PDF Service Manual Allis Chalmers D19 Tractor - 4 MB
Restore and maintain your classic Allis Chalmers D19 diesel tractor with this complete service and repair shop manual.
This comprehensive guide provides all the information you need for teardown, rebuild, and troubleshooting.
It covers the engine, transmission, hydraulics, and electrical systems in great detail.
This manual is indispensable for restorers and owners who want to keep their D19 running for years to come.
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--- Page 1 ---
SHOP MANUAL
ALLIS-CHALMERS
MODELS D-19 D-19 DIESEL
Tractor serial number is stamped on the left front of torque tube. Engine
serial number is stamped on the center left side of the engine block. Trans-
mission serial number is stamped on the lower right hand corner of rear
face of transmission case*
The D-19 tractor is available with an LP-Gas, gasoline or a turbo-charged
diesel engine in dual wheel tric/cle, single wheel tricycle or adjustable
axle versions.
INDEX (By Starting Paragraph)
BELT PULLEY 140 Pistons and rings .51 Bull pinion bearings adjust 132
Rear oil seal 55 Bull pinion renew 132
BRAKES Rocker arms 40 Differential overhaul 129
Adjustment 137 Speed adjustments 88 Final drive units R&R 132
Brakes R&R 138 Tappet gap 40A Wheel axle shafts 134
Timing gear cover 41
CARBURETOR Timing gears 43 FRONT SYSTEM
Gasoline 60 Turbo-charger 90 Adjustable axle 5
LP-Gas 61 Valve guides 35 Dual wheel tricycle 3
Valves & valve seats 33 Manual steering 11
CLUTCH Valve rotators 33 Power steering 17
Valve seals 33 Single wheel tricycle 1
Engine clutch 108
Valve springs 37
Engine clutch shaft 112
Valve timing 42 GOVERNOR (NON.DIESEL)
"Power-Director" clutch 115
ENGINE (NON.DIESEL) Adjustment 95
COOLING SYSTEM Assembly—R&R 28 Overhaul 86
Water pump 98 Cam followers 38
Radiator 97 Camshaft 47 IGNITION SYSTEM
DIESEL FUEL SYSTEM Connecting rods & bearings 52 Distributor 102
Crankshaft & bearings 53 Ignition timing 103
Energy cells 89
Cylinder head 30
Filters and bleeding 76
Cylinder sleeves 50 LP GAS SYSTEM
Injection pump 86
Flywheel 56 Adjustments 61
Injection pump gears 46
Front oil seal. 41 FUter 88
Nozzles 78
Ignition timing 103
Quick checks 75 Regulator 69
Main bearings 53
DIFFERENTIAL Oil pan 57
"POWER-DIRECTOR"
Adjustment 128 Oil pump 58
Piston pins 51A Clutch 115
R&R and overhaul • 129
Piston & rod removal 49 Shafts and gears 119
ELECTRICAL 101 Pistons & rings 50
POWER LIFT SYSTEM
PIGINE (DIESEL) Rear oil seal 55
Rocker arms 39 Pump 157
Assembly—R&R 29 Testing 151
Spark plugs 101
Cam followers 38 Work cylinders 167
Speed adjustment 95
Camshaft 47
Tappet gap 39 A
Connecting rods & bearings 52 POWER TAKE-OFF 145
Timing gear cover 41
Crankshaft and bearings S3
Timing gears 43 STEERING GEAR
Cylinder head 31
Valve guides 34
Cylinder sleeves 51 (Manual) 11
Valves & valve seats 32
Flywheel 56 (Power) 17
Valve rotators 32
Front oil seal 41
Valve seals 32 TRANSMISSION
Injection timing 86
Valve springs 36
Main bearings 53 Bevel pinion shaft llS
Valve timing 42
Oil pan 57 Countershaft 126
Oil pump 58 FINAL DRIVE & DIFFERENTIAL Input shaft 124
Piston pins 51A Bevel gears adjust 130 Reverse idler 127
Piston & rod removal 49 Bull gear renew 133 Shifter assembly 122
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Paragraphs 25-27 ALLIS-CHALMERS 0-19
POWER STEERING GEAR UNIT
The worm and sector type gear
unit is contained in the front support
casting (44—Fig. AC16). Lubricating
oil for the gear unit is also used as
power steering fluid. Oil level should
be maintained at %-inch above the
sector (steering) gear with type "A"
automatic transmission fluid.
25. ADJUSTMENTS. The gear imit
is provided with two adjustments:
Rack mesh position is adjusted by the
number of shims between the front
support casting and the rack adjust-
ing block (48—Fig. AC16). Steering
shaft bearing end play is also adjust-
able by varying the number of shims
(4—Fig. AC17) between the sector
gear (5) and flat washer (3) on single
front wheel models or by varying
the number of shims (60—Fig. AC16)
between the bearing retainer (62)
and the front support casting (44) on
dual wheel tricycle and adjustable
front axle models. However, these ad-
justments are more in the nature of
assembly procedure when overhauling
front support assembly than routine
adjustment to provide better power
steering operation. Therefore, adjust-
ments will be discussed under reas-
sembly of gear unit in front support.
Refer to paragraph 27.
61
26. R&R FRONT SUPPORT
(GEAR UNIT). Support front end of Fig. AC16 — Partially exploded view of the power steering front support. For exploded
tractor. Unbolt and remove single views of the control volve unit (41 PS) and ram (67), refer to Fig. A C M and Fig. AC15
front wheel fork and wheel assembly, respectively.
dual wheel tricycle pedestal and
wheel assembly or adjustable front :i2. Lower steering 48. Rack adjusting 54. Bearing cone 61. Oil seal
shaft block 55. Steering gear 62. Shaft retainer
axle support casting. On adjustable :t3. Roll pin 4n. Rack adjusting 56. Snap ring 63. Idler gear shaft
front axle models, drive pin from cen- 34. Splined coupling shims (0.005 & 57. Steering shaft 64. Idler gear
ter steering arm and remove steering 37. Gasket 0.003) 58. Bearing cone 65. Lock plate
arm from shaft. Drain power steering 41PB. Steering control 50. Piug 59. Bearing cup G7. Steering ram
valve and worm- 52. Breather 60. Shims (0.005 68. Rack
fluid from front support on all shaft unit 5,'t. Bearing cup & 0.010) 76. "O" ring
models. Then remove front support 44. Front support
assembly as outlined in paragraph 21.
Reverse removal procedures to re-
install front support. Refill to %-inch Unbolt and remove control valve front support. (Top end of shaft has
above sector gear with type "A" auto- and wormshaft unit as outlined in threaded hole to facilitate pulling
matic transmission fluid. Start engine paragraph 22. shaft from casting.) Withdraw idler
and cycle system several times after gear through bottom opening in
assembly is completed to bleed any Unbolt bearing retainer (9—Fig. casting.
trapped air from system. Check fluid AC17) on single front wheel models
level and add fluid as necessary. or (62—Fig. AC16) on other models
and remove shaft and sector gear as- Thoroughly clean front support
sembly from front support. Be careful casting prior to reassembly of steer-
not to lose or damage shims (60— ing gear unit. As front support is used
27. OVERHAUL FRONT SUPPORT. Fig. AC16) on dual wheel tricycle and for power steering fluid reservoir,
Remove power steering tubes from adjustable axle models. cleanliness is of utmost importance.
ram cylinder and power steering con- Following procedure should be ob-
trol valve. Unbolt and remove ram Remove idler shaft lock (65—Fig. served in inspecting and renewing
cylinder as outlined in paragraph 24. AC16), then pull idler shaft from parts and in reassembly of unit:
12
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Paragraphs 56-59 ALLrS-CHALMERS D-19
moved and renewal of complete gas-
ket would require removal of engine
front plate, cut lower portion of new 1 2
gasket to fit end of pan and then
apply this cut portion of the gasket
to the front plate with gasket cement.
Use a heavy gasket sealer where gas-
ket meets cylinder block. Apply gas-
ket sealer to rubber sealing ring
around crankshaft rear oil seal re-
tainer and to both sides of pan gasket.
Stick gasket to cylinder block and
carefully lift pan in place after being
sure any distorted part of pan sealing
surface has been straightened. Install
Fig. AC29 — D-19 diesel and non-diesel
cap screws retaining pan to cylinder
flywheel is retained to crankshaft by four
block finger tight; then, apply gasket
cap screws and two dowel pins. Installation
sealer to the four cap screws retaining
of flywheel is possible in one position oniy. pan to front cover and install these
cap screws tightly. Starting at front
of pan, tighten all cap screws to a
FLYWHEEL torque of 18-21 Ft.-Lbs. Reinstall front
support by reversing removal pro-
All Engines
cedures. On power steering models,
56. REMOVE AND REINSTALL. To start engine and cycle power steer-
remove flywheel, first remove engine ing system several times to bleed any
clutch as outlined in paragraph 109. trapped air from system. Check power
The flywheel is retained to the engine steering fluid level and add type
crankshaft with four unequally spaced "A" automatic transmission fluid as
cap screws and two dowel pins. See necessary.
Figs. AC28 and AC29. To renew fly-
wheel ring gear, flywheel must be
removed from crankshaft. Inspect
OIL PUMP AND RELIEF VALVES
clutch friction surface and crankshaft
rear oil seal surface of flywheel. Drive
flywheel ring gear from flywheel. All Engines Fig. AC30 — Expioded view of 0 4 9
diesel and non-diesei oii pump assembiy.
Heat new ring gear evenly until it 58. R&R AND OVERHAUL PUMP. Reiief valve (8) is non-adjustabie and is
will fit over flywheel and install ring Removal procedure will be self-evi- used to prevent surge pressures only. Nor-
gear with tooth bevel to front. Clutch mal oii pressure is controiied by rettef
dent after removal of oil pan as out- vaive shown in Fig. AC31.
pilot bearing in flywheel is a sealed lined in paragraph 57.
unit. 1. Drive gear
2. Pin
8. Relief valve
9. Drive shaft
To disassemble the removed pump, 3. Discharge tube 10. Driven shaft
When reinstalling flywheel, tighten refer to Fig. AC30 and proceed as 4. Pump body 11. Pump gears
5. Adapter flange 12. Cover plate
retaining cap screws to a torque of follows: Remove screen (13) and cov- 6. Gasket 13. Screen
7. Lock washer 14. Retainer
95-105 Ft.-Lbs. Complete reassembly er (12). Extract pin (2), then press
by reversing disassembly procedure. shaft (9) out of gear (1) and body
(4). To remove either pump gear (11),
press shaft out of gear. tributor rotor until it points toward
the number one cylinder terminal on
OIL PAN (SUMF) Renew any parts which are exces- distributor cap and breaker points are
All Engines sively worn, scored or are in any way just open. Install pump with slot in
questionable. Pump gears (11) should pump drive gear engaging drive tang
57. REMOVE AND REINSTALL. have not more than 0.020 back lash on distributor drive shaft. NOTE:
To remove the oil pan, it is first nec- or more than 0.006 end play. Pump The driving slot and tang are off-set
essary to remove the front support body and/or shafts should be re- from center line of shafts. Tighten
as outlined in paragraph 12 or 21. newed if shaft to body clearance ex- pump retaining cap screw to 18-21
ceeds 0.004. Ft.-Lbs. torque. Check ignition tim-
After removing front support, re- ing as outlined in paragraph 103.
move the four cap screws retaining When reinstalling oil pump on die-
lower portion of timing gear cover sel engines, be sure that slot in oil 59. RELIEF VALVES. Two oil pres-
to pan, then remove cap screws hold- pump gear drive engages drive pin on sure relief valves are used in both
ing pan to cylinder block. Pan gen- operation (hour) meter drive shaft. diesel and non-diesel engines. The
erally will be tightly sealed to block Tighten the pump retaining cap screw relief valve (8—Fig. AC30) on the
and care should be taken in prying to a torque of 18-21 Ft.-Lbs. NOTE: oil pump discharge tube adapter is
pan loose in order not to distort rear Flange on pump does not fit against non-adjustable and should by-pass oil
arch and gasket sealing surface of cylinder block. directly into the sump at approxi-
pan. On non-diesel engines, turn crank- mately 80 psi. As this is well above
As gasket between engine front shaft until piston for number one cyl- normal oil pressure of 25-40 psi, valve
plate and cylinder block will prob- inder is at TDC on compression stroke (8) opens only due to surge pressure
ably be damaged when pan is re- (Refer to Fig. AC79). Turn the dis- when oil is cold.
22
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Paragraph 91 ALLIS-CHALMERS D-19
91. OVERHAUL. When servicing Remove snap ring (6), then remove carbon is removed from bottom of
turbocharger as originally installed on oil retainer plate (7 or 7E). On early grooves. Check O.D. of retainer plate
early tractors, it is advisable to use type, retainer plate (7E) must be (7E) for nicks that would damage "'
special tools available from Kent-Moore pressed out of bore using the Kent- ring (9). Inspect bore in retainer pi
Organization, Inc. Some of the early Moore special tool. On later type (7), a for grooving caused by seal rings (V
turbochargers have been changed by %-inch driver can be used as shown in sticking and turning with shaft. Clean
installing later type parts and the Fig. AC55 to remove seal and retainer the bore chamfer to ease installation of
special tools are not required. Atten- plate (7—Fig. AC53), mating piece (10) seals (lOE).
tion will be called to difference in and bearing (12). On late type turbocharger, inspect
service procedure. It is recommended that late type seal seal (7) carefully if the seal is to be
Remove turbocharger unit as out- (7) and mating ring (10) be renewed reinstalled. The carbon face insert
lined in paragraph 90. Scribe a mark each time turbocharger is disassembled should move freely in and out and must
across turbine housing (22—Fig. AC53), for service. The early type turbo- not be scored or excessively worn.
clamp (20), bearing housing (13) and charger can be changed to later type Mating ring (10) should not show evi-
compressor housing (1) to aid reassem- by installing new type parts (5, 7, 10 dence of wear or scuffing on either
bly and proceed as follows: Remove nut and 11). side. Remove any carbon from seal
(19) and clamp (20); then, remove contact side. Examine sleeve (11) for
turbine housing (22). Remove cap Clean all parts except late type oil
burrs, scoring and wear. The sleeve is
screws attaching bearing housing (13) seal (7) by washing in kerosene or precision ground and any defect will
to compressor housing (1) and remove diesel fuel. A nylon bristle brush may distort the mating ring and cause seal
compressor housing. Hold blades of be used to clean carbon from parts. leakage.
turbine wheel (18) with shop towel; CAUTION: Do not use wire brush, On all models, pay particular atten-
remove nut (3) and washer (4) from caustic cleaners, etc., on turbocharger tion to blades of turbine wheel (18) and
turbine shaft (L.H. threads). On early parts. Inspect all parts for burring, compressor impeller (5 or 5E) and to
models, impeller (5E) is a tight fit on eroding, nicks, breaks, scoring, exces- bushing (12). If bushing (12) and/or
turbine shaft (18) and shaft must be sive carbon build-up or other defects turbine shaft is worn excessively, the
pressed out of impeller as shown in and renew all questionable parts. blades of turbine wheel and compressor
Fig. AC54. On later models, impeller impeller may have rubbed against
(5—Fig. AC53) will slide easily off On early type turbocharger, com-
pressor impeller (5E) should be press housings. Shaft clearance in bushing
shaft. should be measured at compressor
fit on turbine shaft (18). Thrust sur-
CAUTION: On all models, do not faces of spacer (HE) must not be impeller end of shaft using a dial
allow turbine wheel and shaft to drop rough. Inspect grooves in spacer (HE) indicator with unit assembled. If indi-
when impeller is removed. for excessive wear and make certain cated clearance exceeds 0.022, bushing
(12) and/or shaft (18) should
renewed. Inspect bore in beari
housing (13) for evidence of stuck se
ring (17). If seal ring was sticking in
shaft groove, the bore in housing will
be grooved and should be renewed.
Make certain that seal bore chamfer is
clean and smooth to ease installation of
shaft and seal ring.
Fig. AC53^Bxploded view of Thompson turbocharger unit used on dieset engines. Inset
shows parts that are different on earlier unit.
16. Turbine wheel
1. Compressor housing 7E. Oil retaining plate llE. Turbine shaft 17. Turbine shaft seal
2. Gasket 8. Shims spacer 18. Turbine wheel &
5 & 5E. Impeller 9. "0" ring 12. Bearing
6. Snap ring 10. Mating ring 13. Bearing housing 20. Clampp ^'9- AC54—View showing method of remov-
7. Oil seal & retaining lOE. Turbine shaft seals 14. Groove pins al. G k t
Gasket ing oarly type impeller using special Kent-
plate 11. Shaft sleeve 15. Spring ring 22. Turbine housing Moore tOOL
32
--- Page 6 ---
Paragraph 115 A L L I S - C H A L M E R S D-19
\\ POWER DIRECTOR
The "Power - Director" (See Fig. New clutch assemblies are provided
AC90) consists of two multiple disc with three 0.090 stacks of shims (51A
wet type clutch packs contained in a & 51B) between each housing and
common housing that is splined to the center plate and three 0.025 stacks of
transmission input shaft. A reduction shims (53) between the two center
gear drive in front of the clutch hous- plates. Thus, the total height of the
ing turns the discs of the front clutch shim packs is 0.205 and this total
pack through a hollow shaft. The en- height must be maintained when ad-
gine clutch shaft passes through the justing the clutch to avoid changing
hollow shaft and turns the discs of clutch housing dimensions. For any
the rear clutch pack at engine speed. thickness of shims added or removed
Both clutch packs are controlled by from the shim stacks between the
a single lever and over-center type housing and center plate of either
linkage. With the control lever in the clutch pack, a like thickness must be
forward position, the r^ur clutch pack removed or added to the shim stacks
is engaged and the clutch housing and between the two center plates.
transmission input shaft are turned at
engine speed. When the lever is in To gain access to the clutch packs
the rear position, the front clutch to check clutch adjustment, first dis-
pack is engaged and the clutch hous- connect the filter lines (5 & 6—Fig.
ing and transmission input shaft are AC92) from the elbow fittings on the
turned at a reduced speed. Placing the clutch cover (7); then remove filter
control lever in center position dis- Fig. AC90 — View showing "Power-Dirvc- and line assembly as a unit. Remove
engages both clutch packs. tor" ciufeh unit on transmission input shaft. the two cap screws (8) and the quad-
rant (4) from clutch cover; then re-
The "Power-Director" clutch packs move cover from clutch housing. Pull
are lubricated by oil from a pump in relief valve body (See Fig. AC93)
the bottom of the torque housing. The from oil lines.
pump is driven by the front power
take-off shaft. Oil from the pump
passes through lines to an external
filter and then to the clutch packs
and reduction gear drive for lubrica-
tion of these laiits. The "Power-Di-
rector" and hydraulic oil sumps are
connected. Sump capacity is approxi-
mately 22 quarts of SAE 20-20W non- 50
detergent service "ML" motor oil. Oil 51A S2A
level is checked with the hydraulic
lift arms lowered and any remote cyl-
inders retracted. Run engine at high
idle speed for at least three min-
utes, shut engine off and immediately
check oil level on dipstick.
"POWER-DIRECTOR" CLUTCH
115. CLUTCH ADJUSTMENT. Refer
to Fig. AC91. Clutch plate pressure is
applied through a spring (Belleville)
washer (46) that is located between 57
the pre-load plate (45) and pressure 58
plate (47) of each clutch pack. The
spring washer must be compressed 54 56
0.042 to 0.048 inch when clutch pack
is engaged. If compression is less, slip-
page of clutch will result. If compres- Fig. AC91 Expioded view of "Power-Director" clutch assembly. Unit is equipped with
sion of spring washer is greater than more drive and driven plates than shown. Refer to text.
0.048, clutch pack will not release
properly. Adjustment is provided with 38. Snap rinsr 44. Snap ring 49. Clutch releasing: 54. Thrust washer
shim packs (51A, 51B and 53) placed 39. Front hub 44A. Pressure plate p^: 55. Snap rin^r
40. Rear hub spacer 50. Clutch plate 56. Rear housing;
between the clutch housings and ad- 41. Heleaae lever 45. Pre-load plate 51A & 51B. Outer shims 57. Snap ring
58. Release lever (rear)
(front) 46. Pressure washer (0.010 & 0.015)
joining center plates and between the 42. Clutch link 47. Pressure plate 52A & 52B. Center plates 59. Release lever link
center plates. 43. Front housing 48. Clutch splined disc 53. Center shims
(0.010 & 0.015)
42
--- Page 7 ---
Paragraphs 136-138 A L L I S - C H A L M E R S D-19
tor for pushing rear wheel from to a torque of 160-170 Ft.-Lbs. Apply graph 135 and hydraulic ram (cyl-
tapered hub. Disconnect lines from No. 3 Permatex or similar sealer to inder) from axle housing. Then, un-
hydraulic control valve; then, unbolt rim of cap (19) before installing cap bolt and remove rear axle housing
and remove valve and manifold as a at inner end of axle shaft. from transmission housing.
unit from transmission rear top cover.
Unbolt and remove PTO output shaft Renew "O" ring (20—Fig. AClll)