Serv

ice

Man

ual

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.

2390 & 2590 Volume 1 of 3

CA-S-2390+

SERIES SECTION 10

1210 1211 1212 1213 1220 1230 1250 1260 1270 1280

20 2201 2202 2210 2215 2225 2235 2245 2255 2265 2565 2275 2290

30 3210 3212 3213

40 4201 4210 4210 4220 4220 4230 4230 4235 4240 4280

50 5205 5210 5220 5230

I Reprinted I

CASE CORPORATION

GENERAL

TABLE OF CONTENTS 2390 AND 2590 TRACTORS

DESCRIPTION

General Specifications - 2390 Tractors ...........•... ' ................ . General Specifications - 2590 Tractors •.•.•...•...•................... Lubrication - 2390 Tractors .••••.......•.........•.....•.....•........ Lubrication - 2590 Tractors •...•.•...•.••....•.•.•......•..........•.. Engine Specifications 504BDT Engine ...•...........•.•.•...•......... Fuel System Specifications ..........•........•••...•..•...•...•...... Steering Specifications ....••.•..••.....•..•..••.•.................... Power Train Specifications ......•...•.........•.............•......•. Brake System Specifications .....•...•.....•........ , ................. . Hydraulic System Specifications ..................................... . ENGINES Trouble Shooting - 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 Bearing, Flywheel and Oil Seals ....•.....•........... Lubrication System - Oil Pump, Oil Pan and Heat Exchanger .......•.... Cooling System ...........•........................•..•..........•... Turbocharger - T04B ......•..............•........................... Turbocharger Failure Analysis ....................................... . Air Induction System ...........................•....•................ Reconditioning Engine Cylinder Block .............................. .. FUEL SYSTEM Fuel System and Filters ........•...................................... Robert Bosch Fuel Injection Pumps ....•.............•................ American Bosch Fuel Injectors ....................................... . ELECTRICAL Electrical System Troubleshooting .•...•.........••..• ' ............... . Tractor Electrical Wiring Diagram (Prior to P.I.N. 8841101) ..•........... Tractor Electrical Wiring Diagram (P.I.N. 8841101 and After) •........... Cab Electrical Wiring Diagram (Prior to Cab SN12013067) ............. . Cab Electrical Wiring Diagram (Cab SN12013067 and After) •........... Starting Motors - Delco Remy ........................................ . 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

8-20800 8-20810 8-20821 8-20831 8-20841 8-20850 8-20070 8-20870 8-20880 8-20890

8-20111 8-20120 8-20900 8-20140 8-20150 8-20160 8-20910 8-20180 8-20190 9-78235 8-20920 8-21170

8-20220 8-20230 8-20240

8-22580 8-20261 8-22640 8-20270 8-22650 8-21420 8-25980 8-20291 8-21430

8-20930

8-20950 8-20341 8-20351 8-20360

Rac 8-20792 Printed in U,S.A. (Revised) July. 1985

SERIES SECTION 60

62()1 6205 6210 6220 6225 6230 6235 6240 6245 6250 6255

70 7210 7215 7220

80 8202 8205 8210 8220 8225 8250 8255 8280 8290

90 9205 9215 9225

9235 9245 9250 9260

100 18201 18225

Rae 8-20792

DESCRIPTION POWER TRAIN Trouble Shooting - RPS-34 Power Shift Transmission and PTO ........ . Testing RPS-34 Power Shift Transmission and PTO ................... . Tractor Split (Between Torque Tube and Transmission) ............... . Torque Limiter Clutch ............................................... . Hydraulic Pump Drive ................................................ . RPS-34 Power Shift ................................................. . RPS-34 Control Valve and Linkage ................................... . Four Speed Transmission ........................................... . Hydraulic PTO ...................................................... . Rear Axles and Planetaries ............... : .......................... . Differential and Differential Lock ..................................... . BRAKES Power Assist Unit and Pedals ........................................ . Park Lock System ................................................... . Brake Cylinders ..................................................... . HYDRAULIC Trouble Shooting - Hitch System ..................................... . Testing Tractor Hydraulic System ........................... ; ......... . Hydraulic Oil Filters ................................................. . Hydraulic Charging Pump ........................................... . Hydraulic Pump .................................................... . Remote Hydraulic Valves .................................. : ......... . Flow Divider and PTO Control Valve ................................. . Hitch System ....................................................... . Break-Away Couplings and Portable Cylinders ........................ . ACCESSORIES Trouble Shooting - 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 ............................................ . Operators Seat Adjustments ......................................... . Removal of Hood, Grill and Side Panels .............................. . HOW IT WORKS Tractor Hydraulics System Oil Flows ................................. . Case CON TROL Hydraulics ........................................ .

FORM NUMBER

8-20370 8-20960 8-20970 8-20980 8-20990 8-21000 8-21010 8-21021 8-21030 8-21040 8-21050

8-21060 8-21070 8-21080

8-21090 8-21101 8-21110 8-21120 8-21131 8-20610 8-21140 8-21151 8-20640

8-20650 8-20660

8-20670 8-20680 8-20690 8-20700 8-20710

8-20750 8-21350

Printed in U.S.A. (Revised) July. 1985

2235-18

CRANKSHAFT AND MAIN BEARINGS

Removal

The engine must be separated from the torque tube before the crankshaft can be removed. See Section 2210 of the Service Manual for engine sep­aration.

STEP 63

Remove the torque limiter or master clutch from the flywheel. See Section 6220, 6320 or 6420 in this Service Manual for removal.

Rae 8-20160

Remove the engine oil pan and gasket. See Section 2245 of the Service Manual for removal.

Remove the engine flywheel.

Issued 8-78 Printed in U.S.A.

STEP 66

Remove the rear seal carrier.

Remove the fuel injector pump. See Section 3212 of the Service Manual for removal.

Remove the timing pointer.

Rae 8-20160

2235-19

Loosen the bolt that holds the pulley to the crank­shaft.

Remove the bolt, washer and spacer.

Issued 8-78 Printed in U.S.A.

3213-2

CAS-10091 DIESEL FUEL INJECTION NOZZLE TESTER (BENCH MODEL)

BOX WRENCH 12 POINT, 15 mm

CROWSFOOT WRENCH SNAP-ON TOOL AN-S50S-11 SNAP-ON TOOL AN-S50S-14

CAS-1357 COMPRESSION SPRING TESTER

Rae 8-20240

SPECIAL TOOLS

CAS-10033 TORQUE WRENCH 150 FOOT POUND

CROWSFOOT WRENCH SNAP-ON TOOL AN-S506-S

ORIFICE CLEANING WIRES 66-0036

65-0S7S

MAGNIFYING GLASS 66-0135

CAS-65-0476 ADAPTER ELBOW

TEST PUMP ADAPTER (TWO REQUIRED)

DEEP WALL SOCKET 12 POINT, 15 mm

CAS-1411 INJECTOR BORE CLEANING TOOL

CAS-10032 TORQUE WRENCH 200 INCH POUND

Issued 8-78 Printed in U.S.A.

4201-10

STEP

Solenoid Testing: 'Hold in" Coil Test

PROBLEM:

STARTER SOLENOID DOES NOT ENGAGE WHEN TRANSMIS­SION IS IN "PARK" (NO SOUND WHEN KEY SWITCH IS TURNED.

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PROCEDURE

a. Using the same test circuit as in Step 4B, remove the test wire between the solenoid "M" terminal and ground.

b. Adjust the variable resistor until the volt­meter has a reading of 10 volts.

c. The ammeter must have a reading of 12.7 to 14.3 amps.

a. Pull the engine fuel stop control out. b. Make sure thatthe tractor transmission is in

"PARK" c. Install a jumper wire across the neutral start

switch wires. d. Turn the key switch to the start position. e. Check starter operation.

ENGINE STOP CONTROL "START"

RESULT

If the results are not to the specifications in part "c" of the procedure, replace the solenoid and

Go back to Step 1 B

a. Starter turns over en­gine: (neutral start switch problem)

I Continue to Step 5B I b. Starter does not turn

over engine:

Connect the switch wires again and

I Continue to Step 5C I

Issued 4-80 Printed in U.S.A.

STEP PROCEDURE

Causes for neutral start switch problems: 1. Connections at switches have too much corrosion or are loose. 2. Switch ball has damage. 3. Switch shim adjustment not correct.

Checking "IGN" fuse: a. Connect one wire of a 12 volt test light to a

Rac 8-22580

good ground. b. Connect the other test light wire to one side

of the "IGN" fuse in the fuse panel. Check for test light illumination.

c. Move the test light wire connected to the fuse in part "b" to the other end of the fuse. Check for test light illumination.

ALSO TEST HERE

TRACTORS BEFORE P.I.N. 8841100

ALSO TEST HERE

TRACTORS AFTER P.I.N. 8841100

4201-11

RESULT

Repair or adjust as neces­saryand

[ Go back to Step 1 B

a. Test light does not illu­minate in either part "b" or "c" of the procedure:

I Continue to Step 5J I b. Tesl light illuminates in

both parts "b" and "c" of the procedure:

I Continue to Step 5D I c. Test light illuminates

when connected to one side of the fuse only: Replace the fuse and

Go back to Step 1 B

Issued 4-80 Printed in U.S.A.

STEP PROCEDURE

HIGH BEAM HEADLIGHTS AND FLOODLIGHTS CIRCUIT: a. Use the circuit diagram below to help find the problem. b. Check for bad fuses or bad light bulbs. c. Check for bad connections at the junction. d. Check for loose or bad ground connections. e. Check for broken wires. f. If floodlights are not working correctly and no problems in parts

"b" through "e", replace the floodlight relay for the bad circuit.

WIRING BEFORE P.I.N. 8841100

OPT. LIGHTING RELAy ...............

~ 40CBLACK~

~/ 3A ORANGE

OPT. REAR

FL7~' 2B RED/WHITE

4201-39

RESULT

Replace bad components, repair wiring as necessary and

Go back to Step 1 A

/44A DK. BLUE

........ ..,..--142 DK. GREENIWHITE

--CLUSTER HARNESS

TO 100 AMP CIRCUIT

_-------- BREAKER

SWAY I I! ~ CONNECTOR ~

142C DK. GREEN/WHITE "' ~ 142B DK. GREEN/WHITE

~ TRANSMISSION FORWARD HARNESS COMPONENTS

44C DK. BLUE

HARNESS 40 BLACK

NOTE: For wiring after P.I.N. 8841100, see next page.

Rae 8-22580

RH HEADLIGHT

Issued 4-80 Printed in U.S.A.

4201-46

STEP

@ TURN SIGNAL SWITCH ELECTRI­CAL CHECKS: Move the turn signal switch to the "OF'F" po­sition.

-"'0' -V'\' LIFT

Move the turn signal switch to the "LEFT" position.

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PROCEDURE

a. Connect one wire of a 12 volt test light to a good tractor ground.

b. Connect the other test light wire to each of the six terminals on the turn signal switch connector and check for test light illumina­tion at each terminal.

NOTE: The six terminal connector must be connected to the turn signal switch while test­ing and the lamp switch must be "OFF".

TURN SIGNAL SWITCH CONNECTOR

STEERING CONSOLE HARNESS

a. Connect one wire of a 12 volt test light to a good tractor ground.

b. Connect the other test light wire to each of the six terminals on the turn signal switch connector and check for test light illumina­tion at each terminal.

NOTE: The six terminal connector must be connected to the turn signal switch while test­ing and the lamp switch must be "OFF".

TURN SIGNAL

/SWITCH

STEERING CONSOLE HARNESS

RESULT

a. Test light only illumi­nates at terminal No. "2": Good,

I Continue to Step 7B I b. Test light illuminates at

any of the terminals ex­cept terminal No. "2": . Bad, replace the turn signal switch and

I Go back to Step 6A

a. Test light has constant illumination at termi­nals "1 ", "2" and "4" and has flashing illumina­tion at terminals "3" and "6": Good,

I Continue to Step 7C I b. Test light does not have

constant illumination at terminals "1", "2" and "4" or does not have flashing illumination at terminals "3" and "6" or has any type of illumina­tion at terminal "5":

Bad, replace the turn signal switch and

I Go back to Step 6A

Issued 4-80 Printed in U.S.A.

STEP

PROBLEM: "ENG OIL" LIGHT DOES NOT ILLUMI­NATE WITH THE KEY SWITCH "ON":

Checking "ENG OIL" light circuit:

Rae 8-22580

PROCEDURE

a. Move the key switch to the "ON" position, but do not start the tractor engine.

b. Remove the wire from the engine oil pres­sure switch.

c. Connect a test wire between the discon­nected wire and a good tractor ground.

d. Check for "ENG OIL" light illuminated.

"ON"

Q) KEY SWITCH

ENGINE HARNESS ~

TEST- ! WIRE

ENGINE OIL PRESSURE SWITCH

a. Use the circuit diagram below to help find the problem.

b. Check for a bad light bulb or bulb holder. c. Check for loose or bad connectins. d. Check for broken wires. e. Check printed circuit board on the back of

the instrument cluster for damage.

INSTRUMENT ENGINE

~/ CLUSTER OIL PRESSURE

1'1 :!~~~~~ ENGIN:W1TC

\

~ '\ iARNESS '- \

CLUSTE! 117"--------1 \ 3~DK. BLUE

CONNECTOR TERMINAL I NO. "7" TERMINAL "BS" ON

TRACTORS BEFORE BULKHEAD P.I.N.8841100 CONNECTOR

TERMINAL "CT" ON TRACTORS AFTER P.I.N.8841100

4201-53

RESULT

a. "ENG OIL" light illumi­nates: Replace the engine oil pressure switch and

I Go back to Step 1A I b. "ENG OIL" light does

not illuminate:

I Continue to Step 2B I

Replace bad components repair wiring as necessary and

[ Go back to Step 1A I

Issued 4-80 Printed in U.S.A.

4201-54

STEP

(0 PROBLEM:

"TRANS OIL" LIGHT DOES NOT ILLUMI­NATE WITH THE KEY SWITCH "ON":

Checking "TRANS OIL" light circuit:

Rae 8-22580

PROCEDURE

a. Move the key switch to the "ON" position, but do not start the tractor engine.

b. Disconnect the harness wires from the transmission oil pressure switch wires.

c. Connect a test wire between the two discon­nected harness wires.

d. Check for "TRANS OIL" light illumination.

"ON"

(/)~TCH

TRANSMISSION -­OIL PRESSURE SWITCH

a. Use the circuit diagram below to help find the problem.

b. Check for a bad light bulb or bulb holder. c. Check for loose or bad connections. d. Check for broken wires. e. Check for a bad ground connection. f. Check the printed circuit board on the back

of the instrument cluster for damage.

INSTRUMENT. CLUSTER

~ /

CLUSTER CONNECTOR

CLUSTER HARNESS

37DK \ BLUTHITE

TERMINAL "DY" ON TRACTORS BEFORE P.I.N.8841100

TERINAL "AX" ON TRACTORS AFTER P.I.N.8841100

/ 37ADK.

BlUE/WHITE

11-BULKHEAD -CONNECTOR I

TRANSMISSION TRANSMISSION HARNESS OIL

PRESSURE SWITCH

RESULT

a. "TRANS OIL" light illu­minates: Replace the transmis­sion oil pressure switch and

I Go back to Step 1 A

b. "TRANS OIL" light does not illuminate:

[ Continue to Step 3B I

Replace bad components, repair wiring as necessary and

Go back to Step 1 A

Issued 4-80 Printed in U.S.A.