500 Series C Crawler

Transcription

1 International Harvester Service Manual 500 Series C Crawler 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-500C CWLR

2 SERIAL NUMBERS FOR 500C CRAWLER RIGHT SIDE OF FRAME ABOVE INSTRUMENT PANEL RIGHT SIDE OF FRAME ABOVE INSTRUMENT PANEL RIGHT SIDE OF FRAME ABOVE INSTRUMENT PANEL RIGHT SIDE OF FRAME ABOVE INSTRUMENT PANEL RIGHT SIDE OF FRAME ABOVE INSTRUMENT PANEL PAINT FOR 500C CRAWLER IHC INDUSTRIAL YELLOW BASE UNIT IHC WHITE TRIM.

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4 General Contents Special Service Tools Required IV Standard Torque Data for Nuts and.bolts V Standard Torque Data for Hydraulic Tubes and Fittings VI Section [}] [ill 1 III

5 Section 1 ENGINE REMOVAL AND INSTALLATION R EMOV AL e It 0 1'1 G it., 0 It 0 0 " II 0 " " " " " " " " " II I!I " It " " II G I!I I!I., II" 1-2 INSTALLATION II) eo., t) 0 0 V Q C e 1'1 e I) " I!I " '1 0 It e ell»" e fi) D " eo. e

6 ,", { ) Section 2 COOLING SYSTEM GENERAL DESCRIPTION Fan 0 III.,., G f) e e 4) I) e)!i>., e c II II., e.,.,., i) II iii II 2-2 Sand Screen II. II III II II II II lit S II II '" 2-2 Engine.... e II 0 I) II Transmission.., 10 II... I) e....,...., Hydraulic Equipment II... I).,., II.. I) II.,., I!!t C " e III 0 I) 2-3 RADIATOR AND COOLER-REMOVAL AND INSTALLATION Transmission Oil Cooler.. 1& II II... II... II II.... f).. II Equipment Hydraulic Cooler Radiator...., ~ II ,.... " II..., ~.,.. " 2-5 RADIATOR AND COOLER-SERVICE PROCEDURE

7 (.-.) ".',./ Section 3 ENGINE CLUTCH SPECIFICATIONS e e e GENERAL DESCRIPTION e 3-2 REMOVAL DISASSEMBLY INSPECTION AND REPAIR Clutch Springs Driven Member 8 * 3-5 Flywheel and Pressure Plate Pilot Bearing Throwout Bearing Release Levers Control Linkage REASSEMBLY AND ADJUSTMENT 3-8 CLUTCH ALIGNMENT Necessity for proper engine clutch alignment Evidence and cause of misalignment Service procedure III 3-10 I NST AL LATION

8 I Section 4 TORQUE CONVERTER, POWERSHIFT REVERSER, AND GEAR DRIVE HOUSING (J o SPECIFICATIONS ea. 8 TORQUE CONVERTER General Removal and Installation 0 Overhaul e 0 Torque Converter Alignment e POWER SHIFT REVERSER General Description Service Procedures General Removal. Disassembly Component Service General Control Valve and Charge Pump Outlet Manifold Charge Pump Forward Clutch Gear Assembly. Clutch Shaft Assembly Inspection and Repair Reassembly. Installation GEAR DRIVE HOUSING General Removal. Disassembly.... Inspection, Repair and Reassembly Installation TEST AND ADJUSTMENTS ~ Reverser Operating Pressures

9 Section 5 TRANSMISSION AND BEVEL GEAR SPECIFICATIONS It I II CI 51 «:0 II II> ~ " 0 CI $ II It f) e II> Ill) 0 II> II., " II eo POWER FLOW DESCRIPTION Standard Gear Drive (4 by 1)., II 0 II e II 5-3 ') Power Shift Reverser without Torque Converter (4 by 4). 5-4 Power Shift Reverser with Torque Converter (3 by 3) Winch Operation - Tractors with Power Shift Reverser 5-6 SERVICE PROCEDURES General Rear FraIrle Removal II 0., e 5-7 Transmission Cover and Gear Shift Service Transmission and Bevel Gear Pinion Service Bevel Gear and Pinion Replacement 5-7 Bevel Gear, Shaft, and Carrier Bearing Service 5-7 Sprocket Drive Pinion and Bevel Gear Oil Seal Replacement 5-7 Rear Section Split Disassembly Transmission Cover and Gear Shift Removal 5-12 Tran.smission Bevel Gear Removal e

10 Inspection and Repair 5-16 Reassembly Bevel Gear Installation Transmission Transmission Cover and Gear Shift Installation Rear Section Recoupling 5-22 SPECI FICATIONS\ Bevel gear carrier bearing preload (measured as rolling torque) with seals installed - in. lbs. 22 Spline shaft rear bearing preload (measured with spring scale and string wrapped around shaft splines) - lbs. 6 to 8 Pinion cone center dimension from pinion face to bevel gear hub See text Backlash - bevel gear to pinion measured on bevel gear perimeter See text Bevel gear pilot shaft O.D. (inch - new).739 to.741 Sprocket drive pinion shaft pilot bushing I.D. (inch - new) to.744 Bevel gear pilot shaft and bushing maximum clearance allowed - inch Special torques Bevel gear to hub capscrews (ft. lb.) Transmission spline shaft bearing retainer nut (ft. lb.) I 5-2

11 , \ ) Section 6 POWER TAKE-OFF AND SPEED REDUCER SPECIFICATIONS II 6-1 GENERAL DESCRIPTION Power Take-Off e 6-2 Speed Reduc er REMOVAL AND DISASSEMBLY 6-2 Speed Reducer Power Take-Off ) INSPECTION AND REPAIR o REASSEMBLY AND INSTALLATION Power Take-Off Speed Reducer Speed Reducer SPECI FICATIONS (" OJ Low Speed Shaft O.D. - inches ~ Low Speed Gear I.D. - inches

12 Section 7 STEERING CLUTCHES AND BRAKES SPECIFICATIONS. e.,., II., 0., II III 7-2 GENERAL DESCRIPTION PRELIMINARY INSPECTION R EMOV AL II., II.,., It III e 7-6 DISASSEMBLY "....,., 7-8 () INSPECTION AND REPAIR Qeneral II., 7-12 Sprocket Drive Pinion Shaft Oil Seal Replacement Bevel Gear Oil Seal Replacement Clutch Brake Assembly REASSEMBLY INSTALLATION II 7-18 l) 7-1

13 Section 8 SPROCKET DRIVES SPECIFICATIONS GENERAL DESCRIPTION SERVICE PROCEDURES General Pinion Shaft and Bevel Gear Oil Seal Replacement Overhaul B II Removal Disassembly... II II) ell. EO Inspection and Repair Reassembly eo.., It,. II Sit.. II 8-6 Installation SPECI FICATIONS Pinion shaft Pilot bushing clearance to bevel gear shaft (allowable wear) - inch 020 max. Pilot bushing I.D. (new) - inch Bevel gear pilot shaft O.D. (new) - inch End play - inch Sprocket drive shaft Rolling end play - inch

14 I nspection and Repair 1. Clean all parts in an evaporative solvent, and dry with compressed air. 2. Inspect the pinion shaft for damaged or worn teeth, splines, and bearing surfaces. 3. Inspect the bearing surface of the bevel gear shaft, and the pinion shaft pilot bushing. The shafts must fit freely, but clearance must not exceed.020 inch. the nut. Replace the shaft or repair damaged threads with a thread chaser. 7. Inspect the housing fol' cracks, damaged bores, and pulled threads. 8. Replace used seals, O-rings, and gaskets. Repair or replace damaged parts. 4. If replacement is necessary, split the pilot bushing with a sharp cape chisel, and remove it. Then press a new bushing into place. 5. Inspect the bull gear for wear, and damaged teeth and splines. 6. If the sprocket drive shaft is to be reused, check for damaged splines. Check for damaged threads by installing Removing the pilot bushing. 8-5 Installing the pilot bushing.

15 Section 9 TRACK AND TRACK FRAMES SPECIFICATIONS &GI. 1t161.e 0... C Ill e e 0 $. eo eo." II:) eel! TRACK CHAIN ASSEMBLY General "' 0.0"... liieo 1110 Removal. O IDO IIIIO " 0 Repair II 'Ill- II 0 " III " II It! " II " " II " II It III III lit e III &'., II 0 Installation Adjustment e I ) TRACK FRAME General e oo.,,,. Removal Disassembly... Top Idler Removal. Front Idler Removal. Track Chain Adjuster Removal. Track Recoil Spring Removal. Roller Removal... Component Service. Track Chain Adj uster. Rollers and Idlers with ElF Seals Rollers and Front Idlers with DIF Seals.. Inspection, Repair, and Reassembly. Roller Installation... Recoil Spring Installation Track Chain Adjuster Installation. Front Idler Installation Top Idler Installation Installation Alignment... II.... II II II II.... II II... II II.. II... II II II II.. II II

16 GAUGE BARS General Front Gauge Bar Removal Installation Rear Gauge Bars Removal Installation CRANKCASE AND TRANSMISSION GUARDS General 0 e Crankcase Guard Removal. Installation Transmission Guard Removal Installation

17 Section 10 ELECTRICAL SPECI FICATIONS Timing.. It It e e e... II>... 8 ~... ~ 10-1 Distributor I e 10-1 Battery... II Alternator AC Regulator Cr~ng-Motor Cr~ng-Motor Switch A.D.L.O. (Automatic Disconnect Lock-Out Relay) 10-3 AUTOMATIC DISCONNECT LOCK OUT RELAY WIRING DIAGRAMS ,7 Complete Overhaul and Testing information is covered in GSS-1052-C. SPECI FICATIONS Timing - Gasoline Engines Ignition Timing (BTDC) IIigh idle ± 1 de~ee At 425 rpm (See Note)... 0 Ii 2 NOTE: Proper ignition timing at high idle is essential for best performance and engine life. Therefore, the distributor should be set to give the exact timing at high idle. Any variance that may exist then will occur at the low idle end of the advance curve. 10-1

18 Section 11 HYDRAULICS AND HITCH SPECI FICATIONS D e GENERAL DESCRIPTION Reservoir Filter Pump Valves Oil Coolers PUMP ') / Removal. Service Inspection and Repair. Installation CONTROL VALVES General Description L.H. Cover. R.H. Cover. Basic Control Valves... Principles of Operation Open Center Fluid Flow... Free Flow Demand Excessive Demand Position 4-Way Control Valve Position 4-Way Control Valve Position 3-Way Control Valve - Hitch ( \ V 11-1

19 Principles of Operation - Continued Valve Port Options Pl-ug Control Valve Application Removal Disassembly Check Valve... Circuit Relief and Check Valve Anti -cavitation and Check Valve Valve Bank Assembly Control Valves Spool Centering Spring Fixture. 3-Position 4-Way - Bullgrader Tilt and Angle; Loader Bucket Clam and Grapple; and Remote Control Without Float.. 4-Position 4-Way - Bullgrader and Loader Wt, and Remote Control With Float Position 3-Way-Hitch Inspection and Repair Reassembly Control Valves Position 4-Way - Bullgrader Tilt and Angle; Loader Bucket Tilt, Clam, and Grapple; and Remote Control Without Float. 4-Position 4-Way - Bullgrader and Loader Lift, and Remote Control With Float 4-Position 3-Way - Hitch... Valve Bank Assembly... Installation... CYLINDER OVERHAUL IH - Loader Lift and Bucket; and Bullgrader Lift, Tilt, and Angle Cylinders..... Drott - Loader Clam and Grapple Cylinders. PUMP TEST PROCEDUR E General Flo-Rater Installation Tractors Without Remote Control or Backhoe Tractors With Remote Control Tractors With Backhoe ) 11-2

20 ,.---" :' \ \. }..:./ ) TROUBLE SHOOTING II eo. THREE POINT HITCH HOUSING General Weight Transfer Hydraulic Flow Depth Control Removal Disassembly 'Reassembly e 0 e 0 e... 'Inspection and Repair II II 'Installation THREE POINT HITCH-LINKAGE SERVICE Top Link Lift Rod Leveling Rod... HYDRAULIC CIRCUIT DIAGRAMS 500-C Crawler Tractor With No. 510 Bullgrader 500-C Crawler Tractor With No. 511 or 512 Bullgrader 500-C Crawler Tractor With No. 511 or 512 Bullgrader and Hitch or Remote Control Single Acting Cylinder 500-C Crawler Tractor With No. 511 or 512 Bullgrader and Remote Control Double Acting Cylinder - Ripper, Plow, etc. 75 Loader With General Purpose Bucket 75 Loader With Drott 4 in 1 Bucket (single or dual cylinders) or Grapple With Dual Cylinders. 500-C Backhoe Hydraulics II C Backhoe Removed

21 4-position 4-way control valve - Port B position Port B Position Fluid flow is blocked in the open center passage. Fluid passes through the check valve at valve port B, past the spool, and out cylinder port B. Return fluid from cylinder port A passes around the check valve capsule in valve port A, past the spool to the return passage. 4-position 4-way control valve - float position Float Position Fluid flow is blocked in the open center passage. Fluid passes through the check valve at port A, past the spool, and out through the open center passage. Fluid passes back and forth as required from the cylinder ports, past the spool, to the return passages. Pump pressure Return fluid 11-24

22 Section 12 ADJUSTMENTS SPECIFICATIONS 9000" DOIIC 116 oe ace$.11 III II ell Ill II.eo. ee 0$ 12-2 DIESEL ENGINE Stop and Start Position... C " e III.. " f) II III II f) 6 8., Il a a 0 0 II e II CI ~.. II II... II Low and lfigh Idle e.... II II II e.. " II e " a II e.. '" ell. f).... II II.,.. 1\ II' 12-3 GASOLINE ENGINE Low and JIigh Idle 0... e.. II).... II ".. II 1\ II 1\.. II "". III II.. 9 II 12-4 THROTTLE LINKAGE ".... ".,..., e II II.. e.... 1\ II '" II., II II FAN BELT TENSION Ga.soline Engine.... II., II.. co II II.. II.. II CI.. Diesel Engine II., III 0.. II " "... Il " lit 1\ III f) eo II., 1\ II ell., ell. If)!It " II DECELERATOR PEDAL 12-6 POWER CONTROL PEDAL CLUTCH PEDAL Standard Mechanical Spur Gear Transmission DIRECTIONAL CONTROL LEVER STARTER SAFETY SWITCH \... ~ STEERING CLUTCHES AND BRAKES TRACK CHAI N TENSION TIGHTENING ROLLER SHAFT BOLTS AFTER LUBRICATION BULLGRADER WEAR SHIMS LOADER TILT LEVER WEAR SHIMS THROTTLE, DECELERATOR, AND DIRECTIONAL CONTROL LINKAGE DIAGRAM (Fold-out No.1)