260A Tractor, Loader & Backhoe S/n & up

Transcription

1 International Harvester Service Manual 260A Tractor, Loader & Backhoe S/n & up 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-260A TLB

2 MODEL 260A WHEEL LOADER TRACTOR AND WHEEL BACKHOE TRACTOR INDEX This manual is divided into major sections covering various components of the MODEL 260A Wheel Loader and Wheel Backhoe tractors. 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. ) SECTION 2 - FRAME SEPARATION SECTION 3 - FRONT END. AXLES AND WHEELS SECTION 4 - STEERING SECTION 5 - ENGINE SECTION 6 - ELECTRICAL SYSTEM SECTION 7 - COOLING SYSTEM SECTIONS - TRANSMISSION SECTION 9 - DIFFERENTIAL SECTION 10 - REAR AXLES AND PLANETARY ASSEMBLIES SECTION 11 - BRAKES SECTION 12 - POWER TAKE-OFF SECTION 13 - HYDRAULIC SYSTEM SECTION 14 - TESTING THE HYDRAULIC SYSTEM II SECTION 1 - SECTION 15 - SECTION 16 - SECTION 17 - HITCH AND DRAFT CONTROL FRONT END LOADER BACKHOE

3 INTRODUCTION PAGE 1 PL Fig. 1 Model 260A Wheel Loader Tractor Fig. 2 Model 260A Wheel Backhoe Tractor

4 SECTION 1 PAGE Specifications 1 Lubrication Gaskets and Seals o o o Bolt Identification Charts o 0 0 0' Standard Torque Data for Nuts and Bolts... 0 ~._.o 0 o Torque Values for Type 8 Phosphate Coated Hardware o. 10 Torque Values for Hose Clamps Torque Values for Split Flange Connections o 0 00' o Torque Values for Tube Nuts Torque Values for "0" Ring Boss Plugs JIC 37 Seat, Swivel Nuts

5 FRAME SEPARATION (SPLITTING THE TRACTOR) SECTION 2 PAGE Specifications Special Tools Removal. Jnstallatio~' I

6 FRONT END, AXLES AND WHEELS SECTION 3 PAGE Specifications 1 Service Diagnosis 1 Description 1 FRONT AXLE Removal 0 2 Installation 3 Service 3 Adjustments 6 I

7 STEERING SECTION 4 PAGE Description.. Specifications.. Special Tools.. Service Diagnosis.. STEERING ASSEMBLY Description 4 Operation 4 Removal 6 Seal Replacement 6 Servicing the Steering Assembly 7 Disassembly 7 Inspection and Repair, Reassembly 13 Installation 18 STEERING CYLINDER Removal 18 Disassembly 18 Inspection and Repair Reassembly 20 Installation 20 TOE-IN ADJUSTMENT

8 STEERING SECTION 4 PAGE 1 DESCRIPTION This machine is equipped with hydraulic power steering. The steering system is the priority system in the hydraulic circuit. Power steering is hydraulicallycontrolled at all tir:nes when adequate fluid is present. Control can be accomplished even when the hydraulic internal gear pump is not operating, however, increased input torque is required. The input torque will be less than 135 N.m (100 ft-ibs) when functioning properly. SPECIFICATIONS Special Torques Steering wheel retaining nut N.m (32-38 ft-ibs) Front wheel mounting bolts N.m ( ft-ibs) Bolt joint to cylinder arm nut N.m ( ft-ibs) Tie rod Steering arm ball stud nut N.m ( ft-ibs) Tie rod adjustment nut N.m ( ft-ibs) Steering assembly Body plug (30, Fig. 6) N.m (10-14 ft-ibs) Upper cover bolts (6, Fig. 6) N.m (18-22 ft-ibs) End cover bolts (41, Fig. 6) Preliminary N.m (2-3 ft-ibs) Final N.m (15-19 ft-ibs) Steering cylinder setscrew 3-4 N.m (2-3 ft-ibs) Opening pressures Steering system relief valve " " " kpa ( psi) Tolerances Steering assembly spool end to valve body mm ( in.) SPECIAL TOOLS OTC 915 Puller tool SERVICE DIAGNOSIS Before investigating any service problem on the hydraulic system, the following ~hould be checked: 1. Fluid level 2. Condition of filters (replace) 3. Efficiency of the hydraulic pump (flow rate) 4. External.leakage 5. Age, condition and type of fl uid 6. Air in the system or suspended in the fluid 7. Fluid operating temperature 8. All hydraulic connections (continued on next page)

9 SECTION 4 PAGE 2 STEERING SERVICE DIAGNOSIS (Continued) PROBABLE CAUSE REMEDY Power Steering is Noisy or Erratic (Manual Steering is Normal) 1. Low hydraulic fluid level Refer to Operator's Manual. 2. Hydraulic fluid is dirty Change fluid. Refer to Operator's Manual. 3. Hydraulic filter and bypass screen dirty (machines equipped w/hydrostatic Transmission) Replace filter and clean the screen as described in the Operator's Manual. No Manual or Power Steering 1. Power steering assembly failure Repair or replace. No Manual Steering - Steering Wheel Moves Freely (Power Steering is Normal) (Wheel Loader Tractor Only) 1. Power steering return port check valve in the MCV is leaking Replace check valve. 1. Air in hydraulic system Power Steering is Slow or Required High Effort 1. Steering linkage is binding Lubricate front axle pivot and steering knuckles as described in the Operator's Manual. 2. Steering relief valve failure Replace valve. 3. Steering cylinder is binding or leaking internally 4. Flo-divider valve in the MCV is sticking (wh~el loader tractor only) Check for a damaged steering arm and/or knuckle. Replace damaged part. Repair or replace cylinder. Remove and clean valve. Also clean valve bore in MCV body. 5. Internal gear pump (wheel backhoe tractor) or MCV gear pump failure Wheel backhoe tractor replace pump. Wheel loader tractor Steering Wheel Slips or Drifts 2. Cylinder internal leakage Repair or replace cylinder. repair pump. Vent hydraulic system as instructed in the Operator's Manual. 3. Steering assembly leakage Overhaul steering assembly.

10 ENGINE SECTION 5 PAGE Description 1 Specifications 1 Special Tools 1 Removal 1 Inspection and Repair 4 Installation 4 Adjustments 5 I

11 ELECTRICAL SYSTEM SECTION 6 PAGE Description. Specifications. Precautions. BATTERIES Connections 3 Connecting Booster Batteries 3 Battery State of Charge 4 WIRING DIAGRAM I

12 COOLING SYSTEM SECTION 7 PAGE Description. Specifications. Service Diagnosis. RADIATOR Removal 3 Inspection and Repair 5 Installation I

13 TRANSMISSION SECTION 8 PAGE Description 1 Specifications 2 Special Tools 2 HYDROSTATIC TRANSMISSION Removal 3 Installation 5 Adjustments 6 TORQU'E CONVERTER TRANSMISSION Removal 8 Installation 9 Adjustments 10 RANGE TRANSMISSION AND PARKING BRAKE Description 11 Removal Inspection and Repair 13 Installation 14 Adjustments 14 I

14 DIFFERENTIAlS SECTION 9 PAGE Description 1 Specifications 2 Specia,1 Tools Service Diagnosis DIFFERENTIAL Removal 4 Disassembly 5 Inspection" ah d Repair 5 Reassembly 8 Checking Bevel Pinion Adjustment Installation I

15 REAR AXLES AND PLANETARY ASSEMBLIES SECTION 10 PAGE Description o. 1 Specifications Special Tools Service Diagnosis Removal Disassembly o. 6 Inspection and Repair o 0 0 o. 6 Servicing the Planet Gear Carrier. o o 0 8 Reassembly Installation ".0. 13

16 BRAKES SECTION 11 PAGE Description 0 1 Specifications 1 Special Tools 1 Service Diagnosis 0 2 BRAKE PEDALS, MASTER CYLINDERS AND EQUALIZER VALVES 0 2 Removal Disassemb.ly Inspection and Repair 4 Reassembly 5 Installation Adjustments 5 BRAKE DISCS AND PISTONS Removal 9 Installation 9 TESTING THE BRAKES I

17 POWER TAKE-OFF SECTION 12 PAGE Description 1 Specifications 1 Special Tools 2 Service Diagnosis 2 POWER TAKE-OFF Removal 2 Disassembly 5 Inspection and Repair 5 Reassembly 5 Installation ~ Linkage Adjustment 10 TESTING AND ADJUSTING IPTO LOCK-UP PRESSURE I

18 HYDRAULIC SYSTEM SECTION 1:: PAGE Description 1 Specifications Special Tools Service Diagnosis 11 MULTIPLE CONTROL VALVE (MCV) AND GEAR PUMP (WHEEL LOADER TRACTOR) Description 13 Removal -.._.' Disassembly 15 Inspection and Repair Reassembly 19 Installation GEAR PUMP (WHEEL BACKHOE TRACTOR) Description 21 Replacement 21 SIDE MOUNTED PUMP AND PUMP DRIVE Description 23 Removal 23 Disassembly 26 Inspection and Repair Reassembly 29 Installation 0 30 I

19 TESTING THE HYDRAULIC SYSTEM SECTION 14 PAGE Specifi.cations 0 Preliminary Checks o LOADER Flo-Rating the Loader. 0 Testing the Loader Lift Check Valves (Drop Poppets).. 0 Testing Loader Cylinders for Internal Leakage.. 0 Flo-Rating the Steering System 0 Testing t~e Steering Cylinder for Leakage ~ o o ' o o FLO-RATING THE DRAFT CONTROL (IF EQUIPPED) INDEPENDENT POWER TAKE-OFF ('PTO) Testing and Adjusting IPTO Lock-Up Pressure Checking IPTO Flow and Pressure o BACKHOE Flo-Rating the Hydraulic System.. 0 Testing Valv,e Bank Sections.. 0 Testing Double Acting Check Valves.0 Testing Cylinders for Internal Leakage ' 0 00' II

20 HITCH AND DRAFT CONTROL SECTION 15 PAGE Description 0 Specific,ations 0 Special Tools. 0 Service 'Diagnosis 0 Removal 0 Disassembly 0 Inspection and Repair.. 0 Reassembly.. 0 Installation o " 0 0 o o. 0 o o 0" 0 o HITCH 0" 0 0 o o " Removal 0"" Disassembly 0 Inspection and Repair. 0 Reassembly. 0 Installation o. 0 Disassembly 0 Inspection and Repair. 0 Reassembly 0 Disassembly 0 Inspection and Repair 0 Reassembly 0 Disassembly o. 0 Reassembly. 0 Inspection and Repair 0 Disassembly. 0 Inspection an-d Repair 00 Reassem'bly.. 0 DRAFTCONT ROL o ;; " UNLOADING AND FLOW CONTROL VALVE o o. o FLOW CONTROL VALVE AND CONTROL LEVERS ASSEMBLY o ACTION CONTROL VALVE o o DRAFT CONTROL VALVE o. 0 o ' o ' ADJUSTMENTS Lever Linkage Setting o Lever Friction Adjustment o " o o Load C..ontrol Lever 0" Position Control Lever Flow L ever Maximum Raise Adjustment o o Drop Poppet Valve Adjustment Drop Control Setting Position Control (Inside Lever) Linkage Adjustment o Load Control Shut-Off o " o " Lower Time 0." Raise Time " 0" I

21 FRONT END LOADER SECTION 16 PAGE Description 1 Specifications 1 Special Tool 2 Service Diagnosis 3 LOADER VALVE BANK Description 4 Removal 4 Disassembly 6 Inspection and Repair Reassembly 10 Installation 12 SELF-LEVELING VALVE Removal Disassembly 14 Inspection and Repair Reassembly 14 Installation LOADER CYLINDERS Removal Disassembly I> Inspection and Repair Reassembly 16 Installation LOADER BUCKET SELF-LEVEL ADJUSTMENT I

22 SECTION 16 PAGE 4 FRONT END LOADER LOADER VALVE BANK DESCRIPTION The loader control valves are open center design sectional valves. The valve sections are Ilstacked" between two end covers forming a IIvalve bank." When the loader is not in operation, fluid entering the pressure end cover (1, Fig. 1) flows through the open center passage, to the convertible end cover (5) and back through the return passage, out the return port of the pressure end cover to the cooler and pump suction manifold. The system relief valve (3) limits fluid pressure during loader operation. On wheel loader machines, the loader system relief valve (3, Fig. 1) is located in the valve bank pressure end cover (1). There are two system relief valves used on the wheel backhoe machine loader system; one is located in the relief valve block and the other is located in the backhoe valve bank port plate (see Section 17). The drop check valves (2) prevent backflow of fluid when a control valve is actuated, and circuit pressure is greater than initial system pressure. REMOVAL 1. Lower loader bucket and backhoe, if equipped, to the ground. 2. Disconnect both batteries. A circuit relief valve located in the control end of the boom control valve (7) limits circuit pressure on the piston side of the boom cylinders when the control valve is in the neutral or hold position. Fig. 2 Air Inlet Screen 4. Loosen filler neck upper hose clamp (3, Fig. 3). 5. Remove bolts securing muffler (1, Fig. 3) to the hood and loosen clamp securing muffler to exhaust pipe. Remove muffler and cover exhaust pipe. Fig. 1 Loader Valve Bank, Assembled View 1. Pressure End Cover 2. Drop Check Valves (2) 3. System Relief Valve (wheel loader) 3. Plug (wheel backhoe) 4. Return Port 5. Convertible End Cover 6. Bucket Control Valve 7. Boom Control Valve 8. Pressure Port Fig. 3 Hood Disconnect Points 1. Muffler 2. Fuel Tank Filler 3. Clamp 4. Filler Wick Connecting Hose

23 BACKHOE SECTION 17 PAGE Description. Specifications 1 Special Tools 2 Service Diagnosis 2 BACKHOE Removal 4 Service 4 Installation 4 SWING ASSEMBLY Description 10 Removal and Disassembly 0 11 Inspection and Repair Reassembly and Installation BACKHOE VALVE BANK Description 13 Removal 13 Disassembly 0 14 Inspection and Repair Reassembly 16 Installation DOUBLE ACTING CHECK VALVE (IF EQUIPPED) Removal 0 Disassembly Inspection and Repair 0 Reassembly... 0 Installation BACKHOE CYLINDERS ;I" ~ o I

24 Shop.Manual 8M-Te TORQUE CONVERTER TRANSMISSION SERIAL NUMBERS ALL

25 SECTION INDEX SECTION ONE - SECTION TWO - REMOVAL AND INSTALLATION OF MAJOR COMPONENTS SECTION THREE - TORQUE CONVERTER UNIT SECTION FOUR - CLUTCH PACK SECTION FIVE - VALVES SECTION SIX - CHARGE PUMP SECTION SEVEN - HYDRAULICS

26 SECTION 1 PAGE DESCRIPTION 1 DESCRIPTION OF OPERATION FIRST SPEED FORWARD 2 SECOND SPEED FORWARD 3 THIRD SPEED FORWARD FIRST SPEED REVERSE SECOND SPEED REVERSE THIRD SPEED REVERSE LUBRICATION GASKETS AND SEALS II D... 8 SERVICE TOOLS SERVICE PARTS SAFETY PRECAUTIONS RECOMMENDED BEARING PROCEDURES BOLT IDENTIFICATION CHARTS STANDARD TORQUE DATA FOR NUTS AND BOLTS D 12 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS TORQUE VALUES FOR TUBE NUTS TORQUE VALUES FOR TYPE 8 PHOSPATE COATED HARDWARE TORQUE VALUES FOR "0" RING BOSS PLUGS, JIC 37 0 SEAT, SWIVEL NUTS 16

27 REMOVAL AND INSTALLATION OF MAJOR COMPONENTS SECTION 2 PAGE REMOVAL OF MAJOR COMPONENTS _ REMOVAL OF TORQUE CONVERTER 2 REMOVING THE DUMP AND MODULATION CONTROL VALVE... 3 REMOVAL OF THE REGULATOR JUNCTION VALVE D.. 4 REMOVAL OF TRANSMISSION TOP COVER REMOVING SHIFTER RAIL AND FORKS REMOVING THE POWER TAKE-OFF SHAFT 8 REMOVING THE OIL DISTRIBUTING HOUSING REMOVING THE REVERSE IDLER GEAR REMOVAL OF THE CLUTCH PACK 13 REMOVAL OF THE TOP DRIVEN GEARS AND SYNCHRONIZERS 14 REMOVING BOTTOM DRIVE GEARS FRONT COVER SERVICE DISASSEMBLY 18 INSPECTION AND REPAIR 19 REASSEMBLY ;, OIL DISTRIBUTING HOUSING SE RVICE DISASSEMBLY II 19 INSPECTION AND REPAI R D D. 20 REASSEMBLY. D 20 TOP DRIVEN GEAR SERVICE INSPECTION AND REPAIR D". D 20 BOTTOM DRIVE GEAR SERVICE INSPECTION AND REPAIR 21 INSTALLATION OF MAJOR COMPONENTS INSTALLING BOTTOM DRIVE GEARS D INSTALLING TOP DRIVE GEARS II II 22 23

28 REMOVAL AND INSTALLATION OF M"AJOR COMPONENTS SECTION 2 PAGE INSTALLING CLUTCH PACK 25 INSTALLING REVERSE IDLER GEAR 25 INSTALL THE OIL DISTRIBUTING HOUSING 25 INSTALLING THE POWER TAKE-OFF SHAFT 26 INSTALLING SHIFTER RAIL AND FORKS 27 INSTALLING TRANSMISSION TOP COVER 27 INSTALLING THE REGULATOR JUNCTION VALVE 28 INSTALLING THE DUMP AND MODULATION CONTROL VALVE 29 INSTALLING TORQUE CONVERTER UNIT 29

29 TORQUE CONVERTER UNIT SECTION 3 PAGE " " " " " PRINCIPLES OF OPERATION """""""".".. "" ".".".".""".""""""".. ".. "" """"".. "". 2 _ SPECIFICATIONS"" " ""." ". "" ".. ".. ".. ". " " ". " ". ". ". " """ "". "."" 4 SPECIAL TORQUES" ". ".. " " " " " " " " " ".. ". " ". ". ".. " ".. 4 DISASSEMBLY... ". ". "".. " ".. e " " " " " " " " " " " " " e 4 INSPECTION AND REPAIR".. "". " " ""." " "" 10 REASSEMBLy,," ".. """" "" "".. ".. """"" "".""",,.. 10

30 CLUTCH PACK SECTION 4 PAGE e e e e e e. 1 PRINCIPLES OF OPERATION. e e e e e e e 2 SPECIFICATIONS e e e e e e e e 3 SPECIAL TOOLS.. e e e. e e e 3 DISASSEMBLY.. e e e 6 INSPECTION AND REPAIR e e. e e 0 10 REASSEMBLy e 11

31 VALVES SECTION 5 PAGE SPECIFICATIONS ~... 1 SPR ING TEST LOAD DATA PRESSURES " DUMP AND MODULAT-ION CONTROL VALVE _ DESCRIPTION 1 OPERATION oisassemb LV INSPECTION AND REPAIR REASSEMBLY 8 REGULATOR JUNCTION VALVE DESCRIPTION 8 OPERATION... 8 DISASSEMBLY INSPECTION AND REPAIR REASSEMB LY 9

32 CHARGE PUMP SECTION 6 PAGE... 1 PRINCIPLES OF OPERATION SPECIFICATIONS DISASSEMBLY INSPECTION AND REPAI R " o REASSEMBLy... 3

33 HYDRAULICS SECTION 7 PAGE. 1 OPERATION TESTING... 4