Serv

ice

Man

ual

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.

Harlo Forklift R-5614, SP-4014 F-3410 & UL25

IH-S-HARLOW FL

.Form GSS-1304

International Harlo Forklift

SHOP SERVICE

File in Special Duty Equipment Service Manual Binder

CONTENTS

Introduction • •• •• · • • •• •••• • 0 • • • • • ••• • •• 80 ••••• •• • • •••• • • • •• ••••

General Information . . . Serial Number Location.

Principles of Operation Lifting Princi pIe Hydr aulic Principle s • • • Fluid Flow Through Gresen Valve Relief Valve Circuit •• . •• Retarder Valve Operation Effect of Changing" Load Center"

*Specifications General Data. Machine Specifications Hydralllic System Specifications. Special Torques . • • • • • • • . • • • •••• Attachm ent Spe cifications (including spe cial torque s) •

Test Procedure and Troubleshooting

. . • eo & • •

Tractor Hydraulic System Service • • . •.•.•.••....••.•.•. • ..• •• •• • ••• .

Lift Cy linder Service . . . . ........ . Packing Gland Replacement . . ••• • .• Lift Cylinder Removal and Installation . • Special Instructions for UL-2 5 Lift Cylinder and Lift Chain.

Tilt Cylinder Service R.em oval •••••..• Disassembly, Inspection and Repair, and Reassembly Installation and Adjustment • •. .••.••.• • Special Instructions for UL-25 Tilt Cylinder. Special Instructions for Front-Mounted Tilt Cylinder

Gresen Hydraulic Control Valve Service Removal and Disas sembI y • . • ••••• Inspection and Repair • ...•• . • ~; •• Reassembly and Adjustment ••••••• Sp~cial Instructions for Three-Spool Valves. Retarder Valve Service .•.••••••••••••

Mast Assembly Service Wear Pad Replacement • • ••• Special Instruc:tions for UL-25 Wear Pads Special Instructions for Wear Pads on Front-Mounted Units Load Rollers • ••••• Mast Chain Sprockets and Rollers. Lift Chain Service

Lift Chain Adjustment ••

*Added Specifications (T-3410, T-3414, T-3421)

4

5

7 7

8 8 8

10 10 10

13 15 17 19 21

27

27 27 30 30

34 34 36 36 36

37 40 41 43 43

44 45 46 46 48 49 49

62

Q

Reverse-Going Units Brakes, Clutch Linkage, Reverse Steering Kit .••

and Foot Accelerator •• 50

Sub-Frame Removal (all units) "SP" Models .. . ... . . . . . . . Reverse-Going Units Except "SP" Models .• Model UL-25 and Front-Mounted Units •. .

Removal of Platform and Control Tower .

Other Structural Service

Attachment Service General Service Hints • • •

Hos e Roller s • . Hold-Down ClaInp • • ••

Cylinder . • •• . .• • Auxiliary Pressure Relief Valve.

Side Shifter • ••. • Hydraulic Bucket ••• Log ClaInp •••• Mortar Hopper .••

Special Service Tools .

Specifications (T-341O, T-3414, T-3421)

50

52 54 55

56

57

57 58

. . . . . 58 58 59 60 60 60 61

61

62

INTRODUCTION

Service probleIns connected with these units will usually be traced to the hydraulic systeIn, provided proper operating tech­niques have been used. The instructions in this Inanual will, therefore, deal priInarily with the hydraulic cOInponents.

Correcting Inechanical or structural failures will not be a probleIn for the aver­age serviceInan, as they are usually very obvious. Be sure, however, that the cause of structural or Ine chanical failures is cor­rected, whether due to iInproper operation, iInproper Inaintenance, faulty hydraulic COIn­ponents, or poor adjustInent.

5

Further faIniliarization with International Harlo forklifts Inay be obtained byr€:lading the Operator's Manuals on these units .

This Inanual is not intended to cover all the variations and adaptations that Inay be encountered by the serviceInan. InforIna­tion contained herein will ,serve as a guide, and should enable the serviceInan to apply correct servicing procedures.

The us e of thought and judgInent cannot be overeInphasized!

0.1 I <

1 -\

~ Fork, tine backing plates

cylinders

IIlust.5. Model R-5614 forklift, showing major components .

6

Mast assembly

FEA-64194

PRINCIPLES OF OPERATION Lifting Principle

The lifting principle of all · forklifts is the same. The lift cylinder's stroke is in­creased by the use of the mUltiplication of forces theory as described on page 26 of Blue Ribbon Service Manual GSS-1277.

Hydraulic Principles

Blue Ribbon Service Manual GSS-1277 covers the basic principles of hydraulics. It is necessary that this information be thoroughly known and understood in order to comprehend the hydraulics involved in International Harlo Forklift units.

From cylinders

It is taken for granted, therefore , that the operation of cylinders is known. How­ever, flow through the Gresen control valve needs some further explanation .

Fluid Flow Through Gresen Valve

The Gresen control valve is a tandem open center type valve. With the system in neutral, fluid from the pump is allowed to flow freely back to the reservoir. (Illust. 8.) The check valve poppets are held tightly on their seats by back pressure from the cyl­inders, thus holding the cylinders in posi­tion.

)I" Single acting spool

Pressure relief valve

Later models have a spring in this position.

~~_~"*'~ Centering spring

~'l===fQ:.'!:~'-+ Centering spring

~ retainer bolt

~~~~~t~~ Stop disc FEA-64J97

lIIust. 8. Gresen control va Ive in neutra I pos ition.

8

(

SPECIFICATIONS

MODE L NUMBER

GENERAL DATA Tractor application

Mounting Shipping weight - -pounds Operating weight- -pounds

(with tractor and counterweight)

Ov er-all length, less forks - feet

Over - all width--inches Lowered height- -feet Extended height--feet Lifting height--feet Maximum capacity at 24 - inch

load center --pounds Lift cylinder diameter --inches Tilt forward - -degrees 'Filt b a ck --degrees Lifting speed with 17 GPM

pump- - fpm

Fork spacing- - inche s inside Pounds counterweight required

Overhead guard Ground c1earanc e--inches Turning radius- - feet Tires, drive wheels , size - ­

inches Tires, steering wheels ,

size- - inc hes

Travel speeds - - MPH 1st Gear - forward

- reverse 2nd Gear - forward

- reverse 3rd Ge a r - forward

- reverse 4th Gear - forward

- reverse 5th Gear - forward

- rever se

I F - 34101 F-4610 UL-25 R-3410 R-3414 R-3421 R-4610 R-4614 R- 4621 HR-4612 HR-4614 HR- 4621 R- 5612 R- 5614 SP - 4010 SP-4014 SP -4021

I ,

1- 340 1-460 1- 240 1- 340 1- 340 1-340 1- 460 1- 460 1- 460 1-460 1- 460 1-460 1-560 1- 560 & 340

Front Front Rear Rear Rea r Rear Rear Rear Rear Rear Rear Rear R ear Rear 1200 1200 1600 2246 2415 2988 2 246 15 2988 2850 2920 3050 3200 3300

(------ ·--------- See the Operat or's Manua1- -the operating weight depends on tire size , fluid and other equipment . ---- - ---)

10 . 5 f 11 . 4 1 12 . 2 1 11 .75 1 11. 7 5 1 11 . 8 1 12.7 1 12 . 7 1 12 . 8 f 13 113 1 13 1 13 . 5 1 3 . 5 ( - - ------ - ---- - ----------- See the Operator ' s Manua1-- the ov er - all width de pends on t~re size, etc . -- -- - - --- - -- - -------- )

12 . 8 12 . 8 10 . 2 12 . 3 16.8 24 . 2 12 . 3 16 . 8 24 . 2 14 . 5 16 . 8 24 . 2 14 . 5 16 . 8 ;

7 . 6 7 . 6 6 . 2 7 . 8 10 . 3 9 . 9 1 7 . 8 10 . 3 9 . 9 8 . 5 10 . 3 9 . 9 8 . 5 9 . 9

10 . 5 10 . 5 8 10 . 5 14 2 1.5 10. 5 2 1. 5 12 14 21.5 12 14

2000 2000 2500 4000 4000 4000* 4000 4000 4000~' 5000 5000 4000* 6000 6000 2. 6 2 . 6 3. 0 3 . 5 3. 5 3 . 5 3 . 5 3 . 5 3. 53. 5 3 . 5 4 . 75 3 . 5 3 . 5 10 10 9 10 10 6 10 10 6 20 20 6 20 20 10 10 12 10 10 14 10 14 10 10 14 10 10

(_ ~4 ( 12 G)PJ-::!_) pump

0 - 40 I 0- 40 F luid in rear

tires and wheel wei ghts

80 68

0- 4 0 0 - 40 1000 2100

68 102 68

0 - 40 0 - 40 0 - 40 2100 2100 21 0 0

102

0 .. 4 0 0 - 40 2100 2100

68

0 - 52 2600

68

0 - 52 26 0 0

55

0 -40 2100

68

0 - 52 2800

68

0 - 52 2800

(- -Special v e r sion of 1- 340--) I' I

(- ------ -. - -lntegra1 ----- - --) 7100

7 100

10 . 5 65 7 . 8 12 . 3 10. 5

4000 3 . 5

1 10 10

68

0 - 40 2000

7275

I 7275 I

10 . 5 65 10 . 3 16 . 8

I 14

4000 3. 5 10 10

68

0 - 40 2000

7750

77 50

10 . 5 65 9 . 9 24 . 2 21. 5

400 0;'< 3 . 5 10 10

102

0- 4 0 2000

(- - - Not Av ailable ---) ( - - Optional- -) · Std . ( - - Opt ion al - -) Std. ( - - --Optional-- --) Std. (---- - ------ Optional-- - --------) Std. 6 10 . 2

( -- --- - - - - - - ----- ---- ---- - See the Operat or ' s Manua1--~hec1earance depends on tire siz~ and other equipment . ------- - --- ) 6 (-- --- --------- - - - -- --- - --- - See the Operator ' s Manual -"' turning radius depends on tire size . - -- -- -- - --- - - - ----------- -) 10 . 2

( - ----- - - - --- --- - - ---- --- - - See the Oper a tor ' s Manual and Price List for tire sizes availab le . -- - --- -- --- - -- ---- --- ---- - )

(-- --- --- - - - --- - -- - - -- - - - - - See the Operator ' s Manual and Price List f o r tire sizes availab le . - - - --- ---- -- - --- --- -- - -- --)

See the Operator'slManua1-- speeds depend upon tire size .

I ~o . 2

7 . 50 - 15, 1 0 ply

6 . 50 - 10 , 6 pI Y

1.5 1. 2 3 . 1 2. 5 4.2 3 . 4 6. 0 4 . 8 13 . 1 10 .5

* - to 15 feet, 2500 pound limit over 15"feet . I

13-14