SERVICE MANUAL Magnum 235 Magnum 260 Magnum 290 Magnum 315 Magnum 340 Tractor PIN ZBRD07000 and after Part number 47386174 English October 2012 Copyright © 2012 CNH America LLC. All Rights Reserved.
SERVICEMANUAL [ZBRD07000-] Magnum340[ZBRD07000-] 4738617426/06/2012
Contents INTRODUCTION Engine.......................................................................................10 Cylinderheads...........................................................................10.101 Pumpdrives..............................................................................10.114 Fananddrive.............................................................................10.414 SelectiveCatalyticReduction(SCR)exhausttreatment.................................10.500 Transmission..............................................................................21 Powershifttransmissionlubricationsystem..............................................21.105 Powershifttransmission..................................................................21.113 Powershifttransmissionexternalcontrols................................................21.135 Gearboxinternalcomponents............................................................21.145 Powershifttransmissioninternalcomponents............................................21.155 Four-WheelDrive(4WD)system..................................................23 Electrohydrauliccontrol...................................................................23.202 Driveshaft................................................................................23.314 Frontaxlesystem.......................................................................25 Poweredfrontaxle.......................................................................25.100 Frontbevelgearsetanddifferential......................................................25.102 Finaldrivehub,steeringknuckles,andshafts...........................................25.108 Rearaxlesystem........................................................................27 4738617426/06/2012
PowerTake-Off(PTO).................................................................31 Rearelectrohydrauliccontrol.............................................................31.104 Two-speedrearPowerTake-Off(PTO)..................................................31.114 FrontPowerTake-Off(PTO)..............................................................31.146 Parkingbrake/Parkinglock..............................................................33.110 Trailerbrakepneumaticcontrol...........................................................33.224 Hydraulicsystems.......................................................................35 Variabledisplacementpump.............................................................35.106 Three-pointhitchcontrolvalve...........................................................35.114 Remotecontrolvalves....................................................................35.204 Reservoir,cooler,andfilters..............................................................35.300 Combinationpumpunits..................................................................35.304 Pneumaticsystem......................................................................36 Rearthree-pointhitch....................................................................37.110 Fronthitch................................................................................37.162 Steering.....................................................................................41 Steeringcontrol...........................................................................41.101 4738617426/06/2012
Pump.....................................................................................41.206 Cabclimatecontrol.....................................................................50 Heating...................................................................................50.100 Electricalsystems.......................................................................55 Frontaxlecontrolsystem.................................................................55.045 Rearaxlecontrolsystem.................................................................55.046 Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.......................55.050 CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.........................55.051 Enginestartingsystem...................................................................55.201 Externallighting..........................................................................55.404 Externallightingswitchesandrelays.....................................................55.405 Electronicmodules.......................................................................55.640 SelectiveCatalyticReduction(SCR)electricalsystem...................................55.988 FAULTCODES..........................................................................55.DTC Platform,cab,bodywork,anddecals.............................................90 Enginehoodandpanels..................................................................90.100 4738617426/06/2012
Pneumatically-adjustedoperatorseat....................................................90.124 4738617426/06/2012
INTRODUCTION 4738617426/06/2012 1
withyou.
Safetyrules
Personalsafety
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE: Noticeindicatesasituationwhich,ifnotavoided,couldresultinmachineorpropertydamage.Thecolor
ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
Information
NOTE:
INTRODUCTION
4738617426/06/2012 3
Safetyrules
Standardsafetyprecautions consultation.
• Wearsuitableworkattireandsafetyglasseswithnojewelrysuchasringsandchainswhenworkingcloseto
• Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
•
• Usingcompressedairorliquidsatapressuregreaterthan 2bar ( 29psi
•
• Alwayswearsafetyshoesandfittingclothes.
•
•
• Inthepresenceofvoltagesexceeding 48-60V
• • • occur.
• 50°C ( 122
• Alwaysuseadequateandsafecontainersforenginefluidsandusedoil.
INTRODUCTION
• • Ensurethatworkingareasareprovidedwithemergencyboxes.Theymustbeclearlyvisibleandalwayscontain
• • • Preventionofinjury
• Duringmaintenance
• •
4738617426/06/2012 4
• • Useofsolventsordetergentsduringmaintenancemayemittoxicvapors.Alwayskeepworkingareasaerated. • •
• • • • • released.Takeallnecessaryprecautionsbleedinganddrainingresidualpressure.Alwaysweartheproper
• Donotalterthelengthsofanywires.
• Donotconnectanyelectronicservicetooltotheengineelectricalequipmentunlessspecificallyapprovedby
• Forengineequippedwithanelectroniccontrolunit
•
• Removetheincaseofworkrequiringheatingover 80°C ( 176°F
•
• electroniccomponentswillvoidenginewarrantyassistanceandmayaffectthecorrectworkingorderandlife
RespectoftheEnvironment
• nel'ssafetyandhealth.
•
• 4738617426/06/2012
INTRODUCTION
5
SERVICEMANUAL Engine
4738617426/06/2012
Magnum235WE Magnum260WE Magnum290WE Magnum315WE Magnum340WE
Engine-Remove
Prioroperation:
Prioroperation:
Prioroperation:
Prioroperation:
Prioroperation:
NOTE: DuringthedisassemblyofcomponentswithO-ringseals,thesealsshouldbediscardedandnewsealinstalled duringassembly.
NOTE:
NOTE: Bepreparedtocollectsomehydraulicoilbyplacing
RCPH10CCH771AAB 1
2.Disconnectthehydraulicline (1) ontheleftside(to
harnessconnector (3)
linefitting(returnfromcondenser) (2) (4)
RCPH10CCH772AAB 2
totubefitting (1) (2)
coolerhoses (3)(4)
RCPH10CCH773AAB 3
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(1)
RCPH10CCH774AAB 4 (1) (2) (3) totheintakemanifold(notshown). RCPH10CCH775AAB 5 RCPH10CCH778AAB 6 13.RemoveanddiscardtheO-ringsealfromtheelbow. RCPH10CCH777AAB 7 4738617426/06/2012 10.001/4
anddisconnectthe airventhose (2) andthehose (3) fromthedeaeration tanktotherecoverybottle.
14.Loosenthehoseclamp (1) attheenginecoolant outletanddisconnectthehosefromthethermostat RCPH10CCH776AAB
16.Removethenuts (1) anddisengagetheengine heatergridcables (2)(3)
(4) forthe 12V RCPH10CCH779AAB
nector (1) bymovingthelockinghandle (2) fromthe right(lockedposition)totheleft(unlockedposition). RCPH10CCH780AAB 11
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8 RCPH10CCH580AAB 9
(1) RCPH10CCH781AAB (1) andtheA/Ccompressorclutch (2) 21.RemovetheupperleftA/Ccompressorboltandremovethegroundwire (3) RCPH10CCH782AAB pressureswitch (1) andtheenginecoolingfandrive (2) RCPH10CCH783AAB (1) tothegrid heatercontroller. RCPH10CCH784AAB 4738617426/06/2012 10.001/6
anddisconnectthefuelsupplyline totheEMCcooler
24.Removethenut (1) andtheclampbolts (2) gagethepowercable (3)
(1)
RCPH10CCH785AAB
RCPH10CCH787AAB (1) turnhose (2)
(1) putcable (2) . RCPH10CCH788AAB 4738617426/06/2012 10.001/7
RCPH10CCH786AAB
28.Loosenthenuts (1)
anddisconnectthecompressor inlet (2) andoutlet (3)
RCPH10CCH789AAB
controlvalvesolenoid (1) (2)
anddisconnecttheheater supplyconnector (3)
RCPH10CCH790AAB
32.Disconnectthemainenginetochassisharnessconnector.
RCPH10CCH791AAB
connectors (1)
RCPH10CCH792AAB
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34.Removetheholdingnut (1) anddisengagethe groundwire (2) RCPH10CCH793AAB (1) RCPH10CCH798AAB (1) RCPH10CCH794AAB (1) catedbetweenthehoodsupportandthecab. RCPH10CCH799AAB 4738617426/06/2012 10.001/9
4738617426/06/2012 10.001/10
RCPH10CCH796AAB (1) anddisengagethecablesfrom RCPH10CCH797AAB (1) (2) andremovethestartersolenoidwire (3) RCPH10CCH818AAB (1) anddisconnectthefill
hoseelbow (2) .
RCPH10CCH795AAB
anddisconnectthecab
andremovetheairbleed hose.
42.Removethesixsocketheadbolts
(1)
(1)
(2)
(3)
(4)
(5)
10.001/11
(1) ingplates (2) securingthedriveshaftassemblyto RCPH10CCH562AAB
fromthecooling RCPH10CCH572AAB bolts (1) securingthebrackettothehoodsupport. RCPH10CCH037BAB
anddisconnectthecoolantfill line.
and
securingthefrontsupport RCPH10CCH038BAB 4738617426/06/2012
NOTE: Squeezethelockingtabs (2) togetherandpull straightupwardontheelbow.
RCPH10CCH359AAB
forclampattheotherendofthepipe (2) thepipeandsetaside.
49.Removethetwobolts (1)
securingtherearsupport
RCPH10CCH800AAB (1) tothedosing
RCPH10CCH801AAB (1)
(1)
10.001/12
RCPH10CCH806AAB 4738617426/06/2012
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53.Removetheclamp (1) attheSCRmuffler.Remove theattachingbolt (2) RCPH10CCH803AAB (1) atthe RCPH10CCH805AAB 55.Disengagetheengineblow-byhoseclamp (1) atthe engine.Removethepipeandsetaside. RCPH10CCH807AAB (1) securingtheintakepipeelbow totheturbocharger.Disconnectfromtheturbo. RCPH10CCH809AAB 4738617426/06/2012 10.001/13
