-
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
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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
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INTRODUCTION Page 1
\.e\t~
Front--.. CE-JJJ948
Fig. 1.510 PAY Loader
Cf-,'296T
Fig. 2. 515 PAY Loader
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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
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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")
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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.
,.--:.:
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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
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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
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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~ ;"
" ~
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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
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BRAKES
CONTENTS
GENERAL
SECTION 8 CONTENTS PAGE
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
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DRIVE SHAFTS
CONTENTS
GENERAL
SECTION 9 CONTENTS PAGE
PAGE
DESCRIPTION
...............................................................................
1 SPECIFICATIONS
............................................................................
1 SERVICE DIAGNOSIS
........................................................................
2
DRIVE SHAFTS REMOVAL
....................................................................................
2 DISASSEMBLY
...............................................................................
3 INSPECTION AND REPAIR
...................................................................
6 REASSEMBLY' . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . .
. . . . . . . . . . . . . . . . . .. 6 INSTALLATION
..............................................................................
7
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DIFFERENTIALS
CONTENTS
GENERAL
SECTION 10 CONTENTS PAGE
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
~:
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AXLES
CONTENTS
GENERAL
SECTION 11 CONTENTS PAGE
PAGE
DESCRIPTION
...............................................................................
1 SPECIFICATIONS
............................................................................
2 SERVICE DIAGNOSIS
....................................•...................................
2 REMOVAL
...............•....................................................................
3 DISASSEMBLY
...............................................................................
4 INSPECTiON AND REPAIR
...................................................................
6 REASSEMBLY
................................................................................
6 INSTALLATION
..............................................................................
8
II
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