CASE Construction CX135SR Crawler Excavator Service Manual 9-40641NA English

Name: CASE Construction CX135SR Crawler Excavator Service Manual 9-40641NA English
SKU: 9-40641NA.pdf
Price: 18.99 USD
Availability: InStock

$ 18.99 USD

Official Manual Overview

Take absolute command over the versatile zero-tail-swing earthmover with this definitive OEM Service Manual, engineered explicitly for the CASE CX135SR Crawler Excavator. Designed for advanced dealership technicians, this volume delivers uncompromising reconstruction protocols for the entire chassis, undercarriage, and complex hydraulic networks. It provides elite-level calibration metrology for the dual 117.2 L/min variable displacement main pumps and dictates absolutely staggering fastening specifications—including the massive 4780 Nm torque requirement for the dipper cylinder nut and 3180 Nm for the boom cylinder. It extensively covers multiple machine configurations, including both the NA (North America) and WE (Europe) variants, alongside specific structural tear-downs for both Monobloc and Offset Boom architectures. Furthermore, it transforms the cabin into an advanced diagnostic command center with detailed electrical pinout mapping and proportional solenoid troubleshooting. Please note: In strict adherence to CASE's publication strategy, while complete engine removal and external sensor diagnostics are covered, deep internal block teardowns for the Isuzu BB-4BG1T diesel engine are explicitly redirected to a dedicated engine manual.

Brands: CASE Construction
Equipment Type: Crawler Excavator
Manuals Type: Service Manual
Machine Model: CX135SR (Includes Monobloc & Offset Boom variants)
Serial Number: N/R
Region: North America, Europe
Book Code: 9-40641NA
Issued: Printed in France, December 2004
Language: English
Pages: 820
File Format: PDF (Searchable)

Core Selling Points

Surgical Pump Reconstruction Metrology: Stop relying on guesswork and rebuild the primary hydraulic pumps with micrometer-level precision. This literature dictates absolute wear tolerances, mandating a strict 0.067 mm discard limit for piston-to-cylinder bore clearance, a 4.7 mm minimum shoe thickness, and a highly specic 0.1 Ra surface roughness threshold for the cylinder block sliding contact surface after grinding.
Advanced RED4 & ECM Interception: Eradicate blind electrical diagnostics by tapping directly into the machine's brain. The manual extensively maps out how to utilize the proprietary CAS-30039 and CAS-40041 test connector kits to intercept signals from the RED4 electronic acceleration module. It provides exact pin-by-pin testing paths for TECH 2 (TXD/RXD) communications, emergency stop motors, and proportional solenoid networks.
Uncompromising Hydraulic Calibration: Master the fluid dynamics required to tune this excavator to absolute factory baselines. Technicians are guided through step-by-step pressure metrology using the Multi-Handy 2051 digital tester and CAS10280 flowmeters. It requires calibrating the negative pressure check to exactly 27 bar (2.7 MPa) and tuning the boom raising secondary relief valve to a strict 391 bar at 20 L/min.

Features & Highlights

Heavy-Duty Valve Bank Architectures: Prevent catastrophic manifold leaks under extreme mining loads. The documentation outlines rigorous teardown and fastening sequences for the main control valves, demanding immense torque applications such as tightening the spool caps to 271.6 - 277.6 Nm and securing the main body plugs to an exact 213.8 - 217.8 Nm spec.
Exhaustive Undercarriage Wear Matrices: Stop replacing expensive tracks and rollers based on visual estimates. Mechanics are provided with absolute mathematical wear limits, mandating a hard replacement when the standard 171.5 mm track chain pitch stretches to 166.95 mm, or when the drive sprocket base diameter wears from 530.7 mm down to 524.7 mm.
Dynamic Fluid Logic & Spool Mapping: Navigating the massive control valve banks is made straightforward. The manual features "Dynamic Description" schematics that completely break down the internal spool logic, illustrating exactly how fluid flows from the P2 pump outlet through the Pa7/A7 circuits during bucket opening sequences, simplifying complex flow restrictions.

Problem Solver

Eradicates Phantom Travel Drift: The step-by-step troubleshooting trees permanently eradicate tracking issues. It instructs technicians to bring hydraulic oil to exactly 50°C on a 30-meter test track, verifying if the pressure difference between P1 and P2 exceeds 30 bar (3 MPa)—instantly pinpointing a failing negative pressure circuit or a defective travel motor displacement spool.
Cures Intermittent Throttle Failures: Troubleshoot the electronic throttle command definitively. By utilizing the exact timing diagrams and resistance benchmarks, mechanics can isolate elusive power drops to the engine speed detector (B41) or the RED4 limp-home mode, preventing unnecessary and expensive computer replacements.
Prevents Fatal Cylinder Reassembly Mistakes: Improperly secured hydraulic cylinders will blow out under load. This guide safeguards your rebuilds by dictating strict fastening architectures, ensuring components like the offset boom cylinder piston nut are secured to a massive 2620 Nm, while the rod gland is locked in at 834 Nm.

Important Pre-Purchase Advisories

Complete "Large Format" Schematics Included: Unlike many digital copies that omit physical pocket inserts, this specific manual fully incorporates the original large-format electrical wiring diagrams and complex hydraulic circuit charts (OEM Reference 9-43660) at the end of the file. Technicians receive 100% unbroken end-to-end component routing.
Dedicated Engine Block Focus: In strict adherence to the manufacturer's publication strategy, this manual exhaustively covers engine removal, installation, electronic acceleration circuits, and external sensor diagnostics. However, deep internal mechanical teardowns of the Isuzu BB-4BG1T diesel engine block are explicitly redirected to the dedicated Engine Service Manual.

Table of Contents

INTRODUCTION
- Foreword
- Safety rules
- Basic instructions
- Torque
- Dimension
- Weight
- Consumables
- Hydraulic contamination
- Product identification
DISTRIBUTION SYSTEMS
- PRIMARY HYDRAULIC POWER SYSTEM
  - TECHNICAL DATA
    - General specification
    - Special tools
    - Seed rates
    - Hydraulic pump
      - Special tools
      - Service limits
  - FUNCTIONAL DATA
    - Static description
    - Dynamic description
    - Stack valve
      - External view
      - Sectional view
      - Inlet section - Sectional view
      - Outlet section - Sectional view
    - Hydraulic pump
      - Sectional view
      - Exploded view
    - Sensing system
      - Temperature sensor - Electronic schema
  - SERVICE
    - Warm up
    - Depressurising
    - Drain fluid
    - Bleed
    - Pressure test
    - Decontaminating
    - Stack valve
      - Remove
      - Outlet section - Disassemble
      - Inlet section - Disassemble
      - Visual inspection
      - Inlet section - Assemble
      - Outlet section - Assemble
      - Install
    - Relief valve
      - Disassemble
      - Assemble
      - Pressure setting
    - Hydraulic pump
      - Remove
      - Disassemble
      - Assemble
      - Install
      - Bleed
      - Pressure test
    - Compensator
      - Disassemble
      - Assemble
    - Reservoir
      - Remove
      - Install
    - Oil filter
      - Remove
      - Install
    - Sensing system
      - Temperature sensor - Electrical test
  - DIAGNOSTIC
    - Troubleshooting
    - Stack valve
      - Troubleshooting
    - Relief valve
      - Troubleshooting
- SECONDARY HYDRAULIC POWER SYSTEM
  - FUNCTIONAL DATA
    - Stack valve
      - Outlet section - Sectional view
      - Inlet section - Sectional view
    - Hydraulic pump
      - Exploded view
      - Sectional view
  - SERVICE
    - Stack valve
      - Disassemble
      - Inlet section - Disassemble
      - Inlet section - Assemble
      - Assemble
    - Relief valve
      - Disassemble
      - Assemble
      - Pressure test
      - Pressure setting
    - Hydraulic pump
      - Remove
      - Disassemble
      - Assemble
      - Install
- HYDRAULIC COMMAND SYSTEM
  - SERVICE
    - Relief valve
      - Pressure test
      - Pressure setting
    - Hydraulic pump
      - Remove
      - Install
    - Accumulator
      - Check
  - DIAGNOSTIC
    - Troubleshooting
- ELECTRICAL POWER SYSTEM
  - TECHNICAL DATA
    - General specification
    - Special tools
    - Battery
      - General specification
  - FUNCTIONAL DATA
    - Static description
    - Overview
    - Fuse and relay box
      - Overview
      - Fuse - Overview
    - Alternator
      - Electronic schema
  - SERVICE
    - Battery
      - Visual inspection
      - Disconnect
      - Remove
      - Check
      - Charging
      - Overhaul
      - Install
      - Connect
- LIGHTING SYSTEM
  - FUNCTIONAL DATA
    - Front work light
      - Electronic schema
POWER PRODUCTION
- ENGINE
  - TECHNICAL DATA
    - General specification
    - Engine horse power
  - FUNCTIONAL DATA
    - Electronic schema
    - Electronic control
      - Electronic schema
  - SERVICE
    - Remove
    - Install
    - Sensing system
      - Speed sensor - Electrical test
- FUEL AND INJECTION SYSTEM
  - FUNCTIONAL DATA
    - Throttle command
      - Electronic throttle - Functional diagram
    - Fuel shut-off
      - Electrical shut-off - Electronic schema
    - Sensing system
      - Level sensor - Electronic schema
  - SERVICE
    - Fuel filler aid
      - Remove
      - Install
    - Fuel tank
      - Remove
      - Install
- AIR INTAKE SYSTEM
  - SERVICE
    - Air cleaner
      - Remove
      - Install
- EXHAUST SYSTEM
  - SERVICE
    - Silencer
      - Remove
      - Install
- ENGINE COOLANT SYSTEM
  - FUNCTIONAL DATA
    - Sensing system
      - Coolant temperature - Electronic schema
  - SERVICE
    - Drain fluid
    - Interior washing
    - Filling
    - Radiator
      - Remove
      - Install
    - Sensing system
      - Coolant temperature - Electrical test
- LUBRICATION SYSTEM
  - FUNCTIONAL DATA
    - Sensing system
      - Oil pressure - Electronic schema
- STARTING SYSTEM
  - TECHNICAL DATA
    - Engine starter
      - General specification
  - FUNCTIONAL DATA
    - Cold start aid
      - Pre-heating - Electronic schema
      - Pre-heating - Dynamic description
    - Start control
      - Start relay - Electronic schema
- PTO POWER IN
  - SERVICE
    - Drive system
      - Remove
      - Visual inspection
      - Install
TRAVELLING
- WHEELS AND TRACKS
  - Tracks
    - TECHNICAL DATA
      - Drive sprocket
        Special tools
        Service limits
      - Steel track
        Service limits
      - Roller
        Lower roller - Special tools
        Lower roller - Service limits
        Upper roller - Special tools
        Upper roller - Service limits
      - Idler wheel
        Special tools
        Service limits
    - FUNCTIONAL DATA
      - Steel track
        Exploded view
      - Track tensioning mechanism
        Shock absorber - Exploded view
        Adjuster-recoil mechanism - Exploded view
      - Roller
        Lower roller - Sectional view
        Upper roller - Sectional view
    - SERVICE
      - Drive sprocket
        Remove
        Install
      - Steel track
        Remove
        Install
        Chain - Measure
      - Rubber track
        Visual inspection
        Remove
        Install
      - Track tensioning mechanism
        Tension adjust
        Shock absorber - Remove
        Shock absorber - Disassemble
        Shock absorber - Assemble
        Shock absorber - Install
        Adjuster-recoil mechanism - Remove
        Adjuster-recoil mechanism - Disassemble
        Adjuster-recoil mechanism - Assemble
        Adjuster-recoil mechanism - Install
      - Roller
        Leakage test
        Lower roller - Remove
        Lower roller - Disassemble
        Lower roller - Visual inspection
        Lower roller - Assemble
        Lower roller - Install
        Upper roller - Remove
        Upper roller - Disassemble
        Upper roller - Visual inspection
        Upper roller - Assemble
        Upper roller - Install
      - Idler wheel
        Disassemble
        Assemble
BODY AND STRUCTURE
- SHIELD
  - SERVICE
    - Side shield
      - Remove
    - Upper shield
      - Remove
    - Engine hood
      - Remove
    - Protective shield
      - Remove
- USER CONTROLS AND SEAT
  - FUNCTIONAL DATA
    - Instrument panel
      - Detailed view
- USER PLATFORM
  - FUNCTIONAL DATA
    - Wiper system
      - Electronic schema
    - Windscreen washer system
      - Electronic schema
- ENVIRONMENT CONTROL
  - Heating, ventilation and air-conditioning
    - TECHNICAL DATA
      - Special tools
    - FUNCTIONAL DATA
      - Dynamic description
      - Command
        Overview
      - Electronic HVAC control
        Electrical schema
    - SERVICE
      - Evacuate
      - Charging
      - Disassemble
      - Compressor
        Remove
        Install
      - Condenser
        Remove
        Install
      - Receiver/drier
        Remove
        Install
    - DIAGNOSTIC
      - Troubleshooting
      - Compressor
        Magnetic clutch - Troubleshooting
      - Ventilation system
        Troubleshooting
- SAFETY SECURITY ACCESSORIES
  - Safety
    - FUNCTIONAL DATA
      - Hydraulic lock-out
        Electrical schema
        Electrovalve - External view
        Electrovalve - Sectional view
    - SERVICE
      - Hydraulic lock-out
        Electrovalve - Electrical test
        Electrovalve - Remove
        Electrovalve - Disassemble
        Electrovalve - Visual inspection
        Electrovalve - Assemble
        Electrovalve - Install
FRAME POSITIONING
- TRAVELLING
  - Travel
    - TECHNICAL DATA
      - Command valve
        Foot command valve - Special tools
        Foot command valve - General specification
      - Hydraulic motor
        Torque
      - Reducer, spur gear
        Special tools
    - FUNCTIONAL DATA
      - Electronic schema
      - Hydraulic schema
      - Command valve
        Foot command valve - Sectional view
      - Control valve
        Sectional view
      - Hydraulic motor
        Exploded view
        Sectional view
      - Reducer, spur gear
        Exploded view
        Sectional view
      - Sensing system
        Alarm - Electronic schema
    - SERVICE
      - Command valve
        Foot command valve - Remove
        Foot command valve - Disassemble
        Foot command valve - Visual inspection
        Foot command valve - Assemble
        Foot command valve - Install
        Speed selection valve - Overhaul
        Speed selection valve - Electrical test
      - Control valve
        Disassemble
        Assemble
      - Relief valve
        Pressure test
        Pressure setting
      - Hydraulic motor
        Remove
        Disassemble
        Check
        Assemble
        Install
        Leakage test
      - Reducer, spur gear
        Remove
        Disassemble
        Visual inspection
        Measure
        Bearing - Preload
        Assemble
        Install
    - DIAGNOSTIC
      - Troubleshooting
      - Command valve
        Foot command valve - Troubleshooting
- STABILISING
  - Ballasting
    - SERVICE
      - Rear ballasting
        Remove
- SWINGING
  - Circular swing
    - TECHNICAL DATA
      - Command valve
        Hand command valve - Torque
      - Hydraulic motor
        Service limits
        Special tools
        Torque
      - Reducer, spur gear
        Special tools
      - Swivel
        General specification
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Command valve
        Hand command valve - Sectional view
      - Control valve
        Sectional view
      - Hydraulic motor
        Sectional view
      - Reducer, spur gear
        Sectional view
      - Hydraulic brake
        Electronic schema
      - Swivel
        Exploded view
    - SERVICE
      - Command valve
        Hand command valve - Remove
        Hand command valve - Disassemble
        Hand command valve - Cleaning
        Hand command valve - Visual inspection
        Hand command valve - Assemble
        Hand command valve - Install
      - Control valve
        Disassemble
        Assemble
      - Relief valve
        Pressure test
        Pressure setting
      - Hydraulic motor
        Leakage test
        Remove
        Disassemble
        Visual inspection
        Assemble
        Install
        Bleed
      - Reducer, spur gear
        Remove
        Disassemble
        Visual inspection
        Assemble
        Install
      - Bearing and ring gear
        Remove
        Check
        Install
      - Hydraulic brake
        Pressure test
        Electrovalve - Electrical test
      - Swivel
        Remove
        Disassemble
        Cleaning
        Assemble
        Install
WORKING ARM
- BOOM
  - Lift
    - TECHNICAL DATA
      - Service limits
      - Command valve
        Hand control valve - Torque
      - Cylinder
        Torque
        Special tools
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Command valve
        Hand control valve - Sectional view
      - Control valve
        Sectional view
      - Cylinder
        Sectional view
      - Arm
        Exploded view
      - Sensing system
        Electronic schema
    - SERVICE
      - Command valve
        Hand control valve - Overhaul
        Cushion valve - Remove
        Cushion valve - Disassemble
        Cushion valve - Assemble
        Cushion valve - Install
      - Control valve
        Disassemble
        Assemble
      - Safety valve
        Remove
        Disassemble
        Assemble
        Install
        Pressure setting
      - Relief valve
        Disassemble
        Assemble
        Pressure test
        Pressure setting
      - Load holding valve
        Disassemble
        Assemble
      - Arm
        Remove
        Install
      - Cylinder
        Remove
        Disassemble
        Visual inspection
        Assemble
        Install
  - Swing
    - TECHNICAL DATA
      - Cylinder
        Torque
      - Boom
        Service limits
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Control valve
        Sectional view
      - Cylinder
        Sectional view
    - SERVICE
      - Command valve
        Foot command valve - Remove
        Foot command valve - Install
        Foot command valve - Overhaul
      - Control valve
        Disassemble
        Assemble
      - Relief valve
        Overhaul
        Pressure test
        Pressure setting
      - Cylinder
        Remove
        Disassemble
        Assemble
        Install
- DIPPER
  - Lift
    - TECHNICAL DATA
      - Service limits
      - Command valve
        Hand control valve - Torque
      - Cylinder
        Torque
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Command valve
        Hand control valve - Sectional view
      - Control valve
        Sectional view
      - Cylinder
        Sectional view
    - SERVICE
      - Command valve
        Hand control valve - Overhaul
        Cushion valve - Remove
        Cushion valve - Disassemble
        Cushion valve - Assemble
        Cushion valve - Install
      - Control valve
        Disassemble
        Assemble
      - Safety valve
        Remove
        Disassemble
        Assemble
        Install
        Pressure setting
      - Relief valve
        Overhaul
        Pressure test
        Pressure setting
      - Load holding valve
        Disassemble
        Assemble
      - Cylinder
        Remove
        Disassemble
        Assemble
        Install
      - Arm
        Remove
        Install
- ARM TOOL ATTACHMENT
  - Tilt
    - TECHNICAL DATA
      - Service limits
      - Command valve
        Hand control valve - Torque
      - Cylinder
        Torque
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Command valve
        Hand control valve - Sectional view
      - Control valve
        Sectional view
      - Cylinder
        Sectional view
    - SERVICE
      - Command valve
        Hand control valve - Overhaul
      - Control valve
        Disassemble
        Assemble
      - Relief valve
        Overhaul
        Pressure test
        Pressure setting
      - Cylinder
        Remove
        Disassemble
        Assemble
        Install
      - Arm
        Remove
        Install
TOOLS AND COUPLERS
- DIGGING
  - Hammer
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Control valve
        Sectional view
    - SERVICE
      - Command valve
        Foot command valve - Overhaul
      - Control valve
        Disassemble
        Assemble
- LANDSCAPING
  - Dozer blade
    - TECHNICAL DATA
      - Service limits
      - Command valve
        Foot command valve - Special tools
        Foot command valve - General specification
      - Cylinder
        Torque
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Control valve
        Sectional view
      - Cylinder
        Sectional view
    - SERVICE
      - Command valve
        Foot command valve - Remove
        Foot command valve - Disassemble
        Foot command valve - Visual inspection
        Foot command valve - Assemble
        Foot command valve - Install
      - Control valve
        Disassemble
        Assemble
      - Relief valve
        Overhaul
        Pressure test
        Pressure setting
      - Cylinder
        Remove
        Disassemble
        Assemble
        Install
    - DIAGNOSTIC
      - Command valve
        Foot command valve - Troubleshooting
Large format hydraulic and electrical schematics