Service Manual

Allis Chalmers
Service Manual
16000H, 19000,
21000H & 25000
Construction Equipment

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-ENG16000H
 SUBJECT INDEX

SUBJECT SECTION

Description and Specifications 1

.. Cooling System 2
Electrical System -3
Fuel System and Accessory Drive 4
Air Cleaner and Air Intake Manifold _ 5
Exhaust Manifold and Turbocharger 6
Valves, Valve .operating Mechanism, and Cylinder Heads 7
Front End and Gear Train 8
Flywheel and Ring Gear; Flywheel Housing and Crankshaft Rear Oil Seal 9
Lubricoting System 10
Camshaft and Camshaft Bearings 11 : .... ,.
"'i:~!~~
';;

. -.
~

Pistons, Piston Rings, Connecting Rods, and Connecting Rod Bearings 12

Crankshaft and Crankshaft Gear, Main Bearings, and Main Bearing Caps 13
Cylinder Block and Cylinder Sleeves 14
Engine Removal and Installation 15
Engine Disassembly and Assembly 16
Fits and Tolerances and Torque Specifications 17
Trouble Shooting 18
Service Tools 19

=~~R~V~Icr~M~ANU~~A~L __________________________________________________________ C.
Form 643980
 slipped off of pulleys. Remove fan belts.

3. Inspect fan belts for excessive slickness, oil-,

soak, wear, tears, cracks, and overstretching.
6 The fan belts are a matched pair. If only one
belt replacement is required, both belts must
be replaced to assure satisfactory belt pe~~
formance.
7

4. Install fan belts by slipping belts into proper

8
grooves in pulleys, and adjusting belts to
proper tension.
9
5. Install fan.

E. Fan Hub Removal, Disassembly, and

Inspection
'--_ _ Fig. JO - Belt Arrangement (Type V) _ _~ Three types of fan hubs, as shown in Figs. 11, 12,
and 13, are used with the various engine appli-
1. Water Pump Drive Belt
2. Water Pump Pulley cations. Types I and II are basically identical and
3. Fan Belt Idler Pulley their removal and disassembly procedures are the
4. Fan Hub same.
5. Air Compressor Drive Belt
6. Air Compressor Pulley 1. Fan Hub Removal (Types I, II)
7. Generator Pulley (Fig. 11 or 12)
8. Generator Drive Belts
9. Accessory Drive Pulley
10. Fan Belts
a. Remove fan and fan belts. Remove any other
11. Water Pump Idler Pulley belts (such as air compressor) from fan pulley.
12. Crankshaft Pulley
b. Remove roll pin (19). Remove slotted nut (20)
c. Fan Removal, Inspection, and and washer (18).
Installation
c. Pull fan hub assembly (17) from bracket (22).
1. Remove fan guard or fan shroud.
2. Fan Hub Disassembly and Inspection
2. Remove capscrews securing fan to fan hub and· (Types I, II) (Fig. 11 or 12)
remove fan and fan spacer if so equipped.
a. Remove snap ring (1) and pulley cap (16).
3. Inspect fan for cracks, loose rivets, or bent
blades. Repair or replace if necessary. b. Remove retainer snap ring (10) and turn seal-
ing washer retainer (7) out of fan pulley. Re-
4. Install fan by a direct reversal of removal move sealing washer (11), bearing retaining
procedure. NOTE: Fan hubs (Type //I) Fig. 13 washer (6), and gasket (12) from the fan
must have a gasket between fan hub and fan pulley (4).
spacer.
c. Place fan hub assembly in a press, with fan
D. Fan Belt Removal, Inspection, and end of pulley up, and press the spindle (8),
Installation bearings (5) and (14), spacing washer (3), and
spacing sleeve (13) from the fan pulley (4).
1. Remove fan.
d. Remove cotter pin (2) and nut (15) from the
2. Relieve tension on fan belts until belts can be spindle (8). Press the spindle from the bearings.
SERVICE MANUAL
Form 643980 Sect. 2 Pg. 9
 inserts with a grinder (refer to "Valve Face
and Valve Seat Grinding" in this Topic).
12. After the inserts have been installed, the ex-
haust valve seat inserts must be staked to
eliminate the possibility of the insert loosening
in its bore. It is not necessary to stake the
intake valve seat inserts. Using a center punch
and hammer, stake each exhaust valve seat
insert at 3 points, approximately 120 apart 0

as illustrated in Figs. 31 and 32 being careful

not to stake in the semicircled area, Fig. 32 (2).
Do not use old staking points. NOTE: Do not
stake 30 exhaust valve.
0

Fig. 29 Reboring Cylinder Head to Accommodate

Oversize Valve Seat Inserts
(T-40245)

an insert into the counterbore (valve seat side

up).
d. Using a valve seat insert installing tool
similar to the one shown in Fig. 30, drive
insert down tightly into counterbore. This
operation must be done quickly while insert
is cold.
e. It will be necessary to refinish valve seat Fig. 31 Staking Exhaust Valve Seat Inserts
(T-37630)

2-;----+1

3-;---HI

90 o 0

.
00 o
Fig. 32 Exhaust Valve Seat Inserts
Staking Points
(T-37720)

1. Staking pOints
2. Do not stake in this area
Fig. 30 Installing Valve Seat Insert 3. Exhaust valve seat insert
(T-37629) 4. Hole for fuel injection nozzle tip
SERVICE MANUAL
Form 643980 Sect. 7, Pg. 17
 g. The difference between the two meas-
urements is the total impeller move-
ment. This movement should not exceed
.008/1. Repeat this procedure several
times before accepting a final reading.
h. If the radial movement exceeds .008/1 it
is an indication of shaft or bearing wear;
or that the bearing bore in the housing
is worn. The unit must then be dis-
assembled and reconditioned. NOTE:
Shaft radial movement can be checked
without removing turbocharger from
the engine. Fig. 3. Remove oil drain line
from the center housing and follow
same procedure as indicated by steps
b through h above.
Checking Shaft Radial Movement - Turbocharger
Installed on Engine (Right Side View)
Turbocharger Installed on Engine (Left Side View)
FIG. 3
V
5. Check shaft end playas follows: (Specified
end play .003/1 to .008/1)
a. Use either a clamp or magnetic base
indicator holder.
b. Place indicator contact point on end of
impeller shaft (Fig.5 ).
c. Move impeller to extreme up position,
note indicator reading.
d. Move impellers to extreme down posi-
9
tion, note indicator reading.
e. The difference between the readings is
the end play .
f. This should be from .003/1 to .008/1.
g. Record the end play. This will be used
to determine if thrust plate assembly or
thrust bearing need to be replaced.
h. If end play exceeds .008/1, it indicates
that thrust ring; thrust bearing, or bear-
ing surface of the center housing thrust
plate assembly are worn. If end play
is less than .003/1, it indicates a carbon
build-up behind the turbine impeller.
Unit must be disassembled and condi-
tion corrected.
Measuring Shaft Radial Movement -
FIG. 4
6. Remove turbine housing. Refer to Topic 5,
/IDISASSEMBLY OF TURBOCHARGER./1
7. Inspect compressor housing, compressor im-
peller, turbine impeller, and turbine hous-
ing, for noticeable dirt accumulation which
will impair turbocharger performance. Ex-
cessive and uneven build-up on the im-
pellers will disturb the precision balance
of the rotor assembly. To clean turbo-
charger, refer to Topic 6, /ICLEANING./1
L...-_ _ _ _ _ Rotating Assembly _ _ _ _ _--'
FIG. 35
asbestos gloves when handling the heated
impeller.
NOTE: If the compressor impeller was not
heated sufficiently or cooled too rapidly; it
may shrink on the shaft before it contacts
the shims and thrust spacer. Do not apply
force. Refer to Topic 5, Paragraphs G and
H for a description of the procedure to
remove the impeller.
L.-_ _ _ _ _ _ Balance Marks _ _ _ _ _ _~
FIG. 36
3. Bottom or seat compressor impeller by in-
stalling impeller locknut. Tighten to 150-
160 Ibs. in.
4. Allow impeller to cool to less than 150 0 F.
and remove locknut. Inspect washer face
of nut and hub of wheel; both must be
32
FIG. 37
smooth and clean. Lubricate fhreads and
washer face of nut.
5. Reinstall the locknut. Place tool /IH/I on the
locknut. Mount a magnetic base or clamp-
type dial indicator on the center housing
(Fig. 38) with the stem of the indicator rest-
ing on a flat surface on the end of the shaft.
Set the dial indicator to read zero. Insert
sliding T-handle into the upper end of tool
/IH./1 Tighten the locknut until the shaft
length increases .006/1 to .001". CAUTION:
Do not use a box wrench to tighten the lock-
nut as excessive side strain may bend the
shaft. By using the sliding T-hand/e with
tool /IHIt and applying even turning pres-
sure on each end of the T-handle, the possi-
bility of bending the shaft while tightening
the locknut is eliminated.
o. Align compressor housing and center housing
marks (Fig. 8). Install clamps, lockwashers,
and capscrews. Tighten capscrews to a torque
of 100-110 Ibs. in.
P. Align turbine housing and center housing
marks. Apply anti-seize lubricant to capscrews.
Install locking plates and capscrews. Tighten
capscrews to a torque of 100 - 110 Ibs. inch.
Secure tabs of locking plates against side .of
capscrew heads'.