HO-S-H100C

HHoouugghhService Manual

H-100CArticulated

Front End Loader

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF HOUGH OR IT’S SUCCESSORS. HOUGH 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.

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Man

ual

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INTERNATIONAL MODEL H-100C RUBBER TIRED LOADER

INDEX

This manual is divided into major sections covering various components of the MODEL H-1 aae RUBBER TIRED LOADER. 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.

CONTENTS

SECTION 1 - CHASSIS -SECTION 2 - ENGINE -SECTION 3 - TORQUE CONVERTER -SECTION 4 - TRANSMISSION -SECTION 5 - DRIVE SHAFTS -SECTION 6 - SOLI D AXLES -SECTION 7 - STEERING AXLES (Not Applicable) -SECTION 8 - STEERING GEAR -SECTION 9 - LINKAGE -SECTION 1 a - HYDRAULIC LINES AND FITTINGS (This Section Included in Section 11) -SECTION 11 - HYDRAULIC SYSTEM -SECTION 12 - ELECTRICAL SYSTEM -SECTION 13 - BRAKE SYSTEM -SECTION 14 - SHIFT MODULATOR SYSTEM -Printed in United States of America

SECTION 1.

TABLE OF CONTENTS PAGE I

Page

INTRODUCTION 1 GENERAL........................................................................ 1 LUBRICATION.. .......... ....... .... ............................................. 2 SERVICE PARTS ................................................................. 2 SERIAL NUMBERS ............................................................... 3 ENGINE ......................................................................... 3 DIESEL FUEL SYSTEM ............................................................ 3 SERVICE TOOLS ................................................................. 3 GENERAL SAFETY PRECAUTIONS................................................. 3 SPECIFICATIONS... ......... ...•... .......•...........................•.......... 4

DIMENSIONS ..............•................•...............•................ 5 WEIGHT ..... ..•..... ..... .•.....•. .......•. .•.. .................... ...... ... 5

GASKETS AND SEALS .....................................................••.... 5 RECOMMENDED BEARING PROCEDURES ........................•.•.............. 5

NEW BEARINGS ...........................•......•....•............•.......• 5 BEARING REMOVAL ............................••.....•...•.....•.•.•....... 6 CLEANING........................... ........... .•.................•...... ... 6 INSPECTION ...•............................................................. 6 BEARING INSTALLATION ..................................................... 7 HEATING BEARINGS FOR INSTALLATION...................................... 7 ADJUSTMENT ..................................•.......................•.... 7

LOCTITE RETAINING AND SEALING COMPOUNDS ..........................•...... 8 STANDARD TORQUE DATA....................................................... 9 SPECIAL TORQUES .................................•...• '. . . . . . . . . . . . . . . • . . . . . . .. 10 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS .......•................•..... 10 TORQUE VALUES FOR HOSE CLAMPS ................•............•.....•..•.••.. 10 TORQUE VALUES FOR TUBE NUTS WITH INVERTED

FLARED FITTINGS ............•..........................................•••.. 11 TORQUE VALUE FOR TUBE NUTS ................................................. 11 TORQUE VALUE FOR "0" RING BOSS PLUGS AND

CONNECTORS, ADJUSTABLE FITTING LOCKNUTS AND SWIVEL JIC-37 DEGREE SEATS .......................................... 11

CHASSIS GENERAL INFORMATION ......................................................... 1

DESCRIPTION ............•....................................•.......•.•.... 1 MAIN FRAME ............•...•.......................•............•....••.......• 2

DESCRIPTION .......................................•.........•....•......•.. 2 SERViCE..................................................................... 3 ADJUSTMENT .........•....•.......................................•....•.•. 4

SHEET COWLING ...................................•...•.........•....•......... 7 DESCRIPTION .......•.............•.................•..........•...•......••. 7 SERViCE................................................ .•.........•.......•. 7

OPERATORS'S COMPARTMENT ....•..........................•..........•........ 8 DESCRIPTION .................................................•.............. 8

BOOM AND BUCKET ...........•......................................•.......... 10 DESCRIPTION ......................................................•.....•... 10 SERViCE ......................................•.............................. 10

LOADER LINKAGE SHIMMING INSTRUCTIONS ..................................... 14 SPECIAL TORQUES .............................................................. 14

PAGE II TABLE OF CONTENTS

Page

SECTION 2. ENGINE TRACTOR POWER UNIT .......................................................... 1

GENERAL.................................................................... 1 REMOVAL................................................................... 1 INSTALLATION.............................. ................................. 2

RADIATOR AND OIL COOLER..................................................... 3 GENERAL....... ........ .... ........... .......... ... ........... ........ ...... 3 REMOVAL ...................................................... ..•... ....... 3 INSTALLATION............................................................... 3

SERVICE INFORMATION..... ..................................................... 4 SPECiFiCATIONS............................................................. 4 SPECIAL TORQUES .......................................................... 4 NORMAL GAUGE READINGS .......................•.................•....... 4

SEeTON 3. TORQUE CONVERTER GENERAL INFORMATION ...................................•..................... 1

DESCRIPTION ................................................................ 1 CONVERTER STALL CHECK.................................................... 3

DISASSEMBLY, INSPECTION AND ASSEMBLY ..................................... 4 REMOVAL ................................................................... 4 DISASSEMBLY .....................................•.............•.•.•....... 4 CLEANING AND INSPECTION ................................................. 10 ASSEMBLY .............................................•..•........•........ 10 INSTALLATION ................................................••.....•....... 19 INPUT PUMP (EARLY TYPE) .........................•.....•................... 20 INPUT PUMP (LATE TYPE) ..................................................... 21

TROUBLESHOOTING ............................................................. 22 SERVICE INFORMATION .......................................................•.. 22

SPECiFiCATIONS •............................................................ 22 SPECIAL TORQUES .......................................................... 22

SECTION 4. TRANSMISSION GENERAL INFORMATION......................................................... 1

DESCRIPTION ..............................•................................. 2 OPERATING TEMPERATURE.................................................. 4 OPERATING PRESSURES..................................................... 4 STALL CHECK ................................................•.............. 5

PREVENTIVE MAINTENANCE ...................................................... 5 LINKAGE ADJUSTMENTS .....................•......•.•...................... 5 EXTERNAL LINES ............................................................ 5 WIRING ..................................................................... 5

DISASSEMBLY, INSPECTION AND ASSEMBLy..................................... 6 REMOVAL .......................................... ................. ........ 6 DISASSEMBLY ............................................................... 8 CLEANING AND INSPECTION ................................................. 15 ASSEMBLY ......................................•........................... 16 INSTALLATION .....................•......................................... 21 CLUTCH PACKS .............................................................. 22 DIRECTIONAL VALVE ......................................................... 32 RANGE VALVE ............................................................... 33 NEUTRAL KNOCKDOWN VALVE ............................................... 34 MAIN REGULATOR VALVE .................................................... 35

TABLE OF CONTENTS PAGE III

Page

TROUBLESHOOTING .......•....•....••••..••.•. 00 0 0 • 0 • 0 0 0 0 0 0 00 • 0 • 0 0 0 ••• 00 0 0 0 0 0 • 0 36 SERVICE INFORMATION 0.0.0 ••• 00 •••• 0 000000.00. 00 0 0 0 0 0 0 0 0.0000 ••• 000.00 ••• 00000. 39

SPECiFiCATIONS .•.... o. 0.0 •• 0 ••••••••• 00 ••• 00 •••••• 0" 0.0 ••• 0.00 •• 00.00000.0 39 OPERATING RANGES ..•. 0 •• 0 ••••••••• 0 ••••• 00 ••• 0 o. 0 ••••• 0 ••••• 0 ••••••••• 0 •• 39 TOLERANCES •....... 0 •• 0 •• 0 0 •••• 0 •• 0 •• 0 •••• 0 •• 0 0 0 0 • 0 ••• 0 • 0 •• 0 • 0 0 0 0 • 0 0 • 0 • 0 0 0 0 39 SPECIAL TORQUES 0.0 •• 0 ••••• 0 •• 00 •• 0 0 0 • 0 0 • 0 • 0.00000000. 00 • 0 0 0 • 000. 0 • 0 0 0 0 0 • 0 40 CLUTCH PLATE INSTALLATION ...• 0 0 0 0.000000 •• 000000 •• 00.0.000 •• 00000000. 00' 41 SPECIAL TOOLS . 0 ••••• 0 •• 0 •• 0 •• 0 • 0 0 • 0 • 0 0 0 0 0 0 ••••• 0 0 0 0 • 0 •• 0 • 0 0 • 0 0 0 0 0 0 •• 0 0 •• 0 0 41

SECTION 5. DRIVE SHAFTS DESCRIPTION 0 ••••••••• 0 • 0 ••• 0 0 ••••••• 0 • 0 0 • 0 •• 0 0 0 • 0 • 0 •• 0 0 0 0 0 • 0 • 0 0 0 • 0 0 0 0 •• 0 0 0 0 0 0 • 0 1

DRIVE SHAFTS o. 0 •••• 0 ••• 0 0 0 0 ••••••• 0 0 0 •• 0 0 0 •• 0 0 0 • 0 0 0 0 0 •• 0 • 0 0 0 0 0 0 0 •• 0 0 0 • 0 0 0 0 0 2 TRANSFER DRIVE ., 0 • 0 • 0 ••• 0 0 • 0 0 ••• 0 0 0 • 0 • 0 0 ••• 0 ••••• 0 •• 0 • 0 • 0 0 • 0 0 0 0 •• 0 •• 0 0 • 0 0 0 2

PREVENTIVE MAINTENANCE 0', 0 0 0 •••••• 0 0 0 ••• , 0 • 0 • 0 0 0 ••• 0 •••• 0 0 0 0 • 0 0 • 0 0 • 0 0 0 0 •• 0 0 0 4 DRIVE SHAFTS. 0 0 •• 0 •••••• 0 0.' 0.' 0 0 0.00.00 •• 0 •• 0. 0 0 0 0.00.0000.00000 •• 0.0.0000 4 TRANSFER DRIVE .. 0 •••• 0 • 0 0 .0. 0 •• 0 0 •••• 00 ••••••• 0 •• 0 •••••• 0 0 •• 00 ••• 0 •••••• 0 • 4

DISASSEMBLY, INSPECTION AND ASSEMBLY 0 •••••••• 0 •••••••• 0 • 0 •• 0 • 0 ••• 0 0 • • • • • • 4 DRIVE SHAFTS .•...•••.••.•..••.•.•••••• 0 •••• 0 0 0 0 •• 0 ••• 0 •••••• 0 • 0 0 ••• 0 • • • • • • • 4 TRANSFER DRIVE .••...•...•••• 0 ••••••••••••••••• 0 ••• 0 •• 0 • 0 • 0 •• 0 0 0 •• ' 0 ••••• 0 0 0 7

TROUBLESHOOTING .•..•.• 0 0 ••••• 0 •••• 0 •••• 0 0 ••• 0 ••••• 0 • 0 •• 0 • 0 0 •• 0 •• 0 0 0 ••••• 0 • •• 14 GENERAL ....•.•..••••• o •••••••••••••• 0 •••••• 00 ••••••• 0.0. 0 0 0.0. 0 0.000 ••• 00.. 14 TROUBLESHOOTING CHART •. 0 ••••••• 0 •• 0 0 • 0 • 0 •• 0 •• 0 0 • 0 • 0 • 0 ••• 0 0 0 • 0 0 • 0 •• 0 • 0 o. 15

SERVICE INFORMATION 0 •••• 0 •••• 00 ••••••• 000. 0 •• 000000000000.0000000.0000 •• 0000. 15 TOLERANCES . 0 • 0 •••••• 0 0 0 •••••••• 0 ••• 0 0 0 0 0 • 0 0 0 ••• 0 0 0 0 •• 0 • 0 0 0 0 0 0 0 0 0 0 00 0 0 • 0 0 o. 15 SPECIAL TORQUES ••. 0 0 0 0 0 0 0 0 0 0 •• 0 0 •• 0 0 • 0 0 • 0 0 0 • 0 0 0 0 0 0 0 • 0 •• 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 o. 15

SECTION 6. SOLID AXLES GENERAL INFORMATION 0000 •••• 0.00000.0. 0 0 0 0 0 0 •• 0. 0.00 •• 0000000 ••• 00000000 •• 0.0 1

DESCRIPTION • 0 • 0 •• 0 ••• 0 • 0 ••• 0 0 0 0 •• 0 0 • 0 0 0 •••• 0 0 0 • 0 0 • 0 • 0 0 • 0 0 0 •• 0 • 0 0 0 0 0 •••• 0 0 • • 1 PREVENTIVE MAINTENANCE 0 •• 000 •• 0 0.0000. 0 •• 00.0 ••• 000 •••• 0.0.000. 0 0.0.0 •• 0 2

AXLE DISASSEMBLY AND ASSEMBLY . 0 0 • 0 0 0 0 •• 0 • 0 • 0 0 •• 00 0 • 0 • 0 •• 0 • 0 0 0 0 0 • 0 0 0 0 0 0 0 • • 3 DISASSEMBLY PREPARATION .00 •• 00 •••• 000 •• o. 0.0000000. 0.00.00000000.00.0.. 3 DISASSEMBLY ..••• 0 • 0 •• 0 • 0 0 0 0 0 0 0 • 0 00 •• 0 .00 • 0 • 0 • o ••• 0 00' .0000.00 • 0 0 0 0000 •• 0 0 • 3 CLEANING AND INSPECTION 0.00 •• 00. 00 • 0 .00 • 0 0 0 ••••• 0 0 • 0 ••••• 0 0 •••• 0 0 0 • 0 0 • 0 • 6 ASSEMBLY .• 0 0 •••• 00 •• 0 •• 00.000 •• 0 0 •••• 0 0 0 0" 0 ••••• 000000 •••• 0000 •• 0 0.000 •• 0 6

DIFFERENTIAL DISASSEMBLY AND ASSEMBLY 000 •• 0 0 ••• 0 o. 0 0 000 ••• 000000000. 0 0 0.. 8 DISASSEMBLY PREPARATION 000 •• 00 •••• 0 00 •• 0.0 ••• 0 0.0000.00.00. 0 0 0 0 0 0.0000. 8 DISASSEMBLY '" 0 0 0 ••••• 0 0 0 0 0 0 0 • 0 0 0 • 0 0 0 0 •• 0 0 0 • 0 •• 0 0 0 0 0 0 0 0 : 0 0 0 •• 0 • 0 0 0 0 •• 0 • • • • 9 CLEAN, INSPECT AND REPAIR .00. 0 • 0 • o •• 0 0 0 • 0 0 ••• 00000 • 0 00000 ••• 0 • 0 0 000000 • •• 13 ASSEMBLY 0 •• 0 ••••• 0 • 00 0 0 • 0 0 0 0 0 • 00 0 •• 0 • 0 •• 0 0 ••• 0 0 0 0 0 0 • 0 0 0 0 0 0 0 0 0 •• 0 0 • 0 •• 0 0 0 o. 14

PLANETARY DISASSEMBLY AND ASSEMBLY. 0 •• 0. 0 0 0000.00.00.000 •• 0 o. 0 0 0 ••• 0000. 20 DISASSEMBLY PREPARATION .•. 000 •••• 0000.00. 0 ••••• 0.00 •••• 0" o. 0 0 0 ••• 0 •• 0. 20 CARRIER •. 0 ••••• 0. 0 •• 0000 ••• 00.00. 0 0.0000 •• 00 •• 0000.00.0 •• 00.000000.0 •••• 0 •• 20 RING GEAR AND HUB .• 0 0 0 • 0 0 0 •• 00 •• 000000 •• 00. 0 •• 0 0 0 •• 0 0 • 0 0 • 0 0 0 • 0 0 0 0 0 0 0 0 0 0 •• 23 WHEEL HUB AND BEARING 0 0 • 0 ••••••••• 0 •• 0 • 0 0 0 0 0 0 0 0 0 •• 0.0. 000 •• 0 0 0 0 0 0 0 • 0 0 •• 24 BRAKE DRUM .... 0 •• 0 • 0 •• 0 •• 0 ••• 0 •••• 0 •• 0 • 0000000 •• 0 • 0 0 0 •• 0 0 ••• 0 .00 0 0 • 0 0 0 0 • 0 24

TROUBLESHOOTING .000. 0 • 0 0 •• 0 .0 •• 00 ••• 000 •••• 0 0 0 0 0 0 • 0 0 0 • 0 0 ••••• 0 • 0 • 0 0 00 •• 0 0 •• 0 25 TROUBLESHOOTING CHART • 0 ••••••• 0 0 0 0 • 0 • 0 0 0 •• 0 ••• 0 • 0 0 0 ••• 0 0 0 • 0 0 0 0 0 ••• 0 •• 0 0 25

SERVICE INFORMATION .. 0 •••• 0.0 •••• 0 ••• 0. 0 ••• 0000 •••• 0 •• 0 ••••• 0 •••• 0.0 •• 00 ••••• 27 SPECiFiCATIONS ..... 0.0 •• 0. 00 ••••••• o. 0 ••••• 0 0.0. 0 0 •• 0 ••••• 0 00 •• 00.0.000 ••• 0 27 TOLERANCES .•.. 0 ••••• 0 • 0 0 • 0 0 • 0 0 0 0 0 0 0 • 0 ••• 0 0 • 0 •• 0 0 0 0 0 0 • 0 •• 0 0 0 0 • 0 0 •••• 0 0 •••• 0 27 SPECIAL TORQUES .•.•.. 0 0 • 0 0 • 0 • 0 ••••• 0 • 0 0 0 0 ••• 0 •• 0 • 0 0 ••• 0 0 •• 0 • 0 0 •• 0 ••• 0 •• o. 28 BRAKE ADJUSTMENT 0 •••• 0 • 00, 0 ••••• 0 •••• 000 ••• 00, 0 ••• 0 0 0 • 0 •• 0. 00 ••••• 0 • 0 • 0 0 29 SPECIAL TOOLS 0 ••• 0 ••• 0 • 0 • 0 ••••••••••••• 0 ••••••••••• 0 •••••••••••••••••••• o. 29

PAGE IV TABLE OF CONTENTS

Page

SECTION 7. STEERING AXLES (Not Applicable)

SECTION 8. STEERING GEAR GENERAL INFORMATION......................................................... 1

DESCRIPTION ................................................................ 2 DISASSEMBLY, INSPECTION AND ASSEMBLY ..................................... 2

STEERING GEAR ............................................................. 2 STEERING COLUMN .......................................................... 7

TROUBLESHOOTING ............................................................. 8 SERVICE INFORMATION.......................................................... 9

COMPONENT SPECIFICATIONS ............................................... 9 SPECIAL TORQUES ................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ADJUSTMENTS .............................................................. 10

SECTION 9. LINKAGE TRANSMISSION CONTROL LINKAGE .............................................. _ 1

REMOVAL...................... ..... ................. ..... ...... ...... ...... 1 INSPECTION ................................................................. 2 ASSEMBLy......... ............ ..... ....... .... ................. ..... ....... 2 ADJUSTMENT ............................................................... 2

STEERING LINKAGE .............................................................. 4 REMOVAL ...... ..... ........... ..... ......... ........ .......... ............. 4 INSPECTION ................................................................. 6 ASSEMBLY AND ADJUSTMENT ............................................... 6

ACCELERATOR LINKAGE ......................................................... 6 REMOVAL. .......... ........... ..... ....... ....... ... ....... ......... ....... 6 INSPECTION ................................................................. 8 ASSEMBLY AND ADJUSTMENT ............................................... 8

PARKING BRAKE LINKAGE ....................................................... 9 REMOVAL ....... ............... ....... ..... ................................. 9 INSPECTION ................................................................. 9 ASSEMBLY. ............................ ........... ..... ................. .... 9 ADJUSTMENT............................................................... 9

HYDRAULIC CONTROL LINKAGE .................................................. 10 REMOVAL ................................................................... 10 INSPECTION ................................................................. 11 ASSEMBLY AND ADJUSTMENT ............................................... 11

SECTION 10. HYDRAULIC LINES AND FITTINGS (This Section Included in Section 11)

SECTION 11. HYDRAULIC SYSTEM GENERAL INFORMATION......................................................... 1

DESCRIPTION ................................................................ 1 DISASSEMBLY, INSPECTION AND ASSEMBLy..................................... 1

HYDRAULIC RESERVOIR ...................................................... 1 RELIEF VALVE ............................................................... 3 DRAIN VALVE................................................................ 4 HYDRAULIC PUMPS.......................................................... 4 MAIN CONTROL VALVE ...................................................... 9 DEMAND VALVE ............................................................. 16

TABLE OF CONTENTS PAGE V

Page

STEERING CONTROL VALVE .•..••....••....••...•.....••.........•........... 17 HYDRAULIC CYLINDERS - BOOM AND aUCKET ....•...•.....•................. 21 HYDRAULIC CYLINDERS - STEERING ..•............••.•.....•................• 25

TROUBLESHOOTING .•...•.•.••.••.•••.•.•..........••...•.•....•....•.•........• 28 GENERAL •.......•...•.•..•.••••••..••..........•.•..••...•..•..••...•....... 28 MAIN CONTROL VALVE .......••••..••••....•..•••...••...•••..••..........•. 30 MAIN CONTROL VALVE - MAIN PRESSURE RELIEF VALVE ...•.•..•.•..•.....•• 31 MAIN CONTROL VALVE - ANTI-VOID VALVE •••.•••...•..•...•....•• '. . • . . . . • •. 32 PUMP ..•......•....••...••••.••••.••••....•••.•••..•.•.•..•...•.•.....•...•. 32 STEERING CONTROL VALVE ...••••.•••.•.•.•...•••..•......••..•..•...•.•..•• 33

SERVICE INFORMATION .if •••••••••••••••• ••••••••••••••••••••••••••••••••••••••••• 34 COMPONENT SPECIFICATIONS •.••....•...•••....•..•.•.•.......•.••.•......• 34 SPECIAL TORQUES .•.•..• • • . • • • • • • • • • • • • . • • • . • . • • . • • . • . . . . • . . • . . • . • . • • . . . . •• 34 SYSTEM PRESSURES ....•••.••••...••••.•••..••••.•.••. ~ ..•..••.•....•...•.. 35 PRESSURE CHECKS AND ADJUSTMENTS .•.•..••••••..•..•....••..•...•...•.• 35 SPECIAL TOOLS ...•.•...•....•.•...••..•..•...•••....•...............•..••.. 38

SECTION 12. ELECTRICAL SYSTEM DESCRIPTION OF SYSTEM ..•...•.••....•.....•.••..••...•..........••..•..•..••.• 1

PRECAUTIONS ...........•.••••.......•..•.....••••.•....•.............•.••.• 1 TROUBLESHOOTING ..•.••.......•....•.•.....••...•••..••...•....•....•..••....• 6

SECTION 13. BRAKE SYSTEM GENERAL INFORMATION ..•..•..•••...•..••..•....•...••......•..•....••••...•... 1

DESCRIPTION .......•.......••..•••••.•..••.......••.•.•.....•......•........ 1 PREVENTIVE MAINTENANCE ..••..•.•..•••••..... :............................ 5 GENERAL...... ..••...•••..• .•....... .•••.•. .••• .•.•.•••..... ..... .••... ..... 8

DISASSEMBLY, INSPECTION AND ASSEMBLy......... ••••....••.•........•....... 8 GOVERNOR .... .......•....• .•. •••.... .•••.... .•. .••. •••.••. .•.. ..•. ...• .•... 8 RESERVOIR .•......•....•....•...••••.••......•.••••...•.••.•......•......... 10 SAFETY VALVE ...•........•....•..•..•...........••.•.•.•........•.........• 11 TREADLE VALVES .....•...............••...••..•.•••..•••...•.....•••.......• 11 DOUBLE CHECK VALVES ..•.•.•........••...•....•••........................• 16 POWER CLUSTERS ...••......•.........••..••...••..•.•.....•..........•.•..• 17 ALCOHOL INJECTOR (WHERE USED) ..........•...••....••....••....•......... 20 WHEEL BRAKES ..•..•.....••....••..•.•........•...•.•••..•.••....••..•••..• 21 BRAKE LINES AND ACCESSORIES .••..•.......•..•....•••.......••..•..•••..• 23 PARKING BRAKE •....••...•.•....•.•.•.....•.•...••...•••..••.•.••.••.......• 23 RELAY VALVE .......••.•...•....•...•....•...•...•...•.....•....•..•...•.... 26

TROUBLESHOOTING ....•.••...•...•••....•••..••.....•...........•.••.•..•••...• 28 GENERAL .•...........•.........••..•.••...•.•..........•.......••••..••..... 28 PARKING BRAKE .......•...•....••.•..••....•...•.••..••....•....••...•••.... 31

SERVICE INFORMATION ..•••.......•••....•...•.••..••.....••...•....•..•..•...•• 32 SPECiFiCATIONS ...•..••..•....•......•..........•...••.....•...•••.•..••..•. 32 SPECIAL TORQUES ...••.......•..........•....•.••..•.................••.. " 32

PAGE VI TABLE OF CONTENTS

Page

SECTION 14. SHIFT MODULATOR SYSTEM GENERAL INFORMATION ............................•.............•............•. 1

DESCRIPTION ......................•............••...........•............... 1 PRINCIPLES OF OPERATION ............•........•............•....•.•............ 1

GENERAL ......•....... :..................................................... 1 ELECTRICAL SENSING SYSTEM ........••..••.••..••..•...••.•................ 1 AIR CONTROL SYSTEM •...........•....•...•...•.•....••..•..•............... 3

DISASSEMBLY, INSPECTION AND ASSEMBLY ....•.•...•.......•.................. 8 GENERAL. . • . • . . . . . . . . . . . . . • . . • . . •• . . . . • . . • . • . . . . . . . . . . • . . . . • . . . . . . . . . . . . . . . . 8 REMOVAL ..............•..•.....•..•..•.......•...•...•..•.................. 8 PRESSURE REGULATOR............ .•.. ••••.•.••..•....•..•...•......... .... . 8 AIR SOLENOID VALVE. ......••......•..•••...•••.•.•..•..•.•.........•...... . 8

SERVICE INFORMATION .....••.........••.•.•...•••.........•.............•...... 12 TROUBLESHOOTING •.....•.......•.•..•...........•..•.•••...•..........•... 12 ADJUSTMENT ..........................••.•..•.•..•.•...•.•.••.............. 14 SPECIAL TOOLS .......••.......•.••.•......•..•...••...•••..••....•••....... 14 SPECIFICATIONS .....•..••...••...••.•••••.••.•....•.••.•.••..•.............. 15 SPECIAL TORQUES .....•.•..•..•...•••.......•.....•••...•.•.•.............. 15

CHASSIS SECTION 1 PAGE 1

GENERAL INFORMATION

DESCRIPTION

The chassis components are divided into four groups to simplify maintenance and to provide a better un­derstanding of each group. The groups are as follows: Main Frame, Sheet Cowling, Operator's Compart­ment, Boom and Bucket.

The forward portion of the articulated frame provides a mount for the operator's compartment. Seated on the forward portion, the operator is always in line with the bucket, allowing a greater degree of control and operating accuracy. The rear section of the main frame provides a platform to mount the engine, con­verter, transmission, grille and bulkhead.

In addition to their center hinge pins the frame sec­tions are linked together by a pair of steering cyl­inders. The bases of the cylinders are anchored in the

1t~~ •... '

~,c::. ••

I ,/ • . I

SHIIT COWLING GROUP

MAIN PRAMI GROUP

forward fra me section with the rod ends pinned to the rear section. As one cylinder extends, the opposite contracts, pivoting the frame sections on the hinge pins and steering the tractor. This type of articulated steering has definite advantages; it eliminates the need of a steering axle with its additional parts, elimi­nates the drag link and tie rod and it allows the rear wheels to track in the path of the front wheels. This latter item insures a much shorter turning radius than that afforded by the more conventional rigid frame and steering axle type.

The front axle is fastened directly to the forward frame section. The rear axle is connected to a bolster, which in turn is fastened by two pins tqthe rearframe section. This allows the rear axle to oscillate on uneven terrain.

OPIUTOR'S COMPARTMINT GROUP

100M .. lUCIen GROUP

CE-JOOOJ.

Fig. 1 Chassis Components

I

SECTION 3 PAGE 14

TORQUE CONVERTER

DISASSEMBLY, INSPECTION AND ASSEMBLY

DISASSEMBLY (Continued)

Fig. 41

Allow housing and shaft assembly to rest on output yoke (1, Fig. 42) and block to avoid tipping.

Install snap ring (2, Fig. 18) in upper groove of output shaft (1).

Fig. 42

Block outer flange of impeller (4, Fig. 43) with blades down. Using a suitable sleeve (1), drive impeller bearing (2) into bore until snap ring (3) bottoms in its groove in impeller.

Align holes in accessory drive gear (2, Fig. 44) with those of impeller, and tap gear with a mallet until it bottoms in recess of impeller. Install retaining cap­screws (1) and tighten to recommended torque. Refer to "SPECIAL TORQUES."

NOTE: Units may be equipped with either 5/16 in. or 7 / 16 in. capscrews. Identify size prior to installation.

Torque - 5/16 capscrew: ____ _ Torque - 7/16 capscrew: ____ _

Fig. 43

Fig. 44

Place drive housing (1, Fig. 45) in press with gear teeth up. Press turbine hub bearing into drive housing until snap ring (3) is bottomed. Use suitable sleeve (2) and press on bearing outer race only.

Place drive housing (1, Fig. 3-46) on a bench with gear teeth up. Snap ring (3) on bearing (4) must be bottomed in drive housing (1) groove. Place original

SECTION 6 PAGE 24

SOLID AXLES

PLANETARY DISASSEMBLY AND ASSEMBLY

RING GEAR AND HUB (Continued) Assembly (Continued)

Fig. 54

Position ring gear (1) on hub. Secure assembly with lock plates (3) and capscrews (4). Tighten capscrews to recommended torque (refer to "SPECIAL TORQUES" under "SERVICE INFORMATION").

Torque: ____ _

WHEEL HUB AND BEARING

Disassembly

Remove seal (6, Fig. 55) and spacer (5) from hub. Discard oil seal.

Remove bearing cone (4) from hub. Mark bearing cup and cone so pair can be rematched ifthey are reused. Examine bearing cone and cups for wear or damage. Check rollers for flat or worn spots.

Fig. 55

Wash all parts in fresh cleaning solvent. Dry with compressed air.

A CAUTION! NEVER dry bearings by spin­a ning with compressed air.

Dip cones in light oil and check for wear, flat spots or damage. If cups or cones are damaged, or worn, re­place complete bearing. Remove damaged bearing cup(s) (1 and/or 3) by pressing from hub.

Assembly

If bearing cups (1 and 3, Fig. 55) were removed from hub (2), press new cups in hub. Lubricate bearing cone (4) with new axle lubricant and install it in bearing cup (3) in hub.

Install spacer (5) against hub shoulder.

Coat 0.0. of a new seal (6) with Mar-Seal or equivalent sealant. Press new seal in hub against spacer.

BRAKE DRUM

Disassembly

If scavenger (3, Fig. 56) is damaged and requires replacement, drive it from drum assembly with a heavy mallet. Remove seal ring (4, Fig. 50) that lies between scavenger and brake drum. Discard seal and scavenger.

Remove felt seal (1, Fig. 56) from it groove in brake drum (2). Discard seal.

If any wheel studs are damaged, replace them. In addition, replace studs on either side of damaged stud. If approximately half of the studs are damaged, replace all studs on that drum

BRAKE SYSTEM SECTION 13 PAGE 13

DISASSEMBLY, INSPECTION AND ASSEMBLY

RIGHT TREADLE VALVE- Remove plunger(2, Fig. 17) from mounting plate (1).

Fig. 17

BOTH VALVES - Punch mark mounting plate (2, Fig. 18) and body (1) for reference during assembly.

Remove screws (3) that secure mounting plate (2) to body (1). Remove mounting plate.

a-III.2

Fig. 18

LEFT TREADLE VALVE - The following instructions are for the extra "Tandemergency" section only.

Punch mark section and body for assembly refer­ence. Carefully remove hardware (4, Fig. 19) secur­ing section (3) to body (1). Remove gasket (2).

AA~ ~.,'-j,..J

CE-r00563

Fig. 19

Remove plugs (5, Fig. 20) from section (1). Do not damage copper washers (3). Remove screens (4) and springs (2) from plugs. Remove snap ring (6) with snap ring pliers. Spring (8) and seat (7) will pop out.

Fig. 20

Push plunger (2, Fig. 21) down through section (1) to remove. Remove and discard seal ring from plunger. Tap section sharply on wooden block to pop valve (3) out of section. Discard valve "0" rings (4).

BOTH VALVES":' Depress primary piston assembly (3, Fig. 22) and remove retaining ring (4). Remove piston assembly and spring (2) from upper body (1 ).

NOTE: Retaining ring (4) not used in "Tandemergency" valve.

Using snap ring pliers, remove retaining ring (5, Fig. 23). Remove spring retainer (4) and spring (3) from piston (1 ). Discard "0" ring (2) from groove in piston.

(continued on next page)