840 & 840B Articulated Wheel Loader

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Allis Chalmers Service Manual 840 & 840B Articulated Wheel Loader Service

WITHOUT THE AUTHORIZATION OF ALLIS CHALMERS OR IT S SUCCESSORS.

1 Allis Chalmers Service Manual 840 & 840B Articulated Wheel Loader Service Manual 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.. AC-S-840,840B

2 TAB SECTION INDEX PAGE 840B DIESEL ENGINE Complete 2800 A C ENGINE 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 MAILING NO. 2 for Manual

3 ENGINE INDEX Adaptor Plate and Crankshaft Rear Ojl Seal.. 54, 55, 56 Removing Tool Camshaft and Gear thru 70 Camshaft Bearings , 70 Thrust Plate 'Connecting Rod and Connecting Rod Bearings thru 78 Crankshaft and Crankshaft Gear thru 82 Gear Removal Crankshaft Pulley and Damper Assembly Cylinder Block.... _... _ Cylinder Head Cylinder Head Removal and Instal lation... 32, 33 Rocker Arm Shaft , 31 Valve Face and Valve Seat Grinding , 41 Valve Lash Adjustment... 34, 35 Valve Springs, Guides and Seats ,37, 38, 39 Cylinder Sleeve thru 91 Resealing thru 94 Engine Cooling System , 17 Engine Disassembly and Assembly Assembly _ Disassembly General Run-In Schedule.. _... _... _ Flywheel and Ring Gear Inspection, Removal and Installation... _ Front Plate <>nd Gear Cover Front Support Plate "Fuel Injection Pump Specifications... _. A 4a, b, c Fuel Pump Drive Gear and Pum"'p Drive Shaft Fuel System thru 133 No MAILING NO. 2 for Manual A-2

4 ENGINE INDEX (Cont'd) Gear Train Hydraulic Pump Drive Assembly , 46 Idler Gear Shaft , 50 Main Bearings thru 85 Bearing Caps Manifold Exhaust Intake Oil Flow , 58 Oil Pan , 60 OiIPump Cleaning and Inspection Engine Breather Tube Installation , 62 Pressure Relief Valve Piston and Piston Rings thru 75 Radiator Fan and Fan Belt Thermostat Specifications General Specifications Fits and Tolerances thru 10 Engine Torque Specifications (Diesel) thru 14 Tach Hourmeter DriVe , 135 Timing Gear Cover and Crankshaft Front Oil Seal , 44 Trouble Shooting fll thru 106 Valve Lifters Water Pump thru 25 Litho in U.S.A. 840B ARTICULATED LOADER A-3 NO MAI LI NG NO. 3 for Manual

5 WATER PUMP 2 3, f 7 8 e. '.' 11 9 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 INFORMATION 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- 10 -::=-, 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. A-21 No MAILING NO.2 for Manual

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.

6 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 clean 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 inches to inches. The specific inside diameter of t he camshaft standard bearings installed is inches to 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. INSTALLING WOODEN OOWEL RODS IN THE VALVE LIFTERS I. Cylinder Head Z. Wooden Dowel Rod J, Rubber Band 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 of inches t o inches when measured at t he center and near both ends. The specified press fit of gear to shaft is.0025 inch to.004 inch. 4. Inspect thrust plate 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 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 MAILI NG NO.2 for Manual

7 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

8 TabJe of Contents FUEL INJECTION SYSTEM FUEL INJECTORS DPA Test Data Pump Adjustment B-30 B-36 B-28 BI :j,: GENERAL INFORMATION & SPECIFICATIONS B- 2 INJECTION PUMP Disassembly & Assembly. Removal & Installation. Test & Adjust Trouble Shooting.. B-10 B-12 B-10 B-21,28 B-29 PRIMARY FUEL PUMP. B-39 Page B-1

9 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. 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 ~ Page C- l

10 ISM 17 Table of Contents AXLE. DIffERENTIAL And BRAKE ~:' AXLE Planetary Internal Axle Assy. W /Sun Gear Floating Ring Gear Hub. Assembly D ~5 BRAKE Brake Shoe Assy. Brake Adjustment Wheel Cylinder D-8 D I DIFFERENTlAL Removal " Disassembly. Plnlon " Gage Assy. Differential & Gear Case ABsy. Reassembly O-ll AXlE 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~ B. piate to sa f el~ 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 the 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

11 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 E-15 E -16 E - 2 E - 4 E-1O E-12 E -13 ARTICULATED JOINT ASSY Lubrication. POWER MODULE Removal.. TOOL MODULE. Removal & Installation. E - 22 E - 24 E - 21 E-24 E-20 E-25 E Page E-l

12 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 F-2 F-3 F-12 F -12 F -12 F - 3 F -IO F - 3 F Page F-l

13 Table of Contents LOADER HYDRAULIC SYSTEM ELECTRICAL SYSTEM FWW RATING HYD. PUMP. WADER HYD. PUMP. Disassembly. Assembly.. WADER HYD. CONTROL VALVES. Disassembly. Inspection G-23 G-13 G-15 G-20 G-2 G-2 G-3 G P age G-l

7010, 7020 & 7045 Volume 1 of 2

Allis Chalmers Service Manual 7010, 7020 & 7045 Volume 1 of 2 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF ALLIS CHALMERS OR IT S SUCCESSORS. ALLIS CHALMERS AND