MAXXUM 115 EP Tier 4A Tractor Service Repair Manual.pdf

Printed in U.S.A.
Copyright © 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.
Part number 47665854
1st
edition English
March 2014
Replaces part number 47461571
SERVICE MANUAL
MAXXUM110EP/MAXXUM110MulticontrollerEP/MAXXUMCVT110/
MAXXUM115EP/MAXXUM115MulticontrollerEP/
MAXXUM125EP/MAXXUM125MulticontrollerEP/
MAXXUM140EP/MAXXUM140MulticontrollerEP
Tier4A
Tractor

SERVICE MANUAL
MAXXUM 110 EP , MAXXUM 110 Multicontroller EP , MAXXUM 115 EP
, MAXXUM 115 Multicontroller EP , MAXXUM 120 EP , MAXXUM 120
Multicontroller EP , MAXXUM 125 EP , MAXXUM 125 Multicontroller EP ,
MAXXUM 130 EP , MAXXUM 130 Multicontroller EP , MAXXUM 140 EP ,
MAXXUM 140 Multicontroller EP , MAXXUM CVT 110 , MAXXUM CVT 120 ,
MAXXUM CVT 130
47665854 27/03/2014
EN

Link Product / Engine
Product Market Product Engine
MAXXUM CVT 110 North America F4DFE413C*A
MAXXUM CVT 120 North America F4DFE413B*A
MAXXUM CVT 130 North America F4DFE413A*A
MAXXUM 110 EP North America F4DFE413E*A
MAXXUM 110 Multicontroller EP North America F4DFE413C*A
MAXXUM 115 EP North America F4DFE613F*A
MAXXUM 115 Multicontroller EP North America F4DFE613F*A
MAXXUM 120 EP North America F4DFE413D*A
MAXXUM 120 Multicontroller EP North America F4DFE413B*A
MAXXUM 125 EP North America F4DFE613E*A
MAXXUM 125 Multicontroller EP North America F4DFE613E*A
MAXXUM 130 EP North America F4DFE413C*A
MAXXUM 130 Multicontroller EP North America F4DFE413A*A
MAXXUM 140 EP North America F4DFE6132*A
MAXXUM 140 Multicontroller EP North America F4DFE6132*A
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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
[10.250] Turbocharger and lines............................................................. 10.5
[10.254] Intake and exhaust manifolds and muffler ......................................... 10.6
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.7
[10.400] Engine cooling system ............................................................. 10.8
[10.414] Fan and drive ...................................................................... 10.9
[10.310] Aftercooler........................................................................ 10.10
Clutch ....................................................................................... 18
[18.112] Slip clutch or flywheel damper ..................................................... 18.1
Transmission.............................................................................. 21
[21.112] Power shuttle transmission......................................................... 21.1
[21.134] Power shuttle transmission external controls ...................................... 21.2
[21.154] Power shuttle transmission internal components .................................. 21.3
[21.111] Semi-Powershift transmission ...................................................... 21.4
[21.133] Semi-Powershift transmission external controls ................................... 21.5
[21.103] Semi-Powershift transmission lubrication system.................................. 21.6
[21.152] Semi-Powershift transmission internal components ............................... 21.7
[21.504] Continuously Variable Transmission (CVT) ........................................ 21.8
[21.505] Continuously Variable Transmission (CVT) external controls...................... 21.9
[21.506] Continuously Variable Transmission (CVT) lubrication system .................. 21.10
[21.507] Continuously Variable Transmission (CVT) internal components................ 21.11
[21.160] Creeper .......................................................................... 21.12
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[21.166] Overdrive......................................................................... 21.13
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
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
[31.114] Two-speed rear Power Take-Off (PTO) ............................................ 31.2
[31.116] Three-speed rear Power Take-Off (PTO) .......................................... 31.3
[31.142] Front Power Take-Off (PTO) control ............................................... 31.4
[31.146] Front Power Take-Off (PTO) ....................................................... 31.5
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
[33.110] Parking brake or parking lock ...................................................... 33.2
[33.204] Front axle brake.................................................................... 33.3
[33.220] Trailer brake hydraulic control...................................................... 33.4
[33.224] Trailer brake pneumatic control .................................................... 33.5
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
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[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.104] Fixed displacement pump.......................................................... 35.3
[35.106] Variable displacement pump ....................................................... 35.4
[35.105] Charge pump....................................................................... 35.5
[35.322] Regulated/Low pressure system ................................................... 35.6
[35.204] Remote control valves ............................................................. 35.7
[35.220] Auxiliary hydraulic pump and lines ................................................. 35.8
[35.114] Three-point hitch control valve ..................................................... 35.9
[35.116] Three-point hitch cylinder ........................................................ 35.10
[35.160] Front hitch controls and lines .................................................... 35.11
Hitches, drawbars, and implement couplings.................................. 37
[37.120] Rear three-point hitch linkage...................................................... 37.1
Frames and ballasting ................................................................. 39
[39.100] Frame .............................................................................. 39.1
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.106] Tie rods............................................................................. 41.2
[41.200] Hydraulic control components...................................................... 41.3
[41.206] Pump ............................................................................... 41.4
[41.216] Cylinders ........................................................................... 41.5
Wheels...................................................................................... 44
[44.511] Front wheels........................................................................ 44.1
[44.520] Rear wheels........................................................................ 44.2
Cab climate control ..................................................................... 50
[50.100] Heating ............................................................................. 50.1
[50.104] Ventilation .......................................................................... 50.2
[50.200] Air conditioning..................................................................... 50.3
Electrical systems....................................................................... 55
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[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
[55.015] Engine control system.............................................................. 55.3
[55.301] Alternator........................................................................... 55.4
[55.302] Battery.............................................................................. 55.5
[55.011] Fuel tank system ................................................................... 55.6
[55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.7
[55.012] Engine cooling system ............................................................. 55.8
[55.640] Electronic modules ................................................................. 55.9
[55.513] Cab transmission controls........................................................ 55.10
[55.024] Transmission control system..................................................... 55.11
[55.020] Transmission speed sensors..................................................... 55.12
[55.021] Transmission pressure sensors .................................................. 55.13
[55.022] Transmission temperature sensors .............................................. 55.14
[55.023] Transmission position sensors ................................................... 55.15
[55.610] Ground speed control ............................................................ 55.16
[55.048] Rear Power Take-Off (PTO) control system ..................................... 55.17
[55.031] Parking brake electrical system .................................................. 55.18
[55.035] Remote control valve electric control ............................................ 55.19
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.20
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system............... 55.21
[55.047] Steering control system .......................................................... 55.22
[55.130] Rear three-point hitch electronic control system ................................. 55.23
[55.911] Global Positioning System (GPS) ................................................ 55.24
[55.405] External lighting switches and relays ............................................ 55.25
[55.510] Cab or platform harnesses and connectors...................................... 55.26
[55.408] Warning indicators, alarms, and instruments .................................... 55.27
[55.DTC] FAULT CODES.................................................................. 55.28
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Platform, cab, bodywork, and decals............................................. 90
[90.150] Cab................................................................................. 90.1
[90.100] Engine hood and panels ........................................................... 90.2
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INTRODUCTION
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1

INTRODUCTION
Foreword
IMPORTANT INFORMATION
All repair and maintenance works listed in this manual must be carried out only by staff belonging to the CASE IH
Service network, strictly complying with the instructions given and using, whenever required, the special tools.
Anyone who carries out the above operations without complying with the prescriptions shall be responsible for the
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 due to the anomalous behavior of parts and/or components not
approved by the manufacturer himself, 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 due to an anomalous behavior of parts and/or components not
approved by the Manufacturer.
No reproduction, though partial of text and illustrations allowed.
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3

INTRODUCTION
Foreword - How to use and navigate through this manual
This manual has been produced by a new technical information system. This new system is designed to deliver
technical information electronically through web delivery (eTIM), DVD, and paper manuals. A coding system called
SAP has been developed to link the technical information to other Product Support functions, e.g., Warranty.
Technical information is written to support the maintenance and service of the functions or systems on a customer's
machine. When a customer has a concern on their machine it is usually because a function or system on their ma-
chine is not working at all, is not working efficiently, or is not responding correctly to their commands. When you refer
to the technical information in this manual to resolve that customer's concern, you will find all the information classified
using the SAP coding, according to the functions or systems on that machine. Once you have located the technical
information for that function or system, you will then find all the mechanical, electrical or hydraulic devices, compo-
nents, assemblies, and sub assemblies for that function or system. You will also find all the types of information that
have been written for that function or system: the technical data (specifications), the functional data (how it works),
the diagnostic data (fault codes and troubleshooting), and the service data (remove, install adjust, etc.).
By integrating SAP coding into technical information, you will be able to search and retrieve just the right piece of
technical information you need to resolve that customer's concern on his machine. This is made possible by attaching
3 categories to each piece of technical information during the authoring process.
The first category is the Location, the second category is the Information Type and the third category is the Product:
• LOCATION - the component or function on the machine, that the piece of technical information is going to describe
(e.g., Fuel tank).
• INFORMATION TYPE - the piece of technical information that has been written for a particular component or func-
tion on the machine (e.g., Capacity would be a type of Technical Data describing the amount of fuel held by the fuel
tank).
• PRODUCT - the model for which the piece of technical information is written.
Every piece of technical information will have those three categories attached to it. You will be able to use any combi-
nation of those categories to find the right piece of technical information you need to resolve that customer's concern
on their machine.
That information could be:
• the procedure for how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool
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4

INTRODUCTION
Manual content
This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the
beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at
the end of each Chapter. Page number references are included for every piece of technical information listed in the
Chapter Contents or Chapter Index.
Each Chapter is divided into four Information types:
• Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components, assemblies or
sub-assemblies.
• Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components, assemblies or
sub-assemblies.
• Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic
devices, components, assemblies or sub-assemblies.
• Service Data (remove disassemble, assemble, install) for all the mechanical, electrical or hydraulic devices, com-
ponents, assemblies or sub-assemblies.
Sections
Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a
number (00, 35, 55, etc.). The Sections included in the manual will depend on the type and function of the machine that
the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This table illustrates
which Sections could be included in a manual for a particular product.
PRODUCT
Tractors
Vehicles with working arms: backhoes, excavators,
skid steers, ….
Combines, forage harvesters, balers, ….
Seeding, planting, floating, spraying
equipment, ….
SECTION Mounted equipment and tools, ….
00 - Maintenance X X X X X
05 - Machine completion and equipment X X X X X
10 - Engine X X X X
14 - Main gearbox and drive X X X X
18 - Clutch X X X
21 - Transmission X X X X
23 - Four wheel drive (4WD) system X X X X
25 - Front axle system X X X X
27 - Rear axle system X X X X
29 - Hydrostatic drive X X X X
31 - Power Take-Off (PTO) X X
33 - Brakes and controls X X X X
35 - Hydraulic systems X X X X
36 - Pneumatic system X X X X
37 - Hitches, drawbars and implement couplings X X X
39 - Frames and ballasting X X X X X
41 - Steering X X X X
44 - Wheels X X X X
46 - Steering clutches
48 - Tracks and track suspension X X X
50 - Cab climate control X X X X
55 - Electrical systems X X X X X
56 - Grape harvester shaking
58 - Attachments/headers X
60 - Product feeding X
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5

INTRODUCTION
61 - Metering system X
62 - Pressing - Bale formation X
63 - Chemical applicators X
64 - Chopping X
66 - Threshing X
68 - Tying/Wrapping/Twisting X
69 - Bale wagons
70 - Ejection X
71 - Lubrication system X X X X X
72 - Separation X
73 - Residue handling X
74 - Cleaning X
75 - Soil preparation/Finishing
76 - Secondary cleaning / Destemmer
77 - Seeding X
78 - Spraying X
79 - Planting X
80 - Crop storage / Unloading X
82 - Front loader and bucket X X
83 - Telescopic single arm X X
84 - Booms, dippers and buckets X X
86 - Dozer blade and arm X X
88 - Accessories X X X X X
89 - Tools X X X X X
90 - Platform, cab, bodywork and decals X X X X
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6

SERVICE MANUAL
Engine
MAXXUM 110 EP , MAXXUM 110 Multicontroller EP , MAXXUM 115 EP
, MAXXUM 115 Multicontroller EP , MAXXUM 120 EP , MAXXUM 120
Multicontroller EP , MAXXUM 125 EP , MAXXUM 125 Multicontroller EP ,
MAXXUM 130 EP , MAXXUM 130 Multicontroller EP , MAXXUM 140 EP ,
MAXXUM 140 Multicontroller EP , MAXXUM CVT 110 , MAXXUM CVT 120 ,
MAXXUM CVT 130
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10

Engine - Engine and crankcase
Engine - Disconnect
MAXXUM 115 EP NA
MAXXUM 115 Multicontroller EP NA
MAXXUM 125 EP NA
MAXXUM 140 EP NA
Prior operation:
Discharge the Air conditioning system, for further information refer to Air conditioning - Discharging (50.200)
Prior operation:
Disconnect battery, for further information refer to Battery - Disconnect (55.302)
Prior operation:
Drain the engine coolant system, for further information refer to Engine cooling system - Drain fluid (10.400)
Prior operation:
Remove the selective catalytic reduction (SRC) muffler, for further information refer to Selective Catalytic Reduction
(SCR) muffler and catalyst - Remove (10.500)
Prior operation:
Remove the selective catalytic reduction (SRC) coolant control valve, for further information refer to Coolant control
valve - Remove (10.500)
WARNING
Heavy objects!
Lift and handle all heavy components using lift-
ing equipment with adequate capacity. Always
support units or parts with suitable slings or
hooks. Make sure the work area is clear of all
bystanders.
Failure to comply could result in death or seri-
ous injury.
W0398A
WARNING
Avoid injury!
Handle all parts carefully. Do not place your
hands or fingers between parts. Use Personal
Protective Equipment (PPE) as indicated in this
manual, including protective goggles, gloves,
and safety footwear.
ous injury.
W0208A
1. Using suitable lifting equipment support the front
weights.
BAIL08CVT011AVA 1
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2. Disconnect and remove the front weights from the
weight carrier.
BAIL08CVT012AVA 2
3. Disconnect the radar electrical connector and remove
the radar (if fitted).
BAIL10CVT358AVA 3
4. Remove the flywheel speed sensor.
BAIS06CCM087AVA 4
5. Disconnect the engine harness electrical connectors.
BAIL12APH142AVA 5
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6. Detach the cab heater return pipe.
BAIL07APH121AVA 6
7. Disconnect the oil cooler supply pipes.
BAIL12APH143AVA 7
8. Disconnect the oil cooler supply and return pipes (1).
Remove the oil cooler pipes (2).
BAIL12APH144AVA 8
9. Disconnect the heater supply hose from the rear of the
engine cylinder head.
BAIL12APH145AVA 9
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10. Remove the starter motor heat shield.
BAIL12APH146AVA 10
11. Remove the starter motor cover.
BAIL10CVT361AVA 11
12. Disconnect the starter motor electrical connector.
BAIL10CVT363AVA 12
13. Disconnect the positive terminal (1), negative terminal
(2) relay and bracket (3) and position to one side.
BAIL12APH147AVA 13
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14. Disconnect the starter motor negative cables.
BAIL10CVT364AVA 14
15. Detach the alternator wiring harness electrical con-
nector from the bracket (1) and detach the wiring har-
ness (2).
BAIL10CVT365AVA 15
16. Disconnect the alternator electrical connectors.
BAIL10CVT366AVA 16
17. Disconnect the brake fluid reservoir electrical connec-
tor (1) and detach the brake fluid reservoir (2) and po-
sition it to one side.
BAIL10CVT367AVA 17
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18. Remove the front brake retaining bracket (1) and re-
move the front brake pipe (2).
BAIL12APH148AVA 18
19. Disconnect the A/C pipe from the A/C compressor.
NOTE: Install blanking plugs/caps to all openings to pre-
vent dirt ingress.
BAIL10CVT368AVA 19
20. Disconnect the high pressure A/C pipe (1).
Disconnect the low pressure switch electrical connec-
tor (2).
BAIL12APH149AVA 20
21. Disconnect the charge air cooler intake pipe.
BAIL12APH150AVA 21
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22. Detach the A/C pipes and position it to one side.
BAIL12APH151AVA 22
23. Disconnect the steering hoses.
NOTE: Mark the hoses to aid installation.
BAIL07APH105AVB 23
24. Disconnect the fuel supply line from the pre-filter/wa-
ter trap.
BAIL12APH152AVA 24
25. Disconnect the fuel return line (1).
Disconnect the flywheel electrical connector (2).
BAIL12APH153AVA 25
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26. Cut the cable ties.
BAIL12APH154AVA 26
27. Cut the starter motor wiring harness cable ties.
BAIL12APH155AVA 27
28. Disconnect the engine earth connector.
BAIL10CVT433AVA 28
29. Disconnect the diff lock supply pipe (1) and pneumatic
brake supply pipe (2).
Remove the pipe retaining bracket (3) and remove the
pipes.
BAIL07APH379AVA 29
NOTE: Repeat the operation on both sides of the vehicle.
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30.
Vehicles with standard front axle
31. Remove the front wheel drive shaft guard and drive
shaft.
NOTE: The type of drive shaft fitted is dependant on type
of front axle installed.
BSD1959A 30
32. Remove the drive shaft flange, where fitted.
BSD1917A 31
Vehicles with suspended front axle
33. Remove the front wheel drive shaft guard.
BAIL12APH156AVA 32
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34. Remove the circlip (1).
Slide the drive shaft sleeve (2).
BAIL12APH182AVA 33
35. Disconnect the drive shaft bearing carrier.
BAIL12APH158AVA 34
All vehicles
36. Using the tractor splitting equipment 380040228 In-
stall the larger wheeled part of the splitting equipment
under the front weight carrier.
BAIL12APH159AVA 35
37. Position the static part of the splitting equipment under
the transmission and secure to the transmission.
Install the smaller wheeled part of the splitting equip-
ment under the engine.
BAIL12APH160AVA 36
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38. Connect the two pieces of the wheeled splitting gear
together with the alignment bar.
BAIL12APH161AVA 37
39. Support the rear of the vehicle.
BAIL07APH145AVA 38
40. Remove the left-hand side engine to transmission se-
curing bolts.
NOTE: Repeat this step for the right-hand side.
BAIL07APH146BVA 39
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41. Remove the centre engine to transmission securing
bolt (2). Remove the top left-hand engine to transmis-
sion securing bolt (1).
BAIL07APH147AVA 40
42. Separate the engine from the transmission.
BAIL12APH161AVA 41
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Engine - Connect
MAXXUM 115 EP NA
MAXXUM 125 EP NA
MAXXUM 140 EP NA
WARNING
Heavy objects!
Lift and handle all heavy components using lift-
ing equipment with adequate capacity. Always
support units or parts with suitable slings or
hooks. Make sure the work area is clear of all
bystanders.
ous injury.
W0398A
WARNING
Avoid injury!
Handle all parts carefully. Do not place your
hands or fingers between parts. Use Personal
Protective Equipment (PPE) as indicated in this
manual, including protective goggles, gloves,
and safety footwear.
ous injury.
W0208A
All vehicles
1. Thoroughly clean the engine to transmission mating
surfaces and apply a bead of sealant.
2. Align the front support and engine assembly to the
transmission and relocate.
Tighten to 285-315 Nm ( 210-232 lb ft).
BAIL12APH161AVA 1
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3. Install the centre engine to transmission securing bolt
(2). Install the top left hand engine to transmission se-
curing bolt (1). Tighten to 285-315 Nm ( 210-232 lb ft).
BAIL07APH147AVA 2
4. Install the left-hand side engine to transmission secur-
ing bolts.
BAIL07APH146BVA 3
5. Remove the support from the rear of the vehicle.
BAIL07APH145AVA 4
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6. Disconnect the two pieces of the wheeled splitting gear
380040228 by removing the alignment bar.
BAIL12APH161AVA 5
7. Remove the smaller wheeled part of the splitting equip-
ment from under the engine.
Remove the splitting equipment securing bolts from the
transmission.
Remove the splitting equipment from under the trans-
mission.
BAIL12APH160AVA 6
8. Place suitable axle stands under the front axle and sup-
port the vehicle. .
9. Remove the larger wheeled part of the splitting equip-
ment from under the front weight carrier.
BAIL12APH159AVA 7
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Vehicles with standard front axle
10. Install the drive shaft flange (if equipped).
BSD1917A 8
11. Install front wheel drive shaft and drive shaft guard.
NOTE: The type of drive shaft fitted is dependant on type
of front axle installed.
BSD1959A 9
12. Connect the drive shaft bearing carrier.
BAIL12APH158AVA 10
13. Slide the drive shaft sleeve (2) and install the circlip
(1).
BAIL12APH182AVA 11
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14. Install the front wheel drive shaft guard.
BAIL12APH156AVA 12
All vehicles
15. Connect the diff lock supply pipe (1) and pneumatic
brake supply pipe (2).
Install the pipe retaining bracket (3).
BAIL07APH379AVA 13
16. Connect the engine earth connector.
BAIL10CVT433AVA 14
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17. Install cable ties to the starter motor wiring harness.
BAIL12APH155AVA 15
18. Install cable ties.
BAIL12APH154AVA 16
19. Connect the brake valve supply hose (if fitted).
BAIL07APH056AVA 17
20. Connect the fuel return line (1).
Connect the flywheel electrical connector (2).
BAIL12APH153AVA 18
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21. Connect the fuel supply line to the pre-filter/water trap.
BAIL12APH152AVA 19
22. Connect the steering hoses.
BAIL07APH105AVB 20
23. Attach the A/C pipes
BAIL12APH151AVA 21
24. Connect the charge air cooler intake pipe.
BAIL12APH150AVA 22
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MAXXUM 115 EP Tier 4A Tractor Service Repair Manual.pdf

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