Case IH Magnum 235 Service Manual Download

Page: 1 / 51

Printed

U.S.A.

Case IH

registered

trademark

CNH America LLC.

Racine Wisconsin 53404 U.S.A.

Magnum 235
Magnum 260
Magnum 290
Magnum 315
Magnum 340
Magnum 370

Continuously Variable Transmission (CVT)

Tractor

PIN ZCRD02588 and above

Part number 47533562

edition English

October 2013

SERVICE MANUAL

Summary of Contents for Magnum 235

Page 1: ...a registered trademark of CNH America LLC Racine Wisconsin 53404 U S A Magnum 235 Magnum 260 Magnum 290 Magnum 315 Magnum 340 Magnum 370 Continuously Variable Transmission CVT Tractor PIN ZCRD02588 a...

Page 2: ...ously Variable Transmission CVT 21 1 21 505 Continuously Variable Transmission CVT external controls 21 2 21 507 Continuously Variable Transmission CVT internal components 21 3 21 506 Continuously Var...

Page 3: ...3 2 33 220 Trailer brake hydraulic control 33 3 33 224 Trailer brake pneumatic control 33 4 Hydraulic systems 35 35 000 Hydraulic systems 35 1 35 102 Pump control valves 35 2 35 106 Variable displacem...

Page 4: ...5 55 050 Heating Ventilation and Air Conditioning HVAC control system 55 6 55 051 Cab Heating Ventilation and Air Conditioning HVAC controls 55 7 55 100 Harnesses and connectors 55 8 55 130 Rear three...

Page 5: ...bodywork and decals 90 90 100 Engine hood and panels 90 1 90 102 Engine shields hood latches and trims 90 2 90 118 Protections and footboards 90 3 90 124 Pneumatically adjusted operator seat 90 4 90 1...

Page 6: ...47533562 02 10 2013 Find manuals at https best manuals com...

Page 7: ...INTRODUCTION 47533562 02 10 2013 1 Find manuals at https best manuals com...

Page 8: ...CRD02588 NA Safety rules Do Not Operate tag 7 Magnum 235 ZCRD02588 NA Magnum 260 ZCRD02588 NA Magnum 290 ZCRD02588 NA Magnum 315 ZCRD02588 NA Magnum 340 ZCRD02588 NA Magnum 370 ZCRD02588 NA Safety rul...

Page 9: ...n national regional or local dealers reject any responsibility for damages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the p...

Page 10: ...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 CAUT...

Page 11: ...ck or lift points indicated in this manual Incorrect towing procedures can cause accidents When you tow a disabled machine follow the procedure in this manual Use only rigid tow bars Stop the engine r...

Page 12: ...ZCRD02588 NA Magnum 290 ZCRD02588 NA Magnum 315 ZCRD02588 NA Magnum 340 ZCRD02588 NA Magnum 370 ZCRD02588 NA Personal Protective Equipment PPE Wear Personal Protective Equipment PPE such as hard hat...

Page 13: ...260 ZCRD02588 NA Magnum 290 ZCRD02588 NA Magnum 315 ZCRD02588 NA Magnum 340 ZCRD02588 NA Magnum 370 ZCRD02588 NA Do Not Operate tag Before you start servicing the machine attach a Do Not Operate warni...

Page 14: ...l avoid skin contact with all fuels oils acids solvents etc Most of them contain substances that may be harmful to your health Modern oils contain additives Do not burn contaminated fuels and or waste...

Page 15: ...0 N m 89 lb in M8 18 N m 163 lb in 25 N m 217 lb in 26 N m 234 lb in 35 N m 311 lb in 17 N m 151 lb in 24 N m 212 lb in M10 37 N m 27 lb ft 49 N m 36 lb ft 52 N m 38 lb ft 70 N m 51 lb ft 33 N m 25 lb...

Page 16: ...N m 343 lb in 18 N m 163 lb in 27 N m 240 lb in M10 40 N m 30 lb ft 54 N m 40 lb ft 57 N m 42 lb ft 77 N m 56 lb ft 37 N m 27 lb ft 53 N m 39 lb ft M12 70 N m 52 lb ft 93 N m 69 lb ft 100 N m 74 lb f...

Page 17: ...t 7 16 48 N m 36 lb ft 65 N m 48 lb ft 68 N m 50 lb ft 91 N m 67 lb ft 50 N m 37 lb ft 71 N m 53 lb ft 1 2 74 N m 54 lb ft 98 N m 73 lb ft 104 N m 77 lb ft 139 N m 103 lb ft 76 N m 56 lb ft 108 N m 80...

Page 18: ...5 lb ft 153 N m 113 lb ft 74 N m 55 lb ft 104 N m 77 lb ft 9 16 117 N m 86 lb ft 156 N m 115 lb ft 165 N m 122 lb ft 221 N m 163 lb ft 106 N m 78 lb ft 157 N m 116 lb ft 5 8 162 N m 119 lb ft 216 N m...

Page 19: ...4 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 T...

Page 20: ...axles 4 pin 100 mm 4 in hub length standard axle Differential 11 8 l 12 US qt 21 6 UK pt Planetary each 1 4 l 3 US pt 2 4 UK pt 4 pin 180 mm 7 in hub length heavy duty axle Differential 11 8 l 12 5 US...

Page 21: ...d count the number of pins 3 on the wheel end to determine axle type for your tractor RCPH11CCH074AAB 1 RCIL08CCH001EAA 2 Axle oil viscosity temperature usage recommendation CASE IH AKCELA GEAR 135 H...

Page 22: ...tion for your machine RCIL11CCH006EAA 1 1 Type Permissible towable mass 2 EEC number 7 Unbraked towable mass 3 Product identification number 8 Independently brakes towable mass 4 Total permissible mas...

Page 23: ...d side of the engine block just below the oil cooler RAIL12TR02140AA 4 Transmission serial number NOTE Located on the right hand side of the transmission to the left of the main hydraulic filter RAIL1...

Page 24: ...CASE IH4 5 fixed 4 75 fixed 4 75 saddle suspended 5 0 fixed and 5 0 saddle suspended front axle housings example shown Located on the rear right hand side of the Dana heavy duty fixed 5 0 fixed and 5...

Page 25: ...SERVICE MANUAL Engine Magnum 235 ZCRD02588 Magnum 260 ZCRD02588 Magnum 290 ZCRD02588 Magnum 315 ZCRD02588 Magnum 340 ZCRD02588 Magnum 370 ZCRD02588 47533562 02 10 2013 10...

Page 26: ...r heads 10 2 10 114 Pump drives 10 3 10 202 Air cleaners and lines 10 4 10 216 Fuel tanks 10 5 10 310 Aftercooler 10 6 10 400 Engine cooling system 10 7 10 414 Fan and drive 10 8 10 500 Selective Cata...

Page 27: ...Engine 10 Engine and crankcase 001 Magnum 235 ZCRD02588 Magnum 260 ZCRD02588 Magnum 290 ZCRD02588 Magnum 315 ZCRD02588 Magnum 340 ZCRD02588 Magnum 370 ZCRD02588 47533562 02 10 2013 10 1 10 001 1...

Page 28: ...ankcase 001 SERVICE Engine Remove 3 Magnum 235 Magnum 260 Magnum 290 Magnum 315 Magnum 340 Magnum 370 ZCRD02588 Install 18 Magnum 235 Magnum 260 Magnum 290 Magnum 315 Magnum 340 Magnum 370 ZCRD02588 4...

Page 29: ...all lines hoses as they are disconnected 1 Disconnect the hydraulic cooling line connection on the right side from oil cooler NOTE Be prepared to collect some hydraulic oil by placing a pan under the...

Page 30: ...turbocharger clamp 1 9 Loosen the air cooler inlet hose clamp 2 10 Remove the pipe 3 and set aside 11 Repeat for the right side air to air tube from the cooler to the intake manifold not shown RCPH10C...

Page 31: ...e engine hose RCPH10CCH580AAB 9 16 Remove the nuts 1 and disengage the engine heater grid cables 2 3 to the fuse block 17 Disconnect the harness connector 4 for the 12 V auxiliary power connection RCP...

Page 32: ...he A C compressor clutch 2 21 Remove the upper left A C compressor bolt and re move the ground wire 3 RCPH10CCH782AAB 13 22 Disconnect the harness connectors to the A C high pressure switch 1 and the...

Page 33: ...B 16 25 Loosen the nut 1 and disconnect the fuel supply line to the EMC cooler RCPH10CCH787AAB 17 26 Disengage the clamp 1 and disconnect the fuel re turn hose 2 from the pipe RCPH10CCH786AAB 18 27 Re...

Page 34: ...lenoid 1 30 Raise the locking wire 2 and disconnect the heater supply connector 3 from the valve 31 Repeat for the outlet hose connection located on the right side of the valve RCPH10CCH790AAB 21 32 D...

Page 35: ...and disconnect the hydraulic oil line 1 right side of engine RCPH10CCH798AAB 25 36 Disconnect the water in fuel sensor connector 1 from the primary fuel filter RCPH10CCH794AAB 26 37 Loosen the nuts 1...

Page 36: ...ut 1 and disengage the cables from the starter RCPH10CCH797AAB 29 40 Remove the plug 1 remove the attaching screw 2 and remove the starter solenoid wire 3 RCPH10CCH818AAB 30 41 Loosen the hose clamp 1...

Page 37: ...d right sides RCPH10CCH572AAB 33 44 Properly support the bracket and remove the four bolts 1 securing the bracket to the hood support Re move the assembly and set aside RCPH10CCH037BAB 34 45 Loosen th...

Page 38: ...dosing valve RCPH10CCH801AAB 37 51 Disconnect the DEF supply and return hoses 1 NOTE Squeeze the locking tabs 2 together and pull straight upward on the elbow RCPH10CCH359AAB 38 52 Remove the clamp 1...

Page 39: ...54 Disengage the engine blow by hose clamp 1 at the intake pipe Disconnect from the intake pipe RCPH10CCH805AAB 41 55 Disengage the engine blow by hose clamp 1 at the engine Remove the pipe and set as...

Page 40: ...he intake support clamp to the bracket Loosen the clamp 2 Remove the upper intake pipe and set aside RCPH10CCH804AAB 45 59 Remove the bolt 1 securing the intake pipe support clamp RCPH10CCH811AAB 46 6...

Page 41: ...the cover bolts 1 Remove the covers and set aside RCPH10CCH813AAB 49 63 Mark the drive shaft 1 Remove the four bolts 2 and disengage the drive shaft from the flywheel RCPH10CCH817AAB 50 64 Remove the...

Page 42: ...ulic hoses Move the assem bly from the left side of the engine off to the side RCPH10CCH829AAB 54 68 WARNING Heavy objects Lift and handle all heavy components us ing lifting equipment with adequate c...

Page 43: ...mage Replace as required Repeat for the left side RCPH07CCH166AAB 56 70 Remove the bolt and nut 1 securing the front mount engine mount 2 Inspect mount for wear and or dam age Replace as required RCPH...

Page 44: ...usly removed 3 Torque the bolts to 110 113 N m 81 83 lb ft 4 Position the mount 3 install the bolt and torque the nut 2 to 160 220 N m 118 162 lb ft RCPH10CCH833AAB 2 5 WARNING Heavy objects Lift and...

Page 45: ...d previously and torque to 125 150 N m 92 111 lb ft RCPH10CCH815AAB 5 10 Install the plate 1 for the left rear mount 11 Install the bolts 2 removed previously along with the grounding strap 3 and torq...

Page 46: ...be sup port bracket 1 Using the bolts 2 removed earlier secure bracket to the engine RCPH10CCH800AAB 10 17 Install the front tube support bracket 1 Using the bolts 2 removed earlier secure bracket to...

Page 47: ...outlet and tighten the hose clamp 2 RCPH10CCH810AAB 13 23 With the bolt removed earlier secure the clamp 1 for the air cleaner outlet pipe to the bracket RCPH10CCH811AAB 14 24 Move the pipe between a...

Page 48: ...he intake pipe support to the bracket NOTICE Tighten all hose clamps at this time It is impor tant to have all hose clamps properly tighten to prevent dirt from entering the intake system RCPH10CCH808...

Page 49: ...e connector 1 between the turbo outlet and converter inlet elbow Engage the lower shown 2 and upper 3 clamps and tighten Using the bolt 4 removed earlier secure the support clamp RCPH10CCH803AAB 21 31...

Page 50: ...nts right side shown 1 for the line and harness assembly Replace as neces sary Place the support alignment holes over the studs and secure with the washers and nuts 2 removed earlier RCPH10CCH572AAB 2...

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