Case Ih Stx440 Service Manual
FILE DETAILS:
Case Ih Stx440 Service Manual
Language : English
Pages : 1278
Downloadable : YES
Format : PDF
Size : 18.9 MB
DESCRIPTION:
Case Ih Stx440 Service Manual
About the Manual:
This manual contains information needed to correctly operate and maintain your engine as recommended by Case Corporation.
This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle service manual for specific maintenance recommendations.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets.
Each section is preceded by a Section Contents to aid in locating information more quickly.
How to Use the Manual:
The manual is organized to provide an easy flow from problem identification to problem correction. A list of troubleshooting symptoms containing most common engine problems begins on Page TS-a in Section TS – Troubleshooting Symptoms. Complete the following steps to locate and correct the problem. Refer to Section TS for a guide to troubleshooting your engine. Follow the directions given on Page TS-1 to locate and correct engine problems.
The Troubleshooting Symptoms Charts are based on the following assumption:
• The engine has been installed according to specifications.
• The easiest repairs are done first.
• Generic solutions to cover problems with the most common applications.
Refer to Section V for specifications recommended by Case Corporation for your engine. Specifications and torque values for each engine system are given in that section.
TABLE OF CONTENTS:
Case Ih Stx440 Service Manual
610450 9L Engine RM 1
Return to Main Index 1
Return to Engine Index 1
9 Liter Engine Troubleshooting and Repair Manual 1
Section i – Introduction 2
Section Contents 2
About the Manual 3
How to Use the Manual 3
Illustrations 4
General Safety Instructions 5
General Repair Instructions 6
General Cleaning Instructions 7
Section E – System Identification 9
Section Contents 9
Engine Identification 11
Engine Dataplate 11
Fuel Injection Pump Dataplate 12
ECM Dataplate 12
Specifications 13
General Specifications 13
Air Intake System 13
Lubricating Oil System 13
Cooling System 13
Exhaust System 13
Fuel System 14
Electrical System 14
Engine Views 15
Section TS – Troubleshooting Symptoms 19
Section Contents 19
Troubleshooting Procedures and Techniques 21
Troubleshooting Symptoms Charts 21
Communication Error Electronic Service Tool or Control Device 22
Coolant Loss External 24
Coolant Loss Internal 25
Coolant Temperature Above Normal Gradual Overheat 26
Coolant Temperature is Above Normal — Sudden Overheat 29
Coolant Temperature is Below Normal 31
Coolant in the Lubricating Oil 32
Crankcase Gases (Blowby) Excessive 33
Cranking Fuel Pressure is Low 34
Engine Acceleration or Response Poor 35
Engine Decelerates Slowly 41
Engine Difficult to Start or Will Not Start (Exhaust Smoke) 42
Engine Difficult to Start or Will Not Start (No Exhaust Smoke) 46
Engine Noise Excessive 49
Engine Noise Excessive Combustion Knocks 52
Engine Noise Excessive Connecting Rod 53
Engine Noise Excessive Main Bearing 54
Engine Noise Excessive Piston 55
Engine Noise Excessive Turbocharger 56
Engine Power Output Low 57
Engine Runs Rough at Idle 64
Engine Runs Rough or Misfires 68
Engine Shuts Off Unexpectedly or Dies During Deceleration 72
Engine Speed Surges at Low or High Idle 74
Engine Speed Surges Under Load or in Operating Range 78
Engine Speed Surges in PTO 83
Engine Starts But Will Not Keep Running 84
Engine Vibration Excessive 86
Engine Will Not Crank or Cranks Slowly (Air Starter) 88
Engine Will Not Crank or Cranks Slowly (Electric Starter) 90
Engine Will Not Reach Rated Speed (RPM) 92
Engine Will Not Shut Off 95
Fault Code Warning Lamps Do Not Illuminate 96
Fuel Consumption Excessive 97
Fuel in Coolant 101
Fuel in the Lubricating Oil 102
Intake Manifold Air Temperature Above Specification 103
Low Idle Adjust Switch Does Not Work 105
Intake Manifold Pressure (Boost) is Below Normal 106
Lubricating Oil Consumption Excessive 107
Lubricating Oil Contaminated 109
Lubricating Oil Pressure High 110
Lubricating Oil Pressure Low 111
Lubricating Oil Sludge in the Crankcase Excessive 113
Lubricating Oil Temperature Above Specification 114
Lubricating or Transmission Oil in the Coolant 115
Smoke, White Excessive 116
Smoke, Black Excessive 120
Turbocharger Leaks Engine Oil or Fuel 123
Engine Noise Diagnostic Procedures General Information 124
Main Bearing Noise 124
Connecting Rod Bearing Noise 124
Piston Noise 124
Section 01 – Cylinder Block – Group 01 125
Section Contents 125
Service Tools 128
Bearings, Connecting Rod (001-005) 130
Bearings, Main (001-006) 136
Camshaft (001-008) 142
Camshaft Bushings (001-010) 148
Camshaft Gear (Camshaft Removed) (001-013) 151
Connecting Rod (001-014) 154
Crankshaft (001-016) 158
Crankshaft Gear, Front (Crankshaft Installed) (001-018) 158
Crankshaft Seal, Front (001-023) 158
Crankshaft Seal, Rear (001-024) 161
Crankshaft Wear Sleeve, Front (001-025) 163
Cylinder Liner (001-028) 166
Gear Cover, Front (001-031) 180
Gear Housing, Front (001-033) 183
Piston (001-043) 187
Piston Rings (001-047) 191
Vibration Damper, Rubber (001-051) 194
Vibration Damper (001-052) 196
Piston and Connecting Rod Assembly (001-054) 198
Crankshaft Wear Sleeve, Rear (001-067) 207
Section 2 – Cylinder Head – Group 02 214
Section Contents 214
Service Tools 215
Crosshead (002-001) 216
Cylinder Head (002-004) 216
Valve, Cylinder Head (002-020) 226
Injector Protrusion (002-022) 233
Section 3 – Rocker Levers – Group 03 236
Section Contents 236
Crankcase Breather (Internal) (003-002) 238
Overhead Set (003-004) 240
Rocker Lever (003-008) 242
Rocker Lever Cover (003-011) 247
Section 4 – Cam Followers/Tappets – Group 04 250
Section Contents 250
Push Rods or Tubes (004-014) 252
Tappet (004-015) 254
Section 5 – Fuel System – Group 05 260
Section Contents 260
Fuel System – General Information 264
Flow Diagram, Fuel System 267
Specifications 268
Service Tools 269
Engine Fuel Heater, Electric (005-008) 270
Fuel Injection Pump, Rotary (005-014) 272
Fuel Pump (005-016) 276
Fuel Pump Delivery Valve (005-020) 280
Fuel Pump Gear Pump (005-025) 283
Fuel Pump Timing (005-037) 284
Fuel Lift Pump (005-045) 286
Rotor, CAPS Fuel Injection Pump (005-072) 289
Fuel Pump Accumulator (005-077) 291
Injection Control Valve (005-078) 291
Pumping Control Valve (005-079) 292
Fuel Pump Cam Housing (005-080) 293
Snubber, Rate Shape (005-081) 293
Fuel Pump Distributor Inlet Fitting (005-084) 296
Fuel Pump Accumulator Module (005-085) 299
Fuel Pump Distributor Module (005-086) 304
Fuel Pump Injection Control Valve Module (005-087) 308
Fuel Pump Cam Housing Module (005-088) 308
Fuel Pump Gear Pump Module (005-089) 311
Fuel Pump Rate Shape Tube (005-090) 315
Fuel Pump Pressure and Temperature Sensors (005-092) 317
Section 6 – Injectors and Fuel Lines – Group 06 322
Section Contents 322
Injectors and Fuel Lines – General Information 324
Air in Fuel (006-003) 326
Fuel Drain Line Restriction (006-012) 328
Fuel Drain Lines (006-013) 329
Fuel Filter (Spin-On Type) (006-015) 330
Fuel Filter Head Bracket (006-018) 332
Fuel Inlet Restriction (006-020) 335
Fuel Supply Lines (006-024) 335
Injector (006-026) 336
Injector Supply Lines (High Pressure) (006-051) 342
Fuel Connector (Head Mounted) (006-052) 345
Fuel Pump Air Bleed Line (006-056) 346
Section 7 – Lubricating Oil System – Group 07 350
Section Contents 350
Lubricating Oil System – General Information 352
Flow Diagram, Lubricating Oil System 359
Lubrication for the Turbocharger 360
Lubrication for the Power Components 361
Lubrication for the Overhead 362
Specifications 363
Engine Oil Heater (007-001) 364
Lubricating Oil and Filters (007-002) 365
Lubricating Oil Cooler (007-003) 366
Lubricating Oil Dipstick (007-009) 370
Lubricating Oil Dipstick Tube (007-011) 371
Lubricating Oil Filter (Spin-On) (007-013) 372
Lubricating Oil Pan (007-025) 373
Lubricating Oil Pressure Regulator (Main Rifle) (007-029) 376
Lubricating Oil Pump (007-031) 378
Lubricating Oil Suction Tube (Block-Mounted) (007-035) 384
Lubricating Oil Thermostat (007-039) 387
Lubricating Oil Pressure Sensor (007-052) 388
Section 8 – Cooling System – Group 08 390
Section Contents 390
Flow Diagram, Cooling System 392
Specifications 394
Drive Belt, Cooling Fan (008-002) 395
Coolant Temperature Gauge (008-004) 396
Coolant Filter (008-006) 396
Coolant Filter Head (008-007) 398
Coolant Filter Valve (008-009) 399
Coolant Heater (008-011) 401
Coolant Thermostat (008-013) 403
Cooling System (008-018) 408
Cooling System Diagnostics (008-020) 410
Fan Clutch, On-Off (008-027) 412
Fan Shroud Assembly (008-038) 413
Fan Spacer and Pulley (008-039) 414
Fan, Cooling (008-040) 415
Radiator (008-042) 416
Radiator Hoses (008-045) 417
Radiator Pressure Cap (008-047) 417
Water Pump (008-062) 419
Section 9 – Drive Units – Group 09 424
Section Contents 424
Hydraulic Pump Drive (009-016) 426
Section 10 – Air Intake System – Group 10 428
Section Contents 428
Air Intake System – General Information 430
Flow Diagram, Air In take System 434
Specifications 435
Air Crossover (010-019) 436
Air Inlet Connection (010-022) 436
Air Intake Manifold (010-023) 437
Air Leaks, Air Intake and Exhaust Systems (010-024) 439
Charge Air Cooler (CAC) (010-027) 444
Cold Starting Aid (010-029) 445
Air Intake Restriction (010-031) 446
Turbocharger (010-033) 447
Turbocharger Axial Clearance (010-038) 452
Turbocharger Blade Damage (010-039) 452
Turbocharger Compressor Seal Leaks (010-040) 453
Turbocharger Oil Drain Line (010-045) 454
Turbocharger Oil Supply Line (010-046) 455
Turbocharger Radial Bearing Clearance (010-047) 457
Turbocharger Turbine Seal Leaks (010-049) 458
Turbocharger Wastegate Actuator (010-050) 460
Turbocharger Wastegate Valve Body (010-055) 466
Boost Pressure (010-057) 467
Section 11 – Exhaust System – Group 11 468
Section Contents 468
Flow Diagram, Exhaust System 470
Specifications 471
Exhaust Manifold, Dry (011-007) 472
Exhaust Restriction (011-009) 474
Section 17 – Miscellaneous – Group 17 476
Section Contents 476
Cup Plug (017-002) 478
Pipe Plug (017-007) 479
Straight Thread Plug (017-011) 481
Section V – Specifications 484
Section Contents 484
Cylinder Block -Specifications 487
Bearings, Connecting Rod (001-005) 487
Camshaft (001-008) 487
Camshaft Bushings (001-010) 488
Measure (001-010) 488
Camshaft Gear (Camshaft Removed) (001-013) 488
Connecting Rod (001-014) 488
Cylinder Liner (001-028) 489
Piston (001-043) 490
Piston Rings (001-047) 491
Piston and Connecting Rod Assembly (001-054) 491
Cylinder Block -Torque Values 491
Bearings, Connecting Rod (001-005) 491
Bearings, Main (001-006) 491
Camshaft (001-008) 491
Connecting Rod (001-014) 491
Cylinder Liner (001-028) 492
Gear Housing, Front (001-033) 492
Vibration Damper, Rubber (001-051) 492
Vibration Damper (001-052) 492
Piston and Connecting Rod Assembly (001-054) 492
Cylinder Head – Specifications 493
Cylinder Head (002-004) 493
Valve, Cylinder Head (002-020) 493
Cylinder Head – Torque Values 494
Cylinder Head (002-004) 494
Valve, Cylinder Head (002-020) 494
Rocker Levers – Specifications 495
Overhead Set (003-004) 495
Rocker Lever (003-008) 495
Rocker Levers – Torque Values 495
Rocker Lever (003-008) 495
Rocker Lever Cover (003-011) 495
Cam Followers/Tappets 496
Tappet (004-015) 496
Fuel System – Specifications 497
Fuel Lift Pump (005-045) 497
Fuel System – Torque Values 497
Fuel Injection Pump, (005-016) 497
Rotor, CAPS Fuel Injection Pump (005-072) 497
Snubber, Rate Shape (005-081) 497
Fuel Pump Distributor Module (005-086) 497
Fuel Pump Rate Shape Tube (005-090) 497
Fuel Pump Pressure and Temperature Sensors (005-092) 498
Injectors and Fuel Lines – Specifications 499
Fuel Drain Line Pressure (006-012) 499
Fuel Inlet Restriction (006-020) 499
Injectors and Fuel Lines – Torque Values 499
Air in Fuel (006-003) 499
Fuel Drain Lines (006-013) 499
Fuel Filter Head Bracket (006-018) 499
Fuel Supply Lines (006-024) 499
Injector (006-026) 500
Injector Supply Lines (High Pressure) (006-051) 500
Lubricating Oil System – Specifications 501
Lubricating Oil Cooler (007-003) 501
Lubricating Oil Pump (007-031) 501
Lubricating Oil System – Torque Values 501
Engine Oil Heater (007-001) 501
Lubricating Oil Cooler (007-003) 502
Lubricating Oil Pan (007-025) 502
Lubricating Oil Pressure Regulator (Main Rifle) (007-029) 502
Lubricating Oil Pump (007-031) 502
Lubricating Oil Suction Tube (Block-Mounted) (007-035) 502
Lubricating Oil Thermostat (007-039) 502
Lubricating Oil Pressure Sensor (007-052) 503
Cooling System – Specifications 504
Coolant Thermostat (008-013) 504
Cooling System – Torque Values 504
Coolant Filter Head (008-007) 504
Coolant Heater (008-011) 504
Coolant Thermostat (008-013) 504
Fan Spacer and Pulley (008-039) 504
Fan, Cooling (008-040) 504
Air Intake System – Specifications 505
Air Intake Restriction (010-031) 505
Axial Clearance (010-038) 505
Radial Bearing Clearance (010-047) 505
Air Intake System – Torque Values 505
Air Crossover (010-019) 505
Air Leaks, Air Intake and Exhaust Systems (010-024) 505
Turbocharger (010-033) 505
Turbocharger Turbine Seal Leaks (010-049) 506
Turbocharger Wastegate Actuator (010-050) 506
Exhaust System – Specifications 507
Exhaust Manifold, Dry (011-007) 507
Exhaust Restriction (011-009) 507
Exhaust System – Torque Values 507
Exhaust Manifold Dry (011-007) 507
Weights and Measures – Conversion Factors 508
Tap-Drill Chart – U S Customary and Metric 509
Pipe Plug Torque Values 510
Capscrew Markings and Torque Values 511
Capscrew Markings and Torque Values – Metric 512
Capscrew Markings and Torque Values – U S Customary 513
Newton-Meter to Foot-Pound Conversion Chart 514
Fraction, Decimal, Millimeter Conversions 515
Section X – Index 516
610630 9L Engine RM 522
Return to Main Index 522
Return to STX 275/325 Fuel System 522
Return to STX 375/440 Fuel System 522
9 Liter Engine Fuel Systems Troubleshooting and Repair Manual 522
Table of Contents 523
Section i – Introduction 524
Section Contents 524
About the Manual 525
How to Use the Manual 526
Illustrations 527
General Safety Instructions 528
General Repair Instructions 529
General Cleaning Instructions 530
Acronyms and Abbreviations 532
Section E – System Identification 533
Section Contents 533
ECM Dataplate 534
Engine Views 535
Front View 535
Rear View 536
Fuel Pump Side View 537
Exhaust Side View 538
Wiring Diagram 539
Section F – Familiarization 542
Section Contents 542
Diagnostic Fault Codes 544
Fault Code Snapshot Data 544
Engine Time Offset 544
Duty Cycle Monitor 544
Section TF – Troubleshooting Fault Codes 546
Section Contents 546
Information Fault Codes 550
Fault Code 211 550
Fault Code 287 550
Fault Code 288 550
Fault Code 319 550
Fault Code 599 551
Fault Code 111 552
Fault Code 115 556
Fault Code 121 567
Fault Code 122 or 123 579
Fault Code 124 590
Fault Code 131 or 132 593
Fault Code 133 609
Fault Code 134 623
Fault Code 135 or 141 638
Fault Code 143 648
Fault Code 144 or 145 651
Fault Code 146 662
Fault Code 147 665
Fault Code 148 675
Fault Code 151 685
Fault Code 153 or 154 688
Fault Code 155 699
Fault Code 221 or 222 702
Fault Code 234 713
Fault Code 241 719
Fault Code 242 731
Fault Code 243 737
Fault Code 245 748
Fault Code 263 or 265 759
Fault Code 268 769
Fault Code 271 or 272 774
Fault Code 273 or 274 785
Fault Code 275 796
Fault Code 276 or 279 799
Fault Code 277 811
Fault Code 278 828
Fault Code 281 or 282 838
Fault Code 283 or 284 841
Fault Code 328 851
Fault Code 329 855
Fault Code 349 860
Fault Code 352 or 386 872
Fault Code 385 or 444 881
Fault Code 387 or 443 891
Fault Code 415 901
Fault Code 418 904
Fault Code 422 907
Fault Code 429 921
Fault Code 431 or 551 928
Fault Code 432 940
Fault Code 433 955
Fault Code 434 963
Fault Code 441 974
Fault Code 442 986
Fault Code 449 991
Fault Code 451 or 452 995
Fault Code 488 1005
Fault Code 489 1008
Fault Code 493 1020
Fault Code 524 1030
Fault Code 527 1041
Fault Code 528 1049
Fault Code 529 1056
Fault Code 539 1067
Fault Code 768 1076
Section TS – Troubleshooting Symptoms 1082
Section Contents 1082
Troubleshooting Procedures and Techniques 1083
Troubleshooting Symptoms Charts 1083
Communication Error – Electronic Service Tool or Control Device 1084
Engine Acceleration or Response Poor 1086
Engine Decelerates Slowly 1093
Engine Difficult to Start or Will Not Start (Exhaust Smoke) 1094
Engine Difficult to Start or Will Not Start (No Exhaust Smoke) 1099
Engine Power Output Low 1103
Engine Runs Rough at Idle 1110
Engine Runs Rough or Misfires 1114
Engine Shuts Off Unexpectedly or Dies During Deceleration 1118
Engine Speed Surges at Low or High Idle 1121
Engine Speed Surges Under Load or in Operating Range 1126
Engine Speed Surges in PTO 1131
Engine Starts But Will Not Keep Running 1132
Engine Will Not Reach Rated Speed (RPM) 1135
Engine Will Not Shut Off 1137
Fault Code Warning Lamps Stay on (No Apparent Reason) 1138
Fault Code Warning Lamps Do Not Illuminate 1139
Fuel Consumption Excessive 1140
Fuel in Coolant 1144
Fuel in the Lubricating Oil 1145
Low Idle Adjust Switch Does Not Work 1147
PTO Does Not Operate 1148
Smoke, Black — Excessive 1150
Smoke, White — Excessive 1153
Section 19 – Electronic Engine Controls – Group 19 1157
Section Contents 1157
Electronic Engine Controls 1163
Ambient Air Pressure Sensor (019-004) 1170
Battery Ground Circuit (019-008) 1171
Coolant Level Sensor (019-017) 1173
Coolant Temperature Sensor (019-019) 1174
Electronic Control Module (ECM) (019-031) 1176
ECM Calibration (019-032) 1179
Engine Position Sensor (EPS) (019-038) 1180
Engine Position Sensor (EPS) Circuit (019-039) 1181
Engine Protection Warning Lamp (019-040) 1183
Engine Speed Sensor (ESS) (019-042) 1184
Engine Wiring Harness (019-043) 1185
Fault Lamp (019-046) 1188
Fault Lamp Circuit (019-047) 1191
Idle Adjust Switch (019-052) 1191
Idle Adjust Switch Circuit (019-053) 1194
Idle Validation Switch (IVS) (019-054) 1196
Idle Validation Switch (IVS) Circuit (019-055) 1198
Intake Manifold Air Temperature Sensor (019-059) 1202
Intake Manifold Air Temperature Sensor Circuit (019-060) 1203
Intake Manifold Pressure Sensor (019-061) 1206
Key Switch Battery Supply Circuit (019-064) 1210
Lubricating Oil Pressure Sensor (019-066) 1212
Vehicle Wiring Harness (019-071) 1216
Programmable Features and Parameters Not Correct (019-078) 1216
Tachometer Circuit (019-083) 1218
Throttle Position Sensor (TPS) (019-085) 1220
Throttle Position Sensor (TPS) Circuit (019-086) 1222
Unswitched Battery Supply Circuit (019-087) 1227
Vehicle Speed Sensor, Digital Input (019-090) 1234
Vehicle Speed Sensor, Magnetic Pick Up (019-091) 1237
Vehicle Speed Sensor Circuit (019-093) 1240
Engine Speed Sensor Circuit (019-106) 1241
Water in Fuel Sensor (019-127) 1246
Fuel Pressure/Temperature Sensor (019-153) 1248
Cold Start Aid Circuit (019-164) 1249
Data Link Circuit, J1939 (019-165) 1251
Data Bus Circuit, J1587 (019-166) 1255
Transient Suppressor (019-184) 1258
Section V – Specifications 1261
Section Contents 1261
Specifications 1262
ELECTRICAL SPECIFICATIONS 1262
SENSOR SPECIFICATIONS 1263
Electronic Engine Controls – Torque Values 1264
Drive Belt Tension 1266
Fraction, Decimal, Millimeter Conversions 1267
Weights and Measures – Conversion Factors 1268
Newton-Meter to Foot-Pound Conversion Chart 1269
Capscrew Markings and Torque Values 1270
Capscrew Markings and Torque Values – Metric 1271
Capscrew Markings and Torque Values – U S Customary 1272
Pipe Plug Torque Values 1273
Tap-Drill Chart – U S Customary and Metric 1274
Detail Index 1275
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
Elliot Banks –
So far going smooth..