AC-S-840,840B

AAll ll iiss CChhaallmmeerrssService Manual

840 & 840BArticulated

Wheel Loader

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF ALLIS CHALMERS OR IT’S SUCCESSORS. ALLIS CHALMERS AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS..

Serv

ice

Man

ual

TAB SECTION

INDEX

840B DIESEL ENGINE Complete 2800 A·C ENGINE

PAGE

AI

FUEL INJECTION SYSTEM •• . ••• .. • ••.• • . • • •• •• • • • • • • ••••. • . • Bl

TRANSMISSION And TORQUE CONVERTER ••• • •• • •. ..••.• • • •• •• Cl

AXLE, DIFFERENTIAL, And BRAKES ..... . . . . ... . . .. . ... . . . ... Dl

POWER STEERING And BRAKE SYSTEM - HYDRAUliC •• • ......•. El

LOADER BOOM ASSEMBLY ............. .... .. . ........ . ..... Fl

LOADER HYDRAUliC SYSTEM ......... . .. .. ................. Gl

ELECTRICAL SYSTEM .... .. ............ ... ................. . HI

No. 9004618 MAILING NO. 2 for Manual 1013042

ENGINE INDEX

Adapto r Plat e and Crankshaft Rear Ojl Seal .. 54, 55, 56 Removing Too l. . . . . . . . . . . . . . . . . . .. . . . . . . 55

Camshaft and Gear ..........• . . • ...... 63 thru 70 Camshaft Bearings ........... .. ......... 69, 70 Thrust Plate5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

'Connecting Rod and Connecting Rod Bearings . . ... .. . . ... ............... 76 thru 78

Crankshaft and Crankshaft Gear .......... 79 thru 82 Gear Removal.......................... 51

Crankshaft Pulley and Damper Assembly . . . . . . . . 42

Cylinder Block ........ . _ ......... _ .. .. . . .. 87

Cylinder Head .. . . . . . . . . . . . . . . . • . . . . . . . . . . 28 Cylinder Head Removal and Instal la t ion ..... 32, 33 Rocker Arm Shaft .................... . . 30, 31 Valve Face and Valve Seat Grinding ..... . ... 40, 41 Valve Lash Adjustment .................. 34, 35 Valve Spri ngs, Guides and Seats. . . .. 36,37, 38, 39

Cylinder Sleeve ............ . .......... 88 thru 91 Resealing ... __ .... . ....•..•........ 92 thru 94

Engine Cooling System . ....... . ....... . 15. 16, 17

Engine Disassembly and Assembly . . . . . . . . . . . . . 95 Assembly ... . . __ . .... _ . . . . . . . • . . • . . • . . . 95 Disassembly . . . . . . . . . . . . . . . . . . . . . • . • • . . . 95 General. . . . . . . . . . . . . . . . . . . • . . • . . • . . • . . . 95 Run-In Schedule .. _ . . . _ ... _. . ........ . .. 96

Flywheel and Ring Gear Inspection, Removal and Installation ... _ . . . . 52.53

Front Plat e <>nd Gear Cover . . . . . . . . . . . . . . . . . . 60

Front Support Plate . . . . . . . . . . . . . . . . . . . . . . . . 51 "F uel Injection Pump Specifications ... _. A · 4a, b, c Fuel Pump Drive Gear and Pum"'p Drive Shaft .... 48

Fuel System ...................... . 121 thru 133

No. 90046 18 MAILING NO. 2 for Manual 1013042

A-2

Litho in U.S.A.

ENGINE INDEX (Cont'd)

Gear Train . . . . . • . • • . • •. • . • • . • • •• . • • . • . . . . 47

Hydraulic Pump Drive Assembly .......•... . . 45, 46

Idler Gear Shaft ..... . ............•....... 49, 50

Main Bearings ......... . .. . . . ......... 83 thru 85 Bearing Caps. . . . . . • . • • . • • . . . . • . . . . . . . . . . 86

Manifold Exhaust . . . . . • . . • . . • . . . . . . . . . . . . • . . . . . . 27 Intake. . . . . . • . • • • ••• • •• • • • • • • •• • . . . . . . 26

Oil Flow ...•...•..•.............. . • ..... 57, 58

Oil Pan ........ . ........... .. •.. • • • ..... 59, 60

OiIPump ....................••..•....... 61 Cleaning and Inspection... ................ 61 Engine Breather Tube .... . . .. . . . . • . . . . . . . 62 Installation ......... ..... ... • ......... 61, 62 Pressure Relief Valve . . . . . . . • . . • . . . . . . . . . . 62

Piston and Piston Rings ... . ...•..•...... 72 thru 75

Radiator . . . . . . . . . . . . . . . . . . . . . • •. . . . . . . . . . 18 Fan and Fan Belt.. ...... ............ • ... 19 Thermostat ............. • • •• • • • ••.• • ... 20

Specifications General Specifications . . . . . . . . . . . . . . . . . . . . 4 Fits and Tolerances ... . ... 5 thru 10 Engine Torque Specifications (Diesel) . ... 11 thru 14

Tach·Hourmeter DriVe ................... 134, 135

Timing Gear Cover and Crankshaft Front Oil Seal . .... . ....... ... .....• . . ...... 43, 44

Trouble Shooting ..... . • . . • ..•........ fll thru 106

Valve Lifters ...... . .. . ..... .. ............ 7 1

Water Pump ....... • ........ .... ...... 21 thru 25

840B ARTICULATED LOADER A-3

NO. 9004625 MAI LI NG NO . 3 for Manual 101 3042

WATER PUMP

3 2

7

8

11 9

10

WATER PUMP ASSEMBLY

1. Pulley Hub 6. Seal Assembly 2. Shaft 7. Impeller 3. Bearing 8. Ceramic Seal 4. Water Pump Body 9. Body Plate 5. Slinger 10. a-Ring

11 . Snap Ring

NOTE: Slinger and Snap Ring not used in 200 Tractor.

GENERAL INFORMAT ION

A centrifugal type water pump is provided for circulating coolant through the engine and rad iator. The water pump is mounted on the front of the cylinder block and is belt driven from the crankshaft pulley. Coolant is drawn through the inlet opening by the pump impeller and forced through the outlet opening located in the outlet of the volute into and through the oil cooler and then into the cylinder block. Also, a portion of the coolant is forced through the volute into the cylinder block. O·ring gaskets are used to assure leak proof connections.

The water pump shaft and bearing assembly does not re­quire lubrication because the bearing is of the sealed-for­life type.

The shaft and bearing assembly is secured in the pump body by a press fit_ The seal between the impeller and pump body is of the pack less type. The seal assembly is spring loaded and is pre5sed into the pump body forming a leak-proof seat at this point_

The carbon sealing surface is bonded to the seal assembly and contacts a ceramic seal insert bonded to the pump impeller. Proper pOSitioning of the impeller on the shaft creates a 9 to 13 pound load on the seal assembling form­ing a tight seal. The ceramic seal insert bonded to the im-

A-21

, f

e.

•

-::=- ,

WATER PUMP INSTALLED 1. Volute 2. Water Pump 3. Front of Cylinder Block

WATER PUMP VOLUTE INSTALLED

1. Volute 2. Cylinder Block 3. Timing Gear Cover

peller cannot be serviced separately. If it is damaged, a new impeller must be installed in the pump_ A pulley hub, pressed on the front end of the water pump shaft and bearing assembly, is the mounting member for the pulley and fan .

No. 9004618 MAILI NG NO.2 for Manual 1013042

'. '

limit of .015 inch with a new thrust plate. the camshaft gear must be replaced. Remove the gear retaining capscrew and washer.

7. Place the camshaft in a press and force the camshaft from the gear.

CAMSHAFT, CAMSHAFT GEAR AND THRUST PLATE INSPECTION

1. If the engine has been operated with c lean oil and the correct quantity in the oil pan, the camshaft bearing joumals seldom wear to the extent that is necessary to replace the camshaft. The specified 0 .0 . of all camshaft bearing journal diameters is 2.130 inches to 2.131 inches. The specific inside diameter o f t he camshaft standard bearings installed is 2.133 inches to 2. 136 inches. The specified running clearance between the camshaft joumals and bearings is .002 inch to -lX)6 inch and must not exceed .008 inch. If the installation of new standard bearing will not reduce the running clearance below .008 inch, it is recommended to grind the camshaft journals to accommodate ,ala inch undersize bearings. Likewise, if the journals are worn or scored to t he extent that they will not accommodate .0 10 inch undersize bearings, the camshaft must be replaced.

2. Inspect the camshaft lobes for roughness. scoring or excessive wear, Replace the camshaft if any of these conditions are found. These conditions can be caused by inferior quality of lubricating oil, excessive valve lash adjustment, contaminated oil or the valve lifters not rotating.

3, Replace camshaft gear if teeth are nicked, scored or broken.

Before reusing a gear t hat has been removed from a camshaft, carefully check iU bore to be sure it is within t he specified size o f 1.373 inches t o 1.374 inches when measured at t he center and near both ends. The specified press fit of gear t o shaft is .0025 inch to .004 inch.

4. Inspect thrust p late for wear. Replace if the wear area is rough or the wear is excessive. New thrust plate thickness is.204 inch to.206 inch.

CAMSHAFT GEAR AND CAM SHAFT INSTALLATI ON<-

1. To install the camshaft gear on the camshaft proceed as follows:

a. Place camshaft in a press with the shoulder of the first journal nlsting 00 parallel bars. NOTE: The thrust plate must be positioned on the camshaft before pressing on the gear.

b. Heat the gear in oil to a temperatue of approximately 350 degrees to 400 degrees F.

A·67

INSTALLING WOODEN OOWEL RODS IN THE VALVE LIFTERS

I . Cylinder Head Z. Wooden Dowel Rod J, Rubber Band

CHECKING CAMSHAFT BEARING JOURNAL

1. Camshaft 2. Camshaft Joumal 3. Camshaft lobe 4. Camshaft Gear 5. Micrometer

c. Using asbestos gloves, position the gear 00 the camshaft and align the gear keyway with the key in the camshaft.

d: Press the gear onto the shaft until the gear hub is flush with the front end of the camshaft. or until the specified end clearance of .001 inch · .011 inch is obtained between the thrust plate and the gear hub.

2. Check camshaft journal to bearing running clearance.

3. Oil the camshaft bearings and carefully insert the camshaft in the cylinder block. Be careful not to scratch or mar the bearings.

NOTE: Make cenain the timing marks on camshaft

No. 9004618 MAILI NG NO.2 for Manual 101 3042

Table of Contents

840 DIESEL ENGINE

Am INTAKE SYSTEM A-56

CAMSHAFT ••••• A-39

CRANKSHAFT AND BEARINGS A-25

CYLINDER HEAD AND VALVES. A-13

CYLINDER LINER . • • • • • • A-23

ENGINE REMOVAL AND INSTALLATION. A- 9

FLYWHEEL • ••••••••••••• A-34

GENERAL INFORMATION AND SPECIFICATIONS. A- 2

LUB. SYSTEM. • • • • • • • •• A-44

PISTONS AND CONNECTING RODS A-19

RADIATOR & HOOD, FUEL TANK. A-58

ROCKER ARM SHAFT • • • • • • A-ll

TIM1NG GEAR COVER AND TIMING GEAR. A-36

TROUBLE SHOOTING ENGINE A-64

WATER PUMP ••••••• • A-51

Page A-I 1013042

FUEL INJECTORS • DPA Test Data Pump Adjustment

TabJe of Contents

FUEL INJECTION SYSTEM

GENERAL INFORMATION & SPECIFICATIONS

INJECTION PUMP ••••• • Disassembly & Assembly. Removal & Installation . Test & Adjust • • Trouble Shooting. .

PRIMARY FUEL PUMP.

Page B-1

B-30 B-36 B-28

B- 2

B-10 B-12 B-10 B-21,28 B-29

B-39

BI

1013042

:j ,:

Tab le of Con tents

TRANSMISSION And TOROUE CONV ERTER

_ DISASSEMBLY (TRANSMISSION & TORQUE CONVERTOR)

DRIVE SHAFT & UNIVERSAL JOINT. • • • • • • • •

OPERATION (TRANSMISSION & TORQUE CONVERTOR)

REASSEMBLY (TRANS. CASE & CLUTCH GROUP).

REMOVAL & INSTAL LATION (TRANSMISSION) •

SERVICING AFTER TRANSMISSION OVERHAUL

TESTING PROCEDURES & PRESSURE CHECKS • Clutch Pressure . .. ... . Pump Volume . . . . • . . . Torque Convertor Out Pressure T rouble Shooting. . . . . . .

TRANSMISSION CONTROL VALVE.

TRANSMISSION CONTROL CABLE. Shifl Cable . • • • • • • • • •

Page C- l

C-30 ~

• C-59

• C- 2 C I • C- 42

• C- 15

• C- 56

· C- IO

• C - ll • C-ll • C- 12 • C - 13

• C- 27

• C- 54 • C- 55

1013042

ISM 17

Table of Contents

AXLE. DIffERENTIAL And BRAKE

AXLE Planetary • • • • • • • • • • Internal Axle Assy. W /Sun Gear Floating Ring Gear Hub. Assembly.

BRAKE •••••• Brake Shoe Assy. Brake Adjustment Wheel Cylinder.

DIFFERENTlAL • • Removal " Disassembly. Plnlon " Gage Assy. Differential & Gear Case ABsy. Reassembly • • • • • • • • •

DISASSEMBLY OF TilE PLANETARY HUB

Bdore 'tarting the disassembly of the planetary rigid type nlc. the following procedures and precautions .hould betaken:

A. Jack up both ends of ule 10 that tires deu the ground due to the elll~rne weight of the vchicle under which planetary type ulet are used. The axle should then be blockcd up under each mountin~

AXlE

B.

0-1 0-1 D-3 0-4

. 0~5

0-6 0-6

D 0-8 D-8

O-ll 0-12 0-14 0-13 0-15

piate to safel~· support the weight and hold nle at

this le'"cl. The jacks may then be removed 10 pro. vide adequate working . pace with no danger of axle falling or .hilling. Remove th e wheel nut.

Remove the tire and wheel •.

C. Rotatc hub assembly 50 that the drain pluJ;" is at the bottom.

Do Rcmo,oc the plug and drain lubrica nt.

Page D-l 1013042

~:'

I

•

•

•

Tabl e of Contents

POWER STEERING And BRAKE SYSTEM

BRAKE HYDRAULIC POWER- MASTER CYL. Power cy!. for Power Master Cyl. . . .

FLOW TESTING STEERING & BRAKE SYSTEM

POWER STEERING VALVE. Hydraulic Lines. Flow Divider Fuel Pump •• •

ARTICULATED JOINT ASSY •• Lubrication.

POWER MODULE Removal . .

TOOL MODULE. Removal & Installation .

Page E-l

., , E-15 E -16

E - 2

E - 4 E-1O E-12 E -13

E - 22 E E - 24

E - 21 E-24

E-20 E-25

1013042

Table of Content,

lOADER BOOM ASSEMBLY

BOOM-REMOVAL, ASSY., 8< DISASSEMBLY.

BOOM CYLINDERS

BUCKET ••••• Bucket Skid Plates Cutting Edge • •

BUCKET CYLINDERS

BUSHING LOCATIONS.

LIFT CYLINDERS •••

Page F-l

F-2

F-3

F-12 F -12 F -12

F - 3

F -IO

F - 3

F

1013042

" ,

Table of Contents

LOADER HYDRAULIC SYSTEM ELECTRICAL SYSTEM

FWW RATING HYD. PUMP.

WADER HYD. PUMP. Disassembly. Assembly ..••

WADER HYD. CONTROL VALVES. Disassembly. Inspection . . • . . . . . . .

P age G-l

G-23

G-13 G-15 G-20

G-2 G-2 G-3

G

1013042