2094, 2294, & 4 Wheel Drive Diesel Volume 1 of 5

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1 J.I. Case Service Manual 2094, 2294, & 4 Wheel Drive Diesel Volume 1 of 5 Service Manual 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. CA-S-2094,2294+

2 ( r,~. \.,J-: SERIES SECTION ( ) 2255 '".' 2265 ""-~ ( \ J ~/ TABLE OF CONTENTS 2094,2294 AND 3294 TRACTORS DESCRIPTION GENERAL General Specifications Tractor General Specifications Tractor.... General Specifications Tractor.... Lubrication Tractor Lubrication Tractor Lubrication 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 and 3294 Tractors.... Air Cleaner System, 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 , ' : , J lease ATenneco Company Printed in U,S:A.. :.'tb

3 SERIES SECTION 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 and 1000 RPM.... Hydraulic PTO 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 Flow Divider and PTO Control Valve P.I.N 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 f:: It ) Rae Printed in U.S.A.

4 11-85 Update Package for 2094 and 2294 Tractor Service Manual Contents of Update Package.( \ ) SECTION DESCRIPTION Binder Sticker Table of Contents General Specifications Tractor Lubrication Tractor Engine Specifications 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 FORM NUMBER Remove and Discard SECTION 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

5 FRONT WHEEL TREAD POSITIONS (Concave Side of Wheel Toward Tractor) 1-1/4 in. (31.8 mm) OFFSET W8L-16 WHEEL RIM & TIRE NO OFFSET W11L-16.1 WHEEL RIM 14L-16.1 TIRE 0"-- ~ CENTERLINE OF TRACTOR INCH INCH ( mm) ( mm) AXLE POSITIONS IN INCHES AND MILLIMETRES 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 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 Printed in U.S.A.

6 STEP 139 STEP 140 SEAL RING PAPER SPACER '\.. 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. 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 mm) all the way around the exhaust elbow casting. Rae Printed in U.S.A.

7 STEP 144 BOLT TORQUE SEQUENCE 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. 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. Rae Printed in U.S.A.

8 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. STEP 148 ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE Hot Setting With Engine Stopped STEP 149 Turn the engine over one complete revolution and align the timing pointer with the Top Dead Center mark on the crankshaft pulley FANt 2 1 E I lee I lee I IE... ~ o o~ o 0. o e e e o~ E I lee.. I lee I IE ~. 0 0 O~. 0 0 O~ o o : NUMBER ONE CYLINDER TOP DEAD CENTER COMPRESSION STROKE 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 " (0.381 mm) EXHAUST VALVES " (0.635 mm) Check and adjust the intake and exhaust valves as the arrows show below. Valve Clearance, Hot: INTAKE VALVES " (0.381 mm) EXHAUST VALVES " (0.635 mm) Rae Printed in U.S.A.

9 STEP 7 Thermostat Installation STEP 9 Lift the thermostats from the water manifold. STEP 8 Thermostat Inspection Install thermostats in manifold. Make sure thermostats point up. 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 Printed in U.S.A.

10 Loosen the set screw in the cutter. 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. 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" ( 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"(+/ mm) 4.125" ( mm) A " ( mm) 4.375" ( mm) A " ( mm) 4.625" ( mm) A " ( mm) NOTE: The micrometer is a direct reading micrometer. The bore size will be what the micrometer measures. Rae Printed in U.S.A.

11 STEP 47 STEP 49 MARK ON SPROCKET --",,,,..;::=~~.. Install the drill and the universal drive on the drive shaft of the tool. 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. 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 Printed in U. S.A.

12 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. The lower bore bushings are available from Service Parts Supply. See the chart below for the correct part number. 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 mm). Clean the bore and remove rough areas with emery cloth so that the repair bushing can be easily installed. LOWER BORE BUSHINGS AND BORE DIAMETER SPECIFICATIONS ENGINE BUSHING BUSHING INSTALLATION BORE PART BORE SIZE SIZE NUMBER +/-0.005" (+/ mm) 4.125" ( mm) A " ( mm) 4.375" ( mm) A " ( mm) 4.625" ( mm) A " ( mm) Rae Printed in U.S.A.

13 STEP 57 Use a cloth to clean the bushing. 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 Spray the outside of the bushing with Loctite Primer T (Case Part Number ). Let the compound dry for approximately three minutes. Install the bushing on top of the bore. Apply a narrow band of special Loctite (Case Part Number A ) completely around the outside of the bushing. NOTE: Make sure that the inside chamfer on the bushing is facing towards the top of the cylinder block. Rae Printed in U.S.A.

14 RECONDITIONING THE UPPER COUNTERBORE AREA FOR THE CYLINDER SLEEVE Using The Upper Counterbore Tool Set STEP 118 STEP 119 The upper counterbore area for the cylinder sleeve must be machined if: UPPER COUNTERBORE TOOL SET (CAS ) The upper counterbore tool set (CAS ) comes complete with three carbide cutters and plates. This tool is used to cut the sleeve counterbore area on the Case 4-1/8" ( mm), 4-3/8" ( mm) and 4-5/8" ( mm) bore engines. the seat for the sleeve is not even. the seat for the sleeve is tilting down. 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" ( mm) bore engine. This special cutter is not part of the upper counterbore tool set (CAS-10138). Order the special cutter separately. 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. Rae Printed in U. S. A.

15 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" ( mm), 4-3/ 8" ( mm) and 4-5/8" ( mm) bore engines. 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. 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" ( mm) bore engines. The bottom surface of the tool must also be clean, flat and free of rough areas. The top surface of the cylinder block must be clean. Remove dirt and gasket material. Select the cutter plate for the correct bore size. The bore size is found on the top of each cutter plate. Rae Printed in U. S. A.

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