International Harvester Service Manual 3400A & 3500A Payline-Hoe 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-3400,3500
General Contents NOTE: Sections are numbered to correspond to the Industrial Tractor and Equipment Time Schedule and Procedure Manual. Only sections which apply to the 3400 and 3500 Series A tractors are listed. Special Service Tools Required... IV Standard Torque Data for Nuts and Bolts... VIII Standard Torque Data for Hydraulic Tubes and Fittings... IX Section D SPLITTING THE TRACTOR D FRONT END, AXLES, AND WHEELS D STEERING D ENGINE REMOVAL AND INSTALLATION D ELECTRICAL SYSTEM c=j COOLING SYSTEM D CLUTCH AND FLYWHEEL D TRANSMISSION c=j DIFFERENTIAL D REAR AXLES, HOUSINGS, AND WHEELS CJ BRAKES D POWER TAKE-OFF [JJ HITCH AND HYDRAULIC SYSTEM I ] ~::~ I TESTING AND TROUBLE SHOOTING THE HYDRAULIC SYSTEM lit rt;~~< I TUNE-UP SPECIFICATIONS ~ FRONT END LOADER BACKHOE III
Section 1 SPLITTING THE TRACTOR REAR SECTION SPLIT 1. Remove the backhoe. Refer to Section 21 for procedure. 2. Remove the operator's seat and deck plates. 3. Support the tractor loader frame on safety stands; and remove the rear wheels. 4. Remove the rear canopy supports and the backhoe subframes. 5. Disconnect linkage and the wiring harness as necessary. 6. Drain the transmission and rear frame. 7. Remove the hydraulic oil filter with suction tubes. Filter assembly removed. 1-1
Section 2 FRONT END, AXLES, AND WHEELS SPECIFICATIONS......... II., 2-1 FRONT AXLE REMOVAL AND INSTALLATION.......... 2-2 SERVICING THE FRONT WHEEL BEARINGS, HUBS, AND SPINDLES...... 2-3 ADJUSTING TOE-IN AND TURN RADIUS..................... 2-4 SPECI FICATIONS Spindle assemblies Toe-in - inch......................... l/s ± 1/16 King pin O.D. - inches (new)............ 1.2337-1.2342 King pin bushing I.D. - inches (new).............. 1.235-1.236 Front axle Pivot pin O.D. - inches (new)....... 1.874-1.876 Pivot pin bushing I.D. - inches (new).......... 1.876-1.880 Pivot bushing bore I.D. - inches..... 1.999-2.001 Special torques - ft. lbs. Front wheel mounting bolts... 135 Tie roo lock nuts........................................... 100 2-1
Section 3 STEERING HOW IT WORKS......, 3-2 STEERING CONTROL VALVE Removal and Installation... 3-5 Disassembly....................................... 3-6 Inspection and Repair......... 3-12 Reassembly...'...,..,. 3-12 SERVICING THE STEERING CYLINDER. 3-17 3-1
, Section 4 ENGINE REMOVAL AND INSTALLATION REMOVAL.................... 4-2 INSTALLATION................................ 4-5 NOTE: Refer to the service manuals listed below for servicing the engine and fuel system: GSS-1377: 0-155,0-179,0-206,0-239,0-310 and 0-358 Oiesel Engine and Fuel System (Robert Bosch) GSS-1395: C-157, C-175 and C-200 Engine and Fuel System 4-1
Section 6 ELECTRICAL SYSTEM SPECIFICATIONS General............................................ 6-1 Voltage Regulators..................................... 6-2 Alternator Generators... 6-2 Alternator Field Current Resistor.. 6-3 CraMing Motors...................................... 6-3 CraMing Motor Solenoid Switches. 6-4 Batterie s........................................... 6-4 WIRING DIAGRAMS Diesel Tractors with Integrated Voltage Regulator... 6-5 Diesel Tractors with External Voltage Regulator. 6-6 Gasoline Tractors with Integrated Voltage Regulator. 6-7 Gasoline Tractors with External Voltage Regulator. 6-8 NOTE: Refer to Service Manual GSS-1052 for Testing and Servicing Electrical Equipment. SPECIFICATIONS General Electrical system - volts... 12 Electrical system - ground Negative 6-1
Section 7 COOLING SYSTEM SPECI FICATIONS e... II... e... $............... 7-1 RADIATOR REMOVAL AND INSTALLATION. 7-2 SPECI FICATIONS Cooling system capacity - qts. Diesel tractors...................................................................... 14-1/2 Gasoline tractors... II... 11-1/2 7-1
Section 8 CLUTCH AND FLYWHEEL NOTE: Refer to GSS-1281 for clutch service information SPECIFICATIONS '................................. 8-1 REMOVAL AND INSTALLATION 8-2 CLUTCH PEDAL ADJUSTMENTS. 8-3 SPECIFICATIONS Clutch pedal free travel - inches....... 1-3/4 Clutch springs 3400A 3500A Free length - inches.... 2-23/32 2-39/64 Test length - inches.... 1-13/32 1-7/16 Test load at test length - lbs....... 200 230 Release lever height - inches..... 2.620 With back plate to pressure plate dimension - inches... 1.063 Release lever adjustment using FES 50 clutch tool Gauge block... #30 (#26) Tubular spacer....... =11=30 (=11=11) 8-1
I Section 9 TRANSMISSION SPECIFICATIONS 9-2 HOW IT WORKS Standard Gear Drive Transmission 9-3 Forward and Reverse Drive Transmission. 9-4 CENTER SECTION REMOVAL AND INSTN-LATION 9-5 FORWARD AND REVERSE DRIVE ASSEMBLY Removal.... Ii 9-a Overhaul................ 9-12 Installation.................... 9-22 SPEED TRANSMISSION OVERHAUL 9-26 RANGE TRANSMISSION OVERHAUL. 9-36 ADJUSTING THE FORWARD AND REVERSE DRIVE LOCK-OUT CONTROL LINKAGE. 9-46 ADJUSTING TRANSMISSION SHI FT LINKAGE. ',' 9-47 CHECKING AND ADJUSTING FORWARD AND REVERSE DRIVE CLUTCH PACK OPERATING PRESSURE 9-48 POWER TRAIN CROSS SECTION DRAWINGS - See the Foldout illustrations at the back of this manual NOTE: Refer to Service Manual GSS-1452 for Complete Specifications, Testing, Servicing, and Adjusting the Hydrostatic Drive Transmission_ 9-1
Section 10 DI FFERENTIAL GENERAL............................................. 10-1 REMOVAL................................................................... 10-2 DISASSEMBLY II... co... e 10-5 INSPECTION AND REPAIR. 10-7 REASSEMBLY........................................................................... 10-7 CHECKING BEVEL PINION ADJUSTMENT. 10-9. INSTALLATION... 10-10 GENERAL Refer to Foldouts Nos. 10 and 11 The differential assembly for the 3500A has four pinions with four shafts whereas the 3400A is a two pinion unit with a straight through shaft. The remaining parts of the differential assemblies are the same. The bevel gear on all models is on the L.H. side. The differential lock is always on the R.H. side on all models, if so equipped. 10-1
Section 11 REAR AXLES, HOUSINGS, AND WHEELS REMOVAL AND INSTALLATION 11-2 DISASSEMBLY....,..... 11-3 SERVICING THE PLANET CARRIER 11-4 REASSEMBLY........ 11-7 11-1
Section 12 BRAKES HOW IT WORKS... II>.,., 12-1 MASTER CYLINDER AND EQUALIZER VALVES- REMOVAL AND INSTALLATION............................. 12-2 BRAKE DISCS AND PISTONS - REMOVAL AND INSTALLATION............................. 12-4 BLEEDING THE BRAKES................................ 12-5 ADJUSTING THE BRAKE PEDALS............................ 12-6 TESTI NG TH E BRAKES................................. 12-7 HOW IT WORKS Return Hy-Tran fluid from the oil cooler maintains a full master cylinder reservoir for both cylinders. This is called our keep fill system. When pressure is applied to the brake pedal, the push rod, of the cylinder, contacts the plunger and pushes it through the bore of the cylinder. In the first 1/32 inch of movement the center valve seal closes the port to the reservoir and as the plunger continues to move up the bore of the cylinder the fluid is forced through the line to brake piston. On the return stroke, the plunger moves back with the return of fluid and the final movement of the plunger lifts the valve 12-1
Section 13 POWER TAKE-OFF SPECI F ICATIONS 13-1 GENERAL... 13-2 DISASSEMBLY. 13-3 INSPECTION AND REPAIR 13-6 REASSEMBLY e 13-7 TESTING AND ADJUSTING IPTO LOCK-UP PRESSURE. 13-9 SPECI F ICATIONS Typ e. Ind ep end ent Driven from...... Splined hub on clutch back plate Lubrication......... In Hy-Tran in rear frame Type.. Multiple disc, wet clutch Control...... Hydraulic 200-230 psi Piston return spring No. of coils....... "... 6-1/2 Free length - inches............... 1-5/32 Test length and load - inch...... 57/64 at 42 lbs. 13-1
I Section 14 HITCH AND HYDRAULIC SYSTEM SPECIFICATIONS 14-2 HOW ITWORKS General... t>....,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., 14-3 Hitch ~eration.,.,.,.,.,.,.,.,.,.,.,.,.,.,., ti.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., 14-4 Neutral.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., 14-4 Raising.,.,.,.,.,.,., III.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., 14-5 Lowering.,.,.,.,.,.,.,.,...,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., II.,.,.,., 14-5 MULTIPLE CONTROL VALVE (MCV) Removal and Installation................... 14-6 Disassembly and Reassembly........... 14-8 MCV PUMP OVERHAUL.. 14-10 Disassembly"., II'.,.,.,.,...,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,...,.,.,.,.,....,.,.,., 14-11 Reassembly.,,,.,...,.,.,.,.,.,.,.,.,.,..,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., 14-11 EXTERNAL SIDE MOUNTED PUMP OVERHAUL 14-14 Di sas sembly.,.,.,.,.,.,.,..,.,..,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,...,...,.,.,.,.,.,.,., 14-15 Reassembly., II.,.,.,.,.,...,., II.,.,.,.,.,.,.,...,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,., 14-15 THREE POINT HITCH (3400A Tractor Only) Removal and Installation.................. 14-18 Disassembly and Reassembly......... 14-21 Servicing the Unloading and Flow Control Valve Assembly 14-29 Servicing the Variable Flow Control Valve and Position Control Lever Shaft Assembly............ 14-30 Servicing the Action Control Valve............ 14-32 14-1
Servicing the Draft Control Valve....... 14-33 Adjustments..... ~.................................. 14-34 Lever Linkage Setting............. 14-34 Lever Friction Adjustment...... 14-35 Draft Control Lever...................... 14-35 Position Control Lever........ 14-35 Raise Response Lever...... 14-35 Maximum Raise Adjustment........ 14-35 Drop Poppet Adjustment.... 14-36 Drop Control Setting..... 14-37 Position Control (Inside Lever) Linkage Adjustment.... 14-37 Draft Control Shut-Off.......... 14-37 Lower Time....................................... 14-37 Raise Time... 14-37 HYDRAULIC SUCTION AND RETURN TUBE VARIATIONS 14-38 HYDRAULIC CIRCUIT DIAGRAMS Refer to the Foldouts in the back of this manual. TESTING AND TROUBLE SHOOTING Tractors without Backhoe - Refer to Section 15 Tractors with Backhoe - Refer to Section 21 SPECI FICATIONS Hydraulic Fluid Capacities Gear drive tractors........................... Hydrostatic drive tractors....... IH Hy-Tran Fluid Gallons 13.5 18.5 14-2
Section 15 TESTING AND TROUBLE SHOOTING THE HYDRAULIC SYSTEM TEST SPECIFICATIONS. 15-2 SPECIAL TOOLSREOUIRED 15-3 PRELIMINARY CHECKS.. 15-4 TESTING THE COOLER BYPASS VALVE (Gear Drive Tractors Only) 15-5 LOADER Flo-Rating the Loader*.................................. 15-6 Testing the Loader Lift Check Valves (Drop Poppets).. 15-14 Testing Loader Cylinders for Internal Leakage. 15-15 FLO-RATING THE HITCH (Tractors With Hitch Only) 15-16 STEERING SYSTEM Flo-Rating the Steering System 15-18 Testing the Steering Cylinder for Leakage... 15-20 TESTING AND ADJUSTING IPTO LOCK-UP PRESSURE... 15-21 TROUBLE SHOOTING General............................................ 15-22 Loader............................................. 15-22 Hitch... ~ 15-23 Steering Sy'stem......................... 15-25 Backhoe - Refer to Section 21 HYDRAULIC CIRCUIT DIAGRAMS - Foldouts No.1 thru 5 at back of this manual * Tractors with Backhoe - Refer to Section 21 15-1
Testing the Loader Lift Check Valves (Drop Poppets) 1. Loader boom circu it rei ief valve 2. Bucket drop poppet 3. Boom drop poppet 4. Loader system rei ief valve 1. Raise the loader; and level the bucket. 2. Stop the tractor engine. 3. Pull the loader control lever back and inward. Boom cylinder movement will indicate a leaking boom control valve drop poppet. Bucket cylinder movement will indicate a leaking bucket control valve drop poppet. 15-14
Section 16 TUNE-UP SPECIFICATIONS.:. GASOLINE TRACTORS. 16-3 DIESEL TRAC,TORS....... -e 16-4 16-1
Section 20 FRONT END LOADER SPECIFICATIONS. 20-2 LOADER CONTROL VALVES General........ 20-3 Bucket Control Valve OVerhaul. 20-4 Boom Control Valve OVerhaul 20-6 LOADER BUCKET SELF LEVELING VALVE (3400A Tractor Only) OVerhaul 20-10 Adjustment 20-11 REBUILDING CYLINDERS 20-12 TESTING AND TROUBLE SHQOTlNG THE HYDRAULIC SYSTEM Tractors without Backhoe - Refer to Section 15 Tractors with Backhoe - Refer to Section 21 HYDRAULIC CIRCUIT DIAGRAMS - Refer to the Foldouts in the back of this manual. 20-1
Section 21 BACKHOE SPECIFICATIONS......... 21-2 TESTING THE HYDRAULIC SYSTEM Special Tool s Required.................................. 21-4 Flo-Rating the Hydraulic System.... 21-6 Flo-Rater Hook-Up..... 21-6 Preparing for Testing................................ 21-8 Testing the Cooler Bypass Valve (Gear Drive Tractors Only)...... 21-9 Testing System Relief Valves.......................... 21-9 Testing Hydraulic Pumps.......... 21-13 Testing the Mid-Inlet Open Center Check Valve - 3152 Backhoe..... 21-15 Testing Circuit Relief Valves................ 21-16 Testing the Cavitation Control........ 21-24 Testing Lift Check Valves (Drop Poppets)... 21-26 Testing the Stabilizer Check Valves... 21-27 Testing Cylinders for Internal Leakage........ 21-27 Swing Cylinders......... "................ 21-27 Boom Cylinder.................................... 21-28 Dipperstick and Bucket Cylinders..................... 21-29 Stabilizer Cylinders............................. 21-30 TROUBLE SHOOTING.............. 21-31 REMOVAL AND INSTALLATION........... 21-33 HYDRAULIC CIRCUIT DIAGRAMS -Foldouts No.1 thru 5 at back of this manual NOTE: Refer to GSS-1372 for Backhoe Service 21-1
Model Gear Drive Hydrostati c Drive 3400 2500 2400 3500 2750 2750 Loader boom circuit relief valve limiting pressure - psi minimum. e. If observed pressure is low, and fluid does not flow from a safety plug, replace the loader boom circuit relief valve. 11. Stop the tractor engine; and install the relief valves that were removed for test purposes. Testing the Cavitation Control Valve bank LH end cover. 1. Valve body 2. Spool assembly (2) 3. Plunger assembly (2) 4. Plunger cyl inder NOTE: If the cavitation control spools do not open properly, the resulting high valve bank return passage pressure will reduce backhoe digging power, and raise backhoe relief valve limiting pressures. Excessive system pressure will cause pump failure. 21-24
Contents SPECIAL SERVICE TOOLS REQUIRED......................... SPECI FICATIONS...................................... V VI STANDARD TORQUE DATA FOR NUTS AND BOLTS............... VIII STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS IX GENERAL INTRODUCTION TO TRANSMISSION SERVICING Handl ing of Parts... 1 Clean Up Procedure.................................... 2 DISASSEMBLY OF TRANSMISSION Hydrostatic Filter..................................... 3 Transmission........................................ 3 Removal of IPTO Shaft.................................. 10 Charge and Servo Pump... 12 REMOVAL AND SERVICING OF HYDROSTATIC COMPONENTS Hydrostatic Pump Hydrostatic Motor 17 19 Charge Pump.................................. 22 Center Section........................................ 25 Servo Cylinders...................................... 26 Multi-Valve... 28 Foot-N-Inch and Deceleration Valve......................... 29 Oil Cooler........................ 30 CHECKING PRESSURES AND CHARGE PUMP FLOW Drive Pressure...................................... 30 Charge and Servo Pressure.......................... 32 Measuring Charge Flow................................. 33 Charge Pump Flow 34 III
ADJUSTMENTS Two Position Deceleration Valve IP 35 Foot-N-Inch Valve..................................... 36 CHECKING FOOT-N-INCH AND DECELERATION VALVE.............. 37 CAM ACTUATING ROD ADJUSTMENT........................ 38 NEUTRAL RESPONSE ADJUSTMENT.......................... 39 TRUNNION SHIM PACK ADJUSTMENT - PRIOR TO REASSEMBLY OF PUMP AND MOTOR.......................... 40 Motor Swash Plate Trunnion Bearings................. 43 Pump Shaft Bearings Motor Shaft Bearings COMPONENT REASSEMBLY II II II II II II II.................................. Suction and Return Tubes...... 50 Hydrostatic Pump Hydrostatic Motor II II II II II II II II II II 0 II II II II II II II II II II II II II II II II II II II IPTO Installation and Bearing Adjustment TRANSMISSION REASSEMBLY Hydrostatic Pump Hydrostatic Motor Servo Regulator. II II II II II II II II II II 59 Charge Pmnp and Return Tubes........................ 59 Motor Servo Pump Servo Servo Supply Tube.. II II II II II II II II II II 61 Check Valves and Check Valve Plugs................... 62 High Pressure Lines II II II II 62 TOP COVER WITH CONTROL CAM... 63 43 47 51 53 54 57 58 60 60 IV