CASE Construction CX225SR Crawler Excavator Service Manual 9-40691GB English

Name: CASE Construction CX225SR Crawler Excavator Service Manual 9-40691GB English
SKU: 9-40691GB.pdf
Price: 18.99 USD
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$ 18.99 USD

Official Manual Overview

Dominate the 22-ton earthmoving class with this definitive OEM Service Manual, engineered explicitly for the CASE CX225SR Crawler Excavator. Covering both the NA (North America) and WE (Europe) regional architectures, this volume bypasses routine upkeep to deliver surgical dealership-level reconstruction protocols for the entire chassis, heavy-duty undercarriage, and complex hydraulic networks. It provides uncompromising calibration metrology, dictating precise flow benchmarks for the massive 2x190 L/min variable displacement twin pumps, and mandates absolutely staggering fastening specifications—such as the immense 10,300 Nm torque requirement for the dipper cylinder piston nut and 2750 to 2940 Nm for the M36 counterweight bolts. Furthermore, it transforms the cabin into an advanced diagnostic command center, mapping out complete electrical schematics for the RED4 electronic acceleration module and proportional solenoid networks. Please note: In strict adherence to CASE's publication strategy, while complete engine removal and external ECM diagnostics are exhaustively covered, deep internal block teardowns for the 6.49L Isuzu BB-6BG1T diesel engine are explicitly redirected to a dedicated engine manual.

Brands: CASE Construction
Equipment Type: Crawler Excavator
Manuals Type: Service Manual
Machine Model: CX225SR
Serial Number: N/R
Region: North America, Europe
Book Code: 9-40691GB
Issued: Printed in France, December 2004
Language: English
Pages: 758
File Format: PDF (Searchable)

Core Selling Points

Elite-Level Hydraulic Calibration: Execute dealership-grade fluid tuning using specified tools like the Multi-Handy 2051 digital tester and OEM1652 pressure assemblies. The manual provides uncompromising parameters, instructing technicians to calibrate the boom, dipper, and bucket secondary relief valves to precisely 392 bar at 20 L/min, and dictating a strict 25.5 bar (2.55 MPa) baseline for the twin pumps' negative pressure networks.
Micro-Tolerance Pump & Motor Reconstruction: Rebuild the massive 2x190 L/min axial piston pumps with absolute mathematical certainty. This guide defines rigid surface finishing standards, demanding a 0.8 Ra maximum roughness for the valve plate and 0.4 Ra for the cylinder barrel, alongside a critical 0.04 mm maximum clearance limit between the piston and cylinder bore to guarantee volumetric efficiency.
Extreme Hydraulic Cylinder Fastening: Safeguard against catastrophic seal blowouts under heavy mining loads. The documentation outlines the mandatory teardown architectures for all articulating cylinders, dictating immense torque applications—including 6650 Nm for the bucket cylinder M62 piston nut, 5500 Nm for the boom, and a staggering 10,300 Nm for the heavy-duty dipper cylinder.

Features & Highlights

Direct RED4 ECM Interception & Pinout Mapping: Eradicate diagnostic blind spots by tapping directly into the machine's electronic brain. The literature provides exact multimeter testing paths for the RED4 acceleration module, detailing the required 0.5 to 4.5-volt benchmarks across specific harness wires (such as the Green/Red and White/Blue circuits) to definitively diagnose Fault Codes like 21, 31, and 32 without unnecessary parts swapping.
Surgical Undercarriage Metrology: Stop replacing tracks and lower assemblies based on visual wear. The manual supplies dedicated fabrication dimensions for custom roller gauges and dictates strict micrometer replacement thresholds—such as condemning the 80 mm dipper cylinder foot pin the moment it wears down to exactly 79 mm, or when the corresponding bushing exceeds 81.5 mm.
Dynamic Spool & Fluid Logic Schematics: Navigating the complex multi-section stack valves is made straightforward. The manual features specialized "Dynamic Description" diagrams that trace exact fluid paths from the D1/D2 pumps through the Pa8/Pb8 boom circuits, mapping exactly how the straight-line travel valve and cushion networks prioritize flow during simultaneous operations.

Problem Solver

Eradicates Throttle & RPM Drops: Troubleshoot the electronic throttle command definitively. By utilizing the provided resistance benchmarks, mechanics can trace elusive engine surging or Fault Code 41 directly to a faulty servomotor tachometer—verifying if the resistance between the blue and yellow wires falls outside the rigid 2000 to 2400 ohms standard.
Cures Phantom Thermal Shutdowns: Resolves hidden overheating issues that trigger emergency back-up modes. The diagnostic trees map out the exact logic of the A2 Engine Control Box, instructing builders to verify that the high-temperature alert correctly triggers ON at exactly 105°C and switches OFF at 92°C, instantly isolating a corrupted ECM from a failing physical thermistor.
Prevents Catastrophic Valve Bank Leaks: Improperly sequenced control valves destroy hydraulic synchronization. This literature safeguards your rebuilds with rigid teardown and fastening sequences, ensuring inner components like the bucket spool screws are locked at exactly 20 to 22 Nm, while main housing plugs are torqued up to 260.3 Nm, restoring absolute factory tightness.

Important Pre-Purchase Advisories

Complete "Large Format" Schematics Included: Unlike many digital copies that omit the physical fold-out inserts, this specific manual fully incorporates the original large-format electrical wiring diagrams and complex hydraulic circuit charts (OEM Reference 9-43710) 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 modules (RED4), and external sensor diagnostics. However, deep internal mechanical teardowns of the Isuzu BB-6BG1T diesel engine block are explicitly redirected to a 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
    - Compensator
      - Sectional view
    - Sensing system
      - Temperature sensor - Electronic schema
    - Powerboost system
      - Electronic schema
  - SERVICE
    - Warm up
    - Depressurising
    - Drain fluid
    - Bleed
    - Pressure test
    - Decontaminating
    - Stack valve
      - Remove
      - Overhaul
      - Outlet section - Disassemble
      - Inlet section - Disassemble
      - Visual inspection
      - Inlet section - Assemble
      - Outlet section - Assemble
      - Install
    - Relief valve
      - Disassemble
      - Assemble
      - Pressure test
      - Pressure setting
    - Powerboost system
      - Electrovalve - Electrical test
    - Hydraulic pump
      - Remove
      - Disassemble
      - Assemble
      - Install
      - Bleed
      - Pressure test
    - Reservoir
      - Remove
      - Install
    - Compensator
      - Disassemble
      - Assemble
    - Oil filter
      - Remove
      - Install
    - Sensing system
      - Temperature sensor - Electrical test
  - DIAGNOSTIC
    - Troubleshooting
    - Stack valve
      - Troubleshooting
    - Relief valve
      - Troubleshooting
- 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
  - DIAGNOSTIC
    - Alternator
      - Testing
- 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
  - DIAGNOSTIC
    - Problem solving
    - Sensing system
      - Speed sensor - No signal
- 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
    - Injection control
      - Electrical test
  - DIAGNOSTIC
    - Throttle command
      - Electronic throttle - Low signal
    - Injection control
      - No signal
      - Low signal
- 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
      - Coolant over-temperature - Wiring schema
  - SERVICE
    - Drain fluid
    - Interior washing
    - Filling
    - Radiator
      - Remove
      - Install
    - Sensing system
      - Coolant temperature - Electrical test
  - DIAGNOSTIC
    - Sensing system
      - Coolant over-temperature - Troubleshooting
      - Coolant temperature - Low signal
- LUBRICATION SYSTEM
  - FUNCTIONAL DATA
    - Sensing system
      - Oil pressure - Electronic schema
      - Oil pressure - Wiring schema
  - DIAGNOSTIC
    - Sensing system
      - Oil pressure - Troubleshooting
- 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
  - DIAGNOSTIC
    - Testing
- PTO POWER IN
  - FUNCTIONAL DATA
    - Drive system
      - Overview
  - SERVICE
    - Drive system
      - Remove
      - Visual inspection
      - Install
TRAVELLING
- WHEELS AND TRACKS
  - TECHNICAL DATA
    - Drive sprocket
      - Service limits
      - Special tools
    - Steel track
      - Service limits
    - Roller
      - Lower roller - Service limits
      - Upper roller - Service limits
      - Upper roller - Special tools
      - Lower roller - Special tools
    - 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
      - Upper roller - Sectional view
      - Lower roller - Sectional view
  - SERVICE
    - Drive sprocket
      - Remove
      - Install
    - Steel track
      - Remove
      - Install
      - Chain - Measure
    - 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
      - Disassemble
      - Evacuate
      - Charging
      - 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
    - 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 - Electrical test
      - Control valve
        Disassemble
        Assemble
      - Relief valve
        Pressure test
        Pressure setting
      - Hydraulic motor
        Leakage test
        Remove
        Disassemble
        Check
        Assemble
        Install
      - Reducer, spur gear
        Remove
        Disassemble
        Visual inspection
        Bearing - Preload
        Assemble
        Install
    - DIAGNOSTIC
      - Troubleshooting
- STABILISING
  - Ballasting
    - SERVICE
      - Rear ballasting
        Remove
        Install
- SWINGING
  - Circular swing
    - TECHNICAL DATA
      - Command valve
        Hand command valve - Torque
      - Hydraulic motor
        Service limits
        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
    - DIAGNOSTIC
      - Troubleshooting
WORKING ARM
- BOOM
  - Lift
    - TECHNICAL DATA
      - Service limits
      - Command valve
        Hand control valve - Torque
      - Cylinder
        Special tools
        Torque
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Command valve
        Hand control valve - Sectional view
      - Control valve
        Sectional view
      - Cylinder
        Sectional view
      - Arm
        Exploded view
      - Overload detection 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
        Install
        Pressure setting
      - Relief valve
        Disassemble
        Assemble
        Pressure test
        Pressure setting
      - Load holding valve
        Disassemble
        Assemble
      - Cylinder
        Remove
        Disassemble
        Visual inspection
        Assemble
        Install
      - Arm
        Remove
        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
      - Control valve
        Disassemble
        Assemble
      - Safety valve
        Remove
        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
    - TECHNICAL DATA
      - Command valve
        Foot command valve - Special tools
        Foot command valve - General specification
    - FUNCTIONAL DATA
      - Hydraulic schema
      - Control valve
        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
    - DIAGNOSTIC
      - Command valve
        Foot command valve - Troubleshooting
Large format hydraulic and electrical schematics