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Case IH Magnum 180 Service Manual

Case IH Magnum 180 Service Manual

Continuously variable transmission (cvt) tractor

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Continuously Variable Transmission (CVT)
Magnum
Magnum
Magnum
Magnum
PIN ZERH08100 and above
SERVICE MANUAL
Part number 47748092
180
200
220
240
Tractor
1
edition English
st
September 2014

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Summary of Contents for Case IH Magnum 180

  • Page 1 Magnum ™ Magnum ™ Magnum ™ Magnum ™ Continuously Variable Transmission (CVT) Tractor PIN ZERH08100 and above SERVICE MANUAL Part number 47748092 edition English September 2014...
  • Page 2 SERVICE MANUAL Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014 Find manuals at https://best-manuals.com...
  • Page 3 Link Product / Engine Product Market Product Engine Magnum™ 180 696110752 CVT North America F4HFE613K*B002 TIER 4B [ZERH08100 - ] Magnum™ 180 696110752 CVT Australia New Zealand F4HFE613K*B002 TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT North America F4HFE613J*B005 TIER 4B [ZERH08100 - ] Magnum™...
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
  • Page 5 [25.108] Final drive hub, steering knuckles, and shafts ........25.3 [25.122] Axle suspension control .
  • Page 6 [41.206] Pump ................41.3 Wheels ..................
  • Page 7 [55.DTC] FAULT CODES..............55.21 Platform, cab, bodywork, and decals ..........
  • Page 8 INTRODUCTION 47748092 26/09/2014 Find manuals at https://best-manuals.com...
  • Page 9: Table Of Contents

    Contents INTRODUCTION Foreword - Important notice regarding equipment servicing ........3 Safety rules .
  • Page 10: Foreword - Important Notice Regarding Equipment Servicing

    Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your CASE IH Sales and Service Networks. 47748092 26/09/2014...
  • Page 11: Safety Rules

    INTRODUCTION Safety rules 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.
  • Page 12: Torque - Minimum Tightening Torques For Normal Assembly

    INTRODUCTION Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. LOCKNUT LOCKNUT SIZE CL.8 CL.10 CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9 CLASS 8 NUT CLASS 10 NUT BOLT BOLT PLATED PLATED UNPLATED UNPLATED W/ZnCr W/ZnCr 2.2 N·m (19 lb...
  • Page 13 INTRODUCTION METRIC FLANGED HARDWARE NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10 W/CL8.8 W/CL10.9 BOLT BOLT PLATED PLATED UNPLATED UNPLATED W/ZnCr W/ZnCr 2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb...
  • Page 14 INTRODUCTION 1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8. INCH NON-FLANGED HARDWARE LOCKNUT LOCKNUT NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT GrB W/ Gr5...
  • Page 15 INTRODUCTION INCH FLANGED HARDWARE NOM- LOCKNUT LOCKNUT SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL GrF W/ Gr5 GrG W/ Gr8 SIZE BOLT BOLT UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 12 N·m (106 lb 13 N·m (115 lb...
  • Page 16 INTRODUCTION Inch Lock Nuts, All Metal (Three optional methods) 20090268 Grade Identification Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3) Grade A No Notches No Mark No Marks Grade B One Circumferential Notch Letter B Three Marks Grade C Two Circumferential Notches...
  • Page 17: Capacities

    Magnum 180, 200, 220 and 240 Metric Imperial System U.S. Engine Oil — CASE IH AKCELA UNITEK NO. 1™ SBL CJ-4 or CASE IH AKCELA NO. 1™ ENGINE OIL No filter change 16 l 4.23 US gal 3.52 UK gal 16.5 l...
  • Page 18: Product Identification

    INTRODUCTION Product identification Tractor model and Product Identification Number (PIN) Write your model number, Product Identification Number (PIN) or serial number of major components on the lines provided. If needed, give these numbers to your dealer when you need parts or information for your machine. RAIL14TR02078EA 1.
  • Page 19 INTRODUCTION Engine serial number NOTE: Located on the right hand side of the engine on the casting. A serial number decal is also located on the top of the valve cover. RCPH10CCH009BAA Transmission serial number NOTE: Located on the right hand side of the Powershift transmission behind and to the left of the battery carrier.
  • Page 20 INTRODUCTION Driveline serial number Located on the right hand side of the drop box below the exhaust elbow. RAIL13TR03700AA 47748092 26/09/2014...
  • Page 21 INTRODUCTION 47748092 26/09/2014...
  • Page 22 SERVICE MANUAL Engine Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014...
  • Page 23 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.216] Fuel tanks .
  • Page 24 Engine - 10 Engine and crankcase - 001 Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014 10.1 [10.001] / 1...
  • Page 25 Contents Engine - 10 Engine and crankcase - 001 SERVICE Engine Remove ................. . 3 Install .
  • Page 26 Engine - Engine and crankcase Engine - Remove Prior operation: Battery - Disconnect (55.302) Prior operation: Air intake lines Air scoop - Remove (10.202) Prior operation: Engine cooling system - Remove (10.400) Prior operation: Air conditioning - Recover - Refrigerant (50.200) 1.
  • Page 27 Engine - Engine and crankcase 4. Remove the air cleaner mounting bolts (1) from each side of the air cleaner bracket (left side shown). RAIL13TR01585AA 5. Remove the air cleaner along with the mounting bracket. RAIL13TR01587AA 6. Disconnect the Diesel Exhaust Fluid (DEF)/AdBlue® line (1), the coolant supply and return lines (2) and the electrical connector (3) from the dosing module.
  • Page 28 Engine - Engine and crankcase 7. Disengage the clamp (1) from the input side of the Diesel Exhaust Catalyst (DOC). RAIL13TR01589AA 8. Disengage the clamp (1) from the output side of the DOC. RAIL13TR01590AA 9. Using proper lifting equipment, secure a strap to the lifting bracket on the DOC.
  • Page 29 Engine - Engine and crankcase 10. With tension on the lifting strap, remove the mounting bracket bolts (1) for the DOC from both sides of the bracket (left hand side is shown). RAIL13TR01593AA 11. Raise the DOC and remove it from the tractor. RAIL13TR01596AA 12.
  • Page 30 Engine - Engine and crankcase 13. Cut the tie straps on the DEF/AdBlue® system har- ness. Disconnect the two harness connectors (1). RAIL13TR01597AA 14. Disconnect the 12 V auxiliary connector (1) and the inlet fuel line from the fuel separator (2). RAIL13TR01603AA 15.
  • Page 31 Engine - Engine and crankcase 16. Remove the cab trim panels from both sides of the cab, (right hand side shown). RAIL13TR01611AA 17. Disconnect and cap the high and low pressure air con- ditioning lines (1) located under the front of the cab. RAIL13TR01599AA 18.
  • Page 32 Engine - Engine and crankcase 19. Remove the bolts (1) for the mounting bracket for the driveshaft cover plate. Disconnect the driveshaft from the engine. RAIL13TR01602AA 20. Remove the bolts (1) for the mounting bracket for the air cleaner/DOC from the hood support bracket. 21.
  • Page 33 Engine - Engine and crankcase 23. Disconnect the starter positive (1) and ground (2) ca- bles. 24. Disconnect the chassis to engine harness connector (3). RAIL13TR01613AA 25. Disconnect the two hydraulic oil cooler lines (1). Cap or plug all fittings and lines. RAIL13TR01615AA 26.
  • Page 34 Engine - Engine and crankcase 27. Disconnect the vacuum line (1) from the air intake col- lector elbow. RAIL13TR01624AA 28. Disengage the P-clamp for the vacuum line from the fly wheel housing. RAIL13TR01621AA 29. Attach appropriate lifting equipment to the front and rear engine lifting brackets.
  • Page 35 Engine - Engine and crankcase 30. Remove the two bolts (1) from the isolation clamp for the front engine mount (right hand side shown). RAIL13TR01626AA 31. Raise the engine from the frame. Check that all har- nesses and hoses are disconnected. Remove the en- gine from the frame.
  • Page 36 Engine - Engine and crankcase Engine - Install (10.001) 47748092 26/09/2014 10.1 [10.001] / 13...
  • Page 37 Engine - Engine and crankcase Engine - Install Prior operation: Engine - Remove (10.001) NOTICE: Check that all fittings are clean and free of foreign matter during assembly. Use new O-rings and lubricate them with petroleum jelly prior to installation. 1.
  • Page 38 Engine - Engine and crankcase 6. Connect the vacuum line (1) for the air intake collector elbow. RAIL13TR01620AA 7. Connect the two coolant lines (1) RAIL13TR01616AA 8. Connect the two hydraulic oil cooler lines (1) using new O-rings. RAIL13TR01615AA 47748092 26/09/2014 10.1 [10.001] / 15...
  • Page 39 Engine - Engine and crankcase 9. Connect the positive starter cable (1) and the ground cable (2). Reconnect the chassis to engine harness connector (3). RAIL13TR01613AA 10. Install the hood support brackets (1) and secure the brackets to the front frame using the bolts previously removed.
  • Page 40 Engine - Engine and crankcase 16. Reinstall the driveshaft cover plate and secure with the bolts previously removed. RAIL13TR01600AA 17. Coat new O-rings for the air conditioning system with mineral oil, and install the O-rings on the high and low pressure fittings.
  • Page 41 Engine - Engine and crankcase 19. Connect the front axle harness connectors. RAIL13TR01625AA 20. Connect the 12 V auxiliary connector (1) and the fuel inlet line to the fuel separator (2). RAIL13TR01603AA 21. Connect the connectors (1) for the Selective Catalytic Reduction (SCR) system.
  • Page 42 Engine - Engine and crankcase 22. Using proper lifting equipment, lower the DOC into place. RAIL13TR01596AA 23. Secure the DOC mounting bracket with the bolts (1) previously removed (left hand side shown). RAIL13TR01593AA 24. Connect the outlet pipe to the DOC, and secure with the clamp previously removed.
  • Page 43 Engine - Engine and crankcase 25. Connect the inlet pipe to the DOC, and secure with the clamp previously removed. NOTE: If the mounting straps were loosened, make sure to tighten the straps after the inlet and outlet pipes are secure. RAIL13TR01589AA 26.
  • Page 44 Engine - Engine and crankcase 28. Reinstall the air cleaner along with its mounting bracket. Secure the bracket to the DOC bracket with the bolts (1) previously removed. Left hand side is shown, repeat for right hand side. RAIL13TR01585AA 29. Connect the air cleaner outlet tube (1) between the turbocharger and the air cleaner (2).
  • Page 45 Engine - Engine and crankcase Air conditioning - Evacuate - Air conditioning system (50.200) Next operation: Air conditioning - Charging - Air conditioning system (50.200) Next operation: Battery - Connect (55.302) 47748092 26/09/2014 10.1 [10.001] / 22...
  • Page 46 Index Engine - 10 Engine and crankcase - 001 Engine - Install ..................14 Engine - Remove .
  • Page 47 47748092 26/09/2014 10.1 [10.001] / 24...
  • Page 48 Engine - 10 Fuel tanks - 216 Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014 10.2 [10.216] / 1...
  • Page 49 Contents Engine - 10 Fuel tanks - 216 SERVICE Fuel tank Remove ................. . 3 Install .
  • Page 50 Engine - Fuel tanks Fuel tank - Remove Prior operation: Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove (10.500) WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing.
  • Page 51 Engine - Fuel tanks For left hand side tank 4. At the tank holding strap (1), remove the adjustment nut (2). RCPH09CCH132AAB 5. Remove the bolts and tank hold-down bracket (1). RAIL13TR01794AA 6. Disengage the fuel vent hose clamp and disconnect the hose (1).
  • Page 52 Engine - Fuel tanks 8. With the help of an assistant, remove the tank from it's support. NOTE: The rear tire may have to be moved outward to remove the tank. RAIL13TR01822AA Right hand side tank 9. If the right hand side tank needs to be removed, the bat- tery must be removed, see Battery - Remove (55.302).
  • Page 53 Engine - Fuel tanks 12. Using proper lifting equipment, apply tension on the lifting strap and remove the four bolts (1) from the front fuel tank support bracket. RAIL13TR01799AA 13. Remove the four bolts (1) from the rear tank support bracket.
  • Page 54 Engine - Fuel tanks Fuel tank - Install Prior operation: Battery - Remove (55.302) Prior operation: Fuel tank - Remove (10.216) Right hand side tank 1. Move the fuel tank along with the support bracket into position. RAIL13TR01801AA 2. Install the four bolts (1) to secure the tank at the rear mounting bracket.
  • Page 55 Engine - Fuel tanks 4. Remove the lifting strap. RAIL13TR01798AA 5. Connect the fuel crossover vent hose (1) and secure with the hose clamp. RAIL13TR01797AA Left hand side fuel tank 6. With the help of an assistant, install the tank on the support.
  • Page 56 Engine - Fuel tanks 8. Reinstall the tank holding strap (1), and tighten the ad- justment nut (2). RCPH09CCH132AAB 9. Install the tank hold-down bracket (1) and secure the bracket with the bolts previously removed. RAIL13TR01794AA 10. Connect the fuel supply fitting (1) and the return hose (2).
  • Page 57 Engine - Fuel tanks 12. Connect the fuel tank crossover hose and secure with hose clamp previously removed. RAIL13TR01796AA 13. Reinstall the fuel tank crossover hose covers (1) and secure the covers with the bolts (2) previously re- moved. Repeat for both tanks. RAIL13TR01795AA WARNING Fire hazard!
  • Page 58 Index Engine - 10 Fuel tanks - 216 Fuel tank - Install ................. . . 7 Fuel tank - Remove .
  • Page 59 47748092 26/09/2014 10.2 [10.216] / 12...
  • Page 60 Engine - 10 Fuel injection system - 218 Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014 10.3 [10.218] / 1...
  • Page 61 Contents Engine - 10 Fuel injection system - 218 SERVICE Pressure regulating valve Configure - Reset ECU data ..............3 Common rail Relief valve - Configure - Reset ECU data .
  • Page 62 Engine - Fuel injection system Pressure regulating valve - Configure - Reset ECU data NOTE: Active dosing faults require additional key cycles in order for the Electronic Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle. 1.
  • Page 63 Engine - Fuel injection system Common rail Relief valve - Configure - Reset ECU data NOTE: Active dosing faults require additional key cycles in order for the Electronic Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle. 1.
  • Page 64 Index Engine - 10 Fuel injection system - 218 Common rail Relief valve - Configure - Reset ECU data ..........4 Pressure regulating valve - Configure - Reset ECU data .
  • Page 65 47748092 26/09/2014 10.3 [10.218] / 6...
  • Page 66 Engine - 10 Air cleaners and lines - 202 Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014 10.4 [10.202] / 1...
  • Page 67 Contents Engine - 10 Air cleaners and lines - 202 SERVICE Air intake lines Air scoop - Remove ............... . 3 Air scoop - Install .
  • Page 68 Engine - Air cleaners and lines Air intake lines Air scoop - Remove 1. Open the hood. RAIL13TR01410AA NOTE: Drain the coolant from the deaeration tank. NOTE: The following steps show the hood removed for photographic clarity. 2. Remove the bolts (1) securing the air scoop/hose bracket.
  • Page 69 Engine - Air cleaners and lines 4. Remove the two air scoop mounting bolts (1) at the air cleaner. Loosen the two lower mounting bolts (not shown) directly under the upper bolts. RAIL13TR01559AA 5. Disconnect the two hoses (1) from the deaeration tank. Disengage the P-clamp (2) from the tank bracket.
  • Page 70 Engine - Air cleaners and lines Air intake lines Air scoop - Install 1. Move the air scoop and deaeration tank into position with appropriate lifting equipment. RAIL13TR01562AA 2. Secure the air scoop with the bolts (1) removed earlier, and tighten the bolts on the bottom of the air scoop. RAIL13TR01559AA 3.
  • Page 71 Engine - Air cleaners and lines 4. Install the two mounting bolts (1) for the air scoop bracket. RAIL13TR01548AA 5. Refill the deaeration tank. 47748092 26/09/2014 10.4 [10.202] / 6...
  • Page 72 Engine - Air cleaners and lines Air cleaner - Remove Prior operation: Air intake lines Air scoop - Remove (10.202) NOTE: The hood is removed for photographic clarity. 1. Disengage the hose clamp (1) from the air intake pipe elbow. RAIL13TR01579AA 2.
  • Page 73 Engine - Air cleaners and lines 4. Remove the two bolts (1) from the air cleaner mounting bracket. Left hand side is shown, repeat for the right hand side. RAIL13TR01585AA 5. Raise the air cleaner along with the mounting bracket with appropriate lifting equipment, and move it aside.
  • Page 74 Engine - Air cleaners and lines Air cleaner - Install Prior operation: Air cleaner - Remove (10.202) 1. Move the air cleaner and bracket into position with ap- propriate lifting equipment. RAIL13TR01587AA 2. Secure the air cleaner bracket with the bolts (1) previ- ously removed.
  • Page 75 Engine - Air cleaners and lines 4. Reconnect the air intake pipe elbow. RAIL13TR01583AA 5. Secure the pipe elbow with the clamp (1) previously removed. RAIL13TR01579AA Next operation: Air intake lines Air scoop - Install (10.202) 47748092 26/09/2014 10.4 [10.202] / 10...
  • Page 76 Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Install ................. 9 Air cleaner - Remove .
  • Page 77 47748092 26/09/2014 10.4 [10.202] / 12...
  • Page 78 Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500 Magnum™ 180 696110752 CVT TIER 4B [ZERH08100 - ] Magnum™ 200 696110762 CVT TIER 4B [ZERH08100 - ] Magnum™ 220 696110772 CVT TIER 4B [ZERH08100 - ] Magnum™ 240 696110782 CVT TIER 4B [ZERH08100 - ] 47748092 26/09/2014 10.5 [10.500] / 1...
  • Page 79 Contents Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500 FUNCTIONAL DATA Selective Catalytic Reduction (SCR) exhaust treatment Dynamic description ............... . 3 Component identification .
  • Page 80 Engine - Selective Catalytic Reduction (SCR) exhaust treatment Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description The Selective Catalytic Reduction (SCR) employs a supply module for the delivery of pressurized Diesel Exhaust Fluid (DEF/AdBlue®) drawn from the storage tank to the dosing module that injects the fluid into the engine exhaust stream.
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Magnum 200Magnum 220Magnum 240
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