840 & 840B Articulated Wheel Loader & 840 Forklift

Transcription

1 Allis Chalmers Parts Manual 840 & 840B Articulated Wheel Loader & 840 Forklift Parts 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-P-840 WL&FL

2 , ;_:",.::3,.. CATALOG ALLIS-CHALMERS TRACTORS models' ". 840 & 8408, Articulated 'WheelLoader., and ;,,840 Forklift.:...' -. p '.,..;.) ',~.,. " LITHO IN, U.$.A. '. :: "', -.~.. FORM May, 978

3 840'& 840B Page 3 INDEX AIR INTAKE & EXHAUST AIR CLEANER ASY. AIR CLEANER GROUP AIR FILTER GROUP. HEATER ELEMENT. air MANIFOLD Exhaust Perkins Allis-Chalmers Intake Perkins Allis-Chalmers MUFFLER. ALPHABETICAL INDEX. ASSEMBLIES & PACKAGED PARTS ATTACHMENTS Blower Asy. Blower Group Bucket Asy. 4 in.. Bucket Asy. 4 in (-/2 Cu. Yd.) Bucket Cylinder Asy. 4 in '. Bucket Cylinder Asy. 4 in (-/2 Cu. Yd.l Buckets. loader. Cab Assembly Canopy Group.. Carriage Group. forklift Hook Mount. Shaft Mount. Counter Weight & Drawbar Group Drawbar Group. Ether Starting Aid. Fresh Air Heater Front Window Defroster Heater Assembly Heater Group Hydraulic Group. third spool Lift Cylinder. forkl ift mast. Lock Assembly. Log Clamp Cylinder Log Clamp Group. Mast Asy. 2 ft. mast Moldboard. rear view. 4 in. Moldboard. rear view. 4 in (-/2 Cu. Yd.) Outside Mirror Group Position Indicator. 4 in Rear Window Wiper. Return to Dig Valve Section Spacer Heater Group. Third Spool Control. Third Spool Control Valve Group. liftfork Third Spool Control Valve Group. 4 in Tilt Cylinder. Tines Group. forklift Vehicle Control Auxiliary Pump & Motor Asy. Windshield Wiper Asy front of cab Wiper Motor Asy. AXLES. STEERING & WHEELS AXLES (Refer to DRIVE TRAIN) & 60 STEERING Column 82 Controls Cylinder (Refer to HYDRAULIC SYSTEM) Lines.. 78 Valve. control (Refer to HYDRAULIC SYSTEM) WHEELS Front & Rear 68 BRAKE BRAKE BRAKE GROUP BRAKE LINES Front. Rear. CABLES. CLUTCH CUT-OFF VALVE ASY. FLOW DIVIDER MANIFOLD. PEDAL. POWER MASTER CYLINDER Master Cylinder. Power Cylinder. PUMP & MANIFOLD COOLING SYSTEM BELT. fan FAN. FAN. pusher. RADIATOR. THERMOSTAT. Sending Unit. WATER OUTLET WATER PUMP. ELECTRICAL SYSTEM ALTERNATOR. BATTERY GROUP. Battery Cables BRAKE STOP LIGHT SWITCH FLASHER LIGHT GROUP FLOOD LIGHT ASY INSTRUMENT PANELS Left Hand Side Horn. Hourmeter Oil Pressure Gauge. converter Oil Temperature Gauge. converter Push-Button Switch. Signal Switch Right Hand Side. Ammeter. Cable. shut-off Fuel Group. Key Switch Oil Pressure Gauge _. Push-Button Switch Water Temperature Gauge. -LIGHT ASY. combination. -'. PULLEY ROAD LIGHT GROUP STARTING MOTOR WIRING HARNESSES Engine to Instrument Panel Front. Instrument Panel - Left. Instrument Panel - Right Rear Frame -. WIRING GROUP Platform. Power Module./? Sending Units / ' Engine Oil ,80 34, ,204 4, , 230, , , , ~ _. 28, , 230, 240, 242, & , Pressure....'I- ~...,..~-:~:--:. 232 Temperature. 232

4 840&8408 Page 4 INDEX ENGINE (ALLIS-CHALIIIIERS) CRANK~HAFT Beangs Gea. Pulley. CYLINDER BLOCK Engine Asy. Short Block Asy. CYLINDER HEAD. Cover. Valve Exhaust.. Intake FRONT PLATE & GEAR COVER FLYWHEEL. Gear, ring FLYWHEEL HOUSING Cover, timing hole IDLER GEAR ASY. LUBRICATING SYSTEM Filter, lube oil Manifold. Oil Pan & Oil Pump. Gear, drive Shaft & Gear Asy. Drive. Idler OIL COOLING GROUP PISTON & CONNECTING ROD Bearings Ring Set. ROCKER ARM GROUP Camshaft. Gear, camshaft lifter, valve. Rocker Arm. ENGINE (PERKINS) CRANKSHAFT Bearings Gear Pulley. CYLINDER BLOCK Engine Asy Short Block Asy. CYLINDER HEAD. Cover. Cover, end Valve Exhaust Intake FRONT PLATE & GEAR COVER FLYWHEEL. Gear, ring FLYWHEEL HOUSING IDLER GEAR LUBRICATING SYSTEM Filter, lube oil Oil Pan & Oil Pump. PISTON & CONNECTING ROD Bearings Ring Set ROCKER AR~ GROUP Camshaft. Gear, camshaft lifter, va Ive Rocker Arm , FORKLIFTS ANCHOR ASY., chain 308,30 ANCHOR ASY., upper chain 308,30 AUXILIARY GROUP 34 BEARINGS, ball 308 CARRIAGE GROUP Hook Mount. 320 Shaft Mount 320 CHAIN, lift 308,30 CYLINDER ASY. lift (4 ft.l 308,36 lift (30 ft.l First Stage. 30,38 Second Stage 30,38 Log Clamp Tilt 36 FLASHER LIGHT 32 FLOW CONTROL 308,30 HARNESS, wiring, front 32 HOSE REEL GROUP 326 HYDRAULIC TUBING & HOSES 306,308,30,32, 34,322, & 324 LIGHT BRACKET 32 LIGHT GUARD Left Hand 32 Right Hand 32 LOG CLAMP GROUP 306,324 MAINFRAME, front 32 Cover Asy. 32 PLATE, hose mount 32,34 RAIL ASSEMBLIES Inner (4 ft.) 308. Inner (30 ft.) 30 Outer (4 ft.) 308 Outer (30 ft.) 30 Second (30 ft.) 30 Third (30 ft.l 30 ROAD LIGHT 32 ROLLER ASY., chain 308,30 SEAT, spring 32 THRUST BEARING 32 TINES GROUP 32 FUEL SYSTEMS (ALLIS-CHALMERS) ELECTRIC SHUT-OFF GROUP FILTER ASY., fuel Elements Fuel Filter Water Separator FILTERS, fuel Pump, hand primer FUEL TANK GROUP. 200 Sending Unit Asy. 96,200 Shut-Off Valve 200 INJECTION NOZZLES & LINES. 84 INJECTION PUMP COMPONENTS Housing & Drive. 86 Transfer Pump, Head & Rotor. 90 NOZZLE HOLDER ASY. 84 THROTTLE LINKAGE 42 Pedal, accelerator 42 FUEL SYSTEMS (PERKINS) FILTER ASY., fuel 32 Primary Secondary 26,28,30

5 840& 8408 Page 5 INDEX FUEL SYSTEMS (PERKINS) (Cont'd) FUEL LIFT PUMP. FUEL TANK GROUP Sending Unit Asy.. Shut-Off Valve Strainer Asy. INJECTION NOZZLE & LINES INJECTION PUMP COMPONENTS Housing & D~ive. Transfer Pump, Head & Rotor. INJECTION PUMP & DRIVE. Gear, drive NOZZLE HOLDER ASY. THROTTLE LINKAGE Pedal, accelerator HYDRAULICS CONTROL GROUP Console Tool Box. CYLINDERS Loader Lift Loader Dump LOADER Pump. Valve. RESERVOIR GROUP, platform Element, filter Valve Asy., relief. POWER MODULE GROUP FENDER GROUP GRILLE, rear HOOD GROUP LADDER GROUP LOCK ASY. PLATFORM ASY. POWER FRAME GROUP Brackets, engine. Brackets, transmission Right & left Mainframe Pivot Asy. REAR HOOD SUPPORT GROUP SEAT GROUP , ,98 36, , ,222 84~ 94 94, , , ,24 22,24 22, ,24 206, TRANSMISSIONS (Cont'd) Forward & 3rd Clutch Gears Gear Shift Linkage Housing, converter Hub, impeller Hub Gear, impeller Hydraulic Piston Housing Idler Shaft Idler Shaft Gear Impeller. Low Speed Clutch Gears Oil Filter Group. Output Shaft Parking Brake Asy. Pressure Regulator Reverse & 2nd Clutch Gears Ring Gear Kit. flywheel Screen Turbine Turbine Shaft Gear. TOOL MODULE GROUP. LOADER BUCKETS, loader LIFT ARM GROUP Bucket Level Asy. Bucket Link Asy. Cylinders Dump Lift LOADER HYDRAULICS Loader Control Valve Pump Asy., hydraulic TOOL MODULE GROUP. front Lights. Flasher Road. Seat. spring Wire Harness , ,90 84, ,252 22,24 28 POWER TRAIN GROUP AXLE ASSEMBLIES Axle Housing Brake Parts Differential Asy. Shaft & Hub. Wheel Cylinder Asy. Wheel Group DRIVE SHAFTS Drive Shaft Asy. Front & Rear Drive Shaft Group' TRANSMISSION Case & Cover Group Case Group. Charging Pump Control Valve Asy. Converter Asy. Cut-Off Valve Drive Gear Drive Gear, low speed 20,28. 36, & 60 20,28. 36, & , & & & & , &

6 840& 840B Page 6 CYLINDER BLOCK ITEM NUMBER QTY. '* ** *** o o - 0 o 0 DESCRIPTION BLOCK ASY., cylmder ( (Use BLOCK ASY ), Incl. Items 2thru 6 BLOCK ASY., cylinder, BLOCK ASY., cylinder HUSHING, camshaft front LINER, cylinder block (straight) LINER, cylinder block (flanged) PLUG, fuel pump side & rear face PLUG, induction'side THIMBLE, main bearing to block CAPSCREW, main bearing to block CAPSCREW, main bearing to block SHIM, capscrew PLUG, for right side drain cock PLUG, fuel pipe side PLUG, lub. oil pres. switch (Short Block) PLUG, pressure rail PLUG, camshaft bearing PLUG, rocker oil feed PLUG, R.H. side PLUG, lub. oil pres. rail PLUG, induction side COCK, drain water GASKET, cylinder head GASKET, cylinder head WASHER, plug WASHER, plug STUD, cylinder head (Prior SIN 248U654) CAPSCREW, cyl.head (Eff. SIN 248U654) STUD, cylinder head (Prior SIN 248U654) STUD; cylinder head (Eff. SIN 248U654) CAPSCREW, cyl. head (Eff. SIN 248U654) STUD, cylinder head (Prior SIN 248U654) CAPSCREW, cyl. head (Eff. SIN 248U654) PLATE, induction side PLATE, induction side GASKET, blanking plate to cyl. block GASKET, blanking plate to cyl. block CAPSCREW, plate to cyl. block WASHER, spring, 7/6 HOUSING, crankshaft rear end (Inc!. Items 27 & 28) HOUSING, crankshaft rear end DOWEL CAPSCREW, housing clamp LOCKWASHER SEAL, rear end oil SEAL, rear end oil GASKET, housing to block GASKET, housing to block CAPSCREW, housing to block CAPSCREW, housing to block LOCKWASHER FI LLER, lube oil CAP, lube oil filler GASKET, cap GASKET, filler flange to block CAPSCREW, filler to block LOCKWASHER BRIDGE PIECE, rear GASKET, bridge piece to block SCREW, bridge piece to block WASHER, plain GASKET KIT (Inc!. Item 8) *Prior SIN 248U654 **Prior SIN 248U7587 ***Eff. SIN 248U7587 & Up ENGINE ASY., replacement (Replaces '004227, Engines prior to and eff. SIN BLOCK ASY., short (Use SHORT BLOCK ASY. with 2043 & Up) of & 25723; 4 of 00438, & ; of 00507, , , , , , Incl. Items to 8, ,0042 & 00422; 2 of 2537; of , 0 to 6, 9 to 2, 9435,257263,00464 & 00465) 26 to 30, & 35 to 37 BLOCK ASY., short BLOCK ASY., short

7 840& Pa OIL S 'O FLFCTOR INCL. WITH OIL SUCTION PIPe Q... '"...,,

8 840 & 840B Page 20 FUEL LIFT PUMP (Under Tractor SIN 255 Loader, Under Tractor SIN 045 Forklift! IT[;M NUMBER OTY DESCRIPTION PUMP ASSY., fuel (Incl. Items 2 thru 8) SCREW, cover to housing (Order ASY.) Washer, screw (Order REPAIR KIT) COVER, pump (Order ASY.) DIAPHRAM, pump (Order REPAIR KIT) HOUSING, pump (Incls. Item 5 & 6) (Order ASY.) VALVE, inlet and outlet GASKET, valve SCREW, housing to body (Order ASY.) Washer, spring (Order ASY.) DIAPHRAM, pump(order REPAIR KIT) SPR I NG, return BODY, pump (Order ASY.) WASHER, primer (Order ASY.) SPRING, primer return (Order ASY.) PRIMER, pump (Order ASY.) LEVER, pump operating (Order REPAIR KIT) PIN, pump arm & lever (Order REPAIR KIT) ARM, pump (Order ASY.) PIN, primer retaining (Order ASY.) SPRING, arm return (Order REPAIR KIT) NUT, inlet port FERRULE, inlet port GASKET, pump to block STUD, pump to block Nut, pump Washer, plain KIT, repair (Incls. Item 3, 5, 6, 8, 4, 5, 8 & 22) KIT, gasket (Inels. Item 2) Fl YWHEEl HOUSING Cylinder block ~~l ITEM NUMBER OTY DESCRIPTION HOUSING, flywheel PLUG PLUG, housing Washer, spring (replaces PLATE, bottom cover CAPSCREW, cover plate to housing (replaces ) Washer, plain Washer, spring (replaces COVER, housing dust CAPSCREW, dust cover (replaces Washer, plain Washer, spring DOWEL, housing to block CAPSCREW, housing to block (replaces Washer, spring (replaces

9 840&8408 Page 53 MUFFLER 2 I 3~ AIR CLEANER GROUP 6 /~ 4.

10 840 & 840B Page 54 MUFFLER GROUP ITEM NUMBER OTY. DESCRIPTION CLAMP, elbow MUFFLER COUPLING, muffler AIR FILTER GROUP ITEM NUMBER OTY. DESCRIPTION AIR CLEANER (See Air Cleaner Assy. For Component Parts) CLAMP, air cleaner mounting CAPSCREW Washer, lock Nut HOSE, air cleaner to engine CLAMP, worm drive CLAMP, (Includes Nut and Bolt) Bolt Nut EXTENSION, air cleaner DUST CAP

11 840&8408 Paae , ~2 74, ' ' '0.238, () , , , ,280, , , ,92, , , ~.92, , , , , ,6, , , ,34 02! , ,339,3.' , , , , , , , , , , , , ~ , & , , , , , , , , , , , , ,28, ,28, , ,26, , , , , , , , ,30, ,

12 840&8408 Page ' ' ' , !U !H , 28, , ,30, , ,250, '48,'50, ,'50,' , , , , , , , , ' ' ' , , i22,'30.38 '.6, ,208, , , , , , ' ,7.,3~ Q.l ~ ' , ' ' ' '435 ~6

13 840& 840B Page 347 P.~T NO. PAG~ : " " : ,,' : , , : , ,6, , ' , , , , '8.92 2' : '." , , ' " ' () ,

14 840&8408 Pape ' " ' , ; o ~ o.92!u :Sl G926GGG ig ; ' ' ' ' ' " ' ' ; iC & G93ft , , , , , ,9 90., ,332 IGGG76~ 9G, , , ,3., '0.00..' , ,9 90., ,3., ' , ,33 IOGI53 82,33~ , , , , ,

15 840&8408 Paae " : , , , ' , , UO, ,,2, , ~ ' ,, , , , ,62, , ' , , '23' , , , , , ,., , ,., " ,.,,., lis , i _ ~ i , , ~ , ' , , , , i ; , ,3.0

16 840& 840B Page 350 PAGI: ' , 'H , , u ,i , ,06, , , , , , , , ,.26,28, , , , , ,38, ,38, ,20,22,24, , , , , ,3.2 50, , ,54 IOb533 22, , ' , , U

17 840&840B Page UO ' ",25" ' , , , , , , , , , " , , , , , ' " " "3 26.., " " " " " , " " " "36 24,26 005"37 24, " " " " " " ,330, , & , ' " ~ , ' ' ' , ' ' ' ' ' ' ' ,' " , ' , ' '

18 840& 8408 CaP, , ,,,.62 ' , U , ' , ao ao a ao , , , , ' l l6.l l6.l , ' ' ' , l , i l ' l ' ' ,, l'o ' l ' ' ' , l , l l0 258 ' l l l l l '03.l 2~6~2' l26.0'0390 l l92 l l26 io'0.0.~ ' l0.38 0' '0.35 6,0, l '7... ' '0' '0' l

19 840& 8408 Pa '353 DART NO. DAGE PAGI! ioi II, , &, io OU ,' ,''' , ' ' ' '.6.5., , ' ' ' ' ' , ~ ' , ' ' , ,5., ' ' ' , ,33 20~' S ,32., , , ' ' '~ '.30 20' ' ,32. 20'3' ' ' , ' ' ' ' '.6.5., S '"

20 840& 840B Page ' ' " '.3, ' '37 a '0 30' I... a ' ' , '2' ' , t3 I.', , , , Uhl66 30' ' ,8656, ' ,, , , , , , ,.30, , ' ~ 22.30,3..6,5., , ' ~ "6,5., , , , ' , , ,,22 30,' '3 ' , , ,30.3'.6.I5.i , ~.3.2, , "' ' ' ' ~*2292 6a , , , ' , ,

21 840&8408 PaP,366 PAGI PAGI , , ,.6, , ,'0 6.,3.a , , ,50 8., , , , '0 80, ".' '5.9.,.80,.9, '.0' ' , ,, sua a a '596, 8', ' '04 86, '0" '30 8 9, : ,, "' , , , ,, "4, , OS09.p 86.a.0509' ' OS.a83 9, a87., , , ,9, ' a ' S" 78.OS S326 6,90.OS l.,9 9., , ' l ' U0... 8' ' ' ' , ,3.a 0~566 '6, ' A a oa o a ' '0... 5' ",' ' ' , , , , ' , ,.9,66,202,20 232, a... '50.8,82 23., ' 34' , ~ , , ' a ,t.U, , , a4