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KOMATSU D40A,P-3 D41A,E,P-3 D41A-3A SHOP MANUAL SEBM0120C07 – PDF DOWNLOAD
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KOMATSU D40A,P-3 D41A,E,P-3 D41A-3A SHOP MANUAL SEBM0120C07 – PDF DOWNLOAD
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Description
KOMATSU D40A,P-3 D41A,E,P-3 D41A-3A SHOP MANUAL SEBM0120C07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D40A,P-3 D41A,E,P-3 D41A-3A SHOP MANUAL SEBM0120C07 – PDF DOWNLOAD
Language : English
Pages : 556
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D40A,P-3 D41A,E,P-3 D41A-3A SHOP MANUAL SEBM0120C07 – PDF DOWNLOAD
COVER............................................................................................ 1 CONTENTS......................................................................................... 2 01 GENERAL....................................................................................... 14 GENERAL...................................................................................... 15 GENERAL VIEW............................................................................. 16 ASSEMBLY DRAWING......................................................................... 19 SPECIFICATIONS........................................................................... 23 ENGINE ASSEMBLY DRAWING.................................................................. 27 ENGINE SPECIFICATIONS.................................................................... 29 WEIGHT TABLE............................................................................. 30 TABLE OF FUEL, COOLANT AND LUBRICANTS.................................................... 32 10 ENGINE........................................................................................ 34 11 STRUCTURE AND FUNCTION.................................................................... 34 STRUCTURE AND FUNCTION................................................................... 35 RADIATOR AND OIL COOLER.............................................................. 36 P.T.O................................................................................ 37 ENGINE CONTROL ...................................................................... 38 FUEL TANK............................................................................ 40 ENGINE MOUNT......................................................................... 41 12 TESTING AND ADJUSTING..................................................................... 42 TESTING AND ADJUSTING.................................................................... 43 STANDARD FOR INSPECTION, ADJUSTMENT AND TROUBLESHOOTING.............................. 44 TOOLS FOR INSPECTION AND ADJUSTMENT.................................................. 45 TESTING AND ADJUSTING ENGINE......................................................... 46 INTAKE AND EXHAUST ENGINE SYSTEM..................................................... 47 ADJUSTING VALVE CLEARANCE............................................................ 49 ENGINE............................................................................... 50 MEASURING COMPRESSION PRESSURE....................................................... 51 LUBRICATION SYSTEM................................................................... 52 FUEL SYSTEM.......................................................................... 55 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................... 56 COOLING SYSTEM....................................................................... 58 CHECKING AND ADJUSTING FAN BELT TENSION.............................................. 59 13 DISASSEMBLY AND ASSEMBLY.................................................................. 60 DISASSEMBLY AND ASSEMBLY................................................................. 61 STARTING MOTOR....................................................................... 62 DISMOUNTING...................................................................... 62 MOUNTING......................................................................... 62 ALTERNATOR........................................................................... 63 DISMOUNTING...................................................................... 63 MOUNTING......................................................................... 63 ENGINE OIL COOLER.................................................................... 64 DISMOUNTING...................................................................... 64 MOUNTING......................................................................... 64 FUEL INJECTION PUMP.................................................................. 65 DISMOUNTING...................................................................... 65 MOUNTING......................................................................... 66 WATER PUMP........................................................................... 68 DISMOUNTING...................................................................... 68 MOUNTING......................................................................... 70 NOZZLE HOLDER........................................................................ 72 DISMOUNTING...................................................................... 72 MOUNTING......................................................................... 72 CYLINDER HEAD........................................................................ 73 DISMOUNTING...................................................................... 73 MOUNTING......................................................................... 80 RADIATOR GUARD....................................................................... 87 DISMOUNTING...................................................................... 87 MOUNTING......................................................................... 91 RADIATOR............................................................................. 95 DISMOUNTING...................................................................... 95 MOUNTING......................................................................... 98 ENGINE (D40).........................................................................101 DISMOUNTING......................................................................101 MOUNTING.........................................................................106 ENGINE (D41).........................................................................111 DISMOUNTING......................................................................111 MOUNTING.........................................................................114 20 POWER TRAIN...................................................................................117 21 STRUCTURE AND FUNCTION....................................................................117 STRUCTURE AND FUNCTION...................................................................118 GENERAL..............................................................................119 POWER TRAIN HYDRAULIC SYSTEM (D41-3).................................................123 MAIN CLUTCH (D40-3)..................................................................125 MAIN CLUTCH CONTROL (D40-3)..........................................................129 MAIN CLUTCH LUBRICATION (D40-3)......................................................130 INERTIA BRAKE (D40-3)................................................................131 TRANSMISSION (D40-3).................................................................132 INTERLOCK MECHANISM (D40-3)..........................................................137 DOUBLE MESH PREVENTIVE DEVICE (D40-3)................................................139 TRANSMISSION CONTROL (D40-3).........................................................140 DAMPER (D41-3).......................................................................141 HYDROSHIFT TRANSMISSION (D41-3)......................................................144 TRANSMISSION LUBRICATION SYSTEM (D41-3)..............................................152 HYDROSHIFT TRANSMISSION CONTROL (D41-3)..............................................153 TRANSMISSION CONTROL VALVE (D41-3)...................................................156 INCHING VALVE AND CONTROL (D41-3)....................................................160 TRANSMISSION OIL FILTER..............................................................164 OIL COOLER BY-PASS VALVE.............................................................165 STEERING HYDRAULIC OIL SYSTEM AND OIL CIRCUIT DIAGRAM................................166 STEERING PUMP........................................................................168 STEERING CLUTCH AND BEVEL GEAR.......................................................169 STEERING CONTROL VALVE...............................................................171 STEERING MAIN RELIEF VALVE...........................................................174 TRANSMISSION AND STEERING CLUTCH PIPING..............................................175 STEERING BRAKE.......................................................................178 STEERING CONTROL.....................................................................181 STEERING CLUTCH AND BRAKE CONTROL LINKAGE............................................182 FINAL DRIVE..........................................................................184 22 TESTING AND ADJUSTING.....................................................................186 TESTING AND ADJUSTING....................................................................187 MEASURING OIL PRESSURE AND TEMPERATURE...............................................188 TESTING AND ADJUSTING TRAVEL.........................................................192 MEASURING OPERATING FORCE............................................................201 TESTING AND ADJUSTING MAIN CLUTCH....................................................204 STANDARD VALVE FOR TESTING AND ADJUSTING.............................................205 23 DISASSEMBLY AND ASSEMBLY..................................................................207 DISASSEMBLY AND ASSEMBLY.................................................................208 MAIN CLUTCH (D40)....................................................................209 DISMOUNTING......................................................................209 MOUNTING.........................................................................213 DISASSEMBLY......................................................................218 ASSEMBLY.........................................................................222 TRANSMISSION (D40)...................................................................226 DISMOUNTING......................................................................226 MOUNTING.........................................................................229 DISASSEMBLY......................................................................232 ASSEMBLY.........................................................................241 DAMPER (D41).........................................................................250 DISMOUNTING......................................................................250 MOUNTING.........................................................................253 REMOVAL..........................................................................256 INSTALLATION.....................................................................258 HYDROSHIFT TRANSMISSION (D41)........................................................260 DISMOUNTING......................................................................260 MOUNTING.........................................................................265 DISASSEMBLY......................................................................270 ASSEMBLY.........................................................................286 TRANSMISSION CONTROL VALVE (D41).....................................................304 DISMOUNTING......................................................................304 MOUNTING.........................................................................304 DISASSEMBLY......................................................................305 ASSEMBLY.........................................................................307 OIL COOLER BYPASS VALVE (D41)........................................................310 DISMOUNTING......................................................................310 MOUNTING.........................................................................310 DISASSEMBLY......................................................................311 ASSEMBLY.........................................................................311 STEERING, WORK EQUIPMENT PUMP (D40)..................................................312 DISMOUNTING......................................................................312 MOUNTING.........................................................................312 STEERING PUMP (D41)..................................................................313 DISMOUNTING......................................................................313 MOUNTING.........................................................................313 BEVEL GEAR AND SHAFT.................................................................314 DISASSEMBLY......................................................................314 ASSEMBLY.........................................................................318 STEERING CLUTCH......................................................................325 DISMOUNTING......................................................................325 MOUNTING.........................................................................329 DISASSEMBLY......................................................................334 ASSEMBLY.........................................................................336 OIL COOLER RELIEF VALVE (D40)........................................................338 DISMOUNTING......................................................................338 MOUNTING.........................................................................338 DISASSEMBLY......................................................................339 ASSEMBLY.........................................................................339 STEERING CONTROL VALVE...............................................................340 DISMOUNTING......................................................................340 MOUNTING.........................................................................340 DISASSEMBLY......................................................................341 ASSEMBLY.........................................................................341 FINAL DRIVE..........................................................................342 DISASSEMBLY......................................................................342 ASSEMBLY.........................................................................349 OPERATOR'S SEAT AND FRAME (D40)......................................................361 DISMOUNTING......................................................................361 MOUNTING.........................................................................364 OPERATOR'S SEAT AND FRAME (D41)......................................................367 DISMOUNTING......................................................................367 MOUNTING.........................................................................370 DASHBOARD (D40)......................................................................373 DISMOUNTING......................................................................373 MOUNTING.........................................................................376 24 MAINTENANCE STANDARD......................................................................379 MAINTENANCE STANDARD.....................................................................380 MAIN CLUTCH..........................................................................381 INERCIA BRAKE........................................................................383 TRANSMISSION.........................................................................384 DAMPER...............................................................................387 HYDROSHIFT TRANSMISSION..............................................................389 TRANSMISSION CONTROL VALVE...........................................................392 OIL COOLER BY-PASS VALVE.............................................................394 BEVEL GEAR SHAFT.....................................................................395 STEERING CLUTCH......................................................................396 STEERING BRAKE.......................................................................398 STEERING MAIN RELIEF VALVE...........................................................399 STEERING CONTROL VALVE...............................................................400 STEERING PUMP........................................................................401 FINAL DRIVE..........................................................................402 SPROCKET.............................................................................405 30 UNDERCARRIAGE.................................................................................406 31 STRUCTURE AND FUNCTION....................................................................406 STRUCTURE AND FUNCTION...................................................................407 UNDERCARRIAGE........................................................................408 RECOIL SPRING........................................................................410 IDLER................................................................................411 TRACK ROLLER.........................................................................412 CARRIER ROLLER.......................................................................412 TRACK................................................................................413 TRACK (SWANP SHOE)...................................................................417 SUSPENSION...........................................................................419 33 DISASSEMBLY AND ASSEMBLY..................................................................420 DISASSEMBLY AND ASSEMBLY.................................................................421 TRACK FRAME..........................................................................422 DISMOUNTING......................................................................422 MOUNTING.........................................................................424 RECOIL SPRING........................................................................426 DISMOUNTING (D40,41A)............................................................426 MOUNTING (D40,41A)...............................................................428 DISMOUNTING (D40,41P)............................................................430 MOUNTING (D40,41P)...............................................................432 DISASSEMBLY......................................................................434 ASSEMBLY.........................................................................435 IDLER................................................................................436 DISMOUNTING......................................................................436 MOUNTING.........................................................................436 TRACK ROLLER.........................................................................437 DISMOUNTING......................................................................437 MOUNTING.........................................................................438 CARRIER ROLLER.......................................................................439 DISMOUNTING......................................................................439 MOUNTING.........................................................................439 TRACK SHOE...........................................................................440 SEPARATION (MASTER PIN TYPE).....................................................440 CONNECTION (MASTER PIN TYPE).....................................................441 SEPARATION (LUBRICATED TYPE).....................................................442 CONNECTION (LUBRICATED TYPE).....................................................442 34 MAINTENANCE STANDARD......................................................................443 MAINTENANCE STANDARD.....................................................................444 TRACK................................................................................445 TRACK (SWANP SHOE)...................................................................449 TRACK FRAME..........................................................................455 RECOIL SPRING........................................................................456 IDLER................................................................................457 BEARING, GUIDE PLATE.................................................................459 CARRIER ROLLER.......................................................................460 TRACK ROLLER.........................................................................461 MEASURING PROCEDURE OF ROLLERS.......................................................463 SUSPENTION...........................................................................465 60 HYDRAULIC SYSTEM..............................................................................466 61 STRUCTURE AND FUNCTION....................................................................466 STRUCTURE AND FUNCTION...................................................................467 GENERAL..............................................................................468 HYDRAULIC CONTROL SYSTEM (D40P-3,D41E,P-3)...........................................471 HYDRAULIC CIRCUIT DIAGRAM (D40P-3,D41E,P-3)..........................................472 HYDRAULIC CONTROL SYSTEM (D41A-3A)...................................................473 HYDRAULIC CIRCUIT DIAGRAM (D41A-3A)..................................................474 HYDRAULIC TANK AND FILTER............................................................475 HYDRAULIC CONTROL....................................................................476 HYDRAULIC PUMP.......................................................................477 BLADE CONTROL VALVE..................................................................478 BLADE LIFT CONTROL...................................................................483 BLADE TILT CONTROL...................................................................485 BLADE LIFT CYLINDER..................................................................486 BLADE TILT CYLINDER..................................................................487 BLADE ANGLING CYLINDER...............................................................488 HYDRAULIC CYLINDER...................................................................489 62 TESTING AND ADJUSTING.....................................................................492 TESTING AND ADJUSTING....................................................................493 PERFORMANCE OF HYDRAULIC PUMP........................................................494 TESTING AND ADJUSTING HYDRAULIC PRESSURE OF WORK EQUIPMENT...........................496 MEASURING TEMPERATURE OF HYDRAULIC OIL...............................................498 TESTING AND ADJUSTING TRAVEL AND OPERATING FORCE OF WORK EQUIPMENT CONTROL LEVERS....498 MEASURING HYDRAULIC DRIFT............................................................499 STANDARD VALUE FOR TESTING AND ADJUSTING.............................................500 63 DISASSEMBLY AND ASSEMBLY..................................................................501 DISASSEMBLY AND ASSEMBLY.................................................................502 HYDRAULIC PUMP (D41).................................................................503 DISMOUNTING......................................................................503 MOUNTING.........................................................................503 WORK EQUIPMENT CONTROL VALVE.........................................................504 DISMOUNTING .....................................................................504 MOUNTING.........................................................................504 DISASSEMBLY......................................................................505 ASSEMBLY.........................................................................507 BLADE LIFT CYLINDER..................................................................510 DISMOUNTING......................................................................510 MOUNTING.........................................................................510 BLADE TILT CYLINDER (D40,41P)........................................................511 DISMOUNTING......................................................................511 MOUNTING.........................................................................511 BLADE LIFT CYLINDER..................................................................512 DISASSEMBLY......................................................................512 ASSEMBLY.........................................................................514 BLADE TILT CYLINDER (D40,41P)........................................................516 DISASSEMBLY......................................................................516 ASSEMBLY.........................................................................518 64 MAINTENANCE STANDARD......................................................................520 MAINTENANCE STANDARD.....................................................................521 CONTROL VALVE........................................................................522 BLADE CONTROL VALVE..................................................................524 LIFT CYLINDER........................................................................526 TILT CYLINDER........................................................................528 ANGLING CYLINDER.....................................................................530 HYDRAULIC PUMP.......................................................................531 70 WORK EQUIPMENT................................................................................532 71 STRUCTURE AND FUNCTION....................................................................532 STRUCTURE AND FUNCTION...................................................................533 ANGLEDOZER...........................................................................534 STRAIGHT-TILTDOZER...................................................................535 POWER ANGLE TILTDOZER................................................................536 73 DISASSEMBLY AND ASSEMBLY..................................................................537 DISASSEMBLY AND ASSEMBLY.................................................................538 ANGLE DOZER (D40,41A)................................................................539 DISMOUNTING......................................................................539 MOUNTING.........................................................................539 DISASSEMBLY......................................................................540 ASSEMBLY.........................................................................540 STRAIGHT-TILTDOZER (D40,41P).........................................................541 DISMOUNTING......................................................................541 MOUNTING.........................................................................541 DISASSEMBLY......................................................................542 ASSEMBLY.........................................................................542 INSTALLATION AND ADJUSTMENT......................................................543 74 MAINTENANCE STANDARD......................................................................545 MAINTENANCE STANDARD.....................................................................546 WORK EQUIPMENT.......................................................................547 90 OTHERS........................................................................................553 90 ELECTRICAL SYSTEM.........................................................................553 ELECTRICAL SYSTEM........................................................................554 ELECTRICAL CIRCUIT DIAGRAM...........................................................555
DESCRIPTION:
KOMATSU D40A,P-3 D41A,E,P-3 D41A-3A SHOP MANUAL SEBM0120C07 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding. the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and junction of each component It serves not only to give an understanding of the structure. but also serves as reference material tor troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts consisting “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when ramming. installing. disassembling or assembling each component. as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 27/12/24
