Allis-Chalmers HD-5

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Subject Index3
General Description5
Section I - Description and Specifications5
Maximum Speeds6
Specifications of Lubricants7
Engine Crankcase Lubricant7
Transmission and Final Drive Lubricant7
Pressure Gun Lubricant7
Specifications of Fuel Oil8
Fuel Storage8
Tractor and Engine Serial Numbers9
Description of System13
Schematic Fuel Flow Diagram13
Section II - Engine Fuel System13
Checking Fuel Supply System14
Check for Clogged Injector Filters14
Locating Faulty Injector14
Fuel Tank and Drain Elbow15
Check for Inoperative Pump15
Excessively High Pressure15
Fuel Filters16
Description of First Stage Fuel Filter16
Service of First Stage Fuel Filter16
Description of Second Stage Fuel Filter16
Fuel Pump17
Service of Second Stage Fuel Filter17
Inspection of Eaton Fuel Pump Parts19
Assembly of Eaton Fuel Pump19
Disassembly of Barnes Fuel Pump20
Inspection of Barnes Pump Parts21
Assembly of Barnes Fuel Pump21
Fuel Pump Drive22
Disassembly of Fuel Pump Drive Shaft Assembly22
Assembly of Fuel Pump Drive Shaft22
Fuel Pump Drive Shaft Details22
Fuel Injectors23
Fuel Injector Mounting23
Fuel Injector Details24
Injector Service25
Injector Removal25
Metering and Injection of Fuel25
Injector Disassembly26
Removing Injector from Engine26
Removing Stop Pin from Injector Follower26
Reaming Injector Spray Tip27
Removing Injector Nut27
Valves and Seats28
Plunger and Bushing28
Injector Nut28
Injector Filters28
Injector Assembly29
Install Injector Filters29
Install Control Rack and Gear29
Assemble Spray Tip and Valves30
Install Plunger and Follower Assembly30
Testing Injector31
Injector Plunger and Follower Details31
Popping the Injector31
Injector Installation32
Pressure Checking Injector32
Injector Timing33
Injector Equalizing33
Injector Copper Tubes34
Copper Tube Removal34
Equalizing Injectors34
Injector Copper Tube Removed Installed34
Copper Tube Installation35
Removing Injector Copper Tube35
Installing Injector Copper Tube35
Cylinder Block35
Flaring End of Copper Tube36
Reaming Bevel Seat in Copper Tube36
Checking Location of Spray Tip36
Fuel Manifolds37
Engine Air Intake System38
Air Flow through Engine38
Air Pre-Cleaner39
Air Cleaner39
To Service Cleaner40
Air Cleaner Service40
Air Intake Tube and Air Shut-Off Valve41
Air Cleaner Removal and Installation41
Hose Clamp41
Blower42
Blower Location42
Blower Removal43
Inspection of Blower Assembly44
Disassembly of Blower44
Pulling Rotor Timing Gear44
Blower Details in Relative Position45
Install Oil Seals in Blower End Plates46
Install Blower Rear End Plate46
Assemble Rotors into Housing47
Install Rotor Shaft Front Bearings47
Install Blower Front End Plate47
Install Rotor Shaft Rear Bearings47
Blower Rotor Timing48
Check Rotor Lobe Clearance48
Attach Blower Assembly48
Air Box and Cylinder Liner Air Ports49
Air Box and Drain Tube49
Cylinder Liner Air Ports49
Air Heater and Air Heater Pump50
Cylinder Liners50
Air Heater Location50
Air Heater Ignition System51
Spray Nozzle51
Air Heater Pump52
Pump Outlet Check Valve52
Air Heater Pump Details52
Starting Fluid Primer53
Air Heater Removal53
Air Heater Installation53
Elbow Primer Assembly Clogged55
Inoperative Primer Pump55
Clogged Dispenser Strainer Screen56
Primer Dispenser Details56
General Maintenance57
Section IV - Engine Cooling System57
Description of System57
Filling and Draining of System58
Cleaning of Cooling System58
Draining Cooling System58
Radiator59
Cleaning Materials59
Cleaning Exterior of Radiator59
Water Pump60
Radiator Assembly60
Water Pump Sectionalized View60
Water Pump Lubrication61
Water Pump Removal61
Water Pump Disassembly61
Water Pump Assembly62
Water Pump Details62
Thermostat and Thermostat Housing63
Assembly of Water Pump to Enigne63
Fan and Belts64
Thermostat Replacement64
Drive Belt Adjustment64
Removal of Fan65
Installation of Fan65
Engine Lubrication Diagram66
Section V - Engine Lubrication System66
Lubricating Oil Pump67
Oil Pump Removal68
Disassembly of Oil Pump68
Cleaning and Inspection of Oil Pump Parts68
Lubricating Oil Pump Assembly68
Lubricating Oil Cooler69
Assembly of Oil Pump69
Oil Pump Installation69
Removal of Oil Cooler70
Cleaning of Oil Cooler70
Lubricating Oil Filter71
Changing Oil Filter Element71
Oil Cooler By-Pass Valve72
Removal of Oil Cooler By-Pass Valve72
Assembly of Oil Cooler By-Pass Valve72
Engine Controls and Governor73
Throttle and Engine Shut-Off Controls73
Governor74
Adjustment of Engine Shut-Off Controls74
Governor Details74
Governor Weight Details74
Governor Inspection and Service75
Governor Removal76
Disassembly of Variable Speed Spring Housing76
Disassembly of Operating Shaft77
Inspection of Governor Parts77
Assembly of Governor77
Governor Installation77
Governor Adjustment78
Section VII - Electrical System80
Wiring System81
Batteries81
Wiring Diagram81
Generator and Generator Regulator82
Step Voltage Control83
Brushes83
Commutator83
Drive Belts83
Testing and Adjusting of Generator and Regulator84
Generator Step-Voltage Control Checks84
Checking Cut out Relay85
Cut out Relay Adjustments85
Voltage Control Adjustments86
Starter87
Generator Removal and Installation87
Starter Drive Assembly88
Starter Drive Adjustments88
Starter Removal and Installation89
Instruments90
Engine Oil Pressure Gauge91
Engine Temperature Gauge91
Ammeter91
Fuel Pressure Gauge91
Engine92
Cylinder Head94
Cylinder Head Assembly94
Cylinder Head Removal95
Cylinder Head Installation96
Exhaust Valves and Operating Mechanism97
Valve Lash Adjustment98
Valve Operating Mechanism98
Rocker Arm Removal, Inspection and Installation99
Exhaust Valve Spring Removal and Installation100
Installing Valve Guides101
Location of Valve Guides102
Removing Valve Seat Insert102
Valve and Valve Seat Reconditioning103
Grinding Valve Seats103
Valve and Insert Relationship104
Lapping Valves104
Cylinder Block and Liners105
Cylinder Liner Removal106
Cylinder Liner Cleaning and Inspection106
Cylinder Liner Service106
Cylinder Liner Installation107
Cleaning and Inspection of Cylinder Block107
Measuring Liner107
Crankshaft, Flywheel and Main Bearings108
Air Box Drain Tubes108
Rear Main Bearing Oil Seal109
Main Bearing Inspection110
Measuring Main Bearing Shells110
Main Bearing Replacement111
Replacement of Pilot Bearing Oil Wick111
Inside Diameter of Bearing Shells111
Pistons and Connecting Rods112
Description of Pistons112
Flywheel112
Description of Connecting Rods113
Service113
Piston Assembly Details113
Connecting Rod Assembly113
Removal of Connecting Rod and Rings from Pistons114
Piston and Piston Ring Inspection114
Inspection of Connecting Rod Assembly115
Fitting Piston Rings116
Measuring Piston Ring Gap116
Camshaft and Balancer Shaft117
Assemble Connecting Rod and Pistons117
Remove Camshaft and Balancer Shaft118
Inspect Camshaft119
Remove Camshaft and Balancer Shaft Bearings119
Installation of Camshaft and Balancer Shaft120
Install Camshaft and Balancer Shaft Rear Balance Weights120
Gear Train121
Removal of Engine Front Cover121
Remove Crankshaft Front Oil Seal from Gear Cover122
Installation of Engine Front Cover122
Repair of Engine While Installed123
Replacement of Crankshaft Main Bearings124
Engine Removal and Installation125
Disassembly of Engine127
Removal of Accessories from Engine127
Disassembly of Engine into Sub-Assemblies128
Assembly of Engine129
Engine Run-In Schedule131
Engine Clutch and Clutch Brake132
Clutch Service132
Engine Clutch Adjustment132
Clutch Adjustment133
Washing Engine Clutch133
Clutch Linkage Adjustment133
Clutch Removal133
Clutch Disassembly134
Clutch Inspection and Repair134
Clutch Assembly135
Inspection and Replacement of Clutch Operating Yoke135
Engine Clutch Brake136
Clutch Installation136
Service Inspection and Repair137
Clutch Brake Removal137
Clutch Brake Installation137
Transmission and Bevel Gear138
Transmission Assembly Cut-A-Way138
Transmission Removal139
Transmission Disassembly139
Transmission Removed from Tractor140
Transmission Case and Covers140
Assembly of Trasmission141
Install the Bevel Pinion Shaft and Gears142
Install the Gear Shift Controls and Input Shaft144
Gear Shift Details144
Bevel Gear146
Removal of Bevel Gear146
Cleaning and Inspection of Parts147
Assembly of Bevel Gear147
Installing Clutch Shaft148
Tooth Bearings149
Universal Joint150
Steering Clutches152
Linkage Adjustment152
Washing Steering Clutches153
Disassemble Steering Clutch153
Steel Discs154
Friction Discs154
Pressure Springs154
Hub154
Assembly of Steering Clutch155
Steering Clutch Throwout Bearing Assembly156
Steering Clutch Brake Service157
Section XIII - Steering Brakes157
Parking Brake Lock157
Brake Adjustment158
Brake Linkage Adjustment158
Washing Brakes159
Brake Band Removal159
Brake Inspection and Repair159
Brake Band Installation159
Removal of Sprocket Shaft160
Section XIV - Final Drives160
Pulling Sprocket Shaft Bracket161
Pulling Track Sprocket161
Pulling Sprocket Shaft161
Removal of Final Drive Intermediate Shaft162
Removal of Final Drive Pinion Shaft162
Intermediate Shaft Bearing Adjustment163
Sprocket Shaft Bearing Adjustment163
Cleaning and Inspection163
Installation of Sprocket Shaft Seal Assembly164
Final Drive Pinion Shaft Details165
Installation of Intermediate Shaft166
Final Drive Intermediate Shaft Details166
Installation of Sprocket Shaft167
Truck Frames170
Truck Frame170
Truck Wheels172
Checking and Removal of Truck Wheels172
Disassemble Truck Wheels172
To Install the Seal Assembly174
Track Release175
Support Roller175
Removal of Support Roller175
Disassembly of Support Roller176
Support Roller Details176
Track Idler177
Idler Slide Bars and Alignment177
Track Idler Removed178
Drawbar181
Tracks182
Track Details182
Track Adjustment183
Track Removal183
Main Frame and Equalizer Spring185
Main Frame and Bumper185
Crankcase Guard185
Equalizer Spring185
Rigid Beam187
Fenders and Seat Group188
Seats188
SECTION XX - Special. EQUIPMENT189
Guard Equipment190
Truck Frame Guard Equipment190
Logging Guard Group190
Cab Group190
Cab191
Hour Meter191
Fuel Oil Pressure Gauge191
Rear Panel191
Check Pressure Switch192
Lights193
Power Take-Off and Power Pulley193
Odometer193
Power Pulley193
General Maintenance Instructions195
Bearings and Bushings195
Ball Bearings195
Needle Bearings195
Shafts and Splines196
Shifting Forks196
Oil Seals196
Lip Type196
Gaskets197
Gears197
Hoses197
Wiring197
Fasteners198
Miscellaneous198
Fits and Tolerances199
Troubleshooting205
Engine will Not Turn205
Incorrect Oil Viscosity205
Batteries Weak205
Engine Fails to Start206
Loss of Power206
Slow Cranking Speed206
Blower Not Turning206
Engine Stalls Frequently207
Engine Detonates207
Black Smoke207
Starting System208
Blue Smoke208
Engine Overheats208
Starter Does Not Turn208
Fuel System209
Checking of Fuel Supply System209
Engine Air Intake System210
Engine Lubricating System212
Generator, Regulator, Lights and Wiring213
Engine Starting Aids214
Failure of Ignition214
Poor Oil Spray214

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