CA-S-2094,2294+

JJ..II .. CCaasseeService Manual

2094, 2294, 32942 & 4 Wheel Drive

DieselVolume 1 of 5

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF J.I. CASE OR IT’S SUCCESSORS. J.I. CASE AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

ice

Man

ual

( \. r,~. ,J-:

SERIES SECTION 10

1210 1211 1211 1212 1213 1214 1220 1320 1420 1230 1250 1260 1270 1280

20 2201 2202 2211 2215 2225 2235 2245

( ) 2255

'" .' 2265 ""-~

2565 2275 2375 2290

30 3210 3212 3213

40 4201 4205 4210 4215 4220 4230 4235 4240 4280

50 5205 5210 5220 5230

( \ J

~/

J lease ATenneco Company

TABLE OF CONTENTS 2094,2294 AND 3294 TRACTORS

DESCRIPTION GENERAL General Specifications - 2094 Tractor ........... . ..................... . General Specifications - 2294 Tractor ................................. . General Specifications - 3294 Tractor ................................. . Lubrication - 2094 Tractor ........................ .. .......... .... ... . Lubrication - 2294 Tractor . . ...................... . .................. . Lubrication - 3294 Tractor ........................................... . Engine Specifications - 504BDT Engine, 3294 Tractor ........... . ...... . Engine Specifications - 504BDT Engine, 2294 Tractor .................. . Engine Specifications - 504BD Engine, 2094 Tractor ................... . Fuel System Specifications ........................................... . Steering System Specifications •.................... ... ......... .. ..... Power Train Specifications ............ ... ... ..... . ......... .......... . Brake System Specifications ........ . ................... , ............ . Hydraulic System Specifications ..................................... . ENGINES Troubleshooting - Engine ............. .. ........ . .. .... ... . .......... . Engine Tune-Up ..................................................... . Tractor Split (Between Engine and Torque Tube) ............... ... .... . Cylinder Head, Valve Train and Camshaft ......•....................... Cylinder BlOck, Sleeves, Pistons and Rods . ......................... .. . Crankshaft, Main Bearings, Flywheel and Oil Seals .............. .. . . .. Lubrication System - Oil Pump, Oil Pan and Heat Exchanger . ... .. . . Cooling System ..................................................... . Turbocharger - T04B ................................................ . Turbocharger - Fa~ure Analysis ...................................... . Air Induction System - 2294 and 3294 Tractors ........................ . Air Cleaner System,- 2094 Tractors ................ ... ................ . Reconditioning Engine Cylinder Block ................................ . FUEL SYSTEM Fuel System and Filters .............................................. . Robert Bosch Fuel Injection Pumps ............................ . ...... . American Bosch Fuel Injectors ...................................... . . ELECTRICAL Electrical System Troubleshooting ........ .. ......................... . Instrument Cluster Troubleshooting .................................. . Tractor Electrical Wiring Diagram .................................... . Power Shift Electrical Wiring Diagram ................................ . Cab Electrical Wiring Diagram .. .. ................................... . Starting Motors - Nippondenso ....................................... . Battery Servicing and Testing .......................................•. Delco-Remy Alternator System ....................................... . Neutral Start Switch Adjustment and Correct Starting Procedure Using Booster Batteries .................................. . STEERING ' Testing Tractor Steering System ..................................... . Steering Column, Pump and Valve ............................ , ....... . Steering Cylinder ....... .... ........ ...... ..................... ... ... . Front Steering Axle and Lines ..................... .. ................. .

FORM NUMBER

8-24830 8-24840 8-26970 8-24780 8-24790 8-26980 8-20841 8-20040 8-20050 8-20062 8-24920 8-24940 8-24860 8-24870

8-20111 8-20120 8-24480 8-20140 8-20150 8-20160 8-20910 8-20180 8-20190 9-78235, 8-20210 . 8-2474'0 . 8-211:70

8-20220 8-20230 8-20240

8-26500 8-26470 8-24360 8-24342 8-24371 8-25980 8-20291 8-25690

8-20310

8-,20330 8-20341 8-20351 8-24720

Printed in U,S:A.

. :.'tb

SERIES SECTION 60

70

80

90

100

Rae 8-24901

6205 6310 6220 6225 6431 6235 6441 6442 6245 6345 6250 6255 6260 6260 6265 6265

7210 7215 7220 7240 7245

8201 8202 8205 8210 8220 8225 8250 8255 8255 8260 8280 8290

9205 9215 9225

9235 9245 9250 9250 9260 9270 9280

14205 16430

18225

DESCRIPTION POWER TRAIN Troubleshooting - Power Shift Transmission .......................... . Tractor Split (Between Torque Tube and Transmission) ................ . Torque Limiter Clutch ............................................... . Hydraulic Pump Drive ................. ' .............................. . Power Shift ......................................................... . Power Shift Control Valve and Linkage ................................ . Four Speed Transmission ............................................ . Transfer Gear Box - MFD Tractors .................................... . Hydraulic PTO - 540 and 1000 RPM ................................... . Hydraulic PTO - 1000 RPM ........................................... . Rear Axles and Planetaries ........................................... . Differential and Differential Lock ..................................... . Differential and Drive Shaf,t - MFD Tractors w/Carraro Axles ........... . Differential and Drive Shaft - MFD Tractors w/ZFAxles ................ . Front Axle and Planetaries - MFD Tractors w/Carraro Axles ............ . Front Axle and Planetaries - MFD Tractors w/ZFAxles ................. . BRAKES Brake Pressure Regulator Valve ...................................... . Park Lock System ................................................... . Brake Cylinder ...................................................... . Brake Valve ......................................................... . Emergency Brake System ............................................ . HYDRAULIC Hydraulic Schematic ................................................ . Troubleshooting - Hitch System ...................................... . Testing Tractor HydraulicSystem .................................... . Hydraulic Oil Filter .................................................. . Hydraulic Charging Pump ........................................... . Hydraulic Pump ..................................................... . Remote Hydraulic Valves ............................................ . Flow Divider and PTO Control Valve Prior to P.I.N. 9937985 ............ . Flow Divider and PTO Control Valve P.I.N. 9937985 and After .......... . Differential Lock Solenoid .....................................•...... H itch System ....................... , ................................. . Break-Away Couplings and Portable Cylinder ......................... . ACCESSORIES Troubleshooting - Air Conditioning System ........................... . Gauging and Testing Air Conditioning System ........................ . Compressor Isolation, Removal, Installation and Evacuation -Discharging, Evacuation and Charging the Air Conditioning System .... . Servicing Air Conditioner Components ............................... . Servicing the Cab Blower ............................................ . Operator Seat Adjustments - Non Air/Oil .............................. . Operators Seat - Air/Oil .............................................. . Removal of Hood, Grill and Side Panels ............................... . Cab Removal ........................................................ . P~daland Lever Adjustments ......................................... . HOW IT WORKS Digital Instrument Cluster ............................................ . Electrically Actuated and Hydraulic Operated 12 and 24 Speed' Power Shift .................................................... . Case CON TROL Hydraulic .......................................... .

FORM NUMBER

8-26780 8-24501 8-20980 8-24820 8-24491 8-24660 8-24521 8-23441 8-20410 8-21290 8-20420 8-20430 8-23430 8-26710 8-23420 8-26720

8-24670 8-20531 8-20540 8-24470 8-24450

8-26940 8-20560 8-26630 8-24570 8-20591 8-20601 8-20610 8-20620 8-26690 8-24690 8-24610 8-20640

8-20650 8-20660

8-20670 8-24770 8-25580 8-24750 8-25511 8-20710 8-24511 8-24680

8-26550

8-24731 8-21350

Printed in U.S.A.

f::

It

)

.( \ )

SECTION

1211 1214 1220 4201 4205 4215 4220 4230 4240 5210 6205 6220 6260 6265 8201 8205 9245 9250 14205

SECTION 4201 4205 4215 4220 4230 4240 5210 6420 8205 9245

11-85

Update Package for 2094 and 2294 Tractor

Service Manual

Contents of Update Package

DESCRIPTION Binder Sticker Table of Contents General Specifications - 3294 Tractor Lubrication - 3294 Tractor Engine Specifications - 3294 Tractor Electrical System Troubleshooting Instrument Cluster Troubleshooting Power Shift Electrical Wiring Diagram Cab Electrical Wiring Diagram Starting Motors - Nippondenso Delco-Remy Alternator System Steering Column, Pump and Valve Troubleshooting - Power Shift Transmission Torque Limiter Clutch Differential and Drive Shaft - ZFAxies Front Axle and Planetaries - ZFAxies Hydraulic Schematic ' Testing Tractor Hydraulic System Servicing the Cab Blower Operators Seat - Air/Oil Digital Instrument Cluster

Remove and Discard

DESCRIPTION Electrical System Troubleshooting Instrument Cluster Troubleshooting Power Shift Electric Wiring Diagram Cab Electrical Wiring Diagram Starting Motors Delco-Remy Alternator System Steering Column, Pump and Valve Torque Limiter Clutch Testing Tractor Hydraulic System Servicing the Cab Blower

FORM NUMBER 8-24851 8-24901 8-26970 8-26980 8-20841 8-26500 8-26470 8-24342 8-24371 8-25980 8-25690 8-20341 8-26780 8-20980 8-26710 8-26720 8-26940 8-26630 8-25580 8-25511 8-26550

FORM NUMBER 8-22580 8-24970 8-24341 8-24370 8-21420 8-21430 8-20340 8-20481 8-20571 8-20690

FRONT WHEEL TREAD POSITIONS

(Concave Side of Wheel Toward Tractor)

1-1/4 in. (31.8 mm) OFFSET

W8L-16 WHEEL RIM

10.00-16 & 11.00-16 TIRE

NO OFFSET

W11L-16.1 WHEEL RIM

14L-16.1 TIRE

0"--

~ CENTERLINE OF TRACTOR

60 - 88 INCH 63-91 INCH (1 524 - 2 235 mm) (1 600-2 311 mm)

AXLE POSITIONS IN INCHES AND MILLIMETRES

1210-15

NOTE: The axle positions are given from the narrow setting to the wide setting in increases of four inches (101.6 mm).

NOTE: Put oil on the threads of the wheel bolts and tighten the 9/16 inch diameter front wheel bolts to a torque of 85 to 100 Ib ft (115.3 to 135.6 Nm)(11.5 to 13.6 kgm). Tighten the 5/8 inch diameter front wheel bolts to a torque of 115 to 130 Ib ft (156 to 176 Nm)(15.6 to 17.6 kgm).

Rae 8-24830 Printed in U.S.A.

2215-42

STEP 139

SEAL RING PAPER SPACER

'\..

Put petroleum jelly on the side of the seal ring that is not split and install the seal ring as shown in the diagram. Install the exhaust paper spacer on the exhaust elbow. Assemble the exhaust elbow to the turbocharger with the mounting bracket. Hold the paper spacer tight against the turbocharger.

NOTE: During the run-in of the engine, the paper spacer will burn up and leave a gap between the turbocharger and the exhaust elbow. Following run-in, this gap must be 0.020" to 0.040" (0.508 to 1.016 mm) all the way around the exhaust elbow casting.

Rae 8-20140

STEP 140

I nstall the bolts and washers that hold the exhaust elbow.

NOTE: The bolts for the mounting bracket must engage the water manifold freely to prevent the turbocharger outlet from receiving a load.

Printed in U .S.A .

Install the air filter assembly. See Section 2275 or 2375 of this Service Manual for installation.

STEP 142 Start and operate the engine for about one hour, under load if possible, to completely warm up the engine and seat the head gaskets. See Section 1220, 1320 or 1420 of the Service Manual for Runln Instructions.

STEP 143 After the engine has been run for one hour, remove the breather tube and cylinder head covers. The cylinder head bolts and rocker arms must be tight­ened to the given torques. The valves must be adjusted again. These functions must be made while the engine is hot.

Rae 8-20140

2215-43

STEP 144

BOLT TORQUE SEQUENCE

Turn back each cylinder head bolt, separately, 1/4 of a turn and tighten to a torque of 210 ft. Ibs. (285 Nm)(28.5 kgm). Follow the sequence shown in the inset.

IMPORTANT: Do not turn back all the bolts at the same time. Check the torque again to make sure that all the bolts have held the 210 ft. Ibs. (285 Nm)(2B.5 kgm).

STEP 145

Tighten the rocker arm bracket studs and nuts to make sure that the studs and nuts have kept the 40 to 45 ft. Ibs. (54 to 61 Nm)(5.4 to 6.1 kgm) torque.

Printed in U.S.A.

2215-44

Turn the engine over until the timing pointer is aligned with the Top Dead Center timing mark on the crankshaft pulley.

Check the push rods on the Number One cylinder for looseness. If the push rods are loose, the Num­ber One cylinder will be at Top Dead Center on the compression stroke. If the push rods are tight, turn the engine over one complete revolution and align the timing pointer with the Top Dead Center mark on the crankshaft pulley.

ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE Hot Setting With Engine Stopped

STEP 148

6 5 4 3 E I lEE I lEE I IE

~. 0 0 O~. 0 0 O~. 0 00

. 0 . o . . 0 . 0 .. . 0. o. . .. 0 · · · . . . ·0 ·· . .. 0 · : · ... . ·0 · · ... 0 · · · .. . · 0·· .. ......

NUMBER ONE CYLINDER TOP DEAD CENTER COMPRESSION STROKE

Check and adjust the intake and exhaust valves as the arrows show below. Valve Clearance, Hot: INTAKE VALVES - 0.015"

(0.381 mm) EXHAUST VALVES - 0.025"

(0.635 mm)

Rae 8-20140

STEP 149 Turn the engine over one complete revolution and align the timing pointer with the Top Dead Center mark on the crankshaft pulley.

6 5 4 3

FANt 2 1

E I lEE I lEE I IE

~. 0 . 0 o~. 0 . . 0 o~ . . 0 . . 0 0 . 0. o . . 0. o .. 0 . o . . . . 0 · ··· . ·0 ·· . .. 0· · ·· . ·0 ·· · ··0 · · . · 0 ··

e e e .......... NUMBER SIX CYLINDER TOP DEAD CENTER

COMPRESSION STROKE

Check and adjust the intake and exhaust valves as the arrows show below.

Valve Clearance, Hot: INTAKE VALVES - 0.015" (0.381 mm)

EXHAUST VALVES - 0.025" (0.635 mm)

Printed in U.S.A .

2255-14

STEP 7

Lift the thermostats from the water manifold .

Thermostat Inspection

STEP 8

Check thermostats for correct operation. Put ther­mostats in a container of hot (Approximately 175° F) (79° C) water. Thermostats must be com­pletely open at 202° F (94°C). Replace thermostats that do not operate correctly.

Rae 8-20180

Thermostat Installation

STEP 9

Install thermostats in manifold. Make sure ther­mostats point up.

Printed in U.S.A .

2290-6

Adjust the cutter size. You must use the cutter with the square face. Do not use the cutter with the tapered face. Put the cutter in the micrometer. The set screw in the cutter must be in the up position. The cutter edge must be against the stationary shaft.

Loosen the set screw in the cutter.

Adjust the micrometer to the correct bore size for the engine block that you are working on. Hold the cutter tight against both surfaces of the micro­meter. See the chart below to find the cutter size adjustment for a given engine bore size. For exam­ple, a 4-3/8" (111 .125 mm) bore in an engine block will require the cutter to be adjusted 5" (127 mm).

LOWER BORE BUSHINGS AND BORE DIAMETER SPECIFICATIONS

ENGINE BUSHING BUSHING INSTALLATION BORE PART BORE SIZE SIZE NUMBER +/-0.005"(+/-0.127 mm)

4.125" (104.775 mm) A150325 4.8125" (122.2375 mm)

4.375" (111.125 mm) A150326 5.0000" (127.0000 mm)

4.625" (117.475 mm) A150327 5.2500" (133.3500 mm)

NOTE: The micrometer is a direct reading micro-meter. The bore size will be what the micrometer measures.

Rae 8-21170 . - -8 Printed in U.S.A .

STEP 47

Install the drill and the universal drive on the drive shaft of the tool.

Operate the drill until the depth standard collar makes contact with the sprockat. There will be an increase in the drill speed when the collar makes contact with the sprocket.

Rae 8-21170

2290-13

STEP 49

MARK ON SPROCKET --",,,,..;::=~~ . .

Find the mark on the main shaft sprocket. Place the mark between you and the main shaft. Loosen the knob on the main shaft. Pull on the knob to fully retract the cutter. Tighten the knob on the main shaft.

Remove the retaining bolts and plates. Tilt the tool towards you and lift the tool out of the cylinder bore. This procedure will make sure that the cutter leaves the bore freely and prevents damage to the cutter.

Printed in U . S .A.

2290-14

Inspect the machined bore. There will be about 1/8" (3 .175 mm) of material between the end of the machined bore and the bottom surface of the lower bore.

NOTE: The engine block does not have to be dis­carded if the lower bore is part way or all the way cut through. The lower edge of the repair bushing must be set at 9.10 to 9.12" (231.1 t.o 231.6 mm).

Clean the bore and remove rough areas with emery cloth so that the repair bushing can be easily in­stalled.

The lower bore bushings are available from Ser­vice Parts Supply. See the chart below for the cor­rect part number.

LOWER BORE BUSHINGS AND BORE DIAMETER SPECIFICATIONS

ENGINE BUSHING BUSHING INSTALLATION

BORE PART BORE SIZE

SIZE NUMBER +/-0.005" (+/-0.127 mm)

4.125" (104.775 mm) A150325 4.8125" (122.2375 mm)

4.375" (111.125 mm) A150326 5.0000" (127.0000 mm)

4.625" (117.475 mm) A150327 5.2500" (133.3500 mm)

Rae 8-21170 Printed in U.S.A.

Use a cloth to clean the bushing.

Spray the outside of the bushing with Loctite

Primer T (Case Part Number 817429). Let the com­pound dry for approximately three minutes.

Apply a narrow band of special Loctite (Case Part

Number A 150328) completely around the outside

of the bushing.

Rae 8-21170

2290-15

STEP 57

Push the bushing through the upper bore. There will be some distortion in the bushing as the bush­ing is pushed through the bore.

STEP 58

Install the bushing on top of the bore.

NOTE: Make sure that the inside chamfer on the

bushing is facing towards the top of the cylinder block.

Printed in U.S.A.

2290-30

RECONDITIONING THE UPPER COUNTERBORE AREA FOR THE CYLINDER SLEEVE

Using The Upper Counterbore Tool Set

STEP 118

UPPER COUNTERBORE TOOL SET (CAS - 10138)

The upper counterbore tool set (CAS -10138) comes complete with three carbide cutters and plates. This tool is used to cut the sleeve counter­bore area on the Case 4-1/8" (104.775 mm), 4-3/8" (111.125 mm) and 4-5/8" (117.475 mm) bore en­gines.

SPECIAL PLATE AND CUTTER FOR 5" BORE ENGINE

A special cutter and plate (CAS-10140) is available for cutting the sleeve counterbore area on the Case 5" (127.000 mm) bore engine. This special cutter is not part of the upper counterbore tool set (CAS-10138). Order the special cutter separately.

Rae 8-21170

STEP 119 The upper counterbore area for the cylinder sleeve must be machined if:

the seat for the sleeve is not even.

the seat for the sleeve is tilting down.

the sleeve protrusion is riot correct.

NOTE: A sleeve seat that is not even or a sleeve seat that is tilting down can cause cracks in the sleeve flange.

Printed in U .S . A .

Shims for correcting sleeve protrusion are avail­able in thickness of 0.005" (0.127 mm) and 0.010" (0.254 mm) for the 4-1 /8" (104.775 mm) , 4-3/8" (111.125 mm) and 4-5/8" (117.475 mm) bore en­gines.

Shims are available in thickness of 0.20 mm, 0.25 mm, 0.30 mm, 0.50 mm and 0.75 mm for the 5" (127.000 mm) bore engines.

The top surface of the cylinder block must be clean. Remove dirt and gasket material.

Rae 8-21170

2290-31

The top surface of the cylinder block must be flat and free of rough areas which can result in a seri­ous cutting error. Use emery cloth or a flat file to smooth the top surface.

The bottom surface of the tool must also be clean, flat and free of rough areas.

Select the cutter plate for the correct bore size. The bore size is found on the top of each cutter plate.

Printed in U . S . A .