510 & 515 Front End Loader

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1 International Harvester Service Manual 510 & 515 Front End Loader 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-510,515

2 SECTION INDEX This manual is divided into major sections covering various components of the 510/515 loaders. These sections 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 corresponding 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 - SECTION 2 - SECTION 3 - SECTION 4 - SECTION 5 - SECTION 6 - SECTION 7 - SECTION 8 - SECTION 9 - SECTION 10 - SECTION 11 - SECTION 12 - ENGINE ELECTRICAL SYSTEM COOLING SYSTEM LOADER LINKAGE HYDRAULIC SYSTEM STEERING SYSTEM TRANSMISSION AND TORQUE CONVERTER BRAKES DRIVE SHAFTS DIFFERENTIALS AXLES CHASSIS -

3 INTRODUCTION Page 1 Front--.. Fig PAY Loader \.e\t CE-JJJ948 Cf-,'296T Fig PAY Loader

4 SECTION 1 SPECIFICATIONS... 1 SAFETY PRECAUTIONS... 6 RECOMMENDED BEARING PROCEDURES NEW BEARINGS BEARING REMOVAL... 6 CLEANING... 7 INSPECTION... 7 BEARING INSTALLATION... 7 HEATING BEARINGS FOR INSTALLATION... 8 ADJUSTMENT..., fh LIQUID GASKET PROPERTIES... 8 APPLICATION... 8 LOCTITE RETAINING AND SEALING COMPOUNDS COMPOUND DESCRIPTION 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) SETTING TIME (Before Placing in Operation) REMOVAL APPLICATION AT LOW TEMPERATURES TORQUE VALUES FOR STANDARD FASTENERS SPECIAL TORQUES TORQUE VALUES FOR HOSE CLAMPS TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS... ; TORQUE VALUES FOR HYDRAULIC FITTINGS... 12

5 SECTION 1 Page 1 SPECIFICATIONS 510 PAY Loader A J!-----G ----I F E Fig. 1. General Dimensions A. Height to top of cab m (123.5") B. Reach at maximum height and 45 dump angle m (36.5") C. Dump clearance at maximum height and 45 dump angle m (108.5") D. Height to bucket pivot m (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 m (96") H. Ground clearance...,... "... '" m (17.5") J. Maximum height m (170.0") Width (at tires)......,...,... '"... "..., 2.22m (87.5") Width (bucket) m {92.0"} Turning radius - outside corner of bucket m (192.5") SAE bucket capacity: Rated cu, yds. (General Purpose) m3 (1.25 yd3) Struck cu. yds. (General Purpose) m3 (1.0 yd3 ) Rated cu. yds. (Basic stockpile) m3 (1.50 yd3 ) Struck cu. yds. (Basic stockpile) m3 (1.30 yd3) Rated cu. yds. (Stockpile) m3 (1.75 yd3) Struck cu. yds. (Stockpile) m3 (1.50 yd3 ) Basic operating weight (no attachments) W/ROPS Kg (13775 Ibs) Shipping weight... " I 6090 Kg (13400 Ibs) Engine Make and model I.H Type Naturally aspirated Number of cylinders..... " Bore..., mm (3.937")

6 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 necessary 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. 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 injection pump. 2. Vent the fuel system as described in the Operator's Manual. 3. Start the engine and check the sight glass. If bubbles or a cloudy appearance is present in t11e glass stop the engine. Check all fuel line fittings and filters 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.,.--:.: Fig. 9. Accelerator Linkage Adjustment 1. Ball Joint 4. Clevis 2. Pump Lever 5. Jam Nut 3. Jam Nut Fuel Filters 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 pedal 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 (engine shutdown position). Fuel Injection Pump CE-J J2344 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.

7 ENGINE SECTION 2 Page 7 2. Remove the air cleaner safety element and securely 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). 5. Maintain kpa (2-4 psi) air pressure in the induction 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 completed remove all seals installed for this test and air pressure setup. Install the plug in the air induction tube. -- Air supply / Air Induction- Tube CE-JJ2B9J Fig. 11. Air Induction Leak Test 515 PAY Loader (0-360) DESCRIPTION The following procedures cover the removal, installation and related tests and adjustments for the International D-360, naturally aspirated, direct injection 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 SPECIFICATIONS Service Information ENGLISH Engine Water temperature - 0 F.... Oil pressure - PSI.... Governed sped - RPM Low idle - RPM.... High idle - RPM Min. IH 0360 Max

8 LOADER LINKAGE HYDRAULIC SYSTEM SECTION 5 DESCRIPTION... 1 SPECIFICATIONS SPECIAL TORQUES... : SERVICE INFORMATION 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 TEST AND ADJUSTMENT STALL TEST PUMP FLOW TEST LOADER LINKAGE CONTROL VALVE DESCRIPTION..., REMOVAL DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY INSTALLATION TEST AND ADJUSTMENT RELIEF VALVE TEST AND ADJUSTMENT AUTOMATIC BOOM KICKOUT TEST BUCKET LEVELER TEST BOOM CYLINDERS REMOVAL..., DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY INSTALLATION TEST AND ADJUSTMENT BUCKET CYLINDER REMOVAL DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY INSTALLATION TEST AND ADJUSTMENT CYLINDER LEAKAGE TEST I

9 STEERING SYSTEM SECTION 6 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 REMOVAL.. o o " o DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY o INSTALLATION TEST AND ADJUSTMENT o 0 STEERING LINKAGE INSPECTION 'AND REPAIR TEST AND ADJUSTMENT " " f. \1 " f: :;; f ;" " <. r. " i. r, I s!i." f 5, t;: t f : 1:';; g s f. c g g :,::. :-; i.- c ". r :

10 TRANSMISSION AND TORQUE CONVERTER SECTION 7 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 REASSEMBLY INSTALLATION TRANSMISSION CONTROL VALVE DESCRIPTION REMOVAL DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY INSTALLATION TRANSMISSION DISCONNECT SOLENOID VALVE DESCRIPTION REMOVAL DISASSEMBLY I INSPECTION AND REPAIR REASSEMBLY INSTALLATION TORQUE CONVERTER DESCRIPTION REMOVAL DISASSEMBLY INSPECTION AND REPAIR REASSEMBLy INSTALLATION TORQUE CONVERTER CHARGING PUMP DESCRIPTION REMOVAL DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY TESTS AND ADJUSTMENTS... 39

11 BRAKES SECTION 8 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 INSPECTION AND REPAIR RELIN I NG BRAKE REASSEMBLY...; TEST AND ADJUSTMENT PARKING BRAKE RUN-IN MASTER CYLINDER DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY... 15

12 DRIVE SHAFTS SECTION 9 DESCRIPTION... 1 SPECIFICATIONS... 1 SERVICE DIAGNOSIS... 2 DRIVE SHAFTS REMOVAL... 2 DISASSEMBLY... 3 INSPECTION AND REPAIR... 6 REASSEMBLY' INSTALLATION... 7

13 DIFFERENTIALS SECTION 10 DESCRIPTION SPECIFICATIONS... 2 SERVICE DIAGNOSIS... 3 STANDARD DIFFERENTIAL DISASSEMBLY... 4 INSPECTION AND REPAIR... 7 REASSEMBLY NO-SPIN DIFFERENTIAL (IF EQUIPPED) DISASSEMBLY INSPECTION AND REPAIR REASSEMBLY :

14 AXLES SECTION 11 DESCRIPTION... 1 SPECIFICATIONS... 2 SERVICE DIAGNOSIS REMOVAL DISASSEMBLY... 4 INSPECTiON AND REPAIR... 6 REASSEMBLY... 6 INSTALLATION... 8

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