3388, 3588, 3788, 6388, 6588 & 6788 Volume 1 of 2

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International Harvester Service Manual 3388, 3588, 3788, 6388, 6588 & 6788 Volume

WITHOUT THE AUTHORIZATION OF INTERNATIONAL HARVESTER OR IT S SUCCESSORS.

1 International Harvester Service Manual 3388, 3588, 3788, 6388, 6588 & 6788 Volume 1 of 2 Service Manual 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. IH-S-3388+

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3 Due to a continuous program of research and development, some procedures, specifications and parts may be altered in a constant effort to improve our products. When changes and improvements are made in our products, periodic revisions may be made to this manual to keep it up-to-date. It is suggested that customers contact their dealer for information on the latest revision. NOTE: Some illustrations in this manual show equipment not currently available. The illustrations are used primarily to cover serviceability and may not always represent production equipment. LIBRARY FILING INFORMATION File this manual, GSS , after Divider Tab GSS Destroy manual GSS CHASSIS 3388,3588,3788, 6388, 6588 & 6788 Tractors GSS w/revision 1 August, 1983 NOTE: Refer to the following service manuals for service information not contained in this manual: GSS-1052-C Testing and Servicing Electrical Equipment GSS and 400 Series Diesel Engines and Fuel System (American Bosch) GSS Basic Air Conditioning GSS-1281-K Clutches GSS-1492 Recharging Hydraulic Accumulators I

4 General Safe Work Rules.... Standard Torque Data for Nuts and Bolts.... Metric Converstion Tables... ".... Standard Torque Data for Hydraulic Tubes and Fittings.... Flangette Bearing Installation.... Special Service Tools Required.... Service Information System (S.I.S.).... IV VI VIII X XII XIII XVIII III

5 Section 1 AIC AND TRACTOR SPLITS Air Conditioning Specifications Efficiency Test Procedure Special Torques Air Conditioning Components Windshield Wiper Motor 1-10 Door Striker Adjustment 1-11 Recirculation Rod and Door (3388, 3588 and 3788) Recirculation Rod and Door (6388, 6588 and 6788)..., Split Between Transfer Case and Transmission Rear Split - Control Center on the Speed Transmission (Includes Splitting the Axle Housings) Rear Split - Control Center on the Speed Transmission (Without Splitting the Axle Housings) Rear Split - Control Center on the Rear Frame Housing (Speed Transmission Overhaul) Isomounts Tractor Ballast NOTE: Refer to Service Manuals GSS Basic Air Conditioning and Heating and GSS-1281-K Clutches. 1-1

6 Section 2 FRONT AXLE ASSEMBLY NOTE: Refer to Section 1 for Tractor Ballast. Front Axle Removal Axle Carrier Disassembly Reassembly and Adjustment Axle Differential and Pinion Pinion Differential Pinion and Differential Adjustment Front Axle Installation 2-25 Planetary Assembly

7 Section 3 STEERING Specifications Steering Cylinder Cylinder Bushings Steering Hand Pump Specifications NOTE: For troubleshooting the steering hydraulic circuit refer to Section 15. Testing the hydraulic system. Power steering relief valve opening pressure to kpa (2150 to 2600 psi) at 2400 rpm Special Torques Recirculation valve ball plug Upper cover capscrews End cover capscrews Steering wheel retaining nut Telescoping shaft locking collar to 19 N m (10 to 14 ft. lbs.) 24 to 30 N' m (18 to 22 ft. lbs.) 24 to 30 N m (18 to 22 ft. Ibs.) 43 to 50 N' m (32 to 37 ft. Ibs.). Hand Tight GSS (Rev. No.1) Printed in the United States of America 3-1

8 Section 4 ENGINE Engine Removal Installation NOTE: For service refer to GSS on 300 & 400 Diesel Engines and Fuel Systems. 4-1

9 Section 5 ~"... FUEL SYSTEM AND HOODS Main Fuel Tank Auxiliary Fuel System Troubleshooting Auxiliary Fuel Tank Front Hood and Rear Hood Adjustment NOTE: Refer to GSS for servicing the fuel injection pump. 5-1

10 Section 6 ELECTRICAL SYSTEM Specifications... " 6-2 Digital Data Center (3388,3588 and 3788 Tractors) Instrument Gauge Transducer Wiring Diagrams Digital Data Center 1A (6388, 6588 and 6788 Tractors) Troubleshooting Transducer Instrument G~uge and/or Light Removal Wiring Diagrams

11 Section 7 COOLING SYSTEM Radiator Removal Installation

12 Section 9 TRANSMISSION AND TRANSFER CASE Special Torques Transfer Case Flywheel Shaft Adjustment I nput/output Shaft Adjustment Engine Drive Shaft Dampener Power F low Gear Drive , 3588, 6388 and 6588 Tractors Torque Amplifier Solenoid , 6588 and 6788 Tractors Transmission Brake , 6588 and 6788 Tractors Power Flow Gear Drive and Speed Speed Transmission Disassembly Clutch Housing Repair Procedure Torque Amplifier Overhaul Speed Transmission Reassembly Mainshaft - 4 Speed Mainshaft - 3 Speed Speed Transmission Spacer Installation I PTO Drive Shaft IPTO Front Bearing Set-Up Procedure Speed Transmission Linkage , 3588 and 3788 Tractors Speed Transmission Linkage , 6588 and 6788 Tractors T A Switch Adjustment , 6588 and 6788 Tractors Range Transmission Disassembly Differential Mainshaft

13 Reverse I die Shaft Countershaft Range Transmission Reassembly Countershaft Countershaft Bearing Set-Up and 6388 Tractors Countershaft Bearing Set-Up , 3788, 6588 and 6788 Tractors Reverse I dler Shaft Assembly Power Take-Off Driven Shaft Mainshaft (Range Transmission) Differential Range Transmission Linkage ,3588 and 3788 Tractors Range'Transmission Linkage Adjustment , 6588 and 6788 Tractors Park Lock Cover , 3588 and 3788 Tractors Park Lock Cover ,6588 and 6788 Tractors Park Lock Adjustment , 6588 and 6788 Tractors.... Park Lock Linkage Adjustment , 3588 and 3788 Tractors...,.... Four Wheel Drive Gear Case.... Understanding the Lube Warning Light at Low Idle NOTE: Refer to Section 1 for Tractor Ballast and Section 14 for Hydraulic System Clean-Up Procedure. 9-2

14 Section 10 REAR DIFFERENTIAL NOTE: Refer to Section 1 for Tractor Ballast, Section 9 for Removal of the Differential Assembly and Section 14 for Hydraulic System Clean-Up Procedure. Specifications Special Torques Pinion and Differential Adjustment Mounting Distance Differential Bearing Preload... _ Backlash Differential Lock..., 10-5 Rear Frame Cover Service Draft Control Cylinder Action Control Valve Draft Control Valve..., Rockshaft Torsion Bar and Crankarm Shaft Bushings Specifications Differential lock pressure to 2068 kpa (230 to 300 psi) Differential case bolts nuts.. Range transmission mainshaft cage bolts Range transmission mainshaft nut Differential bearing retainers Outer dual wheel hub clamp Inside bolts.. Outside baits... Wedge lock wheel bait. Special Torques N m FT. LES

15 Differential Bearing Pre- Load 4. With the differential in place, install both retainers without shims. Torque the left hand bearing retainer with three capscrews to 100 N' m (73 ft. lbs.). 5. Tighten the right hand bearing retainer with three capscrews to 11 N' m (100 in. lbs.) while rotating the differential ring gear. 6. Loosen the three capscrews and retorque them evenly to 2.3 N' m (20 in. lbs. ) while rotating the gear. Then without rotating the gear, torque evenly to 5.6 N" m (50 in. lbs.). NOTE: To assure that the bearings are seated tap the retainers using a rubber mallet. 7. Using a depth micrometer measure through the jack screw holes the distance from the outer surface of the retainers to the rear frame housing surface. Record the readings and average these figures. 8. Support the differential assembly and remove the RH differential bearing retainer. Using a micrometer record the thickness of the retainer flange. The difference between steps 7 and 8 is the desired shim pack 2: 0.06 mm (2:.002 inch). 9. Divide the total shim pack for initial placement on the carrier assembly. Approximately 60% of the shims should be placed on the ring gear side. 10. Remove the LH carrier and place the remaining shims on the carrier and reinstall. 11. Torque the retainer mounting bolts to 100 N m (73 ft. lbs.). 1. Differential bearing retainers Depth micrometer 3. Jack screws holes Backlash 12. USing Dial Indicator Gauge take three readings apart on the ring gear. Backlash should be between.127 to.381 mm (.005 to.015 inch). If necessary, move the retainer shims from one side to the other to accomplish backlash. Do not remove or add shims since this changes bearing preload. NOTE: Refer to Section 12 for complete instructions on installing the brakes Dial Indicator Gauge 2. Differential ring gear 10-4

16 Section 11 REAR AXLE HOUSING AND WHEELS NOTE: Refer to Section 1 for Tractor Ballast and Section 14 for Hydraulic System Clean-Up Procedure. Special Torques ,3588,6388 & 6588 Rear Drive Axle Assembly & 6788 Rear Drive Axle Assembly Rear Axle and Bull Pinion Shaft Removal Disassembly... " Reassembly and Installation Preloading the Bull Pinion Shaft Bearings Rear Axle Bearings Preload Adjustment Special Torques Outer Dual Wheel Hub Clamp Inside bolts. Outside bolts.... Wedge Lock Wheel Bolt N'm Ft. Lbs

17 Section 12 BRAKES NOTE: Refer to Section 14 for Hydraulic Clean-Up Procedure. Specifications Power Hydraulic Multi-Disc Brakes Power Braking (Engine Running) Removal and Disassembly Inspection Reassembly Installation Power Brake Valve Removal Disassembly Inspection and Repair Reassembly and Installation Brake Pedal and Linkage Adjustment Brake Wear Switch Adjustment Bleeding The Brakes Specifications Brake diameter - inches mm (11 inches) Brake pressure - psi kpa ( psi) 12-1

18 Section 13 INDEPENDENT POWER TAKE-OFF Specifications IPTO Assembly Drawings I PTO Introduction Removing the IPTO from the Tractor Servicing I PTO Components IPTO Pump IPTO Clutch Pack Assembly..., IPTO Cover and Valve Housing Installing the IPTO on the Tractor I PTO Control Valve 3388 Tractor SIN and Below IPTO Control Valve 3388 Tractor SIN and Above - and All 3588, 3788, 6388, 6588 and 6788 Tractors Rear Linkage Adjustment 3388,3588 & 3788 Tractors Control Handle and Linkage Adjustment 3388, 3588 & 3788 Tractors..., IPTO Cable Installation and Adjustment 6388,6588 and 6788 Tractors Adjusting IPTO Pressure 3388 Tractor SIN and Below..., Adjusting IPTO Pressure 3388 Tractor SIN and Above - and All 3588,3788,6388,6588 and 6788 Tractors IPTO Pressure Specifications 3388 Tractor SIN and Below to 1654 kpa (230 to 240 psi) 3388 Tractor SIN and Above - and All 3588, 3788, 6388, 6588 and 6788 Tractors to 1482 kpa (205 to 215 psi) 13-1

19 Section 14 HYDRAULIC SYSTEM Basic Hydraulic System Operation of Power Priority Hydraulics Operation of Draft Control, Motor and Auxiliary Valves Multiple Control Valve (MCV) Hydraulic Steering Pump Hydraulic Hitch Pump and Compe'1sator Start-Up Procedure PPH Pump Auxiliary Valve Service Flow Control Valve Motor Priority Valve..., Sump Check Valve Service Alternating Check Valves Coupler Service Hydraulic Seat Recharging Accumulator in Hydraulic Seat Clean-Up Procedure Checks and Adjustments Lever Friction Adjustment Drop Poppet Valve Position Control Lever Drop Control Valve Load Control Lever Internal Sensing Arm Adjustment Variable Raise Rate Position Control Accuracy

20 Section 15 TESTING HYDRAULIC SYSTEM Specifications General Test No.1 Coupler Flow Rate Test No.2 Hitch Raise Time 15-8 Interpreting Test Results Hydraulic System Analyzer (14-557) Installation Test No.3 Pump Flow Rate and Cut-Off Pressure Test No.4 Pump Standby Pressure... "... " Test No.5 Pump Differential Pressure Hydraulic System Problems - Pump O. K. Problem in Motor and Auxiliary Circuits Problem in Motor Circuit Only Problem in Auxiliary or Hitch Circuit Test No.6 Main System Cushion Relief Valve... " Test No.7 Motor and Auxiliary Valve Flow Control Test No.8 Auxiliary Valve Unlatching Pressure

21 Troubleshooting Charts PPH Hydraulics Test No.9 Relief Valve Differential Pressure Steering Supply FlowTest Test No. 10 Oil Cooler By-Pass Valve Test No. 11 Testing Lube, TA and Direct Drive Pressures Lube, TA and Direct Drive Test Evaluation Test No. 12 Brake Pressure Troubleshooting Brakes Test No. 13 Thermal By-Pass Test... ".., Test No. 14 System Aeration Check Preliminary Checks from the Tractor Seat

22 7. Open the restrictor valve on the Flo-Rater. Unlock the tabs on the motor valve handle and leave it in the lower position. With the engine at rated speed, restrict the load valve on the Flo-Rater until unlatching takes place and observe this pressure reading. Unlatching pressure should occur between 13,789 to 16,892 kpa (2000 to 2450 psi). NOTE: Refer to Test No. 8 if unlatching is a problem. 8. Open the Flo-Rater restrictor valve and reverse the Flo-Rater outlet hose to the bottom coupler port and reverse the inlet hose to the top coupler port. Next engage the motor valve handle rearward (upper) position and secure it to prevent unlatching. Then repeat steps 5 and 6. After testing open the Flo-Rater restrictor valve. If the flow specification can be obtained in one direction but not in the reverse direction then the motor valve is suspect. If flow and psi meets specifications on the motor valve then proceed to check all other auxiliary valves in the same manner. NOTE: When checking other than the motor control valve, set the lock tabs so the float position cannot be obtained and tie the valve handle in the direction being tested. If the flow specifications cannot be obtained in either direction then proceed as follows: a. Check hydraulic oil filters. b. Remove the plug and the signal line fitting from the pump flange. Using a screwdriver remove both orifices and clean the orifice screens. c. Be sure the.508 mm (. 020 in. ) orifice is open. Retorque orifice screen to 9 to 10 N m (7 to 8 ft. lbs.). d. Check for system leaks around the pump flange. Recheck the flow. e. If the flow and pressure is low at the auxiliary valves but OK at the motor valve then the motor check valve should be inspected for proper seating. This can be done by disconnecting the signal line at the motor priority valve. Operate the engine at low rpm and activate any of the auxiliary valves. If the flow streams out beyond a few drops then the motor check valve is not properly seating and should be removed for inspection. Replace the motor check valve if necessary. 1. Orifice screen behind plug 2. Orifice behind signal line fitting If pump flow is still below specifications then proceed to Test No

4366, 4386, 4568, 4586 & 4786 Chassis Only

International Harvester Service Manual 4366, 4386, 4568, 4586 & 4786 Chassis Only Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF INTERNATIONAL HARVESTER OR IT S