 ft Arm - 17.6 cubic ft bucket) Arm digging force ............................................................................................................................. 63.9 kN (140 lbf) Bucket digging force ......................................................................................................................... 89.7 kN (198 lbf)

UNDERCARRIAGE One-piece frame with welded components.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks........................................................... 500 mm, 600 mm and 700 mm (19.7 in, 23.6 in, and 27.6 in) Ground pressure with 600 mm track pads and with 2.39 m Arm - 0.5 m3 bucket (7.8 ft Arm - 17.6 cubic ft bucket) Pressure ...............................................................................................................................................0.36 bar (5.2 psi)

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, double horn.

Safety valves with overload indicator ..................................................................................................................optional Inertia reel type safety belt.

Fire extinguisher ..................................................................................................................................................optional

8-4

CHAPTER 8 - SPECIFICATIONS

OPERATOR'S COMPARTMENT Deluxe operator's seat with armrests, inertia type safety belt, multi-position adjustment and headrest Hydraulically assisted controls.

Attachment and swing .............................................................................................................................2 control levers Dozer blade (if equipped) ......................................................................................................................... 1 lever Speed programmer, also provides automatic speed change.

Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation/air conditioning, cab lights, cigarette lighter, 12 V socket, sun shield, optional air conditioner.

Working lights: One on upperstructure............................................................................................................... 24 V (70 W) One on attachment ................................................................................................................... 24 V (70 W) Two on cab................................................................................................................................ 24 V (70 W)

CAB Removable, sound proof, mounted on flexible mountings Foldaway windscreen Rear window emergency exit Sun shield Sliding windows on door Roof curtain Roof hatch Windshield protection grid (optional) Cab protection (optional)

8-5

CHAPTER 8 - SPECIFICATIONS

WEIGHT

Operating weight with 2.39 m Arm - 0.5 m3 bucket (7.8 ft Arm - 17.6 cubic ft bucket), 600 mm show, operator, lubricant, coolant, and full fuel tank ......................................................................................... 13 500 kg (29 762 lbs) Shipping weight with 2.39 m Arm - 0.5 m3 bucket (7.8 ft Arm - 17.6 cubic ft bucket) 9/10 fuel tank capacity 12 900 kg (28 440 lbs)

ARMS Length................................................................................................................................................... 2.39 m (7.8 ft) Length................................................................................................................................................... 2.85 m (9.4 ft)

BACKHOE BUCKETS GENERAL PURPOSE SAE capacity (l)

190

260

330

450

560

640

720

800

Width - mm Width - in

350 14

450 18

600 24

750 30

900 35

1000 39

1100 43

1200 47

Weight - kg Weight - lb

270 595

300 661

330 728

370 816

410 904

440 970

470 1037

490 1080

HEAVY DUTY

DITCH CLEANING WITH TEETH OR BLADE

TRAPEZOID

SAE capacity (l)

640

720

300

620

760

340

Width - mm Width - in

1000 39

1100 43

2200 87

1500 59

1800 71

350-2100 14-83

Weight - kg Weight - lb

450 992

485 1009

430 947

469 1033

492 1085

363 800

DOZER BLADE (if equipped) Width .................................................................................................................................................... 2.59 M (8.5 ft) Height ................................................................................................................................................. 0.57 m (1.88 ft) Maximum lift height............................................................................................................................. 0.44 m (1.44 ft) Min drop below ground ....................................................................................................................... 0.52 m (1.71 ft)

8-6

CHAPTER 8 - SPECIFICATIONS

MACHINE OVERALL DIMENSIONS MONOBLOC BOOM 2.39 M (7.8 FT) AND 2.85 M (9.4 FT) ARM AND DOZER BLADE N D

E C

A B F

M K J L CS00K509C

G H I 1

(A) 2.39 m (7.8 ft) arm .......................................................................................................................... 2.75 m (9.0 ft) (A) 2.85 m (9.4 ft) arm .......................................................................................................................... 2.60 m (8.5 ft) (B) ......................................................................................................................................................... 2.75 m (9.0 ft) (C)......................................................................................................................................................... 2.75 m (9.0 ft) (D)......................................................................................................................................................... 2.42 m (7.9 ft) (E) ......................................................................................................................................................... 1.75 m (5.7 ft) (F) ......................................................................................................................................................... 0.89 m (2.9 ft) (G) ........................................................................................................................................................ 2.79 m (9.2 ft) (H)....................................................................................................................................................... 3.51 m (11.5 ft) (I) (with dozer blade) 2.39 m (7.8 ft) arm ........................................................................................... 7.75 m (25.5 ft) (I) (with dozer blade) 2.85 m (9.4 ft) arm ........................................................................................... 7.72 m (25.3 ft) (J) ......................................................................................................................................................... 1.99 m (3.5 ft) (K) (standard track pads) .................................................................................................................... 0.60 m (1.96 ft) (L) with 600 mm (23.6 in) track pads .................................................................................................... 2.59 m (8.5 ft) (M) ........................................................................................................................................................ 0.44 m (1.4 ft) (N)....................................................................................................................................................... 7.23 m (23.7 ft)

8-7

CHAPTER 8 - SPECIFICATIONS MONOBLOC BOOM 2.39 M (7.8 FT) AND 2.85 M (9.4 FT) ARM N D

E

C

B

A

F

M K J L

G H

CS00K509D

2 (A) 2.10 m (6.9 ft) arm .......................................................................................................................... 2.71 m (8.9 ft) (A) 2.50 m (8.2 ft) arm .......................................................................................................................... 2.81 m (9.2 ft) (B)......................................................................................................................................................... 2.79 m (9.2 ft) (C)......................................................................................................................................................... 2.82 m (9.3 ft) (D)......................................................................................................................................................... 2.54 m (8.3 ft) (E)......................................................................................................................................................... 2.13 m (7.0 ft) (F) ......................................................................................................................................................... 0.89 m (2.9 ft) (G) ...................................................................................................................................................... 3.04 m (10.0 ft) (H)....................................................................................................................................................... 3.76 m (12.3 ft) (J) ......................................................................................................................................................... 1.99 m (6.5 ft) (K) (standard track pads) ....................................................................................................................0.60 m (23.6 in) (L) with 600 mm (23.6 in) track pads .................................................................................................... 2.59 m (8.5 ft) (M) ......................................................................................................................................................0.44 m (17.3 in) (N) 2.39 m (7.8 ft) arm ........................................................................................................................ 7.24 m (23.8 ft) (N) 2.85 m (9.4 ft) arm ........................................................................................................................ 7.23 m (23.7 ft)

8-8

CHAPTER 8 - SPECIFICATIONS

WORKING RANGE

BKMU7006

Figure 1

8-9

CHAPTER 8 - SPECIFICATIONS

WORKING RANGE

BKMU7006

8-10

Figure 2

CHAPTER 8 - SPECIFICATIONS

Bolt and Nut Torque • After the first 50 hours/Maintenance: every 250 hours Tighten the bolts and nuts according to the table. After daily work, check the bolts and nuts for looseness and for any missing. Tighten if loose and replace if missing.

Tighten the bolts and nuts after the first 50 hours of operation and every 250 hours thereafter.

Tightening Torque Table No.

Tightening Point

Bolt Diameter

Wrench

M16

24mm

Tightening Torque [N•m]

①

Travel Motor

267-312

②

Drive Sprocket

M16

24mm

267-312

③

Take-up Roller

M16

24mm

267-312

④

Upper (Carrier) Roller

M16

24mm

267-312

⑤ 6

Lower (Track) Roller

M16

24mm

267-312

Shoe Bolt

M16

24mm

267-312

7

Counterweight

M30

46mm

1335-1550

8

Turntable Bearing (Lower Frame)

M16

24mm

280-312

9

Turntable Bearing (Swing Frame)

M16

24mm

280-312

⑩

Swing Equipment

M16

24mm

280-312

⑪

Engine (Engine Mount)

M16

24mm

265-313

⑫ 13

Engine Bracket

M12

19mm

64-74

Radiator

M12

19mm

64-74

⑭ ⑮

Hydraulic Pump

M10 M16

17mm Hex. Socket

64-73 206-226

⑯

Hydraulic Oil Tank

M16

24mm

232-276

⑰

Fuel Tank

M16

24mm

233-276

⑱

Control Valve

M16

24mm

267-312

⑲

Rotating Joint

M12

19mm

88.3-107

Rotating Joint

M12

19mm

109-127

⑳ Note: Use Loctite No. 262 (adhesive) equivalent on those marked with 〇 and tighten to the torque listed in the above table.

Tightening torque is N•m ÷ 9.8=kgf•m

The tightening torque for the bolts and nuts not listed is:

Bolt Diameter (size) Hex. Bolt

Hex. Socket Head Bolt

M6

M8

M10

M12

M14

M16

M18

M20

Wrench

mm

10

13

17

19

22

24

27

30

Tightening Torque

N m

6.9

19.6

39.2

58.8

98.1

157.0

196.0

274.0

Wrench

mm

5

6

8

10

12

14

14

17

Tightening Torque

N m

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.03

8-11

CHAPTER 8 - SPECIFICATIONS 18

17

16

14 15 Hydraulic oil pump

10 11 12 Engine 13 Radiator

7 Counterweight Turntable bearing

8,9 3 Take-up roller

6

1 ,2

1 2

4

3-0141E

5

8,9 1

8

2

9 3-0145E

3-0142E

3,4,5,6

7

4

3

5

6

3-0143E 3-0144E

8-12

CHAPTER 8 - SPECIFICATIONS

10 Swing equipment

16

Hydraulic oil tank

10

16

3-0150E

3-0146E

11,12

17 Fuel tank

17

3-0147E

3-0151E

18

13

18

3-0152E

3-0148E

14,15

19,20

19

20

3-0153E 3-0149E

8-13

CHAPTER 8 - SPECIFICATIONS

8-14

CHAPTER 9 - INDEX

Chapter 9

INDEX A Air Conditioning Compressor ................................................... 6-12 Condenser ..................................................... 6-12 Air filter ..................................................... 5-23, 5-30 Air recycling ....................................................... 3-23 Anti-Theft Device ............................................... 3-21 Anti-theft protection indicator ............................. 3-16 Attachment failure .............................................. 4-19

B Battery Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operation Safety ...................................... 2-6 Bleeding ............................................................... 5-5

C Cab light ............................................................ 3-33 Cab Service ....................................................... 6-12 Coat hanger hook .............................................. 3-33

E Electrical System ................................................. 7-3 Engine Hourmeter ....................................................... 5-6 Specifications .................................................. 8-3 Engine coolant temperature indicator ................ 3-16 Engine Lubrication ............................................. 5-10 Engine Oil Selection ...................................... 5-10 Engine Oil Level ................................................ 5-13 Engine Oil Selection .......................................... 5-10 Engine Operation .......................................... 4-3, 4-5 Engine Speed .................................................. 4-5 Parking the Machine and Stopping the Engine 4-6 Starting the Engine .......................................... 4-5 Engine Service Engine Oil Level ............................................ 5-13 Oil Change and Filter Replacement .............. 5-25 Engine Speed ...................................................... 4-5 Engine starting procedure ................................... 4-7 Engine stopping procedure ................................ 4-10 Error code indicator ........................................... 3-16

F Fan and alternator drive belt ....................... 5-14, 6-6

Filter Engine ............................................................5-25 Fluid and Lubricants .............................................5-7 Fluids and lubricants ..........................................5-11 Footrest ..............................................................3-32 Front storage box ...............................................3-37 Fuel Handling Precautions ...................................2-9 Fuel level indicator .............................................3-16 Fuel tank .............................................................3-37 Fuel tank filling pump .........................................3-41 Function and message display screen ...............3-16

G General Information ..............................................1-1 General Safety .....................................................5-3

H Hardware torque inspection ..................... 5-22, 6-15 Hazardous Chemical Precautions ......................2-10 Hourmeter, Engine ...............................................5-6 Hydraulic fluid .....................................................5-11 Hydraulic fluid temperature indicator ..................3-16 Hydraulic system ..................................................8-4

I Identification Numbers Engine ..............................................................1-4 Product Identification Number (P.I.N.) .............1-4 Inspecting and cleaning the machine ...................6-7 Instructions, General Safety .................................5-3 Instrument Panel ..................................................3-3

L Lifting loads ........................................................4-14 Load holding control device ................................3-40 Lower panels ......................................................3-38 Lowering the attachment in the event machine failure 4-19 Lubrication/Filters/Fluids Engine Lubrication .........................................5-10 Fluid and Lubricants .........................................5-7

M Machine operation ................................................4-3 Machine Operation Safety ....................................2-6 Machine overall dimensions .................................8-6 Machine storage .................................................4-22 Machine travel ....................................................4-11 9-1

CHAPTER 9 - INDEX Maintenance Precautions .................................... 2-9 Maintenance, 10 Hour ..................... 5-13, 5-14, 5-16 Message display screen .................................... 3-17

O Oil Change Engine ........................................................... 5-25 Oil Viscosity/Temperature Ranges .................... 5-10 Operating in water ............................................. 4-16 Operating Instructions ......................................... 4-5 Operating Precautions ......................................... 2-7 Operating the backhoe bucket ........................... 4-17 Operating the machine in cold weather ............... 4-9 Operating the machine in hot weather ................. 4-9 Operator's seat .................................................... 3-6 Owner, To The ..................................................... 1-1

P Parking the Machine and Stopping the Engine ... 4-6 Parking The Machine Safety ............................. 2-10 Personal Safety ................................................... 2-6 Plastic and Resin Parts ....................................... 5-6

Q Quick coupler locking/unlocking control ............ 3-33

R Radiators and oil coolers ................................... 5-24 Releasing Hydraulic System Pressure ................ 5-4 Replacing a tooth on the backhoe bucket ......... 6-11 Run-In Period of a New Machine Track Shoe Bolts ............................................. 4-3

S Safety Decals .................................................... 2-12 Safety Instructions, General ................................ 5-3 Safety, Battery ..................................................... 7-3 Safety, Decals, and Hand Signals Personal Safety ............................................... 2-6 Safety Rules .................................................... 2-3 Utility Safety .................................................... 2-4 Safety/Decals/Hand Signals Before Operation ............................................. 2-6 Machine Operation .......................................... 2-6 Parking The Machine .................................... 2-10 Safety Decals ................................................ 2-12 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-3 Specifications Engine Specifications ...................................... 8-3 Start Up After Storage ....................................... 4-22 Starting and Stopping Precautions ...................... 2-7 9-2

Starting the Engine ...............................................4-5 Starting the engine ...............................................4-7 Storage tray ........................................................3-35 Storing the machine ...........................................4-22 Sun shield ...........................................................3-35 Swing reduction gear ................................ 5-20, 5-35

T Temperature control system ...............................3-22 To the Owner ........................................................1-1 Towing the machine ...........................................4-19 Track Shoe Bolts ..................................................4-3 Transmission component oil ...............................5-11 Travel control levers and pedals ........................3-31

U Utility Safety Rules Message ................................2-4

W Walk-Around Inspection .......................................4-5 Weights - Operating .............................................8-4 Working mode indicator ......................................3-16

Dealer’s stamp

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.