Case IH Magnum 180 User manual

PrintedinU.S.A.
Copyright © 2014 CNHIndustrial America LLC. All Rights Reserved.
Case IHisaregisteredtrademarkofCNH Industrial America LLC.
Racine Wisconsin 53404 U.S.A.
Magnum™180
Magnum™200
Magnum™220
Magnum™240
Continuously Variable Transmission (CVT)
Tractor
PIN ZERH08100 and above
Part number 47748092
1st edition English
September 2014
SERVICE MANUAL

SERVICEMANUAL
Magnum™180696110752CVTTIER4B[ZERH08100-]
Magnum™200696110762CVTTIER4B[ZERH08100-]
Magnum™220696110772CVTTIER4B[ZERH08100-]
Magnum™240696110782CVTTIER4B[ZERH08100-]
4774809226/09/2014
EN
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LinkProduct/Engine
ProductMarketProductEngine
Magnum™180696110752CVT
TIER4B[ZERH08100-]
NorthAmericaF4HFE613K*B002
Magnum™180696110752CVT
TIER4B[ZERH08100-]
AustraliaNewZealandF4HFE613K*B002
Magnum™200696110762CVT
TIER4B[ZERH08100-]
NorthAmericaF4HFE613J*B005
Magnum™200696110762CVT
TIER4B[ZERH08100-]
AustraliaNewZealandF4HFE613J*B005
Magnum™220696110772CVT
TIER4B[ZERH08100-]
NorthAmericaF4HFE613H*B003
Magnum™220696110772CVT
TIER4B[ZERH08100-]
AustraliaNewZealandF4HFE613H*B003
Magnum™240696110782CVT
TIER4B[ZERH08100-]
AustraliaNewZealandF4HFE613B*B006
Magnum™240696110782CVT
TIER4B[ZERH08100-]
NorthAmericaF4HFE613B*B006
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.216]Fueltanks..........................................................................10.2
[10.218]Fuelinjectionsystem...............................................................10.3
[10.202]Aircleanersandlines..............................................................10.4
[10.500]SelectiveCatalyticReduction(SCR)exhausttreatment...........................10.5
[10.400]Enginecoolingsystem.............................................................10.6
[10.414]Fananddrive......................................................................10.7
[10.310]Aftercooler..........................................................................10.8
[10.304]Enginelubricationsystem..........................................................10.9
Powercoupling...........................................................................19
[19.100]Driveshaft..........................................................................19.1
[19.110]Flywheeldamper...................................................................19.2
Transmission..............................................................................21
[21.200]Dropbox............................................................................21.1
[21.504]ContinuouslyVariableTransmission(CVT)........................................21.2
[21.505]ContinuouslyVariableTransmission(CVT)externalcontrols......................21.3
[21.506]ContinuouslyVariableTransmission(CVT)lubricationsystem....................21.4
[21.507]ContinuouslyVariableTransmission(CVT)internalcomponents..................21.5
Four-WheelDrive(4WD)system..................................................23
[23.202]Electro-hydrauliccontrol...........................................................23.1
[23.314]Driveshaft..........................................................................23.2
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
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[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
[25.122]Axlesuspensioncontrol............................................................25.4
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
PowerTake-Off(PTO).................................................................31
[31.104]Rearelectro-hydrauliccontrol......................................................31.1
[31.114]Two-speedrearPowerTake-Off(PTO)............................................31.2
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
[33.110]Parkingbrakeorparkinglock......................................................33.2
[33.220]Trailerbrakehydrauliccontrol......................................................33.3
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.102]Pumpcontrolvalves................................................................35.2
[35.105]Chargepump.......................................................................35.3
[35.106]Variabledisplacementpump.......................................................35.4
[35.114]Three-pointhitchcontrolvalve.....................................................35.5
[35.116]Three-pointhitchcylinder..........................................................35.6
[35.204]Remotecontrolvalves.............................................................35.7
[35.300]Reservoir,cooler,andlters........................................................35.8
Hitches,drawbars,andimplementcouplings..................................37
[37.110]Rearthree-pointhitch..............................................................37.1
Framesandballasting.................................................................39
[39.140]Ballastsandsupports..............................................................39.1
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
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[41.206]Pump...............................................................................41.3
Wheels......................................................................................44
[44.520]Rearwheels........................................................................44.1
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
[50.300]Cabpressurizingsystem...........................................................50.3
Electricalsystems.......................................................................55
[55.010]Fuelinjectionsystem...............................................................55.1
[55.011]Fueltanksystem...................................................................55.2
[55.014]Engineintakeandexhaustsystem.................................................55.3
[55.024]Transmissioncontrolsystem.......................................................55.4
[55.031]Parkingbrakeelectricalsystem....................................................55.5
[55.045]Frontaxlecontrolsystem..........................................................55.6
[55.046]Rearaxlecontrolsystem...........................................................55.7
[55.047]Steeringcontrolsystem............................................................55.8
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.9
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.10
[55.100]Harnessesandconnectors.......................................................55.11
[55.130]Rearthree-pointhitchelectroniccontrolsystem.................................55.12
[55.201]Enginestartingsystem...........................................................55.13
[55.301]Alternator.........................................................................55.14
[55.302]Battery............................................................................55.15
[55.408]Warningindicators,alarms,andinstruments....................................55.16
[55.512]Cabcontrols......................................................................55.17
[55.518]Wiperandwashersystem........................................................55.18
[55.640]Electronicmodules...............................................................55.19
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem..........................55.20
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[55.DTC]FAULTCODES..................................................................55.21
Platform,cab,bodywork,anddecals.............................................90
[90.100]Enginehoodandpanels...........................................................90.1
[90.102]Engineshields,hoodlatches,andtrims...........................................90.2
[90.124]Pneumatically-adjustedoperatorseat..............................................90.3
[90.150]Cab.................................................................................90.4
[90.151]Cabinterior.........................................................................90.5
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Torque-Minimumtighteningtorquesfornormalassembly.....................................5
Capacities.....................................................................................10
Productidentication..........................................................................11
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor
continuousimprovement.Someinformationcouldnotbeupdatedduetomodicationsofatechnicalorcommercial
type,orchangestothelawsandregulationsofdifferentcountries.
Incaseofquestions,refertoyourCASEIHSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
Throughoutthismanualandonmachinedecals,youwillndthesignalwordsDANGER,WARNING,andCAUTION
followedbyspecialinstructions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworking
withyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.The
colorassociatedwithDANGERisRED.
WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.
ThecolorassociatedwithWARNINGisORANGE.
CAUTION,usedwiththesafetyalertsymbol,indicatesahazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.ThecolorassociatedwithCAUTIONisYELLOW.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationwhich,ifnotavoided,couldresultinmachineorpropertydamage.Thecolor
associatedwithNoticeisBLUE.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationwhichclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
4774809226/09/2014
4

INTRODUCTION
Torque-Minimumtighteningtorquesfornormalassembly
METRICNON-FLANGEDHARDWARE
NOM.
SIZE
CLASS8.8BOLTand
CLASS8NUT
CLASS10.9BOLTand
CLASS10NUT
LOCKNUT
CL.8
W/CL8.8
BOLT
LOCKNUT
CL.10
W/CL10.9
BOLT
UNPLATEDPLATED
W/ZnCrUNPLATEDPLATED W/ZnCr
M42.2N·m(19lb
in)
2.9N·m(26lb
in)
3.2N·m(28lb
in)
4.2N·m(37lb
in)2N·m(18lbin)2.9N·m(26lb in)
M54.5N·m(40lb
in)
5.9N·m(52lb
in)
6.4N·m(57lb
in)
8.5N·m(75lb
in)4N·m(36lbin)5.8N·m(51lb in)
M67.5N·m(66lb
in)
10N·m(89lb
in)
11N·m(96lb
in)
15N·m(128lb
in)
6.8N·m(60lb
in)
10N·m(89lb
in)
M818N·m(163lb
in)
25N·m(217lb
in)
26N·m(234lb
in)
35N·m(311lb
in)
17N·m(151lb
in)
24N·m(212lb
in)
M1037N·m(27lbft)49N·m(36lb
ft)52N·m(38lbft)70N·m(51lb ft)
33N·m(25lb
ft)
48N·m(35lb
ft)
M1264N·m(47lbft)85N·m(63lb
ft)91N·m(67lbft)121N·m(90lb ft)
58N·m(43lb
ft)
83N·m(61lb
ft)
M16158N·m(116lb
ft)
210N·m
(155lbft)
225N·m(166lb
ft)
301N·m(222lb
ft)
143N·m(106lb
ft)
205N·m(151lb
ft)
M20319N·m(235lb
ft)
425N·m
(313lbft)
440N·m(325lb
ft)
587N·m(433lb
ft)
290N·m(214lb
ft)
400N·m(295lb
ft)
M24551N·m(410lb
ft)
735N·m
(500lbft)
762N·m(560lb
ft)
1016N·m
(750lbft)
501N·m(370lb
ft)
693N·m(510lb
ft)
NOTE:M4throughM8hardwaretorquespecicationsareshowninpound-inches.M10throughM24hardwaretorque
specicationsareshowninpound-feet.
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5

INTRODUCTION
METRICFLANGEDHARDWARE
NOM.
SIZE
CLASS8.8BOLTand
CLASS8NUT
CLASS10.9BOLTand
CLASS10NUT
LOCKNUT
CL.8
W/CL8.8
BOLT
LOCKNUT
CL.10
W/CL10.9
BOLT
UNPLATEDPLATED
W/ZnCrUNPLATEDPLATED W/ZnCr
M42.4N·m(21lb
in)
3.2N·m(28lb
in)
3.5N·m(31lb
in)
4.6N·m(41lb
in)
2.2N·m(19lb
in)
3.1N·m(27lb
in)
M54.9N·m(43lb
in)
6.5N·m(58lb
in)
7.0N·m(62lb
in)
9.4N·m(83lb
in)
4.4N·m(39lb
in)
6.4N·m(57lb
in)
M68.3N·m(73lb
in)
11N·m(96lb
in)
12N·m(105lb
in)
16N·m(141lb
in)
7.5N·m(66lb
in)
11N·m(96lb
in)
M820N·m(179lb
in)
27N·m(240lb
in)
29N·m(257lb
in)
39N·m(343lb
in)
18N·m(163lb
in)
27N·m(240lb
in)
M1040N·m(30lbft)54N·m(40lb
ft)57N·m(42lbft)77N·m(56lb ft)37N·m(27lbft)53N·m(39lbft)
M1270N·m(52lbft)93N·m(69lb
ft)
100N·m(74lb
ft)
134N·m(98lb
ft)63N·m(47lbft)91N·m(67lbft)
M16174N·m(128lb
ft)
231N·m(171lb
ft)
248N·m(183lb
ft)
331N·m(244lb
ft)
158N·m(116lb
ft)
226N·m(167lb
ft)
M20350N·m(259lb
ft)
467N·m(345lb
ft)
484N·m(357lb
ft)
645N·m(476lb
ft)
318N·m(235lb
ft)
440N·m(325lb
ft)
M24607N·m(447lb
ft)
809N·m(597lb
ft)
838N·m(618lb
ft)
1118N·m
(824lbft)
552N·m(407lb
ft)
IDENTIFICATION
MetricHexheadandcarriagebolts,classes5.6andup
200836801
1.Manufacturer'sIdentication
2.PropertyClass
MetricHexnutsandlocknuts,classes05andup
200836812
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6

INTRODUCTION
1.Manufacturer'sIdentication
2.PropertyClass
3.ClockMarkingofPropertyClassandManufacturer'sIdentication(Optional),i.e.marks60°apartindicateClass
10properties,andmarks120°apartindicateClass8.
INCHNON-FLANGEDHARDWARE
NOMINAL
SIZE
SAEGRADE5BOLT
andNUT
SAEGRADE8BOLT
andNUT
LOCKNUT
GrBW/Gr5
BOLT
LOCKNUT
GrCW/Gr8
BOLT
UN-
PLATED
or
PLATED
SILVER
PLATED
W/ZnCr
GOLD
UN-
PLATED
orPLATED
SILVER
PLATED
W/ZnCr
GOLD
1/48N·m(71lb
in)
11N·m(97lb
in)
12N·m
(106lbin)
16N·m
(142lbin)8.5N·m(75lbin)12.2N·m(109lb
in)
5/1617N·m
(150lbin)
23N·m
(204lbin)
24N·m
(212lbin)
32N·m
(283lbin)
17.5N·m(155lb
in)
25N·m(220lb
in)
3/830N·m(22lb
ft)
40N·m
(30lbft)
43N·m(31lb
ft)
57N·m(42lb
ft)31N·m(23lbft)44N·m(33lbft)
7/1648N·m(36lb
ft)
65N·m
(48lbft)
68N·m(50lb
ft)
91N·m(67lb
ft)50N·m(37lbft)71N·m(53lbft)
1/274N·m(54lb
ft)
98N·m
(73lbft)
104N·m
(77lbft)
139N·m
(103lbft)76N·m(56lbft)108N·m(80lb
ft)
9/16107N·m
(79lbft)
142N·m
(105lbft)
150N·m
(111lbft)
201N·m
(148lbft)111N·m(82lbft)156N·m(115lb
ft)
5/8147N·m
(108lbft)
196N·m
(145lbft)
208N·m
(153lbft)
277N·m
(204lbft)
153N·m(113lb
ft)
215N·m(159lb
ft)
3/4261N·m
(193lbft)
348N·m
(257lbft)
369N·m
(272lbft)
491N·m
(362lbft)
271N·m(200lb
ft)
383N·m(282lb
ft)
7/8420N·m
(310lbft)
561N·m
(413lbft)
594N·m
(438lbft)
791N·m
(584lbft)
437N·m(323lb
ft)
617N·m(455lb
ft)
1630N·m
(465lbft)
841N·m
(620lbft)
890N·m
(656lbft)
1187N·m
(875lbft)
654N·m(483lb
ft)
924N·m(681lb
ft)
NOTE:ForImperialUnits,1/4inand5/16inhardwaretorquespecicationsareshowninpound-inches.3/8in
through1inhardwaretorquespecicationsareshowninpound-feet.
4774809226/09/2014
7

INTRODUCTION
INCHFLANGEDHARDWARE
NOM-
INAL
SIZE
SAEGRADE5BOLTand
NUT
SAEGRADE8BOLTand
NUT
LOCKNUT
GrFW/Gr5
BOLT
LOCKNUT
GrGW/Gr8
BOLT
UNPLATED
orPLATED
SILVER
PLATED
W/ZnCr
GOLD
UNPLATED
orPLATED
SILVER
PLATED
W/ZnCr
GOLD
1/49N·m(80lbin)12N·m(106lb
in)
13N·m(115lb
in)
17N·m(150lb
in)8N·m(71lbin)12N·m(106lb in)
5/1619N·m(168lb
in)
25N·m(221lb
in)
26N·m(230lb
in)
35N·m(310lb
in)
17N·m(150lb
in)
24N·m(212lb
in)
3/833N·m(25lb
ft)
44N·m(33lb
ft)
47N·m(35lb
ft)
63N·m(46lb
ft)30N·m(22lbft)43N·m(32lbft)
7/1653N·m(39lb
ft)
71N·m(52lb
ft)
75N·m(55lb
ft)
100N·m(74lb
ft)48N·m(35lbft)68N·m(50lbft)
1/281N·m(60lb
ft)
108N·m(80lb
ft)
115N·m(85lb
ft)
153N·m
(113lbft)74N·m(55lbft)104N·m(77lb
ft)
9/16117N·m(86lb
ft)
156N·m
(115lbft)
165N·m
(122lbft)
221N·m
(163lbft)106N·m(78lbft)157N·m(116lb
ft)
5/8162N·m(119lb
ft)
216N·m
(159lbft)
228N·m
(168lbft)
304N·m
(225lbft)
147N·m(108lb
ft)
207N·m(153lb
ft)
3/4287N·m(212lb
ft)
383N·m
(282lbft)
405N·m
(299lbft)
541N·m
(399lbft)
261N·m(193lb
ft)
369N·m(272lb
ft)
7/8462N·m(341lb
ft)
617N·m
(455lbft)
653N·m
(482lbft)
871N·m
(642lbft)
421N·m(311lb
ft)
594N·m(438lb
ft)
1693N·m(512lb
ft)
925N·m
(682lbft)
979N·m
(722lbft)
1305N·m
(963lbft)
631N·m(465lb
ft)
890N·m(656lb
ft)
IDENTIFICATION
InchBoltsandfree-spinningnuts
200836823
GradeMarkingExamples
SAEGradeIdentication
1Grade2-NoMarks4Grade2Nut-NoMarks
2Grade5-ThreeMarks5Grade5Nut-Marks120°Apart
3Grade8-FiveMarks6Grade8Nut-Marks60°Apart
4774809226/09/2014
8

INTRODUCTION
InchLockNuts,AllMetal(Threeoptionalmethods)
200902684
GradeIdentication
GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3)
GradeANoNotchesNoMarkNoMarks
GradeBOneCircumferentialNotchLetterBThreeMarks
GradeCTwoCircumferentialNotchesLetterCSixMarks
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INTRODUCTION
Capacities
Magnum180,200,220and240
SystemMetricU.S.Imperial
EngineOil—CASEIHAKCELAUNITEKNO.1™SBLCJ-4orCASEIHAKCELANO.1™ENGINEOIL
Nolterchange16l4.23USgal3.52UKgal
Withlterchange16.5l4.36USgal3.63UKgal
Coolingsystem23.65l6.25USgal5.2UKgal
Transmission/hydraulicsystem—CASEIHAKCELAHY-TRAN®ULTRACTION
FullPowershift85l22.5USgal18.7UKgal
ContinuousVariable
Transmission(CVT)
100l26.4USgal22.0UKgal
MechanicalFrontDrive(MFD)—TUTELAHYPOIDEEPGEARLUBEorCASEIHAKCELAGEAR135HEP85W-140
CaseIH4.0xedfrontaxle
Differential11l11.6USqt21.6UKpt
Planetary(each)2.3l2.4USqt2.0UKqt
CaseIH4.75saddlesuspendedfrontaxle
Differential17.5l18.5USqt30.8UKpt
Planetary(each)4.3l4.5USqt7.5UKqt
MechanicalFrontDrive(MFD)gearbox—TUTELAHYPOIDEEPGEARLUBESAE85W-140
275mL9.3USoz9.7UKoz
Fueltank586.7l155USgal129UKgal
DEF/AdBlue®tank88.2l23.3USgal19.4UKgal
4774809226/09/2014
10

INTRODUCTION
Productidentication
TractormodelandProductIdenticationNumber(PIN)
Writeyourmodelnumber,ProductIdenticationNumber(PIN)orserialnumberofmajorcomponentsonthelines
provided.Ifneeded,givethesenumberstoyourdealerwhenyouneedpartsorinformationforyourmachine.
RAIL14TR02078EA1
1.Type8.Permissiblerearaxleload(*):
2.EECnumber9.(*)Dependingonthetires
3.YearofconstructionPermissibletowablemass:
4.Modelyear•10.Unbrakedtowablemass:
5.Productidenticationnumber•11.Independently-brakedtowablemass:
6.Totalpermissiblemass(*):•12.Inertiabrakedtowablemass:
7.Permissiblefrontaxleload(*):•13.Towablemassttedwithanassistedbraking
system:(hydraulicorpneumatic)
Model:
PIN
NOTE:Locatedonrighthandfrontframecasting.
RCPH08CCH625AAB2
RollOverProtectiveStructure(ROPS)serialnumber
NOTE:Locatedontherighthandcaboor.
RAIL13TR04461AA3
4774809226/09/2014
11

INTRODUCTION
Engineserialnumber
NOTE:Locatedontherighthandsideoftheengineon
thecasting.Aserialnumberdecalisalsolocatedonthe
topofthevalvecover.
RCPH10CCH009BAA4
Transmissionserialnumber
NOTE:LocatedontherighthandsideofthePowershift
transmissionbehindandtotheleftofthebatterycarrier.
LocatedonthetopoftheContinuouslyVariableTransmis-
sion(CVT)housing,paralleltotheaccumulator(shown).
RAIL13TR03691AA5
Axleserialnumber
Class4.0xedfrontaxle:Locatedonthefrontright
handsideoftheaxlehousing(shown).
Class4.75saddlesuspendedfrontaxle:Locatedonthe
rearlefthandsideoftheaxlehousing(notshown).
RCPH10CCH010BAA6
4774809226/09/2014
12

INTRODUCTION
Drivelineserialnumber
Locatedontherighthandsideofthedropboxbelowthe
exhaustelbow.
RAIL13TR03700AA7
4774809226/09/2014
13