I n t e r n at i o n a l

Service Manual
H a r ve s t e r
Service Manual
510B, 515B,
510C & 515C
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.

IH-S-510B+
 INDEX

This manual is divided into major sections coverting various components of the machine. 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 the 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 1 - INTRODUCTION
SECTION 2 - MACHINE SPECIFICATIONS
SECTION 3 - AIR
SECTION 4 - BRAKES
SECTION 5 - STEERING (MECHANICAL)
SECTION 6 - COOLING
-
SECTION 7 - DRIVE TRAIN
SECTION 7 A - CLUTCH
SECTION 7B - TORQUE CONVERTER
SECTION 7C - TRANSMISSION
-
SECTION 70 - DRIVE AXLE AND DIFFERENTIAL
SECTION 7E - STEERING DRIVE
SECTION 7F - SPROCKET DRIVE
SECTION 8 - ELECTRICAL
SECTION 9 -- FRAME
SECTION 10 - HYDRAULICS
--
SECTION 10A - PUMPS AND MOTORS
SECTION 10B --VALVES
SECTION 10C - CYLINDERS
SECTION 100 - PIPING
SECTION 10E - RESERVOIRS AND FILTERS
SECTION 11 - INSTRUMENTS
SECTION 12 - POWER
SECTION 13 - SUPERSTRUCTURE
SECTION 14 - SUSPENSION
SECTION 15 - WHEELS AND TRACKS
SECTION 16 - BODY AND BOWL
SECTION 17 - MOUNTED EQUIPMENT
SECTION 2 MACHINE SPECIFICATIONS
Page 2

SYSTEM REFILL CAPACITIES

(APPROXIMATE)

Model 510B Model 515B

Axles (each) .................................. . 15.0litres 15.0 Iitres

(4.0 gals.) (4.0 gals,)
Cooling System ............................... . 34.0 Iitres 40.0 Iitres
(36 qts.) (42 qts.)
Crankcase w/Filters ............................ . 9.5 litres 14.0litres
(10 qts.) (15 qts.)
Fuel Tank .................................... . 119.0litres 132.5 Iitres
(31.5 gals.) (35 gals.)
Hydraulic System .............................. . 38.0litres 38.0 litres
(10 gals.) (10 gals.)
Transmission and Torque Converter w/Filter ......... . 14.0 litres 14.0 Iitres
(15 qts.) (15 qts.)

TORQUE VALUES FOR STANDARD FASTENERS

BOLT IDENTIFICATION

U.S. Bolt Type Identification Chart

I.H. S.A.E. BOLTHEAD

TYPE GRADE DESCRIPTION MARKING*

1
~ 1
~or
6-2
w
WILL HAVE A~ STANDARD MONOGRAM IN THE CENTER
OF THE HEAD
Low or Medium Carbon Steel Not Heat Treated
®
WILL HAVE A~AND 3 RADIAL LINES
5 5
Quenched and Tempered Medium Carbon Steel ®
WILL HAVE A~AND 6 RADIAL LINES
8 8
Quenched and Tempered Special Carbon or Alloy Steel ®
* The center marking identifies the bolt manufacturer. The\¢' monogram is currently used; some bolts
may still have an I. H. or a raised dot which previously identified I. H. bolts.
 BRAKES SECTION 4 .
Page 7
SERVICE BRAKES

REMOVAL AND DISASSEMBLY

NOTE: It is necessary to remove the complete

axle in order to service the front axle brakes.
Only the axle shaft assemblies need to be re-
moved for rear axle brake service.

1. Front Axle Only: Remove the axle from the

machine as described in Section 7.

2. Separate the axle shaft assemblies from the dif-

ferential housing as described in Section 7.

3. Using a pry bar, remove outer plate (2, Fig.4)

from the axle shaft housing.

4. Remove planetary drive shaft (1, Fig. 5) with

the brake disc. Remove brake disc (2) from the
shaft.

5. Remove the inner plate (1, Fig. 6).

FIG. 5 - Removing the Planetary Drive Shaft and
Brake Disc

1. Planetary Drive Shaft

2. Brake Disc

FIG. 4 - Removing the Outer Plate

1. Pry Bar
2. Brake Outer Plate
3. Axle Shaft Housing
FIG. 6 - Removing the Brake Inner Plate

1. Inner Plate
2. Brake Piston
3. Differential Bearing Carrier
 FRAME SECTION 9
Page 3

CENTER HINGE PINS

DISASSEMBLY (FIG. 1) 7. Remove the bearings and related parts from the
front frame.

A WARNING! Refer to "SAFETY

PRECAUTIONS" in this section.

NOTE: Disconnected lines must be capped with

the correct size plastic cap. If caps are not avail-
able, use tape or rubber stoppers. Openings must 13
never be plugged with rags as this could introduce
foreign material into the system. Tag all discon- 12
nected lines and cables for ease of correct install- 11
ation. 4

1. Securely block the front and rear frames with 5

floor stands or equivalent. \

\
Front frame
2. Drain the hydraulic reservoir as described in
8
the Operator's Manual.

3. Disconnect all components, cables and hoses

that are connected to both frames. Use the fol-
lowing as a check list before attempting to separ-
ate the frames:

• Transmission-to-hanger bearing drive shaft 14 20

.Steering cylinders

.Hydraulic supply pump outlet hose and sy-

stem return hose

.Steering linkage

.Rear axle brake tube

• Transmission control cables 16

eEngine control cables

eElectrical wire harness junction block on

FIG. 1 - Center Hinge Pins
bulkhead
1. Bolt 11. Retainer
eRelated hose and cable clamps on rear frame
2. Seal 12. Spacer
3. Bolt 13. Shim
4. Attach a mobile lifting device to the rear frame. 4. Bearing cone 14. Bolt
5. Lubrication fitting 15. Bushing
5. Remove bolts (1) and nut (6) from the top 6. Lock nut 16. Lower hinge pin
hinge and bolts (14) from the bottom hinge. 7. Washer 17. Retaining ring
8. Upper hinge pin 18. Roller bearing
6. Remove hinge pins (8 and 16). Separate the 9. Spacer 19. Washer
rear frame from the front frame. Secure the frame 10. 8earing cup 20. Lubrication fitting
with floor stands.
 SECTION 10B VALVES
Page 14
LOADER CONTROL VALVE
SYSTEM RELIEF VALVE TEST AND
ADJUSTMENT -- Continued
EG-124353
FIG. 11 - Loader System Relief Valve
1. Adjusting screw
2. Lock nut
3. Cap nut
4. Washer
BUCKET CIRCUIT RELIEF VALVE TEST
A WARNING! Refer to "SAFETY
PRECAUTIONS" in Section 10.
1. BUCKET "DUMP" CI RCUIT: Remove the test
port plug in the elbow at the rod end of the
bucket cylinder.
BUCKET "ROLL BACK" CI RCUIT: Remove
port plug in the bucket cylinder housing at the
head end.
2. Connect a hand pump, equipped with a 34474
kPa (5000 psi) pressure gauge to the plug port.
IMPORTANT: Be sure the hand pump is filled
with the same oil used in the hydraulic system.
Refer to the Operator's Manual for correct oil
specifications.
3. Operate the hand pump and observe the
highest reading achieved on the pressure gauge,
indicating when the relief valve opens.
4. The circuit relief valve should open at 24132
~ 689 kPa (3500 .:!:. 100 psi). If the test result
meets this specification, the bucket circuit relief
valve is functioning properly.
5. If the test result does not meet the specifica-
tion, replace the circuit relief valve in the loader
control valve as described in th is section.
6. Disconnect the hand pump and reinstall the
port plug.
BUCKET CIRCUIT LOAD CHECK
VALVE TEST
A WARNING! Refer to "SAFETY
~ PRECAUTIONS" in Section 10.
1. Load the bucket.
2. Position the bucket control lever in "RO LL
BACK". Return the control lever to "HO LD"
leaving some travel in the hydraulic cylinder.
3. Shut off the engine.
4. Place the control lever in "ROLL BACK".
The bucket will move to bottom out the cy-
linder if the load check is leaking.
BOOM LOWER CIRCUIT ANTI-CAVITATION
VALVE TEST
WARNING! Refer to "SAFETY
A
PRECAUTIONS" in Section 10.
DANGER! Be sure the area in front
and behind the machine is clear of
personnel and obstructions. Do not
allow anyone near the tires or on the
access ladders during this test.
1. With the engine at high idle, operate the boom
and bucket control levers to warm up the hy-
draulic oil. Decrease the engine speed to low idle.
2. Place the bucket in the "DUMP" position and
lower it to the ground.
 VALVES
LOADER CONTROL VALVE
3. Place the boom control lever in "LOWER" to
raise the front of the machine off the ground a
few feet.
4. Shut off the engine.
5. With the boom control lever in "HOLD", the
machine will lower itself to the ground if the
anti-cavitation valve poppet is leaking.
BOOM CIRCUIT LOAD CHECK VALVE TEST
AWARNING! Refer to "SAFETY
~ PRECAUTIONS" in Section 10.
1. Raise the boom to approximately half of its
operating height. Return the boom control lever
to "HOLD".
2. Shut off the engine.
3. Place the boom control lever in "RAISE".
4. With the bucket control lever in "RAISE", the
boom will begin to drift down if the load check
is leaking.
BUCKET PLUNGER DETENT COIL TEST
(FIG. 12)
.A WARNING! Refer to "SAFETY
~ PRECAUTIONS" in Section 10.
NOTE: A service tool is required for this test.
1. Remove the access cover plate on the front
frame.
2. Disconnect the bucket leveler harness con-
nector from the valve detent housing.
3. Perform the following condition test using
Volt/Ohm Multitester, 06-562 or Volt/Ohm
Meter, PLT-2003-1 set for reading resistance or
ohms.
SECTION lOB
Page 15
4. Hold one probe of the meter on pin "A" in the
detent receptacle. Touch the remaining meter
probe to pins "B ", "C" and "0" and then to a
good ground.
5. If the detent coil is functioning properly, in-
finite resistance should be observed on the meter
in all cases, except at pin "C". The resistance of
the coil measured between pins "A" and "C"
should be very low if the coil is not defective.
6. If the entire detent circuit checks out, then the
problem of no detent application could be caused
by dirt or contaminants on the mating surfaces of
the coil and armature. To correct this problem,
the detent will have to be disassembled and the
cause of the contamination corrected.
7. Check that the detent receptacle and harness
connector are free of corrosion. Reconnect the
harness connector to the valve detent housing
being sure that it is securely tightened.
8. Reinstall the access cover plate on the front
frame.
2
A EG·124804
FIG. 12 - Bucket and Boom Plunger Detent
Receptacle Pin Identification
1. Bucket plunger detent
2. Boom plunger detent
SECTION 12 POWER
Page 14

ENGINE (MODEL 5108)

R EMOVAL Continued INSTALLATION

NOTE: Service tools are required for installation.

1. Thoroughly clean the mating surfaces of the

torque converter housing and the engine flywheel
housing. Install a new seal ring (1, Fig. 10) and
"0" ring (2) on the converter housing. Apply
I.H. Super Grease or I.H. 251 HEP Grease to the
seal ring and "0" ring.

2. If removed, install the torque converter drive

ring to the engine flywheel using the mounting
bolts with Loctite Grade 262 applied to the bolt
threads.

3. MACHINES EQUIPPED WITH A TACH-

OMETER: If removed, install the tachometer
pickup into the flywheel housing as follows:

a. Rotate the flywheel until a ring gear tooth

FIG. 9 - Lifting Engine from Machine tip is centered in the hole for the tachometer
pickup.
1. Load positioning sling (PLT-103-1 or
PLT-103-2) b. Completely back off the lock nut on the
2. Engine mounting bracket pickup.
3. Engine mounting support
4. Transmission/torque converter c. Screw the pickup into the hole by hand
only until contacts the tip of the gear tooth.

IMPOftTANT: Do NOT over tighten the pick-

up or damage to the pickup may fesult.

d. Back out the pickup 3/4 to one turn leav-

ing a gap of 1.194 - 1.587mm (0.0470 - 0.0625
in.) between the end of the pickup and the tip
of the gear tooth. With the pickup in this posi-
tion, lock it in place by torquing the lock nut
to 1 N'm (10 Ibf.-ft.).

4. Install the engine mounting support to the fan

end of the engine. Torque the support to engine
bolts to 156 N'm (115 Ibf.-ft.).

NOTE: Inspect the engine rubber shock mounts

for cracking and deterioration. Replace, if neces-
sary.

FIG. 10 - Torque Converter Housing Seal 5. To replace the engine rubber shock mounts,
Ring and "0" Ring proceed as follows:

1. Seal ring
2. "0" ring