SHOP MANUAL

ALLIS-CHALMERSMODELS D-21, D-21 SERIES II, TWO-TEN AND TWO-TWENTY

Tractor serial number is located on the front flange of the torque (clutch)housing at left hand side of tractor. Engine serial number is located onnameplate which is attached to the upper rear corner of cylinder blockon the left hand side of tractor.

Model D-21 tractors were available with a naturally aspirated diesel en-gine. D-21 Series II, Two-Ten and Two-Twenty tractors are equipped with aturbo-charged diesel engine. All models are available with an adjustable,wide front axle. Two-Twenty models are also available with a drivingfront axle (Front Wheel Assist).

INDEX (By Starting ParagrapK)

BRAKESAdjustment (D-21 & D-21 Series ID 105

Two-Twenty 106R&R and Overhaul (D-21 &

D-21 Series 11) 105ATwo-Twenty 106A

CLUTCHEngine Clutch 72Engine Clutch Shait 76

COOLING SYSTEMRadiator 67Water Pump 68

DIESEL FUEL SYSTEMFilters and Bleeding 51Injection Pump 56Injection Pump Gears 34Nozzles 53

DIFFERENTIALAdjustment 95R&R and Overhaul 96F.W.A 172

ELECTRICAL 70

ENGINEAssembly—R&R 20Cam Followers 26Camshaft 36Connecting Rods & Bearings 41Crankshaft & Bearings 42Cylinder Head 21Cylinder Sleeves 39

ENGINE (Cont)Flywheel 45Front Oil Seal 43Injection Timing 56Main Bearings 42o n Cooler 49Oil Pan 46Oil Pump 47Piston Pins 40Piston & Rod Removal 38Pistons & Rings 39Rear Oil Seal 44Rocker Arms 27Speed Adjustments 58Timing Gear Cover 30Timing Gears 31Turbochargar 60Valve Guides 24Valves & Valves Seats 22Valve Springs 25

FINAL DRIVE & DIFFERENTIALBevel Gears, Adjust 97Bull Gears, Renew 100Bull Pinion Bearings, Adjust 99Bull Pinion, Renew 99Differential Overhaul 96Wheel Axle Shafts 103

FRONT SYSTEM (Without Front Wheel Assist)Adjustable Front Axle 1Power Steering 8

FRONT WHEEL ASSISTDrive Adapter 165Front Axle Assembly 168Idler Gear, Shaft and Bearings 167Lubrication 164Power Steering 8

POWER LIFT SYSTEMChecks and Adjustments 12L 123Filters .155Pump 137Valves 150,154Work Cylinders 129

POWER STEERING 8

POWER TAKE-OFFClutch and Brake 114.115Controls 110,112Output Shaft and Bearings 116,117Reduction Gears and Shafts 113Test and Adjust 107,109

TRANSMISSION (FRONT)Assembly, R&R 80ACountershaft 87Mainshaft 86Reverse Idler 85Shifter Assembly 80

TRANSMISSION (DUAL RANGE)Bevel Pinion Shaft 92Countershaft 94Shifter Assembly 90

CONDENSED SERVICE DATAGENERAL

Liquid Capacities D-21 Series IICooling System 21 Qts. 31 Qts.Crmkcase (with filter) . . . . 12 Qts. 12 Qts.Fuei Tank 52 Gals. 52 Gals,Transmission (approx.) 21 Gals. 21 Gals.tCapacity is 15 qts. for 220 model.

Front WheelsToe-In iV-% Inch-

SpeedsNumber Forward 8Number Reverse 2

Electrical SystemVoltage ' 12Ground Polarity Negative —

No. of Batteries 2or4——

Battery Yoltage, each 12

210

21 Qts.t21 Qts.

51 Gals.27 Gals.

Printed in U.S.A. Copyright 1971 by Intertec Publishing Corp.,

D-21, D'21 Series II. 210, 220 Paragraphs 1-5

CONDENSED SERVICE DATA (Cont.)DIESEL ENGINE

D-21 210General D-21 SeHes II 220

Make OwnModel 3400 3500 3500No. of Cylinder 6 6 6Bore—Inches 4 1/4 4 ^4 41/4Stroke—Inches 5 5 5Displacement-Cubiclnches 426 426 426Compression Ratio 16:1 16:1 16:1Firing Order 1-5-3-6-2-4

Compression Pressure @150 RPM* 400 psi 400 psi 400 psi600 RPM* 500 psi 500 psi 500 psi

^Compression pressures given are approximate and at sea level.

Tappets & ValvesTappet Gap, Hot 0.015 0.015 0.015Cold 0.018 0.018 0.018

D-21 210Valve Face & Seat Angle<- D-21 Series II 220

Intake 30'' 30* 30"Exhaust 45" 45* 45"

Diesel SystemPump Make Roosa-MasterInjection Timing. Static . . . 34"BTDC 34"BTDC 34"BTDCTiming Mark on Crankshaft PulleyNozzles Make OwnOpening Pressure 2750 psi 2900 psi 3125 psi

Governed SpeedLow Idle RPM 675 675 675High Idle RPM 2400 2400 2400Rate Load RPM 2200 2200 2200

Tightening Ibrques (Ft.-Lbs.)General Recommendations See End of Shop ManualCylinder Head See Paragraph 21Crankshaft Pulley 200-220 200-220 200-220Flywheel 95-105 95-105 95-105Main Bearing Cap Screws. 170-190 170-190 170-190Rod Cap Screws See Paragraph 38

FRONT AXLE SYSTEM

(Models without Front Wheel Assist)

SPINDLES

1. K&R SPINDLES. To remove frontspindle (10—Fig. ACl), support frontof tractor, remove front wheel andproceed as follows: Remove snapring (6) and pull steering arm (8)from spindle. Remove key (K) fromspindle and withdraw spindle frombottom of axle extension (5). Removethrust washers from spindle.

2. SPINDLE BUSHINGS. Spindlebushings can be renewed after remov-ing spindle as outlined in paragraph1. Remove bushings (7) using suitabledrift punch. New bushings are pre-sized and should not require ream-ing if carefully installed. Renew thrustwashers if necessary before reinstall-ing spindle.

TIE-RODS AND TOE-IN3. Refer to Figs. ACl and AC2. Toe-

in of front wheels should be 1/16 toVs-inch, and can be adjusted bylengthening or shortening tie-rods(12) equally as follows: Remove bolt(B) from outer ends of tie-rods andloosen clamp bolts (C) at inner ends.Turn the tie-rod tubes (12) in or outon inner tie-rod ends (13) to obtaincorrect adjustment. Reinstall andtighten bolt (B), then tighten clampbolt (C) and recheck toe-in. Readjustif necessary.

Tie-rod end sockets are non-adjust-able automotive type and except fordust cover, must be renewed as acomplete unit.

AXLE EXTENSIONS

4, To renew either axle extension(5—Fig, ACl or Fig. AC2), removespindle as outlined in paragraph 1;then, remove tread width adjustingbolts and withdraw axle extensionfrom main member.

STEERING ARM

5. To renew the steering arm (15—Fig. ACl) or steering arm bushings(16), proceed as follows: Disconnectsteering cylinder piston rod and tie-rods from the steering arm, then re-move steering arm from pivot pin (P)on the crossbar in front axle mainmember.

17

Fig. A C l — Exploded view of Model D-21 front axle ossembly. Bolt (R) retains frontpivot pin ( 3 ) . To ad|ust front wheel toe-in, remove boit (B) , loosen clamp (C ) and turn

tie rod tube (12) In or out as required.

B. BoltC. ClampK. KeyP. Pivot for (15)R. Retainer bolt

1. Rear pivot bolt2. Axle main member3. Front pivot pin4. Flat washer5. Axle extension

6. Snap ring7. Spindle bushings8. Spindle arm

10. Spindle11. Outer tie rod end

12. Tie rod tube13. Inner tie rod end15. Steering arm16. Bushings17. Retainer washer

3

Paragraphs 6-7

Drive the bushings (16) out ofsteering arm using a suitable bushingdriver. New bushings are pre-sizedand should not require reaming ifcarefully installed.

The steering arm pivot pin (P) isan integral part of the axle center(main) member and radius rod assem-bly.

AXLE CENTER (MAIN) MEMBERAND PIVOT PINS

6. The axle center (main) memberand the radius rods are welded one-piece assembly (2—Fig. ACl or Fig.AC2). The center member pivots ona bolt (1) at rear end of assembly anda pin (3) at front end. The bolt andpin pivot in renewable bushings in theclutch (torque) housing and in thefront support casting.

To renew the pivot bolt or pivotpin, proceed as follows; Support trac-tor under the torque housing so thatno weight is carried on the front axle.Then, remove the retaining bolt (R—Fig. ACl) and drive the front pivotpin out towards front of tractor. Theplug (3—Fig. AC3) with lubricatingfitting will be driven out with pin.Then, raise front of tractor until frontsupport is clear of axle and drivebushing (2) out to rear with suitabledriver. New bushing is pre-sized andshould not require reaming if care-fully installed. Install pivot pin andretaining bolt, then drive the plug(3) into front support with a hollowdriver so that plug is flush with cast-ing.

To remove rear pivot bolt, supportrear (radius rod) end of axle mainmember and remove cotter pin and

Fig. AC2 — View show-ing front axie extension.Toe-in should be correctfor each treod width po-sition when bolt (B) isiocated in proper notch(N) in tie rod. Refer to

Fig. ACl for iegend.

slotted nut from pivot bolt. Then, re-move pivot bolt from axle and torquehousing. Drive bushing out of torquehousing. New bushing is pre-sized andshould not require reaming if care-fully installed. Install pivot boltthrough torque housing, install slottednut and tighten nut to a torque of150 Ft.-Lbs. If slot in nut does notalign with hole in bolt, continue totighten nut until cotter pin can beinserted.

To renew the axle center (main)member, remove both axle extensionsas outlined in paragraph 4, disconnectrear end of power steering cylinder,remove steering arm from pivot pinand remove the front axle pivot pinand rear pivot bolt.

i ALLIS-CHALMBRS

FRONT SUPPORT

7. The front support (1— Fig. AC3)is a heavy one-piece casting. The frontaxle pivot bushing (2) and plug (3)can be renewed as outlined in para-graph 6 without removing the frontsupport. To remove front support forother jobs, proceed as follows: Drainthe cooling system. Remove hood andair cleaner to intake manifold tube.On Two-Twenty models, disconnecthydraulic lines to the oil cooler. Onall models, disconnect both radiatorhoses, then unbolt hood front supportpanels from side rails, and remove thepanels, radiator and air cleaner as aunit. Disconnect front of steering cyl-inder from steering arm (15— Fig.ACl). Support the tractor undertorque housing so there is no weighton front axle pivot pin. Attach a hoistto front support at lifting point pro-vided, remove cap screws retainingside rails to front support and removethe front support from side rails andfront axle pivot pin. NOTE: If frontsupport casting binds between the siderails, loosen the bolts retaining siderails to engine front support plate.Any front end weights attached tofront support casting should be re-moved before unbolting and removingthe front support.

POWER STEERING SYSTEMAll models are equipped with hydrostatic

power steering system that has no mech-anical linkage between the steering wheeland tractor front wheels. Refer to Fig. AC4for drawing showing the steering system.

Power for steering is supplied by a geartype pump that is driven from the enginetiming (camshaft) gear. On models with ahydraulic lift system, the hydraulic andpower steering pumps are an integral unit.Transmission oU is utilized as fluid for thesystem.

The control valve unit (1—Fig. AC4) con-tains a rotary metering motor, a commuta-tor feed valve sleeve and a selector valvespool. In the event of engine or hydraulicpower failure, the metering motor becomesa rotary hand pump to actuate the powersteering cylinder when the steering wheelis turned. A check valve within the control

Fig. AC3—View of frontsupport easting and r^iated parts. Additionalflat front weigiits can beboited onto the weight

shown.

1. Front support2. Pivot bushing3. Plug4. Front weight

valve housing allows redrculation of fluidwithin the control valve and steering cylin-der during manual operation. NOTE: Themaintenance of absolute cleanliness of allparts is of the utmost importance in theoperation and servicing of the hydraulicpower steering system. Of equal importance

Fig. AC4—Drawing showing components ofhydrauiic power steering system. No me-clionicoi linicage is used between the steer-ing wheei and troctor front wheeis. Notethat the components are not located in po-sition in which they are installed on trac-tor. Cooier (8) is not used on D-21 modeis.

1. Control valve unit2. Pressure tube3. Return tube4. "Right turn" tube

5. "Left turn" tube8. Oil cooler9. "T" fitting to

PTO valve

Q.21. D-21 Series II. 210, 220 Poragraphs 8-lOA

i8 the avoidance of nicks or hvms on anyof the working parts. Do not use cloth shoptowels in cleaning the system internal parts;use only lint free power shop towels.

TROUBLE SHOOTING

8. Before attempting to adjust orrepair the power steering system, thecause of any malfunction should belocated. Refer to the following para-graphs for possible causes of powersteering system malfunction:

Irresrular or "Sticky" Steering. Ifirregular or **sticky" feeling is notedwhen turning the steering wheel withforward motion of tractor stopped andwith engine running at rated speed,or if steering wheel continues to ro-tate after being turned and released,foreign material in the power steeringfluid (transmission oil) is the prob-able cause of trouble. Clean or renewall hydraulic system filters. It maybe necessary to also drain the trans-mission oil and refill with clean oil.If trouble is not corrected, the powersteering valve assembly should be re-moved and serviced; refer to para-graph 12.

Steering Cylinder "Hesitates". Ifsteering cylinder appears to pause intravel when steering wheel is beingturned steadily probable cause oftrouble is air trapped in the powersteering cylinder. Bleed the cylinderas outlined in paragraph 9.

Slow Steering. Slow steering maybe caused by low oil flow from pump.Check time required for full stroketravel of power steering cylinder; firstwith tractor weight on the frontwheels, then with front end of trac-tor supported by a jack. If time be-tween the two checks varies consider-ably, overhaul the power steeringpump as outlined in paragraph 139.

Loss of Power. Loss of steeringpower may be caused by system re-lief setting being too low. Check andadjust relief valve setting as outlinedin paragraph lOA or lOB.

System Overheats. Overheating ofsystem may be caused by neutral (by-pass) pressure being too high. Checkneutral pressure as outlined in para-graph lOA. If neutral pressure is ex-cessive, check for obstructions in sys-tem such as kinked tube, etc. If neu-tral pressure is erratic, check for bind-ing of control valve shaft, spool and/or sleeve.

LUBRICATION AND BLEEDING

9. Transmission lubricating oil isutilized as the power steering fluid;refer to note preceding paragraph 80.The power steering system is usuallyself-bleeding. With engine running athigh idle speed, cycle system throughseveral full strokes of the cylinder. Insome cases, it may be necessary toloosen connections at cylinder to bleedtrapped air.

Fig. AC4A—View of OTC hydraulic fesfer connected to D-21 fracfor for testing thepower steering system. Both pressure and return tubes must be disconnected from pumpand return connection must have cap CO installed. Outlet hose must return oil to sump

OS shown.

SYSTEM OPERATING PRESSUREAND RELIEF VALVE

10. Tests of the power steering sys-tem will disclose whether the pump,relief valve or some other unit in thesystem is malfunctioning. To makesuch a test, proceed as outlined in theappropriate following paragraph:

D-21 and D-21 Series II10A. Power steering relief pressure

can be checked by connecting a highpressure (3000 psi) hydraulic gage intothe pressure line between the pumpand power steering control valve.Turn the steering wheel to one endof its travel and hold in that positiononly long enough to read the pressuregage. CAUTION. Never hold steeringwheel in this position for longer thana few seconds at a time; overheatingof oil and possible damage to pumpwill occur if wheel is held in thisposition for an extended period oftime. System relief pressure should be1500 PSI at 2200 engine RPM. Pres-sure relief valve is located in mani-fold of hydraulic pump and can beadjusted as outlined in paragraph 141.

Check the neutral (by-pass) systempressure as follows: With pressuregage connected as outlined in preceed-ing paragraph, slowly turn steeringwheel in each direction and stopwheel in position that shows lowestgage reading; this reading is the neu-tral (by-pass) pressure. Turn wheelto limit stop in either direction andhold wheel against stop for one totwo seconds, then release the wheel;gage pressure should drop to nearlythe same as neutral pressure reading.If gage remains considerably higherthan neutral pressure reading, a bind-ing control shaft or foreign materialbetween control valve sleeve andvalve spool is indicated.

A hydraulic tester (such as OTCY81-21) can be connected as shown inFig. AC 4A to check pump volumeand relief pressure. The outlet hoseshould be routed to sump as shown.With engine operating at approxi-mately 1600 RPM, close the testervalve until pressure is approximately1200 psi. When oil temperature reaches100* F., the volume of flow shouldbe 5.25 GPM with engine speed be-tween 1050 and 2200 RPM. Withtester valve completely closed, pres-sure should be 1500 psi. Add or re-move shims under pressure reliefvalve plug to change pressure. Thepump and/or flow control valveshould be serviced if volume of flowis incorrect.

Paragraphs 10B-13 ALLIS-CHALMERS

210 and 220 ModelslOB. The PTO clutch (on models

so equipped) is operated by return orby-pass oil from the power steeringsystem. PTO clutch operating pres-sure must be tested as outlined inparagraph 109 before checking powersteering relief pressure.

Power steering relief valve pres-sure on all models can be checked byinstalling a high pressure (3000 psi)hydraulic gage in port (P-Fig.AC4B) after removing the plug. Turnthe steering wheel briefly to one endof its travel and observe pressure. Iftractor is not equipped with PTO,power steering relief pressure shouldbe 1690-1810 psi. If tractor is equippedwith PTO, relief pressure should be1925-2075 psi. Power steering reliefpressure can be adjusted at screw (S)after removing cap nut (C). Theneutral by-pass system pressure canbe checked as outlined in paragraphlOA.

The flow divider located in pumprear cover first supplies 4.25 GPM of

Fig. AC4B—Power sfeering pressure can becheciced at port (P) on 210 and 220tractors. Reiief vaive adiusting screw (S)and cap nut (C) are iocated on engine

Me of pump.

Fig. AC5 — View of steering controi vaiveshowing port locations. Pressure tube frompump connects to " i N " port; return tube tosump connects to "OUT" port; tube to rearend of cylinder connects to " L " (left turn)port; and tube to rod end of cyiinder con-

nects to "R" (right turn) port.

1.2.3.4.5.6.7.8.9.

10.11.12.13.14.15.16.17.18.Id.20.21.

Oil sealMounting plateQua4 ling eeal" 0 " ringBushing**0" ringPlugCheck seatCheck valveValve springControl valve bodyCentering springs (6)Centering pinSleeveValve spoolPlateDrive shaftRotorRingSpacerCover (cap)

vr

Fig. AC6—Exploded view of steering control valve assembly which is shown assembiedin Fig. AC4. Centering springs (12) are instGiied in two groups of three springs with archin each group back-to-bacic. Some modeis are equipped with needie thrust bearing (5A

& 5B) and different type locator bushing (5C).

oil to the power steering system, withremainder of oil used for the powerlift system. A hydraulic tester (suchas OTC Y81-21) can be attached toport (P—Fig. AC4B) with outlet fromtester routed to sump filler opening.With engine operating at approxi-mately 1600 RPM, first check reliefpressure. Refer to preceeding para-graph for recommended settings. Opentester valve until pressure is approxi-mately 300 psi below relief pressureand observe volume of flow. Volumeshould be 4.25 GPM with enginespeed between 1050 and 2200 RPM.The pump and/or flow divider valveshould be serviced if volume of flowis incorrect.

POWER STEERING PUMP

11. A gear type pump driven fromthe engine camshaft gear is used asthe power source for the steeringsystem. On tractors equipped with ahydraulic system, the power steeringpump is an integral part of the hy-draulic system pump.

For service information on the pow-er steering pump, on tractors bothwith and without a hydraulic system,refer to paragraph 139.

CONTROL VALVE

12. REMOVE AND REINSTALL.Remove the hood and disconnect thefour hoses from control valve. Unboltand remove the control valve as-sembly from the steering shaft hous-ing.

Reinstall the control valve assemblyby reversing the removal procedure.Refer to Fig. AC5 for proper hose

locations. Install new "O" ring sealson the hose fittings before connectinghoses to control valve and tightenfittings securely. Bleed trapped airfrom the power steering cylinder asoutlined in paragraph 9 after assemblyis completed.

13. OVERHAUL CONTROL VALVE.After removing the control valve as-sembly as outlined in paragraph 12,proceed as follows: Clean the valvethoroughly and remove paint frompoints of separation with a wire brush.Note: A clean work bench is neces-sary. Also, use only lint free papershop towels for cleaning valve parts.

If oil leakage past seal (1—Fig.AC6) is the only difficulty, a newseal can be installed after removingthe mounting plate (2) only. Removeplug (7) from valve body with a bentwire, install new "O" ring on plug,lubricate plug and *'O" ring with mo-tor oil and reinstall in valve body. In-stall new quad seal (3) and "O" ring(4) in mounting plate, reinstallmounting plate and tighten retainingcap screws equally to a torque of 250inch-pounds.

To completely disassemble and over-haul the power steering control valve,refer to exploded view in Fig. AC6and proceed as follows: Clamp valvemounting plate in vise with cap endof valve up. Remove end cap retain-ing cap screws. Remove end cap (21),gerotor set (18 & 19), plate (16) anddrive shaft (17) from valve body asa unit. Remove valve from vise, placea clean wood block in vise throat andset valve assembly on block withmounting plate (2) end up. Lightlyclamp vise against port face of valve

D-21. D-21 Series II, 210. 220 Paragrapks 14-15

1 17 2 3 4 6 16 11 13 12 13 16 15

15 16 8 9 5

Fig. AC7—View of eorly power steering cylinder. Refer to Fig. AC8 for later type.

1. Cylinder rod2. Snap ring3. Spacer4. Snap ring

5. SupportG. *'O" ring8. Back-up ring9. "O** ring

body and remove mounting plate re-taining screws. Hold spool assemblydown against wood block while re-moving mounting plate. Remove valvebody from vise and place on workbench with port face down. Carefullyremove spool and sleeve assemblyfrom 14-hole end of valve body. Usebent wire to remove check valve plug(7) and use ^ -inch Allen wrench toremove check valve seat (8). Thenremove check valve (V4-inch steelball) (9) and spring (10) from valvebody.

Remove centering pin (13) fromspool and sleeve assembly, hold sleeveand push spools (splined end first)out of sleeve. Remove the six center-ing springs (12) from slot in spool.

Separate the end cap and plate fromthe gerotor set and remove the driveshaft, rotor and spacer.

Inspect all moving parts for scor-ing. Slightly scored parts can becleaned by hand rubbing with 4D0grit abrasive paper. To reconditiongerotor section surfaces place a sheetof 600 grit paper on plate glass, lap-ping plate or other absolutely flatsurface and remove sharp particlesfrom paper with a flat piece of scrapsteel. Stroke each surface of thegerotor section over the abrasivepaper; any small bright areas indicateburrs that must be removed, Polisheach part, rinse in clean solvent andair dry; keep these parts absolutelyclean for reassembly.

Renew all parts that are excessivelyworn, scored or otherwise damaged.Install new seal kit when reassem-bling.

To reassemble valve, proceed as fol-lows: Install check valve spring withsmall end out. Drop check valve ballon spring and install valve seat withcounterbored side towards valve ball.Tighten seat to a torque of 150 inch-pounds.

10. "O" ring11. Piston12. "O" ring13. BacU-up rings

14. Lock nut15. Swivei16. Tube seats17. Snap ring18. Scraper

Lubricate the valve spool and care-fully insert spool in valve sleeveusing a twisting motion; be sure thatspring slots in spool and sleeve areat same end of assembly. Stand theassembly on end with spring slots upand aligned. Assemble the springs intwo groups with extended edges ofsprings down. Place the two groupsof springs back-to-back (arched sec-tions together) and install the springsinto the spring slot in sleeve andspool in this position. Use a smallscrewdriver to guide the springsthrough slots in opposite side of as-sembly. Center the springs in thesleeve with edges of springs flushwith upper surface of sleeve. Insertcentering pin (13) through the spooland sleeve assembly so that both endsof pin are below flush with outside ofsleeve (14). On some models, nylonplugs are located at ends of centeringpin to prevent pin from contactinginside diameter of valve body. Care-fully insert spool and sleeve assem-bly, splined end first, in 14-hole endof valve body (11).

Set valve body on clean surfacewith 14-hole end down. Install new"O" ring (6) on check valve plug (7),lubricate plug and insert in checkvalve bore. Install locator bushing (5or 5C) in valve bore with chamferedside up. On models so equipped, in-stall thrust bearing assembly (5A and5B) over valve spool (15). Install newquad seal (3) and *'O" ring (4) inmounting plate, lubricate seal and in-stall mounting plate over valve spooland locator bushing. Tighten themounting plate retaining screwsevenly to a torque of 250 inch-pounds.Clamp the mounting plate in a visewith 14-hole end of valve body up.Place plate (16) and gerotor outerring (19) on valve body so that boltholes align. Insert drive shaft (17) ingerotor inner rotor so that slot inshaft is aligned with valleys in rotor

and push shaft through rotor so thatabout Vi of length of the splines pro-trude. Holding the shaft and rotor inthis position, insert them in valvehousing so that notch in shaft engagescentering pin in valve sleeve andspool. Install spacer (20) at end ofdrive shaft; if spacer does not dropdown flush with rotor, shaft is notproperly engaged with centering pin.Install end cap and tighten the retain-ing screws equally to a torque of 150inch-pounds.

POWER STEERING CLYINDER

14. REMOVE AND REINSTALL.Thoroughly clean cylinder and hosefittings to avoid entry of dirt whenlines are disconnected. Turn frontwheels to right as far as possible. Re-move the bolt at each end of cylinder.Disconnect hose fittings at cylinderand remove cylinder from tractor.Work the cylinder piston each wayto end of stroke to expel all excessoil. Note: Only about 1 pint of oilwill drain from hose when cylinderis disconnected.

When reinstalling cylinder, first at-tach hose fittings leaving the flarenuts loose. Install the two bolts retain-ing cylinder to crossbar and pistonrod to steering arm with bolt headsup, then tighten the nuts and securewith cotter pins. Check to see thathoses are properly located, then tight-en the flare nuts.

Bleed the power steering system asoutlined in paragraph 9, check trans-mission oil level and add oil as neces-sary to bring oil level to full markon dipstick,

15. OVERHAUL STEERING CYL-INDER. After removing power steer-ing cylinder as outlined in paragraph14, refer to Fig. AC7 or AC8. Theearlier type is shown in Fig, AC7.

On early models (Fig. AC7), re-move snap ring (2) and withdrawspacer (3) from cylinder tube. Pushsupport (5) into tube far enough toremove snap ring (4), Remove snapring, then use piston rod to bump thesupport out of the cylinder tube. Re-move nut (14) from inner end ofpiston rod, carefully remove the burrleft from staking nut to rod, thenremove piston (11). Remove **O" ring(10) and slide the support (5) off rod.

On later models (Fig. AC8), re-move fitting (20) push support (5)into tube far enough to remove snapring (4). Remove snap ring, then usepiston rod to bump the support outof cylinder tube.

ParograpKs 20-21 ALLIS-CHALMBRS

19 21 6 5 11 22 23 22 IB

Fig. AC8—View

7. Cylinder tube19. Scraper20. FlttlnK

25

steering cyiinder. Refer to Fig. AC7 for iegend except tiiefoiiowing.

21. Back-'ip ring22. Split wear ring23. Sealing ring

24. "O" ring25. Nut

The sharp edge of scrapers (18—?ig. AC7 and 19—Fig. AC8) should3e toward outside. Refer to Figs. AC7k AC8 for remainder of assembly.Stake the piston retaining nut to rodifter tightening. Support (5) must be)ushed into cylinder enough to in-tall snap ring (4), then bump theupport back out against snap ring)y pulling on rod. On later models,nake certain that hole in support is

aligned with hole in cylinder, so thatfitting (20—Fig. AC8) can be in-stalled. On all models be sure thatall parts are lubricated when assem-bling and carefully work seals ontorod and into cylinder.

ENGINE AND COMPONENTS

R&R ENGINE WITH CLUTCHASSEMBLY

20. To remove the engine, first re-move the cover(s) from the batteriesand disconnect all battery groundstraps. Note that each battery has aseparate ground strap. Then, proceedas follows:

Drain oil pan if engine is to bedisassembled. It is not necessary todrain the transmission as front endof pump suction tube is higher thantransmission oil level. Remove thefront support casting as outlined inparagraph 7. Unbolt and remove bothside rails from tractor. Disconnect thestarter cable from starting motor anddisconnect all wiring to engine elec-trical units by separating the plug-inconnectors or detaching from elec-trical units. Move wires out of theway. Disconnect power steering, hy-draulic system and "Traction Booster**lines from pump, remove clamps andreposition lines away from^ engine.NOTE: Cap all openings as lines aredisconnected. Shut off fuel supply anddisconnect fuel lines. Disconnect speedcontrol rod, fuel shut-off cable (orwires) and engine hour-meter cable.

NOTE: Depending on reason for en-gine removal, it may be easier to re-move other components from engineat this time.

Attach hoist to lift hooks providedat front and rear end of cylinderhead, then unbolt and remove the en-gine from torque housing. Refer toFig. ACIO.

Reinstall engine and clutch assem-bly by reversing removal procedures.Bleed the fuel system as outlined inparagraph 51 and, if necessary, bleedthe power steering system as outlinedin paragraph 9.

CYLINDER HEAD21. REMOVE AND REINSTALL.

Drain cooling system and remove aircleaner inlet cap and pipe, hood topand side panels. Disconnect upper ra-diator hose from thermostat housing

and remove tube from air cleaner tointake manifold or turbocharger. Dis-connect water by-pass tube from wa-ter pump and thermostat housing, dis-connect temperature gage senderswitch wire and remove thermostathousing from cylinder head. On turbo-charged models, remove the turbo-charger. On all models, remove ex-haust manifold. Remove the intakemanifold if so desired.

Disconnect breather tube fromrocker arm cover, remove rocker arm

Fig. ACIO—View of engine removed from D-21 tractor. Two-Ten, Two-Twenty and D-21Series II engines are simiiar.

1. Lift hook2. Lift hook

3. Oii filters4. TDO timing pin5. Fuel primer pump

6. Fuel filter7. Timing window

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D-21, D.21 Series II, 210, 220 Paragrophs 22-23

cover, remove oil supply line to rock-er arm assembly and equally loosenand remove the rocker arm assemblyretaining cap screws. Lift off rockerarm assembly and remove the pushrods. Disconnect fuel return line atfront injector and cap all openingsas each line is disconnected.

NOTE: Although not required for removalof the cylinder head, it is recommended thatthe fuel injector assemblies be removedfrom cylinder head at this time. The in-jector nozzle tips protrude through the flatbottom surface of the cylinder head and, ifinjectors are not removed, extreme caremust be taken when removing and handlingthe removed cylinder head.

Remove the cylinder head retain-ing cap screws and carefully pry cyl-inder head up off of the dowel pins(DP—Fig. ACll) located at front andrear of cylinder block. Lift cylinderhead from tractor.

When reinstalling cylinder head, besure that gasket surfaces of cylinderhead and block are clean and free ofburrs. Check cylinder liner standoutas outlined in paragraph 39, Placenew gasket with side marked "THISSIDE DOWN" against cylinder blockand be sure gasket is properly lo-cated on the two dowel pins. Note:Do not apply grease or gasket sealerto gasket surfaces, block or cylinderhead; new gasket is treated with phe-nolic sealer. Locate fire rings aroundcylinder sleeves then position cylin-der head on the dowel pins. Lubricatethe cylinder head retaining cap screwswith motor oil and install the 20 shortcap screws as indicated in View "A",Fig, AC12; t ighten the short capscrews to a torque of 90-100 Ft.-Lbs.in sequence shown. Install the pushrods and rocker arm assembly. Start-ing in the center and working towardeach end, tighten the six long cylinderhead retaining cap screws to a torqueof 90-100 Ft.-Lbs. Retighten all 26cylinder head retaining cap screws toa torque of 130-140 Ft,-Lbs, in se-

17 16 8 ? 14 15 20

Fig. ACl 2 — Drawingshowing proper sequencefor tightening cy l inderhead retaining capscrews.Refer to paragraph 21for procedure and torque

values.

VIEW "

^ f oQo I oQoToQo T oOo foOo | ,

18 14 10 6 1 15 19 23

quence shown in View "B'*, Fig. AC 12,and tighten the six %-in rocker armbracket cap screws to a torque of 28-33 Ft.-Lbs. NOTE: Adt.pter must beused to correctly tighten the screwslocated under rocker arm shaft. Ad-just valve tappet gap cold as outlinedin paragraph 28, s tar t engine andbring to normal operating tempera-ture. After engine has operated forone hour (preferably under load), re-torque the cylinder head screws andreadjust valve gap hot. After ten hoursof normal tractor operation, retightenthe cylinder head cap screws to atorque of 130-140 Ft.-Lbs, and re-adjust valve tappet gap to 0.015 hot,

NOTE: All torque values are given iorclean threads lubricated with motor oil.Allis-Chalmers recommends that no othertype of thread lubricant be used,

VALVES AND VALVE SEATS

Intake Valves22. Intake valves have a face and

seat angle of 30 degrees, A one degreeinterference angle may be used bymachining the seat to 31 degrees. Theseat width can be narrowed by using15 and 60 degree stones to obtain the

Fig. ACn — View of engine showing cyiinder head removed. Note the cylinder headlocating dowei pin CDP) at each end of biock. Cylinder numbers (CN) ore stamped onside of piston towards the camshaft. Disregard number stamped on opposite side of piston.

desired seat width of ^-inch. Intakevalve stem diameter is 0,3715-0.3720,

Intake valves seat directly in thecylinder head although intake valveseats are available for service. Wheninstalling service intake valve seat in-serts, machine counter bore in cylin-der head to a diameter of 1.814-1,815and to a depth of 0.4585-0.4605, Out-side diameter of seat insert is 1,816-1,817 which provides a 0.001-0,003 in-terference fit.

Surface of intake valve head mustbe recessed at least 0.054 from cylin-der head surface to provide properclearance between valve head and thepiston.

Exhaust Valves23, Exhaust valves have a face and

seat angle of 45 degrees. A one degreeinterference angle may be used bymachining seat to 46 degrees. The seatwidth can be narrowed by using 30and 60 degree stones to obtain desiredseat width of ^-inch. Exhaust valvestem diameter is 0,3705-0,3710.

Exhaust valves seat in renewableinserts. Seat insert diameter of 1.667-1.668 provides a 0.001-0,003 interfer-ence fit in the 1,665-1.666 diametercounterbore in cylinder head. If newexhaust valve seat inser t fits tooloosely, machine the counterbore di-ameter to 1,670-1,671 and install a0,005 oversize insert. Depth of thecounterbore should be 0,4735-0,4755for both the standard size and 0.005oversize inserts. Stake the seat insertat 3 points 120° apart after seat is in-stalled. NOTE: Do not stake the seatnear the injector nozzle hole.

Surface of exhaust valve head mustbe recessed at least 0.053 from cylin-der head surface to provide properclearance between valve head and thepiston.

Paragraphs 24-27 ALLIS-CHALMERS

VALVE GUIDES

24. Renew valve guides when stemto guide clearance exceeds 0.0035 onintake valves or 0.0055 on exhaustvalves. Desired stem to guide clear-ance is 0.001-0.0015 for intake valvesand 0.002-0.0025 for exhaust valves.

Intake and exhaust valve guides areinterchangeable. When installing newguides, press new guides in from bot-tom of cylinder head. The top of in-take valve guides should be 25/32-inch from counterbore around guideand bottom of guide should be ap-proximately 1%-inches from cylinderhead gasket surface. The top of ex-haust valve guides should be 1^-inches from counterbore around guideand bottom of guide should be approx-imately lH-inches from cylinder headgasket surface. Refer to Fig. AC13.

After installing guides, ream insidediameter of both intake and exhaustvalve guides to 0.373 to provide properstem to guide clearance.

VALVE SPRINGS

25. The interchangeable intake andexhaust valve springs should be re-newed if rusted, distorted or if theyvary more than 5% from followingspecifications:Pounds pressure @

2,237 inches 40-46Pounds pressure @

1.780 inches 105-115Spring free length,

approx 2JJ inchesSpring are installed with flat steel

dampener coil inside spring. Spring ordampener coil are not available sepa-rately.

CAM FOLLOWERS26. The 0.748-0.7485 diameter mush-

room type cam followers (valve lift-ers) ride directly in unbushed cylin-der block bores and can be removedafter removing the camshaft. Cam fol-lowers are available in standard sizeonly and should be renewed if eitherend is chipped or worn or if they areloose in cylinder block bores. Desiredfollower to bore clearance is 0.001-0.0025.

Fig. AC13 —yr«w $how-inq method of measuringvaive guide height aboveeyiinder head counterborewhen instaiiing new valveguides. Refer to para-

graph 24.

Fig. ACT4—^View of roeicer arm assembiy and related parts. Disconnect oUing tube (OT)from rear end of roeicer arm shaft before removing the assembiy. Note the position ofshaft locating capscrew (LC). Oii return tube (RT) is iocated at front end of roeicer arm

ROCKER ARMS

27. R&R AND OVERHAUL. Rockerarms and shaft assembly can be re-removed after removing hood top andrear side panels, disconnecting breath-er tube and removing rocker armcover and oiling tube. Loosen andremove all retaining cap screwsequally, then lift rocker arms andshaft assembly from the cylinder head.

The hollow rocker arm shaft isdrilled for lubrication to each rockerarm. Lubricating oil to the oiling tubeis supplied through a drilled passagein cylinder head and engine block.

To disassemble the rocker arms andshaft assembly, remove the hex plugs,spring washers and spacer washersfrom each end of shaft and removelocating cap screw and lock washerfrom No. 3 rocker arm support. Slidethe rocker arms, supports and spacersprings from shaft.

Rocker arm shaft diameter is 0.999-1.000. Bore in rocker arm is 1.001-1.002 providing a clearance of 0.001-0.003 between shaft and rocker arms.If clearance is excessive, renew theshaft and/or rocker arms. All rockerarms are alike.

To reassemble the rocker arms andshaft assembly, proceed as follows:Place shaft on work bench with endnearest to the detent hole (DH— Fig.AC15) to left. Slide rocker arm sup-port with locating capscrew (LC) onshaft with flat mounting surface downand large capscrew hole towards you.Tighten the locating capscrew into thehole in shaft to 28-33 Ft.-Lbs. torque.Complete the assembly of rocker armshaft using Figs. AC 14 and AC 15 asa guide. End plugs (12—Fig. AC15)should be torqued to 40 Ft.-Lbs. Therestrictor elbow (7) with a ^-inchopening should be installed in rearplug and the inlet oil line (16) shouldbe attached. The elbow at front isnot a restricted type.

Before reinstalling the rocker armassembly, loosen each tappet adjustingscrew about two turns to prevent in-terference between valve heads andpistons due to interchanged compo-nents. Tighten the %-inch support re-taining capscrews to a torque of 28-33 Ft.-Lbs. and the A-inch (cylinderhead) capscrews to a torque of 130-140 Ft.-Lbs. Adjust valve tappet clear-ance cold as outlined in paragraph 28.Complete the reassembly of tractor,then readjust tappet clearance afterengine has reached normal operatingtemperature.

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D-2T. D-21 Series II, 210. 220 Paragraphs 28-30

VALVE CLEARANCE

28. Because of the limited clearancebetween the head of the valve andtop of piston, valve clearance (TappetGap) should be checked and adjustedonly with engine stopped. After anyservice to valve system, valve clear-ance should be adjusted cold beforeengine is started. Valve clearanceshould be rechecked with engine atoperating temperature.Clearance Cold—

Inlet & Exhaust 0.018 in.Clearance Hot—

Inlet & Exhaust 0.015 in.

Fig. AC15 — View ofvaive oc tua f f nq parts.Upper d rawinq showsrocker arm shaft assem-bled with locating cap-screw at inset. Restrictorelbow (7) U on inlettube at rear. Thrust plate(3) may encircie cam-shaft on some modeis.

Locating capscrewCamshaft gearLock plateThrust plateCamshaftCam followerOiling tubeElbow fittingPushrodRocker arm shaftWasherWave washerEnd plugon return tubeRocker armSupportCylinder head capscrewSelf-lock ing screwSpacer spring

Two-position adjustment of allvalves is possible as shown in Figs.AC15A & AC15B. To make the adjust-ment turn the crankshaft until No. 1cylinder is at TDC on compressionstroke. Mark on crankshaft pulley(Fig. AC43) indicates TDC and ifclearances are nearly correct, bothfront rocker arms will be loose andboth rear rocker arms will be tightwith No. 1 cylinder on compressionstroke. Adjust the six valves indicatedin Fig. AC15A to the correct clear-ances. Turn the crankshaft one com-plete revolution until TDC marks areagain aligned. This will position No. 6

cylinder at TDC on compressionstroke. Adjust the remaining sixvalves shown in Fig. AC15B.

NOTE: When adjusting valve tappet clear-ance, be sure to note that the intake valverocker arm is always to the right side ofrocker arm support (as viewed trom leftside ol engine) and exhaust valve rockerarm is to left side of support. There is arocker arm support between the rocker armsfor the valves of each cylinder. Refer toFig. AC14.

TIMING GEAR COVER ANDCRANKSHAFT

FRONT OIL SEAL

30. REMOVE AND REINSTALL.To remove the timing gear cover, firstremove the front support casting asoutlined in paragraph 7, then proceedas follows:

Remove the fan blades, fan beltsand the cap screw and washer fromfront end of crankshaft. Using a pull-er threaded into the tapped holes incrankshaft pulley hub as shown inFig. AC 16, remove pulley from crank-shaft. CAUTION: Do not attempt toremove pulley by pulling on outerdiameter as vibration dampener builtinto pulley will be damaged.

It is suggested to loosen all oil pancap screws enough to lower the frontof oil pan or preferably remove oilpan. Remove the plate from cover infront of the fuel injection pump drivegear and remove the thrust plungerif so equipped. Remove screws thatattach timing gear cover to front ofcrankcase, and carefully pry coverforward to slide seal and cover for-ward off of crankshaft. NOTE: Someof the attaching screws enter from

FRONT

E l E l E l E l E l

E I E I E I E 1 E 1

Fig. AC15A—With No. Tcylinder at TDC on com-pression stroke, a d I u s ttoppet gap on valvesshown. Refer to text for

clearance.

Fig. AC15B—With No. 6cylinder at TDC on com-pression stroke and No.1 cylinder at TDC of ex-haust sTroke, adiust valvesshown. Refer to text forrecommended clearance.

E I

Fig. ACT6~Do not pull crankshaft pulleyby outer rim; thread iiuliers into hub ofpulley as shown. Place correct size centerplug over end of cranicshaft after remov-ing pulley retaining oipscrew (CS) and

washer.

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