SHOP MANUAL

ALLIS - CHALMERSMODEL 160

NOTE

Throughout this manual, it will be noted that in the course of setting end-play,pre-load or clearances to specification that certain shim thicknesses proposed foruse are somewhat unusual. For example: a shim may be offered as having athickness of 0.0039 inches. This thickness corresponds to I / IO millimeter, just as0.00039 is I/IOO of a millimeter. The number thirty-nine will often appear as amultiple in some shim material proposed, just as 0.00196 (5x0.00039) is 5/100(0.05) millimeter. Sometimes values will be rounded-off: Instead of 0.0039,0.004 may be used. In almost every case, tolerance allowed is sufficient so thatUS-produced shim stock, available from suppliers in thicknesses of 0.002, 0.004,0.005, etc., will serve in place of the metric material.

I N D E X ( B y S t a r t i n g P a r a g r a p h )

BRAKESAdjustment 96R&R, Overhaul 97

CLUTCH

Adjustment 64Clutch Split 65Clutch Overhaul 66Release Bearing 67

COOLING SYSTEMRadiator 56Water Pump 60

DIESEL FUEL SYSTEMBleeding 45Cold Start Preheater 57Fuel Filters 44Fuel Lift Pump 44AInjector Nozzles 46Testing 46Timing Injection Pump 56

DIFFERENTIAL & FINAL DRIVE

Adjustments 89R&R and Overhaul 86.90

DIFFERENTIAL LOCK

Adjust 93

ELECTRICAL SYSTEM

Alternator 61Regulator 62Starting Motor 63

ENGINE AND COMPONENTSCamshaft 33Camshaft Gear 26

Connecting Rods & Bearings 37Crankshaft & Bearings 36Crankshaft Front Seal 25Crankshaft Gear 30Cylinder Head, R&R 16Flywheel • 40Idler Gear 27Injection Pump Drive 29Oil Pan 41Oil Pressure Relief Valve 43Oil Pump 42Piston Pins 36Pistons. Rings. Sleeves 35Rear Oil Seal 39R&R. Engine w/Clutch 17Rocker Arms & Shaft 21Rod & Piston Units 34Tappet Gap Adjustments 20Timing Gear Cover 25Timing Gears 26.31Valves & Seats 19Valve Guides 22Valve Springs 23Valve Tappets 24

FINAL DRIVE GEARSR&R Bull Gears 91R&R Bull Pinions 91A

FRONT SYSTEMAxle Adjustments 2Front Split 5Front Support Bushings 4Spindle Bushings 3Wheel Assembly 1

HYDRAULIC SYSTEMChecks and Adjustments 101

Hydraulic Pump. R&R 109Lift Control Valve. R&R 113Relief Valve Block. R&R 110Remote Ram Valves. R&R 112

IMPLEMENT LIFT AND DRAFT CONTROLS

Draft Control Shaft 118Lift Piston & Seal 117Lift Shaft & Bushings 115

POWER TAKE-OFFShaft & Gears 100

REAR AXLESR&R and Overhaul 94

STEERING SYSTEMBleeding Power Steering 7Power Steering Cylinder 14Power Steering Pump. R&R 10Steering Control Valve 11Tests and Adjustments 8Trouble Shooting 6

TRANSMISSIONAdjust Pinion Depth 81Adjust Pinion Shaft Bearings 62Main Transmission. Overhaul 75Pinion Shaft, Gears.

Synchromesh Assembly 79. 83Power Take-Off Shaft 72Range Transmission 73Reverse Gear Shaft & Cluster 77,85Shift Controls 76. 66Transmission. R&R 68Upper Main Shaft & Gears 78. 84

WIRING DIAGRAMGeneral Electrical Fig. 146

MODEL 160 Paragraphs 1-4

CONDENSED SERVICE DATAGENERAL:Tractor Model 160Engine Make PerkinsEngine Model AD 3.152Cylinders 3Bore, inches 3.6Stroke, inches 5.0Dispiacement, Cubic Inches 152.7Conipression Ratio 18.5 : 1Pistons removed from? AboveCylinder sleeves DryMain Bearings, Number of 4Alternator, make Delco-RemyStarter, make Delco-RemyFuel Injection Pump, make CAVInjection Nozzle, make CAVBattery 12V, Neg. Grnd.Forward Speeds 10Reverse Speeds 2Fuses, lights & instruments 20 Amp

TUNE-UPFiring Order 1-2-3Valve Tappet Gap, Intake 0.010 Hot, 0.012 ColdValve Tappet Gap, Exhaust 0.010 Hot, 0.012 ColdIntake Valve Face Angle 45®Exhaust Valve Face Angle 45®Low Idle RPM 725-775High Idle RPM 2425-2475Rated Speed RPM 2250PTO RPM at 2160 Engine RPM 540Injection Timing (Static) 24® BTDCTiming Mark Location See text

Injector Opening Pressure (New) 2750 PSIInjector Opening Pressure (Used) . . 2500 PSISpray Hoie Diameter 0.0098

SIZES-CAPACIiriES>CLEARANCES:Crankshaft Journal Diameter 2.7485-2.749Crankpin Diamet€r 2.2485-2.249Piston Pin Diameter 1.2497-1.250Valve Stem Diamoter 0.311 -0.312Camshaft Journal Diameters:

No. 1 1.869-1.870No. 2 1.859-1.860No. 3 1.839-1.840

Piston Ring Specifications See Text, Para. 35Connecting Rod Eiearing Clearance 0.0025-0.004Main Bearing Clearance 0.0025-0.004Crankshaft End Play 0.002-0.015Cooling System Capacity 8 Qts. (US)Crankcase Capacity 6 Qts. (US)Crankcase Capacity (With Fiiter) . . . . 6.5 Qts. (US)Fuel Tank 13.5 Gals. (US)Transmission, Final Drive &

Hydraulic System 29 Qts. (US)

TORQUE VALUES-TIGHTENING TENSIONCylinder Head Nuts 55-60 Ft.-Lbs.Connecting Rod Nuts (plain) 65-70 Ft.-Lbs.Connecting Rod Nuts (cadmium-plated) .. 45-50 Ft.-Lbs.Main Bearing Cap Screws 110-115 Ft.-Lbs.Fiywheel Cap Screws 75 Ft.-Lbs.Atomizer (injector) Holding Nuts 10-12 Ft.-Lbs.

FRONT SYSTEM

7 8 9 10 11 12

Fig. 1 — Expioded view,spindie and wheel hub.

10.11.12.

Spindle assemblyThrust washersSnap ringKit, seal wearInner bearing coneInner bearing cupHub assemblyOuter bearing cupOuter bearing coneWasher "Wheel nutCap

1. WHEEL ASSEMBLY. Conven-tional steel disc wheels are reversibleon hubs. Wheel bearings should becleaned and repacked with No. 2wheel bearing grease after each 500hours operation. To adjust, tightenaxle spindle nut until a distinct dragis felt, loosen nut one castellation andinstall new pin. Always renew sealassembly (4—Fig. 1) when bearingsare repacked.

2. AXLE ADJUSTMENTS. Frontwheel tread is adjustable from 52 to72 inches in 4 inch increments withthe wheels dished in and from 57 to77 inches with the wheels dished out.L&R tie rod extensions (10—Fig. 2)are grooved at 2-inch intervals tocorrespond to hole spacing in spindlesupport bars (14) for ease in realign-ment; however, it is advisable tocheck and reset toe-in at i^ to Vs-

inch whenever front wheel tread ischanged. Adjust at tie rod end (11)when required.

3. SPINDLE BUSHINGS. With trac-tor front supported, remove frontwheels, snap ring (3—Fig. 1), steeringarm (13—Fig. 2) and Woodruff key.Spindle can then be pushed down insupport tube and removed. Drivebushings (15) from tube bore anddrive or press in new bushings untilflush with tube ends. Spindle bushingsare furnished pre-sized and reamingis not normally required. Reinstallthrust washers (2—Fig. 1) on spindleand reassemble. A single grease fit-ting, located at a midpoint of thespindle support tube, eliminates theneed for aligning bushings with lubeports.

4. FRONT SUPPORT BUSHINGS.Axle pivot pin bushings (5—Fig. 2)are renewable. New bushings are pre-sized and require no reaming. Defec-tive bushings may be pressed ordriven from support (4) when frontaxle is removed.

Paragraphs 5-6

Rg. 2—Front axle, tie rod, front support and associated parts.

1. Axle as9enilil>'1. lUvot bolt;{. I'lvot bear I UKA. Front support

PlugsPivot pinRoll pinTie rodTJe rod exteiiHionTie rod endradjustable>

l:!. l*ower steeringram

i:t. HteeriiiK armsH, Spindle support

assemblylTi. Spindle bushiims

rRONT SPLIT

5. Detachment (splitting) of thefront wheels, axle support and radi-ator assembly from tractor is a pre-liminary step to repair procedureswhich demand unrestricted access tothe engine for engine removal or forengine work which does not call forremoval of flywheel or crankshaft.The following procedures will apply:

First, remove hood, support tractorunder flywheel housing, drain coolantand remove radiator hoses. Disconnectcables and remove battery. Disconnectair cleaner duct at partition forwardof radiator and flex tube (filter indi-cator) from air cleaner duct. Removeradiator brace cap screw from top ofthermostat cover casting. Drain powersteering fluid by separating reservoirto pump tube at coupling located be-tween power steering pump and en-gine block and collect fluid in a con-tainer placed below the axle. Then,remove the tube at reservoir end andset aside. The two remaining flexiblelines may then be separated at reser-voir fittings, capped or taped off. Re-move pins from each end of powersteering ram (12—Fig. 2) and securecylinder with wire hangers from en-gine front support brackets to preventdamage to hydraulic lines and fittings.

Remove power steering tube supportbrackets from right hand frame rail.Release drive belt tension and unboltpower steering pump from left framerail and secure to engine for protec-tion. Unbolt engine front mounts (onebolt each side) from frame rails. At-tach hoist to front assembly so it willnot tip, remove three cap screwswhich attach each frame rail to fly-wheel housing and roll front assemblyforward and away from tractor.

STEERINGSYSTEM

Model 160 tractors utilize a hydrostaticsteering system which is without directmechanical linkage between the steeringwheel and the tractor front wheels. Thecontrol valve unit (Fig. 5 & 6) contains arotary metering motor, a commutator feedvalve sleeve and a selector valve spool.Should power steering failure occur due toengine stoppage, belt breakage or troublewithin the power steering system itself, the

ALLIS-CHALMERSmetering motor becomes a rotary pumpwhich drives the power steering cylinderto provide steering control. A check valvein the control valve housing allows recircu-lotion of flmd between the control valveand the steering cylinder (ram) for manualoperation.

Primary power for steering is supplied bya belt-driven gear pump mounted on thefront inboard end of the left engine framerail, with the power steering system inde-pendent of all other hydraulics.

TROUBLE SHOOTING

6. Should failure or malfunctionoccur in the power steering system,refer to the following paragraphsbefore attempting adjustments orrepairs.

Irregular or "Sticky'' steering. Ifirregular power flow or a binding"sticky** feeling is noted with the trac-tor halted and the engine operatingat rated speed, or, if the wheel con-tinues to rotate when turned andreleased, probable cause is contamin-ated hydraulic fluid. If trouble does

4

11

Fig. 3 — Exploded view, power steeringreservoir.

1. Cover screwvv/washer

2. Dipstick, inchseal

3. Cover4. Cover seal5. Snap ring

U. Spring,w/vvashers

7. Filter assembly8. Snap ring9. Filter seal

10. Reservoirassembly

XI. Tube fitting seals

MODEL 160 Paragraphs 7-9

Fig. 4—Expioded view ofpower sfeering pump.

10.11.12.1314.15.16.17.18.

Drive beltPulleyPump supportCover assemblyNeedle bearings (2)Idler gear & shaftDrive shaft & gearGear plateDowel pin (2)Needle bearingPump bodyNeedle bearings (2)Oil sealPressure relief vaiveSpring, innerSpring, outerShims (as required)Valve plug & gasket

not clear up after renewal of dispos-able filter (7—Fig. 3) in the powersteering fluid reservoir, drain andrefill the system with new fluid.Should this procedure not solve theproblem the steering valve should beremoved and overhauled as outlinedin paragraphs 11 and 12.

Steering Cylinder "Hesitates". Ifpower steering ram appears to pausein motion when steering wheel isbeing turned steadily, it is likely thatair is trapped in the cylinder. Usebleeding procedure described in para-graph 7.

Slow Steering. If steering responseseems slow, flow rate (volume) isprobably at fault. Design volume ofthe power steering pump is 7.5 GPMat 2250 engine RPM. Check may bemade with an in-line flow meter orby using the following procedure:

Time the rate of travel of steeringram from left to right extremes withfront wheels resting on the groundand compare against the travel timewith front end jacked up. Use lowengine speed. A considerable differ-ence in elapsed time indicates low

•1. Seal2. Mounting plate3. Quad rlQg seal4. "O" ring

5. Locator bushingC. Bearing assembly7, Valve body8. Centering pin

flow volume and pump will requireoverhaul as in paragraph 10.

Loss of Power. If steering boostpower seems low, probable cause isinadequate system pressure. Checkand adjust setting of relief valve (14—Fig. 4) in steering pump as detailedin paragraph 8. If this by-pass pres-sure check indicates no problem, thenpressure loss is due to piston sealfailure in the steering cylinder (ram)which will require overhaul. See para-graphs 15 & 16.

Overheating. If system operates ex-tremely hot, install a high pressuregage as outlined in paragraph 8 andfind the neutral position of the controlvalve by rotating wheel slowly ineach direction, halting at point oflowest pressure reading. Control valveis then at its neutral point. Turnsteering wheel to a limit stop, hold asecond or two and release, observingthe pressure gage. If pressure doesnot fall back very close to the neutralreading, a binding control shaft orforeign material between the valvespool and sleeve are likely causes forthe overheated condition.

Fig. 5—Exploded view ofsteering control valve.Troctor may have eitherlocator ( 5 ) or thrustbearing assembiy (6) in-stalled. Centering springs(17) are installed in twopacks of three each,

arched baci(-to-bacit.

9. Sieeve10 Valve spool11. Plate

Drive shaftSpacerRotor (Gerotor)Ring (Gerotor)End capCentering springs (6)Valve spring

19. Check valve ball20. Valve seat21. Plug22. "O" ring

12.13.1-1.15.16.17.18.

Fig. 6—View of steering control valveidentifying inlet and outlet ports with lo-

cations and functions.

BLEEDING

7. This system is usually self-bleed-ing; however, if air is trapped, turn-ing the wheel back and forth throughseveral full strokes of the cylinderwill release such trapped air. If thisprocedure fails, repeat with ram con-nections loosened slightly to providean escape outlet.

TESTS AND ADJUSTMENTS

8. To locate the cause of malfunc-tion in the steering system, it is neces-sary to measure line pressure of fluidby using a high pressure (minimum3500 psi) hydraulic test gage. Thetester inlet should be connected "teedin" to the line between the steeringvalve *'IN" port (Fig. 6) and the pumpoutlet. With test gage so installed, en-gine speed regulated at 2250 RPM andfluid at normal operating temperature,the pressure relief valve in the pumpshould open (by-pass) at 1000-1200psi. To obtain this by-pass reading,turn steering gear to extreme left orright limit and hold just long enoughfor a gage reading—one or twoseconds. Holding the by-pass positionmore than momentarily will causerapid overheating of the system andpossible damage. Removal or additionof one shim (17—Fig. 4) will changerelief pressure by approximately 50psi. If system pressure does not re-spond satisfactorily to shim changes,need for overhaul of pump is indi-cated. See paragraph 10.

PUMP

9. A belt-driven gear pump mountedinside the frame rail at left front ofengine is the pressure source for thepower steering system. See Figure 4.

Paragraphs 10-13

10. R&R AND OVERHAUL. Drainsystem fluid and thoroughly cleanpump body, frame channel, adjacentengine parts and hydraulic line fit-tings. Unit may be removed afterbacking off four cap screws whichhold pump body to its mountingbracket, releasing belt tension, remov-ing drive pulley'and uncoupling fluidlines. Lines, fittings and ports shouldbe taped over or otherwise protectedfrom dirt and damage. Pump cover(4—Fig. 4) gear plate (8), and pumpbody (11) should be marked (scribed)for convenience of reassembly. Re-move assembly screws from pumpcover and pull cover away from gearplate and hollow alignment dowels.Do not wedge or pry between ma-chined mating surfaces which join thecover, gear plate or pump body withany tool, as mars or scratches willcause oil leaks under high pressure.Remove idler gear and drive shaftgear assembly, then pull gear platefrom pump body and dowels, againtaking care not to damage the ma-chined finish of joining surfaces. Re-move oil seal from pump body, and,if they are to be renewed, removethe needle bearing sets from pumpbody and cover. Remove relief valveplug and internal components group,shims, inner and outer springs andthe valve. All parts must be thor-oughly cleaned in solvent or cleaningfluid and air-dried with special at-tention to passages and grooves whichroute fluid under pressure through-out the unit.

Needle bearings (12) are pressedinto the pump body with the innerbearing against bore shoulder andouter bearing flush with face of count-erbore. NOTE: Pressure is appliedonly to lettered end of bearing cage.New seal is installed in counterborewith lip facing inward and flush withbody surface. Bearings (5 & 10) arepressed into pump cover and idlershaft bore 0.020 past flush with adja-cent surfaces. Install dowels and gearplate to pump body, observing thealignment marks made before disas-sembly. NOTE: When installing thedrive gear (7) use a seal protectorcap over threaded end of shaft, orcarefully guide seal lip over driveshaft shoulder with a suitable tool ora narrow, flexible, piece of shim stockto prevent damage to the seal lip.Install idler gear (6), checking forfree rotation and noting any bindingor obstruction between the meshedgear surfaces. Install pump cover overhollow dowels and shaft ends, againchecking alignment marks on case.

Secure with the two % x 2^-inchAllen head screws and four -fi^ x 2^inch cap screws, to 190-210 inch-pounds torque. NOTE: This pump usesno gasket or sealing material betweenmated surfaces; so, leak preventiondepends entirely upon cleanliness andfinish of these surfaces and the appli-cation of the torque specificationsfurnished. Install expansion plugs (notshown) in rear bearing bores andcoat with shellac. Install relief valve(14), inner and outer springs (15 &16) followed by the set of pressure-adjusting shims (17). Reinstall valveplug (18) after fitting with a new**O" ring seal and turn the pump shaftby hand to recheck for free move-ment. Relocate the pump on itsmounting bracket, set in the Woodruffkey at threaded end of drive shaft,install the drive pulley and completereinstallation in the tractor with drivebelt adjustment. Refer to paragraph8 for relief (by-pass) pressureadjustments.

CONTROL VALVE

11. REMOVE AND REINSTALL.Remove right side shield below fueltank. Clean steering valve and hy-draulic connections thoroughly usinga wire brush at cap and cover platejoints to insure removal of loose paintflakes and imbedded dirt; then, dis-connect and separate all lines fromvalve, taping over or capping openlines and ports to insure cleanliness.Remove four cap screws which retainvalve body to steering shaft supportand withdraw valve assembly. Afterreinstallation, tighten mounting capscrews to 280 inch-pounds torque, re-connect hose lines (refer to Fig. 6)and bleed system as in paragraph 7.

12. OVERHAUL. To disassemblevalve, place in a heavy-duty vise,clamped across edges of mountingplate with end cap facing up. Afterremoving the seven cap screws, liftoff the cap, gerotor assembly, plateand drive shaft (11 thru 16—Fig. 5)as a unit. Set these parts aside in aclean location or in clean solvent tosoak. Place a clean wood block invise throat below jaws to supportexposed sleeve valve parts and i e-clamp valve body across the port facewith mounting plate upward. Removefour remaining cap screws and lift offmounting plate. At this time, care-fully inspect all machined faces forevidence of leakage and evaluate con-dition of locator (5) or thrust bearing(6) depending upon which is used intractor. To remove spool and sleeveassembly (8, 9 & 10), place housing.

ALLIS-CHALMERS

port face down, on a solid surfacesuch as a wood block set in vise jawsand slide spool assembly from the14-hole (gerotor) end of housing.These parts are fitted to close toler-ances and require very careful hand-ling. Rotate slightly during removalto prevent binding and set aside in aclean, secure location to protect fromdirt or damage. To remove checkvalve from housing, insert a bentwire through the "OUT" port (Fig. 6)from outside and push out seal plug(21—Fig. 5) with "O" ring, takingcare not to damage edges or scratchbore; then, use a A-inch Allen wrenchto unscrew the check valve seat. Liftand invert steering valve so that seat,check valve ball and spring (18, 19& 20) can be caught as they drop out.Remove centering pin (8) from spooland sleeve assembly by pushing fromeither end. (Some units may havenylon plugs fitted in sleeve outersurface over pin ends to protect valvebody bore.) Holding sleeve firmly inone hand, carefully push spool out atsplined end and lift* set of six center-ing springs from their slot in spool,noting arrangement for conveniencein reassembly.

Separate end cap and gerotor sec-tions and remove drive shaft andspacer. These parts must be handledwith great care. Inspect contact sur-faces of all parts for scores andscratches. Minor flaws can be cleaned-up by hand rubbing with 400 gritabrasive paper.

Gerotor parts surfaces are recondi-tioned by stroking over a sheet of600 grit abrasive paper laid over asmooth, flat surface such as plateglass or equivalent. Paper finishshould first be cleared of sharp,irregular grit particles by rubbingwith a piece of flat steel stock toinsure against scratches or surfacescoring. Each finished area should beinspected for small bright patches,especially near edges, after severalrub strokes on the abrasive. Suchshiny spots indicate burrs which mustbe removed. As with all other steeringvalve parts, rinse clean in solventafter polishing and blow dry. Maintainabsolute cleanliness for reassembly.

13. After all parts have been cleaned,polished and blown dry, coat internalparts with steering fluid. Positionvalve body with mounting plate (6-hole) side upward and insert checkvalve spring, larger end down. Setcheck ball in place, centered onsmaller end of spring and insert valveseat, counterbored face against check

4

•

MODEL 160 Paragraphs 14-17

ball, with a ^^-inch Allen hex wrenchand torque to 150 inch-pounds. Ballaction should be checked by depress-ing with a small, clean pin or softwire. Using a new **O" ring seal,reinstall the plug, taking care not todamage new seal against shoulder ofplug hole.

Slip valve spool into sleeve with atwisting motion. Note that centeringspring slots of these mated parts areat the same end. Spool should rotatefreely inside the sleeve with justfinger-tip force applied to the spline.Align centering spring slots and standassembly on its opposite end. Preparecentering springs for installation bymatching two sets of three springs,arched centers of each stack opposingthe other. Holding in this position,insert one end of all springs intorespective slots in spool and sleeve.Then, compress extended ends andpush into place, guiding into slotswith a small screwdriver from oppo-site end. Center all springs so theyexert an even pressure and are flushwith spool and sleeve surfaces. Installcentering pin through matching holesin sleeve and spool to just belowflush with sleeve outer circumferenceand insert nylon plugs, if provided,into sleeve to protect finished boreof valve body. Set housing on a clean,solid work surface, port side down,and insert sleeve assembly, splinedend leading, into the gerotor (14-hole)end of housing. Rotate sleeve slightly,being very careful not to cock or jamthe parts, while inserting into valvebody until flush, no farther. Checkfreedom of rotation with light fingerpressure at splined end of spool; thenplace housing assembly on its gerotorend on a clean, firm, work surface.

Covering bench or work area with alint-free paper shop towel is recommendedpractice when assembling parts which de-mand total cleanliness.

Steering valve unit may have eithera locator bushing or a three-pieceroller bearing assembly (5 or 6). Iflocator bushing (5) is used, installchamfered side up, rotating slightlyto insure proper free fit. If a bearing

Fig. 7—Exploded view ofpower steering eyiinder

(ram).

Barrel assemblyNut, 14-Inch N.C.PistonPiston ring (teflon)"O" ring seai"O" ring sealBearingSnap ring**O" ringBaclc-up washerWiper sealBearing nutPiston rod assemblyRing and seal kit

6 7

(6) is used, it is installed with a raceon each side of roller cage. Wheninstalling mounting plate, first insurethat seal grooves are clean and clearand carefully install a new set ofseals. Observing alignment, installmounting plate and cap screws, gradu-ally tightening to 250 inch-poundstorque. Next, invert housing so thatgerotor (14-hole) side faces up andinstall 14-hole plate (11) and outersection of gerotor (15) with capscrewholes aligned. Insert splined end ofdrive shaft (12) into female splinesof gerotor center section (14) so thatslot at drive end of shaft aligns acrosstwo opposing valleys of rotor. CAU-TION: If drive slot is mistakenlyaligned with peaks of rotor teeth, unitwill be out of time. Holding the rotorand shaft firmly as assembled, withabout half the length of shaft splinesprotruding from rotor, lower assem-bly into housing so that drive shaftpin slot engages drive pin withinvalve spool and insert spacer (13)next to splined end of shaft. If spacerdoes not fit flush to gerotor surface,then the pin is not properly engagingslot in shaft. With housing set in vise,install end cap and gradually torqueall cap screws to 150 inch-pounds.

CYLINDER

14. REMOVE AND REINSTALL. Toremove steering cylinder (ram), dis-connect both lines and drain fluid.Cap or tape over line fittings to main-tain cleanliness. Remove anchor pin

which attaches fixed end of ram tofront axle and disconnect rod endfrom tie rod clamp. Reverse this pro-cedure for reinstallation and bleedsystem as in paragraph 7.

15. OVERHAUL. Refer to Fig. 7 andremove spanner bearing nut (12). Re-move fitting from rod end of steeringcylinder, push bearing assembly (7)deeper into cylinder (1) and removesnap ring (8). Pull rod, bearing andpiston assembly from cylinder. Dis-assemble rod, piston and bearing, re-moving all old seals and the teflonpiston ring. Clean all parts in solventand arrange in assembly order on aclean paper towel. Carefully inspectand evaluate condition of cylinderbore, surface of rod and bearing andall threaded sections.

16. Install new "O" ring seal (9),back-up washer (10), and wiper seal(11) in sequence into rod bearing (7).Install new "O" ring (6) in outergroove of bearing; then install span-ner nut (12), snap ring (8) and bear-ing assembly over piston rod, takingcare not to damage new seals. Installnew teflon piston ring (4) and "O"ring (5) on piston, then reinstallpiston on threaded rod end and tightenretaining nut securely. Slip piston intocylinder bore followed by bearingassembly, depressing bearing farenough into bore to accomodate re-seating of snap ring (8). Install andtighten bearing nut securely and re-install line fitting at rod end ofcylinder.

ENGINE AND COMPONENTS

R&R ENGINE WITH CLUTCHNOTE: This procedure is intended

for use only if complete removal ofengine from tractor is planned with

detailed engine disassembly in mindFor simple separation of engine andclutch from clutch housing, refer toparagraph 65.

17. ENGINE REMOVAL. First, splitfront assembly from tractor as out-lined in paragraph 5, and if engineis to be disassembled, drain oil pan.

Paragraph 18 ALLIS-CHALMERS

Fig. 8—Tighten cylinder head nuts to atorque of 5S-60 foot pounds in sequenceshown. Washer (W) should be instaiied as

shown with 2 grip rings on bolt.

Fig. 9—Measuring valve head clearancebelow surface of cylinder head.

VALVE HEAD 0.066-0.084 INCHBELOW FACE OF CYLINDER HEAD

Fig. 10—Seated valve showing clearanceas measured in Fig. 9.

Disconnect throttle control and fuelshut-off linkage, tachometer drivecable (at rear of camshaft) and flex-ible fuel lines from intake manifoldand final fuel filter at the fuel mani-fold mounted forward of fuel tank.Remove flexible line connecting fueltank filter to fuel lift pump.

Fig. 11—Bottom face ofcylinder head showingcylinder and vaive num-ber arrangement. Notemushroom face of eachtappet opposite each

valve.

4

FLARE

Fig. 12—Finished dimen-sions of vaive seats orinserts. Note depth of

flare.

0.130" to 0.138"t

NOTE: Be sure to close valve atfuel tank filter and cap off or tapeall lines and fittings to prevent con-tamination or damage.

Disconnect cold start pre-heatercable and fuel line at forward end ofintake manifold and both hydrauliclines from main hydraulic pump.Lower (inlet) hydraulic tube shouldalso be separated where coupled underhigh pressure filter at joining pointof clutch and flywheel housings. Re-move all steering system hydrauliclines along with power steering pumpand cylinder (ram). Be sure to protectall open ports or lines in steering andhydraulic systems.

With engine supported from its liftrings by a suitable hoist, remove 15capscrews which retain clutch hous-ing to flywheel housing and two capscrews which hold forward leg offuel tank front support to flywheelhousing.

NOTE: If fuel tank is near empty,no problem will exist, but if tankcontains a high level of fuel, it isadvisable to place a temporary sup-port under front of fuel tank adjacentto the high pressure hydraulic filter.After double-checking for possible in-terference, swing hoist-supported en-gine forward off clutch shaft and freeof tractor.

CYLINDER HEAD

18. REMOVE AND REINSTALL.With cooling system drained, de-

tach water connections from thermo-stat housing and remove radiator sup-port brace. Remove exhaust pipe andmuffler. NOTE: Some mechanics pre-fer to remove the exhaust manifold,pipe and muffler as a unit—this pro-cedure will also improve access tofuel injector lines which must also beremoved. Remove the air cleaner ducthose from intake manifold and crank-case breather tube from rocker armshaft cover. Remove cold start elec-trical and fuel connections from intakemanifold, and after removing mani-fold, detach external oil line from thehead to camshaft oil reducer inengine block.

CAUTION: All fuel system parts must bekept absolutely clean by capping or tapingall delivery ports and lines.

Remove injector (atomizer) tubesand leak-down pipes from injectors,then remove injectors from head. Re-move rocker arm cover and discon-nect rocker arm oil supply pipe fromhead. Remove four rocker shaft standnuts and lift off the rocker assembly.Next, remove cylinder head nuts,observing the REVERSE of torquingsequence shown in Fig. 8, and lift,DO NOT PRY, head from block. Placecylinder head on a flat surface, pre*ferably wood. ^

•

8

MODEL 160 Paragraphs 19-20

TOP FACE OFCYLiNDER HEAD

\J I 0.584-0.594 INCH

20* CHAMFER

Fig. 13 — New vaiveguides should be pressedIn to dimension shown.

FROMT-

Fig.. 15A—With number 1 cyiinder on com-pression strolce (see paragraph 20) ad-just valves 1, 2, 3 and 5 to 0.012 coid or0.010 hot. Refer to Fig. 15B to continue

adjustment.

IISILETVALVE

EXHAUSTVALVE

INLETA-1.874" to 1.875"B - 0.248" to 0.250"C - 0.040" to 0.050" (Radius)

Fig. 14—Dimensions formachining counterboresfor renewed vaive seats.Install new valve guidefirst to provide accuratecenter far machine cut-

ter piiot.

EXHAUSTA-1.678" to 1.679"B-0.310" to 0.312"C - 0.015" (Maximum Radius)

Before installing head, be sure thatall block and head passages for cool-ant and oil are clean and clear andproperly aligned with openings in newhead gasket. Note position of FRONTand TOP marks on new gasket. Re-moval of surface defects by millinghead is allowable up to 0.012, or untiltotal thickness of head is reduced to2.988 from original 3.0. If and whenhead is resurfaced, valve height mustbe measured as in paragraph 19, andby procedure shown in Fig. 9 & 10.Injector nozzle protrusion from under-surface of the head must never exceed0.184. Do not shim under the injectorto reduce this dimension. With allmating surfaces thoroughly clean, in-stall new treated head gasket dryand with two grip rings on stud boltshown as No. 15 in Fig. 8, install cyl-inder head. Observing the sequenceof Fig. 8, torque all cylinder headnuts to 55-60 foot-pounds. Be sure toinstall washer under No. 15, as shown.Install rocker shaft assembly, performvalve tappet adjustment as in para-graph 20. Complete the assembly, run

engine until normal operating tem-perature is reached, then retorquehead nuts and readjust tappet gap tospecifications.

VALVES AND SEATS

19. As manufactured, intake andexhaust valves are directly seatedinto cylinder head. All valve facesare production ground to 45® andseats are flared 30*, to the surface ofcylinder heads, with preferred seatwidth of ^-inch. See Fig. 12. Loca-tions of valve heads and seats arenumbered consecutively front to rearas shown in Fig. 11. Clearance ofvalve heads must be held within indi-cated tolerances, measured as shownin Fig. 9 & 10. When such clearancecannot be achieved, replacement seatsare available for refitting heads asshown in Fig. 14. Note: To insureaccuracy in machining counterboresfor replacement valve seats, a newvalve guide must be installed, observ-ing placement and dimensions shownin Fig. 13. Valves should be discardedif thickness of margin is less than

NFig. 15B—After adjusting vaives 1, 2. 3and 5. (Fig. 15A) rotate engine ane revo-iution (360°) and adjust vaives 4 and 6.

Tappet gap is 0.012 cold or 0.010 hot.

. Specifications are as follows:Face Angle, In. & Ex 45®Stem Dia., In. & Ex *0.311-0.312Valve Length, In. & Ex 4.5Head Dia., In 1.532-1.536

Ex 1.313-1.317Head Margin, Min ^-inchGuide I.D., In. & Ex. . .**0.3145-0.3155Head Clearance, In. & Ex.. .0.066-0.084Tappet Gap, In. & Ex.

Hot 0.010Cold 0.012

Discard if 0.310 or scored.**Discard if more than 0.3155.

TAPPET GAP ADJUSTMENTS

20. A two-position procedure foradjusting valve lash (tappet clear-ance) is both practical and recom-mended. To make the adjustment,proceed as follows: Rotate engine(injectors removed) until key way incrankshaft pulley is at top and bothvalves of number one cylinder arefully closed—this is compressionstroke. Refer to Fig. 15 A, and adjusttappets to 0.012 cold (0.010 hot) onvalves numbered 1, 2, 3 and 5. Then,refer to Fig. 15B, rotate engine 360**,(one revolution) and set tappets 4 and6. If head is re-torqued followingthis adjustment or if rocker shaft is

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Paragraphs 21-24 ALLIS-CHALMERS

removed, repeat the process withfinal setting at 0.010 for all valveswhen engine is at normal operatingtemperature.

ROCKER ARMS AND SHAFT

21. After rocker shaft has been dis-assembled and thoroughly cleaned,with parts laid out in assemblysequence, it is advisable to checkrocker arms (levers) for condition.Rocker arms should be a slip fit onthe shaft and the bushing bore shouldnot exceed 0.6257 or a measured fitto the shaft should not exceed 0.0034clearance. Rockers are complete as-semblies and new bushings cannot befitted. On reassembly, correct normalposition of the slotted end of rockerarm shaft is shown in relation to apunched mark in front stand. SeeFig. 16.

This arrangement controls flow of oil torocker arms. When need for increaseor decrease of flow is confirmed, flow maybe cut back by turning shaft slot to ver-tical« or increased by turning toward hori-lontal, which is the maximum flow rateposition.

VALVE GUIDES

22. Replacement cast iron valveguides are available pre-sized forpress fit and do not require reaming.Inside diameter of guide is 0.3145-0.3155 for both intake and exhaustwith a stem to guide clearance of0.0025-0.0045. If maximum figures areexceeded, renewal of guides is indi-cated. Consult Fig. 13, and press innew guides with 20"* chamfered endtoward combustion chamber, observ-ing 0.584-0.594 clearance from top ofnew guide to top surface of cylinderhead. While pressing, it is advisableto use a pilot drift 0.002 smaller thanguide inside diameter. IMPORTANT:If guides only are renewed, be sureto reface valve seats lightly to insureproper concentric seal of valve facesto seats.

VALVE SPRINGS

23. Springs are interchangeable be-tween intake and exhaust valves, andearly models use two springs on eachvalve. See Fig. 17 for overall arrange-ment. The following table proposesspecifications against which springsshould be tested and compared. Beforeusing spring tester, springs should beevaluated by inspection for discolor-ation, bent coils, ends out of square,or other apparent damage.

Fig. 16 —View of frontrocker arm stand showingcorrect position of shaftslot for normal oil flowcontrol. 1-Punch mark onstand. 2-Correct (30°from verticai) position of

siot.

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Fig. 17—Intake and ex-haust valve assemblies forearly models. Late mod-els do not have inner

springs (4).

1. Kxliaust valve*J. Intake valve'{. Spring seats•1. Inner valve sprlngfl.

early models5. Outer valve springs0 Upper spring caps7. Retainers

Spring Free Length, I . & Ex.Outer lfl inchesInner* 1% inches

Length, Valve Closed, In. & Ex.Outer 1^ inchesInner l ^ inches

Pressure, Valve Closed, In. & Ex.. Outer 21-25 lbs.

Inner 7-9 lbs.Length, Valve Open, In. & Ex.

Outer 1^ inchesInner H inches

Pressure, Valve Open, In. & Ex.Outer 48-52 lbs.Inner 21-25 lbs.*Inner spring discontinued in pro-

duction following September 1970.There is no change in specificationsfor the single outer spring.

VALVE TAPPETS

24. Valve tappets (cam followers)are a snug slip fit in bored hole.s inthe cylinder head. Normal wear isnegligible; however, if mushroom face,adjustment threads, tappet body orscrew head have been damaged dueto overheating, oil starvation or otherabnormal condition, renew tappet.New tappets should fit with sideclearance of 0.0008-0.0034 betweentappet body and cylinder head bore.With cylinder head removed, tappetseasily withdrawn when adjustingscrew and locknut are removed. Besure of observe location arrangementfor convenience in reassembly. Tap-pets, like valves, must always be re-turned to same location from whichremoved.

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