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Copyright Š 2014 CNH Industrial America LLC. All Rights Reserved.
Case IH is a registered trademark of CNH Industrial America LLC.
Racine Wisconsin 53404 U.S.A.
Magnum™
180
Magnum™
200
Magnum™
220
Powershift Transmission (PST)
Tractor
PIN ZERH08100 and above
Part number 47748093
1st
edition English
September 2014
SERVICE MANUAL
SERVICE MANUAL
Magnum™ 180 696110052 PST TIER 4B [ZERH08100 - ]
Magnum™ 200 696110062 PST TIER 4B [ZERH08100 - ]
Magnum™ 220 696110072 PST TIER 4B [ZERH08100 - ]
47748093 26/09/2014
EN
Link Product / Engine
Product Market Product Engine
Magnum™ 180 696110052 PST
TIER 4B [ZERH08100 - ]
North America F4HFE613K*B002
Magnum™ 180 696110052 PST
TIER 4B [ZERH08100 - ]
Australia New Zealand F4HFE613K*B002
Magnum™ 200 696110062 PST
TIER 4B [ZERH08100 - ]
Australia New Zealand F4HFE613J*B005
Magnum™ 200 696110062 PST
TIER 4B [ZERH08100 - ]
North America F4HFE613J*B005
Magnum™ 220 696110072 PST
TIER 4B [ZERH08100 - ]
North America F4HFE613H*B003
Magnum™ 220 696110072 PST
TIER 4B [ZERH08100 - ]
Australia New Zealand F4HFE613H*B003
47748093 26/09/2014
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.216] Fuel tanks .......................................................................... 10.2
[10.218] Fuel injection system............................................................... 10.3
[10.202] Air cleaners and lines .............................................................. 10.4
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.5
[10.400] Engine cooling system ............................................................. 10.6
[10.414] Fan and drive ...................................................................... 10.7
[10.310] Aftercooler.......................................................................... 10.8
[10.304] Engine lubrication system.......................................................... 10.9
Power coupling........................................................................... 19
[19.100] Drive shaft.......................................................................... 19.1
[19.110] Flywheel damper ................................................................... 19.2
Transmission.............................................................................. 21
[21.113] Powershift transmission ............................................................ 21.1
[21.135] Powershift transmission external controls.......................................... 21.2
[21.155] Powershift transmission internal components...................................... 21.3
[21.160] Creeper ............................................................................ 21.4
[21.166] Overdrive........................................................................... 21.5
[21.200] Dropbox ............................................................................ 21.6
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
47748093 26/09/2014
[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
Rear axle system........................................................................ 27
[27.100] Powered rear axle.................................................................. 27.1
[27.106] Rear bevel gear set and differential................................................ 27.2
Power Take-Off (PTO)................................................................. 31
[31.104] Rear electro-hydraulic control...................................................... 31.1
[31.114] Two-speed rear Power Take-Off (PTO) ............................................ 31.2
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
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.102] Pump control valves................................................................ 35.2
[35.104] Fixed displacement pump.......................................................... 35.3
[35.105] Charge pump....................................................................... 35.4
[35.106] Variable displacement pump ....................................................... 35.5
[35.114] Three-point hitch control valve ..................................................... 35.6
[35.116] Three-point hitch cylinder .......................................................... 35.7
[35.204] Remote control valves ............................................................. 35.8
[35.300] Reservoir, cooler, and filters........................................................ 35.9
Hitches, drawbars, and implement couplings.................................. 37
[37.110] Rear three-point hitch .............................................................. 37.1
Frames and ballasting ................................................................. 39
[39.140] Ballasts and supports .............................................................. 39.1
Steering..................................................................................... 41
47748093 26/09/2014
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.206] Pump ............................................................................... 41.3
Wheels...................................................................................... 44
[44.520] Rear wheels........................................................................ 44.1
Cab climate control ..................................................................... 50
[50.100] Heating ............................................................................. 50.1
[50.200] Air conditioning..................................................................... 50.2
[50.300] Cab pressurizing system ........................................................... 50.3
Electrical systems....................................................................... 55
[55.010] Fuel injection system............................................................... 55.1
[55.011] Fuel tank system ................................................................... 55.2
[55.014] Engine intake and exhaust system................................................. 55.3
[55.024] Transmission control system....................................................... 55.4
[55.031] Parking brake electrical system .................................................... 55.5
[55.045] Front axle control system .......................................................... 55.6
[55.046] Rear axle control system........................................................... 55.7
[55.047] Steering control system ............................................................ 55.8
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system................. 55.9
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.10
[55.100] Harnesses and connectors....................................................... 55.11
[55.130] Rear three-point hitch electronic control system ................................. 55.12
[55.201] Engine starting system ........................................................... 55.13
[55.301] Alternator......................................................................... 55.14
[55.302] Battery............................................................................ 55.15
[55.408] Warning indicators, alarms, and instruments .................................... 55.16
[55.512] Cab controls...................................................................... 55.17
[55.518] Wiper and washer system........................................................ 55.18
47748093 26/09/2014
[55.640] Electronic modules ............................................................... 55.19
[55.988] Selective Catalytic Reduction (SCR) electrical system .......................... 55.20
[55.DTC] FAULT CODES.................................................................. 55.21
Platform, cab, bodywork, and decals............................................. 90
[90.100] Engine hood and panels ........................................................... 90.1
[90.102] Engine shields, hood latches, and trims ........................................... 90.2
[90.124] Pneumatically-adjusted operator seat.............................................. 90.3
[90.150] Cab................................................................................. 90.4
[90.151] Cab interior......................................................................... 90.5
47748093 26/09/2014
INTRODUCTION
47748093 26/09/2014
1
INTRODUCTION
Foreword - 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 Sales and Service Networks.
47748093 26/09/2014
3
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. 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 which, if not avoided, will result in death or serious injury. The
color associated with DANGER is RED.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
The color 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 CAUTION is YELLOW.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color
associated with Notice is BLUE.
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 which 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.
47748093 26/09/2014
4
INTRODUCTION
Torque - Minimum tightening torques for normal assembly
METRIC NON-FLANGED HARDWARE
NOM.
SIZE
CLASS 8.8 BOLT and
CLASS 8 NUT
CLASS 10.9 BOLT and
CLASS 10 NUT
LOCKNUT
CL.8
W/CL8.8
BOLT
LOCKNUT
CL.10
W/CL10.9
BOLT
UNPLATED
PLATED
W/ZnCr
UNPLATED
PLATED
W/ZnCr
M4
2.2 N¡m (19 lb
in)
2.9 N¡m (26 lb
in)
3.2 N¡m (28 lb
in)
4.2 N¡m (37 lb
in)
2 N¡m (18 lb in)
2.9 N¡m (26 lb
in)
M5
4.5 N¡m (40 lb
in)
5.9 N¡m (52 lb
in)
6.4 N¡m (57 lb
in)
8.5 N¡m (75 lb
in)
4 N¡m (36 lb in)
5.8 N¡m (51 lb
in)
M6
7.5 N¡m (66 lb
in)
10 N¡m (89 lb
in)
11 N¡m (96 lb
in)
15 N¡m (128 lb
in)
6.8 N¡m (60 lb
in)
10 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
ft)
48 N¡m (35 lb
ft)
M12 64 N¡m (47 lb ft)
85 N¡m (63 lb
ft)
91 N¡m (67 lb ft)
121 N¡m (90 lb
ft)
58 N¡m (43 lb
ft)
83 N¡m (61 lb
ft)
M16
158 N¡m (116 lb
ft)
210 N¡m
(155 lb ft)
225 N¡m (166 lb
ft)
301 N¡m (222 lb
ft)
143 N¡m (106 lb
ft)
205 N¡m (151 lb
ft)
M20
319 N¡m (235 lb
ft)
425 N¡m
(313 lb ft)
440 N¡m (325 lb
ft)
587 N¡m (433 lb
ft)
290 N¡m (214 lb
ft)
400 N¡m (295 lb
ft)
M24
551 N¡m (410 lb
ft)
735 N¡m
(500 lb ft)
762 N¡m (560 lb
ft)
1016 N¡m
(750 lb ft)
501 N¡m (370 lb
ft)
693 N¡m (510 lb
ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
47748093 26/09/2014
5
INTRODUCTION
METRIC FLANGED HARDWARE
NOM.
SIZE
CLASS 8.8 BOLT and
CLASS 8 NUT
CLASS 10.9 BOLT and
CLASS 10 NUT
LOCKNUT
CL.8
W/CL8.8
BOLT
LOCKNUT
CL.10
W/CL10.9
BOLT
UNPLATED
PLATED
W/ZnCr
UNPLATED
PLATED
W/ZnCr
M4
2.4 N¡m (21 lb
in)
3.2 N¡m (28 lb
in)
3.5 N¡m (31 lb
in)
4.6 N¡m (41 lb
in)
2.2 N¡m (19 lb
in)
3.1 N¡m (27 lb
in)
M5
4.9 N¡m (43 lb
in)
6.5 N¡m (58 lb
in)
7.0 N¡m (62 lb
in)
9.4 N¡m (83 lb
in)
4.4 N¡m (39 lb
in)
6.4 N¡m (57 lb
in)
M6
8.3 N¡m (73 lb
in)
11 N¡m (96 lb
in)
12 N¡m (105 lb
in)
16 N¡m (141 lb
in)
7.5 N¡m (66 lb
in)
11 N¡m (96 lb
in)
M8
20 N¡m (179 lb
in)
27 N¡m (240 lb
in)
29 N¡m (257 lb
in)
39 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
ft)
134 N¡m (98 lb
ft)
63 N¡m (47 lb ft) 91 N¡m (67 lb ft)
M16
174 N¡m (128 lb
ft)
231 N¡m (171 lb
ft)
248 N¡m (183 lb
ft)
331 N¡m (244 lb
ft)
158 N¡m (116 lb
ft)
226 N¡m (167 lb
ft)
M20
350 N¡m (259 lb
ft)
467 N¡m (345 lb
ft)
484 N¡m (357 lb
ft)
645 N¡m (476 lb
ft)
318 N¡m (235 lb
ft)
440 N¡m (325 lb
ft)
M24
607 N¡m (447 lb
ft)
809 N¡m (597 lb
ft)
838 N¡m (618 lb
ft)
1118 N¡m
(824 lb ft)
552 N¡m (407 lb
ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
47748093 26/09/2014
6
SERVICE MANUAL
Engine
Magnum™ 180 696110052 PST TIER 4B [ZERH08100 - ]
Magnum™ 200 696110062 PST TIER 4B [ZERH08100 - ]
Magnum™ 220 696110072 PST TIER 4B [ZERH08100 - ]
47748093 26/09/2014
10
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. Disconnect the air sensor connector (1) and the
crankcase vent hose (2) from the air cleaner outlet
tube.
RAIL13TR01577AA 1
2. Disengage the clamp and remove the air cleaner outlet
hose (1) from the turbocharger.
RAIL13TR01582AA 2
3. Disengage the clamp at the air cleaner and remove the
air outlet tube.
RAIL13TR01583AA 3
47748093 26/09/2014
10.1 [10.001] / 3
Engine - Engine and crankcase
4. Remove the air cleaner mounting bolts (1) from each
side of the air cleaner bracket (left side shown).
RAIL13TR01585AA 4
5. Remove the air cleaner along with the mounting
bracket.
RAIL13TR01587AA 5
6. Disconnect the Diesel Exhaust Fluid (DEF)/AdBlueÂŽ
line (1), the coolant supply and return lines (2) and
the electrical connector (3) from the dosing module.
Squeeze the tabs together and lift the hose straight off
of the fitting.
RAIL13TR01586AA 6
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10.1 [10.001] / 4
Engine - Engine and crankcase
7. Disengage the clamp (1) from the input side of the
Diesel Exhaust Catalyst (DOC).
RAIL13TR01589AA 7
8. Disengage the clamp (1) from the output side of the
DOC.
RAIL13TR01590AA 8
9. Using proper lifting equipment, secure a strap to the
lifting bracket on the DOC.
RAIL13TR01592AA 9
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10.1 [10.001] / 5
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 10
11. Raise the DOC and remove it from the tractor.
RAIL13TR01596AA 11
12. Remove the four mounting bolts (1) for the window
step. Remove the step.
RAIL13TR01594AA 12
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10.1 [10.001] / 6
Engine - Engine and crankcase
13. Cut the tie straps on the DEF/AdBlueÂŽ system har-
ness. Disconnect the two harness connectors (1).
RAIL13TR01597AA 13
14. Disconnect the 12 V auxiliary connector (1) and the
inlet fuel line from the fuel separator (2).
RAIL13TR01603AA 14
15. Disconnect the two connectors (1) for the front axle
harness.
RAIL13TR01625AA 15
47748093 26/09/2014
10.1 [10.001] / 7
Engine - Engine and crankcase
16. Remove the cab trim panels from both sides of the
cab, (right hand side shown).
RAIL13TR01611AA 16
17. Disconnect and cap the high and low pressure air con-
ditioning lines (1) located under the front of the cab.
RAIL13TR01599AA 17
18. Remove the cover plate from the driveshaft (left hand
side shown).
RAIL13TR01600AA 18
47748093 26/09/2014
10.1 [10.001] / 8
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 19
20. Remove the bolts (1) for the mounting bracket for the
air cleaner/DOC from the hood support bracket.
21. Remove the mounting bolts (left hand side shown)
which secure the hood support bracket to front frame
and remove the bracket. Repeat for right hand side.
RAIL13TR01608AA 20
22. Remove the air cleaner/DOC bracket.
RAIL13TR01609AA 21
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10.1 [10.001] / 9
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 22
25. Disconnect the two hydraulic oil cooler lines (1). Cap
or plug all fittings and lines.
RAIL13TR01615AA 23
26. Disconnect the two coolant hoses (1).
RAIL13TR01616AA 24
47748093 26/09/2014
10.1 [10.001] / 10
Engine - Engine and crankcase
27. Disconnect the vacuum line (1) from the air intake col-
lector elbow.
RAIL13TR01624AA 25
28. Disengage the P-clamp for the vacuum line from the
fly wheel housing.
RAIL13TR01621AA 26
29. Attach appropriate lifting equipment to the front and
rear engine lifting brackets.
RAIL13TR01622AA 27
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10.1 [10.001] / 11
Engine - Engine and crankcase
30. Remove the two bolts (1) from the isolation clamp for
the front engine mount (right hand side shown).
RAIL13TR01626AA 28
31. Raise the engine from the frame. Check that all har-
nesses and hoses are disconnected. Remove the en-
gine from the frame.
32. Inspect the rear engine mounts for damage and/or
wear. Replace as necessary.
RCPH07CCH166AAB 29
33. Inspect the front engine support (1) and isolation
mount (2) for damage/and or wear. Replace as nec-
essary.
RCPH07CCH040BAB 30
34. Refer to the engine repair manual for information on
supporting the engine during repair.
Next operation:
47748093 26/09/2014
10.1 [10.001] / 12
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. Properly support the engine and lower the engine into
the front frame.
RAIL13TR01627AA 1
2. Retain tension on the lifting equipment to align the front
isolation mount clamping bolts. Install the clamp and
bolts. Remove the tension on the lifting equipment.
3. Torque the engine mounting bolts to 59 - 106 N¡m (44
- 78 lb ft).
4. Remove the lifting equipment.
RAIL13TR01626AA 2
5. Install the P-clamp (1) for the vacuum line on the fly-
wheel housing.
RAIL13TR01621AA 3
47748093 26/09/2014
10.1 [10.001] / 14
Engine - Engine and crankcase
6. Connect the vacuum line (1) for the air intake collector
elbow.
RAIL13TR01620AA 4
7. Connect the two coolant lines (1)
RAIL13TR01616AA 5
8. Connect the two hydraulic oil cooler lines (1) using new
O-rings.
RAIL13TR01615AA 6
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10.1 [10.001] / 15
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 7
10. Install the hood support brackets (1) and secure the
brackets to the front frame using the bolts previously
removed.
11. Torque the bolts to 125 - 150 N¡m (92 - 111 lb ft).
12. Reinstall the mounting bracket for the air cleaner/
Diesel Oxidation Catalyst (DOC). Secure the bracket
to the hood support bracket with the bolts (2) previ-
ously removed.
RAIL13TR01608AA 8
13. Align the yolk for the driveshaft with the flywheel adap-
tor plate, and install the bolts (1).
14. Torque the 101 - 113 N¡m (75 - 83 lb ft).
15. Reinstall the mounting bracket (2) for the driveshaft
cover plate, and secure with the bolts previously re-
moved.
RAIL13TR01602AA 9
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10.1 [10.001] / 16
Engine - Engine and crankcase
16. Reinstall the driveshaft cover plate and secure with
the bolts previously removed.
RAIL13TR01600AA 10
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. Connect the high and low pressure
lines (1).
RAIL13TR01599AA 11
18. Reinstall the cab trim panels.
RAIL13TR01611AA 12
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10.1 [10.001] / 17
Engine - Engine and crankcase
19. Connect the front axle harness connectors.
RAIL13TR01625AA 13
20. Connect the 12 V auxiliary connector (1) and the fuel
inlet line to the fuel separator (2).
RAIL13TR01603AA 14
21. Connect the connectors (1) for the Selective Catalytic
Reduction (SCR) system.
RAIL13TR01597AA 15
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Engine - Engine and crankcase
22. Using proper lifting equipment, lower the DOC into
place.
RAIL13TR01596AA 16
23. Secure the DOC mounting bracket with the bolts (1)
previously removed (left hand side shown).
RAIL13TR01593AA 17
24. Connect the outlet pipe to the DOC, and secure with
the clamp previously removed.
NOTE: The mounting straps around the DOC may need to
be loosened to line up the outlet and inlet pipes.
RAIL13TR01590AA 18
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10.1 [10.001] / 19
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 19
26. Connect the electrical connector (1) and the coolant
lines (2) to the dosing module. Connect the Diesel
Exhaust Fluid (DEF)/AdBlueÂŽ line (3) to the dosing
module.
RAIL13TR01586AA 20
27. Install the window step and secure the step with the
bolts (1) previously removed.
RAIL13TR01594AA 21
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10.1 [10.001] / 20
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 22
29. Connect the air cleaner outlet tube (1) between the
turbocharger and the air cleaner (2).
RAIL13TR01583AA 23
30. Connect the air sensor connector (1) and the
crankcase vent hose (2) to the air cleaner outlet tube.
RAIL13TR01578AA 24
31. Check that all connectors and hoses are connected.
Use tie straps to secure loose harnesses and hoses
as required.
Next operation:
Engine cooling system - Install (10.400)
Next operation:
Engine cooling system - Filling (10.400)
Next operation:
Air intake lines Air scoop - Install (10.202)
Next operation:
47748093 26/09/2014
10.1 [10.001] / 21
Engine - Fuel tanks
Fuel tank - Remove
Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlueÂŽ tank - Remove (10.500)
1. 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. Always work
in a well-ventilated area. Clean up spilled fuel
immediately.
Failure to comply could result in death or seri-
ous injury.
W0904A
At the rear of the fuel tank, place a clean suitable con-
tainer under the drain and drain the tank. Repeat for
left hand side tank.
NOTE: Both tanks need to be drained even if only one tank
is being removed.
RAIL13TR01800AA 1
2. Loosen the bolts (1) securing the cover plate for the
crossover tube under the fuel tanks. Remove the cover
plates from the tank that is being removed.
RAIL13TR01795AA 2
3. Disengage the hose clamps, and disconnect the
crossover hoses from the tank.
RAIL13TR01796AA 3
47748093 26/09/2014
10.2 [10.216] / 3
Engine - Fuel tanks
For left hand side tank
4. At the tank holding strap (1), remove the adjustment
nut (2).
RCPH09CCH132AAB 4
5. Remove the bolts and tank hold-down bracket (1).
RAIL13TR01794AA 5
6. Disengage the fuel vent hose clamp and disconnect the
hose (1).
RCPH09CCH131AAB 6
7. Disconnect the fuel supply fitting (1) and the return hose
(2).
RAIL13TR01823AA 7
47748093 26/09/2014
10.2 [10.216] / 4

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Case ih magnum 180 powershift transmission (pst) tier 4 b tractor service repair manual (pin zerh08100 and above)

  • 1. Printed in U.S.A. Copyright Š 2014 CNH Industrial America LLC. All Rights Reserved. Case IH is a registered trademark of CNH Industrial America LLC. Racine Wisconsin 53404 U.S.A. Magnum™ 180 Magnum™ 200 Magnum™ 220 Powershift Transmission (PST) Tractor PIN ZERH08100 and above Part number 47748093 1st edition English September 2014 SERVICE MANUAL
  • 2. SERVICE MANUAL Magnum™ 180 696110052 PST TIER 4B [ZERH08100 - ] Magnum™ 200 696110062 PST TIER 4B [ZERH08100 - ] Magnum™ 220 696110072 PST TIER 4B [ZERH08100 - ] 47748093 26/09/2014 EN
  • 3. Link Product / Engine Product Market Product Engine Magnum™ 180 696110052 PST TIER 4B [ZERH08100 - ] North America F4HFE613K*B002 Magnum™ 180 696110052 PST TIER 4B [ZERH08100 - ] Australia New Zealand F4HFE613K*B002 Magnum™ 200 696110062 PST TIER 4B [ZERH08100 - ] Australia New Zealand F4HFE613J*B005 Magnum™ 200 696110062 PST TIER 4B [ZERH08100 - ] North America F4HFE613J*B005 Magnum™ 220 696110072 PST TIER 4B [ZERH08100 - ] North America F4HFE613H*B003 Magnum™ 220 696110072 PST TIER 4B [ZERH08100 - ] Australia New Zealand F4HFE613H*B003 47748093 26/09/2014
  • 4. Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase ............................................................. 10.1 [10.216] Fuel tanks .......................................................................... 10.2 [10.218] Fuel injection system............................................................... 10.3 [10.202] Air cleaners and lines .............................................................. 10.4 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.5 [10.400] Engine cooling system ............................................................. 10.6 [10.414] Fan and drive ...................................................................... 10.7 [10.310] Aftercooler.......................................................................... 10.8 [10.304] Engine lubrication system.......................................................... 10.9 Power coupling........................................................................... 19 [19.100] Drive shaft.......................................................................... 19.1 [19.110] Flywheel damper ................................................................... 19.2 Transmission.............................................................................. 21 [21.113] Powershift transmission ............................................................ 21.1 [21.135] Powershift transmission external controls.......................................... 21.2 [21.155] Powershift transmission internal components...................................... 21.3 [21.160] Creeper ............................................................................ 21.4 [21.166] Overdrive........................................................................... 21.5 [21.200] Dropbox ............................................................................ 21.6 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 47748093 26/09/2014
  • 5. [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 Rear axle system........................................................................ 27 [27.100] Powered rear axle.................................................................. 27.1 [27.106] Rear bevel gear set and differential................................................ 27.2 Power Take-Off (PTO)................................................................. 31 [31.104] Rear electro-hydraulic control...................................................... 31.1 [31.114] Two-speed rear Power Take-Off (PTO) ............................................ 31.2 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 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems.................................................................. 35.1 [35.102] Pump control valves................................................................ 35.2 [35.104] Fixed displacement pump.......................................................... 35.3 [35.105] Charge pump....................................................................... 35.4 [35.106] Variable displacement pump ....................................................... 35.5 [35.114] Three-point hitch control valve ..................................................... 35.6 [35.116] Three-point hitch cylinder .......................................................... 35.7 [35.204] Remote control valves ............................................................. 35.8 [35.300] Reservoir, cooler, and filters........................................................ 35.9 Hitches, drawbars, and implement couplings.................................. 37 [37.110] Rear three-point hitch .............................................................. 37.1 Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports .............................................................. 39.1 Steering..................................................................................... 41 47748093 26/09/2014
  • 6. [41.101] Steering control .................................................................... 41.1 [41.200] Hydraulic control components...................................................... 41.2 [41.206] Pump ............................................................................... 41.3 Wheels...................................................................................... 44 [44.520] Rear wheels........................................................................ 44.1 Cab climate control ..................................................................... 50 [50.100] Heating ............................................................................. 50.1 [50.200] Air conditioning..................................................................... 50.2 [50.300] Cab pressurizing system ........................................................... 50.3 Electrical systems....................................................................... 55 [55.010] Fuel injection system............................................................... 55.1 [55.011] Fuel tank system ................................................................... 55.2 [55.014] Engine intake and exhaust system................................................. 55.3 [55.024] Transmission control system....................................................... 55.4 [55.031] Parking brake electrical system .................................................... 55.5 [55.045] Front axle control system .......................................................... 55.6 [55.046] Rear axle control system........................................................... 55.7 [55.047] Steering control system ............................................................ 55.8 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system................. 55.9 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.10 [55.100] Harnesses and connectors....................................................... 55.11 [55.130] Rear three-point hitch electronic control system ................................. 55.12 [55.201] Engine starting system ........................................................... 55.13 [55.301] Alternator......................................................................... 55.14 [55.302] Battery............................................................................ 55.15 [55.408] Warning indicators, alarms, and instruments .................................... 55.16 [55.512] Cab controls...................................................................... 55.17 [55.518] Wiper and washer system........................................................ 55.18 47748093 26/09/2014
  • 7. [55.640] Electronic modules ............................................................... 55.19 [55.988] Selective Catalytic Reduction (SCR) electrical system .......................... 55.20 [55.DTC] FAULT CODES.................................................................. 55.21 Platform, cab, bodywork, and decals............................................. 90 [90.100] Engine hood and panels ........................................................... 90.1 [90.102] Engine shields, hood latches, and trims ........................................... 90.2 [90.124] Pneumatically-adjusted operator seat.............................................. 90.3 [90.150] Cab................................................................................. 90.4 [90.151] Cab interior......................................................................... 90.5 47748093 26/09/2014
  • 9. INTRODUCTION Foreword - 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 Sales and Service Networks. 47748093 26/09/2014 3
  • 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 and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. 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 which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color 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 CAUTION is YELLOW. FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. 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 which 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. 47748093 26/09/2014 4
  • 11. INTRODUCTION Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT CLASS 10.9 BOLT and CLASS 10 NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr M4 2.2 N¡m (19 lb in) 2.9 N¡m (26 lb in) 3.2 N¡m (28 lb in) 4.2 N¡m (37 lb in) 2 N¡m (18 lb in) 2.9 N¡m (26 lb in) M5 4.5 N¡m (40 lb in) 5.9 N¡m (52 lb in) 6.4 N¡m (57 lb in) 8.5 N¡m (75 lb in) 4 N¡m (36 lb in) 5.8 N¡m (51 lb in) M6 7.5 N¡m (66 lb in) 10 N¡m (89 lb in) 11 N¡m (96 lb in) 15 N¡m (128 lb in) 6.8 N¡m (60 lb in) 10 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 ft) 48 N¡m (35 lb ft) M12 64 N¡m (47 lb ft) 85 N¡m (63 lb ft) 91 N¡m (67 lb ft) 121 N¡m (90 lb ft) 58 N¡m (43 lb ft) 83 N¡m (61 lb ft) M16 158 N¡m (116 lb ft) 210 N¡m (155 lb ft) 225 N¡m (166 lb ft) 301 N¡m (222 lb ft) 143 N¡m (106 lb ft) 205 N¡m (151 lb ft) M20 319 N¡m (235 lb ft) 425 N¡m (313 lb ft) 440 N¡m (325 lb ft) 587 N¡m (433 lb ft) 290 N¡m (214 lb ft) 400 N¡m (295 lb ft) M24 551 N¡m (410 lb ft) 735 N¡m (500 lb ft) 762 N¡m (560 lb ft) 1016 N¡m (750 lb ft) 501 N¡m (370 lb ft) 693 N¡m (510 lb ft) NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet. 47748093 26/09/2014 5
  • 12. INTRODUCTION METRIC FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT CLASS 10.9 BOLT and CLASS 10 NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr M4 2.4 N¡m (21 lb in) 3.2 N¡m (28 lb in) 3.5 N¡m (31 lb in) 4.6 N¡m (41 lb in) 2.2 N¡m (19 lb in) 3.1 N¡m (27 lb in) M5 4.9 N¡m (43 lb in) 6.5 N¡m (58 lb in) 7.0 N¡m (62 lb in) 9.4 N¡m (83 lb in) 4.4 N¡m (39 lb in) 6.4 N¡m (57 lb in) M6 8.3 N¡m (73 lb in) 11 N¡m (96 lb in) 12 N¡m (105 lb in) 16 N¡m (141 lb in) 7.5 N¡m (66 lb in) 11 N¡m (96 lb in) M8 20 N¡m (179 lb in) 27 N¡m (240 lb in) 29 N¡m (257 lb in) 39 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 ft) 134 N¡m (98 lb ft) 63 N¡m (47 lb ft) 91 N¡m (67 lb ft) M16 174 N¡m (128 lb ft) 231 N¡m (171 lb ft) 248 N¡m (183 lb ft) 331 N¡m (244 lb ft) 158 N¡m (116 lb ft) 226 N¡m (167 lb ft) M20 350 N¡m (259 lb ft) 467 N¡m (345 lb ft) 484 N¡m (357 lb ft) 645 N¡m (476 lb ft) 318 N¡m (235 lb ft) 440 N¡m (325 lb ft) M24 607 N¡m (447 lb ft) 809 N¡m (597 lb ft) 838 N¡m (618 lb ft) 1118 N¡m (824 lb ft) 552 N¡m (407 lb ft) IDENTIFICATION Metric Hex head and carriage bolts, classes 5.6 and up 20083680 1 1. Manufacturer's Identification 2. Property Class Metric Hex nuts and locknuts, classes 05 and up 20083681 2 47748093 26/09/2014 6
  • 13. SERVICE MANUAL Engine Magnum™ 180 696110052 PST TIER 4B [ZERH08100 - ] Magnum™ 200 696110062 PST TIER 4B [ZERH08100 - ] Magnum™ 220 696110072 PST TIER 4B [ZERH08100 - ] 47748093 26/09/2014 10
  • 14. 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. Disconnect the air sensor connector (1) and the crankcase vent hose (2) from the air cleaner outlet tube. RAIL13TR01577AA 1 2. Disengage the clamp and remove the air cleaner outlet hose (1) from the turbocharger. RAIL13TR01582AA 2 3. Disengage the clamp at the air cleaner and remove the air outlet tube. RAIL13TR01583AA 3 47748093 26/09/2014 10.1 [10.001] / 3
  • 15. Engine - Engine and crankcase 4. Remove the air cleaner mounting bolts (1) from each side of the air cleaner bracket (left side shown). RAIL13TR01585AA 4 5. Remove the air cleaner along with the mounting bracket. RAIL13TR01587AA 5 6. Disconnect the Diesel Exhaust Fluid (DEF)/AdBlueÂŽ line (1), the coolant supply and return lines (2) and the electrical connector (3) from the dosing module. Squeeze the tabs together and lift the hose straight off of the fitting. RAIL13TR01586AA 6 47748093 26/09/2014 10.1 [10.001] / 4
  • 16. Engine - Engine and crankcase 7. Disengage the clamp (1) from the input side of the Diesel Exhaust Catalyst (DOC). RAIL13TR01589AA 7 8. Disengage the clamp (1) from the output side of the DOC. RAIL13TR01590AA 8 9. Using proper lifting equipment, secure a strap to the lifting bracket on the DOC. RAIL13TR01592AA 9 47748093 26/09/2014 10.1 [10.001] / 5
  • 17. 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 10 11. Raise the DOC and remove it from the tractor. RAIL13TR01596AA 11 12. Remove the four mounting bolts (1) for the window step. Remove the step. RAIL13TR01594AA 12 47748093 26/09/2014 10.1 [10.001] / 6
  • 18. Engine - Engine and crankcase 13. Cut the tie straps on the DEF/AdBlueÂŽ system har- ness. Disconnect the two harness connectors (1). RAIL13TR01597AA 13 14. Disconnect the 12 V auxiliary connector (1) and the inlet fuel line from the fuel separator (2). RAIL13TR01603AA 14 15. Disconnect the two connectors (1) for the front axle harness. RAIL13TR01625AA 15 47748093 26/09/2014 10.1 [10.001] / 7
  • 19. Engine - Engine and crankcase 16. Remove the cab trim panels from both sides of the cab, (right hand side shown). RAIL13TR01611AA 16 17. Disconnect and cap the high and low pressure air con- ditioning lines (1) located under the front of the cab. RAIL13TR01599AA 17 18. Remove the cover plate from the driveshaft (left hand side shown). RAIL13TR01600AA 18 47748093 26/09/2014 10.1 [10.001] / 8
  • 20. 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 19 20. Remove the bolts (1) for the mounting bracket for the air cleaner/DOC from the hood support bracket. 21. Remove the mounting bolts (left hand side shown) which secure the hood support bracket to front frame and remove the bracket. Repeat for right hand side. RAIL13TR01608AA 20 22. Remove the air cleaner/DOC bracket. RAIL13TR01609AA 21 47748093 26/09/2014 10.1 [10.001] / 9
  • 21. 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 22 25. Disconnect the two hydraulic oil cooler lines (1). Cap or plug all fittings and lines. RAIL13TR01615AA 23 26. Disconnect the two coolant hoses (1). RAIL13TR01616AA 24 47748093 26/09/2014 10.1 [10.001] / 10
  • 22. Engine - Engine and crankcase 27. Disconnect the vacuum line (1) from the air intake col- lector elbow. RAIL13TR01624AA 25 28. Disengage the P-clamp for the vacuum line from the fly wheel housing. RAIL13TR01621AA 26 29. Attach appropriate lifting equipment to the front and rear engine lifting brackets. RAIL13TR01622AA 27 47748093 26/09/2014 10.1 [10.001] / 11
  • 23. Engine - Engine and crankcase 30. Remove the two bolts (1) from the isolation clamp for the front engine mount (right hand side shown). RAIL13TR01626AA 28 31. Raise the engine from the frame. Check that all har- nesses and hoses are disconnected. Remove the en- gine from the frame. 32. Inspect the rear engine mounts for damage and/or wear. Replace as necessary. RCPH07CCH166AAB 29 33. Inspect the front engine support (1) and isolation mount (2) for damage/and or wear. Replace as nec- essary. RCPH07CCH040BAB 30 34. Refer to the engine repair manual for information on supporting the engine during repair. Next operation: 47748093 26/09/2014 10.1 [10.001] / 12
  • 24. 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. Properly support the engine and lower the engine into the front frame. RAIL13TR01627AA 1 2. Retain tension on the lifting equipment to align the front isolation mount clamping bolts. Install the clamp and bolts. Remove the tension on the lifting equipment. 3. Torque the engine mounting bolts to 59 - 106 N¡m (44 - 78 lb ft). 4. Remove the lifting equipment. RAIL13TR01626AA 2 5. Install the P-clamp (1) for the vacuum line on the fly- wheel housing. RAIL13TR01621AA 3 47748093 26/09/2014 10.1 [10.001] / 14
  • 25. Engine - Engine and crankcase 6. Connect the vacuum line (1) for the air intake collector elbow. RAIL13TR01620AA 4 7. Connect the two coolant lines (1) RAIL13TR01616AA 5 8. Connect the two hydraulic oil cooler lines (1) using new O-rings. RAIL13TR01615AA 6 47748093 26/09/2014 10.1 [10.001] / 15
  • 26. 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 7 10. Install the hood support brackets (1) and secure the brackets to the front frame using the bolts previously removed. 11. Torque the bolts to 125 - 150 N¡m (92 - 111 lb ft). 12. Reinstall the mounting bracket for the air cleaner/ Diesel Oxidation Catalyst (DOC). Secure the bracket to the hood support bracket with the bolts (2) previ- ously removed. RAIL13TR01608AA 8 13. Align the yolk for the driveshaft with the flywheel adap- tor plate, and install the bolts (1). 14. Torque the 101 - 113 N¡m (75 - 83 lb ft). 15. Reinstall the mounting bracket (2) for the driveshaft cover plate, and secure with the bolts previously re- moved. RAIL13TR01602AA 9 47748093 26/09/2014 10.1 [10.001] / 16
  • 27. Engine - Engine and crankcase 16. Reinstall the driveshaft cover plate and secure with the bolts previously removed. RAIL13TR01600AA 10 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. Connect the high and low pressure lines (1). RAIL13TR01599AA 11 18. Reinstall the cab trim panels. RAIL13TR01611AA 12 47748093 26/09/2014 10.1 [10.001] / 17
  • 28. Engine - Engine and crankcase 19. Connect the front axle harness connectors. RAIL13TR01625AA 13 20. Connect the 12 V auxiliary connector (1) and the fuel inlet line to the fuel separator (2). RAIL13TR01603AA 14 21. Connect the connectors (1) for the Selective Catalytic Reduction (SCR) system. RAIL13TR01597AA 15 47748093 26/09/2014 10.1 [10.001] / 18
  • 29. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 30. Engine - Engine and crankcase 22. Using proper lifting equipment, lower the DOC into place. RAIL13TR01596AA 16 23. Secure the DOC mounting bracket with the bolts (1) previously removed (left hand side shown). RAIL13TR01593AA 17 24. Connect the outlet pipe to the DOC, and secure with the clamp previously removed. NOTE: The mounting straps around the DOC may need to be loosened to line up the outlet and inlet pipes. RAIL13TR01590AA 18 47748093 26/09/2014 10.1 [10.001] / 19
  • 31. 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 19 26. Connect the electrical connector (1) and the coolant lines (2) to the dosing module. Connect the Diesel Exhaust Fluid (DEF)/AdBlueÂŽ line (3) to the dosing module. RAIL13TR01586AA 20 27. Install the window step and secure the step with the bolts (1) previously removed. RAIL13TR01594AA 21 47748093 26/09/2014 10.1 [10.001] / 20
  • 32. 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 22 29. Connect the air cleaner outlet tube (1) between the turbocharger and the air cleaner (2). RAIL13TR01583AA 23 30. Connect the air sensor connector (1) and the crankcase vent hose (2) to the air cleaner outlet tube. RAIL13TR01578AA 24 31. Check that all connectors and hoses are connected. Use tie straps to secure loose harnesses and hoses as required. Next operation: Engine cooling system - Install (10.400) Next operation: Engine cooling system - Filling (10.400) Next operation: Air intake lines Air scoop - Install (10.202) Next operation: 47748093 26/09/2014 10.1 [10.001] / 21
  • 33. Engine - Fuel tanks Fuel tank - Remove Prior operation: Diesel Exhaust Fluid (DEF)/AdBlueÂŽ tank - Remove (10.500) 1. 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. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or seri- ous injury. W0904A At the rear of the fuel tank, place a clean suitable con- tainer under the drain and drain the tank. Repeat for left hand side tank. NOTE: Both tanks need to be drained even if only one tank is being removed. RAIL13TR01800AA 1 2. Loosen the bolts (1) securing the cover plate for the crossover tube under the fuel tanks. Remove the cover plates from the tank that is being removed. RAIL13TR01795AA 2 3. Disengage the hose clamps, and disconnect the crossover hoses from the tank. RAIL13TR01796AA 3 47748093 26/09/2014 10.2 [10.216] / 3
  • 34. Engine - Fuel tanks For left hand side tank 4. At the tank holding strap (1), remove the adjustment nut (2). RCPH09CCH132AAB 4 5. Remove the bolts and tank hold-down bracket (1). RAIL13TR01794AA 5 6. Disengage the fuel vent hose clamp and disconnect the hose (1). RCPH09CCH131AAB 6 7. Disconnect the fuel supply fitting (1) and the return hose (2). RAIL13TR01823AA 7 47748093 26/09/2014 10.2 [10.216] / 4