Case IH Magnum 250 Service Manual
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Case IH Magnum 250 Service Manual

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Magnum 250
Magnum 280
Magnum 310
Magnum 340
Powershift Transmission (PST)
Tractor
PIN ZERF04500 and above
SERVICE MANUAL
Part number 47685449
1
edition English
st
May 2014

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  • Page 1 Magnum 250 Magnum 280 Magnum 310 Magnum 340 Powershift Transmission (PST) Tractor PIN ZERF04500 and above SERVICE MANUAL Part number 47685449 edition English May 2014...
  • Page 2 Link Product / Engine Product Market Product Engine Magnum 250 696110023 PST North America F2CFE613G*B002 TIER 4b [ZERF04500 - ] Magnum 280 696110033 PST North America F2CFE614G*B003 TIER 4b [ZERF04500 - ] Magnum 310 696110043 PST North America F2CFE614D*B003 TIER 4b [ZERF04500 - ]...
  • Page 3 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.101] Cylinder heads .
  • Page 4 Front axle system ............... 25 [25.100] Powered front axle ..............25.1 [25.102] Front bevel gear set and differential .
  • Page 5 Pneumatic system ..............36 [36.100] Pneumatic system..............36.1 Hitches, drawbars, and implement couplings........
  • Page 6 [55.301] Alternator ............... . . 55.12 [55.302] Battery.
  • Page 7 INTRODUCTION 47685449 08/05/2014 Find manuals at https://best-manuals.com...
  • Page 8 Contents INTRODUCTION Foreword - Important notice regarding equipment servicing ........3 Safety rules .
  • Page 9 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. 47685449 08/05/2014...
  • Page 10 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 you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.
  • Page 11 INTRODUCTION Safety rules - General maintenance safety General maintenance safety Keep the area used for servicing the machine clean and dry. Clean up spilled fluids. Service the machine on a firm, level surface. Install guards and shields after you service the machine. Close all access doors and install all panels after servicing the machine.
  • Page 12 INTRODUCTION Safety rules - Personal Protective Equipment (PPE) Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, pro- tective clothing, etc. 47685449 08/05/2014...
  • Page 13 INTRODUCTION Safety rules - Do Not Operate tag Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible. 47685449 08/05/2014...
  • Page 14 • Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your CASE IH dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.
  • Page 15 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 16 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 17 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 18 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 19 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 20 INTRODUCTION Capacities System Metric U.S. Imperial 9.0 l engine CASE IH AKCELA UNITEK NO. 1™ SBL CJ-4 Engine oil – no filter 6.6 US gal 5.5 UK gal 25 l change Engine oil – with filter 6.6 US gal 5.5 UK gal...
  • Page 21 INTRODUCTION Product identification Tractor model and product identification number RAIL14TR00786EA 1. Type Permissible towable mass: 2. EEC number • 7. Unbraked towable mass 3. Product identification number • 8. Independently brakes towable mass 4. Total permissible mass • 9. Inertia braked towable mass 5.
  • Page 22 INTRODUCTION Engine serial number NOTE: Located on the valve cover. The serial number is also etched into the left hand side of the engine block, just below the oil cooler. RAIL12TR02140AA Transmission serial number NOTE: Located on the right hand side of the transmission to the left of the main hydraulic filter.
  • Page 23 INTRODUCTION Axle serial number Located on the rear left hand side of the class 4.5 fixed, 4.75 fixed, 4.75 saddle suspended, 5.0 fixed and 5.0 saddle suspended front axle housings. (example shown) RAIL12TR02142AA 47685449 08/05/2014...
  • Page 24 INTRODUCTION 47685449 08/05/2014...
  • Page 25 SERVICE MANUAL Engine Magnum 250 696110023 PST TIER 4b [ZERF04500 - ] Magnum 280 696110033 PST TIER 4b [ZERF04500 - ] Magnum 310 696110043 PST TIER 4b [ZERF04500 - ] Magnum 340 696110053 PST TIER 4b [ZERF04500 - ] 47685449 08/05/2014...
  • Page 26 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.101] Cylinder heads .
  • Page 27 Engine - 10 Engine and crankcase - 001 Magnum 250 696110023 PST TIER 4b [ZERF04500 - ] Magnum 280 696110033 PST TIER 4b [ZERF04500 - ] Magnum 310 696110043 PST TIER 4b [ZERF04500 - ] Magnum 340 696110053 PST TIER 4b [ZERF04500 - ] 47685449 08/05/2014 10.1 [10.001] / 1...
  • Page 28 Contents Engine - 10 Engine and crankcase - 001 SERVICE Engine Remove ................. . 3 Install .
  • Page 29 Engine - Engine and crankcase Engine - Remove Prior operation: Battery - Disconnect (55.302) Prior operation: Hood - Remove (90.100) Prior operation: Side shield - Remove (90.102) Prior operation: Air conditioning - Recover (50.200) Prior operation: Engine cooling system - Emptying (10.400) Prior operation: Engine cooling system - Remove (10.400) Prior operation:...
  • Page 30 Engine - Engine and crankcase 3. Cut the wire tie (1) securing the harness to the hood support (2). RAIL13TR04204AA 4. Disconnect the starter cables (1) and the auxiliary wire (2). RAIL13TR04209AA 5. Remove the three bolts (1) securing the hood support to the frame.
  • Page 31 Engine - Engine and crankcase 7. Disconnect the high pressure A/C hose (1) and the coolant lines (2). Cap or plug all fittings and lines. RAIL13TR04230AA 8. Remove the two bolts (1) from the rear engine mount plate. RAIL13TR04243AA 9. Remove the engine mount cover plate. RAIL13TR04244AA 10.
  • Page 32 Engine - Engine and crankcase 11. On the rear of the engine, remove the oil cooler tube clamp (1). Move the oil cooler lines to the side. RAIL13TR04236AA 12. Disconnect the low pressure A/C line (1). Cap or plug all fittings and hoses. RAIL13TR04228AA 13.
  • Page 33 Engine - Engine and crankcase 15. Remove the fuse panel. RAIL13TR04214AA 16. Disconnect the harness connector (1) for the engine grid heater and the power supply cable (2). RAIL13TR04219AA 17. Disconnect the vent hose (1) from the intake manifold. RAIL13TR04218AA 18.
  • Page 34 Engine - Engine and crankcase 19. Remove the A/C compressor mounting bolt (1) and disconnect the ground wire (2). RAIL13TR04224AA 20. Disconnect the harness connector (1) to the A/C pres- sure switch. RAIL13TR04223AA 21. Disconnect the alternator excite wire connector (1) and the CAN bus connector (2).
  • Page 35 Engine - Engine and crankcase 23. Disconnect the engine controller connector (1). RAIL13TR04226AA 24. Remove the bolts (1) and cover for the drop box drive shaft. Set the cover aside. RCPH10CCH813AAB 25. Mark the drive shaft (1). Remove the four bolts and disengage the drive shaft from the flywheel.
  • Page 36 Engine - Engine and crankcase 27. Attach appropriately rated lifting equipment to the lift- ing brackets on the engine. Carefully remove the engine while making certain all harnesses, lines and hoses have been disconnected. RAIL13TR04247AA 28. Remove the right hand rear engine mount. Inspect for wear and/or damage.
  • Page 37 Engine - Engine and crankcase Engine - Install Prior operation: Engine - Remove (10.001) 1. If removed, install the front engine mounting brackets (1). 2. Torque the four mounting bolts (2) to 101 - 113 N·m (75 - 83 lb ft). 3.
  • Page 38 Engine - Engine and crankcase 10. Making sure the marks (1) are aligned, attach the en- gine output drive shaft to the engine flywheel. 11. Using the four bolts (2) removed earlier to secure the drive shaft to the flywheel. 12.
  • Page 39 Engine - Engine and crankcase 16. Connect the alternator excite wire connector (1) and the CAN bus connector (2). RAIL13TR04221AA 17. Connect the harness connector (1) to the A/C pres- sure switch. RAIL13TR04223AA 18. Connect the ground wire (1) and secure the wire with the A/C compressor mounting bolt (2).
  • Page 40 Engine - Engine and crankcase 20. Connect the vent hose (1) to the intake manifold. RAIL13TR04218AA 21. Connect the harness connector (1) for the engine grid heater and the power supply cable (2). RAIL13TR04219AA 22. Install the fuse panel. RAIL13TR04214AA 23.
  • Page 41 Engine - Engine and crankcase 24. Connect the oil line (1) and secure with the hose clamp removed previously. RAIL13TR04213AA 25. Lubricate a new O-ring with PAG or mineral oil and install the O-ring. Connect the low pressure A/C line (1).
  • Page 42 Engine - Engine and crankcase 28. Install the cover plate for the left hand rear engine mount. Torque the bolts (1) to 125 - 150 N·m (92.2 - 110.6 lb ft). RAIL13TR04243AA 29. Lubricate a new O-ring with PAG or mineral oil and install the O-ring;...
  • Page 43 Engine - Engine and crankcase 33. Connect the starter cables (1) and the auxiliary wire (2). RAIL13TR04209AA 34. Install a wire tie (1) to secure the harness to the hood support (2). RAIL13TR04204AA 35. Install the air intake tube (1) and secure with the hose clamps (2) previously removed.
  • Page 44 Engine - Engine and crankcase Air conditioning - Charging (50.200) Next operation: Next operation: Engine cooling system - Filling (10.400) Next operation: Engine cooling system - Install (10.400) Next operation: Hood - Install (90.100) Next operation: Side shield - Install (90.102) Next operation: Battery - Connect (55.302) 47685449 08/05/2014...
  • Page 45 Index Engine - 10 Engine and crankcase - 001 Engine - Install ..................11 Engine - Remove .
  • Page 46 47685449 08/05/2014 10.1 [10.001] / 20...
  • Page 47 Engine - 10 Cylinder heads - 101 Magnum 250 696110023 PST TIER 4b [ZERF04500 - ] Magnum 280 696110033 PST TIER 4b [ZERF04500 - ] Magnum 310 696110043 PST TIER 4b [ZERF04500 - ] Magnum 340 696110053 PST TIER 4b [ZERF04500 - ] 47685449 08/05/2014 10.2 [10.101] / 1...
  • Page 48 Contents Engine - 10 Cylinder heads - 101 SERVICE Valve cover Remove - Over head components ............3 Install - Over head components .
  • Page 49 Engine - Cylinder heads Valve cover - Remove - Over head components Prior operation: Hood - Remove (90.100) Prior operation: Air conditioning - Recover (50.200) Prior operation: Engine cooling system - Emptying (10.400) NOTE: During the disassembly of components with O-ring seals, it is recommended that the seals be discarded and new seal installed during assembly.
  • Page 50 Engine - Cylinder heads 4. Disconnect the hydraulic lines (1) using special tool 380000795. NOTE: Be prepared to collect some hydraulic oil by placing a pan under the fitting. RAIL13TR04535AA 5. Disconnect the air conditioning high pressure hose from the tube fitting (1) and the coolant hose (2). RAIL13TR04537AA 6.
  • Page 51 Engine - Cylinder heads 8. Disconnect the low pressure A/C line (1), loosen the hose clamps (2) securing the overflow hose. RAIL13TR04542AA 9. Disconnect the overflow hose (1) and remove the top bracket mounting bolts (2). RAIL13TR04543AA 10. Remove the two mounting bolts (1) on the rear of the top bracket and remove the bracket.
  • Page 52 Engine - Cylinder heads 12. Remove the NOx sensor (1) from the exhaust pipe. RAIL13TR04185AA 13. Disconnect the electrical connector (1) for the temper- ature sensor. RAIL13TR04183AA 14. Disengage the clamp (1) from the exhaust pipe to the turbo. RAIL13TR04177AA 15.
  • Page 53 Engine - Cylinder heads 16. Remove the two nuts (1) from the C-clamp (2) secur- ing the exhaust pipe. Remove the exhaust pipe and set aside. RAIL13TR04181AA 17. Disengage the clamp (1) from the outlet side of the catalyst. RAIL13TR04192AA 18.
  • Page 54 Engine - Cylinder heads Valve cover - Install - Over head components (10.101) 47685449 08/05/2014 10.2 [10.101] / 8...
  • Page 55 Engine - Cylinder heads Valve cover - Install - Over head components Prior operation: Valve cover - Remove - Over head components (10.101) Prior operation: Install the valve cover. 1. Inspect the O-ring seal for the valve cover and replace as required.
  • Page 56 Engine - Cylinder heads 7. Secure the straps with the two nuts (1) previously re- moved. RAIL13TR04190AA 8. Install the clamp (1) on the exhaust pipe on the outlet side of the catalyst. RAIL13TR04192AA 9. Install the exhaust pipe between the catalyst and the turbo.
  • Page 57 Engine - Cylinder heads 11. Secure the exhaust pipe with the C clamp (1) and secure the C clamp with the two nuts (2) previously removed. RAIL13TR04181AA 12. Connect the harness connector (1) for the tempera- ture sensor. RAIL13TR04183AA 13. Install the NOx sensor (1). RAIL13TR04185AA 14.
  • Page 58 Engine - Cylinder heads 15. Install the top bracket and secure the rear bracket mount with the previously removed bolts (1). RAIL14TR00391AA 16. Connect the overflow hose (1) and secure the front of the bracket with the previously removed bolts (2). RAIL13TR04543AA 17.
  • Page 59 Engine - Cylinder heads 19. Secure the hydraulic tube with the tube clamp (1). RAIL13TR04536AA 20. Connect the A/C high pressure hose (1) and the coolant hose (2). RAIL13TR04537AA 21. Connect the hydraulic lines (1). Secure the lines with the tube (2). RAIL13TR04534AA 22.
  • Page 60 Engine - Cylinder heads 23. Connect the opposite end of the air cooler tube to the air cooler and secure the hose clamp (1). RAIL13TR04527AA Next operation: Engine cooling system - Filling (10.400) Next operation: Air conditioning - Evacuate (50.200) Next operation: Air conditioning - Charging (50.200) Next operation:...
  • Page 61 Index Engine - 10 Cylinder heads - 101 Valve cover - Install - Over head components ............9 Valve cover - Remove - Over head components .
  • Page 62 47685449 08/05/2014 10.2 [10.101] / 16...
  • Page 63 Engine - 10 Air cleaners and lines - 202 Magnum 250 696110023 PST TIER 4b [ZERF04500 - ] Magnum 280 696110033 PST TIER 4b [ZERF04500 - ] Magnum 310 696110043 PST TIER 4b [ZERF04500 - ] Magnum 340 696110053 PST TIER 4b [ZERF04500 - ] 47685449 08/05/2014 10.3 [10.202] / 1...
  • Page 64 Contents Engine - 10 Air cleaners and lines - 202 SERVICE Air cleaner Remove ................. . 3 Install .
  • Page 65 Engine - Air cleaners and lines Air cleaner - Remove 1. Remove the two cover mounting bolts (1) on top of the DEF/A ® tank. RAIL14TR00885AA 2. Remove the cover (1). RAIL14TR00886AA 3. Remove the air cleaner cover panel (1). RAIL14TR00888AA 4.
  • Page 66 Engine - Air cleaners and lines 5. Disengage the hose clamp (1) from the air intake bel- lows to the air pre cleaner. RAIL14TR00890AA 6. Remove the three bolts (1) from the fuel pump mount. Remove the two bolts (2) from the fuel water separator mount.
  • Page 67 Engine - Air cleaners and lines 9. Remove the air cleaner along with the mounting bracket. RAIL14TR00917AA 10. Remove the bolts (1) that secure the air cleaner to the mounting bracket. RAIL14TR00922AA 11. Remove the mounting bracket. RAIL14TR00921AA Next operation: Air cleaner - Install (10.202) 47685449 08/05/2014 10.3 [10.202] / 5...
  • Page 68 Engine - Air cleaners and lines Air cleaner - Install Prior operation: Air cleaner - Remove (10.202) 1. Install the air cleaner into the mounting bracket. RAIL14TR00921AA 2. Secure the air cleaner assembly to the mounting bracket with the bolts (1) removed previously. RAIL14TR00922AA 3.
  • Page 69 Engine - Air cleaners and lines 5. Secure the top of the bracket with the bolts (1) removed previously. Reposition the window step to the proper position. RAIL14TR00923AA 6. Reinstall the fuel pump and secure the pump with the bolts (1) removed previously. Reinstall the fuel water separator and secure with the bolts (2) removed previ- ously.
  • Page 70 Engine - Air cleaners and lines 9. Reinstall the air cleaner cover panel (1). RAIL14TR00888AA 10. Reinstall the cover (1) on the DEF/A ® tank and secure the cover with the bolts (1) removed previously. RAIL14TR00885AA 47685449 08/05/2014 10.3 [10.202] / 8...
  • Page 71 Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Install ................. 6 Air cleaner - Remove .
  • Page 72 47685449 08/05/2014 10.3 [10.202] / 10...
  • Page 73 Engine - 10 Fuel tanks - 216 Magnum 250 696110023 PST TIER 4b [ZERF04500 - ] Magnum 280 696110033 PST TIER 4b [ZERF04500 - ] Magnum 310 696110043 PST TIER 4b [ZERF04500 - ] Magnum 340 696110053 PST TIER 4b [ZERF04500 - ] 47685449 08/05/2014 10.4 [10.216] / 1...
  • Page 74 Contents Engine - 10 Fuel tanks - 216 SERVICE Fuel tank Remove ................. . 3 Install .
  • Page 75 Engine - Fuel tanks Fuel tank - Remove Remove both rear tires and support the rear axles with appropriate support stands. Prior operation: Only for the right side tank : Battery - Remove (55.302) 1. Remove the cab steps. RCPH10CCH689BAO 2.
  • Page 76 Engine - Fuel tanks 4. Loosen the two bolts (1) and raise the tank hold down bracket, retighten the bolts to hold the bracket in place. Disconnect the DEF/A ® line (2) and the coolant lines (3) from the SCR control module. Disconnect the electrical connector at the bottom of the control module (not shown).
  • Page 77 Engine - Fuel tanks Left hand tank 8. Remove the fuel tank hold-down bracket. RAIL14TR00739AA 9. Disengage the clamp and disconnect the fuel tank vent hose. RCPH11CCH037AAB 10. Disconnect the fuel tank supply (1) and return (2) lines. RCPH11CCH038AAB 11. Remove the cab steps upper support bracket. RCPH11CCH042AAB NOTE: Remove the cab pressurization filter assembly only if required for clearance to remove the fuel tank.
  • Page 78 Engine - Fuel tanks 12. Remove the cab air pressurization filter. RCPH11CCH043AAB 13. Remove the four nuts and washers (1) securing cab filter air box to the blower housing. 14. Remove the nut and washer (2) securing the housing to the cab floor plate. RCPH07CCH285ABC 15.
  • Page 79 Engine - Fuel tanks Right hand tank 17. Remove the tank hold-down bracket. RAIL14TR00738AA 18. Disconnect the level sensor harness (1) from the P-clamps (2) and disconnect the harness connector. RAIL14TR00834AA 19. Remove the right side fuel tank. RAIL14TR00835AA Next operation: Fuel tank - Install (10.216) 47685449 08/05/2014 10.4 [10.216] / 7...
  • Page 80 Engine - Fuel tanks Fuel tank - Install Prior operation: Fuel tank - Remove (10.216) Right hand tank 1. Slide the tank onto the support making certain that it is completely captured inside the support outer edge and sitting flat on the support. RAIL14TR00835AA 2.
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