Komatsu TD-40C Dump Truck Shop Manual SMTD40C98/1 E – PDF DOWNLOAD

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Komatsu TD-40C Dump Truck Shop Manual SMTD40C98/1 E – PDF DOWNLOAD

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Komatsu TD-40C Dump Truck Shop Manual SMTD40C98/1 E – PDF DOWNLOAD

Language : English
Pages :425
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu TD-40C Dump Truck Shop Manual SMTD40C98/1 E – PDF DOWNLOAD

SERIAL NUMBERS 1501 AND UP

INTRODUCTION SECTION 1
SAFETY PRECAUTIONS

1. GENERAL
The instructions contained in this service manual are for information and guidance of service personal who are responsible for overhaul and repair of the machine. In this manual, use of terms left, right, front and rear must be understood to avoid confusion when following instructions. These terms indicate sides of machine when facing forward in operator’s seat. Due to a continuous program of research and development, some procedures, specifications and parts may be altered in a constant effort to improve this machine. Some illustrations are of a general application and may not show component parts accurately in all details.

TABLE OF CONTENTS:

Komatsu TD-40C Dump Truck Shop Manual SMTD40C98/1 E – PDF DOWNLOAD

‘SERIAL NUMBERS 1501 AND UP

MAIN MENU 0
COVER 1
CONTENTS 2
1 INTRODUCTION 4
SAFETY PRECAUTIONS 5
1 GENERAL 5
2 BEFORE STARTING THE ENGINE 6
3 OPERATION 7
4 MAINTENANCE AND SERVICE 9
5 SHUTDOWN 11
SERVICE INFORMATION 12
6 PIN AND SERIAL NUMBERS 12
7 INSPECTION AND REPAIR 12
LOCTITE USAGE 13
8 SURFACE PREPARATION 13
9 APPLICATION 13
10 SETTING TIME (BEFORE PLACING IN OPERATION) 14
11 REMOVAL 14
12 APPLICATIONS AT LOW TEMPERATURES 14
STANDARD TORQUES 15
13 BOLT IDENTIFICATION CHART 15
14 TORQUE VALUES FOR STANDARD FASTENERS 15
15 SPLIT FLANGE CONNECTIONS 17
16 HYDRAULIC TUBES AND FITTINGS 17
17 HOSE CLAMP 18
SERVICE/SPECIAL TOOLS 18
18 SERVICE/SPECIAL TOOLS 18
2 COOLING SYSTEM 53
GENERAL 54
1 DESCRIPTION 54
2 OPERATION 54
3 SPECIFICATION 54
4 SERVICE DIAGNOSIS 55
RADIATOR 56
5 DESCRIPTION 56
6 REMOVAL 56
7 DISASSEMBLY 60
8 INSPECTION AND REPAIR 60
9 REASSEMBLY 61
10 INSTALLATION 62
3 ELECTRICAL 65
GENERAL 66
1 DESCRIPTION 66
WIRING DIAGRAM 66
2 ELECTRICAL TRACTOR SYTEM 66
ALTERNATOR 69
3 SPECIFICATION 69
4 INTRODUCTION 69
5 OPERATION PRINCIPLES 70
6 TROUBLESHOOTING PROCEDURES 71
7 INTEGRAL CHARGING SYSTEM REPAIR 73
BATTERY 78
8 SAFETY PRECAUTIONS 78
9 ELECTROLYTE STATE OF CHARGE 78
10 ELECTROLYTE IN TROPICAL AND ARCTIC CLIMATES 79
11 TESTING AND MAINTENANCE OF THE BATTERY 80
12 BATTERY CHARGING GUIDE 81
13 BATTERY STORAGE 82
14 BATTERY PRIMARY RATINGS 82
15 COLD ENGINE CRANKING PERFORMANCE 82
16 DRY CHARGE ACTIVATION 83
17 TYPICAL CAUSE OF BATTERY FAILURE 83
18 VISUAL INSPECTION OF BATTERY 84
CRANKING MOTOR 85
19 SPECIFICATION 85
20 INTRODUCTION 85
21 OPERATION 86
22 TROUBLESHOOTING THE CRANKING CIRCUIT 86
4 ENGINE 96
1 DESCRIPTION 97
2 SPECIFICATION 97
3 AIR INDUCTION SYSTEM TEST 98
4 ENGINE CONTROLS ADJUSTMENT 99
5 REMOVAL100
6 ENGINE REPAIR104
7 INSTALLATION105
5 HYDRAULIC TORQUE CONVERER108
GENERAL109
1 DESCRIPTION111
2 OPERATION111
3 SPECIFICATIONS111
4 SERVICE DIAGNOSIS112
TORQUE CONVERTER113
5 REMOVAL113
6 DISASSEMBLY117
7 INSPECTION AND REPAIR119
8 REASSEMBLY119
9 INSTALLATION122
6 TRANSMISSION127
GENERAL129
1 DESCRIPTION129
2 SPECIFICATIONS132
3 SERVICE DIAGNOSIS135
TEST AND ADJUSTMENT137
4 CHECKING DRIVE TRAIN OIL PRESSURE137
5 DIAGNOSTIC CHART138
6 DRIVE TRAIN CLUTCH TEST140
COMPLETE ASSEMBLY140
7 REMOVAL140
8 DISASSEMBLY146
9 INSPECTION AND REPAIR150
10 REASSEMBLY150
11 END PLAY ADJUSTMENT151
DIRECTIONAL CLUTCH PACK156
12 DISASSEMBLY156
13 REASSEMBLY159
RANGE CLUTCH PACKS164
14 DISASSEMBLY164
15 REASSEMBLY166
COUNTERSHAFT170
16 DISASSEMBLY170
17 REASSEMBLY171
REVERSE IDLER GEAR171
18 DISASSEMBLY AND ASSEMBLY171
INSTALLATION172
19 INSTALLATION OF TRANSMISSION172
MAIN REGULATING VALVE176
20 SERVICE176
RANGE SELECTOR VALVE178
21 SERVICE178
RATE OF RISE VALVE180
22 SERVICE180
23 MANIFOLD PLATE182
PILOT CONTROL VALVE182
24 REMOVAL182
25 DISASSEMBLY183
26 INSPECTION AND REPAIR OF PILOT CONTROL VALVE ASSEMBLY184
27 REASSEMBLY184
28 SERVICE OF THE MANIFOLD185
29 INSTALLATION185
TRANSMISSION PUMP186
30 REMOVAL186
31 SERVICE187
32 INSTALLATION189
7 STEERING SYSTEM191
GENERAL192
1 DESCRIPTION192
2 STEERING DRIVE192
3 STEERING VALVE192
4 HYDRAULIC PRESSURE FLOW193
SPECIFICATIONS199
5 CLUTCH BRAKE STEERING DRIVE199
6 SPRING SPECIFICATION199
SERVICE DIAGNOSIS201
7 TROUBLESHOOTING201
8 OIL PRESSURE CHECK202
9 DIAGNOSTIC CHART205
10 STEERING SYSTEM FUNCTIONAL CHECK205
STEERING DRIVE206
11 REMOVAL206
12 DISASSEMBLY212
13 INSPECTION218
14 REASSEMBLY218
15 INSTALLATION224
STEERING VALVE226
16 REMOVAL226
17 DISASSEMBLY226
18 UPPER STEERING VALVE227
19 LOWER STEERING VAVLE229
20 STEERING VALVE REASSEMBLY231
21 INSTALLATION231
STEERING MANIFOLD232
22 REMOVAL232
23 DISASSEMBLY232
24 REASSEMBLY233
25 INSTALLATION233
STEERING VALVE FEEL POINT233
26 TEST AND ADJUSTMENT233
8 SPROCKET DRIVE235
GENERAL236
1 DESCRIPTION236
2 SPECIFICATION237
3 SERVICE DIAGNOSIS237
SPROCKET238
4 REMOVAL AND INSTALLATION238
COMPLETE ASSEMBLY238
5 REMOVAL238
6 DISASSEMBLY241
7 INSPECTION AND REPAIR243
8 REASSEMBLY244
9 INSTALLATION246
PLANETARY CARRIER HOUSING246
10 REMOVAL246
11 DISASSEMBLY246
12 REASSEMBLY247
13 INSTALLATION247
PINION GEAR HOUSING247
14 REMOVAL247
15 DISASSEMBLY247
16 REASSEMBLY248
17 INSTALLATION248
9 TRACK AND TRACK FRAME ASSEMBLY250
GENERAL252
1 DESCRIPTION253
2 MAINTENANCE253
3 SPECIFICATIONS254
4 SERVICE DIAGNOSIS256
TRACK CHAIN257
5 DESCRIPTION257
6 MAINTENANCE257
7 REMOVAL260
8 TRACK CHAIN REPAIR261
9 INSTALLATION269
10 CHECKING UNDERCARRIAGE WEAR270
FRONT IDLER272
11 DESCRIPTION272
12 REMOVAL272
13DISASSEMBLY273
14 REASSEMBLY AND INSTALLATION274
TRACK ADJUSTER277
15 DESCRIPTION276
16 REMOVAL276
17 DISASSEMBLY277
18 REASSEMBLY277
19 INSTALLATION277
TOP IDLER277
20 DESCRIPTION277
21 REMOVAL278
22 DISASSEMBLY278
23 INSPECTION AND REPAIR280
24 REASSEMBLY280
25 INSTALLATION280
TRACK ROLLER281
26 DESCRIPTION281
27 REMOVAL281
28 DISASSEMBLY281
29 INSPECTION AND REPAIR282
30 REASSEMBLY283
31 INSTALLATION285
32 ARRANGEMENT OF TRACK ROLLERS286
TRACK FRAME SPRING286
33 DESCRIPTION286
34 REMOVAL286
35 INSPECTION AND REPAIR289
36 INSTALLATION289
TRACK FRAME GUIDE290
37 DESCRIPTION290
38 REMOVAL291
39 INSPECTION AND REPAIR291
40 INSTALLATION291
PIVOT SHAFT291
41 DESCRIPTION291
42 REMOVAL291
43 INSTALLATION293
TRACK FRAME294
44 DESCRIPTION294
45 REMOVAL295
46 INSPECTION AND REPAIR296
47 INSTALLATION296
48 TRACK FRAME ALIGNMENT298
EQUALIZER BAR299
49 DESCRIPTION299
50 REMOVAL299
51 INSPECTION AND REPAIR300
52 INSTALLATION300
10 HYDRAULICS302
GENERAL303
1 DESCRIPTION302
2 SPECIFICATION306
3 SERVICE DIAGNOSIS306
TEST AND ADJUSTMENT308
4 RELIEF VALVE PRESSURE TESTS308
4A PILOT SUPPLY VALVE PRESSURE TEST310
5 BLADE LIFT CYLINDER DRIFT TEST311
5A RIPPER LIFT CYLINDER DRIFT TEST312
6 CYLINDER TIME CYCLE313
7 PISTON PACKING TEST315
8 PRESSURE DIAGNOSTIC CHART315
10A PUMPS317
SERVICE DIAGNOSIS318
1 TROUBLESHOOTING318
EQUIPMENT PUMP319
2 DESCRIPTION AND OPERATION319
3 SPECIAL TORQUES319
4 REMOVAL319
5 PUMP SERVICE 321
COMPLETE ASSEMBLY321
FRONT PUMP321
REAR PUMP325
6 INSTALLATION326
SCAVENGE AND PILOT PUMPS326
7 DESCRIPTION326
8 SPECIAL TORQUE327
9 REMOVAL327
10 PUMPS SERVICE 329
COMPLETE ASSEMBLY329
SCAVNGE PUMP AND PILOT PUMP329
11 INSTALLATION330
TRANSMISSION PUMP186
10B VALVES333
BLADE PILOT VALVE334
1 SPECIFICATIONS334
2 REMOVAL AND INSTALLATION334
3 SERVICE335
RIPPER PILOT VALVE341
4 SPECIFICATIONS341
5 REMOVAL AND INSTALLATION341
6 SERVICE341
QUICK DROP VALVE346
7 SPECIFICATIONS346
8 REMOVAL AND INSTALLATION346
9 SERVICE347
BLADE TILT VALVE – STACK TYPE VALVE348
10 SPECIFICATIONS348
11 DESCRIPTION349
12 REMOVAL AND INSTALLATION351
13 SERVICE351
PILOT SUPPLY VALVE354
14 SPECIFICATIONS355
15 DESCRIPTION355
16 REMOVAL AND INSTALLATION356
17 SERVICE356
UNLOADING VALVE357
18SPECIFICATIONS357
19 REMOVAL AND INSTALLATION358
20 SERVICE 359
10C CYLINDERS361
GENERAL363
1 REMOVAL363
2 DISASSEMBLY364
3 INSPECTION AND REPAIR366
4 REASSEMBLY367
5 INSTALLATION368
BLADE TILT CYLINDER (WITHOUT PITCH CYLINDER)368
6 REMOVAL368
7 DISASSEMBLY369
8 INSPECTION AND REPAIR371
9 REASSEMBLY372
10 INSTALLATION373
BLADE TILT CYLINDER (WITH PITCH CYLINDER)373
11 REMOVAL373
12 DISASSEMBLY374
13 INSPECTION AND REPAIR376
14 REASSEMBLY377
15 INSTALLATION378
BLADE PITCH CYLINDER378
16 REMOVAL378
17 DISASSEMBLY379
18 INSPECTION AND REPAIR381
19 REASSEMBLY381
20 INSTALLATION382
RIPPER LIFT AND PITCH CYLINDER382
21 REMOVAL382
22 DISASSEMBLY384
23 INSPECTION AND REPAIR386
24 REASSEMBLY386
25 INSTALLATION387
RIPPER PIN PULLER CYLINDER388
26 REMOVAL388
27 DISASSEMBLY389
28 REASSEMBLY390
29 INSTALLATION390
CROSSTUBE392
30 SPECIFICATIONS392
31 REMOVAL392
32 INSTALLATION392
11 MOUNTED EQUIPMENT394
BULLDOZER395
1 SPECIFICATIONS396
2 REMOVAL AND INSTALLATION397
3 SEMI U BLADE399
4 FULL U BLADE403
5 PUSHARMS406
6 TRUNNIONS408
7 DIAGONAL STRUT409
8 UPPER STRUT410
9 STRESS RELIEVER BUSHING411
MULTI SHANK RIPPER413
10 SPECIFICATIONS415
11 REMOVAL415
12 FIXED UPPER LINK418
13 DRAFT FRAME418
14 INSTALLATION418
SINGLE SHANK RIPPER419
15 SPECIFICATIONS421
16 REMOVAL421
17 FIXED UPPER LINK424
18 DRAFT FRAME424
19 INSTALLATION424
PIN PULLER LINKAGE425
20 PIN PULLER LINKAGE425

IMAGES PREVIEW OF THE MANUAL:

S.M 18/12/24