the best service manual

1. CRAWLER EXCAVATOR
SERVICE MANUAL
Issued 01Dec 08
84187486A NA
CX135SR
TIER 3

2. Copyright © 2008 CNH France S.A.
Printed in France
CNH Lep SM135SRTOC-0NA December 2008
CRAWLER EXCAVATOR CX135SR TIER 3
SERVICE MANUAL
TABLE OF CONTENTS
DIVISION/SECTION SECTION N° REFERENCE N°
1 GENERAL INFORMATION
Safety, general information and standard torque data..................................... 1001 7-27691NA
General specifications and special torque setting ........................................... 1002 SC135SR1002-1NA
2 ENGINE
Removal and installation of the engine............................................................ 2000 SM135SR2000-0EN
Engine specifications..............................................................................................*
Disassembly and assembly of the engine ..............................................................*
3 FUEL SYSTEM
Removal and installation of the fuel tank......................................................... 3001 SM135SR3001-0EN
Fuel engine system ................................................................................................*
4 ELECTRICAL SYSTEM
Electrical and engine functions and service support....................................... 4001 SC135SR4001-1NA
5 UNDERCARRIAGE
Removal and installation of tracks................................................................... 5001 SM75SR5001-0EN
Rollers ............................................................................................................. 5003 SM135SR5003-0EN
Take-up roller................................................................................................... 5005 SM135SR5005-0EN
6 DRIVE TRAIN
Removal and installation of the drive motor and
final drive transmission................................................................................ 6001 SM135SR6001-0EN
Disassembly and assembly of the drive motor and
final drive transmission................................................................................ 6002 SM135SR6002-0EN
Removal and installation of the swing motor and
swing reduction gear ................................................................................... 6003 SM135SR6003-0EN
Disassembly and assembly of the swing reduction gear................................. 6004 SM135SR6004-0EN
7 UNDERCARRIAGE HYDRAULICS
* Consult the Engine Service Manual

3. Lep SM135SRTOC-0NA Issued 03-08
DIVISION/SECTION SECTION N° REFERENCE N°
8 UPPERSTRUCTURE HYDRAULICS
Specifications, troubleshooting, checks and
hydraulic pressure settings..........................................................................8001 SC135SR8001-1NA
Removal and installation of the hydraulic reservoir .........................................8002 SM135SR8002-0EN
Removal and installation of the main hydraulic pump......................................8003 SM135SR8003-0EN
Removal and installation of the main hydraulic control valve...........................8004 SM135SR8004-0EN
Removal and installation of the attachment cylinders......................................8005 SM135SR8005-0EN
Removal and installation of the hydraulic swivel..............................................8006 SM135SR8006-0EN
Removal and installation of the pilot blocs.......................................................8007 SM75SR8007-0EN
Disassembly and assembly of the main hydraulic pump .................................8010 SM135SR8010-0EN
Disassembly and assembly of the main hydraulic control valve ......................8011 SM135SR8011-0EN
Disassembly and assembly of the attachment cylinders .................................8012 SM135SR8012-0EN
Disassembly and assembly of the hand control levers ....................................8013 SM75SR8013-0EN
Disassembly and assembly of the foot control levers ......................................8014 SM135SR8014-0EN
Disassembly and assembly of the solenoid valve block ..................................8015 SM75SR8015-0EN
Disassembly and assembly of the cushion valve.............................................8016 SM135SR8016-0EN
Disassembly and assembly of the hydraulic swivel .........................................8018 SM135SR8018-0EN
Disassembly and assembly of the swing motor ...............................................8019 SM135SR8019-0EN
Hydraulic functions ..........................................................................................8020 SC135SR8020-0NA
Hydraulic component functions........................................................................8030 SC135SR8030-0NA
9 UPPERSTRUCTURE
Air conditioning unit .........................................................................................9007 SM75SR9007-0EN
Large size hydraulic schematics................................................................... Pocket 87746261A
Large size electrical schematics................................................................... Pocket 87746254A
NOTE: CNH Company reserves the right to make changes in the specification
and design of the machine without prior notice and without incurring any obliga-
tion to modify units previously sold.
The description of the models shown in this manual has been made in accord-
ance with the technical specifications known as of the date of design of this
document.

4. CNH
Copyright © 2006 CNH America LLC.
All rights reverved.
Printed in U.S.A.
Issued February, 2006Lep 7-27691NA
1001
SAFETY, GENERAL INFORMATION
AND TORQUE SPECIFICATIONS
Section
1001

5. 1001-3
Lep 7-27691NA Issued 02-06
GENERAL INFORMATION
Cleanning
Clean all metal parts except bearings, in a suitable
cleaning solvent or by steam cleaning. Do not use
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable cleaning
solvent, dry the bearings completely and put oil on
the bearings.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for
indications of wear, pitting and the replacement of
parts necessary to prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle bearings
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.
Gears
Check all gears for wear and damage. Replace gears
that have wear or damage.
Oil seals, O-rings and gaskets
Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service parts
Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
replacement parts are not covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
use of non-specified oils and lubricants are not
covered by warranty.

6. 1001-4
Lep 7-27691NA Issued 02-06
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
!
To prevent injury always follow the Warning, Caution
and Danger notes in this section and throughout the
manual.
Put the warning tag shown below on the key for the
keyswitch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags Part Number 331-4614 are available
from your service parts supplier
.
WARNING: Read the operator’s manual to
familiarize yourself with the correct control
functions.
!
WARNING: Operate the machine and
equipment controls from the seat position
only. Any other method could result in
serious injury.
!
WARNING: This is a one man machine, no
riders allowed.!
WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
all safety signs on machine. Clear the area of
other persons. Learn and practice safe use
of controls before operating.
It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service and to observe
pertinent laws and regulations. Operator’s
and Service Manuals may be obtained from
your Case dealer.
!
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
!
WARNING: When working in the area of the
fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests
on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
!
WARNING: When putting the hydraulic
cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
!

7. 1001-5
Lep 7-27691NA Issued 02-06
WARNING: Use insulated gloves or mittens
when working with hot parts.!
WARNING: Lower all attachments to the
ground or use stands to safely support the
attachments before you do any maintenance
or service.
!
WARNING: Pin sized and smaller streams
of hydraulic oil under pressure can penetrate
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
immediately. Maintain all hoses and tubes in
good condition. Make sure all connections
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
damaged. DO NOT use your hand to check
for leaks, use a piece of cardboard or wood.
!
WARNING: When removing hardened pins
such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
!
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
!
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in place
with suitable safety stands.
!
WARNING: When servicing or repairing the
machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
!
WARNING: Some components of this
machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
!
WARNING: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the doors and get outside
air into the area.
!
WARNING: When the battery electrolyte is
frozen, the battery can explode if (1), you try
to charge the battery, or (2), 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.
!

8. Lep SC135SR1002-1NA Issued 12-08
1002-33
MQ09001-001
3
4 6
5
7
1 ,
3 , ,5 6,4 7
FRONT
2
1
1 2,
188
19 ,20
17
166
1514
12
21
4
5
100
3
7
13
6
8, 9

9. Lep SC135SR1002-1NA Issued 12-08
1002-34
10
11 12 13
1514
16
16
8,9
8 9
10
16
1211 ,
1514 ,
13,
MQ09001-002

10. Lep SC135SR1002-1NA Issued 12-08
1002-35
MQ09001-003
17
17
A
B
C
D
E
F
H
20 19
21
22
18
17 18
19 21
22
20,

11. Lep SC135SR1002-1NA Issued 12-08
1002-36
MACHINE OVERALL DIMENSIONS
NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (20 mm (0.79 in)
Mono Boom Spec.
Standard Arm (Dipper) (2390 mm (94.09 in))
Long Arm (Dipper) (2850 mm (112.20 in))
MO03001-005
Height of grouser shoe lug
MO03001-006
Height of grouser shoe lug

12. Lep SC135SR1002-1NA Issued 12-08
1002-37
Mono Boom Spec. With Dozer Blade
Standard Arm (Dipper) (2390 mm (94.09 in))
Long Arm (Dipper) (2850 mm (112.20 in))
MO03001-007
Height of grouser shoe lug
MO03001-008
Height of grouser shoe lug

13. Lep SC135SR1002-1NA Issued 12-08
1002-38
NOTES
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14. CNH
Copyright © 2008 CNH France S.A.
Printed in France
November 2008Lep SM135SR2000-0EN
2000
REMOVAL AND INSTALLATION OF THE ENGINE
Section
2000

15. Lep MSM-17-11-001E Issued 11-2008
2000-2
ENGINE
4.9 - 5.9 Nm
54.1 - 63.9 Nm
68.7 - 98.1 Nm
63.8 - 73.6 Nm
8.8 - 9.8 Nm
63.8 - 73.6 Nm
4.9 - 5.9 Nm
8.8 - 9.8 Nm
8.8 - 9.8 Nm
8.8 - 9.8 Nm
8.8 - 9.8 Nm
244
X4X4
5
233
222
X6
11
166
177
X2
144
122
A
432 6
7
9
133
155
2 188 199 200
B
100
21
233
199 21
X4 X44
344
D
366
X2
377
322
333
288
277
X2
255266
299
X2
1
277
322
277
2 188
2 188
199
222
2 3 4
199 200 21
244
2 188
KMH10730-E00

16. Lep MSM-17-11-001E Issued 11-2008
2000-3
63.8 - 73.6 Nm
63.8 - 73.6 Nm
4.9 - 5.9 Nm
Nm
4.9 - 5.9 Nm
10.8 - 16.3 Nm
4.9 - 5.9 Nm
8.8 - 9.8 Nm
54.1 - 63.9 Nm
X2
X4
422
400
577
X4
633
612
588
599
X2
522
533
544
C
566555
X2
77
X2 X2
655644
699
444
45
466
477
488
X
499 500 51
A
71
E
X2
722
31
100
144
266255
31
31
299
277
31
233
233
KMH10730-E00

17. Lep MSM-17-11-001E Issued 11-2008
2000-4
NOTE:
1. Coat the thread of sym (4) (21) (61) with loctite 262
or equivalent after removing any oil film and fasten
by tightening torque.
2. The elastic rubbers of sym (22) (24) should be
assembled after confirming the discrimination
color.
3. Apply packing liquid (26) to the connection of radia-
tor hose after removing any oil film and fasten by
tightening torque.
4. Tighten up the clip; jubilee from the direction
shown on the drawing.
5. Arrow mark ( ) in the labels (12) represent the top.
SYM. PART NAME QTY. SYM. PART NAME QTY.
1 ENGINE SUPPORT 1 37 RADIATOR STAY 1
2 BOND #262 NEED 38 JUBILEE CLIP 50-65 1
3 HIGE STRENGTH WASHER 12 8 39 AIR HOSE 1
4 HIGH STRENGTH BOLT M12 x 35 8 40 VACUUM INDICATOR 1
5 SPL CLAMP 1 41 SEMS BOLT M8 x 20 4
6 MUFFLER 1 42 AIR CLEANER 1
7 EXHAUST PIPE 1 43 JUBILEE CLIP 87-112 1
8 HIGH STRENGTH NUT M8 6 44 RESERVE TANK 1
9 ELBOW G3/4 2 45 BRACKET 1
10 DIESEL ENGINE 1 46 HOLDER 1
11 RADIATOR (STANDARD) ASSY 1 47 RUBBER HOSE (L=1300) 1
12 LABEL 1 48 HOSE BAND 2
13 BRACKET 1 49 HARNESS BAND L=250 NEED
14 JUBILEE CLIP 2 50 MOUNT CLAMP 4
15 AIR HOSE 1 51 PAN HD SCREW M6 x 8 4
16 SPL BOLT 4 52 AIR INLET PIPE 1
17 RADIATOR STAY 1 53 CUSHION SEAL 1
18 NUT 4 54 CUSHION SEAL 1
19 PLATE 4 55 SEMS BOLT M10 x 20 2
20 HIGE STRENGTH WASHER 16 4 56 BRACKET 1
21 HIGH STRENGTH BOLT M16 x 130 4 57 U-BOLT M10 2
22 ELASTIC RUBBER 4 58 FLANGED NUT M10 8
23 HOSE 1 59 MUFFLER BRACKET 1
24 ELASTIC RUBBER 4 60 HOSE BAND 1
25 HOSE CLAMP 2 61 HIGH STRENGTH BOLT M10 x 35 3
26 LIQUID PACKING NEED 62 HIGH STRENGTH WASHER M10 3
27 HOSE CLAMP 4 63 TUBE L=750 1
28 AIR INLET PIPE 1 64 HOSE CLAMP 2
29 SEMS BOLT 8 65 CLAMP 1
30 BRACKET 1 66 HIGH STRENGTH BOLT M8 x 110 2
31 SEMS BOLT M10 x 25 10 67 HIGH STRENGTH WASHER M8 4
32 HOSE CLAMP 2 68 HIGH STRENGTH BOLT M8 x 140 2
33 AIR HOSE 1 69 SEMS BOLT M10 x 16 1
34 ENGINE SUPT 1 70 CUSHION SEAL 1
35 AIR HOSE 1 71 HOSE ADAPTER 2
36 ACOUSTIC INSULATION 1 72 BRACKET 1

18. CNH
Copyright © 2008 CNH France S.A.
Printed in France
November 2008Lep SM135SR3001-0EN
3001
REMOVAL AND INSTALLATION
OF THE FUEL TANK
Section
3001

19. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

20. Lep MST-15-07-002 Issued 11-2008
3001-3
FUEL TANK
A
1
1
6
7
2 3 4 5
A-A
X5
8
10 11
9
232.4 - 276.0 Nm
25.0 - 30.0 Nm
KMH10750-D00
Apply liquid packing
Fuel outlet
Tank backside view

21. Lep MST-15-07-002 Issued 11-2008
3001-4
1. Fuel tank
2. Seems bolt M16x55
3. Bond 262
4. Plate shim (t=0.8)
5. Plate shim (t=2.0)
6. Plug G3/4
7. Cock drain
8. Pan screw HD M5x12
9. Sensor cover
10. Rubber packing
11. Liquid packing
12. Rubber plate
B
20.5
89251297
104˚
R350
21
B20
KMH10750-D00
Fuel outlet
Fuel rest 128.8 L
Fuel rest 20.4 L

22. CNH Lep SC135SR4001-1NA
4001
Copyright @ 2008 CNH America LLC.
All rights reserved.
Printed in USA.
December 2008
ELECTRICAL AND ENGINE FUNCTIONS,
&
SERVICE SUPPORT
Section
4001

23. Lep SC135SR4001-1NA Issued 12-08
4001-2
TABLE OF CONTENTS
Monitor Display ...................................................................................................................................................... 5
Engine Control ....................................................................................................................................................... 7
Monitor Output Control ........................................................................................................................................ 12
Monitor Display Control ....................................................................................................................................... 19
SERVICE SUPPORT ................................................................................................................................................... 31
Diagnosis and rewriting tools ............................................................................................................................. 31
Screen Operations ............................................................................................................................................... 32
Screen Display List .............................................................................................................................................. 35
CHK (status display) Screen List ....................................................................................................................... 35
MAIN .............................................................................................................................................................. 35
MNT ............................................................................................................................................................... 38
H / W-A ........................................................................................................................................................... 40
H / W-B ........................................................................................................................................................... 43
H / W-M .......................................................................................................................................................... 46
DIAG (trouble diagnosis) Screen ....................................................................................................................... 47
Screen ............................................................................................................................................................ 47
Operation ....................................................................................................................................................... 48
Reset .............................................................................................................................................................. 48
HR (usage log) Screen List ................................................................................................................................ 49
MAIN .............................................................................................................................................................. 49
ENG ............................................................................................................................................................... 51
CFG (setting change) Screen ............................................................................................................................ 54
Operation ....................................................................................................................................................... 54
Screen ............................................................................................................................................................ 55
CAL (troubleshooting support) Screen ............................................................................................................... 57
Operation ....................................................................................................................................................... 57
Screen ............................................................................................................................................................ 57
Check the Monitor Switch (Self-diagnosis function) ........................................................................................... 59
Screen ............................................................................................................................................................ 59
Configuration .................................................................................................................................................. 59
Differences from CHK screen [CHK | H/W-M | 1] ........................................................................................... 60
Model Setting ..................................................................................................................................................... 61
Engine Screen Information ................................................................................................................................. 63
Purpose .......................................................................................................................................................... 63
How to go to this screen ................................................................................................................................. 63
Engine start restriction ................................................................................................................................... 63
Screen ............................................................................................................................................................ 63
Operating method .......................................................................................................................................... 63
Screen Display Details ......................................................................................................................................... 64
Message Display List ......................................................................................................................................... 64
Trouble Display .................................................................................................................................................... 66
Diagnostic Trouble Code Display ....................................................................................................................... 66
Main Unit Diagnostic Trouble Code List ............................................................................................................. 67
Diagnostic Trouble Code (Monitor Display) ....................................................................................................... 73
EPF (engine protection feature) ......................................................................................................................... 81