Case CX75SR User manual

CX75SR, CX80 AND
CX135SR
EXCAVATORS
OPERATOR’S MANUAL
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.
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.
Part Number: 6-34551NA

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 © 2004 CNH America LLC Bur 6-34551NA
All Rights Reserved Issued August, 2004
CASE and IH are registered trademarks of CNH America LLC
M171D
Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:
● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or
serious injury. The color associated with Danger is RED.
● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury. The color associated with Warning is ORANGE.
● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices. The color associated with
Caution is YELLOW.
If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:
● The first panel indicates the nature of the hazard.
● The second panel indicates the appropriate avoidance of the hazard.
● Background color is YELLOW
● Prohibition symbols such as and if used, are RED.
WARNING_01_NA
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
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 CNH America LLC
instructions on machine operation and maintenance.
STOP

I
6-34551NA Issued 8-04 Bur
TABLE OF CONTENTS
CHAPTER 1
GENERAL INFORMATION
To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CHAPTER 2
SAFETY, DECALS, AND HAND SIGNALS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
CHAPTER 3
INSTRUMENTS AND CONTROLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Position of the Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Right-hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Left-hand Control Arm for CX75SR, CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Left-hand Control Arm for 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 cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Arm and upperstructure Swing Left-hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Boom and Bucket Right-hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Offset Boom Control Pedal (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Option Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Unlocking and Locking of Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Dozer Blade Control Lever (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Cab Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Coat Hanger Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Rear Right-hand Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Glove Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Storage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Cab Radio Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Speaker Compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Window-Breaker Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Air Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Rear View Mirrors - CX75SR, CX80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

II Issued 8-04 Bur 6-34551NA
Rear View Mirrors CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Upper Hood - CX75SR, CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Side Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Rotating Beacon Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Towing Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Load Handling Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Tool Supply Valves (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Tool Flow Selector Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHAPTER 4
OPERATING INSTRUCTIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Run-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Bringing the Machine up to Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Operating the Machine in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Operating the Machine in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Transport Position 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
Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Operating the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Lowering the attachment in the event of a machine failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
CHAPTER 5
LUBRICATION, FILTERS, AND FLUIDS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Lubrication and Maintenance Chart For CX75SR, CX80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lubrication and Maintenance Chart For CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fluid and Lubricant Capacities and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Engines - CX75SR, CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Engine - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Cooling System - CX75SR, CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Cooling System - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

III
6-34551NA Issued 8-04 Bur
Swing Reduction Gear - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Travel Reduction Gears - CX75SR, CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Travel Reduction Gears - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
CHAPTER 6
MAINTENANCE AND ADJUSTMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Checking the Condition of Rubber Tracks (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Replacing the Rubber Tracks (CX75SR, If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Track Rollers and Idler Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Radiator and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Fan and Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Fuel Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Inspecting and Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Replacing a Bucket - CX75SR, CX80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Replacing a Bucket - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Fire Extinguisher (Not Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Two Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Replacing a Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Adjusting The Working Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
CHAPTER 8
SPECIFICATIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Hydraulic System - CX75SR, CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Hydraulic System - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Undercarriage - CX75SR, CX80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Undercarriage - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Capacity of Systems and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Esco Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Machine Overall Dimensions - CX75SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Machine Overall Dimensions - CX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Machine Overall Dimensions - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Working Range - CX75SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Working Range - CX80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Working Range - CX135SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

IV Issued 8-04 Bur 6-34551NA
CHAPTER 9
INDEX

CHAPTER 1 - GENERAL INFORMATION
1-1
6-34551NA Issued 8-04 Bur
Chapter 1
GENERAL INFORMATION
TO THE OWNER
CT02C001FX Figure 1
HYDRAULIC CRAWLER EXCAVATORS SERIES CX75SR, CX80 AND CX135SR
Your machine has been designed and built to the highest standards of quality. It conforms to all current safety
regulations. See Official documents. However, the risk of accidents can never be completely excluded. That is why
it is essential to observe elementary safety rules and precautions.
Read this manual carefully, paying particular attention to the instructions concerning safety, operation and
maintenance so as to avoid the risk of injury while operating or servicing the machine.
The standard attachments and tools of this machine are designed to carry out all kinds of earth 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 application, the machine must be equipped
with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its
attachment and a load fixing point. All legal requirements must also be strictly observed.
Do not use this machine for any application or purpose other than those described in this manual. If the machine is
to be used for work involving the use of special attachments, accessories or equipment, consult your Dealer in
order to make sure that any adaptations or modifications made are in keeping with the machine's technical
specifications and with prevailing safety requirements.
Any modification or adaptation which is not approved by the manufacturer may invalidate the machine's initial
conformity with safety requirements.

CHAPTER 1 - GENERAL INFORMATION
1-2 Issued 8-04 Bur 6-34551NA
The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult
your Dealer.
Before permitting a new operator on this machine, make sure:
1. That the operator has received the necessary training on how to operate the machine correctly and safely in
one of our training centres 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 the operator's seat). Make sure it
is always complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that
of the country of use, consult your Dealer.
Your Dealer is at your disposal for any further information. He will also provide any after-sales service you may
require, and genuine CASE spare parts, your guarantee of quality and match.

CHAPTER 1 - GENERAL INFORMATION
1-3
6-34551NA Issued 8-04 Bur
MACHINE COMPONENTS
CT02C001 Figure 2
MAIN COMPONENTS
The CX75SR, CX80 and CX135SR are fully hydraulic machines. They consist of an undercarriage fitted with tracks
and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the
attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the
controls, the engine-driven pump delivers hydraulic fluid to the control valves. The control valves distribute the
hydraulic fluid to the various cylinders and motors concerned. A cooling system maintains the hydraulic fluid at
normal operating temperature.
1. CAB/OPERATOR'S COMPARTMENT 9. ARM CYLINDER 17. IDLER WHEELS
2. UPPERSTRUCTURE 10. BACKHOE BUCKET 18. TRACKS
3. UNDERCARRIAGE 11. BACKHOE BUCKET CYLINDER 19. HYDRAULIC RESERVOIR
4. STEPS 12. ENGINE COMPARTMENT 20. FUEL TANK
5. ACCESS HANDLES 13. COUNTERWEIGHT 21. DOZER BLADE (IF EQUIPPED)
6. BOOM 14. UPPER ROLLERS 22. DOZER BLADE CYLINDERS (IF EQUIPPED)
7. BOOM CYLINDERS 15. LOWER ROLLERS
8. ARM 16. TRAVEL REDUCTION GEARS
6
1
12
10
7
8
11
2
9
13
16
14
18 17 15 43
22
21
1920
5
5

CHAPTER 1 - GENERAL INFORMATION
1-4 Issued 8-04 Bur 6-34551NA
RIGHT, LEFT, FRONT AND REAR OF THE MACHINE
CT02D269 Figure 3
1. FRONT
2. REAR
3. RIGHT-HAND SIDE
4. LEFT-HAND SIDE
5. TRAVEL REDUCTION GEARS
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 illustration below shows the machine in normal
TRAVEL position. In normal TRAVEL position, the
cab is over the idler wheels. The travel reduction
gears are at the rear of the upperstructure.
1
66
34
55
2

CHAPTER 1 - GENERAL INFORMATION
1-5
6-34551NA Issued 8-04 Bur
IDENTIFICATION NUMBERS
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE
When ordering parts, obtaining information or assistance, always supply your Dealer with the type and serial
number of your machine or accessories.
Write the following in the spaces below: The type, serial number and year of manufacture of your machine,
accessories and the serial numbers of the various hydraulic and mechanical components.
Machine
Figure 4
CX75SR, CX80 Engine
CT02C062 Figure 5
CX135SR Engine
CT02C050 Figure 6
COMPONENT SERIAL NUMBERS
Hydraulic pump............................................................................................................................................................
Swing reduction gear...................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Travel control valve......................................................................................................................................................
Attachment control valve .............................................................................................................................................
Swing control valve......................................................................................................................................................
CX75SR, CX80 Engine
➤
Make and Model
➤
Serial Number
CX135SR Engine
➤
Make and Model
➤
Serial Number

CHAPTER 1 - GENERAL INFORMATION
1-6 Issued 8-04 Bur 6-34551NA
NOTES

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

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-2 Issued 8-04 Bur 6-34551NA
NOTES

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-3
6-34551NA Issued 8-04 Bur
SAFETY RULES
M171C
Most accidents involving machine operating 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 signs on the machine before
you operate or service the machine. See your dealer
if you have any questions.
RD98K305 Figure 1
1. OPERATOR’S MANUAL STORAGE BOX
READ THIS MANUAL COMPLETELY and make sure
you understand the controls. All equipment has a
limit. Make sure you understand the speed, brakes,
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. Also see the manual information on the
inside of the rear cover of this manual.
The safety information given in this manual does not
replace safety codes, insurance needs, federal, state
or local laws. Make sure that your machine has the
correct equipment according to these rules or laws.
Additional safety messages are used in the text of
the manual to show specific safety hazards.
IMPORTANT: The safety messages in this chapter
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 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 if
used, are RED.
SAFETY AREA
CS97M019 Figure 2
1. WORKING AREA
2. SAFETY AREA
The safety area is the space necessary for the
machine to operate at the maximum range of the tool
and a full 360°swing plus 6 feet (2 metres).
UTILITY SAFETY
Safety precaution MUST be followed when working
near buried and over head Utility Lines.
During operation it is likely that you will be working
around or near buried or over head utility lines which
may include, but are not limited to:
• Electrical Power Line
• Gas Line
• Water Line
• Communication Line - Telephone or Cable
Television
Before beginning any machine operation, it is
your responsibility to be aware of all such utility
lines buried and over head in the area of your
project and to avoid them.
WARNING: This safety alert symbol
indicates important safety messages in this
manual. When you see this symbol, carefully
read the message that follows and be alert to
the possibility of death or serious injury.
1
STOP
1
2

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-4 Issued 8-04 Bur 6-34551NA
ALWAYS have all local utility companies mark the
location of their lines.
In U.S.A. and Canada call one of many “One Call
System Director” services. If you do not know the
local number, call the national number (U.S.A. and
Canada only): 1-888-258-0808.
Check with local authorities for laws, regulations
and/or strict penalties requiring you to locate and
avoid existing utilities.
RH99G001 Figure 3
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 any buried 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.
OPERATOR PRECAUTIONS
PERSONNEL
• 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
be worn when operating this machine. Hard hats,
protective glasses, protective shoes, gloves,
reflector type vests, respirators and ear protection
are examples of typed of equipment that may be
required.
• Certain protective equipment should be replaced
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
recommendation.
• Do not rush. Walk, do not run.
• Know and use the hand signals required for
particular jobs and know who has the
responsibility for signaling.
GENERAL
• It is the responsibility of the operator to read and
understand the Operator’s Manual and other
information provided and use the correct operating
procedure. Machines should be operated only by
qualified operators.
• Do not operate this machine or perform
maintenance work if you have not had appropriate
training and read and fully understand the
instructions and warnings in this manual.
• Wear the seat belt to maximize the protection
capability of a ROPS (Roll Over Protective
Structure) when the machine is so equipped.
• Inspect the ROPS and seat belt mounting bolts on
a daily basis to ensure their integrity.
• Do not permit riders on the machine if there is no
manufacturer’s designated place for a rider.
• Make sure that all protective guards, canopies,
doors, etc. are in place and secure.
• Remove all loose object stored in the machine.
Remove all objects which do not belong in or on
the machine and its equipment.
MOUNTING AND DISMOUNTING PRECAUTIONS
• Use the recommended hand holds and steps with
at leas three points of support when getting on and
off the machine. Keep steps and platform clean.
Face the access system when climbing up and
down
• Do not jump off the machine.
• Do not dismount while the machine is in motion.
• Foreign material or grease on the steps and hand
rails can cause an accident. Keep the steps and
hand rails clean.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-5
6-34551NA Issued 8-04 Bur
STARTING AND STOPPING PRECAUTIONS
• Walk around the machine and warn all personnel
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, if equipped, before starting.
• Walk around the machines tool, attachment, or
furthermost contact point to view operation danger
area from the work site personnel view and angle.
• Check that the parking device is applied, place the
transmission in neutral or park as specified by the
manufacturer, and disengage the PTO, if so
equipped, before starting the machine.
• 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 neutral-start system.
The neutral-start system must be repaired if it
malfunctions.
• Use jumper 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 jumper cables will not
interfere 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 wheels or track securely
blocked.
• Before leaving the operator’s station, place the
transmission in the park position as specified by
the manufacturer, lower the equipment to the
ground or put in the locked position, disengage the
PTO, if so equipped, set the parking device and
shut off the engine.
• Remove the starter key or disconnect switch when
leaving the machine parked or unattended.
OPERATING PRECAUTIONS
• Check brakes, steering and other machine control
devices in accordance with the manufacturers
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
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 towed.
• Understand the machine limitations and keep 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.
• When roading a machine, know and use the
signaling devices required on the machine.
Provide and escort for roading where required.
• On machines with independently operated wheel
brakes, lock the brake pedals together when
roading to provide equalized brake application.
• Use the recommended transport devices when
roading the machine.
• Use the approved drawbar and / or 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.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-6 Issued 8-04 Bur 6-34551NA
• 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.
• If your machine has a cab make sure that all
windows are clean and that the windshield wipers
work correctly.
• 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 at least 4.6 m (15 feet) 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.
• If you have extreme conditions, such as a fire, etc.,
and you are forced to leave the machine, do not
step off the machine. Jump as far from the
machine as possible with your feet together and do
not touch the ground with your hands.
• Do not operate the machine if you do not feel well.
This can be dangerous for you and for the people
around you.
• 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.
MAINTENANCE PRECAUTIONS
• Do not attempt repairs unless trained. Refer to
manuals and experienced repair personnel for
help.
• Before you service the machine, put a Do Not
Operate tag on the key switch. The Do Not
Operate tag is included with your new machine.
Addition tags, part number 321-4614 are available
from your Dealer.
321-4614 Figure 4
• Wear protective glasses and other required safety
equipment when servicing or repairing the
machine.
• Wear gloves to protect hands when handling
cable.
• Disconnect the battery before working on the
electrical system. Know the consequences of
disconnecting any electronic or computer devices.
• Avoid lubrication or mechanical adjustments with
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 wheels and use
extreme caution.
• Securely block the machine or any component that
may fall before working on the machine or
component. If possible, use a back up or
secondary blocking device, also.
• To prevent unexpected movement, securely block
working elements when repairing or changing
working tool parts such as cutting edges.
• Never make repairs on pressurized components,
fluid, gas or mechanical until the pressure has
been relieved according to the manufacturer’s
instructions.
• Use extreme caution when removing radiator
caps, drain plugs, grease fittings or pressure taps.
Park the machine and let it cool down before
opening a pressurized tank.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-7
6-34551NA Issued 8-04 Bur
• 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 manufacturers. recommendations.
• When inflating tires, use a self-attaching inflation
chuck with remote shutoff and stand clear of the
tire. Position yourself beside the tire and not
beside the rim.
• 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 braked, a towbar 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.
• Observe proper maintenance procedures.
• Whenever servicing or replacing hardened pins,
etc., use a brass drift or other suitable material
between the hammer and pin. Alt: Use a brass
hammer, drift or suitable material on the pin, etc.
• Keep the brakes and steering systems in good
operating condition.
• Replace all missing, illegible or damaged safety
signs. Keep all safety signs 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
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.
• To avoid spilling fuel maintain control of the fuel
filler nozzle when filling the tank.
• Do not fill the fuel tank completely to the top. Allow
room for expansion.
• Clean up spilled fuel immediately and dispose of
contaminated material in an environmentally
correct manner.
• Tighten the fuel tank cap securely. Should the fuel
cap be lost, replace it only with the original
manufacturers approved cap. Use of a
non-approved cap without proper venting may
result in pressurization of the tank.
• Never use fuel for cleaning purposes.
• Use the correct fuel grade for the operating
season.
BURN PREVENTION
M144B
• When the battery electrolyte is frozen, the battery
can explode if, you try to charge the battery, or you
try to jump start and run the engine. To prevent the
battery electrolyte from freezing, try to keep the
battery at full charge. If you do not follow these
instructions, you or others in the area can be
injured
• Hot coolant can spray out if the radiator cap is
removed. To remove the radiator cap, let the
cooling system cool, turn to the first notch, wait
until the pressure is released, then remove the
radiator cap.
HAZARDOUS CHEMICAL PRECAUTIONS
• If you are exposed to or come in contact with
hazardous chemicals you can be seriously injured.
The fluids, lubricants, paints, adhesives, coolants,
etc., used with your machine can be hazardous.
• Material Safety Data Sheets (MSDS) provide
information about the chemical substances within
a product, safe handling procedures, first aid
measures and procedures to be taken when the
product is accidentally spilled or released. MSDS
are available from your dealer.
• Before you service your machine, check the
MSDS for each fluid, lubricant, etc., used in this
machine. This information indicates what the risks
are and how to service the machine safely. Follow
this information when servicing the machine.
• Before you service this machine and before you
dispose of the old fluids and lubricants, always
remember the environment. DO NOT put oil or
fluids into the ground or into containers that can
leak.
WARNING: BATTERY ACID CAUSES
SEVERE BURNS. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or
clothing.
Antidote: EXTERNAL - Flush with water.
Antidote: INTERNAL - Drink large quantities
of water or milk.
DO NOT induce vomiting. Seek medical
attention immediately.
EYES - Flush with water for 15 minutes and
seek medical attention immediately.
WARNING: BATTERIES PRODUCE
EXPLOSIVE GASES. Keep sparks, flame,
cigars and cigarettes away. Ventilate when
charging or using in enclosed area. Always
wear eye protection when working near
batteries. Wash hands after handling. KEEP
OUT OF REACH OF CHILDREN.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
2-8 Issued 8-04 Bur 6-34551NA
• Check with your local environmental or recycling
center or your dealer for correct disposal
information.
TRANSPORTING PRECAUTIONS
• Know the rules, laws, and safety equipment
necessary for transporting this machine on a road
or highway.
WHEEL, TIRE, AND TRACK SAFETY
• Explosive separation of the tire and/or rim parts
can cause injury or death. When tire service is
necessary, have a qualified tire mechanic service
the tire.
ROLL-OVER PROTECTIVE STRUCTURE
• Do NOT modify the ROPS in any manner.
Unauthorized modifications such as welding,
drilling, cutting, or adding attachments can weaken
the structure and reduce your protection. Replace
ROPS if it is subjected to roll-over or damage. Do
not attempt to repair.
FIRE EXTINGUISHER
It is recommended that you have a fire extinguisher
on your machine. The fire extinguisher shown is
available from your dealer and can be installed on the
machine.
SEAT BELT PRECAUTIONS
CD00E032 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 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.
M422A
M437
SPECIFIC PRECAUTIONS TO THIS MACHINE
• Keep the load or tool as low as possible while
moving the machine around the job site.
• Never smoke while refuelling.
12
3
WARNING: Before starting the engine
ensure seat belts are securely fastened. The
seat belt can help insure your safety if it is
used and properly maintained. Never wear a
seat belt loosely or with slack in the belt
system. Never wear the belt in a twisted
condition or pinched between the seat
structural members.
WARNING: Securely fasten your seat belt.
Your machine is equipped with a ROPS cab,
ROPS canopy or ROPS frame for your
protection. The seat belt can help insure your
safety if it is used and maintained. Never
wear a seat belt loosely or with slack in the
belt system. Never wear the belt in a twisted
condition or pinched between the seat
structural members.