Case IH Magnum 250 Service Manual Download

Page: 1 / 81

Printed

U.S.A.

Case IH

registered

trademark

CNH Industrial America LLC.

Racine Wisconsin 53404 U.S.A.

Magnum 250
Magnum 280
Magnum 310
Magnum 340
Magnum 380

Continuously Variable Transmission (CVT)

Tractor

PIN ZERF04500 and above

Part number 47685447

edition English

May 2014

SERVICE MANUAL

Summary of Contents for Magnum 250

Page 1: ...se IH is a registered trademark of CNH Industrial America LLC Racine Wisconsin 53404 U S A Magnum 250 Magnum 280 Magnum 310 Magnum 340 Magnum 380 Continuously Variable Transmission CVT Tractor PIN ZER...

Page 2: ...96110733 CVT TIER 4b ZERF04500 North America F2CFE614G B003 Magnum 310 696110743 CVT TIER 4b ZERF04500 North America F2CFE614D B003 Magnum 340 696110753 CVT TIER 4b ZERF04500 North America F2CFE614C B...

Page 3: ...ing 19 19 100 Drive shaft 19 1 19 110 Flywheel damper 19 2 19 120 Drive shaft shield assembly 19 3 Transmission 21 21 504 Continuously Variable Transmission CVT 21 1 21 505 Continuously Variable Trans...

Page 4: ...Take Off PTO 31 3 31 146 Front Power Take Off PTO 31 4 Brakes and controls 33 33 110 Parking brake or parking lock 33 1 33 202 Hydraulic service brakes 33 2 33 220 Trailer brake hydraulic control 33...

Page 5: ...Fuel injection system 55 1 55 012 Engine cooling system 55 2 55 014 Engine intake and exhaust system 55 3 55 024 Transmission control system 55 4 55 045 Front axle control system 55 5 55 046 Rear axle...

Page 6: ...5 19 55 640 Electronic modules 55 20 55 988 Selective Catalytic Reduction SCR electrical system 55 21 55 DTC FAULT CODES 55 22 Platform cab bodywork and decals 90 90 100 Engine hood and panels 90 1 90...

Page 7: ...INTRODUCTION 47685447 10 05 2014 1 Find manuals at https best manuals com...

Page 8: ...neral maintenance safety 5 Safety rules Personal Protective Equipment PPE 6 Safety rules Do Not Operate tag 7 Safety rules Ecology and the environment 8 Torque Minimum tightening torques for normal as...

Page 9: ...es caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warra...

Page 10: ...CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Mach...

Page 11: ...an cause accidents When you tow a disabled machine follow the procedure in this manual Use only rigid tow bars Stop the engine remove the key and relieve pressure before you connect or disconnect flui...

Page 12: ...les 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...

Page 13: ...ODUCTION 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 47685447 10 05 201...

Page 14: ...contain substances that may be harmful to your health Modern oils contain additives Do not burn contaminated fuels and or waste oils in ordinary heating systems Avoid spillage when draining off used...

Page 15: ...n 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 ft 48 N m 35 lb ft M12 64 N m 47...

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: ...y duty rear axle 206 l 54 5 US gal 45 4 UK gal Mechanical Front Drive MFD axles TUTELA HYPOIDE EP GEAR LUBE or CASE IH AKCELA GEAR 135 H EP 85W 140 Class 4 5 fixed front axle Differential 11 l 11 6 US...

Page 21: ...Total permissible mass 9 Inertia braked towable mass 5 Permissible front axle load 6 Permissible rear axle load 10 Towable mass fitted with an assisted braking system hydraulic or pneumatic Model PIN...

Page 22: ...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 23: ...e 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 7 476854...

Page 24: ...INTRODUCTION 47685447 10 05 2014 18...

Page 25: ...50 696110723 CVT TIER 4b ZERF04500 Magnum 280 696110733 CVT TIER 4b ZERF04500 Magnum 310 696110743 CVT TIER 4b ZERF04500 Magnum 340 696110753 CVT TIER 4b ZERF04500 Magnum 380 696110763 CVT TIER 4B ZER...

Page 26: ...cleaners and lines 10 3 10 216 Fuel tanks 10 4 10 218 Fuel injection system 10 5 10 304 Engine lubrication system 10 6 10 310 Aftercooler 10 7 10 400 Engine cooling system 10 8 10 414 Fan and drive 10...

Page 27: ...250 696110723 CVT TIER 4b ZERF04500 Magnum 280 696110733 CVT TIER 4b ZERF04500 Magnum 310 696110743 CVT TIER 4b ZERF04500 Magnum 340 696110753 CVT TIER 4b ZERF04500 Magnum 380 696110763 CVT TIER 4B ZE...

Page 28: ...Contents Engine 10 Engine and crankcase 001 SERVICE Engine Remove 3 Install 11 47685447 10 05 2014 10 1 10 001 2...

Page 29: ...em Remove 10 400 Prior operation Diesel Oxidation Catalyst DOC Remove 10 500 NOTE Clean all fittings before disconnecting NOTE Cap or plug all lines and ports when disconnecting hydraulic components 1...

Page 30: ...he hood support 2 RAIL13TR04204AA 3 4 Disconnect the starter cables 1 and the auxiliary wire 2 RAIL13TR04209AA 4 5 Remove the three bolts 1 securing the hood support to the frame RAIL13TR04209AA 5 6 R...

Page 31: ...g all fittings and lines RAIL13TR04230AA 7 8 Remove the two bolts 1 from the rear engine mount plate RAIL13TR04243AA 8 9 Remove the engine mount cover plate RAIL13TR04244AA 9 10 Disconnect the front s...

Page 32: ...isconnect the low pressure A C line 1 Cap or plug all fittings and hoses RAIL13TR04228AA 12 13 Disengage the hose clamp and disconnect the engine controller oil line 1 RAIL13TR04227AA 13 14 Remove the...

Page 33: ...t the harness connector 1 for the engine grid heater and the power supply cable 2 RAIL13TR04219AA 16 17 Disconnect the vent hose 1 from the intake manifold RAIL13TR04218AA 17 18 Disconnect the harness...

Page 34: ...TR04224AA 19 20 Disconnect the harness connector 1 to the A C pres sure switch RAIL13TR04223AA 20 21 Disconnect the alternator excite wire connector 1 and the CAN bus connector 2 RAIL13TR04221AA 21 22...

Page 35: ...d cover for the drop box drive shaft Set the cover aside RCPH10CCH813AAB 24 25 Mark the drive shaft 1 Remove the four bolts and disengage the drive shaft from the flywheel RCPH10CCH817AAB 25 26 Remove...

Page 36: ...27 28 Remove the right hand rear engine mount Inspect for wear and or damage Replace as required Repeat for the left hand side RCPH07CCH166AAB 28 29 Remove the four bolts 1 securing the brackets 2 for...

Page 37: ...and left rear engine ISO mounts RCPH07CCH166AAB 2 5 Properly support the engine Raise and move the en gine into the front support frame RAIL13TR04248AA 3 6 Install the holding plate 1 for the right r...

Page 38: ...que the bolts to 101 113 N m 75 83 lb ft RCPH10CCH817AAB 5 13 Install the engine output drive shaft cover 1 Use the bolts 2 removed earlier to secure the cover to the flywheel housing RCPH10CCH813AAB...

Page 39: ...13TR04221AA 9 17 Connect the harness connector 1 to the A C pres sure switch RAIL13TR04223AA 10 18 Connect the ground wire 1 and secure the wire with the A C compressor mounting bolt 2 RAIL13TR04224AA...

Page 40: ...harness connector 1 for the engine grid heater and the power supply cable 2 RAIL13TR04219AA 14 22 Install the fuse panel RAIL13TR04214AA 15 23 Secure the fuse panel bracket with the three mounting bol...

Page 41: ...g with PAG or mineral oil and install the O ring Connect the low pressure A C line 1 RAIL13TR04228AA 18 26 On the rear of the engine secure the oil cooler tubes with the tube clamp 1 previously remove...

Page 42: ...ft RAIL13TR04243AA 21 29 Lubricate a new O ring with PAG or mineral oil and install the O ring reconnect the high pressure A C hose 1 30 Reconnect he coolant lines 2 RAIL13TR04230AA 22 31 Install the...

Page 43: ...the air intake tube 1 and secure with the hose clamps 2 previously removed RAIL13TR04211AA 27 36 Connect the harness connectors for the humidity sen sor 1 and the air restriction sensor 2 Connect the...

Page 44: ...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 ope...

Page 45: ...Index Engine 10 Engine and crankcase 001 Engine Install 11 Engine Remove 3 47685447 10 05 2014 10 1 10 001 19...

Page 46: ...47685447 10 05 2014 10 1 10 001 20...

Page 47: ...696110723 CVT TIER 4b ZERF04500 Magnum 280 696110733 CVT TIER 4b ZERF04500 Magnum 310 696110743 CVT TIER 4b ZERF04500 Magnum 340 696110753 CVT TIER 4b ZERF04500 Magnum 380 696110763 CVT TIER 4B ZERF0...

Page 48: ...Contents Engine 10 Cylinder heads 101 SERVICE Valve cover Remove Over head components 3 Install Over head components 9 47685447 10 05 2014 10 2 10 101 2...

Page 49: ...th O ring seals it is recommended that the seals be discarded and new seal installed during assembly NOTE Cap all fittings and plug all lines hoses as they are disconnected 1 Loosen the hose clamp 1 a...

Page 50: ...he fitting RAIL13TR04535AA 4 5 Disconnect the air conditioning high pressure hose from the tube fitting 1 and the coolant hose 2 RAIL13TR04537AA 5 6 Remove the hydraulic tube clamp 1 from the hydrauli...

Page 51: ...e overflow hose 1 and remove the top bracket mounting bolts 2 RAIL13TR04543AA 9 10 Remove the two mounting bolts 1 on the rear of the top bracket and remove the bracket RAIL14TR00391AA 10 11 Disconnec...

Page 52: ...onnect the electrical connector 1 for the temper ature sensor RAIL13TR04183AA 13 14 Disengage the clamp 1 from the exhaust pipe to the turbo RAIL13TR04177AA 14 15 Disengage the clamp 1 from the exhaus...

Page 53: ...6 17 Disengage the clamp 1 from the outlet side of the catalyst RAIL13TR04192AA 17 18 Remove the two nuts 1 from the catalyst mounting straps RAIL13TR04190AA 18 19 Slide the catalyst forward from unde...

Page 54: ...Engine Cylinder heads Valve cover Install Over head components 10 101 47685447 10 05 2014 10 2 10 101 8...

Page 55: ...alve cover and replace as required 2 Install the valve cover with the 18 bolts 1 removed earlier 3 Starting at the center of the valve cover tighten the bolts in a crossing pattern 2 4 Torque all bolt...

Page 56: ...pipe on the outlet side of the catalyst RAIL13TR04192AA 5 9 Install the exhaust pipe between the catalyst and the turbo Secure the pipe to the catalyst with the clamp 1 previously removed RAIL13TR041...

Page 57: ...sly removed RAIL13TR04181AA 8 12 Connect the harness connector 1 for the tempera ture sensor RAIL13TR04183AA 9 13 Install the NOx sensor 1 RAIL13TR04185AA 10 14 Connect the two coolant lines 1 the DEF...

Page 58: ...ect the overflow hose 1 and secure the front of the bracket with the previously removed bolts 2 RAIL13TR04543AA 13 17 Connect the low pressure A C line 1 and connect the overflow hose 2 RAIL13TR04542A...

Page 59: ...AA 16 20 Connect the A C high pressure hose 1 and the coolant hose 2 RAIL13TR04537AA 17 21 Connect the hydraulic lines 1 Secure the lines with the tube 2 RAIL13TR04534AA 18 22 Install the air cooler t...

Page 60: ...e air cooler and secure the hose clamp 1 RAIL13TR04527AA 20 Next operation Engine cooling system Filling 10 400 Next operation Air conditioning Evacuate 50 200 Next operation Air conditioning Charging...

Page 61: ...Index Engine 10 Cylinder heads 101 Valve cover Install Over head components 9 Valve cover Remove Over head components 3 47685447 10 05 2014 10 2 10 101 15...

Page 62: ...47685447 10 05 2014 10 2 10 101 16...

Page 63: ...250 696110723 CVT TIER 4b ZERF04500 Magnum 280 696110733 CVT TIER 4b ZERF04500 Magnum 310 696110743 CVT TIER 4b ZERF04500 Magnum 340 696110753 CVT TIER 4b ZERF04500 Magnum 380 696110763 CVT TIER 4B Z...

Page 64: ...Contents Engine 10 Air cleaners and lines 202 SERVICE Air cleaner Remove 3 Install 6 47685447 10 05 2014 10 3 10 202 2...

Page 65: ...mounting bolts 1 on top of the DEF ADBLUE tank RAIL14TR00885AA 1 2 Remove the cover 1 RAIL14TR00886AA 2 3 Remove the air cleaner cover panel 1 RAIL14TR00888AA 3 4 Disengage the hose clamp 1 from the...

Page 66: ...e two bolts 2 from the fuel water separator mount Set the fuel pump and water separator to the side The fuel lines do not need to be disconnected RAIL14TR00915AA 6 7 Lift the window step and remove th...

Page 67: ...ith the mounting bracket RAIL14TR00917AA 9 10 Remove the bolts 1 that secure the air cleaner to the mounting bracket RAIL14TR00922AA 10 11 Remove the mounting bracket RAIL14TR00921AA 11 Next operation...

Page 68: ...ing bracket RAIL14TR00921AA 1 2 Secure the air cleaner assembly to the mounting bracket with the bolts 1 removed previously RAIL14TR00922AA 2 3 Install the air cleaner along with the mounting bracket...

Page 69: ...ith the bolts 1 removed previously Reinstall the fuel water separator and secure with the bolts 2 removed previ ously RAIL14TR00915AA 6 7 Connect the air intake bellows to the air intake pre cleaner a...

Page 70: ...lines 9 Reinstall the air cleaner cover panel 1 RAIL14TR00888AA 9 10 Reinstall the cover 1 on the DEF ADBLUE tank and secure the cover with the bolts 1 removed previously RAIL14TR00885AA 10 47685447 1...

Page 71: ...Index Engine 10 Air cleaners and lines 202 Air cleaner Install 6 Air cleaner Remove 3 47685447 10 05 2014 10 3 10 202 9...

Page 72: ...47685447 10 05 2014 10 3 10 202 10...

Page 73: ...96110723 CVT TIER 4b ZERF04500 Magnum 280 696110733 CVT TIER 4b ZERF04500 Magnum 310 696110743 CVT TIER 4b ZERF04500 Magnum 340 696110753 CVT TIER 4b ZERF04500 Magnum 380 696110763 CVT TIER 4B ZERF045...

Page 74: ...Contents Engine 10 Fuel tanks 216 SERVICE Fuel tank Remove 3 Install 8 Fuel cooler Remove 13 Install 15 47685447 10 05 2014 10 4 10 216 2...

Page 75: ...ion Only for the right side tank Battery Remove 55 302 1 Remove the cab steps RCPH10CCH689BAO 1 2 Drain the fuel tanks Remove the tank hold down bracket 1 and the brackets 2 that secure the fuel tank...

Page 76: ...isconnect the electrical connector at the bottom of the control module not shown RAIL14TR00744AA 4 5 Disconnect the tank to tank air balance tube RCPH11CCH041AAB 5 NOTE In the following steps be prepa...

Page 77: ...ect the fuel tank vent hose RCPH11CCH037AAB 9 10 Disconnect the fuel tank supply 1 and return 2 lines RCPH11CCH038AAB 10 11 Remove the cab steps upper support bracket RCPH11CCH042AAB 11 NOTE Remove th...

Page 78: ...ng cab filter air box to the blower housing 14 Remove the nut and washer 2 securing the housing to the cab floor plate RCPH07CCH285ABC 13 15 Remove the housing assembly RCPH11CCH044AAB 14 16 Pry up on...

Page 79: ...ket RAIL14TR00738AA 16 18 Disconnect the level sensor harness 1 from the P clamps 2 and disconnect the harness connector RAIL14TR00834AA 17 19 Remove the right side fuel tank RAIL14TR00835AA 18 Next o...

Page 80: ...it is completely captured inside the support outer edge and sitting flat on the support RAIL14TR00835AA 1 2 Install the hold down bracket and bolts removed earlier RCPH07CCH803ABC 2 3 Connect the fue...

Page 81: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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