AC-S-650,52,53

AAll ll iiss CChhaallmmeerrssService Manual

650, 652 & 653

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.

Serv

ice

Man

ual

ALLIS-CHALMERS

INDUSTRIAL SERVICE MANUAL

650 Crawler Tractor, 652, 653, Dozers ,

& 655 Loader

Index

SPECIFICATIONS-TORQUES, FITS & TOLERANCES, & TROUBLE DIAGNOSIS CHECK OUT PROCEDURE

ENGINE ...

FUEL SYSTEM

ELECTRICAL SYSTEM .

SEAT, FUEL TANK, HOOD PLATFORt\1 & GUARDS.

TORQUE CONVERTER.

TORQUE HOUSING . .

POWER SHUTTLE CLUTCH .

TRANSMISSION . . . . .

BEVEL PINION & RING GEAR.

FINAL DRIVE . . .

STEERING CLUTCH .

BRAKES.

TRACKS.

HYDRAULIC SYSTEM

A B C D E F G H I J K L M N o

Specifications, Torques, Fits & Tolerances, & Trouble Diagnosis

Check-Out Proceedure

Contents

CAPACITIES .....

FITS and TOLERANCES

FLOW TEST FITTINGS .

HYDRAULIC SYMBOLS

LUBRICATION and MAINTENANCE

LUBRICATION and SERVICE INSTRUCTIONS

SPECIFICATIONS .. Engine. . . . . General . . . .

TROUBLE SHOOTING Engine. . . . . . Power Shuttle Clutch Torque Converter .

TORQUE SPECIFICATIONS .

Specifications A-I

· A-S

· A-7

A-i8

A-19

· A-S

· A-6

· A-2 · A-2 · A-3

A-17 A-17 A-18 A-17

A-13

A

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Engine

Contents AIR CLEANER

Dry Air Cleaner Inspection & Installation Dry Type ..... . Removal & Disassembly Service. . . . Air Heater . .

BEARINGS (Main) . BODY ASSEMBLY

Front Grille. . Frortt Grille Shell Hood .. Side Skirt

CAMSHAFT .. Inspection . Thrust Plate. Timing Marks Camshaft Bearings

CONNECTING RODS & CONNECTING ROD BEARINGS Bushing Replacement Inspection

CRANKSHAFT Gear Pulley . .

CYLINDER BLOCK CYLINDER SLEEVE

Reseating. . . CYLINDER HEAD & V ALVES . . . . .

Cylinder Head (Fuel Injection Nozzles) Inspection . . . . . . Installation . . . . . . Rocker Arms & Push Rods . . Removal ........ . Torque Sequence. '. .. . . . Valve Guide & Valve Seat Insert Valve Operating Mechanism. Valve Spring Removal. .

ENGINE Bumper Stop Bracket . . Disassembly & Assembly . Engine Mount & Stop Bracket .. Removal & Installation . . . . Run-In Schedule (Engine) . . .

ENGINE COOLING SYSTEM. . . . Radiator & Torque Converter Cooler Assembly Thermostat . . . . . . Water Pump ...... . Water Pump Pulley & Belt .

EXHAUST MANIFOLD . . . . FAN DRIVE SHAFT ASSEMBLY

Baffle . . Fan Blade ... . Pusher Fan ... .

FLYWHEEL Engine Adapter Plate Installation . . . . Ring Gear Inspection & Removal Wear Sleeve. . . . . . . . .

Engine B-1 A

B-4 B-2 B-3 B-2

B-36 B-55

B-5 B-6 B-5 B-5

B-26 B-28 B-27 B-53 B-29 B-61 B-62 B-61

· B-25, B-52 · B-2l, B-54

B-63 B-64 B-67 B-37 B-42 B-42 B-44 B-40 B-42 B-44

· B-46, B-51 B-39 B-45

B-19 B-20 B-18 B-18 B-20 B-I0 B-11 B-10 B-12 B-17 B-34 B-7 B-9 B-8 B-8

B-74 B-75 B-76 B-77

Engine Contents

FRONT SUPPORT PLATE ....... . FUEL INJECTION PUMP DRIVE GEAR . . GEAR TRAIN & FRONT SUPPORT PLATE. HYDRAULIC PUMP DRIVE ASSEMBLY

Housing & Gear . . IDLER GEAR & SHAFT INTAKE MANIFOLD. . LUBRICATING SYSTEM

Oil Flow Diagram OIL PAN ...... . OIL PRESSURE PUMP .

Assembly ..... Inspection of Oil Pump Parts Installation . . . . . . . Pump Removal & Disassembly

PISTONS & PISTON RINGS Connecting Rods to Pistons. . . .. ...

TIMING GEAR COVER & CRANKSHAFT FRONT OIL SEAL TROUBLE SHOOTING

Air Intake System Cooling System . Electrical System. Engine ... Fuel System . General . . . Instruments. . Lubricating. . Starting System

VALVE LIFTERS .

Engine B-IB

B-33 B-31 B-23 B-24

B B-2S B-32 B-35

B-68 B-73 B-69 B-7l B-70 B-72 B-69

B-S7 B-22 B-78 B-84 B-84 B-87 B-78 B-83 B-78 B-87 B-8S B-83 B-30

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REMOVE FRONT GRILLE SHELL ASSEMBLY

The front grille shell assembly is a one-piece welded assem­bly held in place by two bolts, lockwashers, nuts and two capscrews and lockwashers. To remove the grille shell assembly, it is necessary to remove the hood, side skirt assembly and front grille. Disconnect torque converter pump-to-filter line and the line from filter-to-shuttle clutch valve. Disconnect fuel line to filter and line from filter-to­injection pump. Remove the attaching capscrews and bolts.

T-tIotZI

INSTALL FRONT GRILLE SHELL ASSEMBLY

The front grille shell assembly can be installed by setting it in place and installing two bolts, lockwashers, and nuts, plus two capscrews and lock washers. Connect the torque converter pump-to-filter line and the line from the filter­to-shuttle clutch valve at the filter. Connect the fuel line from tank-to-filter and line from filter-to-injection pump. Install the front grille, side skirt assembly and the hood.

9003436 Engine B-6

~ 18 16 10 8 1 4 6 12 14

CYLINDER HEAD TORQUING SEQUENCE

13. Fill the cooling system. Run engine for approxi­mately one hour, preferably under load, with a minimum coolant temperature of l600 F.

14. Remove cylinder head cover and retighten all cap­screws to 150 lbs. ft. torque, following sequence. If cap­screw does not move when this specified torque is reached, back it off slightly by loosening, then retighten to speci­fied torque. This is important in eliminating possible false torque readings due to temporary thread seizure.

15. Adjust valve lash.

16. Inspect engine for fuel, water, or oil leaks and correct any leaks found.

NOTE: With the use of a special cylinder head wrench, equivalent to Snap-On S-8684-A, is required for tightening the capscrews under the rocker arm shaft.

TORQUE CYLINDER VAL VE SPRING REMOVAL

The intake and exhaust valve springs and valve spring re­tainers may be removed without removing the cylinder head from the engine. When the cylinder head is removed from the engine the valve springs can be removed with a tool similar to the one illustrated. To remove the valve springs without removing the cylinder head, proceed as follows:

1. Remove cylinder head cover.

2. Make certain the piston in the cylinder from which the valve springs are to be removed is at top dead center. Using a suitable spring compressing tool, remove spring re­tainer locks and carefully release tension on the valve spring. Remove spring retainer and valve spring.

3. Inspect the valve springs for cracks. Both the intake and exhaust valve springs which are identical should have a specified load of 41-45 lbs. when compressed to a length of 2.223" (valve closed) and a load of 73-81 lbs. when compressed to a length of 1.836" (valve open). Install a new spring when old spring is 5% under or over the speci­fied load limits.

NOTE: The valve spring must be installed with damper end, small spaces between coils, seated in the cylinder hea~ .

4. Install the valve springs, valve spring retainers and valve spring retainer locks using a direct reversal of the re­moval procedure.

Engine B-45

~!1---3

TESTING VALVE SPRING

1. TORQUE WRENCH 2. VALVE SPRING TESTING TOOL 3. VALVE SPRING

T-61502

\

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Fuel System Contents

AUTOMATIC SPEED ADVANCE .

CALIBRATION SPECIFICATIONS

FUEL SYSTEM . . . . Cleaning . . . . . Fuel Filter . . . . Priming the System .

FUEL INJECTION NOZZLE HOLDER ASSEMBLY. Cleaning . . . . . Timing Window . . . . . . .

FUEL INJECTION PUMP . . . . . Installation, Inspection, Removal

HAND PRIMER PUMP . . . . . . Installation, Inspection, Removal

Fuel System C·1

C-13

C-15

C-2. C-IO

C-3 C C-4

C-6 C-9

C-13

C-4 C-5

C-12 C-12

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Electrical System Contents

ALTERNATOR

BATTERIES General Installation Maintenance & Service Operation Storage Testing

DELCOTRON.

GENERATOR.

PINION

SPECIFIC A nONS

STARTER Charts & Tests. Removal & Installation

STARTER MOTOR Checking. Description . Disassembly. Inspection Maintenance Reassembly. Removal. Testing

VOLTAGE REGULATOR Checking Settings Maintenance

Field Relay Points Voltage Settings . Operation Testing & Adjustment.

WIRING DIAGRAMS.

Electrical System D-l

. D-16, D-17

D-4 D-5 D-7 D-5 D-5 D D-6 D-6

D-19

D-18

D-15

D-2

D-I0 D-9

D-12 D-ll D-13 D-13 D-ll D-14 D-12 D-12

D-27 D-23 D-24 D-24 D-23 D-22 D-22

D-3

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Seat, Fuel Tank, Platform & Guards Contents

FUEL TANK Removal & Installation

GUARDS Remove Lower Cover . Remove Rear Bottom Pan

PLATFORM & TANKS Installation . . . . Removal & Assembly

PUSHER FAN Baffles. . Fan Blades

SEAT ....

TANK & SUPPORT

Sheet Metal E-l

E-3

E-4 E-7

E-5 E-4

E-7 E-7

E-2

E-2

E

9003436

Torque Converter Contents

CLEANING & INSPECTION Torque Converter Pump Assembly " " " " " " " " " " " " " " " F-15

FRONT ENGINE MOUNT & BUMPER STOP Installation " " " " Bumper Stop Bracket

PERFORMANCE YC Piggy Pump Y-90 Flow Tester Y-81 Flow Tester

POWER SHUTTLE CLUTCH & TORQUE CONVERTER HYDRAUUC SYSTEM

Change of Oil " " " " " Control Valve Clutch " " Heat Exchange " " " " Hydraulic System Check " Pressure Line Filter " Temperature Gauge" Torque Converter Torque Housing " " Hydraulic Schematic

TORQUE CONVERTER Checking Parts" Installa tio n " " " " Pump" " " " """

Assembly" " " Removal & Installation

Torque Converter Run Out "

Torque Converter F-l

F-7 F-7

F-12 F-13 F-13

F-8 F-IO F-II F-12 F-12 F-IO F-12 F-12 F-I2

F-9

" E-4, F-5 " F-2, F-6

F-14 F-14

" F-2, F-6 F-3

F

Torque Housing Contents

CHECK OUT Cold Check Oil & Filters Standing Check

HOLLOW CLUTCH SHAFT Wj26T Gear.

ID LER SHAFT . . . .

INTERMEDIATE SHAFT

RELIEF VALVE (Torque Converter) .

SHUTTLE CLUTCH & TORQUE CONVERTER

STATOR SUPPORT ASSEMBLY

TORQUE HOUSING . . . . .

TURBINE OUTPUT SHAFT ASSEMBLY

TURBINE SHAFT .

WINCH DRIVE . . Cover Assembly Drive Shaft Idler Shaft Shifter. . . .

Torque Housing G-I

G-3 G-3 G-3

G-4 G-4

G-8

G-8

G-9

G-2

G-7

G G-2

G-6

G-5

. G-lO, G-15 G-13 G-14

. G-IO, G-12 G-12

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Power Shuttle Clutch Contents

CONSOLE & HAND CONTROLS Removal & Installation

POWER SHUTTLE CLUTCH Assembly & Disassembly. Illustration . . . Removal .... Trouble Shooting

POWER SHUTTLE CLUTCH CONTROL VALVE ASSEMBLY. Adjustment (Relief Valve) . . . . . . Checking Pressure (Power Shuttle Clutch) Directional Control Valve Spool General Information Modulating Valve . . . . . Trouble Shooting . .. . .

Control Valve Disassembly Relief Valve. . . Accumulator Valve Modulator Valve.

SHUTTLE CLUTCH & TORQUE CONVERTER Hose Arrangement . . . . Schematic . . . . . . . Sump & Lines (Illustration) . Tubes & Fittings . . . . .

Power Shuttle Clutch H-l

H-5

H-ll H-12

H-7 H-11

H-7

H-5 H-6 H-5

H-lO, H-8 H-5 H-9 H-7 H-7 H-7 H-7 H-8

H-3 H-lO

H-2 H-14

H

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Transmission Contents

TRANSMISSION Removal & Installation I-I

TRANSMISSION DISASSEMBLY (H-4) ... Assembly of First Gear Shift Rod & Fork Assembly of Second & Third Shift Rod & Fork Bearing Removal. . . . . . . .

1-2 1-2 1-3 1-4 1-2 1-4 1-6 1-2

Gear Shift Lever & Cover Assembly Pinion Assembly & Removal Pinion Shaft End Play. . . . . . . Removal & Assembly of Gear Shift Lever

TRANSMISSION MAIN SHAFT. Assembly of Main Shaft Front Bearing Removal Rear Winch Drive Shaft Seals & Bushings. . .

1-7 1-8 1-7 1-9 1-9

I

Transmission REMOVAL

To remove transmission drain oil from transmission and torque. Remove ROP canopy and ROPS brackets, bat­teries, transmission dip stick, floor plates, gear shift lever, and unhook steering cylinders. Remove shuttle clutch manifold and extension tubes. Remove rear belly pan and split rails at master pin (see undercarriage group). Remove capscrew from angle support to final drives. Raise platform approximately three inches. Support transmission and final drive assembly with floor jack. Remove 12 capscrews at­taching transmission to torque housing. Remove capscrews attaching the frame pivot axle to final drive housing. Supporting assembly roll assembly out from tractor. Remove final drives from transmission.

INSTALLATION

To install transmission clean gasket surface on transmission and torque housing. Clean capscrews and threads in torque housing. Shellac both surfaces (or use hardening sealer) and install gasket. Install transmission by reversing removal procedure using care not to bend shuttle clutch tubes. In­stall 12 capscrews attaching transmission to torque tube, using locktite and torque to 100 ft. lbs. Fill transmission and torque housing with oil (refer to torque housing for proper filling instructions).

Transmission 1·1

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Bevel Pinion & Ring Gear Contents

BEVEL RING GEAR Backlash & Gear Tooth Contact Pattern .

High Contact . . . Low Contact . . . Short Heel Contact . Short Toe Contact

RING GEAR & CARRIER Assembly. Removal ..... .

Bevel Pinion & Ring Gear 1-1

J-4 J-5 J-5 J-6 J-6

J-3 J-2

J

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Steering Clutch Contents

CLUTCH RELEASE BEARING AND FORK .

POWER STEERING Adjustment. . . . Control Rod . . . Control Valve . . . Hydraulic Schematic Steering Cylinder.

Free Travel Removal. Rebuild .

PRESSURE PLATE

STEERING CLUTCH Assembly .. Disassembly. First Method . Installation . . Removal ... Second Method Steering Clutch Lever & Shaft .

Steering Clutch L·l

L-3

L-7 L-7 L-7 L-8 L-7 L-7 L-7 L-7

L-4

L-5 L-4 L-5 L-5 L-2 L-6 L-6

L

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Undercarrage Contents

DIMENSIONS Rollers.. . . . . . . . . . . . Support Rollers .' . . . .. . . Track Idlers. . . . . . . . . . Track Side Bars (Interlocking Track)

DRIVE SPROCKET Installation Removal.

FRONT IDLER Assembly ...... . Disassembly & Removal . Installation & Adjustment Inspection & Rebuilding .

GENERAL DESCRIPTION.

GROUSER WEAR . . . .

GREASE SPECIFICATIONS (Idler & Rollers)

IDLER FLANGE WEAR. . . . . . . .

PROLONGING UNDERCARRIAGE LIFE Operating Techniques

RAIL ASSEMBLY ....

ROLLER FLANGE WEAR.

SPROCKETS (Full Sprocket)

TRABK

TRACK Adjustment . Alignment . Frame ... Hydraulic Track Adjuster Idler & Rollers. . . Pin & Bushing Wear. . . Release . . . . . . . Removal ...... . Roller Assembly & Disassembly Roller Removal . . Rollers. . . . . . . . . . Service & Inspection . . . . Support Rollers . . . . . . Support Rollers Assembly & Disassembly Tension Spring Removal . Track Guards . . . . . Turning Pins & Bushings .

WEAR GAUGE ..

WEAR PATTERNS.

Tracks N-l

N-33 N-34 N-33 N-34

N-30 N-30

N-20 N-18 N-21 N-19

N-2

N-7

N-21

N-7

N-3

N-6

N-6

. N-13, N-3l

N-4 N-13

N-4 N-31 N-29 N-3 N-4

N-32 N-IS N-23 N-22 N-22 N-4

N-2S N-26 N-32 N-14 N-17

N-S

N-8, N-12

N

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(

Hydraulic System Contents

CONTROL VALVE .... Disassembly. . . . . . Dozer Control Valve Bank Exploded View . . . . Inspection .'. . . . . Reassembly. . . . . . Removal & Inspection. . . . . . Section Identification (Control Valve) Valve Operation, Internal Diagrams.

CYLINDERS Loader ......... . Dozer ......... .

DOZER HYDRAULIC (Schematic)

HYDRAULIC PUMP Assembly .. Disassembly. . Installa tion . . Removal ...

HYDRAUliC RESERVOIR Filter . . . . . Installation . . . . . Magnet & Screen. . . Removal ..... .

LOADER HYDRAULIC (Schematic)

PILOT OPERATED CUSHION OR RELIEF VALVE PUMP PERFORMANCE CHART

Performance Curve for YD 15 & 25 G. P. M.

SPECIFICATIONS: (Cylinders) .

TROUBLE SHOOTING CHART.

Hydraulic System 0-1

0-10 0-14 0-10 0-18 0-15 0-15 0-14

... 0-10

.0-11,0-13

0-19 0-23

0-4

0-7 0-7 0-6 0-6

0-2 0-3 0-3 0-3

0-5

0-17 0-9

.0-22,0-25

. .. 0-16

o

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