7010, 7020 & 7045 Volume 1 of 2

Transcription

1 Allis Chalmers Service Manual 7010, 7020 & 7045 Volume 1 of 2 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF ALLIS CHALMERS OR IT S SUCCESSORS. ALLIS CHALMERS 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. AC-S-7010+

2 ALLIS-CHALMERS SERVICE MANUAL Madel 7010 J 7020 and 7045 TRACTORS AGRICUL TURAL EGUIPMENT tho in U.S.A. Part No

3 ENGINE _,'T' 6491 ENGINE CONTENTS Adaptor Plate and Crankshaft Rear Oil Seal... A-80 - A-82 Removing Tool A-81 Ai Research Turbocharger... A-27 Description A-27 Removal A-27 - A-29 Disassembly A-29 - A-30 Inspection A-31 - A-33 Reassembly A-33 - A-34 Installation A-34 Camshaft and Gear A-92 - A-98 Camshaft Bearings , A-98 - A-99 Thrust Plates A-97 Connecting Rod and Connecting Rod Bearings A A-107 Crankshaft and Crank haft Gear..... A A-111 Gear Removal A-77, A-111 Crankshaft Pulley and Damper Assembly... A-70 Cylinder Block A-116 Cylinder Head... A-50 Cylinder Head Removal and Installation... A-54, A-61 Rocker Arm Shaft A-52 - A-53 Valve Face and Valve Seat Grinding A-68, A- 69 Valve Lash Adjustment A-62, A-63 Valve Springs, Guides and Seats... A-64, A-68 Cylinder Sleeve A A-120 Reseating A A-123 Engine Cooling System. A Engine Disassembly and Assembly... A-124 Assembly A-124 Disassembly A-124 General A-124 Run-In Schedule A-125, ':-, Flywheel and Ring Gear Inspection, Removal and Installation... A-78, A-79 Front Plate and Gear Cover A-77 Litho in U.sA. 649 I ENG TR. A 1 Mailing No.4 of

4 ENGINE Front Support Plate... A-77 Fuel Pump Drive Gear and Pump Drive Shaft... A-74 Fuel Injection Nozzle Holder Sleeves... A-55 - A-59 Gear Train... A-73 Idler Gear Shaft... A-75, A-76 Main Bearings... A A-114 BearingCaps... A-ll0,A-115 Manifold Exhaust... A-26 Intake... A-25 Oil Flow... A-83 - A-87 Oil Pan... A-88, A-89 Oil Pump... A-90 Cleaning and Inspection... A-90 Engine Breather Tube... A-91 Installation... A-91 Pressure Relief Valve... A-91 Piston and Piston Rings A A-l05 Radiator... A-17 Fan and Fan Belt... A-18 Thermostat... A-19 Specifications (649 I) General Specifications... A-3 Fits and Tolerances (649 I)... A-8 Engine Torque Specifications..., A-9-13 Timing Gear Cover and Crankshaft Front Oil Seal... A-71 - A-73 Troubleshooting... A-96 - A-l 05 - Dyno. Testing... A A-136 Tractor Engine Data... A-137 Turbocharger Troubleshooting... A-37 - A-49 Valve Lifters... A-l00 Water Pump... A-20 - A-24 Mailing NO.4 of I ENG TR. A-2

5 ENGINE TURBOCHARGERS Figure 4 - Bar Type Adapter for Measuring Radial Movement. 1. Dial indicator 2. Adaptor Figure J - Checking Shaft End Play 1. Dial indicator 2. Compressor wheel 3. Back plate assembly 4. Turbine housing 5. Spindle Clamp CHECK SHAFT END PLAY Remove the compressor housing. Check shaft end playas follows: (Specified end play.001 inch to.004 inch) ( mm). a. Clamp the turbine housing flange (Figure 3) in a vise. b. Use either a clamp or magnetic base dial indicator. c. Place indicator contact point on end of impelier shaft. d. Press up on turbine wheel to force the impeller to extreme up position; record indicator reading. e. Press down on impeller; again record indicator reading. Figure 5 - Rod Type Adapter for Measuring Radial Movement 1. Dial indicator 2. Adaptor rod 3. Spindle clamp 4. Indicator extension f. The difference between the readings is the end play. g. End play should be from.001" to.004" ( mm). h. Record the end play. nis will be used to determine if thrust plate assembly or thnjst Dearing need to be replaced. i.!f en":! play exceeds.004" (0.10 mm), it indicates that thru:;t collar, thrust bearing, or thrust bearing surface of the back plate assembly are worn. If end play is less than.001" (0.03 mm) it indicates a carbon build-up behind the turbine wheel. Unit must be disassembled and condition corrected I ENG TR. A-28

6 ENGINE CYLINDER BLOCK GENERAL The cylinder block the main structural part of the engine, is a one-piece casting made of alloy cast iron. Transverse members, cast integral, provide rigidity and strength, assuring accurate alignment of the crankshaft bearings and cylinder sleeves. The cylinder block is cored to receive removable wet-type cylinder sleeves. The cylinder sleeves are completely surrounded by water jackets which extend the full length of the cylinder walls for maximum cooling. The cylinder block contains a main oil gallery which extends lengthwise through the cylinder block. Oil passages direct the oil from the main oil gallery to main bearings. A vertical oil passage from the bottom of the cylinder block extends to the filter. The oil from the filter flows out through an external tube, around the rear of the block and into the oil cooler. An internal gallery plug directs the oil via the external tube through the oil cooler before entering the main oil gallery. The cylinder block, when ordered for service, is furnished with camshaft bearings, main bearing caps and capscrews, drain cock and necessary plugs. Six dowel pins, a rebuilt engine name plate and attaching screws, a distributor hole plug and a gallery plug and spring are also included. Install the two 3/8 inch x 3/4 inch long dowel pins in the top deck of the cylinder block. Install the two 1/2 inch x 1-1/4 inch long dowel pins in front of the block and the two 1/2 inch x 1 inch long dowel pins in the rear of the block. For location of the gallery plug, refer to illustration. Install gallery plug with large end toward spring. The removable wet-type cylinder sleeves are made of alloyed cast iron. Packing rings, fitted into the grooves in the lower outside circumference of the sleeve, prevent water leakage into the oil pan. The sleeve is retained at the top by a flange which fits into a machined recess in the cylinde.r block. The cylinder head gasket is compressed between this flange and the cylinder head, holding the sleeve in place and serving as a coolant and pressure seal at the upper end of the sleeve. CRANKSHAFT AND PISTON DIMENSIONAL TOLER ANCES IN RELATIONSHIP TO THE TOP DECK OF THE CYLINDER BLOCK The tolerances as tabulated should be an aid when machining or verifying a cylinder block and head. Dimensions are listed as minimum and maximum machining tolerances and not to be construed as wear limits for service parts. Dimension A shows the relationship of the top of the piston to the top deck of the cylinder block with the piston at Top Dead Center (T.D.C.) Above means that the top of the piston is.0299" above the Top Deck. of the cylinder block with the piston at T.D.C.. Dimension 0, E, G & I are diametral clearance dimensions ( 1/2 u sed for calcu lations). TOP DECK OF CYLINDER BLOCK "A" TOP OF PISTON TO TOP DECK OF CYLINDER BLOCK li'--~=r~-----r-r----~ "e" PISTON PI N TO TOP OF PISTON,"0" PISTON PIN TO PISTON CLEARANCE "'E" PISTON PIN TO CONNECTING ROD BUSHING CLEARANCE CONNECTING ROD LENGTH-CENTER TO CENTER I "G" CONNECTING ROD -! BUSHING TO CRANK SHAFT JOURNAL '",,,,.,,,.-- - CLEARANCE "'Hu CRANK THROW RADIUS CRANKSHAFT "I" Mailing No.4 of I ENG TR. A-116

7 ENGINE CYLINDER SLEEVES CYLINDER SLEEVES A. CYLINDER SLEEVE INSPECTION AND REMOVAL The cylinder sleeves may be removed and replaced while the engine is installed in the unit by removing the cylinder head, oil pan, oil pump and associated tubing, and the piston and connecting rod assemblies. NOTE: Removal of the cylinder sleeves while the engine is installed is only recommended in emergencies or when it is impractical to remove the engine from the unit. FIGURE 1 - Checking Cylinder Sleeve for Roundness 1. Cylinder Sleeve 2. Cylinder Diameter Checking Gauge 1. Check cylinder sleeves for roundness by means of a gauge similar to the one shown in Figure 1. Using an inside micrometer, measure cylinder sleeve for taper and wear. The specified inside diameter of a cyl inder sleeve is " " ( mm mm). When measuring cylinder sleeves with an inside micrometer, first measure in a position parallel to crankshaft and then at right angles to crankshaft. These measurements should be taken at several locations within the area of piston ring travel. F1GURE 2 - Removing Ring Travel Ridge from Cylinder Sleeve 1. Ridge Reamer Tool 2. Cylinder Sleeve 3. Capscrew and Washer 4. Capscrew The normal pattern of wear in cylinder sleeves will show maximum wear at the top three-fourths of ring travel. If maximum sleeve wear at top of ring travel does not exceed.0015" (.038 mm) out-of-round,.0015" (.038 mm) taper,.008" (.20 mm) total wear, and if no deterioration of the flange has occurred to decrease the specified protrusion (standout), the sleeves may be reinstalled with a life expectancy of approximately one-half to three-fourths of new sleeves. The sleeves must be free of cracks, scores, and other physical defects. Mailing No.4 of T ENG TR. A 106

8 TROUBLESHOOTING THE HYDRAULIC SYSTEM HYDRAULICS PROCEDURE FOR USE OF GUIDE To correctly use this guide, follow the steps listtld below: 1. Determine which hydraulic circuit is involved. 2. Turn to the index page for that circuit. (See main index below). 3. Choose the heading on the circuit index page which best describes the problem. 4: Check the causes listed under that heading. The causes are listed in order of the easiest to check. This is to make troubleshooting as quick and easy as possible. Under each cause are listed the particular symptom(s) that it will produce. Eliminate the causes that do not fit the problem until the one is found that does. 5. Correct the problem as determined above & 7045 TRACTOR TROUBLESHOOTING INDEX MAIN INDEX I. OIL TRANSFER BETWEEN SUMPS... C -80 II. POWER STEERING CIRCUIT... C-83 III. 3-POINT HITCH AND REMOTE RAM CIRCUIT... C-89 IV. BRAKE AND P.T.O. CLUTCH CIRCUIT... C-l03 V. "POWER DIRECTOR" TRANSMISSION CiRCUiT... :... C-115 litho in U.S.A TRACTORS C

9 HYDRAULICS OIL TRANSFER I. TRANSFER OF OIL BETWEEN TRANSMISSION AND REAR HOUSING SUMPS TROUBLESHOOTING PROCEDURE If a transfer of 0;1 is suspected, have the operator check oil levels in the morning after the tractor has not been run for several hours. This will give the oil levels a chance to stabilize so proper readings can be obtained. The five minute waiting period specified. on the decals at the checking points is not long enough for the oil level to stabilize if the oil is cold. If a definite oil level change in the sump is established, and there are no external leaks, proceed as outlined below. INDEX A. TRANSFER OF OIL FROM TRANSMISSION SUMP TO REAR HOUSING SUMP... C-SD B. TRANSFER OF OIL FROM REAR HOUSING SUMP TO TRANSMISSION SUMP... C-Sl NOTE: For additional information, refer to Service Bulletin No. WA TRACTORS C-80

10 HYDRAULICS POWER STEERING CIRCUIT TROUBLE SHOOTING INDEX II. POWER STEERING CIRCUIT TROUBLE SHOOTING PROCEDURE INDEX A. COMPLETE LOSS OF POWER STEERING Page C-84 B. STEERING WHEEL TURNS FREELY WITH NO ACTION OF FRONT WHEELS... C-B4 C. STEERING IS HARD OR SLUGGISH... C-B5 D. STEERING WHEEL KICKS, JERKS, OR TURNS BY ITSELF C-B6 E. STEERING OK HYDRAULICALLY BUT TAKES EXCESSIVE EFFORT TO TURN WHEEL... C-B6 F. STEERING WHEEL DRIFTS TO RIGHT... C-B6 G. NOT ENOUGH PRESSURE TO TURN WHEELS.... C-B7 H. FRONT WHEELS TURN TO LEFT AND STAY THERE... C-87 I. TAKES MORE TURNS OF STEERING WHEEL TO MAKE FULL TURN IN ONE DIRECTION THAN IN OTHER... C-B7 J. CONTINUOUS FAILURE OF GEAR PUMP... C-87 K. OVERHEATING OF OIL IN REAR HOUSING SUMP... C-88 L. FAILURE OF BRAKE OR P.T.O. CLUTCH PLATES DUE TO LACK OF LUBRICATION... C-88 Litho in U.S.A TRACTORS C 83 Mailing No.4 of

11 HYDRAULICS TROUBLE SHOOTING 3-POINT HITCH & REMOTE RAM CIRCUIT III. 3-POINT HITCH AND REMOTE RAM CIRCUIT TROUBLE SHOOTING PROCEDURE INDEX 1. 3-POINT HITCH PROBLEMS A. 3-POINT HITCH VALVE WILL NOT LIFT A LOAD - Remote Valves Okay C-90 B. 3-POINT HITCH VALVE WILL NOT LIFT A LOAD - Remote Valves Do No Work Either C-91 C. 3-POINT HITCH RAISES LOAD TOO SLOW C-92 D. 3-POINT HITCH WILL NOT LOWER C-93 E. 3-POINT HITCH WILL NOT STAY UP C-94 F. ERRATIC TRACTION BOOSTER SYSTEM C-94 G. 3-POINT HITCH FALLS WHEN REMOTE VALVE IS USED... C REMOTE VAL VE PROBLEMS A. REMOTE VALVES WILL NOT RAISE LOAD - 3-Point HitchWorks Okay... C-95 B. REMOTE VALVES WILL NOT RAISE LOAD - 3-Point Hitch Will Not Raise Load Either C-96 C. REMOTE VALVES WILL NOT WORK ONLY WHEN 3-POINT HITCH IS RAISED... C-96 D. REMOTE RAMS OPERATE TOO SLOW C-96 E. REMOTE RAMS RAISE TOO FAST... C-96 F. REMOTE RAM DROPS IMPLEMENT TOO FAST....,... C-97 G. REMOTE RAM HESITATES BEFORE OPERATION WHEN VALVE IS OPENED C-97 H. REMOTE RAMS LOCK UP WHEN HEAVY TOOL IS LOWERED... C-98 I. REMOTE RAMS LOCK UP WHEN RAISING TOOL C-98 J. TOO MUCH PRESSURE AT REMOTE OUTLET... C-98 K. PRESSURE DOES NOT FALL BACK TO STAND-BY WHEN REMOTE VALVES ARE RETURNED TO NEUTRAL... C-99 L. ACTS LIKE CAVITATING PUMP IF VALVES ARE OPERATED SEVERAL TIMES C-99 M. REMOTE VALVE SPOOL DETENTS DO NOT WORK... ~... C-99 N. REMOTE VALVE WILL NOT SELF-CANCEL C-100 O. REMOTE COUPLERS HARD TO HOOK UP C-100 P. REMOTE VALVE SPOOL SEAL BLOWS OUT C OTHER 3-POINT HITCH & REMOTE CIRCUIT PROBLEMS A. CHATTERING NOISE IN VALVES... _... C-10l B. LINES OR O-RINGS KEEP BURSTING... C 10l C. OIL FILTER WARNING LIGHT ON... C-102 Page TRACTORS C-89 Mailing No.4 of

12 HYDRAULICS TROUBLE SHOOTING BRAKE & P.T.O. CLUTCH CIRCUIT IV. BRAKE AND P.T.O. CLUTCH CIRCUIT TROUBLE SHOOTING PROCEDURE INDEX A. P.T.O. CLUTCH WILL NOT ENGAGE... C-l04 B. P.T.O. CLUTCH SLIPS UNDER LOAD...,... C-10S C. P.T.O. CLUTCH ENGAGES TOO QUICKLY... C-106 D. P.T.O. CLUTCH DISENGAGES TOO SLOWLY... C-106 E. P.T.O. CLUTCH DISENGAGES ITSELF... C-107 F. P.T.O. SHAFT WILL NOT STOP TURNING OR P.T.O. BRAKE DOES NOT WORK... C-107 G. P.T.O. CLUTCH OR BRAKE PRESSURE TOO HIGH... C-10S H. P.T.O. CLUTCH PRESSURE TOO LOW (See "A" & "B" above) I. P.T.O. BRAKE PRESSURE TOO LOW (See "F" above) J. NO POWER BRAKES (Both Sides)... C-10S K. NO POWER BRAKE (One Side Only)... C-109 L. NO MANUAL BRAKE (One Side Only), BUT BRAKES WORK OKAY WITH ENGINE RUNNING... C-110 M. NO MANUAL BRAKES (Both Sides) BUT BRAKES WORK OKAY WITH ENGINE RUNNING C-110 N. BRAKE PEDAL GOES SOLID BUT BRAKE DOES NOT APPLY.. C-110 O. DELAY BETWEEN TIME BRAKE PEDAL IS DEPRESSED AND BRAKE APPLIES OR "SPONGY" FEEL ON BRAKE PEDAL... C-110 P. CANNOT FEATHER BRAKES, OR BRAKES "GRAB"... C-111 Q. BRAKES REQUIRE TOO MUCH PEDAL PRESSURE TO APPLY. C-11l R. DIFFERENTIAL LOCK DOES NOT ENGAGE... C-ll2 S. DIFFERENTIAL LOCK DOES NOT RELEASE C-ll3 Litho in U.S.A TRACTORS C-103 Mailing No.4 of

13 CHASSIS AND OPTIONAL EQUIPMENT Description CAPSCREW TORQUES CHASSIS TRACTORS Ft.-Ibs. Torque N m Torque 14L-16 Front Wheel to Hub Front Wheel to Hub.... All Others.... Front Axle to Spindle Support.... Side Frames to Front Support.... Side Frames to Engine Front Plate.... Transmission to Side Frame.... Engine Adaptor Plate to Transmission.... Rear Wheel Bushing.... Rear Wheel to Rim Nut 5/8" Non-Power Adjust.... 3/4" Non-Power Adjust.... 3/4" Power Adjust TRACTORS G 22

14 HIGH CLEARANCE TRACTOR SECTION H - HIGH CLEARANCE TRACTOR MODELS 7010, 7020 AND 7045 CONTENTS GENERAL FRONT AXLE ASSEMBLY H-2 H-2 FINAL DRIVE ASSEMBLY Removal... H-3 Installation ' o. H-4 Axle & Bull Gear Removal H-5 Rear Axle Oil Leakage o 0 o H-5 Intermediate Shaft Removal o '0 - '0' o. H o6 Mainshaft Removal H-8 Mainshaft Installation o. H 8 I ntermediate Shaft Installation H-8 Mainshaft Bearing Adjustment H-8 Axle Shaft & Bull Gear Installation ' o. 0 H-9 Axle Shaft Bearing Adjustment H-lO TORQUE REFERENCE CHARTS... o H ll & H-12 Litho in U.S.A TRACTORS H o 1 Mailing No.4 of