1978–1985 Case/International 2090, 2290, 2390, 2590, 2094, 2294, 2394, 2594 Tractor Shop Manual

This shop manual covers service and repair for 1978–1985 Case/International 2090, 2290, 2390, 2590, 2094, 2294, 2394 and 2594 tractors, with mechanical and power shift transmission coverage.

• Engine overhaul: Cylinder head and block service, wet cylinder sleeves, pistons, crankshaft bearings, timing gears, lubrication checks and valve adjustment references.

• Diesel fuel and cooling: Bosch injection pump timing, injector testing and overhaul, turbocharger inspection, thermostat checks, radiator removal and water pump service.

• Transmission service: Master clutch and torque limiter work, mechanical gearbox rebuilds, power shift clutch packs, planetary assemblies, control valves and pressure testing.

• Axles, steering and brakes: Front axle pivots, Carraro and ZF drive axles, power steering, differential lock, final drives, park lock and brake bleeding.

• Hydraulics and PTO: Pump and compensator tests, remote valve service, independent PTO repairs, hitch control adjustments, lift cylinders and rockshaft overhaul.

• Electrical equipment and cab: Alternator testing and overhaul, starter test specifications, solenoid diagnosis and cab removal and installation.

The manual is suited to experienced agricultural technicians and mechanically experienced owners with suitable lifting equipment, measuring tools and hydraulic test equipment.

Engine, Injection and Turbocharger Service

Engine procedures distinguish cylinder-head work, staged head-bolt tightening and retorquing from wet-liner, piston and crankshaft inspection. The tappet adjustment chart and timing-gear alignment details support valve-train work; bearing dimensions distinguish the smaller and larger tractor groups.

Fuel-system scope: Bosch pump coverage includes removal, installation, bleeding, timing and minor adjustments. Governor service beyond minor speed adjustments is referred to an authorized Bosch service station. Injector opening-pressure, spray-pattern and leakage tests use a nozzle tester, with CAS-10091 identified in the manual.

Injector overhaul notes explain how nozzle rotation during cap-nut removal can damage dowels or the valve stop. The Garrett (AiResearch) T04B turbocharger section covers clearance checks and overhaul, including shaft-bending risks during compressor-nut work. Cooling-system procedures address thermostat testing and water pump disassembly.

Mechanical Gearboxes and Power Shift Diagnosis

Mechanical-transmission chapters cover clutch hydraulics, gear lash, intermediate-shaft shim selection and gearbox assembly. Power shift coverage extends to clutch packs, planetary drives and hydraulic control valves, with separate procedures for manual and solenoid-operated controls.

A three-speed power shift cutaway and clutch-application charts show internal relationships; the optional six-speed unit has separate Hi/Low clutch coverage. C-2/C-3 retard-valve synchronization uses the CAS-1072 clutch monitor, while the later solenoid-controlled system has its own diagnostic checks and CAS-1712 monitor reference.

Axles, Steering, Brakes and PTO

Carraro and ZF axle sections cover pivot housings, hubs, bearings and gear adjustments. The steering-spindle exploded view, pivot-pin section and steering hydraulic schematic connect component positions with circuit operation. Ross steering tests distinguish hand-pump slip and cylinder leakage.

Rear drivetrain chapters address differential and final-drive overhaul, differential-lock controls and park-lock mechanisms. Wet-disc brake coverage includes pressure checks, control-valve service and bleeding. Independent PTO sections cover clutch, brake and shaft service for the documented single- and dual-speed arrangements.

Hydraulic Fault Isolation, Hitch Controls and Electrical Tests

Hydraulic procedures cover charge, gear and piston pumps, flow checks and compensator pressures. Power shift leakage tests relate clutch engagement to leakage readings, helping distinguish an individual clutch fault from losses elsewhere in the shared hydraulic circuits.

Hitch and remote valves: Coverage includes remote-valve flow control and detent release, hitch load tests, linkage adjustments, single- and dual-cylinder layouts, and rockshaft repairs. Hitch testing identifies the CAS-1455 fixture.

Delco Remy alternator procedures include regulator, diode, rectifier and rotor checks. Starter coverage provides no-load specifications and solenoid fault diagnosis; it does not provide a starter teardown. Cab removal and installation are covered separately.

Servicing agricultural equipment involves heavy components and highly pressurized hydraulic systems. Always follow standard shop safety practices and the complete procedures in the manual before teardown or hydraulic testing.

A Sample of Engine and Fluid Service Data

These examples are a small selection of the manual's specifications. Compression at cranking speed is listed as 400 psi (2758 kPa) for all covered models.

Transmission and hydraulic capacity is 100 US qt (94.6 L) for 2090, 2290, 2094 and 2294, versus 128 US qt (121.1 L) for 2390, 2590, 2394 and 2594. Cooling capacity is 38 US qt (36 L) for the first group and 44 US qt (41.6 L) for the second.

Bosch injection pump timing is 27° BTDC for the 504BD and 25° BTDC for the 504BDT.

PDF Search, Navigation and Included Pages

Text search and diagram detail: The PDF includes searchable OCR text, although recognition errors can affect results. Bookmarks are only partly functional; the printed index provides paragraph references. Small hydraulic schematic labels generally require enlargement, and some lettering remains soft. Electrical illustrations support component tests; complete tractor wiring diagrams are not included.

The download contains one printable PDF with 118 pages total: three opening title/index pages, one condensed service-data page and 114 pages of technical procedures and illustrations. These opening and reference pages are already included in the total.