the best service manual

1. Part number 47505517
SERVICEMANUAL
1/2 SERVICE MANUAL
CVX 140
CVX 150
CVX 160
CVX 175
CVX 195
Tractor
CVX 140
CVX 150
CVX 160
CVX 175
CVX 195
Tractor
Part number 47505517
English
February 2013
Copyright © 2013 CNH Europe Holding S.A. All Rights Reserved.

2. SERVICE MANUAL
CVX 140
CVX 150
CVX 160
CVX 175
CVX 195
47505517 11/02/2013
EN

3. Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.106] Valve drive and gears .............................................................. 10.2
[10.101] Cylinder heads ..................................................................... 10.3
[10.105] Connecting rods and pistons....................................................... 10.4
[10.103] Crankshaft and flywheel............................................................ 10.5
[10.218] Fuel injection system............................................................... 10.6
[10.250] Turbocharger and lines............................................................. 10.7
[10.254] Intake and exhaust manifolds and muffler ......................................... 10.8
[10.400] Engine cooling system ............................................................. 10.9
[10.414] Fan and drive .................................................................... 10.10
[10.304] Engine lubrication system........................................................ 10.11
Transmission.............................................................................. 21
[21.504] Continuously Variable Transmission (CVT) ........................................ 21.1
[21.505] Continuously Variable Transmission (CVT) external controls...................... 21.2
[21.506] Continuously Variable Transmission (CVT) lubrication system .................... 21.3
[21.507] Continuously Variable Transmission (CVT) internal components.................. 21.4
Four-Wheel Drive (4WD) system .................................................. 23
[23.202] Electro-hydraulic control ........................................................... 23.1
[23.314] Drive shaft.......................................................................... 23.2
Front axle system ....................................................................... 25
[25.100] Powered front axle ................................................................. 25.1
[25.102] Front bevel gear set and differential ............................................... 25.2
[25.108] Final drive hub, steering knuckles, and shafts ..................................... 25.3
[25.122] Axle suspension control............................................................ 25.4
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4. Rear axle system........................................................................ 27
[27.100] Powered rear axle.................................................................. 27.1
[27.106] Rear bevel gear set and differential................................................ 27.2
[27.120] Planetary and final drives .......................................................... 27.3
Power Take-Off (PTO)................................................................. 31
[31.104] Rear electro-hydraulic control...................................................... 31.1
[31.119] Four-speed rear Power Take-Off (PTO)............................................ 31.2
[31.142] Front Power Take-Off (PTO) control ............................................... 31.3
[31.146] Front Power Take-Off (PTO) ....................................................... 31.4
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
[33.110] Parking brake or parking lock ...................................................... 33.2
[33.220] Trailer brake hydraulic control...................................................... 33.3
[33.204] Front axle brake.................................................................... 33.4
[33.200] Brake cooling....................................................................... 33.5
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.106] Variable displacement pump ....................................................... 35.2
[35.359] Main control valve.................................................................. 35.3
[35.204] Remote control valves ............................................................. 35.4
[35.114] Three-point hitch control valve ..................................................... 35.5
[35.116] Three-point hitch cylinder .......................................................... 35.6
Steering..................................................................................... 41
[41.200] Hydraulic control components...................................................... 41.1
[41.216] Cylinders ........................................................................... 41.2
[41.432] Autoguidance steering ............................................................. 41.3
Cab climate control ..................................................................... 50
[50.104] Ventilation .......................................................................... 50.1
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5. [50.200] Air conditioning..................................................................... 50.2
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
[55.525] Cab engine controls................................................................ 55.3
[55.015] Engine control system.............................................................. 55.4
[55.301] Alternator........................................................................... 55.5
[55.302] Battery.............................................................................. 55.6
[55.202] Cold start aid ....................................................................... 55.7
[55.011] Fuel tank system ................................................................... 55.8
[55.010] Fuel injection system............................................................... 55.9
[55.014] Engine intake and exhaust system............................................... 55.10
[55.012] Engine cooling system ........................................................... 55.11
[55.013] Engine oil system ................................................................ 55.12
[55.640] Electronic modules ............................................................... 55.13
[55.513] Cab transmission controls........................................................ 55.14
[55.024] Transmission control system..................................................... 55.15
[55.020] Transmission speed sensors..................................................... 55.16
[55.021] Transmission pressure sensors .................................................. 55.17
[55.022] Transmission temperature sensors .............................................. 55.18
[55.023] Transmission position sensors ................................................... 55.19
[55.045] Front axle control system ........................................................ 55.20
[55.048] Rear Power Take-Off (PTO) control system ..................................... 55.21
[55.049] Front Power Take-Off (PTO) control system ..................................... 55.22
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.23
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system............... 55.24
[55.519] Cab brake controls ............................................................... 55.25
[55.030] Service brake electrical system .................................................. 55.26
[55.032] Trailer brake electrical system ................................................... 55.27
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6. [55.512] Cab controls...................................................................... 55.28
[55.035] Remote control valve electric control ............................................ 55.29
[55.036] Hydraulic system control ......................................................... 55.30
[55.047] Steering control system .......................................................... 55.31
[55.523] Cab hitch controls ................................................................ 55.32
[55.130] Rear three-point hitch electronic control system ................................. 55.33
[55.160] Front hitch electronic control system............................................. 55.34
[55.680] Autopilot/Autoguidance .......................................................... 55.35
[55.510] Cab or platform harnesses and connectors...................................... 55.36
[55.408] Warning indicators, alarms, and instruments .................................... 55.37
[55.DTC] FAULT CODES.................................................................. 55.38
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7. INTRODUCTION
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1

8. 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. 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 that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
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.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
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 that 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.
47505517 11/02/2013
9

9. INTRODUCTION
Basic instructions - Important notice regarding equipment servicing
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - 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 product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. 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 AGRICULTURE Sales and Service Networks.
47505517 11/02/2013
10

10. SERVICE MANUAL
Engine
CVX 140
CVX 150
CVX 160
CVX 175
CVX 195
47505517 11/02/2013
10

11. Engine - Valve drive and gears
Valve drive and gears - Service instruction
Maintaining the rocker arm system
1. Check the valve tappet, especially the guide face on
the camshaft. Replace any worn and bent valve tap-
pets.
2. Check that the push rod is straight. Also check the
condition of the spherical faces on the ends of the
push rod.
SS05N311 1
3. Dismantle the rocker arm mechanism and clean the
individual parts. Check the rocker arm shaft for wear
and check the condition of the oil lines.
4. Check the diameter of the bore in the rocker arm
(23.000 - 23.021) and replace if necessary. If the
rocker arm's pressure face is worn, grind this to the
right shape. Do not grind off more than necessary
since the pressure face is surface hardened.
SS05N312 2
SS99N072 3
SS05N313 4
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12. Engine - Valve drive and gears
5. Secure a flange seal to one end of the rocker arm
shaft. Apply oil to shaft and assemble the parts in
the correct order. Ensure that the bearing brackets
and shaft are positioned correctly. As shown in the
diagram, the split half of the bracket and oil bores in
the shaft must be facing the valve side. Secure the
other flange seal.
SS06N008 5
Replacing the camshaft / camshaft gear
6. Remove the suction pipe from between the tur-
bocharger and intake manifold. Remove the valve
mechanism's cover and bleeder pipe. Remove the
rocker arm mechanism.
7. Remove the cooler package, fan, alternator and
belts.
8. Remove the pulley and vibration absorber.
9. Loosen the crankshaft nut and remove the hub.
10. Remove the timer case cover.
11. Lock the valve tappets such that they do not fall
out when removing the camshaft and prevent the
camshaft from being fitted. Lift two neighbouring
valve push rods by tilting them a little towards one
another. Clamp neighbouring push rods together in
pairs (e.g. using an O-ring) such that they are ten-
sioned slightly and the tappet remains in the top po-
sition.
ATTENTION: Overtensioning the push rods results in de-
formations.
SS05N315 6
12. Rotate the crankshaft such that the position marks on
the camshaft gear and intermediate gear meet. Pull
out the camshaft.
13. Remove the camshaft gear from the camshaft.
14. If you are refitting the used camshaft or camshaft
gear, clean the parts before assembling.
15. Slide the fitting key into the corresponding camshaft
groove and fit the camshaft gear. Tighten the nut to
200 Nm.
16. Lubricate the bearing faces and slide shaft into
cylinder block noting the positioning marks of the
camshaft gear.
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13. Engine - Valve drive and gears
17. Fit timer case cover and pulley with hub. (see Crank-
shaft - Service instruction (10.103))
18. Lower the push rods and fit the rocker arm mecha-
nism. Set the valves. Then screw the valve cover
and ventilation hose onto the cylinder head. Also
fit the intake tube which belongs between the tur-
bocharger and intake manifold.
19. Fit the alternator and belts. Tension the belts to the
correct tension. Fit the cooler package.
Checking and setting the valve clearance
The valve clearance of the inlet and outlet valve is 0,35
mm. The check can be undertaken when the engine is
cold and warm. Check and regulate the valve clearances
of a cylinder when the piston is in the upper top dead
centre of the compression stroke. Proceed in the order
of engine fuel injection.
If the valve clearance deviates from the specified value,
loosen the lock nut and correctly set the valve clearance
with the setting screw. The 0,35 mm feeler gauge must
fit tightly between the rocker arm and valve shaft end.
SS05N314 7
- Turn the crankshaft in the direction of travel until the
valves of the 6th cylinder are overlapping. (outlet valve
is closed, inlet valve is open). Check the valves of the
first cylinder.
- Turn the crankshaft 1/3rd of a revolution in the direction
of travel such that the valves of the 2nd cylinder overlap.
Check the valves of the 5th cylinder.
- Continue your work in the order of fuel injection:
SS05N317 8
Injection sequence: 1 - 5 -3 - 6 - 2 - 4
Valve overlap: 6 - 2 - 4 - 1 - 5 - 3
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14. Engine - Valve drive and gears
Camshaft gear - Service instruction (timing gears)
Timing gear case removal
The timing gear case protects the components against leaks originating in the oil pan.
For this reason, the timing box can only be removed once the oil pan has been taken out.
1. Drain the engine oil and remove the oil pan.
2. Remove the ventilator, alternator, pulley and belt. If
the tractor is fitted with an air-conditioning or com-
pressed air system, the compressor must also be re-
moved.
Key for viscous fan: 380001791
Key for reversible fan: 380002657
NOTICE: Do not disconnect the refrigerant lines! When the
lines are connected, only tilt the air-conditioning compres-
sor backwards. Hang the compressor up to avoid straining
the lines.
3. Remove the pulley and vibration damper.
4. Loosen the crankshaft nut using key 380002658.
5. Loosen the mounting bolt for the double idler bearing.
6. Lift off the timing gear case cover and remove the oil
seal ring from the crankshaft.
7. Remove the high-pressure fuel pump. Refer to High
pressure pump - Remove (10.218).
8. Remove the double idler gear.
9. Unscrew the idler gear screws. Remove the flange,
tooth gear and bearing journal.
10. Remove the camshaft.
NOTE: If the cylinder head and valve mechanism are not
being removed, the valve tappets must be prevented from
falling off. (Refer to Valve drive and gears - Service in-
struction (10.106)).
11. Unscrew the screws from the timing gear case and
remove it. If a soft wedge needs to be placed be-
tween the engine block and gear case, ensure that
you do not damage the sealing surfaces!
12. Remove the foremost crankshaft sealing ring from
the gear case and clean all the parts that have been
removed.
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15. Engine - Valve drive and gears
Replacing the idler gear bearing bush
When replacing the idler gear bearing bush, ensure that
the new bearing bush is inserted so that its rear edge is
positioned 0.1 - 0.25 mm (0.004 - 0.010 in) inside the
rear gear wheel edge (refer to diagram).
SS05N336 1
1. Lathe chuck
2. Roller ø = 5 mm (0.20 in)
After installation, machine the inside diameter of the idler
gear bearing bush to the correct dimensions. Centre the
idler gear as shown in the diagram above so that the
backlash is maintained at a constant level.
SS05N337 2
Installing the timing gear case
The position of the timing gear case and the cover is determined by two roll pins. Centring should therefore not be
performed as part of the installation, but it is necessary to check the free play between the various tooth gears. The
timing gear case and cover supplied as spare parts are already equipped with pre-processed bores for the roll pins.
13. Seal the timing gear case with surface sealant and
fit it on the cylinder block. Use a mandrel to drive in
the roll pins. Tighten the bolts and nuts.
14. Lubricate the camshaft bearing and insert the shaft
into the cylinder block. If the push rods and valve
tappets were suspended, release them.
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16. Engine - Valve drive and gears
15. Install the idler gear with the shaft stud bolt and en-
sure that the markings are properly aligned. Add the
washer and tighten the bolts to the correct torque.
SS05N365 3
16. Place the angular ball bearing in the double idler
gear. Fit the idler gear in the gear case using the
mounting bolt.
NOTE: Use new O-rings!
SS05N364 4
17. Check the backlash.
The backlash must be between 0.05 - 0.25 mm
(0.002 - 0.010 in) .
SS05N338 5
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17. Engine - Valve drive and gears
18. Place the oil seal ring onto the crankshaft and fit the
gear case cover using a new seal. Drive the roll
pins in using a mandrel (assemble the tubing around
the stud). Tighten the bolts and nuts to the correct
torque.
SS05N339 6
19. Correctly position the guard ring in the seal seat (re-
fer to diagram 8) and install the foremost crankshaft
seal ring using special tool 380000002, pushing it up
to the stops.
SS99N114 7
20. Lubricate the sealing surfaces of the sealing ring and
crankshaft. Also lubricate the hub fixture profile.
SS07A002 8
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18. Engine - Valve drive and gears
21. Align the hub markings with the markings on the
crankshaft (refer to diagram).
SS06J620 9
22. Slide the hub onto the crankshaft profile.
23. Lightly lubricate the crankshaft nut thread. Fit the
nuts and tighten using key 380002658.
Tightening torque: 1000 Nm (738 lb ft)
24. Fit the vibration damper and V-pulley onto the hub.
Tighten the bolts to the correct torque.
25. Reinstall all other components that have been re-
moved.
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20. Engine - Cylinder heads
Cylinder head - Service instruction
Removing the cylinder head
1. Clean engine from the outside.
Allow coolant to drain out of drain plug on engine
and drain cock on underside of radiator. Discon-
nect coolant hoses from cylinder head and thermo-
stat housing.
SS05N360 1
2. Remove intake lines between exhaust gas tur-
bocharger and air filter and charged air lines from
turbocharger and intake manifold
3. Remove oil lines from exhaust gas turbocharger.
4. Unscrew screw connections of electrical lines from
injectors.
5. Remove high pressure lines and leak oil lines. Re-
move injectors. Fit all open connections with seal
caps.
6. Remove intake and exhaust manifold as well as ther-
mostat housing.
7. Remove valve cover and breather hose.
8. Remove rocker arm mechanism and push rods.
9. Initially loosen all cylinder head screws by ¼ a turn
and then unscrew. Remove the cylinder head
Removing the valves
Ensure that the valves that are to be reused are marked accordingly so that they can be reinserted in their original
position.
10. Screw a nut onto a grub screw for the rocker arm
mechanism. There are no grub screws for the valves
of the central cylinders. Instead, use a screw of the
corresponding length
SS05N298 2
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21. Engine - Cylinder heads
11. Press the valve springs together with the 380000008
lever. Remove collets, spring guide and springs.
Take out valves.
Checking the cylinder head
12. Remove carbon deposits from outlet ducts, clean
sealing faces and wash down cylinder head.
13. Check cylinder head for cracks and other damage.
SS05N299 3
14. Use a straight edge to check the evenness of the
cylinder head. An uneven or contorted surface must
be surface ground. After grinding, the height of the
cylinder head must not be less than 104.00 mm. The
valve plate depth from the cylinder head surface for
inlet valves must be 0.55 - 0.75 mm and for outlet
valves must be 0.65 - 0.85 mm.
15. If necessary, use a reamer to clean the contact sur-
face of the injector in the cylinder head.
SS05N300 4
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22. Engine - Cylinder heads
16. Measure the clearance between the valve shaft and
valve guide using a dial gauge. Raise the valve
so that the valve plate protrudes out of the cylin-
der head surface by 15 mm and then measure the
clearance. For the inlet valves, this must not exceed
0.30 mm and for the outlet valves 0.35 mm. You will
have to use a new valve when measuring to estab-
lish whether the valve guide is worn or not.
SS05N301 5
Changing the valve guides
17. Use a mandrel to press or drive out the old guides.
Clean the valve guide seats.
SS05N303 6
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23. Engine - Cylinder heads
18. Insert the new guides using the press-in tool
380000007 (for valve shaft guides without caps) or
380200151 (for valve shaft guides with caps). This
ensures the correct installation height of 21 mm
above the spring’s flat surface.
NOTE: In case of repair, the valve shaft guides with caps
can also be fitted into an engine in which guides without
caps were previously fitted.
SS09M077 7
19. The same guides are used for inlet and outlet valves.
Ensure that the bevelled end of the guide points to
the valve spring. Ensure that the valves do not jam
in the guides.
Machining the valve seat
Do not machine a damaged valve seat with a milling
tool. If the width of the seat for an outlet valve exceeds
2.3 mm and that of an inlet valve exceeds 3.7 mm, it
is mainly the outer edge that needs reducing. On the
outlet valve the valve seat angle is 45 ° ( +20 ´) and on
the inlet valve 35 ° ( +20 ´).
SS05N302 8
Changing the valve seat rings
The outlet valves and inlet valves have separate valve seat rings. If the sealing face is so badly damaged that it
cannot be repaired through machining, the valve seat rings will have to be replaced.
20. Grind the valve plate of a discarded valve so that it
lies fully in the valve seat. Fit the valve and weld
correctly onto the seat. Cool with water.
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