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IH-S-5088+

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Service Manual5088, 5288 & 5488

Chassis OnlyVolume 1 of 2

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

General Contents Page

Safe Work Ru les .....................................................•..................•.... IV Standard Torque Data for Hydraulic Tubes and Fittings ................................... VI Metric Conversion Tables .................................................................. VIII Standard Torque Data for Nuts and Bolts ................................................... X Special Service Tools Required ..................... " .................................... XIII Service Information System (S.I.S.) ...............................•.......•............... XIX

III

Section 1

TRACTOR SPLITS

Contents

Page

Speed Transmission Split ...................... 0 0 0 0 0 • 0 0 0 .00.000000000.000000000.0 •• 1-2

Range Transmission and Rear Frame Split 000000000. 0 0 0 •• 000.000.00000. 0 0 0 0 0 0 .0000 1-11

All Wheel Drive Attachment 000.000000000000.0.0000000 ••• 0 •• 00.0.0 ••• 000000 .000 •• 0 0 0 1-20

Isomounts 000.0 •• 0000.000 •• 0 0 0 0000000000.0.0 0 0 •• 0 0 • 0 0 .00 .000000. 0 0 • 0 • 0 • 0 00 ••• 0 0 .0000 1-22

AlC Specifications 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 00 0 0 0 0 ••• 1-23

Special Torques 0 • 0 0 0 0 0 .00.0 ••• 0 • 0 0000.000000.00000.00000.0 ••• 0 0 0 • 0 0 0 • 0 0 0 • 0 •••• 0 • 0 0 0 1-24

Air Conditioning Components 00000. 00.0.00000000. 0 0 0 0 0 .00 •• 000.00000.00.0.000000 0 0 1-25

Windshield Wiper Motor .0000000000. 00000 ••• 0 0 ••• 0 • 0 •• 0 • 0 0 0 0 .00.0.00000.000000 •• 0 o. 1-27

Door Striker Adjustment 00 ••••••• 000000.00.0.0. 0000000.0 000.0.000 ••• 0 0 ••••• 00.0.000 1-28

Tractor Ballast . 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. 0 0 00 o. 1-29

1 -1

I

Section 2

FRONT AXLE, BOLSTER AND WHEELS

Contents

Page

Torque Specifications ................................................................ 2- 2

Standard Adjustable Front Axle ....................................................... 2- 4 Bolster ........................................................................... 2- 8 Spindle and Hub ................................................................. 2-12 Adjusting Toe-in .................................................................. 2-16

High Capacity Front Axle ............................................................. 2-17 Pivot Bushings ........................................................ , .......... 2-18 Spindle and Hub ................................................................. 2-20 Lu brication ....................................................................... 2-21 Tread Adjustment ................................................................ 2-22 Adjusting Toe-in .................................................................. 2-23

All Wheel Drive Axle .................................................................. 2-24 Axle Shaft and Spindle yoke ..................................................... 2-30 Planetary Assembly .............................................................. 2-33 Differential ....................................................................... 2-42 Tie Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Bolster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-62 Lubrica tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-65 Adjusting The Toe-in ................ eo. • • • • • • • • • • • • • • • • • • • • • • • • • • • 2-66 Tread Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . 2-67 Steering Stops All-Wheel Drive. . . . . • • . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . 2-67 Oscillation Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Fenders ....................................................... 2-70 Wheel Positioning ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-71 Tread Chart All Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

GSS-1505-1 (Rev. No. 11 IJ'"N,IO ". UNITI.O ,fA". 01' "MCRICA

2 -1

Standard Adjustable Front Axle

1. Safety stands 2. Front side panels removed 3. Front grill removed 4. Lift chain 5. Weight bracket

Removal

1. Remove both front side panels and the front grill for lift chain clearance.

2. Secure a chain around the weight bracket.

3. Disconnect the power steering hoses from the bolster.

1. Hoses 2. Steering tubes

Section 3

STEERING

Contents

Page

Specifications ...................................................................... 3-2

Power Steeri ng ..................................................................... 3-2

General ............................................................................. 3-2

Principles of Operation ............................................................ 3-2 Control Valve ...................................................................... 3-4 Metering Section ..................•............................................... 3-4 Rotor Operation in the Metering Element .......................................... 3-5 Manual Steering Operation ........................................................ 3-5

Steering Wheel and Shaft .......................................................... 3-6

Steeri ng Wheel Tu be ............................................................... 3-7

Tilt Steering Support Housing ..................................................... 3-9

Steering Hand Pump ............................................................... 3-11

Power Steering Cylinder (Standard and High Capacity Front Axle) ............... 3-24

Power Steering Cylinders (A"-Wheel Drive Front Axle) ............................ 3-29

3-1

Section 4

ENGINE

Contents

Page

Engine Flywheel Split .•. , .............................•......................•...... 4-2

Engine Removal ..................... IS •••••••••••••••••••••••••••••••••••••••••••••• 4-3

Throttle Adjustment Procedure .................................................... 4-6

4-1

Section 5

FUEL SYSTEM

Contents

Page

Main Fuel Tank ..................................................................... 5-2

Auxiliary Fuel Tank ................................................................. 5-3

5 -1

-Section 6

ELECTRICAL SYSTEM

Contents

Specifications ..................................................................... . Alternator ........................................................................ . Resistance Unit .................................................................. . Cranking Motor Cranking Motor Switch Battery- ............................................................................ .

Digital Data Center 1 A

Page

6-2 6-2 6-2 6-3 6-3 6-3

6-4

Transducer ......................................................................... 6-11

Instrument Gauges 6-12

Instrument Lights 6-12

Sentry Syste m ...................................................................... 6-1 3

Wiring Diagrams ................................................................... 6-20 Cranking and Charging Circuit •.•••.•.••..•....•.•.................•....•.•...••..• 6-20 Differential Lock and 7 Pole Connector Circuit ..•................•...•..•.....•.... 6-23 Sentry Circuit ....•...•....•.•.•....•.•.•..........•....................••......... 6-24 Warning Light Circuit .••.•.•.••..•..•.....•........•.............•............... .. 6-27 Instrument Cluster Warning Circuit .•..•.....••...•......•........•...........•.•.. 6-28 Lighting Circuit ............•...••.•.•......•......•••......•....................•.. 6-29 Data Center 1 A ..........•..........•...............•.........•.............•...... 6-30 Control Center Circuit .••..•.....•..•...••......................•................... 6-31 Neutral Start Switch Adjustment ...•..•....•.....................•................. 6-32

6-1

Section 7

COOLING SYSTEM

Contents

Page

Forward Air Flow ................................................................... 7-3

Radiator ............................................................................ 7-4

Radiator Fan Drive Installation .................................................... 7-9

Sealing of Air Box .................................................................. 7-10

7 -1

Section 8

MASTER CLUTCH

Contents

Page

Master Clutch ...................................................................... 8·2

Testing the Master Clutch ......................................................... 8·8

NOTE: Refer to Section 1 for "Tractor Ballast."

8 ·1

Section 9

TRANSMISSION

Contents

Page Power Train Operation ............................................................. 9-2

Range Transmission Shift Fork and Rail Removal In Chassis ..................... 9-4

Range Transmission Overhau I ...•................................................. ~-7

Input Shaft Medium - High Range Synchronizer ................................. 9-15

Countershaft Low Range Synchronizer ............................................ 9-21

Hydraulic Pump Drive Gear ........•..........................................•.... 9-23

Hydraulic Pump Drive Gear Bearing Setup ........................................ 9-25

Speed Transmission Fork Removal in Chassis (5th & 6th Shift Fork) ............. 9-27

(1 st - 2nd & 3rd - 4th Shift Fork) ... 9-30 Speed Transmission Overhaul ..................................................... 9-32

Testing the Hydraulic Clutch Pack ................................................• 9-49

Park Lock Cable Adjustment .....................................................•. 9-50

Clutch Cable Adjustment .......................................................... 9-52

Transmission Linkage Adjustment ................................................ 9-54

Speed Transmission Switch Adjustment .........•................................ 9-55

All Wheel Drive CI utch ..•.....................................................•...• 9-56

Clutch Replacement ................................................. 9-56

Driven Shaft And Bearing ..........................................• 9-68

Output Shaft And Bearing ..............................•..........• 9-73

Clutch Disc Replacement-In Tractor-Early Style Only .............• 9-75

NOTE: Refer to the Power Train Cross Section illustration (Foldout No.1) at the back of this manual.

NOTE: If the range transmission housing requires replacement, the bolt hole at the right side top of the speed transmission housing must be enlarged to accept a 20 mm diameter bolt which is required for the new range housing, per Service Bulletin S-4813.

GS8-1505-1 (Rev. No.2) 9 -1

PRIN'£O IN UNITED STATE. 0" AMERICA

Section 11

REAR AXLE ASSEMBLY

Contents

Page

Rear Ax.le •••••.•.•••.••..•••••••••.•.••••••••••••••.••...••..•.•••••••.•.....•..••• 11-2

Planetary Assembly •.•.••..•...•........•.............•..........................• 11-12

Seal and Sleeve Installa.tion • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• 11-15

NOTE: Refer to Section 1 for "Tractor Ballast"

aS8-1505-1 (Rev. No.2) 11 ·1 ""INTID IN UNITED .TATlS 0" .. _.".ca

Section 12

BRAKES

Contents

Page

Brakes ..... II II ••• II II •••• II ••••••• II II II ••••••••••• II ••• II ••••••••• II ••••••••••• II •••••• II • II •• 1 2·2

Brake Valve Serv-ice .. II II ••••••••••••••••••• II II •••• II •••••••••• II •• II •• • ~ •• II •••• II ••••• II. 12·6

Brake Pedal and Linkage Adjustment ............................................ 12·9 Height Adjustment .......•.......•............•••••.•..•.•....•..•....•........•• 12·9 Brake Pedal Travel ................................•..•..•..••••...........•..•... 12·10 Brake Linkage Adjustment ........•...............•.••••..•...•............•....• 12;.10

Bleeding the Brakes .............................................................. 12·11

Brake Testing ..................................................................... 12·12

SPECI FICATION

Brake Pressure ................................................... 1655 ± 70 kPa (240 ± 10 psi)

12-1

Section 13

IPTO ASSEMBLY

Contents

Page

I PTO Assem bly . . . . . . . . . . . • . . . • . . . . . . • . • . . . . . . • . . . • • • • . • . . . . . . • . . . . • . . . . . . . . . . • • . .• 1 3-2

Dual Speed IPTO Assembly •....•.....••....•...........••....•.......•....•...... 13-12

IPTOValveAdjustment .................................•..•....•..........•.•.... 13-17

I PTO Drive and Driven Gear ......................•.........•.•..•........•...•.•.. 1 3-18

IPTO Cable Adjustment ..•.•..............••.•.•...•..•..•.................•...... 13-21

13·1

Section 14

HYDRAULIC SYSTEM

Contents

Page

Power Priority Hydraulic (PPH) System Introduction 00000000000000000000000000000 14-3

Power Priority Hydraulic (PPH) System Operation 0000000000000000000000000000000 14-5 Stand-by 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 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 4-6 Load Sensi ng on Demand 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 14-7 Increased Flow Demand 00 0 0 0 0 00 0 0 0 0 0 0 0 0 0 00 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 0 0 0 000 000 0 0 0 14-8 Cut-Off ••.•..•....•••••••.....•......•..........•..••..•..•........•....•..•••••• 1 4·9

Motor Priority Valve 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 000 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 14-10

Motor and Auxil iary Valves 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 000 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 14-11

Variable Raise Rate Valve 0000000000000000000000000000000000000000000000000000 0 0 0 0 14-17

Draft Control Valve 0000000000000000000000000000000000000000000000000000 0 0 0 0 0 0 0 0 0 000 14-18

Drop Control Valve 000 0 0 0 0 0 0 00 0 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 000 14-20

Steering/Regulated Pump Flow 0000000000000000000000000000000000000000000000000 0 14-22

Priority Flow Divider 00 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 000 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 14-23

Transmission Control Valve 0000000000000000000000000000000000000000000000000000 0 0 14-26

Lu brication Flow 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 14-27

Transmission Lubrication Valve 0000000000000000000000000000000000000000000000000 0 14-28

Hitch Control Checks and Adjustments 000000000000000000000000000000000000000000 14-30

Lever Friction Adjustment 0000000000000000000000000000000.00000000000000000000 0 000 14-30

Drop Poppet Valve 000000000000 •• 0000. 00 •••••• 0 •• 0 •• 0 • 0 ••• 0 0 0 •• 0 0 0 0 0 0 0 0 0 0 0 ••••• 0 0 • 0 14-31

Position Control Lever Adjustment ... 0 •••• 0 o. 0 ••• 0 • 00 •••••• 0 •••• 0 • 0 0 • 0 0 0 • 0 • 0 • 0 0 • 0 14-34

Drop Control Valve Adjustment .. 0 0 0 0 •• 0. 0 0 • 0 •• 0 0 •• 0 00 •••••••••••• 0 •• 0 .0 •• 0 • 0 • 0 000 14-36

Load (Draft) Control Lever Adjustment .. 0 •• 0.0 •••••• 000 •••• 00 ••• 000 •• 0 •• 00 •• 000.0 14-37

14 ·1

Page

Torsion Bar and Internal Sensing Arm Adjustment .............................. 14-38

Variable Raise Rate ............................................................... 14-39

Position Control Accuracy Test ................................................... 14-40

Checking Raise and Drop Time ................................................... 14-41

Checking Leakage and Settling .................................................. 14-41

Steeri ng/Lu brication Pu m p ...................................................... 1 4-42

Pump Drive Housing .............................................................. 14-45

PPH Pu m p ........................................................................ 1 4-47 Start-up Procedure .............................................................. 14-51

Draft Control Valve ................................................................ 14-52

H itch Assist Cyli nder ............................................................. 1 4-53

PPH Motor and Auxiliary Valves .................................................. 14-54

Flow Control Valve ................................................................ 14-60

Alternating Acting Check Valve .................................................. 14-61

Coup4er Service ................................................................... 14-63

Hyd ra u Ii c Seat .................................................................... 1 4-75

Recharging Accumulator in Hydraulic Seat ...................................... 14-79

Hydraulic Filters .................................................................. 14-81

Hydraulic System Clean Up Procedure ........................................... 14-83

Auxiliary Valve Linkage ........................................................... 14-88

All Wheel Drive Sc>lenoid •••• ., •••••••••••••••••••••••.•••••••••.••.• _ .. ~. 14-90

GSS-1506-1 CR •• No. 11 PRINTED IN UNITED STATEI OF" AM£RICA

14-2.

Sperry-Vickers Pump

G8S-1505-1 (Rev. No.2)

14- 46

7. After establishing the shim pack remove the adapter housing and install the shim pack and O-ring. Reinstall the adapter housing onto the pump housing and secure the pump housing mounting bolts and torque to 54 to 61 N·m (40 to 45 ft. lbs.) and take end play reading at the pump shaft.

8. Position a dial indicator gage at the pump shaft. Pry up on the drive gear to register end play of .025 to .1 mm (.001 to .004 inch) if proper end play is not obtained, add or remove shims to correct.

9. Install the bearings (2) in the idler gear. Next install the idler gear with a thrust washer on each side, oil groove toward washer on each side, oil groove toward gear, and install the idler shaft. Install the idler shaft retaining bolt and torque to 94 to 106 N·m (69 to 78 ft. lbs.).

10. Install lube tube with new O-ring and torque to 27 to 31 N'm (19 to 21 ft. lbs.).

11. Install on range transmission using Loc­tite Gasket Eliminator 515 (474 517 C2).

Cessna Pump

PRINTED IN U"IT[O STATES OF' AM[LIIIIC~

Section 15

TESTING HYDRAULIC SYSTEM

Contents

Page

Specifications . . • . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . • . . . • . . . . . . . . . . . • . . . . . . .• 15-3

Troubleshooting Power Priority PPH System Steering/Regulated System

Test No.1

15-6 15-11

Coupler Flow Rate .........................•...........•................... 15-15

Test No.2 Variable Raise Rate 15-17 Interpreting Test Results ..........................•......................... 15-18

Hydraulic System Analyzer (14-557) Installation .................................... 15-19

Test No.3 Pump Flow Rate and Cut-Off Pressure .......................................... 15-21

Test No.4 Pump Standby Pressure ...................................................... 15-22

Test No.5 Pump Differential Pressure .................................................. , 15;22

Hydraulic System Problems - Pump OK ........................................... 15-23

Test No.6 Motor and Auxiliary Valve Flow .............................................. 15-24

Test No.7 Auxiliary Valve Unlatching Pressure ............................................ 15-25

Test No.8 Lubrication Pressure ........................................................ 15-27

15 -1

Test No.2

Variable Raise Rate

1. Over-ride linkage 2. Variable raise rate control

Slow Setting

IMPORTANT: Before proceeding with the test be sure the hitch is adjusted properly. Refer to Section 14.

1. Place a load 1360 Kg (3000 Ibs. ) on the hitch that will allow the hitch to travel from full lower to full upper posi­tion.

2. With the hitch raise rate handle in the slow position (at front of quadrant) run the engine at 2400 rpm. Be sure the variable raise rate lever is against stop for slow setting.

NOTE: Be sure the Hy-Tran temger­ature is at least 3So -650 C (1000 -150 F).

3. Place fue position control lever in the extreme lower position. Move the load control lever to the light position to raise the hitch from the full lower to the full upper position three times. Record the time of each raise cycle.

4. Calculate the average of the three times. The average time must be at least fifteen (15) seconds. If the average time is less than fifteen (15) seconds, adjust slow speed control as follows:

a. Loosen bolt in front end of the control rod.

b. Adjust rod to lever position in slot until a speed of 15 seconds or more is obtained. (Forward in slot to increase, back to decrease.)

Fast Setting

1. Use the same load on the hitch. Place the hitch raise rate handle in the fast position (at rear of quadrant).

2. Be sure the draft control lever is still in the off position. Using the posi­tion lever only, raise the hitch from the full lower to the full upper position three times. Record the time of each raise cycle.

15-17

3. Calculate the average of the three times. The average time must not be greater than three (3) seconds. If the time is more than three (3) seconds, ad­just the fast speed control linkage.