i inntteerrnnaattiioonnaall hhaarrvveesstteerr service manual · 2017. 11. 6. · ih-s-510,515...

IH-S-510,515

IInntteerr nnaattiioonnaallHHaarr vveesstteerr

Service Manual510 & 515

Front End Loader

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF INTERNATIONAL HARVESTER OR IT’S SUCCESSORS. INTERNATIONAL HARVESTER 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

http://www.jensales.com/products/international-harvester-front-end-loader-service-manual-ih-s-510-515.html

SECTION INDEX

This manual is divided into major sections covering various components of the 510/515 loaders. These sec-tions are also indexed by title with thumb index tabs as shown below and to the right. To use this manual, grasp the right-hand side of book between thumb and fingers. Bend book back and find the pages containing the cor-responding section index tab. Section identification is also contained in the upper corner of each page.

This manual has been prepared to help you operate and maintain your machine with utmost efficiency and safety. Read this manual thoroughly and learn your machine before you attempt to operate it.

SECTION 1 - GENERAL

SECTION 2 - ENGINE

SECTION 3 - ELECTRICAL SYSTEM

SECTION 4 - COOLING SYSTEM

SECTION 5 - LOADER LINKAGE HYDRAULIC SYSTEM

SECTION 6 - STEERING SYSTEM

SECTION 7 - TRANSMISSION AND TORQUE CONVERTER

SECTION 8 - BRAKES

SECTION 9 - DRIVE SHAFTS

SECTION 10 - DIFFERENTIALS

SECTION 11 - AXLES

SECTION 12 - CHASSIS

II II II II II II II II II II II

-


INTRODUCTION Page 1

\.e\t~

Front--.. CE-JJJ948

Fig. 1.510 PAY Loader

Cf-,'296T

Fig. 2. 515 PAY Loader


GENERAL

CONTENTS

SECTION 1 CONTENTS PAGE

PAGE

SPECIFICATIONS ............................................................................... 1 GENERAL SAFETY PRECAUTIONS .............................................................. 6 RECOMMENDED BEARING PROCEDURES

NEW BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 6 BEARING REMOVAL ........................................................................ 6 CLEANING .................................................................................. 7 INSPECTION ................................................................................ 7 II BEARING INSTALLATION ................................................................... 7 HEATING BEARINGS FOR INSTALLATION................................................... 8 ADJUSTMENT ......................... , . .. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

fH LIQUID GASKET PROPERTIES ................................................................................ 8 APPLICATION ................................................................................ 8

LOCTITE RETAINING AND SEALING COMPOUNDS GENERAL

COMPOUND DESCRIPTION ..........................•.................................. 9 LOCTITE GRADES (General Usage) ...................................................... 9 TEMPERATURE RANGE ................................................................. 9

SURFACE PREPARATION PLAIN AND PHOSPHATE COATED PARTS ............................................... 9 ZINC OR CADMIUM PLATED PARTS OR FOR RAPID HARDENING ....................... 9 DRAWBAR STUDS OR SPECIAL STUD APPLlCAT!ON .................................... 9 FACE SEALANT (Plastic Gasket) ......................................................... 9

APPLICATION CAPSCREWS AND PIPE THREADS ...................................................... 9 STUDS .................................................................................. 9 FACE SEALANT (Plastic Gasket) ......................................................... 10

SETTING TIME (Before Placing in Operation) ................................................. 10 REMOVAL ................................................................................... 10 APPLICATION AT LOW TEMPERATURES .................................................... 10

TORQUE VALUES FOR STANDARD FASTENERS ................................................. 10 SPECIAL TORQUES ............................................................................. 10 TORQUE VALUES FOR HOSE CLAMPS .......................................................... 11 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS ................................... ;...... 11 TORQUE VALUES FOR HYDRAULIC FITTINGS ................................................... 12


SPECIFICATIONS 510 PAY Loader

A

GENERAL

!-----G ----I

~----------F--~------------~ 1----------E ---------1

Fig. 1. General Dimensions

J

SECTION 1 Page 1

A. Height to top of cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . .. 3.14m (123.5") B. Reach at maximum height and 45° dump angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.92m (36.5") C. Dump clearance at maximum height and 45° dump angle................. .......... 2.76m (108.5") D. Height to bucket pivot ............................................................... 3.33m (131") E. Overall length with bucket on ground .............................................. S.30m (208.5") F. Overall length with bucket at carry ............................................... " 5.22m (205.5") G. Wheelbase........................................................................... 2.44m (96") H. Ground clearance .................................. , .............. " •........ '" . .. 0.45m (17.5") J. Maximum height ...........•...................................................... 4.33m (170.0")

Width (at tires) ..........•....................... , ........... , ....... '" ...... " ...... , 2.22m (87.5") Width (bucket) .... ~. . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.33m {92.0"} Turning radius - outside corner of bucket....... .... .................................. 4.90m (192.5") SAE bucket capacity:

Rated cu, yds. (General Purpose) .................................................. 1.0m3 (1.25 yd3) Struck cu. yds. (General Purpose) . . .. . . . . .. .. . . .. . .. . . . . . . .. . .. .. . . .. . . .. . . . ... .. . .. 0.8m3 (1.0 yd3 ) Rated cu. yds. (Basic stockpile) .................................................... 1.2m3 (1.50 yd3 ) Struck cu. yds. (Basic stockpile). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.0m3 (1.30 yd3) Rated cu. yds. (Stockpile) . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . • . . • . . . . . . . . . . . . • . . . .. 1.3m3 (1.75 yd3) Struck cu. yds. (Stockpile) ........................................................ 1.13m3 (1.50 yd3 )

Basic operating weight (no attachments) W/ROPS ........................•........ 6260 Kg (13775 Ibs) Shipping weight ...... " . . . . . . . . . . . . .. . ............•....................... I ••• •• 6090 Kg (13400 Ibs)

Engine Make and model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.H. 0-268 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . .. Naturally aspirated Number of cylinders .......................................•.. ~". . . . . . . . . . . . . . . . . . • . . . . . . . . . . • . . .. 4 Bore ......................................................................... , . . 100.0mm (3.937")


SECTION 2 Page 6

ENGINE

2. Disconnect ball joint (1) from pump lever (2). Loosen jam nut (3).

3. Hold pump lever down all the way (towards front of machine). Adjust the ball joint in or out as neces-sary to align with the mounting hole in the pump lever.

4. Secure the ball joint to the lever and tighten the jam nut. Remove the weight from the accelerator pedal.

Fig. 9. Accelerator Linkage Adjustment

1. Ball Joint 4. Clevis 2. Pump Lever 5. Jam Nut 3. Jam Nut

5. If adjustment at the pump lever is not sufficient disconnect clevis (4) from the pedal and loosen jam nut (5).

6. Adjust the clevis out in order to increase the ped-al stroke.

7. Connect the clevis to the pedal and tighten jam nut.

Starting Aid and Engine Shutdown Control Cable AdJustment

1. Pull the control cable handle out all the way (en-gine shutdown position).

2. Disconnect the ball joint from the pump lever and loosen the ball joint jam nut.

3. Pull the pump lever back all the way and adjust the ball joint in or out as necessary to align with the mounting hole in the lever.

4. Secure the ball joint to the lever and tighten the jam nut.

Fuel Line Suction Leak Test

1. Install a sight glass gauge in the low pressure fuel line between the final fuel filter and the fuel injec-tion pump.

2. Vent the fuel system as described in the Opera-tor's Manual.

3. Start the engine and check the sight glass. If bub-bles or a cloudy appearance is present in t11e glass stop the engine. Check all fuel line fittings and fil-ters for tightness. Vent the fuel system and perform test again.

4. After test is completed remove the sight glass, connect the fuel line and vent the fuel system.

Fuel Filters

Fuel Injection CE-J J2344 Pump

Fig. 10. Fuel Line Suction Leak Test Sight Glass

Air Induction Leak Test

1. Check the air cleaner hoses to be sure they are well fitted over the tubes and clamped securely. Hoses should fit over the tube ends about 3 times the width of the hose clamp.

,.--:.:


ENGINE SECTION 2 Page 7

2. Remove the air cleaner safety element and se-curely wind tape around the length of the filter to make it air tight. Install the sealed filter in the air cleaner housing. An air tight covering may be placed over the air cleaner stack instead of sealing the air cleaner element.

3. Seal off the engine exhaust tube.

4. Remove the plug in the air induction tube (tube between the air cleaner and engine). Install an air pressure supply with a regulating valve and a low pressure gauge in the tube (refer to Fig. 11).

Air supply

/ --

Air Induction--Tube

CE-JJ2B9J

Fig. 11. Air Induction Leak Test

SPECIFICATIONS

Service Information

5. Maintain 15-30 kPa (2-4 psi) air pressure in the in-duction system.

6. Coat all hoses and tube, connections, air cleaner body seams and the intake manifold with a sudsing soap and water solution. Check for air leakage. No leakage is permissible at the clean air side of the air cleaner and connections.

7. After leakage is corrected and testing is com-pleted remove all seals installed for this test and air pressure setup. Install the plug in the air induction tube.

515 PAY Loader (0-360)

DESCRIPTION

The following procedures cover the removal, instal-lation and related tests and adjustments for the In-ternational D-360, naturally aspirated, direct injec-tion diesel engine. This engine is a six cylinder (straight configuration), four cycle, direct starting, valve-in-head type and using a 24 volt starting system.

The engine is mounted to the transmission and the rear frame.

For detailed information on the repair of the engine, refer to Engine Service Manual 155-1524.

ENGLISH

Engine Water temperature - 0 F ...................................................... . Oil pressure - PSI ............................................................ . Governed sp~ed - RPM ..............................................•....•... Low idle - RPM .............................................................•. High idle - RPM ...............................•..............................

IH 0360

Min. Max.

150 180 45 60

2500 650 750

2600 2710


LOADER LINKAGE HYDRAULIC SYSTEM SECTION 5 CONTENTS PAGE

CONTENTS

PAGE GENERAL

DESCRIPTION ............................................................................. . 1 SPECIFICATIONS

SPECIAL TORQUES .............................. : ..................................... . 2 SERVICE INFORMATION ............................................................... . 3 SPRING TEST LOAD DATA ............................................................. . 3

SERVICE DIAGNOSIS .......................................................................... . 4 HYDRAULIC RESERVOIR ....................................................................... . 7 HYDRAUUC SUPPLY PUMP

DESCRI PTION ............................................................................. . 7 REMOVAL .................................................................................. . 7 DISASSEMBLY AND REASSEMBLY

VICKERS PUMP ........................................................................ . 7 TYRONE PUMP ......................................................................... . 7 HYDRECO PUMP ....................................................................... . 8

INSTALLATION ............................................................................ . 10 TEST AND ADJUSTMENT

STALL TEST ........................................................................... . 10 PUMP FLOW TEST ......................................................................... . 10

LOADER LINKAGE CONTROL VALVE DESCRIPTION ..... , ....................................................................... . 11 REMOVAL .................................................................................. . 12 DISASSEMBLY ............................................................................. . 13 INSPECTION AND REPAIR ................................................................. . 18 REASSEMBLY .............................................................................. . 18 INSTALLATION ............................................................................ . 19 TEST AND ADJUSTMENT

RELIEF VALVE TEST AND ADJUSTMENT ............................................... . 19 AUTOMATIC BOOM KICKOUT TEST .................................................... . 20 BUCKET LEVELER TEST ............................................................... . 20

BOOM CYLINDERS REMOVAL ............................................................... , .................. . 21 DISASSEMBLY ............................................................................. . 22 INSPECTION AND REPAIR ................................................................. . 23 REASSEMBLY .......•....................................................................... 23 INSTALLATION ............................................................................ . 24 TEST AND ADJUSTMENT .................................................................. . 24

BUCKET CYLINDER REMOVAL .................................................................................. . 24 DISASSEMBLY ............................................................................. . 25 INSPECTION AND REPAIR ................................................................. . 26 REASSEMBLY .............................................................................. . 27 INSTALLATION ............................................................................ . 28 TEST AND ADJUSTMENT

CYLINDER LEAKAGE TEST ............................................................. . 28

I


STEERING SYSTEM SECTION 6 CONTENTS PAGE

CONTENTS

PAGE GENERAL

DESCRIPTION ........................................•..................................... SPECIFICATIONS .....................................•.....................................

SPECIAL TORQUES ............................ _ ....................................... . SPRING TEST LOAD DATA .....................•........................................ SHIMS ............................................•..........•...............•..........

SERVICE DIAGNOSIS ......................................•................................ STEERING CONTROL VALVE

DESCRIPTION ..•.....................................•............•........................ REMOVAL ...........................................•.........•..................•.......... DISASSEMBLY ...........•......................••.•.............•.......................... INSPECTION AND REPAIR .........................................•........................ REASSEMBLY ............................................•.......................•.......... INSTALLATION ......................................•...•.......................•.......... ADJUSTMENT ................•.....................................•...................•....

STEERING CYLINDER RELIEF VALVE REMOVAL AND DISASSEMBLy ............................................................. . INSPECTION AND REPAIR ................................................................. . REASSEMBLY AND INSTALLATION ..............•...••...................................... ADJUST CYLINDER RELIEF VALVES ........................................................ .

STEERING CYLINDERS REMOVAL ..........................................••.....•..............•.................. DISASSEMBLY .................................................•............................ INSPECTION AND REPAIR ................................................................. . REASSEMBLY .............................................................................. . INSTALLATION ................................•.........................•.................. TEST AND ADJUSTMENT .....................•.............................................

STEERING COLUMN REMOVAL .................................................................................. . DISASSEMBLY .................................••..........................•................. INSPECTION AND REPAIR ..........•.•........•.•.•..................•...................... REASSEMBLY ..................................•............................................ INSTALLATION ...........................................••.......•................•.......

STEERING GEAR DESCRIPTION ..........•................... 0 ••• 00 •• 0 ••••• 0 • 0 •• 0' •• 0 •••••••••••••••••••••••• REMOVAL •.. o •• o •• 0 0 ••••••••••••••••••• 0 ••••• 0 •••• 0 0" 0 ••••••• 0 0 o. 000.0. 0 •••• 0 •••• 0 ••• 0 ••••• DISASSEMBLY ................................ 00 ••••••••• 0 ••• 0 •••••••• 0 ••••••••••••••••••••• INSPECTION AND REPAIR ......... 0 •••••••••••••• 0 ••••••••••••• 0 ••••••••••••••••••• 0 ••••••• REASSEMBLY .......... 0 ••••••••••• 0 •• 0 ••••••• 0 ••••• 0 0 •••••••••••••••••••••••••••••••• o ••••• INSTALLATION ....................................•........ 0 ••••••••• 0 •••••••••••••••••• ••• TEST AND ADJUSTMENT ..... 0 • 0 ••••••••••••••••••••••••• 0 •••• 0 •••• 0 o ••••••••••••••••••••• 0

STEERING LINKAGE INSPECTION 'AND REPAIR .....................•............................................ TEST AND ADJUSTMENT ...........................................................•.......

1 1 1 1 2 2

5 5 8 8 8 8 9

10 10 10 10

1 1 1 1 12 12 13 13

14 14 15 15 15

15 15 16 18 1 8 20 20

21 21

" ~ ~

" f. \1 ~ " ~~

f:~ :;; ~ f~ ;"

" ~

TRANSMISSION AND TORQUE CONVERTER SECTION 7 CONTENTS PAGE

CONTENTS

PAGE GENERAL

SPECIFICATIONS ........................................................................... 1 SERVICE INFORMATION ............................................. .................... 1 SPECIAL TORQUES ..................................................................... 1 SHIMS .................................................................................. 1 SPRING TEST LOAD DATA.............................................................. 2

SERVICE DIAGNOSIS ....................................................................... 2 TRANSMISSION

DESCRIPTION .............................................................................. 4 REMOVAL................................................................................... 7 DISASSEMBLY .............................................................................. 8 INSPECTION AND REPAIR .................................................................. 18 REASSEMBLY ............................................................................... 18 INSTALLATION ............................................................................. 24

TRANSMISSION CONTROL VALVE DESCRIPTION .............................................................................. 24 REMOVAL ................................................................................... 24 DISASSEMBLY .............................................................................. 25 INSPECTION AND REPAIR .................................................................. 27 REASSEMBLY ............................................................................... 27 INSTALLATION ............................................................................. 28

TRANSMISSION DISCONNECT SOLENOID VALVE DESCRIPTION .............................................................................. 28 REMOVAL ................................................................................... 29 DISASSEMBLY .............................................................................. 29 I INSPECTION AND REPAIR .................................................................. 30 REASSEMBLY ............................................................................... 30 INSTALLATION ............................................................................. 30

TORQUE CONVERTER DESCRIPTION .............................................................................. 30 REMOVAL ................................................................................... 31 DISASSEMBLY .............................................................................. 31 INSPECTION AND REPAIR .................................................................. 34 REASSEMBLy ............................................................................... 35 INSTALLATION ............................................................................. 37

TORQUE CONVERTER CHARGING PUMP DESCRIPTION .............................................................................. 37 REMOVAL ................................................................................... 37 DISASSEMBLY .............................................................................. 37 INSPECTION AND REPAIR .................................................................. 38 REASSEMBLY ............................................................................... 39 TESTS AND ADJUSTMENTS ................................................................. 39


BRAKES

CONTENTS

GENERAL


PAGE

DESCRIPTION .............................................................................. 2 SPECIFICATIONS ........................................................................... 2 SERVICE DIAGNOSIS ....................................................................... 3

SERVICE BRAKES REMOVAL AND DiSASSEMBLy.............................................................. 5 INSPECTION AND REPAIR .................................................................. 7 REASSEMBLY AND INSTALLATION.......................................................... 7 TEST AND ADJUSTMENT ................................................................... 8 BLEEDING AND FLUSHING ................................................................. 9

PARKING BRAKE DISASSEMBLY .............................................................................. 11 INSPECTION AND REPAIR .................................................................. 12 RELIN I NG BRAKE ........................................................................... 12 REASSEMBLY ......................................................................... ;..... 12 TEST AND ADJUSTMENT ................................................................... 12 PARKING BRAKE RUN-IN ................................................................... 13

MASTER CYLINDER DISASSEMBLY .............................................................................. 14 INSPECTION AND REPAIR .................................................................. 15 REASSEMBLY ............................................................................... 15


DRIVE SHAFTS

CONTENTS

GENERAL


PAGE

DESCRIPTION ............................................................................... 1 SPECIFICATIONS ............................................................................ 1 SERVICE DIAGNOSIS ........................................................................ 2

DRIVE SHAFTS REMOVAL .................................................................................... 2 DISASSEMBLY ............................................................................... 3 INSPECTION AND REPAIR ................................................................... 6 REASSEMBLY' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . .. 6 INSTALLATION .............................................................................. 7


DIFFERENTIALS

CONTENTS

GENERAL


PAGE

DESCRIPTION ......................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS ........................................................................... 2 SERVICE DIAGNOSIS ....................................................................... 3

STANDARD DIFFERENTIAL DISASSEMBLY .............................................................................. 4 INSPECTION AND REPAIR .................................................................. 7 REASSEMBLY ............•.................................................................. 7

NO-SPIN DIFFERENTIAL (IF EQUIPPED) DISASSEMBLY .............................................................................. 11 INSPECTION AND REPAIR .................................................................. 12 REASSEMBLY ................................................................................ 12

~:


AXLES

CONTENTS

GENERAL


PAGE

DESCRIPTION ............................................................................... 1 SPECIFICATIONS ............................................................................ 2 SERVICE DIAGNOSIS ....................................•................................... 2 REMOVAL ...............•.................................................................... 3 DISASSEMBLY ............................................................................... 4 INSPECTiON AND REPAIR ................................................................... 6 REASSEMBLY ................................................................................ 6 INSTALLATION .............................................................................. 8

II


i inntteerrnnaattiioonnaall hhaarrvveesstteerr service manual · 2017. 11. 6. · ih-s-510,515...

Documents