service repair manual

4. Case
Copyright  2002 Case France
Printed in U.S.A.
June 2002Cre 9-53360
1001
SAFETY, GENERAL INFORMATION
Section
1001

5. 1001-3
Cre 9-53360 Issued 06-02
GENERAL INFORMATION
Cleaning
Clean all metal parts except bearings, in a suitable
cleaning solvent or by steam cleaning. Do not use
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable cleaning
solvent. Dry the bearings completely and put oil on
the bearings.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for
indications of wear, pitting and the replacement of
parts necessary to prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action, replace the bearing. Wash
bearings with a suitable cleaning solvent and permit
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle Bearings
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position, put
petroleum jelly on the inside and outside diameter of
the bearings.
Gears
Check all gears for wear and damage. Replace gears
that have wear or damage.
Oil Seals, O-rings and Gaskets
Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service Parts
Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
replacement parts are not covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
use of non-specified oils and lubricants are not
covered by warranty.

6. 1001-4
Cre 9-53360 Issued 06-02
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
!
To prevent injury always follow the Warning, Caution
and Danger notes in this section and throughout the
manual.
Place a “Do not operate“ tag on the starter switch key
before carrying out any service or repair work on the
machine.
.
WARNING: Read the operator’s manual to
familiarize yourself with the correct control
functions.
!
WARNING: Operate the machine and
equipment controls from the seat position
only. Any other method could result in
serious injury.
!
WARNING: This is a one man machine, no
riders allowed.!
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 operating.
It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service and to observe
pertinent laws and regulations. Operator’s
and Service Manuals may be obtained from
your Case dealer.
!
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
!
WARNING: When working in the area of the
fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests
on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
!
WARNING: When putting the hydraulic
cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
!

7. 1001-5
Cre 9-53360 Issued 06-02
WARNING: Use insulated gloves or mittens
when working with hot parts.!
WARNING: Lower all attachments to the
ground or use stands to safely support the
attachments before you do any maintenance
or service.
!
WARNING: Pin sized and smaller streams
of hydraulic oil under pressure can penetrate
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
immediately. Maintain all hoses and tubes in
good condition. Make sure all connections
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
damaged. DO NOT use your hand to check
for leaks, use a piece of cardboard or wood.
!
WARNING: When removing hardened pins
such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
!
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
!
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in place
with suitable safety stands.
!
WARNING: When servicing or repairing the
machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
!
WARNING: Some components of this
machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
!
WARNING: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the doors and get outside
air into the area.
!
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.
!

8. Case
Copyright  2002 Case France
Printed in U.S.A.
June 2002Cre 9-43540GB
2000
REMOVAL AND INSTALLATION
OF THE ENGINE
Section
2000

9. 2000-3
Cre 9-43540GB Issued 06-02
ENGINE
Removal and installation
STEP 1
JS00163A
Park the machine on hard, flat ground. Lower the
attachment to the ground.
STEP 2
Release pressure in the hydraulic system and in the
hydraulic reservoir (see Section 8000).
STEP 3
CD01C162
Disconnect the battery ground (-) cable (1) from the
battery.
STEP 4
Refer to Section 8003 and remove the hydraulic
pump.
STEP 5
Refer to Section 2001 and remove the radiator and
oil-cooler assembly.
STEP 6
CD02C151
Remove the engine shutdown control (arrow).
Disconnect the fuel supply pipe (1) and the fuel return
pipe (2) and plug them.
STEP 7
CD01D131
Remove the screws (1) from the compressor and put
it away from the engine.
1
1
2
1
1

10. 2000-4
Cre 9-43540GB Issued 06-02
STEP 8
CD02C152
Label and disconnect the electrical connections from
the water temperature sensor (1).
STEP 9
CD02C153
Label and disconnect the electrical connections from
the oil pressure sensor (1).
STEP 10
CD00J030
Label and disconnect the electrical supply (1) to the
pre-heating plugs.
STEP 11
CD02C154
Label and disconnect the electrical connections to
the starter motor (1). Remove the earth cable (2) at
the engine end.
STEP 12
CD02C152
Label and disconnect the electrical connections of
the electronic regulation (1) from the engine.
STEP 13
CD02C155
Remove the hose connecting the turbo-charger to the
air filter (1).
1
1
1
1
2
1
1

11. 2000-5
Cre 9-43540GB Issued 06-02
STEP 14
CD01M004
Label and disconnect the electrical connections to
the alternator (arrows).
STEP 15
Remove all the clips, etc, which fasten the electrical
harnesses to the engine and move the harnesses out
of the way.
STEP 16
Install a suitable lifting device on the engine lifting
rings (for the weight of the engine, see Section 1002).
STEP 17
Remove the engine retaining hardware.
NOTE: When installing, make a visual inspection of
the condition of the rubber flexible mountings and
change them if necessary. Respect the colours, light
blue on the fan side, light green on the hand-wheel
side. Tighten the engine retaining screws to a torque
of 231 ± 18 lb-ft.
STEP 18
When there is nothing interfering with the removal of
the engine, raise the engine carefully and install it on
a suitable repair bench.
NOTE: When installing the engine in the machine,
proceed in the reverse order from removal.
Before operating the machine, carry out the following
operations:
- Bleed and prime the fuel system (see Operator’s
Manual).
- Fill and bleed the engine cooling system (see Oper-
ator’s Manual).
- Check the hydraulic, fuel and cooling systems for
leaks.
- Check the oil level in the hydraulic reservoir. Top up
if necessary.

12. 2001-3
Cre 9-43480GB Issued 06-02
CHANGING THE RADIATOR OR THE OIL-COOLER
Description
CI02A513
1 SCREW
2 PIPE
3 OIL COOLER
4 OIL-COOLER
5 HOSE
6 HOSE
7 RADIATOR
8 HOSE
9 HOSE
10 HOSE
11 HOSE
6
4
8
7
2
1
10
9
2
1
5
9
11
5
3

13. 2001-4
Cre 9-43480GB Issued 06-02
RADIATOR AND OIL-COOLER
Before carrying out any operation on the machine, perform the following operations in the order shown:
- Park the machine on hard, flat ground.
- Lower the attachment to the ground.
- Shut down the engine.
- Remove the starter switch key.
- Make sure that pressure in the hydraulic system has been completely released (see Operator’s Manual).
Removal of the radiator and oil-
cooler assembly
STEP 1
CD01K055
Remove the hood (1) from the engine.
STEP 2
Remove the inner cover plate from the engine.
STEP 3
Remove the cap from the expansion reservoir.
IMPORTANT: Do not remove the cap when the
engine is hot, since the system would still be under
pressure and you could be scalded.
STEP 4
Drain the cooling system (see Operator’s Manual).
STEP 5
Release pressure in the hydraulic reservoir to allow
the vacuum pump to be mounted (see Section 8000).
NOTE: The numbers within brackets refer to the fig-
ure on page 3.
STEP 6
Remove the screws (1), then the pipe (2) from the oil
cooler (3), finally drain the latter into a clean con-
tainer.
STEP 7
Disconnect the radiator hoses (5) and (6) from the oil-
cooler, finally drain the latter into a clean container.
STEP 8
Remove the expansion reservoir hose (8) from the
radiator (7). Disconnect the return hose (9) and the
water pump suction hose (10) from the engine.
STEP 9
Disconnect the radiator hose (11) from the oil drain
plug.
STEP 10
CS02C554
Remove the screws (A) and remove the guardrails
(B). Remove the screws (C).
WARNING: When the machine is working, the engine components and the hydraulic pump reach a high
temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the
machine to cool down before starting any servicing operation.!
1
A
B
C

14. 2001-5
Cre 9-43480GB Issued 06-02
STEP 11
CS00G513
Pass a suitable sling right around the radiator and oil-
cooler assembly and, using a suitable lifting device,
remove the radiator and oil-cooler assembly.
NOTE: During the lifting operation, unlock the radia-
tor and oil-cooler assembly in order to free the engine
cooling fan.
Installation
When installing, proceed in the reverse order from
that of removal.
Before operating the machine:
- Check the oil level in the hydraulic reservoir. Top up
if necessary.
- Check the hydraulic fluid cooling circuit for leaks.
- Fill and bleed the engine cooling system (see Oper-
ator’s Manual).
- Check the engine cooling system for leaks.

15. 4001-6
Cre 9-53640 Issued 06-02
General location of the components (outside the cab)
CS02M515
Y18
B27
B81
B2
M13
B22
K15
G2B8
K7
F30
F29
G1
Y8 H2 R6 A2
B43
Y7
B44
B42
R5
X1
M4
E1
E2
Y16
X3
Y17
B7
S52
F22
F23
F24
F32
Y2
B41B6 B21B1 B46 B47
M1
B26
Y4
Y6
Y1
Y3
Y5
K13
M9 B48
M12
B25Y9 B23

16. 4001-7
Cre 9-53640 Issued 06-02
A2 Engine controller
B1 Coolant temperature sensor
B2 Hydraulic oil temperature sensor
B6 Air temperature sensor
B7 Water in fuel sensor
B8 Coolant level sensor
B21 Engine oil pressure switch
B22 Swing pilot pressure switch
B23 Breaker / crusher pilot pressure switch
B25 Breaker pilot pressure switch
B26 Upper pilot pressure switch
B27 Travel pilot pressure switch
B41 Engine rpm sensor
B42 Pump pressure sensor (P1)
B43 Pressure sensor (nega-cont)
B44 P2 Pump pressure sensor (yellow band)
B46 Engine position sensor
B47 Boost pressure sensor
B48 Ambient air pressure sensor
B81 Horn
E1 Working light (upperstructure)
E2 Working light (attachment)
F22 Fuse 20 A; main fuse for circuits F1, F11 and F12 circuits
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 circuits
F24 Fuse 20 A; main fuse for circuit F2
F29 Fuse 120 A; gread heater
F30 Box fuse
F32 Engine controller fuse box
G1 Batteries
G2 Alternator
H2 Travel alarm
K7 Relay-battery
K13 Relay-starter
K15 Relay-gread heater
M1 Starter motor
M4 Washer motor
M9 Air conditioner condensor fan motor
M12 Fuel pump
M13 Prime pump motor
R5 Fuel sensor
R6 Gread heater
S52 Air conditioning compressor clutch switch
X1 Fuel filler pump connector
X3 Optional power connector (breaker and crusher)
Y1 Swing pilot shut-off solenoid valve (green band)
Y2 Pilot pressure solenoid valve (blue band)
Y3 Swing brake solenoid valve (pink band)
Y4 2 stage travel solenoid valve (red band)
Y5 Power-up solenoid valve (yellow band)
Y6 Cushion control solenoid valve (light green band)
Y7 Main pump proportional solenoid
Y8 Air conditioner magnet clutch
Y9 Crusher / breaker option two flow solenoid valve
Y16 Multi-purpose solenoid valve (R) (optional)
Y17 Multi-purpose solenoid valve (L) (optional)
Y18 Free swing solenoid valve

17. 4001-8
Cre 9-53640 Issued 06-02
Relay and main fuses (battery compartment)
CS02M505
1 Battery cables
2 Bloc ; terminal
F22 Fuse 20 A; main fuse for circuits F1, F11 and F12
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 circuits
F24 Fuse 20 A; main fuse for circuit F2
F29 Fuse 120 A; gread heater
F30 Box fuse
F32 Engine controller fuse box
K7 Relay-battery
K13 Relay-starter
K15 Relay-gread heater
F23F24F22
K13F32
F30 K15F29
K71 2

18. 4001-10
Cre 9-53640 Issued 06-02
General location of the components (inside the cab)
CS02M517
U1A1
F21
E53
S13
S53
S24
S51
S15
X8
R3
S1
P8
E4
E51
B61
A4M3
S54
S16
P1
S25
S21
S14
X5
X4
P6
E52
R4
M7
M8
M5
M6 K3K4K1X10K6

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20. 4001-11
Cre 9-53640 Issued 06-02
A1 Computer
A4 Wiper controller
B61 Sunload sensor
E4 Cab light
E51 Cigarette lighter
E52 Air conditioner
E53 Heater
F21 Fuse box
K1 Relay-engine emergency stop
K3 Relay-horn
K4 Relay -working lights
K6 Relay-air conditioner condensor fan
M3 Wiper motor
M5 Motor (air changing)
M6 Air vent direction control motor
M7 Motor act (air-mix)
M8 Blower motor
P1 Instrument panel
P6 Air conditioner control panel
P8 Heater control panel
R3 Throttle volume
R4 Thermistor
S1 Key switch
S13 Overload switch
S14 Breaker/crusher switch
S15 Horn switch
S16 One touch idle
S21 One touch multipurpose switch (R)
S24 Option line switch
S25 One touch multipurpose switch (L)
S51 Hydraulic function cancellation lever switch
S53 Door limit switch
S54 Front window limit switch
U1 DC-DC converter 24 V - 12 V
X8 Radio connector
X4 Engine test point connector
X5 Controller test point connector
X10 Condensor fan relay connector

21. 4001-12
Cre 9-53640 Issued 06-02
Fuse box
CM00E005
F1 Fuse 10 A: Engine controller test point connector
F2 Fuse 20 A: Computer, instrument panel and diagnostic test socket
F3 Fuse 20 A: Computer power
F4 Fuse 10 A: Hydraulic function cancellation lever switch
F5 Fuse 10 A: Optional power connector
F6 Fuse 20 A: Option line connector
F7 Fuse 20 A: Fuel filler pump
F8 Fuse 10 A: Cab seat air sus (not used)
F9 Fuse 10 A: Condensor fan relay
F10 Fuse 10 A: Breaker and crusher option / second option
F11 Fuse 10 A: Back-up
F12 Fuse 10 A: Key switch
F13 Fuse 20 A: Heater / air conditioner
F14 Fuse 5 A: Air conditioner compressor
F15 Fuse 15 A: Working lights
F16 Fuse 15 A: Optional power connector
F17 Fuse 10 A: DC-DC converter (24 V - 12 V)
F18 Fuse 15 A: Wiper and washer
F19 Fuse 10 A: Horn
F20 Fuse 15 A: Cigarette lighter

22. 4001-13
Cre 9-53640 Issued 06-02
Instrument panel
CM00K003
H1 Audible warning device
P4 Monitor display
P5 Hourmeter
S2 Travel mode switch
S3 Work mode switch
S4 Auto mode switch
S5 Cushion control switch
S7 Audible alarm cut out switch
S8 Swing brake switch
S9 Engine emergency stop switch
S10 Working light switch
S11 Wiper switch
S12 Washer switch
S22 Free swing
CS00F521
1 Travel speed indicator
2 Work mode indicator
3 Idle mode indicator
4 Coolant temperature indicator
5 Hydraulic oil temperature indicator
6 Fuel level indicator
S5
P5S9S8S7S4S3S2P4
S22 S10 S11 S12H1
1 2 3 P4
4 5 6

23. 4001-14
Cre 9-53640 Issued 06-02
Working Mode Selection
1) Circuit configuration
CS00F505
2) Timing diagram
1. Engine
2. Serial communication
A1.Computer
A2.Engine controller
A3.Electronic acceleration
P1.Instrument panel
P4.Monitor display
S3.Work mode switch
S4.Auto mode switch
Y7.Main pump proportional solenoid
S4
S3
P4
P1
A1
2
Y7
A2
1
A3
AUTO H L
24V
0V
a
Contact
switch
Working
mode
b
S AUTO H L S AUTO H L AUTO H
c
5V
0V
5V
0V
S3
S4