PDF Service Manual Komatsu TD-40C - 1 MB
This service manual is designed for the Komatsu TD-40C dozer, serial numbers 1501 and up.
It provides detailed, step-by-step procedures for repair and maintenance of all major components.
Technicians will find critical information on troubleshooting, specifications, and assembly.
This is the definitive guide for keeping your TD-40C dozer running efficiently and reliably.
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--- Page 3 ---
INTRODUCTION SECTION 1
Page 7
SAFETY PRECAUTIONS
Observe the following precautions:
1. Follow the correct method for starting the engine. Refer to the OPERATOR'S MANUAL.
2. Do not use the ether injector when the ambient temperature is above freezing.
3. For your own personal safety, always remove the ether container when welding, grinding
or using a torch on the machine.
4. Do not let ether come in contact with your skin, as it can cause localized freezing.
5. Do not breathe the hazardous ether vapor.
6. Keep the fluid container out of the reach of children.
7. Never puncture the fluid container or put it into a fire. Dispose of empty container properly.
8. Do not store fluid containers in the operator’s compartment.
Never mix gasoline, gasohol or alcohol with diesel fuel. This creates an extreme fire or explosion
hazard, which could result in personal injury or death.
5. SHUTDOWN
If parking on or near traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and
warning signals. Also provide advance warning signals in the traffic lane for approaching traffic.
Park the machine in a non-operating and non-traffic area. Park machine on level ground whenever
possible. Lock the transmission selector in neutral.
Do not leave the machine with the attachment raised above the ground.
In case the machine is left without supervision, interlock the gear change lever in the neutral
position and the foot brake should be applied and interlocked. The working equipment of the
machine should be positioned or supported in such a way so as to exclude the possibility
of damage or accident. Main electrical switch should be in the OFF position and key removed.
The machine should be left in such a place that it makes no obstacle for other machines working
close by.
IF THE MACHINE IS LEFT WITHOUT SUPERVISION, THE WORKING EQUIPMENT
CAN NOT BE HELD BY THE HYDRAULIC SYSTEM.
Leaving the machine, lock the cab door with key.
When the machine is to be loaded onto a transport truck and trailer do so carefully. Load only
when the trailer is level. The steel track shoes will slide easily on the trailer. When the machine
is properly positioned, chain it securely so it can not move on the trailer.
When operating in bad weather and storm lightning is nearby, dismount and seek shelter away
from the machine. Lightning will be attracted to the machine and cause serious injury or death.
DRESSTA TD-40C
--- Page 4 ---
INTRODUCTION SECTION 1
Page 17
SERVICE / SPECIAL TOOLS
1st Speed Range Clutch Bridge
Fig. 1.6. 1st Speed Range Clutch Bridge
A ..............................................................................................................................................................114 mm
B ..............................................................................................................................................................102 mm
C ..............................................................................................................................................................318 mm
D ................................................................................................................................................................25 mm
E ................................................................................................................................................................20 mm
F.................................................................................................................................................................90 mm
G ................................................................................................................................................................38 mm
H ................................................................................................................................................................50 mm
I................................................................................................................................................................127 mm
J .................................................................................................................................................................14 mm
K ................................................................................................................................................................13 mm
L............................................................................................................................ 4 slots to dimensions D and E
DRESSTA TD-40C
--- Page 5 ---
INTRODUCTION SECTION 1
Page 27
SERVICE / SPECIAL TOOLS
Bulkhead Spacer Fixture
Fig. 1.16. Bulkhead Spacer Fixture
A ...................................................................................................................................................................Plate
B ....................................................................................................................................................... Plate (2pcs)
C ................................................................................................................................................................20 mm
D ................................................................................................................................................................76 mm
E ............................................................................................................................................................... 32 mm
F...............................................................................................................................................................330 mm
G ..............................................................................................................................................................229 mm
H ..............................................................................................................................................................190 mm
DRESSTA TD-40C
--- Page 6 ---
INTRODUCTION SECTION 1
Page 37
SERVICE / SPECIAL TOOLS
Pivot Shaft Seal Tool
Fig. 1.29. Pivot Shaft Seal Tool
A ................................................................................................................................. 198 ± 0.1 mm
B .................................................................................................................................... 190 ± 1 mm
C ............................................................................................................................................40 mm
O
D .................................................................................................................................. 30 Chamfer
E ................................................................................................................................. 187 ± 0.5 mm
O
F......................................................................................................................................... 0.5 x 45
G .................................................................................................................................... 220 ± 2 mm
H ......................................................................................................................................80 ± 1 mm
I .................................................................................................................................... 50 ± 0.1 mm
J ................................................................................................................................................... R2
O
K ........................................................................................................................................ 0.4 x 45
DRESSTA TD-40C
--- Page 7 ---
INTRODUCTION SECTION 1
Page 47
SERVICE / SPECIAL TOOLS
Stress Reliever Bushing Tool
Fig. 1.41. Stress Reliever Bushing Tool
A .......................................................................................................................................... 140 MM
B .......................................................................................................................................... 114 MM
C .......................................................................................................................................... 180 MM
DRESSTA TD-40C
--- Page 8 ---
SECTION 2 COOLING SYSTEM
Page 8
RADIATOR
Fig. 2.6. Radiator Exploded View
1. Over Flow Tube 4. Top Core 7. Header Bars 10. Bottom Core 13. Gaskets
2. Top Tank 5. Header Bars 8. Spacer 11. Header Bars
3, 3a. Gaskets 6, 6a. Side Channels 9. Tie Rod 12. Bottom Tank
9. REASSEMBLY (Refer to Fig. 2.6)
1. Be sure gasket surface of cores (4, 10), spacer (8) and tanks (2, 12) are clean.
2. Set bottom tank (12) in flat position. Position new gasket (3a).
3. Set radiator core (10) on bottom tank. Position header bars (11) and secure loosely with mounting
hardware.
TD-40C DRESSTA
--- Page 9 ---
SECTION 3 ELECTRICAL
Page 6
ALTERNATOR
As the speed and voltage increase the voltage between (R2) and (R3) increases to the value
where Zener diode (D1) conducts. Transistor (TR2) then turns on and (TR1) and (TR3) turn off.
With (TR1) off, the field current and system voltage decrease and (D1) then blocks current flow
causing (TR1) and (TR3) to turn back on. The field current and system voltage increase and this
cycle then repeats many times per second to limit the voltage to the adjusted value.
If the connection between "BAT" and (R2) should become open-circuit (TR3) and (TR1) will turn
off, thus preventing high system voltage.
Capacitor (C1) smoothes out the voltage across (R3), resistor (R4) prevents excessive current
through (TR1) at high temperatures, and diode (D2) prevents high-induced-voltages in the field
windings when (TR1) turns off.
6. TROUBLESHOOTING PROCEDURES
a. Energizing speed
The energizing speed is the rpm at which the regulator turns on to energize the field coil. This
speed is higher than some speeds at which output can be obtained. Therefore, when checking
output at low speeds, increase the speed until the regulator turns on, then reduce the speed
to check the output. No output can be obtained until the regulator turns on. Once the regulator
turns on, it will remain turned on until the engine is stopped.
b. Rated voltage
The Integral Charging System output preferably should be checked at the "RATED VOLTAGE”
given below. However, it is permissible to check the output in amperes at any voltage within the
"OPERATING RANGE" listed below, since the current output will be quite close to the value that
would be obtained at "RATED VOLTAGE". The voltage should never be allowed to rise above the
"OPERATING RANGE" for any length of time.
SYSTEM RATED OPERATING
VOLTAGE VOLTAGE RANGE
24 28.0 26.0÷30.0
It should be noted that the voltage may be below the "OPERATING RANGE" if the battery is in
a low state of charge. However, as the battery receives a charge, the voltage will rise to some
value within the "OPERATING RANGE"
c. Magnetizing the rotor
The rotor normally retains magnetism to provide voltage buildup when the engine is started. After
disassembly or servicing, however, it may be necessary to reestablish the magnetism.
To magnetize the rotor connect the Integral Charging System to the battery in a normal manner,
then momentarily connect a jumper lead from the battery positive post to the Integral Charging
System relay terminal, identified in Fig. 3.6. This procedure will restore the normal residual
magnetism in the rotor.
TD-40C DRESSTA
--- Page 10 ---
SECTION 3 ELECTRICAL
Page 16
BATTERY
Voltage Chart
Estimated Electrolyte Temperature Minimum Required voltage is under 15 second load
21°C and above 9.6
16°C 9.5
10°C 9.4
4°C 9.3
-1°C 9.1
-7°C 8.9
-12°C 8.7
-18°C 8.5
If the voltage is less than the minimum specified, replace the battery. If the voltage meets
or exceeds the specified minimum, return it to service.
d. Charging low water loss batteries
Refer to "SAFETY PRECAUTIONS". If, when charging the battery, violent gassing or spewing
of electrolyte occurs, or the battery case feels hot 52°C, reduce or temporarily halt charging
to avoid damaging the battery. For best results, batteries should be charged while the electrolyte
is at room temperature (13-30)°C. Since age, state of charge of batteries vary. Time and attention
must be given to batteries during any charging process.
The charge a battery receiver is equal to the charge rate in amperes multiplied by the time
in hours. Thus a five ampere rate applied to a battery for ten hours would be a 50 ampere-hour
charge to the battery. To fully recharge a battery, you must replace the ampere-hours or ampere-
minutes removed from it: plus an extra 20% charge.
12. BATTERY CHARGING GUIDE
Recommended Rate and Time for Fully Discharged Condition
Rated Battery Capacity Slow Charge Fast Charge
Above 170 to 250 Minutes 23 hrs. @ 6 Amperes 7,5 hrs. @ 20 Amperes
3 hrs. @ 50 Amperes
Determine the state-of-charge of the battery with a hydrometer or open circuit voltmeter. The best
method of making certain a battery is fully charged, is to measure the specific gravity of a cell
once per hour. The battery is fully charged when the cells are gassing freely at low charging rate
and less than 0.003 change in specific gravity occurs over a three hour period.
When any battery is being charged, periodically measure the temperature of the electrolyte, if the
temperature exceeds 52°C, or if violent gassing or spewing of electrolyte occurs, the charging rate
must be reduced or temporarily halted.
The battery generally cannot be fully charged the fast charge method. But it will receive sufficient
charge (70 to 90%) for practical service. To completely recharge a battery, follow the fast charge
with a slow charge until to change in specific gravity occurs over a three hour period.
TD-40C DRESSTA
--- Page 11 ---
SECTION 3 ELECTRICAL
Page 26
CRANKING MOTOR
H O L D -IN
W IN D IN G P U L L -IN
W IN D IN G
G S
M B A T.
S TA R T
S W IT C H
B AT TE R Y
Fig. 3.14 Internal Solenoid Circuit ("G" and "S" Terminals Moved to Clarify Illustration)
n. Field Coil Checks
The various types of circuits used are shown in the wiring diagrams of Fig. 3.13. The field coils can
be checked for grounds and opens by using a test lamp. Grounds-if the motor has one or more
coils normally connected to ground, the ground connections must be disconnected during this
check.
Connect one lead of the 110-volt test lamp to the field frame and the other lead to the field
connector. If the lamp lights, at least one field coil is grounded which must be repaired or replaced.
This check cannot be made if the ground connection cannot be disconnected.
Opens-Connect test lamp leads to ends of field coils. If lamp does not light, the field coils are
open.
o. Field Coil Removal
Field coils can be removed from the field frame assembly by using a pole shoe screwdriver.
A pole shoe spreader should also be used to prevent distortion of the field frame. Careful
installation of the field coils is necessary to prevent shorting or grounding of the field coils as the
pole shoes are tightened into place. Where the pole shoe has a long lip on one side and a short lip
on the other, the long lip should be assembled in the direction of armature rotation so becomes the
trailing (not leading) edge of the pole shoe.
p. Solenoid Checks
A basic solenoid circuit is shown in Fig. 3.14. Solenoids may differ in appearance but can be
checked electrically by connecting a battery of 24 V a switch, and an ammeter to the two solenoid
windings. With all leads disconnected from the solenoid, make test connections as shown to the
solenoid switch terminal and to the second switch terminal, (G), to check the hold-in winding
(Fig. 3.15). Use the carbon pile to decrease the battery voltage to the value specified in Service
Bulletin IS-188 and compare the ammeter reading with specifications. A high reading indicates
a shorted hold-in winding, and a low reading excessive resistance. To check the pull-in winding
connect from the solenoid switch terminal (S) to the solenoid motor (M or MTR) terminal
(Fig. 3.16).
TD-40C DRESSTA
--- Page 12 ---
ENGINE SECTION 4
Page 5
5. Disassembly side doors and shields of engine.
WARNING! This procedure requires extreme caution. Use suitable blocking
equipment while under confines of machine.
6. Remove bolts securing oil sump shield and lower it on the ground.
7. Open valve (1, Fig. 4.4) and drain coolant from cooling system.
NOTE: In order to completely drain engine cooling system open drain valves (1, Fig. 4.5) and
(1, Fig. 4.8).
8. Remove bracket (2, Fig. 4.4) of suction tube. Loosen clamp and remove the rubber link
(2, Fig. 4.5) from the water pump.
9. Remove baffle (1, Fig. 4.6)
10. Remove bolts securing front shield (3, Fig. 4.3). Remove the shield.
Fig. 4.3. Disassembly Points. Fig. 4.4. Disassembly Points.
1. Exhaust Pipe 4. Front Shield 1. Drain Valve 3. Connector
2. Air Precleaner 5. Bolts 2. Bracket 4. Engine Front Support
3. Roof
11. Remove bolts (5) securing roof (3, Fig. 4.3) to bracket and catch (1, Fig. 4.7). Remove the roof.
12. Remove tube (2, Fig. 4.8) between air cleaner and muffler.
13. Disconnect wire from air cleaner restriction indicator switch (3, Fig. 4.8) at air cleaner tube.
14. Remove rubber link (4, Fig. 4.8).
15. Remove air cleaner assembly (5, Fig. 4.8) from the bracket.
16. Loosen clamp (1) remove bolts (2) and muffler (3, Fig. 4.9).
IMPORTANT: Turbocharger openings must be capped with correct size plastic cap. Turbocharger
openings must never be plugged with rags. This practice could introduce dirt or lint into turbocharger.
17. Remove pipes (1) and venting hose (2, Fig. 4.10).
18. Remove rod type shield (3, Fig. 4.10) of fan.
19. Remove radiator fan and remove it.
20. Disconnect water temperature gauge wire (3, Fig. 4.5).
21. Disconnect harness cables from the alternator (4, Fig. 4.5).
DRESSTA TD-40C
--- Page 13 ---
HYDRAULIC TORQUE CONVERTER SECTION 5
Page 3
GENERAL
1. DESCRIPTION
The torque converter automatically varies the output required at the tracks to meet the changing
load requirements of the machine. Engine power is transferred by the converter with little change
in torque when the load is light. When a heavy load is encountered, the torque multiplication
becomes greater, but with a resulting loss of machine speed. It is important to note that the
converter does not increase engine horsepower, but does increase the amount of torque available
at the tracks.
The converter has three basic parts (Fig.’s 5.1 and 5.2). The IMPELLER (21) is bolted to the
converter drive housing and the drive housing is driven by the engine flywheel. The STATOR (16)
is splined to the stationary ground sleeve hub and contains a row of stationary blades, sometimes
called guide blades or reactor blades. The TURBINE (13) is splined to the output shaft. These
three parts, when assembled in place, form a torque transmitting unit. This unit is filled with fluid
and held at a pressure above 345 kPa during operation to suppress vacuum pockets which form
at the blades under high fluid velocities. There is no direct mechanical connection between the
impeller and turbine or stator.
2. OPERATION
The impeller (21) draws fluid from the opening surrounding the hub and ejects it from its blades
at high velocity. The turbine (13) is positioned opposite the impeller and its blades receive the full
impact of this velocity. Fluid exits from the turbine in the opposite direction of rotation from that
of the impeller. The curved blades of the stator (16) (positioned between the impeller and turbine)
re-directs the flow back to the impeller in the same direction as the impeller is moving, completing
the cycle.
Torque multiplication is determined by the speed of the turbine in relation to the impeller. A ball
thrown at a paddle will strike it with more force if the paddle is stationary than it will if the paddle
is moving in the same direction as the ball. Similarly, when the turbine is rotating as fast as the
impeller, the fluid passes easily through the turbine applying little or no force to the blades. As the
output shaft slows down, the fluid strikes the turbine blades with more force. The maximum striking
force of the fluid is reached when the turbine is stopped. This occurs in the machine when the
output shaft is stalled by a heavy load.
The reservoir for the torque converter fluid is in the rear main frame. The flow from the reservoir
to the converter and from the converter back into the lubricating system is covered in Section 6,
"TRANSMISSION". Also covered in Section 6 is the procedure for checking the pressures in the
transmission / converter circuit.
3. SPECIFICATIONS
Special Bolt and Nut Torque Data
Universal joint mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 to 275 Nm
Torque converter mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Input drive cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 60 Nm
Drive housings retainer plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 90 Nm
Spur gear mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 to 130 Nm
Rear bearing retainer mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 60 Nm
Yoke retainer flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 60 Nm
Drive housing to impeller housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 to 130 Nm
Torque converter leakage rate (high idle neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 9.5 lpm
DRESSTA TD-40C
--- Page 14 ---
HYDRAULIC TORQUE CONVERTER SECTION 5
Page 13
TORQUE CONVERTER
4. An output shaft end gap of 0 to 0.1 mm must be maintained in the converter assembly. Proceed
as follows for checking and obtaining the proper end gap (Fig. 5.22).
Be sure bearing (29) is bottomed on hub (2). Install virgin lead (~ 1.5 mm thick) on
outer bearing race. Install retainer (31) and gasket (30), (DO NOT install shims) and
tighten mounting bolts to standard torque. Remove retainer (31) and compressed
lead. Carefully measure thickness of compressed lead with a micrometer. This
measurement, less 0 to 0.1 mm, is amount of shims (33) to be installed between
output shaft bearing and retainer (31, Fig. 5.23). Install retainer (31) with gasket (30)
and secure with hardware. Torque to specifications.
NOTE: Shim pack should never be same or greater than thickness of gap measurement
(compressed lead).
Fig. 5.24. Installing Flange
5. Install output flange (26, Fig. 5.14), flange retainer (25) and lock plate (24) and secure with
bolts. Bend up tabs of lock plate (24) after torquing to specifications. Press bearing (3) into
gear (22) until it bottoms. Secure gear (22) to impeller (21) with hardware and torque bolts
to specifications. Bend up tabs retainer plate
6. Place housing (11) on bench with gear up. Position bearing (12) in bore of housing (11) so that
retaining ring end is up. Drive bearing into bore until retaining ring bottoms. Turn housing (11)
over and position turbine (13) inside housing (11) so that hub of the turbine enters bearing (12).
Tap turbine (13) into bearing being careful not to drive bearing out of housing (11). Position
bearing (19), thrust ring (18) in turbine (13). Be sure pins (17) are in position in stator (16).
Position stator (16) in turbine (13) so that pin (17) engages ring (18). Position ring (18) on
stator (16) so that it engages pin (17). Place bearing (19) on ring (18). Position impeller (21)
over turbine (13). Secure impeller (21) to housing (11) with bolts (21A) with washer (21B) and
torque to specifications.
7. Turn complete assembly over so that gear (22) is down. Secure a hoist as shown in Fig. 5.4 and
lower assembly into housing (4). As assembly is lowered into housing (4), splines of stator (16)
will engage with splines of hub (2); then splines of turbine (13) will engage splines of shaft (27)
and finally, gear (22) will mesh with gears (7). If at any point when contact is made, hoist sling
becomes slack, place a slight strain on sling and rotate housing (11) to engage properly, then
continue to lower assembly onto housing (4).
DRESSTA TD-40C
--- Page 15 ---
TRANSMISSION SECTION 6
Page 3
Fig. 6.1. Hydraulic Oil Flow with Transmission in Third Reverse
DRESSTA TD-40C
--- Page 16 ---
TRANSMISSION SECTION 6
Page 13
COMPLETE ASSEMBLY
NOTE: When disconnecting hydraulic lines for any reason, they should be properly capped with
correct size plastic cap. If these caps are not available, tape or clean rubber corks may be used.
Hydraulic openings must never be plugged with rags. This practice could easily introduce dirt or lint
into critical hydraulic components of machine. Tag all disconnect oil lines to facilitate installation.
WARNING! Turn master switch to OFF position and remove key or remove one of
cables from battery to prevent accidental starting.
2. Unscrew ten bolts securing shield ROPS. Remove shield (Fig. 6.5). Disconnect cab panel electric
connector (4, Fig. 6.7) from platform. Unscrew bolts (1, Fig. 6.7) securing the cab. Remove cab
using a hoist (Fig. 6.6).
Fig. 6.5. Disassembly Shield ROPS Fig. 6.6. Disassembly Cab.
Fig. 6.7. Platform Fig. 6.8. Mounted Equipment Steering
Disconnecting Points
1. Bolts 4. Electric Connector 1. Return Hose 6. Ripper Pilot Valve
2. Plate 5. Bolts 2. Control Hoses 7. Control Hoses
3. Armrest 3. Blade Pilot Valve 8. Return Hose
4. Supply Hose 9. Ripper Pin Puller Valve
5. Supply Hose 10. Hoses
DRESSTA TD-40C
--- Page 17 ---
TRANSMISSION SECTION 6
Page 23
COMPLETE ASSEMBLY
3. Apply Loctite #515 gasket (purple color) eliminator to flange surface of cover. With input (11) and
output (32) manifolds and countershaft (14) cover removed from case, lower housing over cover
assembly guiding upper end of three shaft assemblies into their respective bores in case until
mating surfaces of housing (6) and cover (1) are contacting each other. When case and cover
flange surfaces are in full contact and dowelled together, install and torque case and cover bolts to
75 to 88 Nm.
4. Install baffle (37) bolts through case using special copper washers.
Fig. 6.31. Reverse Idler Gear Installation
1. Mounting Bolt 4. Rear Cover
2. Spacer 5. Reverse Idler Gear Assembly
3. O-ring (Shaft and Tapered Bearings)
11. END PLAY ADJUSTMENT
Directional Clutch
1. Assemble an oversize shim pack of 4.32 mm from shims (12) and position on manifold (11).This
will give an excess end float condition. Install directional shaft manifold (11) with oversize shim
pack, being sure to align pilot dowel in manifold with slot in manifold. Do not install O-ring (13) at
this time.
NOTE: Direction shaft assembly must have its bearing cones pressed solidly against its respective
shoulder before end play (float) is adjusted.
2. With orifice plug still removed from direction shaft place a 90 mm diameter x 6.5 mm thick plate
over end of directional shaft to act as a pusher plate. Place a 250 mm puller bridge across two
aligning manifold mounting holes. Install the puller bridge as shown in Fig. 6.32 utilizing the two
selected manifold mounting bolt holes. Torque the pusher screw to 108 Nm. Then remove the
puller bridge and pusher plate.
DRESSTA TD-40C
--- Page 18 ---