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7020 PS with Cummins 5.9 transplant |
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SteveM C/IL ![]() Orange Level Access ![]() Joined: 12 Sep 2009 Location: Shelbyville IL Points: 8547 |
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...and a lifetime of experience to know what works and what doesn't.
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Transaxial ![]() Bronze Level ![]() Joined: 19 Apr 2014 Location: Tofield,Alberta Points: 96 |
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That is a great project you and your brother have going! Congratulations on getting it to the point of working. A successful plan has come together! I love the detail and thought process you describe in the bell housing and clutch setup that is the key part to do any repopwer. I went through it all back in 1989, feasibility, sourcing parts for a reasonable cost, then actually being the design engineer for the machining and fabrication of all the precise measurements required to allow the proper alignment for long life at work. I needed a new engine for my 8550 and looked at lots of options. A good and simple solution would have been to buy a complete Cat 3306 with bell housing from a Steiger CM or KM280 that used the AC 20 speed power director transmission to get live pto. That was not quite enough power though and at the top end of both engines so I opted to build my own housing and clutch setup and go with a rebuilt Cummins 855 350 hp. It was a lot of work but has worked out very well over 30+ years. I worked with a local machine shop to build the adapter plate with a center hole to work out from for turning the 24" housing in their lathe. I had the diagrams and measurements and we would go over the next step of process every few days and eventually it all came together. After looking at lots of ideas, I settled on a 14" Cummins dish flywheel, a Lipe 14" 1139 pressure plate with release fingers removed because it is just a torque limiter on this tractor. The service clutch is the low range of the power director, like all 7000 and 8000 tractors I believe. We used the standard AC 12" friction discs to fit the odd AC input shaft to the transmission. I increased the spring pressure in the Lipe pressure plate to compensate for the smaller disc size. I wish I had kept track of actual hours spent but estimated at something like 1500 hours with rebuilding the transmission, drop box, both drive shafts, center hinge pins and bushings, gear set in pto to get 1000 rpm out at 2150 engine speed, cab interior and instrument cluster with actual gauges for oil pressure, oil temp, pyrometer, boost pressure, air cleaner vacuum, volt meter, air pressure (truck engine had air compressor), and a big warning light for over temp and low engine oil pressure. I have all the critical measurements and details if anyone is interested. Over the years I have seen quite a few 8550s and mostly 305s with Cummins conversions. I suppose they are way too old and obsolete now to put that much work into though. This tractor is still a source of pride (by me!) and interest by many people 30 years later.
Thanks for posting Dr Allis! These are cool projects that will be around for a long time. |
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jeickman01 ![]() Silver Level ![]() Joined: 24 Feb 2017 Location: Dyer, TN Points: 210 |
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Was the stock engine unreliable? Are repair/replacement parts for it now hard to come by or too expensive? Other than the extra horsepower and the availability of Cummins parts I'm wondering about the motivation to do this swap. As I said, just wondering.
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DrAllis ![]() Orange Level Access ![]() Joined: 12 Sep 2009 Points: 21571 |
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Original A-C 731 cube engine wasn't all that great, especially when they tried running it at 2650-2700 RPM all the time. Rated load speed was 2500 RPM. In the early years, we had a campaign to replace all the pistons and valve rotocaps for failures because of the high RPM. That was more of an 1800-2000 RPM speed engine. Increased speed was due to the transmission engineers demands.
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Transaxial ![]() Bronze Level ![]() Joined: 19 Apr 2014 Location: Tofield,Alberta Points: 96 |
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Back in 1989 when my 731 literally blew up I was forced to make a call whether to fix it or replace it. Those tractors and mainly the engine had a really bad reputation at the time. After doing the repower I sent a writeup to Farmshow magazine and had 12 or 15 calls back about how the repower worked out and if it was worthwhile etc etc. Several callers comments were that they had one or two of these tractors parked in the weeds with 1200 - 1500 hours and a blown engine and they didn't know what to do with them. Not everyone had the time and people that I did to engineer a repower. I recall that parts were crazy expensive like $1200 a hole for sleeves and pistons compared to about that much for a whole set of 6 for a Cummins 855. Considering that I needed a block ($6000) and crank ($6000) and those were hard to come by because that was what failed on most engines, it just was not feasible to go the route of the AC 731. I could buy a new Cat 3306 with a bell housing that bolted right up to the Allis transmission for about $15,000 but it was on the small side of what I needed. A complete rebuilt NTC 350 with access to wrecking yard parts for bell housing, flywheel, clutch parts, motor mounts, fan hub, accessory brackets, air intake pipe and elbows, linkage parts and all the little things that you need for $10,000, made the choice easy.
My understanding of AC history in the industrial line of equipment was that they had the 844 cu in Budda Lanova engine which was a very good well built long life engine when run at 1600 - 2100 rpm like all the other main US brands Cat, Cummins, 60 Detroit, etc. The 844 or 6138 or 25,000 had a bore of 5.25 and stroke of 6.5". The 731 used the same block with a bore of 5.25 and destroked to 5.625". Originally the 844 ran 1400 rpm with max hp of 197 and torque of 740 ft lbs. Later as a purple Mack FS-700 truck engine they made 375 hp and some were juiced to 675 hp. The 731 and 844 were the same block and bore and weighed 5900 lbs according to one report. Way more than modern Cat or Cummins engines. None of the others ever had a version that the high idle speed was 2800 rpm. As Dr Allis suggests the transmission used in the 4WD Allis tractors was just a modified version of the 7000 and 8000 2 wheel drive tractors and was not able to take the torque of a big industrial engine at normal speed of 1800 to 2100 rpm. I learned the hard way that by running the 8550 transmission in 5th gear, low range in the drop box and low range in the power director clutches, you were flowing the power straight through the transmission and it would take the torque fairly well. That was about 5 mph I think. So because of the economic uncertainty of building new a 4WD tractor line at that time in history, just as the great depression of the 80s was about to hit North America, AC chose to "cheap out" and speed up the engine to crazy rpm to reduce the torque down to where the transmission had a chance of not melting down. I had a discussion with 427435 another very smart Allis guy on this forum about that very thing. He referred me to a book that explained what was going on in America at that time that led to the collapse of numerous old successful companies like AC, IHC, Versatile, Steiger, and a long list of companies that had been around since the beginning of the industrial boom in North America. The inflation of the 70s came to a head and Volkers 20% interest rates was needed to stop the runaway train. Companies had gotten used to ever increasing wages, costs, retirement plans, unproductive policies that made them all unviable in the new reality of the mid 80s. I believe I heard that in some of those years there were only 1200 4WD tractors in total of all brands sold in some of those years. I miss 427435 for his knowledge and insight but anyone can read what he spoke of in the book "The Turnaround Experience" by Frederick M Zimmerman. A worthwhile book to own and take to heart as we enter another inflationary and dysfunctional period of history. There is another thread from a few years ago that discusses some of this if you are interested "6138 truck engine" topic 74441 |
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DrAllis ![]() Orange Level Access ![]() Joined: 12 Sep 2009 Points: 21571 |
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The 8550/4W-305 transmissions were unique to the A-C tractor line. Every gear and shaft was different, wider and stronger than the 7580/4W-220 and smaller. The P.D. clutch itself utilized the same clutch disc/separator plates, but had many more of them. It was truly bigger and heavier than it's smaller brother BUT, it apparently had it's limits and more speed/less torque was the way to make it live. Almost like in the initial design, the engineers were told 500 ft lbs is all it would ever see, but as time went on the numbers kept getting larger. It was maxxed out at 300 HP and 600 ft lbs of torque and even at that the Power Director clutches had their issues, like having a tranny brake strong enough to hold them back when cold...… It would never have been used in a next size bigger tractor.
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JPG AUSTRALIA ![]() Orange Level ![]() Joined: 13 Sep 2009 Points: 761 |
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So dr,what would be the best engine for replacement for the 8550?
Maybe 300hp 8.3 cummins turning 2400rpm? |
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DrAllis ![]() Orange Level Access ![]() Joined: 12 Sep 2009 Points: 21571 |
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That engine has been operated before at 2500 or maybe 2600 RPM high idle, so yes, I think that would be a pretty "safe" match-up. Faster the better. The thing that one has to remember on a 4WD or FWA tractor with duals, is the engine and transmission are under much more strain than a simple 2 WD with duals. More traction and weight makes the engine and tranny/rear end work harder.
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Transaxial ![]() Bronze Level ![]() Joined: 19 Apr 2014 Location: Tofield,Alberta Points: 96 |
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After Case bought IH in about 85 they started using 5.9 Cummins instead of IH 466. The IH could handle 2600 rpm in the 1480 combine but at that speed the 5.9 didn’t have good pulling power and often had pistons come apart, skirts coming off. By 1993 Case redesigned the rotor drive up to triple C belts and slowed down the new 8.3 to 2150 or 2200 rpm. Much better setup and allowed the 8.3 to produce 260 hp. I wouldn’t run a Cummins that fast. Are there any CR or KR Steigers around the wreckers? They used a 3306 at about 270 hp or L10 at around 280 hp and had the AC 20 speed power director. Either would be a better match to the tractor. Or I could just sell you my 8550 with the 855 Cummins already installed.
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JPG AUSTRALIA ![]() Orange Level ![]() Joined: 13 Sep 2009 Points: 761 |
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Transaxial, 2388 combines run 2500 rpm all day on there 8.3 cummims, factory settings.
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SteveM C/IL ![]() Orange Level Access ![]() Joined: 12 Sep 2009 Location: Shelbyville IL Points: 8547 |
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No authority here but my 4000+ hr R62 8.3 is 2400 and change high idle and runs 22-2350 all day in field. I'm 3rd owner but I believe head gasket replacement Last summer and rod and mains is its only maintenance.
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Transaxial ![]() Bronze Level ![]() Joined: 19 Apr 2014 Location: Tofield,Alberta Points: 96 |
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OK I didn't realize that they they ran that fast. I thought my 1688 was more like 2200??? They must have changed to a different piston and the fuel pump setting too. |
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pirlbeck ![]() Silver Level ![]() Joined: 01 Dec 2009 Location: West Central IA Points: 229 |
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The first Cummins equipped axial flow combines ran the engine at 2700-2750 RPM's. They had some engine problems running them this fast, so the later models they slowed the engine down to 2500 RPM's .
I have a Cummins equipped 1660 that I slowed the engine down when I had the engine gear case off for seal replacement. Here are some of the things I changed. Different gear set in engine gear case to keep the machine speed the same at lower engine RPM's Different hyd pump drive pulley and belt to keep the hyd pump speed the same. Re-calibrate injection pump for lower RPM's and more fuel delivery to keep the HP the same (or more). Different tach that had a lower set point for the low engine RPM warning. I think that was most of the changes. You will lose a little ground speed, as the hydro pump runs directly off the back of the main shaft that connects to the flywheel. |
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Transaxial ![]() Bronze Level ![]() Joined: 19 Apr 2014 Location: Tofield,Alberta Points: 96 |
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[QUOTE=pirlbeck] The first Cummins equipped axial flow combines ran the engine at 2700-2750 RPM's. They had some engine problems running them this fast, so the later models they slowed the engine down to 2500 RPM's . I have a Cummins equipped 1660 that I slowed the engine down when I had the engine gear case off for seal replacement. Here are some of the things I changed.
Interesting project! It has been 25 years since I bought that 1688 so I might be off on some of the numbers. Your numbers look about right. It was the early 1680 combines, about 1986, that had the water jacket intercooled IH 466 that ran real fast. Maybe up in the 26 - 2700 range. I think they were rated at 235 hp. After Case bought them did they use the 5.9 for a while at that high rpm? Those were the ones that didn't stay together and didn't pull as well as the earlier 466 engine. Do you know what the gearset you used came out of? Could that have been from a later 1688 or 2388 or 2588? How fast does yours run now? My reason for this discussion is to help the guys installing either a 5.9 or a 8.3 in a tractor and what is the best rpm to run those Cummins engines at based on almost 40 years of experience. I know the 6.7 Cummins in my one ton does not pull well at 2500. It likes to run 19 -2200 best. I like what you did to your 1660. |
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IBWD MIke ![]() Orange Level ![]() ![]() Joined: 08 Apr 2012 Location: Newton Ia. Points: 4010 |
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2700 is not real fast for an IH 400 series diesel. Had the pump on my 1460, 436 cid, rebuilt this year. Tag says Idle, 1000/2500. Top number must be working speed as it high idles about 2750.
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DrAllis ![]() Orange Level Access ![]() Joined: 12 Sep 2009 Points: 21571 |
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Nebraska Test IH1466/1486 (second test in April 1973 for the 1466) the DT-436 engine had a high idle of 2850 RPM and rated load speed of 2600 RPM.
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ajl ![]() Bronze Level ![]() Joined: 31 Dec 2009 Location: Alberta Points: 115 |
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In the 1680 combine the 8.3 ran at 2600 rpm and that was later slowed to 2400 rpm in all the 88 series. Spent many hours behind the wheel of these machines. Usually the high rpm motor would blow at around 3500 hrs. The slower version was much more reliable. The 8.3 in my MF 8570 is rated at 2300 rpm.
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AC7060IL ![]() Orange Level ![]() Joined: 19 Aug 2012 Location: central IL Points: 3499 |
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