Part of the Case Repair Manuals.
Case wrote this book for its own dealer technicians, and it reads that way. It covers the 2016 CX235C SR from the 4HK1 common rail engine back through the pumps, the swing and travel circuits, the undercarriage, the cab and the wiring. The electrical schematic, the hydraulic schematic and a special tool index are at the back.
The figures are the ones you need with a gauge on the machine. Main relief is 32.3 - 36.3 MPa standard, pilot pump 2.9 - 4.9 MPa and idle 880 - 920 RPM. Valve clearance is 0.4 mm with the engine cool. The maintenance reset is written out step by step.
The pages print cleanly, so you can pull one section and keep it as a working copy beside the machine.
What's Inside This Case CX235C SR Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 9-70 | Safety, General Specifications, Torque Charts, Fluids and Lubricants |
| Engine | 71-436 | Engine and Crankcase, Fuel Injection System, Turbocharger and Lines, Engine Cooling System, Engine Lubrication System |
| Hydraulic Systems | 437-1166 | Variable Displacement Pump, Main Control Valve, Pilot System, Hydraulic Swing System, Hydraulic Travel System |
| Frames and Ballasting | 1167-1178 | Ballasts and Supports |
| Tracks and Track Suspension | 1179-1274 | Track Frame and Driving Wheels, Tracks, Track Tension Units, Track Rollers |
| Cab Climate Control | 1275-1340 | Heating, Air Conditioning, Ventilation |
| Electrical Systems | 1341-1905 | Electrical System, Harnesses and Connectors |
| Engine Control System | 1906-2155 | Engine Starting System, Alternator, Battery, Cold Start Aid, Fuel Injection System, Electronic Modules |
| Cab Controls | 2156-2375 | Hydraulic System Control, Swing Control System, Travel Control System, Camera, External Lighting, Anti-Theft System |
| Fault Codes | 2376-2638 | Pressure Sensor Signal Abnormality, Swing Brake Solenoid Signal Abnormality, Fuel Level Sensor Signal Abnormality |
| Booms, Dippers, and Buckets | 2639-2686 | Boom, Dipper Arm, Bucket |
| Platform, Cab, Bodywork, and Decals | 2687-2725 | Cab, Cab Glazing, Mechanically-Adjusted Operator Seat, Engine Hood and Panels |
| Special Tool Index | 2726-2727 | Special Tools Listed by Section |
| Electrical Schematic | 2728-2729 | Fold-Out Electrical Schematic Sheets |
| Hydraulic Schematic | 2730-2731 | Fold-Out Hydraulic Schematic Sheets |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | 4HK1 | p. 74 |
| Cylinder bore x stroke | 115 mm (4.528 in) x 125 mm (4.921 in) | p. 74 |
| Displacement | 5.193 l (317 in³) | p. 74 |
| Compression ratio | 17.5 | p. 74 |
| Injection order | 1, 3, 4, 2 | p. 74 |
| Fuel system | Electronic control common rail type | p. 74 |
| Lubrication oil amount | 20 - 27 l (5.28 - 7.13 US gal) | p. 74 |
| Valve clearance (engine cool) | 0.4 mm (0.016 in) | p. 74 |
| Coolant capacity (radiator procedure) | 30.9 L (8.163 US gal) | p. 360 |
| Alternator regulated voltage | 27.5 - 29.5 V | p. 75 |
| Idling engine speed | 880 - 920 RPM | p. 526 |
| No load SP mode engine speed | 1630 - 1670 RPM | p. 526 |
| Main relief pressure, standard | 32.3 - 36.3 MPa (4685 - 5265 psi) | p. 526 |
| Main relief pressure, boosted | 35.1 - 39.1 MPa (5091 - 5671 psi) | p. 526 |
| Swing relief pressure | 28.8 - 32.8 MPa (4177 - 4758 psi) | p. 526 |
| Travel relief pressure | 32.3 - 36.3 MPa (4685 - 5265 psi) | p. 526 |
| Pilot pump pressure | 2.9 - 4.9 MPa (421 - 711 psi) | p. 526 |
| Blade pump pressure | 23.8 - 27.8 MPa (3452 - 4032 psi) | p. 526 |
Case CX235C SR Common Problems This Manual Covers
Hydraulics slow, weak or stalling under load
Check the oil level and condition first, then the return filter. On machines with a breaker, code 7424 flags a clogged return filter, and the fix is a new filter. Next, put a gauge on pilot pressure (2.9 - 4.9 MPa), then on main relief (32.3 - 36.3 MPa). The Variable displacement pump and Main control valve sections cover what to check after that.
Manual Section: Hydraulic systems - Variable displacement pump, Main control valve, Pilot system p. 2467High coolant temperature or repeated overheating
Blow out the radiator and coolers, then check the coolant level and the fan before you blame the thermostat. The ECM starts controlling fuel above 100 °C and logs code 7400 at 105 °C. The Engine cooling system section gives a fill of 30.9 L (8.163 US gal) for the radiator procedure.
Manual Section: Engine - Engine cooling system p. 2016Weak swing or excessive swing drift
Check swing relief against the 28.8 - 32.8 MPa spec before you pull the motor. After any work on the swing reduction motor, bleed the air out. Run the engine at low idle, remove the air bleed plug and make sure oil oozes from the port. The Hydraulic swing system section covers the motor.
Manual Section: Hydraulic systems - Hydraulic swing system p. 934Warning lamps, no start or intermittent electrical functions
With the engine running, check alternator output against the 27.5 - 29.5 V regulated range. Then load-test the batteries. Clean the grounds and connectors before you condemn a controller or sensor. The Alternator, Battery and Harnesses and connectors sections cover these checks, and the electrical schematic lets you trace each circuit.
Manual Section: Electrical systems - Alternator, Battery, Harnesses and connectors p. 75Frequently Asked Questions
How do I reset the maintenance reminder on a CX235C SR?
Open the RESET screen on the monitor and select ALL. Then hold the light switch for 3 seconds to clear the maintenance items. Do the service first, because the reset only clears the counter. p. 2043
What do fault codes 7400 and 0217 mean, and how do I clear them?
Both codes mean the engine is running hot. 0217 is the engine coolant high temperature error. 7400 is a main unit code that sets at 105 °C (221 °F) or higher. The ECM starts controlling fuel flow once coolant goes past 100 °C (212 °F), so expect power to drop as the engine heats up. Fix the cause, then clear the code with the trouble diagnosis scan tool. p. 2138
How do I check and adjust track tension?
Tension is measured as distance A, from the lower frame to the lowest hanging part of the shoe plate. The spec table gives two ranges: 300 - 330 mm (11.811 - 12.992 in) and 260 - 280 mm (10.236 - 11.236 in). Use the one that matches your setup. The Track tension units section covers the adjuster. p. 1249
What pressures should I see when the hydraulics feel slow?
Start at the pilot pump, which should read 2.9 - 4.9 MPa (421 - 711 psi). If pilot pressure is low, every function gets lazy. Main relief is 32.3 - 36.3 MPa (4685 - 5265 psi) standard and 35.1 - 39.1 MPa (5091 - 5671 psi) boosted. Swing relief is 28.8 - 32.8 MPa (4177 - 4758 psi). Having every relief figure in one place is reason enough to own the book. p. 526
How is the diesel particulate filter regenerated?
The manual covers 4 regeneration methods for the DPF. If the engine is losing power, read that material along with the fuel and air intake checks. An emissions derate can feel a lot like a fuel restriction. p. 2087
