Case CX235C SR Tier 4 Crawler Excavator Workshop Service Repair Manual

Download Service Repair Manual for Case CX235C SR Tier 4 Crawler Excavator.

Lep 84577148 EN
Issue date February 2012
Printed in France

Part number 84577150
1st edition English
February 2012

This Factory Service Repair Manual offers all the service and repair information about Case CX235C SR Tier 4 Crawler Excavator. With this in-depth & highly detailed manual you will be able to work on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your investment. The information on this manual covered everything you need to know when you want to repair or service on Case CX235C SR Tier 4 Crawler Excavator.

Models Covered:

Case CX235C SR Tier 4 Crawler Excavator

Manual Contents:

1 GENERAL INFORMATION
Safety, general information and standard torque data . . . . . . . . . . . . . . . . . . . . . . . 1001
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002A
Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002B
Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002C
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002D
Bolt Size and Torque Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002E
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002F
New Machine Performance Judgment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002G
List of special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
Conversion Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900
2 ENGINE
Removal and Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . 2000
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler . . . 2001
Removal and Installation of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2004
Removal and Installation of EGR Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005
Removal and Installation of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2006
Removal and Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2007
Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2401
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2415
Removal and Installation of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2445
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455
Removal and Installation of Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2465
Disassembly, Removal and Installation of DPD Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2470
3 FUEL SYSTEM
Removal and Installation of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
Removal and Installation of Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . 3004A
Removal and Installation of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . 3004B
Removal and Installation of Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3005
4 ELECTRICAL SYSTEM
Electrical and Engine Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001A
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001B
Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001C
Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001E
Functional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001F
Engine, Electronic and Programming Maintenance Precautions . . . . . . . . . . . . . 4001G
Removal and Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4004
Removal and Installation of Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
Preheating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4008
Electrical Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020A
Connection Connector Pin Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020B
Sequence Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020C
Engine-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4021
Main Unit-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4022
Introduction to the trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023B
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023D
Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023G

Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023H
Data Reference Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023K
Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4040
5 UNDERCARRIAGE
Removal and Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5001A
Removal and Installation of Shoe Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001B
Removal and Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003A
Assembly and Disassembly of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003B
Removal and Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003C
Assembly and Disassembly of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 5003D
Removal and Installation of the Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5004
Removal and Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005A
Assembly and Disassembly of Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . 5005B
Removal and Installation of Grease Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . 5005C
Assembly and Disassembly of Tension Shock Absorbed . . . . . . . . . . . . . . . . . . . . . . . 5005D
6 DRIVE TRAIN
Removal and Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
Assembly and Disassembly of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Removal and Installation of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
Assembly and Disassembly of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6004
7 UNDERCARRIAGE HYDRAULICS
8 UPPER-STRUCTURE HYDRAULICS
Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001A
Port Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001B
Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001C
Pressure Measurement and Adjustment Procedures . . . . . . . . . . . . . . . . 8001D
Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . 8001E
Drain Volume Measurement Procedures. . . . . . . . . . . . . . . . . . . . . . . 8001F
Air Bleed Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001G
Removal and Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . 8002
Removal and Installation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 8003
Removal and Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8004
Removal and Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005A
Removal and Installation of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 8005B
Removal and Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . 8005C
Removal and Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006
Removal and Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . 8007A
Removal and Installation of Operation Remote Control Valve. . . . . . . . . . . . . . . . 8007B
Removal and Installation of 5 Stack Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 8007C
Removal and Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007D
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit . . . . . . . 8008
Pump Main Unit Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8010
Procedures for Assembly and Disassembly of Control Valve . . . . . . . . . . . . . . . . . . 8011
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder (made by KYB) 8012
Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . 8013
Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . 8014
Assembly and Disassembly of Cushion Valve . . . . . . . . . . . . . . . . . . . . .. . . . . 8016
Removal and Installation of Arm HBCV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8017A
Removal and Installation of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8017B
Assembly and Disassembly of Center Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8018
Assembly and Disassembly of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8019
Explanation of Hydraulic Circuit and Operations (standard model) . . . . . . . . . . . . . . 8020A
Explanation of Hydraulic Circuit and Operations (option) . . . . . . . . . . . . . . . . . . . . . . . 8020B

Structure and Operation Explanation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . 8030A
Structure and Operation Explanation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . 8030B
Structure and Operation Explanation of Swing Motor . . . . . . . . . . . . . . . . . . . . 8030C
Structure and Operation Explanation of Control Valve . . . . . . . . . . . . . . . . . . . . . 8030D
5 Stack Solenoid Valve Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030E
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) . . . . . . . . 8030F
Structure and Operation Explanation of Travel Pilot Valve (remote control valve). . . . . . . . 8030G
Structure and Operation Explanation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . 8030H
9 UPPER-STRUCTURE
Removal and Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Removal and Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003A
Removal and Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003B
Removal and Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003C
Removal and Installation of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003D
Removal and Installation of Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Removal and Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005A
Removal and Installation of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005B
Removal and Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005C
Removal and Installation of Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . 9005D
Removal and Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005E
Removal and Installation of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005F
Window Lock Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005G
Cab Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005H
Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006
Assembly and Disassembly of Air Conditioner Units. . . . . . . . . . . . . . . . . . . . . 9007
Removal and Installation of Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009
Removal and Installation of Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010
Removal and Installation of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011
Air Conditioning Gas Vacuum and Filling Operations . . . . . . . . . . . . . . . . . . . . . . . . 9015
10 LARGE SIZE SCHEMATICS
Large size hydraulic schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84591421EN
Large size electrical schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84591419EN

This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings. Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

Language: English
Format: PDF
PAGES: 2061
Platform: Windows Phone, Ipad and Mac
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Download Case CX235C SR Tier 4 Crawler Excavator Workshop Service Repair Manual