TM 10-3930-644-14&P TECHNICAL MANUAL OPERATOR'S .

TM 10-3930-644-14&PTECHNICAL MANUALOPERATOR'S, ORGANIZATIONAL,DIRECT SUPPORT AND GENERAL SUPPORTINSTRUCTIONSMAINTENANCE MANUAL(INCLUDING REPAIR PARTS INFORMATION ANDSUPPLEMENTAL MAINTENANCE AND REPAIR INSTRUCTIONSREPAIRINSTRUCTIONSTRUCK, FORK LIFTGASOLINE ENGINE DRIVEN, 4,000 LB.CAPACITY,ALLIS-CHALMERSMODEL ACP-40-PSMHE 234NSN 3930-01-040-4594(144" LIFT HEIGHT & PNEUMATIC TIRES)MODEL ACC-40-PSMHE 232NSN 3930-01-039-8291(144" LIFT HEIGHT & SOLID RUBBER TIRES)NSN 3930-01-039-8292(180" LIFT HEIGHT & SOLID RUBBER TIRES)SUPPLEMENTAL OPERATINGMAINTENANCE AND REPAIRPARTS INSTRUCTIONSPARTS LISTHEADQUARTERS, DEPARTMENT OF THE ARMYJUNE 1984

FOREWORDAllis-Chalmers Lift Trucks are designed, operator-engineered, and manufactured to rigidspecifications so that your company can achieve the most production for its investment.Correct operation and regular preventive maintenance, coupled with authorized AllisChalmers service and parts will ensure long operational life and continued topperformance of your lift truck. This Operator's Manual is your guide to proper operationand service intervals. By using this manual, veteran operators can gain additionalinformation on techniques, while operators with little or no experience can learn properoperation in less time and with less chance of an accidentINTENDED USEA lift truck is a mobile, self propelled machine intended to lift, stock and carry materialwithin its rated capacity in and around plants, warehouses, yards, loading platforms,docks, railroad cars and highway trailers over paved and well graded, semipreparedsurfaces for short distances. It is usually associated with manufacturing or warehousingand is not intended for such uses as earth moving, snow removal or over the roadhauling. Any unintended use may seriously affect its operational safety, reliability andlongevity.

WARNINGDry cleaning solvent, used to clean parts, is potentially dangerous to personneland property. Do not use near open flame or excessive heat. Flash point of thissolvent is 138 F.WARNINGWhen removing radiator cap, use a rag to protect your hand. Loosen cap only 1/4turn and let pressure release. Steam produced can scald.WARNINGNo smoking or open sparks, arcs, or flame allowed in area while fueling or workingon any part of fuel system.WARNINGBrake assembly parts may be coated with asbestos dust. Breathing asbestos dustmay be hazardous to your health. Never use compressed air or dry brush to cleanthese assemblies. Dust shall be removed using an industrial type vacuum cleanerequipped with a high efficiency filter system. Clean dirt or mud from brakeassemblies with water and a bristle brush or a cloth.WARNINGCarbon monoxide poisoning can be deadly. Do not operate in an enclosed areaunless adequate ventilation is provided.WARNINGWhen backing forklift look where you are going and what your load is doing.Crushing may result. When you turn around to see, care must be taken to keep allof your body within the overhead protection frame.

TM 10-3930-644-14&PWARNINGIt is normal for the battery to generate hydrogen gas which is explosive whenmixed with air. Never expose the battery to an open flame or to an electric spark.Do not remove or install battery cables while vent plugs are removed. Battery fluidis a sulfuric acid solution. Avoid getting it on skin, clothing, painted surfaces, etc.Should any of the solution come in contact with your Clothing or skin, flush thearea immediately with cold water. If the solution gets on your face or in your eyes,flush the area with cold water and get medical help immediately.WARNINGThis (testing of ignition switch circuits) could be dangerous work. Electrically it isalways wisest to disconnect the battery when any troubleshooting or maintenanceis performed on the electrical system.WARNINGBe sure to properly support the carrier assembly as the cap screws are removed.WARNINGBe certain that hoist chain and lift are adequately rated for estimatedcounterweight mass density. Do not attempt to lift counterweight with a hoistrated below estimated counterweight mass.WARNINGAlways provide adequate ventilation of the working area during this operation(cleaning radiator cooling fans) to avoid possible toxic effects of the cleaningspray.WARNINGBefore proceeding further (with exhaust system removal), be absolutely sure thatengine has not been running for at least an hour or two. This will insure thatexhaust system has cooled adequately.

TM 10-3930-644-14&PHEADQUARTERSDEPARTMENT OF THE ARMYWashington, DC, 12 June 1984OPERATOR, ORGANIZATIONAL,DIRECT SUPPORT AND GENERAL SUPPORTMAINTENANCE MANUAL(Including Repair Parts Information andSupplemental Maintenance and Repair PartsInstructions)TRUCK, FORK LIFT, 4,000 LB.CAPACITYGASOLINE ENGINE DRIVEN (Allis Chalmers)MODEL ACP-40-PSMHE 234NSN 3930-01-040-4594(144" LIFT HEIGHT & PNEUMATIC TIRES)MODEL ACC-40-PSMHE 232NSN 3930-01-039-8291(144" LIFT HEIGHT & SOLID RUBBER TIRES)NSN 3930-01-039-8292(180" LIFT HEIGHT & SOLID RUBBER TIRES)REPORTING ERRORS AND RECOMMENDING IMPROVEMENTSYou can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures,please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms),or DA Form 2028-2 located in the back of this manual direct to: Commander, US Army Tank-AutomotiveCommand, Warren, MI 48090, ATTN: DRSTA-MBS. A reply will be furnished to you.TABLE OF CONTENTSCHAPTER IPAGEOPERATING INSTRUCTIONS .1-1CHAPTER I INDEX.1-1CGENERAL DESCRIPTION.1-1EPREPARING A NEW TRUCK FOR SERVICE .1-3OPERATING CONTROLS .1-4OPERATION OF LIFT TRUCK .1-7BATTERY .1-14LUBRICANT SPECIFICATIONS .1-15LUBRICANT AND SERVICE .1-17CHAPTER IIMAINTENANCE INSTRUCTIONS .2-1MAINTENANCE INDEX.2-1AENGINEDESCRIPTION AND SPECIFICATIONS .2-1Ba

TM 10-3930-644-14&PVALVE ADJUSTMENT.2-4OIL FILTER.2-5OIL PRESSURE RELIEF VALVE .2-5ENGINE TUNE- UP .2-6TROUBLESHOOTING CHART.2-11FUEL SYSTEMFUEL SYSTEM (PRT) .2-16AIR CLEANER (PRT) .2-18AIR CLEANER (SRT) .2-18AFUEL TANK .2-19FUEL PUMP AND FILTER.2-19CARBURETOR .2-20ACCELERATOR LINKAGE.2-21GOVERNOR.2-22ELECTRIC SYSTEMELECTRICAL SYSTEM .2-23BATTERY .2-24ALTERNATOR AND REGULATOR .2-25STARTER MOTOR .2-27ELECTRICAL WIRING .2-28HORN AND HORN RELAY.2-29IGNITION COIL.2-30DISTRIBUTOR.2-32INSTRUMENT PANEL.2-35COOLING SYSTEMCOOLING SYSTEM .2-39RADIATOR.2-41WATER PUMP.2-43THERMOSTAT .2-45FAN AND FAN BELT.2-47TRANSMISSIONTRANSMISSION .2-49POWER SHIFT TRANSMISSION CHECKOUT PROCEDURES.2-53SHIFTING MECHANISM.2-56OIL COOLER .2-58OIL FILTER.2-59UNIVERSAL JOINT.2-61DRIVE AXLEDRIVE AXLE.2-63HYDRAULIC BRAKES .2-69DIFFERENTIAL .2-69DRIVE WHEEL PNEUMATIC TIRES (PRT ONLY) .2-73b

TM 10-3930-644-14&PBRAKE SYSTEMBRAKES.2-75MASTER CYLINDER.2-76DRIVE WHEEL BRAKES.2-77PARKING BRAKE .2-78POWER STEERING SYSTEMSTEERING .2-79STEER AXLE .2-80STEERING WHEEL AND COLUMN.2-82DRAG LINK .2-82TIE ROD.2-83POWER STEER CYLINDER.2-83WHEELS AND TIRES.2-83AHYDRAULIC SYSTEMHYDRAULIC SYSTEM SERVICE .2-85COUNTERWEIGHT AND FRAME .2-91COUNTERWEIGHT AND FRAME.2-91COUNTERWEIGHT.2-91BODY COMPONENTS .2-94OVERHEAD GUARD.2-96HIGH FREE LIFT MASTGENERAL .2-97MAST ASSEMBLY .2-98LIFT CYLINDERS .2-99CARRIAGES, SIDESHIFTER AND FORKSCARRIAGE.2-101SIDESHIFTER (PRT ONLY) .2-103FORKS.2-104TROUBLESHOOTING CHARTSFUEL SYSTEM .2-105COOLING SYSTEM .2-107HYDRAULIC SYSTEM .2-108DRIVE UNIT.2-109HYDRAULIC BRAKE SYSTEM .2-110POWER STEERING SYSTEM .2-111MAST HYDRAULIC SYSTEM .2-112POWER SHIFT TRANSMISSION.2-113ELECTRICAL SYSTEM .2-114LUBRICANT AND FUEL SPECIFICATIONSLUBRICANT SPECIFICATIONS.2-116FUEL SPECIFICATIONS .2-117C

TM 10-3930-644-14&PLUBRICATION CHART.2-119CHAPTER IIIREPAIR INSTRUCTIONS .3-1REPAIR INDEX.3-1AENGINE ASSEMBLYFITS AND TOLERANCES.3-1BENGINE SERVICE AND MAINTENANCE .3-4MANIFOLD.3-5VALVES, INTAKE AND EXHAUST.3-7CYLINDER HEAD .3-13CRANKSHAFT AND CRANKSHAFT COMPONENTS .3-15FLYWHEEL AND HOUSING.3-23PISTON AND CONNECTING RODS .3-27CAMSHAFT, CAMSHAFT BEARINGS, AND VALVE TAPPETS .3-33GEAR TRAIN.3-35CYLINDER BLOCK .3-39OIL PUMP .3-43OIL PRESSURE RELIEF VALVE .3-45FILLER BLOCKS AND OIL GUARD .3-46OIL PAN.3-48ENGINE RUN-IN SCHEDULE .3-49ENGINE REMOVAL/INSTALLATION.3-50FUEL SYSTEMFUEL SYSTEM .3-53FUEL TANK .3-55FUEL PUMP AND FUEL FILTER .3-57CARBURETOR (TYPE II) (PRT) .3-59CARBURETOR (SRT) .3-66ACCELERATOR LINKAGE.3-67GOVERNOR.3-69AIR CLEANER (PRT) .3-70ELECTRICAL SYSTEMBATTERY .3-71ALTERNATOR.3-81STARTER MOTOR .3-91DISTRIBUTOR (TYPE II) .3-98COOLING SYSTEMCOOLING SYSTEM DESCRIPTION.3-103WATER PUMP.3-105RADIATOR.3-109EXHAUST SYSTEM .3-113TRANSMISSIONTRANSMISSION.3-115d

TM 10-3930-644-14&PTORQUE CONVERTER A ND PUMP .3-125DRUM ASSEMBLY .3-127CONTROL VALVE .3-129UNIVERSAL JOINT .3-131DRIVE AXLEDRIVE AXLE.3-135DIFFERENTIAL.3-142DRIVE WHEEL PNEUMATIC TIRES (PRT) .3-146BRAKE SYSTEMDRIVE WHEEL BRAKES.3-147MASTER CYLINDER.3-151WHEEL CYLINDERS .3-153PARKING BRAKE .3-153BLEEDING THE BRAKE SYSTEM .3-155POWER STEERING SYSTEMGENERAL DESCRIPTION.3-157STEER AXLE .3-157STEERING VALVE UNIT.3-163STEERING CYLINDER AND DRAG LINK.3-171TIE RODS .3-175STEER WHEELS (PRT) .3-176STEER WHEELS (SRT) .3-178aHYDRAULIC SYSTEMHYDRAULIC PUMP .3-179CONTROL VALVE .3-182TILT CYLINDER .3-185MASTS, CARRIAGES AND FORKSMASTS .3-189LIFT CYLINDERS .3-192CARRIAGES .3-195FORK .3-197WELDING REPAIR PROCEDURE .3-199SIDE SHIFTERS .3-201HOSE REEL .3-204SUPPLEMENTAL OPERATING, MAINTENANCEAND REPAIR PARTS INSTR UCTIONS.iGENERAL.1MAINTENANCE.3REPAIR PARTS SUPPLY .5e

TM 10-3930-644-14&PAPPENDIX A-L.8WARRANTY .8ASL/PLL .9MAC.10MEL CHART.25MAOSL.26MAINTENANCE OF NEW VEHICLE.28PREVENTIVE MAINTENANCE CHECKS AND SERVICES(PMCS).30BASIC ISSUE ITEMS LIST.42DISTRIBUTION CODES .44FLOW OF REQUISITIONS AND MATERIEL PARTS, NSN.

technical manual operator's, organizational, direct support and general support instructions maintenance manual (including repair parts information and supplemental maintenance and repair parts instructions) truck, fork lift gasoline engine driven, 4,000 lb.capacity, allis-chalmers model acp-40-ps mhe 234 nsn 3930-01-040-4594