Case IH Magnum 235, Magnum 260, Magnum 290, Magnum 315, Magnum 340 Service Manual

MAGNUM 235 MAGNUM 260 MAGNUM 290 MAGNUM 315 MAGNUM 340 Tractor from PIN ZBRD07000 and above Part number 47442317 2nd edition English September 2012 Replaces part number 47386173 SERVICE MANUAL

Contents INTRODUCTION Engine....................................................................................... 10 Engine and crankcase .................................................................... 10.001 Cylinder heads ........................................................................... 10.101 Pump drives .............................................................................. 10.114 Air cleaners and lines..................................................................... 10.202 Fuel tanks ................................................................................ 10.216 Aftercooler ................................................................................ 10.310 Engine cooling system ................................................................... 10.400 Fan and drive ............................................................................. 10.414 Selective Catalytic Reduction (SCR) exhaust treatment ................................. 10.500 Transmission.............................................................................. 21 Powershift transmission lubrication system .............................................. 21.105 Powershift transmission .................................................................. 21.113 Powershift transmission external controls ................................................ 21.135 Gearbox internal components ............................................................ 21.145 Powershift transmission internal components ............................................ 21.155 Drop box .................................................................................. 21.200 Four-Wheel Drive (4WD) system .................................................. 23 Electrohydraulic control ................................................................... 23.202 Drive shaft ................................................................................ 23.314 Front axle system ....................................................................... 25 Powered front axle ....................................................................... 25.100 Front bevel gear set and differential ...................................................... 25.102 Final drive hub, steering knuckles, and shafts ........................................... 25.108 Axle suspension control .................................................................. 25.122 Rear axle system ........................................................................ 27 47386173 15/06/2012

Powered rear axle ........................................................................ 27.100 Rear bevel gear set and differential ...................................................... 27.106 Planetary and ﬁnal drives................................................................. 27.120 Power Take-Off (PTO) ................................................................. 31 Rear electrohydraulic control ............................................................. 31.104 One-speed rear Power Take-Off (PTO) .................................................. 31.110 Two-speed rear Power Take-Off (PTO) .................................................. 31.114 Front Power Take-Off (PTO) .............................................................. 31.146 Brakes and controls .................................................................... 33 Parking brake / Parking lock .............................................................. 33.110 Hydraulic service brakes ................................................................. 33.202 Trailer brake hydraulic control ............................................................ 33.220 Trailer brake pneumatic control........................................................... 33.224 Hydraulic systems....................................................................... 35 Hydraulic systems ........................................................................ 35.000 Pump control valves ...................................................................... 35.102 Variable displacement pump ............................................................. 35.106 Three-point hitch control valve ........................................................... 35.114 Remote control valves .................................................................... 35.204 Reservoir, cooler, and ﬁlters .............................................................. 35.300 Combination pump units .................................................................. 35.304 Pneumatic system ...................................................................... 36 Pneumatic system ........................................................................ 36.100 Hitches, drawbars, and implement couplings .................................. 37 Rear three-point hitch .................................................................... 37.110 Front hitch ................................................................................ 37.162 Steering..................................................................................... 41 Steering control ........................................................................... 41.101 47386173 15/06/2012

Hydraulic control components ............................................................ 41.200 Pump ..................................................................................... 41.206 Cab climate control ..................................................................... 50 Heating ................................................................................... 50.100 Air conditioning ........................................................................... 50.200 Cab pressurizing system ................................................................. 50.300 Electrical systems ....................................................................... 55 Engine cooling system ................................................................... 55.012 Front axle control system ................................................................. 55.045 Rear axle control system ................................................................. 55.046 Heating, Ventilation, and Air-Conditioning (HVAC) control system ....................... 55.050 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls ......................... 55.051 Harnesses and connectors ............................................................... 55.100 Three-point rear hitch electronic control system ......................................... 55.130 Engine starting system ................................................................... 55.201 Alternator ................................................................................. 55.301 Battery .................................................................................... 55.302 External lighting .......................................................................... 55.404 External lighting switches and relays ..................................................... 55.405 Warning indicators, alarms, and instruments ............................................. 55.408 Cab controls .............................................................................. 55.512 Cab lighting ............................................................................... 55.514 Wiper/Washer system .................................................................... 55.518 Electronic modules ....................................................................... 55.640 Selective Catalytic Reduction (SCR) electrical system ................................... 55.988 FAULT CODES .......................................................................... 55.DTC Platform, cab, bodywork, and decals ............................................. 90 Engine hood and panels .................................................................. 90.100 Engine shields, hood latches, and trims .................................................. 90.102 47386173 15/06/2012

Protections and footboards ............................................................... 90.118 Pneumatically-adjusted operator seat .................................................... 90.124 Cab ....................................................................................... 90.150 Cab interior ............................................................................... 90.151 47386173 15/06/2012

47386173 15/06/2012

INTRODUCTION 47386173 15/06/2012 1

Contents INTRODUCTION Safety rules ..................................................................................... 3 Magnum 235 NA, Magnum 260 NA, Magnum 290 NA, Magnum 315 NA, Magnum 340 NA Safety rules ..................................................................................... 4 Magnum 235, Magnum 260, Magnum 290, Magnum 315, Magnum 340 Basic instructions - Important notice regarding equipment servicing ........................... 6 Magnum 235 NA, Magnum 260 NA, Magnum 290 NA, Magnum 315 NA, Magnum 340 NA Torque - Minimum tightening torques for normal assembly ..................................... 7 Magnum 235, Magnum 260, Magnum 290, Magnum 315, Magnum 340 Capacities ..................................................................................... 12 Magnum 235, Magnum 260, Magnum 290, Magnum 315, Magnum 340 47386173 15/06/2012 2

INTRODUCTION Safety rules Magnum 235 NA, Magnum 260 NA, Magnum 290 NA, Magnum 315 NA, Magnum 340 NA Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW. FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety. Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage. 47386173 15/06/2012 3

INTRODUCTION Safety rules Magnum 235, Magnum 260, Magnum 290, Magnum 315, Magnum 340 Standard safety precautions Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for consultation. • Keep working areas as clean as possible. • Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain adequate sanitary equipment. • Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked on a regular basis and personnel must be trained on proper interventions and priorities. • Keep all emergency exits free of obstructions and clearly marked. • Smoking in working areas subject to fire danger must be strictly prohibited. Prevention of injury • Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to engines and equipment in motion. • Wear safety gloves and goggles when performing the following operations: • Topping off or changing lubrication oils. • Using compressed air or liquids at a pressure greater than 2 bar (29 psi). • Wear a safety helmet when working close to hanging loads or equipment working at head level. • Always wear safety shoes and fitting clothes. • Use protection cream for hands. • Change wet clothes as soon as possible. • In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connec- tions. Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with electricity. • Do not smoke or start an open flame close to batteries and any fuel material. • Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers. • Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may occur. • If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes. During maintenance • Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F). • Never add coolant to an overheated engine and use only appropriate liquids. • Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be aware of all the risks involved with such an operation. • Always use adequate and safe containers for engine fluids and used oil. • Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents. • Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated. Wear a safety mask if necessary. • Do not leave soiled rags that may contain any flammable substances close to the engine. • Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air in case of engine runaway. 47386173 15/06/2012 4

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Case IH Magnum 235, Magnum 260, Magnum 290, Magnum 315, Magnum 340 Service Manual

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