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Case CX135SR, Operator'S Manual

The Case CX135SR Operator's Manual is essential for proper operation of the machine. Users can easily download the manual for free from manualshive.com. This comprehensive manual provides all the information needed to safely and efficiently operate the Case CX135SR, ensuring optimal performance and longevity.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

2-1

Issued 8-04  Bur

6-34551NA

Chapter 2

SAFETY, DECALS, AND HAND SIGNALS

TABLE OF CONTENTS

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

PERSONAL SAFETY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

SAFETY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

UTILITY SAFETY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

OPERATOR PRECAUTIONS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Personnel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Mounting and Dismounting Precautions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operating Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fuel Handling Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Burn Prevention  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hazardous Chemical Precautions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Transporting Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Wheel, Tire, and Track Safety  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Roll-Over Protective Structure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fire Extinguisher   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Specific Precautions to this Machine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

DECALS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Summary of Contents for CX135SR

Page 1: ...om 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...

Page 2: ...o 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 na...

Page 3: ...or CX135SR 3 10 Working Light Switch 3 11 Windshield Washer Switch 3 11 Windshield Wiper Switch 3 11 High Speed Travel Switch 3 11 Heating ventilation and air conditioning control 3 12 Function cancel...

Page 4: ...sition for 2 85 m arm CX135SR 4 10 Transporting the Machine 4 11 Handling the Machine 4 14 Operating the Machine In Water 4 14 Parking the Machine 4 14 Operating the Machine on Sloping Ground 4 15 Tow...

Page 5: ...6 15 Welding on the Machine 6 15 Plastic and Resin Parts 6 15 Air conditioning 6 16 Hardware torque inspection 6 18 CHAPTER 7 ELECTRICAL Table of Contents 7 1 Fuses 7 3 Battery 7 5 Connecting One Or...

Page 6: ...IV Issued 8 04 Bur 6 34551NA CHAPTER 9 INDEX...

Page 7: ...h moving and rehandling operations If you want to use this machine to handle a load pipes culverts framework etc make sure that it is designed to carry out this kind of work For this type of applicati...

Page 8: ...ntres or from an approved organization 2 That the operator has read and understood the instructions given in this manual Always keep this manual in the operator s compartment in the seat back behind t...

Page 9: ...ydraulic fluid to the control valves The control valves distribute the hydraulic fluid to the various cylinders and motors concerned A cooling system maintains the hydraulic fluid at normal operating...

Page 10: ...6 IDLER WHEELS The terms Right hand Left left Front and Rear are used in this manual to indicate the sides as they are seen from the operator s seat when the cab is over the idler wheels The illustrat...

Page 11: ...the spaces below The type serial number and year of manufacture of your machine accessories and the serial numbers of the various hydraulic and mechanical components Machine Figure 4 CX75SR CX80 Engin...

Page 12: ...CHAPTER 1 GENERAL INFORMATION 1 6 Issued 8 04 Bur 6 34551NA NOTES...

Page 13: ...eneral 2 4 Mounting and Dismounting Precautions 2 4 Starting and Stopping Precautions 2 5 Operating Precautions 2 5 Maintenance Precautions 2 6 Fuel Handling Precautions 2 7 Burn Prevention 2 7 Hazard...

Page 14: ...CHAPTER 2 SAFETY DECALS AND HAND SIGNALS 2 2 Issued 8 04 Bur 6 34551NA NOTES...

Page 15: ...ter point out situations which can happen during the normal operation and maintenance of your machine These safety messages also give possible ways of dealing with these conditions PERSONAL SAFETY If...

Page 16: ...aced and renewed upon age and wear Old hard hats may not afford the original users intention Faded and soiled vest are no longer as highly visible as original intent See the manufacture s recommendati...

Page 17: ...ion 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 cor...

Page 18: ...rous 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...

Page 19: ...er venting may result in pressurization of the tank Never use fuel for cleaning purposes Use the correct fuel grade for the operating season BURN PREVENTION M144B When the battery electrolyte is froze...

Page 20: ...D00E032 Figure 5 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...

Page 21: ...perator s compartment BS00M141 Figure 7 This decal warns of Danger and to keep clear of swinging upperstructure to prevent serious bodily injury KHP1533 00 Figure 8 This decal warns of the hazard asso...

Page 22: ...r death 321 7040 Figure 13 This decal warns that starting in gear can cause serious injury or death and the engine should be started from the operator s seat only 167327A1 Figure 14 This decal warns t...

Page 23: ...nd using jumper cables CS00F530 Figure 18 This decal shows the function of the left hand and right hand control levers BS02G143 Figure 19 This decal warns the operator to change the function decal in...

Page 24: ...ulic Pressure in this manual CT02C010 Figure 23 This decal warns that the radiator system must be allowed to cool and pressure must be released before removing the radiator cap 321 3596 Figure 24 This...

Page 25: ...00 Figure 28 This decal cautions not to walk on engine cover BS04H100 Figure 29 This decal cautions of a crush hazard from a swinging boom which can cause serious injury or death BS04H101 Figure 30 T...

Page 26: ...ctly sure that you and the signalman understand the signals to be used PDE0002A Figure 32 START THE ENGINE PDE0002 Figure 33 SHUT DOWN THE ENGINE PDE0003A Figure 34 COME TO ME Wave hands back and fort...

Page 27: ...re 42 SLOWLY RAISE THE LOAD OR TOOL PDE0007 Figure 43 SLOWLY LOWER THE LOAD OR TOOL PDE0009A Figure 44 RAISE TOOL PDE0008A Figure 45 TURN THE MACHINE TO THE LEFT SWING LOAD LEFT To stop movement stop...

Page 28: ...AND HAND SIGNALS 2 16 Issued 8 04 Bur 6 34551NA PDE0010A Figure 48 RAISE TOOL PDE0010 Figure 49 LOWER TOOL PDE0011A Figure 50 RETRACT ARM PDE0011 Figure 51 EXTEND ARM PDE0012A Figure 52 FILL TOOL PDE0...

Page 29: ...NTROL 3 12 FUNCTION CANCELLATION LEVER 3 13 ARM AND UPPERSTRUCTURE SWING LEFT HAND CONTROL LEVER 3 13 BOOM AND BUCKET RIGHT HAND CONTROL LEVER 3 14 TRAVEL CONTROL 3 15 OFFSET BOOM CONTROL PEDAL IF EQU...

Page 30: ...25 FUEL TANK 3 25 UPPER HOOD CX75SR CX80 3 25 ENGINE HOOD 3 26 CX75SR CX80 3 26 CX135SR 3 26 SIDE DOORS 3 27 Left hand rear side door 3 27 Right hand rear side door 3 27 Right hand front side door 3 2...

Page 31: ...lever 3 downward CT02C032 Figure 3 WARNING When seated in the operator s compartment with the engine running make sure that you do not to operate the left hand control lever inadvertently when unlocki...

Page 32: ...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...

Page 33: ...CONTROL LEVER 4 FOOT REST PEDAL LOCKED 12 AIR VENTS 5 LEFT HAND TRAVEL CONTROL PEDAL AND LEVER 13 RIGHT HAND CONTROL ARM 6 RIGHT HAND TRAVEL CONTROL PEDAL AND LEVER 14 LEFT HAND CONTROL ARM 7 DOZER BL...

Page 34: ...ing Instructions section This key is also used to lock the cab door the engine hood the side doors and the fuel tank cap 3 ENGINE THROTTLE BUTTON This button enables the increase or reduction in the e...

Page 35: ...is running Its operation is indicated by the blinking of a green indicator lamp See section Servicing intervals 135_TBD7 Figure 10 135_TBD8 Figure 11 2 3 1 4 5 WARNING The role of the instrument pane...

Page 36: ...or it will be necessary to bleed the fuel circuit 7 BATTERY CHARGE INDICATOR LAMP The audible warning device will sound This indicator lamps up when the alternator fan belt is broken or when the alte...

Page 37: ...ation lever 3 OPTION CONTROL Optional This two position switch enables the activation of options such as the hydraulic breaker grab shears etc Place the switch in one of the two positions depending on...

Page 38: ...shears etc Place the switch in one of the two positions depending on the accessories to be used See Auxiliary hydraulic systems in the Operating Instructions section 4 EMERGENCY SHUT DOWN SWITCH This...

Page 39: ...ntermittent operation of the windshield wiper the lamp I comes on Press the switch again to obtain continuous operation of the windshield wiper the lamp II comes on Press the switch once more for the...

Page 40: ...he temperature press the Left Hand button The temperature is controlled by the increase or reduction in the number of segments 5 AIR FLOW DIRECTION These push buttons 5 are used for the selection of t...

Page 41: ...25 In the lowered position all hydraulic controls are operational ARM AND UPPERSTRUCTURE SWING LEFT HAND CONTROL LEVER The speed of movement of the arm or the upperstructure swing depends on the contr...

Page 42: ...l depends on the control lever tilt angle In the intermediate position both movements can be obtained simultaneously 5 The boom lowers 6 The boom raises 7 The bucket retracts filling 8 The bucket exte...

Page 43: ...and the travel reduction gears are to the rear of the upperstructure If the upperstructure is turned 180 degrees in relation to the undercarriage to move the machine forward the levers have to be pull...

Page 44: ...80 Press the front of the pedal the equipment pivots to the right Press the rear of the pedal the equipment pivots to the left Offset angle see Working ranges in the Specifications section CT02C042 Fi...

Page 45: ...osition With the engine stopped if the dozer blade is in the raised position it is still possible to lower it using the control lever until it touches the ground CT02C041 Figure 37 CAB LIGHT Located o...

Page 46: ...indow bring the handle back towards the inside of the cab CT02C061 Figure 41 STORAGE COMPARTMENT The glove compartment is located on the right hand side in front of the cab CT02C068 Figure 42 STORAGE...

Page 47: ...CX135SR car radio For operating instructions see the radio manual provided by the manufacturer SPEAKER COMPARTMENTS Located behind the cab these compartments are designed for installing speakers CT02C...

Page 48: ...o suit the weight and size of the operator NOTE The adjustment of the seat can be done correctly only when the operator is seated in the seat and the engine is shut down 1 SUSPENSION ADJUSTMENT 4 SEAT...

Page 49: ...d then release the lever To raise or lower the rear of the seat hold the lever 3 in lowered position Move with the seat to the desired position and then release the lever CT02C078 Figure 50 4 Seat bac...

Page 50: ...ge it in the kink system 9 If the section of belt pulled out is not long enough release it so it rolls up and then pull it out again To fasten the seat belt insert the buckle in the slide closing of t...

Page 51: ...ngages CT02C086 Figure 58 CT02C087 Figure 59 3 Engage the right hand latch 5 in the cab upright CT02C088 Figure 60 CLOSING 1 Unlock the right hand latch 5 of the cab upright CT02C089 Figure 61 2 Hold...

Page 52: ...the left of the operator s seat and then engage it correctly CT02C093 Figure 66 WINDOW BREAKER HAMMER Located on the right hand cab upright the window breaker hammer is to be used to break the rear w...

Page 53: ...0 Before any travel operation make sure that the rear view mirrors are correctly adjusted ON THE CAB CT02C097 Figure 71 ON THE UPPERSTRUCTURE CT02C098 Figure 72 REAR CT02C099 Figure 73 REAR VIEW MIRRO...

Page 54: ...ation Capacity of the reservoir 100 liters 21 gal Located under the upper hood on the right hand side CT02C103 Figure 77 CX75SR CX80 Capacity of the reservoir 165 liters 44 gal Located on the right ha...

Page 55: ...s to be open to lift section 2 To close operate the screw of the supporting prop then pull down and slam the hood both sections close CT02D070 Figure 81 ENGINE HOOD CX75SR CX80 To open press the butto...

Page 56: ...to the batteries the air filter etc Use the outside handle to open the doors To hold the doors open remove the struts from their storage position and install them in the holes provided When closing pu...

Page 57: ...the machine see Towing the machine in section Operating instructions Make sure that the slings chains and accessories are in perfect condition and can bear the load to be moved WARNING Always install...

Page 58: ...inside the front right hand side door this reservoir is equipped with an electric pump controlled by the windshield wiper windshield washer control In cold weather add anti freeze to the windshield wa...

Page 59: ...e type of flow to be used depending on the tool installed on the machine See Auxiliary hydraulic systems in the Operating Instructions section IMPORTANT Consult your Dealer before mounting optional to...

Page 60: ...CHAPTER 3 INSTRUMENTS AND CONTROLS 3 32 Issued 8 04 Bur 6 34551NA...

Page 61: ...luid 4 7 Coolant Solution 4 7 OPERATING THE MACHINE IN HOT WEATHER 4 8 OPERATION 4 8 MACHINE TRAVEL 4 8 TRANSPORT POSITION FOR 2 85 M 9 FT 4 IN ARM CX135SR 4 10 TRANSPORTING THE MACHINE 4 11 By Rail 4...

Page 62: ...CHAPTER 4 OPERATING INSTRUCTIONS 4 2 Issued 8 04 Bur 6 34551NA...

Page 63: ...ow glass in the event of the cab door being jammed or the machine turning over See Windshield in the Controls Instruments Accessories section 16 Before undertaking any travel or working operations dur...

Page 64: ...ing in the direction of the cab RUN IN PERIOD Your machine will last longer and will give better and more economical performance if you pay particular attention to the engine during the first twenty h...

Page 65: ...o turn If the engine stops wait about a minute and recommence the operation IMPORTANT Do not operate the starter motor for more than 20 seconds at one time Do not operate the starter motor when the en...

Page 66: ...the engine idle for about five minutes until it has warmed up 2 Move the engine throttle button to the maximum speed position Once normal operating temperature has been reached check the following 1 T...

Page 67: ...tery charge and engine electrical circuit indicators light up Bring the starter switch key back to the OFF position To restart the engine press again on the STOP switch then turn the starter switch ke...

Page 68: ...conditions See Starting the engine 4 Check all instruments are operating correctly 5 Sound the horn 6 Lower the function cancellation lever 7 Try out all the controls in a safe open area MACHINE TRAVE...

Page 69: ...y press the left hand pedal or the left hand lever rearwards CS98M550 Figure 18 7 Turning on the spot to the right Press the left hand pedal or the left hand lever forwards and at the same time press...

Page 70: ...y 3 Using a suitable lifting device hold the arm cylinder CT02C200 Figure 22 4 Remove the retaining hardware from the shaft then drive the shaft out 5 Start the engine retract the arm cylinder rod to...

Page 71: ...e in line with the trailer with the travel reduction gears towards the access ramps Raise the attachment and bring it to about twenty centimeters above the bed of the trailer CT02C197 Figure 29 IMPORT...

Page 72: ...and then move forward until the machine is resting entirely on the trailer PDH0249 Figure 32 7 Machine with attachment When the machine is completely on the trailer raise the attachment slightly and s...

Page 73: ...know the overall height See Machine overall dimensions in the Specifications section PDH0251 Figure 38 CS99B519 Figure 39 UNLOADING 1 Remove the blocks and fastening chains 2 Start the engine 3 Lower...

Page 74: ...ver work in water if the water level is higher than the tracks 3 Before immersing the machine inject large quantities of fresh grease into the attachment linkages and the dozer blade if equipped also...

Page 75: ...hen the machine has broken down First make sure that it can be towed without risk of further damage As far as possible try to carry out repairs on spot or contact your Dealer WARNING Never jump down f...

Page 76: ...g on the type of material EXCAVATING METHOD PDH0493M Figure 45 PDH0494M Figure 46 1 CORRECT 2 INCORRECT THE BUCKET WILL DIG IN AND CAUSE A STALL 3 INCORRECT THE BUCKET IS PUSHED UPWARDS THIS WILL ALSO...

Page 77: ...re and the flow required for the use of the option correctly CONFIGURING THE HYDRAULIC BREAKER DEMOLITION GRAB TO A FLOW OR BUCKET 1 Connect the accessory to the supply valves at the end of the arm 2...

Page 78: ...plug them CT02C124 Figure 56 TWO FLOW DEMOLITION GRAB CONFIGURATION 1 Proceed to connect the accessory on the supply valves at the end of the arm 2 Using a hex wrench turn the supply valves 90 to the...

Page 79: ...ion CT02C228 Figure 61 7 Operate the Option Pedal See Option Pedal in the Controls Instruments Accessories section CT02C235 Figure 62 8 When removing the demolition grab turn the supply valves to the...

Page 80: ...ll warm drain the oil sump fill with anti corrosive oil and replace the engine oil filter 6 When the engine is cold clean the outer parts of the engine with diesel fuel 7 Clean or replace the air filt...

Page 81: ...Check the travel reduction gears oil level and add more oil if necessary 10 Clean the cylinder rods 11 Unplug the air filter inlet and the exhaust pipe 12 Remove the Do not operate tag and start the e...

Page 82: ...CHAPTER 4 OPERATING INSTRUCTIONS 4 22 Issued 8 04 Bur 6 34551NA NOTES...

Page 83: ...5SR 5 14 Offset Boom arm Lubrication 5 15 Machine Lubrication 5 15 Greasing the Turntable Teeth 5 16 Greasing the Swing Reduction Gear CX135SR only 5 17 FLUID LEVELS 5 18 Every 10 hours 5 18 Every 250...

Page 84: ...lacement 5 37 Ultra Clean Filter Replacement 5 37 Replacing the Reservoir Breather 5 38 Replacing the Hydraulic Fluid 5 39 Bleeding Air from the Hydraulic Components 5 39 Hydraulic Breaker Optional Re...

Page 85: ...er scale stripping foundry cleaning operation under water etc For special applications consult your Dealer DAILY INSPECTIONS Every day before starting work it is necessary to inspect the machine and s...

Page 86: ...or water or oil leaks on the components Check the audible alarm devices working lights and windshield wipers Check that all circuits travel swing and tool are functioning correctly IMPORTANT If the sl...

Page 87: ...in 1 50 5 14 Connecting rod Cylinder top pin 3 50 5 14 Connecting rod bottom pin 1 50 5 15 Offset boom Arm pin 9 50 5 16 Blade 6 50 5 28 Drain fuel tank sediment 1 50 5 29 Drain water separator 1 50 5...

Page 88: ...element see note 8 9 1 1000 5 13 Boom Arm pin 1 1000 5 24 Cooling system see note 3 1 1000 5 33 Hydraulic fluid condition 1000 5 35 Pilot circuit filter see note 7 1 1000 5 38 Hydraulic reservoir brea...

Page 89: ...1 50 5 14 Connecting rod Cylinder top pin 3 50 5 14 Connecting rod bottom pin 1 50 5 15 Offset boom Arm pin 9 50 5 16 Blade 6 50 5 28 Drain fuel tank sediment 1 50 5 29 Drain water separator 1 50 5 4...

Page 90: ...8 9 1 1000 5 14 Boom Arm pin 1 1000 5 24 Cooling system see note 3 1 1000 5 33 Hydraulic fluid condition 1000 5 35 Pilot circuit filter see note 7 1 1000 5 38 Hydraulic reservoir breather 1 1000 5 49...

Page 91: ...d They must be stored and removed by a company which is responsible for their recycling or their disposal HYDRAULIC FLUID CASE AKCELA hydraulic fluid is specially designed for high pressure applicatio...

Page 92: ...CASE No 1 Multi performance or Performance engine oil cannot be obtained use only oil of the API CG CF category NOTE Do not put any Performance Additive or other additive in the sump Oil change interv...

Page 93: ...uel should be kept as low as possible Drain off water and impurities regularly COOLANT SOLUTION Put only ethylene glycol coolant solution in the cooling system Use good quality ethylene glycol that ha...

Page 94: ...gal TRAVEL REDUCTION GEARS Type of oil API GL5 grade 80W90 or ISO VG 150 Capacity per reduction gear 1 3 liters 3 gal CX135SR ENGINE Type of oil CASE No 1 Capacity with filter change 15 liters 4 gal C...

Page 95: ...s mentioned on the right of the description indicate the number of lubrication points EVERY 1000 HOURS 1 Boom foot pin 1 EVERY 50 HOURS CX75SR EVERY 1000 HOURS CX80 2 Boom cylinder bottom pin 1 CT02C2...

Page 96: ...foot pin 3 EVERY 50 HOURS 2 Boom cylinder bottom pin 2 CT02C279 Figure 10 Figure 11 EVERY 50 HOURS 3 Boom cylinder top pins 2 4 Arm cylinder bottom pin 1 CT02C280 Figure 12 EVERY 50 HOURS 5 Arm cylin...

Page 97: ...Number of points 9 CT02C284 Figure 16 CT02D346 MACHINE LUBRICATION Use the following grease EP NLGI grade 2 for temperate and hot climates 20 C to 60 C EP NLGI grade 0 for cold climates 40 C to 20 C...

Page 98: ...e the second plate 3 and the 2 screws 4 check for damage on the gear teeth and also the general condition of the gear teeth If the gear surface is not well greased add grease If the grease is white du...

Page 99: ...5000 hours remove the lower panel remove the air bleed plug 1 and refill with grease through the grease point 2 A certain amount of grease should run out from the air bleed plug 1 IMPORTANT When grea...

Page 100: ...Coolant solution expansion reservoir 1 Ethylene glycol and water CT02C288 Figure 27 CX135SR Coolant solution expansion reservoir 1 Ethylene glycol and water CT02C289 Figure 28 CX75SR CX80 Engine oil 1...

Page 101: ...2D002 Figure 33 CX135SR Batteries 2 CT02D003 Figure 34 CX75SR CX80 Travel reduction gears 2 Type API GL5 grade 85W90 or ISO VG 150 CT02D006 Figure 35 CX135SR Travel reduction gears 2 Type API GL5 grad...

Page 102: ...level is situated between the marks A and B of the dipstick the level is correct CS98M579 Figure 39 4 If the oil level is at mark A min or below remove the filling plug and add oil up to mark B max o...

Page 103: ...seal comes into contact with the filter head then tighten an extra half turn by hand IMPORTANT Do not use a filter wrench to tighten the filter Excessive tightening can damage the filter and their sea...

Page 104: ...vel is situated between the marks A and B on the dipstick the level is correct CS98M579 Figure 46 4 If the oil level is at mark A min or below remove the filling plug and add oil up to mark B max of t...

Page 105: ...ome into contact with the filter head then tighten an extra half turn by hand IMPORTANT Do not use a filter wrench to tighten the filters Excessive tightening can damage the filters and the seals 8 Fi...

Page 106: ...radiator Consult your Dealer for suitable coolant solution LEVEL The level of coolant solution should be checked when the engine is cold On flat level ground before using the machine while the engine...

Page 107: ...ut 80 C 176 F 4 Drain the system once more 5 Repeat Steps 1 to 4 until the water drained is clear 6 Install the panel under the upperstructure FILLING 1 Fill with coolant solution via the radiator unt...

Page 108: ...Consult your Dealer for suitable coolant solution To access the expansion tank remove the two thumb screws then completely lower the hood located at the front of the machine CT02D030 Figure 58 LEVEL T...

Page 109: ...es to bring the engine temperature up to about 80 C 4 Drain the system once more 5 Repeat Steps 1 to 4 until the water drained is clear 6 Install the panel under the upperstructure FILLING 1 Fill with...

Page 110: ...eed the system when The tank has been completely emptied The fuel filter has been replaced Parts of the fuel system have been removed for servicing or repair work The machine has been in storage for a...

Page 111: ...n under the drain plug 3 Loosen the drain plug 1 and drain the water and sediment 4 When the float 2 settles on the bottom tighten the drain plug 1 5 Verify that there are no fuel leaks CX75SR CX80 To...

Page 112: ...vertightening the filter can damage the seal and filter NOTE If the engine does not regain full power after replacing the filter bleed the system CX75SR CX80 CT02D042 Figure 74 CX135SR CT02D044 Figure...

Page 113: ...X80 To access the tank cap open the upper hood on the front right hand side of the machine NOTE The gauge 1 located beside the plug shows the fuel level in the tank CT02D046 Figure 76 CX135SR The tank...

Page 114: ...79 4 Operate the control levers from right to left and front to rear a dozen times approximately CT02D057 Figure 80 5 Turn the starter switch key to the OFF position shut down CT02C195 Figure 81 CX75...

Page 115: ...whichever comes first NOTE If the machine is new or if a major component has been overhauled or replaced in the hydraulic system replace the pilot filter and return filter after 50 hours of operation...

Page 116: ...middle of the indicator Top up if necessary See Filling CT02D058 Figure 85 ACCESSING THE HYDRAULIC RESERVOIR CX75SR CX80 1 Open the 2 hoods 1 and 2 and lock them with the lever 3 CT02D070 Figure 86 2...

Page 117: ...1 A Clean the cover and around the cover B Remove the 4 screws 2 and the cover to access the reservoir CT02D069 Figure 92 3 Fill the reservoir as required A Check the max and min level at the dipstic...

Page 118: ...of the inlet filter rod assembly 4 Remove the inlet filter 3 and clean with solvent Dry it completely and check it for any damage If there is any damage on the surface replace it with a new one 5 Ins...

Page 119: ...To access the filter remove the screws and the upper plate CT02D073 Figure 101 ULTRA CLEAN FILTER REPLACEMENT 1 Release all pressure in the hydraulic reservoir See Releasing Pressure in the Hydraulic...

Page 120: ...R BREATHER 1 Press the button 1 to release all pressure in the hydraulic reservoir 2 Remove the nut 2 and the cover 3 from the breather 3 Remove and discard the used filter 4 4 Install a new element m...

Page 121: ...let filter and Return filter replacement Install the reservoir drain plug Put new hydraulic fluid into the reservoir See Filling the reservoir Install the reservoir cover plate and seal IMPORTANT Befo...

Page 122: ...idle speed Extend and retract the attachment cylinder rods four or five times without bringing them to end of stroke Then repeat the operation three or four times this time bringing the cylinder rods...

Page 123: ...rvoir See Releasing Pressure in the Hydraulic System IMPORTANT It is mandatory to use the option control pedal to release all pressure in the hydraulic breaker circuit This filter is equipped with an...

Page 124: ...4 screws and the hood CT02D099 Figure 118 CT02D114 Figure 119 CHECKING THE HYDRAULIC SYSTEM LINES Make sure there are no leaks from the hydraulic system hoses pipes plugs connections and fittings and...

Page 125: ...s and hose clamps for tightness The hoses should be replaced before they are worn AIR FILTER RESTRICTION INDICATOR Located above the air filter this indicator 1 shows the state of the air filter eleme...

Page 126: ...air nozzle should be held at least 3 cm from the inside wall of the element Cleaning is completed once no more dust comes out of the element IMPORTANT Compressed air pressure should not exceed 7 bar...

Page 127: ...Install the primary element CT02D118 Figure 130 3 Install the cover with the word TOP at the top and close the fasteners CT02D117 Figure 131 4 Check that the dust ejector under the filter is working c...

Page 128: ...a If necessary top up through the filler port 2 Install the dipstick after topping up the level if required CT02D008 Figure 134 DRAINING AND REFILLING 1 Park the machine on flat horizontal ground Stop...

Page 129: ...ugh the filler port until the level is correct 6 Install the dipstick and the filling plug 7 Wait ten minutes and then use the dipstick to check the level again If necessary top up through the filler...

Page 130: ...ure 139 5 Install the plugs 2 and 3 6 Repeat Steps 2 to 5 for the other travel reduction gear Travel slowly with the machine and make sure there are no leaks DRAINING AND REFILLING 1 Park the machine...

Page 131: ...lug 2 6 Repeat Steps 2 to 5 for the other travel reduction gear Travel slowly with the machine and make sure there are no leaks CT02D142 Figure 143 DRAINING AND REFILLING 1 Park the machine on flat ho...

Page 132: ...CHAPTER 5 LUBRICATION FILTERS AND FLUIDS 5 50 Issued 8 04 Bur 6 34551NA NOTES...

Page 133: ...ance Specifications 6 9 Cleaning 6 9 FAN AND ALTERNATOR DRIVE BELT 6 10 Maintenance Specifications 6 10 Checking the Tension 6 10 Adjusting the Tension 6 10 Replacing the Belt 6 10 FUEL TANK FILTER 6...

Page 134: ...CHAPTER 6 MAINTENANCE AND ADJUSTMENTS 6 2 Issued 8 04 Bur 6 34551NA...

Page 135: ...oncrete or striated plates CLEANING When the machine has been working in mud a reduction in temperature can cause the mud to solidify 1 Place the upperstructure at right angles to the undercarriage Us...

Page 136: ...e ground opposite the blade CT02D176A Figure 6 ADJUSTING THE TENSION This operation is to be carried out after the tension has been checked TO INCREASE TENSION 1 With the track raised clean the grease...

Page 137: ...adaptor regularly and replace it if necessary CT02D178 Figure 8 TRACK TENSION VALUE The value A should be between TIGHTENING TORQUE OF THE TRACK SHOE The tightening torque of the bolts should be betw...

Page 138: ...e ground and lower the boom until the track is raised off the ground NOTE For machines fitted with the dozer blade the machine can be lifted by completely lowering the blade and by using the attachmen...

Page 139: ...247 Figure 16 3 Operate the travel lever of the track concerned in the reverse travel direction Stop the movement when the tubes are pressing against the idler wheel 4 Stop the engine and remove the s...

Page 140: ...er 1 and lower rollers 2 and idler wheels 3 use a permanent floating seal type sealing mechanism The service life normally lasts until overhaul but check visually from time to time before work for oil...

Page 141: ...se perchlorethylene The use of trichlorethylene is strictly forbidden CX75SR CX80 1 Loosen the six wing nuts 1 and remove the three protective grilles 2 to access the radiator 2 Install the grilles 2...

Page 142: ...the pulley grooves If the belt is stretched cracked or frayed it must be replaced IMPORTANT If the engine runs with the belt slack the belt can slip in its housing and cause the engine to overheat or...

Page 143: ...e mounting bolts 1 6 Run the engine for about an hour and then check the belt tension again CT02D201 Figure 30 CX135SR IMPORTANT The two belts have to be changed at the same time 1 Remove the mounting...

Page 144: ...f 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 CHECKING FOR CYLINDER LEAKAGE A cylinder rod s...

Page 145: ...the linkage seals CT02E005 Figure 34 INSTALLATION 1 Install the linkage seals on the arm bushing shoulders Change them if necessary 2 Start the engine Extend the bucket cylinder rod to bring it into...

Page 146: ...he linkage seals for re use CT02D212 Figure 39 INSTALLATION 1 Make sure the bucket is in a stable position 2 Install the linkage seals on the arm bushing shoulders Change them if necessary 3 Start the...

Page 147: ...er and in accordance with his instructions disconnect the batteries disconnect the alternator B and D terminal wires and connect the welding apparatus ground cable to the component on which the weldin...

Page 148: ...r to ensure the air conditioning functions correctly inspect the air conditioner using the procedure outlined below before starting work CLEANLINESS OF THE CONDENSER If the condenser is dirty it will...

Page 149: ...increase engine speed slightly 1400 to 1600 rpm and look for bubbles through the sight glass 1 2 This check should be made approximately one minute after turning on the air conditioning A Very few bub...

Page 150: ...Component Screw Wrench mm Torque setting Nm Travel reduction gear M16 24 267 312 Drive sprocket M14 22 173 202 Idler wheel M10 17 62 73 Upper roller M16 24 267 312 Lower roller M20 30 521 608 Track s...

Page 151: ...24 267 312 Lower roller M16 24 267 312 Track shoe M16 24 390 430 Counterweight M30 46 1335 1550 Turntable undercarriage M16 24 280 322 Turntable upperstructure M16 24 280 322 Swing reduction gear M16...

Page 152: ...CHAPTER 6 MAINTENANCE AND ADJUSTMENTS 6 20 Issued 8 04 Bur 6 34551NA NOTES...

Page 153: ...to The Batteries 7 5 Checking A Battery 7 6 Replacing A Battery CX75SR CX80 7 6 Replacing the Batteries CX135SR 7 7 CONNECTING ONE OR TWO BOOSTER BATTERIES 7 8 ALTERNATOR 7 8 Maintenance Specification...

Page 154: ...CHAPTER 7 ELECTRICAL 7 2 Issued 8 04 Bur 6 34551NA NOTES...

Page 155: ...amperage The fuse box is located in the operator s compartment at the back on the left hand side CT02D244 Figure 1 To access the fuses remove the cover of the box A notice on the cover gives the func...

Page 156: ...ptional power connector 17 10 Travel mode relay 18 10 Fuel filling pump optional 19 10 Optional power connector 20 10 Optional power connector 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 FUSE A...

Page 157: ...nk large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES flush with water for 15 minutes and get prompt medical attention WARNING W...

Page 158: ...REMOVAL 1 Remove the terminal sleeves disconnect the cable negative terminal then the cable positive terminal CT02D259 Figure 8 2 Remove the nuts the washers and the angle iron CT02D260 Figure 9 3 Rem...

Page 159: ...nt remove all foreign bodies clean any spilled electrolyte CT02D254 Figure 14 INSTALLATION 1 Install new batteries Clean the cables and battery terminals and coat them with grease 2 Install the holdin...

Page 160: ...ssary ALTERNATOR MAINTENANCE SPECIFICATION Check Every 1000 hours Do not use steam cleaning equipment or a cleaning solvent to clean the alternator Ask your Dealer to check the alternator Make sure th...

Page 161: ...ing screws CT02D261 Figure 18 2 Tilt the working light and disconnect the plug CT02D262 Figure 19 3 Pull the clip outwards remove the bulb and install a bulb of the same wattage CX75SR CX80 55 W for l...

Page 162: ...LECTRICAL 7 10 Issued 8 04 Bur 6 34551NA ADJUSTING THE WORKING LIGHTS CAB Cab working lights are adjusted manually CT02D265 Figure 21 ATTACHMENT Attachment working lights are adjusted manually CT02D26...

Page 163: ...TEMS AND COMPONENTS 8 6 CX75SR CX80 8 6 CX135SR 8 6 WEIGHTS 8 6 CX75SR CX80 8 6 CX135SR 8 6 GROUND PRESSURE 8 6 BOOMS 8 6 ARMS 8 7 ESCO BUCKETS 8 8 CX75SR CX80 8 8 CX135SR 8 8 MACHINE OVERALL DIMENSIO...

Page 164: ...CHAPTER 8 SPECIFICATIONS 8 2 Issued 8 04 Bur 6 34551NA...

Page 165: ...rpm CX135SR Make ISUZU Type BB 4BG1T Turbo yes Electronically controlled injection Number of cylinders 4 Bore stroke 105 mm x 125 mm 4 13 x 4 92 Displacement 4329 cm3 264 CID Power EEC 80 1269 65 6 kW...

Page 166: ...p upperstructure swing speed 10 rpm TRAVEL Variable flow hydraulic motors with axial pistons Planetary reduction gears Two speeds controlled from the instrument panel Low speed 0 to 3 4 km h 0 to 2 1...

Page 167: ...E Width 2 32 m 7 ft 6 in Height 0 45 m 1 ft 4 in Maximum elevation height 0 41 m 1 ft 3 in Maximum depth below ground level 0 20 m 6 in UNDERCARRIAGE CX135SR SPECIFICATIONS PER TRACK ASSEMBLY Number o...

Page 168: ...in shoes offset boom 1 75 m 5 ft 9 in arm 210 kg 460 lb bucket 1 220kg 2 690 lb counterweight operator and full fuel tank 8060 kg 17 800 lb CX80 With 450 mm 17 7 in track pads one piece boom 1 70 m 5...

Page 169: ...8 04 Bur CX135SR Monobloc length 4 75 m 15 ft 6 in ARMS CX75SR Length 1 70 m 5 ft 7 in and 2 12 m 6 ft 11 in Offset arm 1 75 m 5 ft 9 in CX80 Offset arm 1 70 m 5 ft 7 in and 2 10 m 6 ft 9 in CX135SR...

Page 170: ...270 kg STDP CAPACITY 50 cu yd 66 cu yd 82 cu yd 98 cu yd WIDTH OUTSIDE LIP 24 in 610 mm 30 in 762 mm 36 in 914 mm 42 in 1 067 mm WEIGHT 791 lb 351 kg 889 lb 359 kg 1 007 lb 457 kg 1 110 lb 503 kg HDP...

Page 171: ...7 m 19 ft 7 in D Length from swing pivot to end of arm transport position 4 45 m 14 ft 5 in E Overall width of upperstructure 2 23 m 7 ft 4 in F Length from track to end of dozer blade 3 27 m 10 ft 7...

Page 172: ...22 ft 1 in D Length from swing pivot to end of arm transport position with 1 71 m 5 ft 6 in arm 5 00 m 16 ft 4 in with 2 12 m 6 ft 9 in arm 5 09 m 16 ft 7 in E Overall width of upperstructure 2 23 m 7...

Page 173: ...ransport 5 49 m 18 ft 0 in E Overall width of upperstructure 2 42 m 7 ft 11 in F Length from track to dozer blade not shown on diagram 4 02 m 13 ft 2 in G Tail swing radius 1 48 m 4 ft 10 in H Overall...

Page 174: ...50 m 21 ft 5 in B Maximum reach at ground level 6 40 m 21 ft 0 in C Maximum digging depth 4 15 m 13 ft 9 in D Maximum digging depth over a length of 2 44 m 8 ft 3 80 m 12 ft 6 in E Maximum dump heigh...

Page 175: ...m 22 ft 8 in B Maximum reach at ground level 6 75 m 22 ft 3 in C Maximum digging depth 4 55 m 14 ft 10 in D Maximum digging depth over a length of 2 44 m 8 ft 4 25 m 14 ft 0 in E Maximum dump height 5...

Page 176: ...5 m 20 ft 10 in zero offset C Maximum digging depth 3 75 m 12 ft 4 in maximum offset 4 20 m 13 ft 9 in zero offset D Maximum digging depth over a length of 2 44 m 8 ft 3 40 m 11 ft 2 in maximum offset...

Page 177: ...Maximum digging depth 4 18 m 13 ft 7 in 4 59 m 15 ft 1 in D Maximum digging depth over a length of 2 44 m 8 ft 3 80 m 12 ft 5 in 4 23 m 13 ft 9 in E Maximum dump height 4 39 m 14 ft 4 in 4 60 m 15 ft...

Page 178: ...each 8 20 m 26 ft 11 in B Maximum reach at ground level 8 05 m 26 ft 6 in C Maximum digging depth 5 45 m 17 ft 11 in D Maximum digging depth over a length of 2 44 m 8 ft 5 25 m 17 ft 3 in E Maximum du...

Page 179: ...ft 1 in B Maximum reach at ground level 8 43 m 27 ft 8 in C Maximum digging depth 5 93 m 19 ft 5 in D Maximum digging depth over a length of 2 44 m 8 ft 5 70 m 18 ft 9 in E Maximum dump height 7 10 m...

Page 180: ...onditions such as soft or uneven ground non level conditions side loads hazardous conditions experience of personnel etc The operator and other personnel should fully acquaint themselves with the oper...

Page 181: ...209 kg 462 lb bucket Load Lift Point Height Load Radius End Side End Side End Side End Side 5 ft 10 ft 15 ft Lb Cap at Max Reach 15 ft 3 250 3 150 3 000 2 750 10 ft 4 150 4 150 3 400 3 050 2 300 2 050...

Page 182: ...0 11 450 16 800 10 400 8 350 5 550 5 400 3 600 5 000 3 350 10 ft 17 900 17 900 15 200 10 600 8 400 5 600 6 450 4 350 15 ft 7 650 7 650 6 300 6 300 NOTE 4 73 m 15 ft 6 in Boom and 398 kg 879 lb bucket...

Page 183: ...CHAPTER 8 SPECIFICATIONS 8 21 6 34551NA Issued 8 04 Bur NOTES...

Page 184: ...CHAPTER 8 SPECIFICATIONS 8 22 Issued 8 04 Bur 6 34551NA...

Page 185: ...speed selector 3 6 Engine oil pressure indicator lamp 3 7 Engine operation 4 6 Engine throttle button 3 6 Environment 5 11 F Fan and alternator drive belt 6 10 Fire extinguisher 6 15 Fluid and lubric...

Page 186: ...bucket CX135SR 6 14 Replacing a backhoe bucket CX75SR CX80 6 13 Replacing a bulb 7 9 Replacing the rubber tracks 6 6 Retro offset boom arm lubrication 5 15 Right hand control arm 3 6 Rotary light 3 10...

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