Allis-Chalmers HD-5 Manuals

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Allis-Chalmers HD-5 Manual (221 pages)

Brand: Allis-Chalmers | Category: Tractor | Size: 10.82 MB

Subject Index
3
General Description
5
Section I - Description and Specifications
5
Maximum Speeds
6
Specifications of Lubricants
7
Engine Crankcase Lubricant
7
Transmission and Final Drive Lubricant
7
Pressure Gun Lubricant
7
Specifications of Fuel Oil
8
Fuel Storage
8
Tractor and Engine Serial Numbers
9
Description of System
13
Schematic Fuel Flow Diagram
13
Section II - Engine Fuel System
13
Checking Fuel Supply System
14
Check for Clogged Injector Filters
14
Locating Faulty Injector
14
Fuel Tank and Drain Elbow
15
Check for Inoperative Pump
15
Excessively High Pressure
15
Fuel Filters
16
Description of First Stage Fuel Filter
16
Service of First Stage Fuel Filter
16
Description of Second Stage Fuel Filter
16
Fuel Pump
17
Service of Second Stage Fuel Filter
17
Inspection of Eaton Fuel Pump Parts
19
Assembly of Eaton Fuel Pump
19
Disassembly of Barnes Fuel Pump
20
Inspection of Barnes Pump Parts
21
Assembly of Barnes Fuel Pump
21
Fuel Pump Drive
22
Disassembly of Fuel Pump Drive Shaft Assembly
22
Assembly of Fuel Pump Drive Shaft
22
Fuel Pump Drive Shaft Details
22
Fuel Injectors
23
Fuel Injector Mounting
23
Fuel Injector Details
24
Injector Service
25
Injector Removal
25
Metering and Injection of Fuel
25
Injector Disassembly
26
Removing Injector from Engine
26
Removing Stop Pin from Injector Follower
26
Reaming Injector Spray Tip
27
Removing Injector Nut
27
Valves and Seats
28
Plunger and Bushing
28
Injector Nut
28
Injector Filters
28
Injector Assembly
29
Install Injector Filters
29
Install Control Rack and Gear
29
Assemble Spray Tip and Valves
30
Install Plunger and Follower Assembly
30
Testing Injector
31
Injector Plunger and Follower Details
31
Popping the Injector
31
Injector Installation
32
Pressure Checking Injector
32
Injector Timing
33
Injector Equalizing
33
Injector Copper Tubes
34
Copper Tube Removal
34
Equalizing Injectors
34
Injector Copper Tube Removed Installed
34
Copper Tube Installation
35
Removing Injector Copper Tube
35
Installing Injector Copper Tube
35
Cylinder Block
35
Flaring End of Copper Tube
36
Reaming Bevel Seat in Copper Tube
36
Checking Location of Spray Tip
36
Fuel Manifolds
37
Engine Air Intake System
38
Air Flow through Engine
38
Air Pre-Cleaner
39
Air Cleaner
39
To Service Cleaner
40
Air Cleaner Service
40
Air Intake Tube and Air Shut-Off Valve
41
Air Cleaner Removal and Installation
41
Hose Clamp
41
Blower
42
Blower Location
42
Blower Removal
43
Inspection of Blower Assembly
44
Disassembly of Blower
44
Pulling Rotor Timing Gear
44
Blower Details in Relative Position
45
Install Oil Seals in Blower End Plates
46
Install Blower Rear End Plate
46
Assemble Rotors into Housing
47
Install Rotor Shaft Front Bearings
47
Install Blower Front End Plate
47
Install Rotor Shaft Rear Bearings
47
Blower Rotor Timing
48
Check Rotor Lobe Clearance
48
Attach Blower Assembly
48
Air Box and Cylinder Liner Air Ports
49
Air Box and Drain Tube
49
Cylinder Liner Air Ports
49
Air Heater and Air Heater Pump
50
Cylinder Liners
50
Air Heater Location
50
Air Heater Ignition System
51
Spray Nozzle
51
Air Heater Pump
52
Pump Outlet Check Valve
52
Air Heater Pump Details
52
Starting Fluid Primer
53
Air Heater Removal
53
Air Heater Installation
53
Elbow Primer Assembly Clogged
55
Inoperative Primer Pump
55
Clogged Dispenser Strainer Screen
56
Primer Dispenser Details
56
General Maintenance
57
Section IV - Engine Cooling System
57
Description of System
57
Filling and Draining of System
58
Cleaning of Cooling System
58
Draining Cooling System
58
Radiator
59
Cleaning Materials
59
Cleaning Exterior of Radiator
59
Water Pump
60
Radiator Assembly
60
Water Pump Sectionalized View
60
Water Pump Lubrication
61
Water Pump Removal
61
Water Pump Disassembly
61
Water Pump Assembly
62
Water Pump Details
62
Thermostat and Thermostat Housing
63
Assembly of Water Pump to Enigne
63
Fan and Belts
64
Thermostat Replacement
64
Drive Belt Adjustment
64
Removal of Fan
65
Installation of Fan
65
Engine Lubrication Diagram
66
Section V - Engine Lubrication System
66
Lubricating Oil Pump
67
Oil Pump Removal
68
Disassembly of Oil Pump
68
Cleaning and Inspection of Oil Pump Parts
68
Lubricating Oil Pump Assembly
68
Lubricating Oil Cooler
69
Assembly of Oil Pump
69
Oil Pump Installation
69
Removal of Oil Cooler
70
Cleaning of Oil Cooler
70
Lubricating Oil Filter
71
Changing Oil Filter Element
71
Oil Cooler By-Pass Valve
72
Removal of Oil Cooler By-Pass Valve
72
Assembly of Oil Cooler By-Pass Valve
72
Engine Controls and Governor
73
Throttle and Engine Shut-Off Controls
73
Governor
74
Adjustment of Engine Shut-Off Controls
74
Governor Details
74
Governor Weight Details
74
Governor Inspection and Service
75
Governor Removal
76
Disassembly of Variable Speed Spring Housing
76
Disassembly of Operating Shaft
77
Inspection of Governor Parts
77
Assembly of Governor
77
Governor Installation
77
Governor Adjustment
78
Section VII - Electrical System
80
Wiring System
81
Batteries
81
Wiring Diagram
81
Generator and Generator Regulator
82
Step Voltage Control
83
Brushes
83
Commutator
83
Drive Belts
83
Testing and Adjusting of Generator and Regulator
84
Generator Step-Voltage Control Checks
84
Checking Cut out Relay
85
Cut out Relay Adjustments
85
Voltage Control Adjustments
86
Starter
87
Generator Removal and Installation
87
Starter Drive Assembly
88
Starter Drive Adjustments
88
Starter Removal and Installation
89
Instruments
90
Engine Oil Pressure Gauge
91
Engine Temperature Gauge
91
Ammeter
91
Fuel Pressure Gauge
91
Engine
92
Cylinder Head
94
Cylinder Head Assembly
94
Cylinder Head Removal
95
Cylinder Head Installation
96
Exhaust Valves and Operating Mechanism
97
Valve Lash Adjustment
98
Valve Operating Mechanism
98
Rocker Arm Removal, Inspection and Installation
99
Exhaust Valve Spring Removal and Installation
100
Installing Valve Guides
101
Location of Valve Guides
102
Removing Valve Seat Insert
102
Valve and Valve Seat Reconditioning
103
Grinding Valve Seats
103
Valve and Insert Relationship
104
Lapping Valves
104
Cylinder Block and Liners
105
Cylinder Liner Removal
106
Cylinder Liner Cleaning and Inspection
106
Cylinder Liner Service
106
Cylinder Liner Installation
107
Cleaning and Inspection of Cylinder Block
107
Measuring Liner
107
Crankshaft, Flywheel and Main Bearings
108
Air Box Drain Tubes
108
Rear Main Bearing Oil Seal
109
Main Bearing Inspection
110
Measuring Main Bearing Shells
110
Main Bearing Replacement
111
Replacement of Pilot Bearing Oil Wick
111
Inside Diameter of Bearing Shells
111
Pistons and Connecting Rods
112
Description of Pistons
112
Flywheel
112
Description of Connecting Rods
113
Service
113
Piston Assembly Details
113
Connecting Rod Assembly
113
Removal of Connecting Rod and Rings from Pistons
114
Piston and Piston Ring Inspection
114
Inspection of Connecting Rod Assembly
115
Fitting Piston Rings
116
Measuring Piston Ring Gap
116
Camshaft and Balancer Shaft
117
Assemble Connecting Rod and Pistons
117
Remove Camshaft and Balancer Shaft
118
Inspect Camshaft
119
Remove Camshaft and Balancer Shaft Bearings
119
Installation of Camshaft and Balancer Shaft
120
Install Camshaft and Balancer Shaft Rear Balance Weights
120
Gear Train
121
Removal of Engine Front Cover
121
Remove Crankshaft Front Oil Seal from Gear Cover
122
Installation of Engine Front Cover
122
Repair of Engine While Installed
123
Replacement of Crankshaft Main Bearings
124
Engine Removal and Installation
125
Disassembly of Engine
127
Removal of Accessories from Engine
127
Disassembly of Engine into Sub-Assemblies
128
Assembly of Engine
129
Engine Run-In Schedule
131
Engine Clutch and Clutch Brake
132
Clutch Service
132
Engine Clutch Adjustment
132
Clutch Adjustment
133
Washing Engine Clutch
133
Clutch Linkage Adjustment
133
Clutch Removal
133
Clutch Disassembly
134
Clutch Inspection and Repair
134
Clutch Assembly
135
Inspection and Replacement of Clutch Operating Yoke
135
Engine Clutch Brake
136
Clutch Installation
136
Service Inspection and Repair
137
Clutch Brake Removal
137
Clutch Brake Installation
137
Transmission and Bevel Gear
138
Transmission Assembly Cut-A-Way
138
Transmission Removal
139
Transmission Disassembly
139
Transmission Removed from Tractor
140
Transmission Case and Covers
140
Assembly of Trasmission
141
Install the Bevel Pinion Shaft and Gears
142
Install the Gear Shift Controls and Input Shaft
144
Gear Shift Details
144
Bevel Gear
146
Removal of Bevel Gear
146
Cleaning and Inspection of Parts
147
Assembly of Bevel Gear
147
Installing Clutch Shaft
148
Tooth Bearings
149
Universal Joint
150
Steering Clutches
152
Linkage Adjustment
152
Washing Steering Clutches
153
Disassemble Steering Clutch
153
Steel Discs
154
Friction Discs
154
Pressure Springs
154
Hub
154
Assembly of Steering Clutch
155
Steering Clutch Throwout Bearing Assembly
156
Steering Clutch Brake Service
157
Section XIII - Steering Brakes
157
Parking Brake Lock
157
Brake Adjustment
158
Brake Linkage Adjustment
158
Washing Brakes
159
Brake Band Removal
159
Brake Inspection and Repair
159
Brake Band Installation
159
Removal of Sprocket Shaft
160
Section XIV - Final Drives
160
Pulling Sprocket Shaft Bracket
161
Pulling Track Sprocket
161
Pulling Sprocket Shaft
161
Removal of Final Drive Intermediate Shaft
162
Removal of Final Drive Pinion Shaft
162
Intermediate Shaft Bearing Adjustment
163
Sprocket Shaft Bearing Adjustment
163
Cleaning and Inspection
163
Installation of Sprocket Shaft Seal Assembly
164
Final Drive Pinion Shaft Details
165
Installation of Intermediate Shaft
166
Final Drive Intermediate Shaft Details
166
Installation of Sprocket Shaft
167
Truck Frames
170
Truck Frame
170
Truck Wheels
172
Checking and Removal of Truck Wheels
172
Disassemble Truck Wheels
172
To Install the Seal Assembly
174
Track Release
175
Support Roller
175
Removal of Support Roller
175
Disassembly of Support Roller
176
Support Roller Details
176
Track Idler
177
Idler Slide Bars and Alignment
177
Track Idler Removed
178
Drawbar
181
Tracks
182
Track Details
182
Track Adjustment
183
Track Removal
183
Main Frame and Equalizer Spring
185
Main Frame and Bumper
185
Crankcase Guard
185
Equalizer Spring
185
Rigid Beam
187
Fenders and Seat Group
188
Seats
188
SECTION XX - Special. EQUIPMENT
189
Guard Equipment
190
Truck Frame Guard Equipment
190
Logging Guard Group
190
Cab Group
190
Cab
191
Hour Meter
191
Fuel Oil Pressure Gauge
191
Rear Panel
191
Check Pressure Switch
192
Lights
193
Power Take-Off and Power Pulley
193
Odometer
193
Power Pulley
193
General Maintenance Instructions
195
Bearings and Bushings
195
Ball Bearings
195
Needle Bearings
195
Shafts and Splines
196
Shifting Forks
196
Oil Seals
196
Lip Type
196
Gaskets
197
Gears
197
Hoses
197
Wiring
197
Fasteners
198
Miscellaneous
198
Fits and Tolerances
199
Troubleshooting
205
Engine will Not Turn
205
Incorrect Oil Viscosity
205
Batteries Weak
205
Engine Fails to Start
206
Loss of Power
206
Slow Cranking Speed
206
Blower Not Turning
206
Engine Stalls Frequently
207
Engine Detonates
207
Black Smoke
207
Starting System
208
Blue Smoke
208
Engine Overheats
208
Starter Does Not Turn
208
Fuel System
209
Checking of Fuel Supply System
209
Engine Air Intake System
210
Engine Lubricating System
212
Generator, Regulator, Lights and Wiring
213
Engine Starting Aids
214
Failure of Ignition
214
Poor Oil Spray
214

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