‘'SEBM0120C07 DITOR IMTANINTUANILs KOMATSU D40A.P-3 D41A.E.P-3 D41A-3A MACHINE MODEL _ SERIAL No. D40A-3 60001 and up D4o0P-3 60001 and up D40PL-3 60001 and up D40PLL-3 60001 and up D41A-3 60001 and up D41E-3 60001 and up D41P-3 60001 and up D41A-30 60001 and up © This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. ‘© 40 - 41-3 mount the 6D105-1 engine. For details of the engine, see the 105 Series Engine Shop Manual. ©1994 KOMATSU Al Rights Reserved 00-1 Printed in Japan 11-94(03)0000001 10 20 30 60 70 90 00-2 CONTENTS No. of page GENERAL .... ee eee . 1-1 ENGINE 11 STRUCTURE AND FUNCTION ......... eee ital 12 TESTING AND ADJUSTING....... eee ee e124 13. DISASSEMBLY AND ASSEMBLY ......... ee Se 1ael POWER TRAIN 21 STRUCTURE AND FUNCTION ... ee 2 214 22 TESTING AND ADJUSTING...... = 22-1 23 DISASSEMBLY AND ASSEMBLY 23-1 24 MAINTENANCE STANDARD . : 24-1 UNDERCARRIAGE 31 STRUCTURE AND FUNCTION .... Se see 81 33 DISASSEMBLY AND ASSEMBLY . 33-1 34 MAINTENANCE STANDARD . 344 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION . . 61-4 62 TESTING AND ADJUSTING..... 62-1 63 DISASSEMBLY AND ASSEMBLY . 63-1 64 MAINTENANCE STANDARD .... 64-1 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION wee T11 73 DISASSEMBLY AND ASSEMBLY ceeeseee 7341 74 MAINTENANCE STANDARD ........ 74-1 OTHERS 90 ELECTRICAL SYSTEM = 90-1 D40- 41AP.3The affected pages are indicated by the use of the following marks. tis requested thet necessary actions [yay a one must be taken to these pages according to the list below. © | Page to be newly added | Add @ | Page to be repla Replace () | Page to be deleted Discard Pages having no marks are not revised at this time. LIST OF REVISED PAGES Mark Pages Romper | Mark Pages ROO" | sank Pages FEVHIOM Taran, pages REVO” | tan. pages Rison © 00-1 ® ee 13:25 © 24 © 214-43 © 02 © 21 @ 1328 © 25 © 2-46 2 002-1 23 0 1327 2-8 Oo 2145 © 0-220 24 © 1328 ® 27 245-1 @ © 023 @ 25 @ 13-29 © 21-8 21-45-2 @ 00.3 26 O 1330 a9 2148 © 00. 27 oO B32 O 21-10 214641 © 00-5 ze Oo 333 0 zen 2087 @ 00. 6 2s oO ne O 2u12 2148 00. 7 210 1335 2113 | 2x40 00. 8 21 336 © zie 2150 © 00. 9 22 @ 1337 2115 251 00-10 213 1338 2116 2152 © 0 @ zu 1339 © 2017 21524 @ od @ 12-15 © 13-40 © 21-18 2163 @ 2 @ 216 O 1341 ane 2154 @ 1.3 @ 2417 @ 132 © 21-20 2155 4 @ 28 O 343 221 2156 1-5 @ 1219 0 1348 222 287 O 6 @ 21 Oo 1345 223 2158 06-1 @ 23 @ 1348 2248 @ 2159 @ 062 @ w4 Oo 347 21241 © 2460 0-6-4 25 O B48 2125 2061 01-65 @ %6 @ 1349 @ 21-26 2142 @ 01-6-6 @ 327 © 1350 © 21-27 21463 @ 7 @ 38 0 1351 O 2128 @ 21 Oo 9 @ 39 0 1382 21.29 23 @ a0 @ 1310 -O 353 21-30 24 © 01-11 @ 13-11 ® 13-54 © 21-31 22-5 @ 01-12 @ 1312, © 13-55 © 21-32 2-6 @D 01-13 © 13-13 @ 1356 @ 21:33 @® 27 @ 01-14 © 13-14 © 1357 @ 21-34 2-8 @ 15 © 1318 O 1358 © 2135 @ 22 o 0 1317 1359 2138 @ 20 © 1 oO 1318 B80 0 237 22.01 © a2 B19 1361 © 21-38 2102 © 11-3 1320 © lea eee 2139 © 21 © Ww 1321 © 2-1 @ 240 @ 22-12 @ is 32 O 22 © 21 ® 2.13 me 1324 23 © 242 24 O 40-41 AP-.3 00-2-1Mark Poses Fomoor [Mark Pages Fever | wai Pages RVs | mark pages FeVBlOn | tare Pagen Revision 22:15 @ 2353-1 © 23-107 © 23-165 @O 33-3 @ 218 @ 23532 © 23.108 © 23.168 a4 0 2.17 @ 23533 © 23.109 © 2187 BS 0 22.174 © 23534 © 10 © 23.168 © 36 Oo 218 © 254 © 211 O 23.169 O a7 o 219 © 2355 © 2112 2.170 38 © 21D 2356 © 23-113 D 23-171 @ 339 @ 23 © 257 O 14 O 23.172 3310 34 O 2358 © 215 O 2173 ® Bn 9 235 © 2359 @ 23-116 @ 23-174 © 33-12 @® 26 © 60 23117 © 23.175 O 3213 27 @ 2381 © 2118 © 23.178 a4 2a © 262 © 2119 © 217 215 39 @ 23-63 @ 23-120 @ wo ® 33-16 @ 10 2364 2.12 © m1 @ a7 21 O 26 © 2.129 © m2 ® 3318 212 @ 265 23-124 © ma 3 @ 220 @ 24 O 287 © 23-125 m4 @ 22D 245 2368 © 23.128 © 2 51 @ 3322 2316 @ 23-69 @ 23-127 @ @ 62 @ 33-23 @ 23-17 © 2370 © 23-128 © uw 6 @ 33-24 @ 2318 an © 23.129 © “7 ® 32 0 219 Br o 23.130 © ma 71 ® 30 232 © 273 23.182 © me @ 1 ® 2321 2m @ 2.133 O 2% 81 @ 2 o 2322 © 215 © 214 © 2% 82 @ 32-1 @ 2323 @O 23-76 OD 23-135 @ 2% 10 @ 342-2 @ 2324 © 277 O 23.138 © m1 3 2325 278 O 2137 © a2 @ 33-1 23-26 O 23-79 O 23-138 OD 24130 © 4-3-2 @ 2327 2380 © 23.139 © m6 @ 3633 @ 2328 © 281 @ 20 © 15 @ 3-4 @ 23-29 @ 23-82 OD 23-141 OD a6 @ 344 2330 © 2383 © 23-142 © 24- 16-1 @ 34 5 2331 © ne O 218 © 24 162 © 36 @ 222 © 2388 © us 17 @ u7 @ Ba © 2387 © 23105 © ma O ae @ 234 © 2388 © 23.48 O a1 ® 2 @ 2335 OD 2389 @D 23-148 @ 24-20 © 34-10 ® 23-36 @ 2390 OD 23-149 © a 21 © 3411 @® 2338 © 291 © 23.150 @ a. 0 2 O 2339 @ 22 © 20.151 @ 1 @ 3413 @ 2340 2393 © 23.182 © 3-2 @ ae 241 2394 © 23.153 © a 24 3615 242 © 2395 © 23.158 © a 3 ® 3418 @ 2343 2398 @ 23.155 © at 4 8-0 23-44 OD 2397 O 23-156 © 31. 5 61-1 ® 2345 298 23.187 © 3 6 6-2 @ 2348 299 © 23.158 O a. 7 3 ® 23-48 © 23-100 © 23-159 @ 3-8 @ 61-3-1 @ 2349 © 23.101 © 23.160 © 3 81 @ es @ 2350 © 23.102 © 23.161 Br 82 @ os @ 2351 © 23.103 © 23.182 © ar 83 6-5-1 ® 2382 © 23-106 © 23.163 © ar 9 6.5.2 @ 253 © 23.106 © 20-166 B10 6 00-2-2 D40-41AP.3ison Revision wae Pages Pion Tan, pages Pevton Tsar. Pages Revision 645 @ 7-0 @ 7-1 @ m2 fee eo) m1 © 3-3 @ 34 @ 325 © 36 @® 37° @ 38 @ 39 @ a0 @ m1 @ #2 @ me o ma O m6 @ a6 ® m7 ® 9-0 @® © 01 ® (80.2) oM3 ® 004 @ 0-2-3 40-41 AP-3Ay important sarety NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this ‘manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols AM and “A cautions in this manual. The cautions accompanying these symbols should always be followed carefull. f any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. are used to mark safety pre- A SAFETY GENERAL PRECAUTIONS rakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. ‘« Always wear safety glasses when hitting parts with a hammer. * Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work, 4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the ‘machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned, ‘Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13, Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct Places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not, to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fires, 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘© When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24, Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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 sec STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for 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 correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, 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. NOTICE ations contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series joe Each issued as one Attachments volume hapenhehatelal models ‘These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any work FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page ‘umber. Example 1 (Chassis volume} 21-3 Unit number (2. Power train) tem number (1. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume) 12-410 Unit number (1. Engine) ter number (2. Testing and Adjusting) Group No. (4. Fuel syste) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page ‘number. File as in the example. Example: 21-4 12-203 21-41 12-203-1 21-4.2-}— Added pases —["2°203-2 21-5 12-204 00-6 REVISED EDITION MARK (O@@--) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol | fem Remarks Special safety precautions are A necessary when performing the work Satety Extra special safety precautions are necessary when performing the work because itis under internal pressure. ‘Special technical precautions or other precautions for IK | Caution | preserving standards are necessary when performing the work. Weight of parts or systems. Caution necessary when ‘Weight | selecting hoisting wire, or when working posture is important, ete. Places that require special ng t0rave) torque during assembly. Places to be coated with Coat | adhesives and lubricants etc. Places where oil, water or fuel Oil, water | must be added, and the Gz |, Tighten: | attention for the tightening — ‘a capacity. Places where oil or water must Drain | be drained, and quantity to be drained.HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ay Peavy parts (25 kg or more) must be lifted with @ hoist etc. In the Disassembly and As- sembly section, every part weighing 25 kg,or more is indicated clearly with the symbol 1. If @ part cannot be smoothly removed from the ‘machine by hoisting, the following checks should be made: © Check for removal of all bolts fastening the part to the relative parts. © Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "2" or “S” twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 10 112 14 125 16 14 22 16 28 18 36 20 44 224 56 30 10.0 40 18.0 50 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wite ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and @ serious accident can result. Hooks have maximum strength at the middle portion, bhea 100% «88% 1% 41% Fs008e 3} Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. A, Sinsing with one rope may couse turing of the load during hoisting, untwisting of ‘the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when. hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force 28 large as 4000 kg if they sling a 2000 kg load at alfting angle of 150° A&A i ml fe A i+ 1 a 00-7STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of Disassembly and Assembly”. eens Thread diameter Width of bolt across flat (mm) (mm) kgm Nm 6 10 1.354015 | 13.2414 8 13 32403 31.4429 10 7 67207 65.7+68 12 19 11.5210 112498 14 22 18.020 177419 16 24 28543 27929 18 27 3944 38339 20 30 56+6 549 +68 22 32 768 745+78 24 36 94.510 927498 27 a 135415 1320140 30 46 175+20 | 1720%190 33 50 225+25 2210240 36 55 280+30 2750+290 39 60 335435, 3280+340 —L This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): 1Nm 1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flenge bolts. Thread diameter Width Tightening torque ‘of bolt across flats (mmm) (mm) kgm Nm 10 14 67407 65.7468 12 7 11841 112498 16 22 28.543 279429 00-8STANDARD TIGHTENING TORQUE . TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. ‘Sealing surface = ‘Thread diameter | Width across flats Tightening torque of nut part ‘of nut part (om) (om) kgm Nm 14 19 25205 245249 18 24 542 49196 22 27 8x2 7854198 24 32 1423 137.3294 30 36 1843 176.5+29.4 33 a 2025 196.149 36 46 2525 245.2449 42 55 30+5 294.249 ‘The recommended costing materials prescribed in Komatsu Shop Manuals are listed below. COATING MATERIALS 7 —- Nomenctoure Konan ode Applestone ura Uses sp ter pads uber gst nd con pan. Used to apy rem bbe, maison ire tomes prs whens oot Sete Sais ee Adhesives rh So ais ene. ue Preventing bts, its and lis fom losenng a ain : Provides an th eleteay nslting sa — Used for aluminum surfaces. ie ‘sed with gbket and packings oerease seating ert we Hestesstont gate for precombustin chambers and esha ping Lui pnt ae Used ts on mouning sac ni ave ard waramision cass Cimento 8388 mt Used fees sen rease Tenge. tpeed sre Frings od apred ore G5 fittings in hyGraulic circuits of less than 50 mm in diameter. Taticaonconpoond ‘Appl wo berngs ane taper sats eitae pee ting anda neat nc wwe Anionic Bren stg Being org. Grane ; Tepe bear, ing pars aa ls or ubcavon Wk (Lithium grease) = ‘Prevention and facilitation of assembling work. Vesene = Use or protecting ete eecrode temas fom crosion “LT-2is aso caled LOCTITE inthe shop manuals, 00-9ELECTRIC WIRE CODE aesH GL In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. ELECTRIC WIRE CODE ‘This wire code table will help you understand WIRING DIAGRAMS. Example: SWE indicates a cable having a nominal number 5 and white coating with black stripe, CLASSIFICATION BY THICKNESS oer Pees as CLASSIFICATION BY COLOR AND CODE Pree | casa Charging | Ground Starting Lighting | Instrument Signal Other 2 Color} White & Red - Black & White | Red & White | Yellow &Red | Green& White | Blue & White a a 7 : ‘uxi-| Color] White & Black | — [Black & Yellow] Red Black | Yellow & Black | Greon&Red | Blue& Red . Color] White SB | — | Biock&nea | Red Votow |Yelow & Green| Green & Yeiow] Sue & Yalow : Color | White & Green = = Red & Green | Yellow & Blue | (Green & Black) | (Blue & Black) — Code = = = RL Yw (Gu) = = Color | - = - Red & Bie | Yellow & White | (Green & Blue) = 00-10SHOP MANDAL D40-41A,P-_s O1 GENERALD40-41A,P-3 GENERAL General view ..... Assembly drawing ‘Specifications ee Engine assembly drawing ....... Engine specifications. . Weight table os Table of fuel, coolant and lubricants or 2 os Or 6a ors ont oni2 onaGENERAL VIEW GENERAL GENERAL VIEW D40A-3 Blade Head lamp Exhaust pipe Cap for air cleaner Lift eylinder Sprocket Carrier roller Track roller Idler ‘Track shoe 124P001 Daop-3 Blade Head lamp Exhaust pipe Lift eylinder Cap for air cleaner Sprocket Track roller Carrier rolter Idler Track shoe Beomxogpena 124P002 01-2 40-41 AP-3GENERAL GENERAL VIEW D4a1A3 Blade 9. Head lamp 3. Exhaust pipe Cap for air cleaner Lift eylinder Sprocket ‘Track roller 3. Carrier roller Idler Track shoe Bepxsemsenan Da1p-3 Blade Head lamp Exhaust pipe . Lift eylinder (Cap for air cleaner Sprocket . Track roller Carrier roller 9. Idler 10. Track shoe Px ogeeya 1247004 D40+41 A,P-3GENERAL VIEW GENERAL D41A34 1. Lift eylinder 2. Fuel tank 3. Track shoe 4, Sprocket 5. Track frame 6. Blade frame 7. End bit 8. Cutting edge 9. Blade 01-4 40-41 AP-3GENERAL ASSEMBLY DRAWING ASSEMBLY DRAWING D40A-3 2706- Lal a8 B Fiz0coo! Daop-3 920 240. D40-41 AP-3 01-5 ®‘ASSEMBLY DRAWING GENERAL D41A3 2180. Oo cI 1540 2250. I D41P-3 F120co03 d fees ig L—ze0 eae Fi20coos 01-6 D40+41 AP-3GENERAL ASSEMBLY DRAWING D40PL-3 124F009 D40PLL-3 a 1500 40-41 A,P-3 @ASSEMBLY DRAWING GENERAL DAES —- D41A-3A, B ES EG / —=PsOT. St ( t z i ve —|A aa } ae a§ @ le e- Val fa = 4 & - Fizocis6 (): with 9 ft, wide blade 01-6-2 D40-41 AP-3 @‘SPECIFICATIONS GENERAL SPECIFICATIONS D40AP-3PL-3,PLL-3 D4IA.EP3 41430, Mechine Mode psoas | oaors | baorta | oaorita | oaaa Serial Number 6001 and up | 6001 and up | 6001 end uw [600% end up | 600% and uP (Operating weight with workequipment) ka | 9800 | 10620 | 11400 | 12100 | 9.600 Tractor weight to | 2390 9.000 | 1000 | tos10 | 2,90 Overall ength ith bags) mm | 4.250 505 | 4630 | aso | 4250 (hou ada) mm | 3410 sss | 357 | 3e05 | 2410 (Overall width ith blade) mm | 3.180 302s | aoa | 4650 | 3.100 {without bade) mm | 1.940 2480 | 3480 | 4.00 | 1,940 5 | ovr aioe tooo operator set mm | 2,005 2028 | 2028 | 2025 | 2,005 Ground elaarancs mm | 360 430 420 420 360 “Track gauge mm | 1.540 1760 | 2260 | 2540 | 1500 Length of rack on ground mm | 2,060 2800 | 2500 | 2850 | 2,060 Shoe width mm | 400 vo | 120 | 1500 400 Ground pressure with work equioment kglem? | 0.69 028 ose ona 089 Ground presure ony tractor alent | ot 028 016 ox2 ost Forward tt rom | 28 25 25 25 24 2nd tmm | 32 32 a2 a2 44 ar tom | 48 45 45 45 18 i amy tm | 62 68 63 68 . sli sh nm | 827 a a7 87 - B|Elpewe ie mm | 30 30 30 30 30 ; ad wom | 38 a8 38 38 5s ar km | 53 83 53 53 oa at tm | 80 80 80 80 . Min, turning raion m| 7305 | 7500 | oa an | 7305 Gradenbtty ogre 30° stabil ears a Note: Figures in parentheses marked ( _) denote the minimum turning radii of bare tractors. 01-6-4 D40+41 A.P-3. @GENERAL SPECIFICATIONS. paisa | oates | patra {6001 end up [600% ena up | G00t and up 10,700 | 10300 | 10620 9020 | 3760 | 9,000 4500 | 43s | 4505 sao | 34t0 3.595 260 | 2730 | 3025 2i60 | 140 | 2480 2705 | 2.795 2818 2005 | 2005 20025 380 360 430 1760 [140 1.760 228 | 2206 2,590 400 400 720 060 oss 028 ost 049 0.26 24 24 2a 4a 4a 4a 18 18 78 30 30 30 55 55 85 94 94 94 73 [| 7500 | 7500) 30° a8 40-41 A.P-3 01-6-5‘SPECIFICATIONS GENERAL Machine Moga Daons aor Deore DAOrLLS Ser Nom 00% ond oP Wain catch ie, double cn, ovecent engnerent with ria brake, Rendoperaed «| Tension Spur ger, seceding, Fandoperate, Spat ubiaton, 5 forward, A reverse womeds 5 [eve erste Spiel bevel er, Spleh lubrication J | seri cuch Wot, mltinledis, hanchoperated with hvereule booster Sterna bake Wa, contacting band, hand nd foot operated, interconnected with stewing ich Final ve Spur gar, double reduction, Sah lubrication Suspension Oration woe, eqalizr bar Corie ol ‘re each a Track roller Five (each) ‘Six (each) T ‘Six (each) ‘Seven (each) 2 Track shoe Single groner soe Swamp shor Swomp shoe Snare shoe feo srs | any sstochsin | suns 3] pitch mam 15 178 178 wien oom 400 120 1220 1.500 Grose hight mm 0 os as 5 Tyee ‘nciedorr Sveighe a doer “it: Manual ausment “Tit: dali contro by slender ht side trace length _, [Rate vae setting 210 koe [reruns cymaer Doubles, pitonvee 3 Contol valve ‘Spool type ‘Spool type =| Poston Lit eytindr: a, ol Lit evtindr: Rais, old, tomer an let 3 i {FI Shinde: Fugt old and et rau ame hn 2.380,om ave tank Eavipped with exera contol valve Fediotor cor Davee ; Max. ting anc 388 920 318 1056 2] E| dese? a6 240 x5 20 55) FS erunes 81 stax sting - a |_| Gitance "mm 3 yeoman a a co] 2 ade height 780 00 500 580 | Btedeede ante s 88 86 86 01-6-6 D40-41 A.P-3GENERAL SPECIFICATIONS Machine Mods! | datas DaTAgA Dates Dae Sera Nembers | 6001 and up Main eutch Wier, spring fition Ta Manual adjustment ‘of brace ingen frit: Hydrauic control by tikteylinaer (ight ede) «| Teninin ry ray eed fren enon oon Cano ET eowioursnt Sola bt er oh ion Ese aun Tie mle, hd oprd ih yrs Door . ‘Steering brake Wet, contracting band, hand and foot-operated, interconnected with steering clutch Fin Se Severo a er One we Trek oer Fi es) rs) Fie ea tea Ere re er ry i No of shoes 37 (each side) 39 leach side 39 loch side) 43 (och ide) | . 1% 8 115 oe oo oo «0 no roses neat mm - 0 so te Te Tadcca | Power sng aan Soar Tilt Hydraulic contol by tlt eylinder (right sie) Angle: nydraule control By angle evinder __ | elie wave siting 2i0 kale E [ Hvaroutic evinder Doute-ctng, piston type Z| conor Oneso0! “Threespoo! Twospo0! =| Position Litt eylinder: Rake, hola, Litteylinder: Raise, nold,| Lift cylinder: Ralse hold, lower and float, 2 Tower snd fos i ‘i Tit elinder: Right, hol and itt Hvdiauie par {8 min. ot 2.360 rom) Hydraulic tank Eauipped with externa contra valve Rediator core Davee “om gona ce om oad 2 i Max. dowring || Soe a8 205 436 40 EL€| (trom ground) Siz z i 460 330 (365) 500 480 | | stosewiaes 3,180 72580 (2988) 270) 3,028 j| eenoom 750 840 890 890 | Side edge ance 35 58 ss 6 (with 9. wide blade 40-41 A.P-3 01-7GENERAL ENGINE ASSEMBLY DRAWING ENGINE ASSEMBLY DRAWING \ Fuel niet Right side view F120c00s 40-41 A.P-3 01-9ENGINE ASSEMBLY DRAWING GENERAL 40-41 A,P-3GENERAL ENGINE SPECIFICATIONS: ENGINE SPECIFICATIONS Engine Model 601051 Mounted Mechi pao pats Type Water-cooled, 4cycle,direct-injection No.of eylinder — Bore x Stroke mm 6 105% 125 Piston displacement © 6,480 Firing order 1-5-3-6-2-4 fleciess = rv E | Overall width mm 780 é & | Overa height (Flywheel housing to lr cleaner) mm 12a dt Flywheel horsepower HP/pm 93/2,350 | Mox tore kam/rpm 37/1;300 40/1,500 E | win, fuel consumption ratio a/Pih 170 £ é rem 2,520 — 2,620 2,620 — 2,720 rom 700 - 750 700-760 Dry weight kg 610 590 Fuel oit ‘ASTM D975 No. 1 and No. 2 Fuel pump Bosch type PESA Governor Bosch RSV centrifuga, all speed type Oil capacity 2 2 Coolant capacity 2 35 Baring motor PAV EBRW Alterantor 2AV 258 Battery 24V (12V x2) — 120Ah 40-41 AP-3 01-11WEIGHT TABLE GENERAL WEIGHT TABLE Unit ko ‘Mactine Modet DaOAS (40-3, D40PL3, DAOPLLS Serial Numbers 600% and up Engine and main clutch aeembiy 756 Engine only (ary weight) 610 Main clutch only (ry weighe) 142 FRadiotor guord ssembly (onc. radiator mask 30 a7 Faidator anombly eo Fuel toni (empev) 710 “Traneminion ably 73 Shifter fork assembly 51 Bevel gear shaft ond steering clutch ewembly 161 Steering clutch assembly (aach) 35 Final ive ease and sprocket eesmby (ech) 385 6 Sprocket (each) a Final rive cas (cach) a2 368 Sprocket shat (eoch) as 478 Sprocket hub and 2nd driven gear asembly o n ‘Steering case and main fare 870 quatizer bar assembly 0 m5 “Track shoe assembly (each) 785 1,098 Link asombly (each) 419 498 “Track frame asembly 22 7086 {ler assernby (ech) 150 Corres roller assembly (one nit) ‘0 “Track roller asembiy Sinae flange (one unit) 4s Double lenge (one unit 50 Recoil spring assembly (each) 108 7 “Track frame only (each) m 380 Hydraulic tank onembly 3 {Gi evlinder assembly (each) 34 Tuveyinder assembly (ach) = 3 Bade (enel. cuttng edge and end bits 60 630 Dozer frame Cteame: 418 "ram: 131 teseh) nine underovard| oa ‘Transmission underguad oe ‘Operator's seat and box assembly 130 Operators vest assembly only 335 Battery (one unit) “4 ‘Conopy ssembly 68 01-12 40-41 AP. @GENERAL WEIGHT TABLE ait: kp Machine Mode pains oars Seril Numbers Cory Engin end damper asembly 626 Engine ony (dry wah) 590 Demperasemby 36 Fedor guard esembly (ond rditor meat) 310 37 Fdiatr assembly Fost onk empwv 110 HYOROSHIFT transmission sembly 380 Bevel gor shaft ond sering ich axerbiy 168 Steering clutch amey esch) 5 ‘Sterng contol valve over anebly @ Final drive cas nd sprocket esemby (ech) m8 08 Sprocket coc a Final deve cas (each) 2 se Sprocka hat (ach) a6 we Sprocket hub an 2nd ivan gear avembly o n Steering cove and main frame 70 Eauatzer bar exembly 20 m5 “rack show esembly cach) 785 1088 Link asembly (ech) a0 409 “rack frame osembiy 922 1046 later asembiy(coen) 180 Corie ole asembty (oe unit) “ “rock roller esombly Single flange (one unit) 4 Double lange fone une) so Reco sring assembly (each) 106 a “rack trae only (each) m a Hydraulic tank eerbiy % [Ut eytinder asl (each Es Tit eytnde assembly (och) - 2 Boe (ene. eating edpe and end bie 460 30 Doser trae frame: 418 {rame: 191 (seh) Engine underauerd 4 ‘Transmison underuard Ca Operator's seat and box assembly 130 Operator's seat assembly only as Bete (oe unit) Canopy assembly oa 40-41 AP-3 01-13TABLE OF FUEL, COOLANT AND LUBRICANTS D40A, P, PL, PLL-3 RESERVOIR Engine ol pan Main clutch case Transmission ‘Steering clutch case (inc. bevel goar caso) Final drive case (each) Hydraulic tank Idler (each) “Track roller (each) Carrier roller (each) Fuel take Cooling system AMBIENT TEMPERATURE ‘Add antifroeze CAPACITY (1) 1oeF | Specified | Refit les 2 2 6 6 a a Daa | BaATIO orrspurelosrAructe 023 020 028 * ASTM D975 No. 1 NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic main- tenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %. Fuel sulphur content in engine oil pan 0.5 to 1.0 % 1/2 of regular interval Above 1.0% 11/4 of regular interval ASTM: American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute (2) When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAEI0W, SAE10W-30 and ‘SAE15W-40 even though an atmospheric tem- perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to haf. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. (6) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equip- ‘ment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 01-14 © D40 + 41AP-3DA1A, E, P-3 D41A-3A AMBIENT TEMPERATURE RESERVOIR Engine oil pan Damper case ‘Transmission case ata Steering ol (incl. bevel gear case) Hydraulic tank Ider (each) “Track roller (each) Carter roller (each) Fuel tank Cooling system ‘Add antiteeze CAPACITY (:) mz =~ s08| Specified | Refi oe te ee Fy 4 14 a a 8 et DaTA E70 [DATA ETO eerie | pane: 14 Dera «957 oer. Pa peraaices | osiaaa: 46 oz | oz 020 | 020 02 | ozs * ASTM D975 No. 1 NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic mai tenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %. Fuel suiphur content | Change interval of o in engine oil pan 0.5 to 1.0 % 1/2 of regular interval Above 1.0 % 1/4 of regular interval ASTM: American Society of Testing and Material Society of Automotive Engineers. SAE: ‘API: American Petroleum institute (2) When starting the engine in an atmospheric, temperature of lower than 0°C, be sure to use engine oil of SAEOW, SAEIOW-30 and ‘SAE15W-40 even though an atmospheric tem- perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if, API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. (6)We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equip- ment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oll needed to refill system during normal inspection and maintenance. 40+ 41AP-3 01-15 ©SHOP MUAUAG D40-41A,P-s SERIAL NO. D40A,P-3 6001 and up SERIAL NO. D41A,P-3 6001 and up 11 ENGINE STRUCTURE AND FUNCTIOND40+41A,P-3 STRUCTURE AND FUNCTION Radiator and oil cooler . PTO Re Engine control Fuel tank . . Engine mount NonunRADIATOR AND OIL COOLER STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER ‘The radiator core is of the D type. Air is forced out when the fan rotates. An oil cooler is mounted in the radiator lower tank to cool the main clutch oil (D40-3) or HYDROSHIFT transmission oll (041-3), Radiator is mounted on main frame using the rubbers to absorb shock. Radiator core: Daype core Section AA F120¢007 11-2 D40, 414, PSTRUCTURE AND FUNCTION P.T.O(Power Take Off) D40A, P-3 ‘The PTO is mounted on the engine flywheel housing. With this PTO, the power from the engine crankshaft (1) is taken out t0 drive gear (2). The rotation of drive gear (2) is transmitted to PTO gear (4) through idler gear (3). PTO gear is provided with a spline hole. ‘The spline shaft of grear pumps for hydraulic and steering is fitted in the spline hole, Section A-A 1. Crankshaft 2. Drive gear 3. Driven gear 4, Pump drive gear 5. Hydraulic pump 6. Steering pump 7. Flywheel D40, 41A, P P10. F1z0co08 11-3ENGINE CONTROL STRUCTURE AND FUNCTION ENGINE CONTROL D40A-3 ‘A fuel control lever ( 1) is installed on the left side of the dashboard. ‘The governor can be controlled by operating the fuel control lever. ‘Stop position sopper Pn n re [ ‘0p Ful ‘Low ating || Low F120c009 1-4 D40, 414, PSTRUCTURE AND FUNCTION ENGINE CONTROL, DaIAs ‘A fuel control lever is installed on the side of the gear shift lever box. Fiz0co10 40, 41A, P 11-5FUEL TANK STRUCTURE AND FUNCTION FUEL TANK A fuel tank is on the rear part of the machine body. Fuel flows into the fuel tank through the strainer. ‘The fuel gauge can be found by removing the fil The fuel from the fuel tank flows into the Pump through the hose. ‘There are the fuel stopcock and the water drain cock on ‘the back side of the fuel tank. |. Fuel dipstick . Fuel strainer Drain cock |. Fuel cock 5. Piping . Injection pump 11-6 D40, 41A, PSTRUCTURE AND FUNCTION ENGINE MOUNT ENGINE MOUNT ‘The engine is mounted with its four points to the main frame, ‘The rubber sheets ( 3) are fitted between the engine (4 ) and the main frame to decrease vibration and Section A-A 1. Collar 2. Sheet 3, Rubbers 4. Engine bracket 5. Stopper 6. Main frame 40, 414, P 11-7SHOW MWAMWANE D40-41A,P-_s SERIAL NO. D40A,P-3 6001 and up SERIAL NO. D41A,P-3 6001 and up 12, ENGINE TESTING AND ADJUSTINGTESTING AND ADJUSTING ‘* These methods are for testing and adjusting For testing and adjusting the engine sepa- rately, refer to the Shop Manual for Komatsu engine 6D105-1 series. Standard for inspection, adjustment and troubleshoo: Tools for inspection and adjustment Testing and adjusting engine . Intake and exhaust engine system ......12- 7 Adjusting valve clearance . seee129 Engine . +1210 Measuring compression pressure . «12-411 Lubrication system . + 12-12 Fuel system . eee 12-15, Testing and adjusting fuel injection timing system Checking and adjusting fan belt tension ... NS When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety pins and block the tracks. When working in groups, use agreed signals and do not allow unaut ‘persons near the machine, Be careful not to get caught in rotating parts, or burnt by not parts. D40-41A,P-3, er oSTANDARD FOR INSPECTION, ADJUSTMENT AND TROUBLESHOOTING TESTING AND ADJUSTING STANDARD FOR INSPECTION, ADJUSTMENT AND TROUBLESHOOTING Engine 6D105-1 Machine Mode! paoa,Ps | Da1A,Ps Cate: i : Repair Se Check item Conditions Unit | Standard Standard | Repel Rated horsepower | Specification value HP rpm | 90/2350 | - | 0/2360 | — | Max. torque ‘Specification value kom/rom | 37/1300 | - | 40/1,500 | — z Max. speed atno toad | rpm —|2,620-2,620| ~ |2,620-2,720| ~ Engine speed = | Ene Min. speed atmo toad | rpm | 700-760 | + | 700-750 | + é Spaed needed for start-| O°C ‘pm 200 . 200 . ing |-20°C(Using starting aid} rpm 100 - 100 = Intake resistance ‘Atrated horsepower | mmHz0 | 380 | 635 | 380 | 635 ‘At rated horsepower | mmHg ‘At rated horsepower | mmHg E | Exraust temperature | Whole speed range@'o)| °C eo | = - + BT nau oot Sudden acceleration | Bosch index 7 - cl) ‘At high iting Bosch index} 5.5 = 55 = $2 | Valve clearance Intake valve mm 0.35 - 0.35 = Es cold Exhaust valve mm 06s = 0.65 - ‘compres Oil temp.40~60°C | kolo? 2 + + - fompression pressure 2 ie {Engine speed) (rom) | (320~360)] + + + 2 a ‘At high iting ae Blowby pressure | Gy MOn IAG coe #20 | 100 | 150 | 100 | 160 Oil presgure (SAO, | At high iting keer? | 35-55 |< < | over 80°C) At low idling ka/em? 16 19 15 10 3 Whole speed range “ 2 i Oil temperature leceon a ¢ | 90-110 | 120 | e0-110 | 120 7 ‘At continuous rated Oil consumption horsepower (Proportion | % 10 + « + 6f fuel consumption) g & | Fuel injection Nozzle tester ka/em? 225 - 25 - a2 & | Fuel injection timing | B.7.0.c. °c 2 - 2 - erature | Whole speed range = = = = Coolant temperature | (pole speed nae, 70-80 Valve eracking temp. °c |745—7a5| + « + ‘Thermostat funetion | Full open temp. °c 0 7 90 - a5 Full open lite mm . 8 - 8 function {pressure difference) Fan belt tension (fan - | Deflection when push plley—crankshaft | ing with finger force of | mm to |s-15| 10 | 5-15 pulley) &kg 12-4 D40+41A,P-3TESTING AND ADJUSTING ‘TOOLS FOR INSPECTION AND ADJUSTING TOOLS FOR INSPECTION AND ADJUSTMENT No, (Check itm Tool Part Number ‘Remarks = : Digital display 11 Engine speed Tachometer 799-203-8000 eo ices 2 | Specifie gravity 11-13 — Specifie grauity tester | 795-500-1000 = 3 | Coolant freezing temperature —5— 50°C 4 | Water, oi! and intake air temperature 0 200°¢ Thermistor kit 790-500-1300 = 5 | Exhaust gas temperature (0- 1,000°C 6 | Lubricant pressure 0 20 kale? 7 | Fuel pressures (0 50 kg/em? 8 | intake, exhaust pressure Pressure measuring kit | 799-203-2002 [~_0—1,000mmrig 9 Blow-by pressure 0 — 500 mm, 0 10 | intake resistance =1,000 — 0 mmHz0 "796-502-1204 2 11 | Compression pressure ‘Compression guage See E02 1960) 0 — 70 kalem 12 | Blow-by checker Blow-by checker 798-201-1503 (0— 500 mm, 13 | Valve clearance 795-116-1330 Discoloration 0 — 70% standard color 14 Exhaust color Smoke checker 798-201-9000 | ipscsioration dem 1/10 = Bosch index) 15 | Water fuel in oit Engine oil checker 799-201-6000 | Water content 0.1%, 0.2% Fuel injection pressure mre 16 Nozzle tester oo a © ~ 300 kg/em? Nozzle spray condition available : Water quality tester PH, Nitrous acid fe and corrosion test kit | 79%202-7001 ion density Pressure valve function 18 Radiator cap tester 799-202-9001 0-2 kg/cm? Leakage from cooling system 19 | Clogging of radiator (wind speed) ‘Anemometer 799-202-2001 1=40m/s For engine with DC, 24V 20 | Engine cranking Cranking kit 795-610-1000 Seria mae = — ‘Commercially Current, voltage 21 | Electric circuit Circuit test eae urea AX When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety pins and block the tracks. QQ When working in groups, use agreed signal and do not allow unauthorized persons near the machine. A When checking the water level in the radiator wait forthe water to cool. Do not remove the radiator cap whi ‘the water is hot. Boiling water may spurt out. AS be caret not to get caught in rotating parts. 40-41 A.P-3 12-5‘TESTING AND ADJUSTING TESTING AND ADJUSTING ENGINE (GENERAL) TESTING AND ADJUSTING ENGINE (GENERAL) ENGINE CRANKING METHOD ‘Special tools required Part No. 795-610-1000 (Cranking kit Method using cranking kit 1) Connect cranking kit as show in Connector NOTE: Sine Chasis cable large current is flowing, thohten the met ESE Ma safety reloy “a oS = De ee EC B MM, S ‘Always remove this short bar. ee eG a seem) SES eae | gears sine cones Les emote switch Press to crank engine, release to stop engine ‘Can be extended to postion where crakshafe ‘angle canbe sen) 2) Before turing handle, lock fuel control lever in NO INJECTION position. 3) Turn handle clockwise fully and press remote switch, Watch engine speed and turn handle ‘counterclockwise to reduce engine speed. When ‘engine speed reaches suitable level, stop handle, 4) Use remote to inch crankshaft until crank- shaft pulley match mark is aligned top dead center. Depending on the level of the battery charge, the ‘engine may be difficult to crank during inching ope- rations. In such cases, adjust the handle agai % When the crankshaft returns due to reaction from the compression inside the cylinder, stop for several seconds between each inching operation. 12-6 D40-41A,P-3INTAKE AND EXHAUST SYSTEM INTAKE AND EXHAUST ENGINE SYSTEM + CLOGGING OF AIR CLEANER ELEMENT 1. Checking dust indicator ‘Cheek if dust indicator (1) has reached service level (red). % The dust indicator is actuated by the increase in intake pressure caused by clogging of the ele- ‘ment, etc. When this negative pressure reaches 1635 mmAq, a ed piston moves into sight. 2. Directly checking air cleaner element When the dust indicator is red, or the exhaust gas is black, check the element as follows. 1). Loosen clamp and remove dust cap. 2) Remove wing nut, then remove outer (1) and check for clogging. ‘When checking, cleaning or replacing the element, be careful not to let dust enter the element case. 3) After checking or cleaning outer element, push ‘button of dust indicator to return red piston to original position, ment D40-41A,P-3 TESTING AND ADJUSTINGTESTING AND ADJUSTING MEASURING GAS COLOR MEASURING EXHAUST GAS COLOR AN When imoeuing the exhaust ge color, be cart otto be burned by the exheust pipe or matin, * Measure the exhaust gas color with the engine ‘warmed up (oil temp. 60°C). 1) Insert probe A in outlet of exhaust pipe (1), then tighten clip to hold probe in exhaust pipe. 2) Connect probe hose, plug B of accelerator ‘switch, and air hose C to diesel smoke tester D. Air pressure should be under 18 kg/em?, 3) Connect power cord E to 100V, AC outlet, % Check that the power is OFF before con: necting the cord. 4) Loosen cap nut of suction pump and fit filter paper. Fit filter paper securely to prevent leakage of exhaust gas. 5) Turn power switch ON. 6) Accelerate engine sharply and at the same time depress accelerator pedal. Operate relief valve and collect exhaust gas color with filter paper. 7) Remove filter paper from suction pump, lay on paper (at least 10 layers) inside filter holder and ‘ead value shown by meter, : AERATION 7, f ee f iesess6 ‘For details of operation, see the instructions supplied with the diesel smoke tester. D40-41A,P-3ADJUSTING VALVE CLEARANCE TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE * Adjust clearance between valve and rocker lever as follows. mm Intake valve | Exhaust valve Cold 0.36 0.65 1. Remove cylinder head cover. 2. Rotate the crankshaft in the normal direction to align pointer (1) with the 1.6 TOP mark on the in- jection pump shaft. When rotating, check the move: ‘ment of the valves. When the pointer isin line with the 1.6 TOP mark, No, 1 cylinder is at compression top dead center When No. 1 eylinder is at compression top dead ‘center, adjust the valves marked @, When No. 6 cylinder is at compression top dead center, adjust the valves marked ©, % Valves position Gyiinderso| 1 | 2 | 3 | 4] s [oe Tatake | Ext fe] [ol fel fol lel lo 4. To adjust insert tool A between rocker arm and valve stem and turn adjustment screw until clear ‘ance is a sliding fit. Then tighten lock nut to hold adjustment screw in position, SD Lock nut: 3.2403 kgm 5. Next, rotate crankshaft one tum in the normal direction and adjust the valve clearance of the remaining valves marked 0. sett dh 2ar6s2 ‘* After adjusting No, 1 cylinder at compression top dead center, it is also possible to turn the crankshaft 120” each time and adjust the valve clearance of each cylinder according to the firing order. order: 1-5—3-6-2-4 * After tightening lock nut, check clearance again, D40+41A,P-3 12-9ENGINE TESTING AND ADJUSTING ENGINE MEASURING BLOW-BY * Warm up engine until oil temperature is at least 60°C, Special tools required Part Ne Part Name A 795-201-1802 Blow-by checker 1 1 Install too! A on oil filler or breather. 2. Run engine at full stall and measure pressure of blow-by at point where pressure gauge remains steady. # When it is impossible to test at full stall measure at high idling. This will give a value of about 80% of the value at full stall % Blow-by varies greatly with the condition of the engine. When the blow-by value is considered abnor |, check for excessive oll consumption, discolored exhaust gas, early deterioration or contamination of il or any other symptom related to abnormal blow-by. 12-10 D40+41A,P-3TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE MEASURING COMPRESSION PRESSURE ‘Special tools requi —————— Part No. Part Name JA ee "795-502-1203 ‘Compression gauge 1 AA Wren measuring the compression pressure, be careful not to touch the exhaust manifold or rmurfle, oF to get caught in rotating parts, % Measure the compression pressure with the engine warmed up (oil temperature 40 ~ 60°C). 1. Adjust valve clearance For details, see ADJUSTING VALVE CLEAR. ANCE. 2. Remove spill tube (1) and disconnect fuel injection, pipe (2). 3. Remove nozzle holder assembly, 4, Install adapter A in mount of nozzle holder assem- bly, and tighten to specified torque. 5. Connect tool A (gauge, hose) to adapter. 6. Place fuel control lever in NO INJECTION position, Crank engine with starting motor and measure com- pression pressure where pressure gauge indicator re- mains steady, AN 1 0 tut cont ever snot st 0 the NO IN- SECTION portion, te engine wl start * Coat the adapter mount with a small amount of oil to prevent leakage, D40+41A,P-3LUBRICATION SYSTEM LUBRICATION SYSTEM CHECKING OIL LEVEL ‘© Pull out dipstick (1) and check that oil level is between H and L marks on dipstick, %* Stop the machine in a level place and check the oil level with the engine stopped. CHECKING FOR WATER MIXED IN OIL Special tools required Part No. Part Name A 799-201-6000 Engine oil checker 1 1. Remove oil filler cap (1) and check if there are eny drops of water inside the cap. 2. Start the engine and let oil drip from the dipstick fon to the exhaust manifold, If there is water in the cil, it will spit or form bubbles when it contacts the hot metal. 3. When using the hot plate of the engine oil checker, ut 1-2 drops of oil on top of the plate and check if bubbles are formed. ‘* If bubbles are formed, put 1-2 drops of stand- ard oil and oil from the dipstick on the hot plate at the same time. Compare what percent- ‘age of water is contained in the oil + Limit of water content: Max. 0.2% 12-12 O TESTING AND ADJUSTING D40-41A,P-3‘TESTING AND ADJUSTING LUBRICATION SYSTEM CHECKING CONTAMINATION OR DETERIORATION OF ENGINE OIL ‘Special tools required Part No, Part Name A 799-201-6000 Engine oil checker 1 ee 1. Mix the oil well, then take @ sample and let it drip ‘on to the sensor of tool A to measure the level con- ‘tamination. ‘# The level of contamination is indicated by the following lamps. Green: Usable Yellow: Pay attention Red: Replace immediately D40+41A,P-3 12-13 ®LUBRICATION SYSTEM TESTING AND ADJUSTING MEASURING OIL PRESSURE ‘Special tools required Part No. Part Name A 790-301-1101 Hydraulic tester 1 AN stop the engine before removing or installing the plug or oll pressure gauge. * When measuring oil pressure, measure with oil ter: erature at over 80°C. 1) Remove plug (1). 2) Install oil pressure gauge A. % Connect the oil pressure gauge so that is affected as little as possible by engine vibration 3) Start engine and measure oil pressure. MEASURING OIL TEMPERATURE Special tools required Part No. Part Name A "790-500-1300 “Thermistor kit 1 Remove dipstick and push in sensor of thermistor ‘temperature gauge. Connect sensor to thermistor temperature gauge and measure temperature of cil in oil pan. 12-14 D40-41A,P-3 oOTESTING AND ADJUSTING FUEL SYSTEM FUEL SYSTEM CHECKING FUEL SYSTEM 1, Checking for water mixed in fuel. Loosen drain cock (1) at bottom of fuel tank and check for dirt or water, 2. Checking breather in fuel tank cap. (Check that breather of cap (1) is not clogged. ‘% If the breather is clogged, negative pressure will be formed inside the fuel tank and will prevent the supply of fuel. 3. Bleeding fuel injection pump. 1) Loosen air bleed plug (1) of fuel injection Pump. Operate priming pump (2) until no ‘more bubbles come out with fuel from plug hole. 2). Tighten the plug (1). 4. Checking fuel injection pressure. 1) Set injection nozzle (1) on nozzle tester A. 2) Operate handle of nozzle tester and check injec- tion pressure and nozzle spray. AN Be careful not to inject fuel with nozzle facing hand or body. ‘* When adjusting the fuel injection pressure, turn the adjustment screw at the top of the nozzle holder with a serewdriver D40-41A,P-3, 12-15 ®TESTING AND ADJUSTING FUEL INJECTION TIMING TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING TESTING AND ADJUSTING FUEL INJEC- TION TIMING BY DELIVERY VALVE SYSTEM 1. Disconnect fuel injection pipe (1) of No. 1 cylinder. 2. Remove delivery valve holder. Remove delivery valve spray (2) and delivery valve (3) from holder, ‘then install holder again. 3, Place fuel control lever at FULL position. When doing this, remove the control rack cap. and install washers (01643-30623 x 5); or replace rack cap (554040-1000). 4, Operate priming pump and rotate crankshaft slowly in normal direction, Examine point where fuel stops flowing from delivery holder. 5. Check that pointer (5) and ‘19° 1.4.” fine on erank: shaft pulley (4) are aligned when fuel stops flowing, BEYOND injection timing line: Timing RETARDED % BEFORE injection timing Ii ADVANCED ‘To adjust injection timing, move position of Injection pump, To ADVANCE, move to CYLINDER BLOCK. To RETARD, move to OUTSIDE. 12-16 D40+41A,P-3 oOTESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING 6. When injection timing is incorrect, adjust as follows. 1) Rotate crankshaft 30 ~ 40° back from top dead center. 2) Rotate crankshaft in normal direction and align pointer correctly with “19° 1.1," line on erank- shaft pulley. 3) Loosen nut (6) of elongated hole in flange mounting fuel injection pump, then loosen four ‘mounting botts (7) of injection pump. 4) Move injection pump to outside, operate prim- ing pump and move injection pump slowly back ‘towards cylinder block. Stop at position where ‘uel stops flowing from delivery valve holder. 5) Tighten four mounting bolts (7) of injection pump in turn 6) Tighten nut (6) of elongated hole in flange mounting injection pump. 4% Check the injection timing again to check ‘that the timing is correct, D40+41A,P-3,COOLING SYSTEM TESTING AND ADJUSTING COOLING SYSTEM CHECKING COOLING SYSTEM 1. Checking cootant level AN Wren checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap while the water is hot. Boiling water may spurt out, Remove radiator cap (1) and check that water level is at top surface of upper tank, 2, Measuring coolant temperature Special tools required Part No. Part Name [a 790-500-1300 ‘Thermistor kit 1 as Raise lever of radiator cap and release pressure inside radiator. 1) Remove water temperature gauge sensor (1), in- stall sensor of tool A and measure temperature of coolant. AS Wen meatuing the temperature of the coolant, be earful motto et your Fingers or te enor ale ca nthe rte ort. 12-18 D40-41A,P-3TESTING AND ADJUSTING FAN BELT TENSION CHECKING AND ADJUSTING FAN BELT TENSION 1, Checking fan belt tension ‘Check amount fan belt deflects when pressed with a force of 6 kg at midpoint between fan pulley and alternator pulley. 2. Adjusting fan bett tension If fan belt tension is not standard, adjust as follows. 1) Loosen mount bolt and nut (1) and mounting bolt of adjustment plate (2). 2) Using a bar, raise alternator and adjust tension, of belt (3). ‘Fan belt tension: Approx. 10 mm. 3) Tighten mount bolt and nut (1) and mounting bolt of adjustment plate (2) to hold alternator assembly. D40+41A,P-3 12-19SLOP MUA WG D40-41A,P-s SERIAL NO. D40A,P-3 6001 and up SERIAL NO. D41A,P-3 6001 and up 13 ENGINE DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY STARTING MOTOR Dismounting . Mounting . . ALTERNATOR Dismounting . Mounting ENGINE OIL COOLER Dismounting . Mounting ....... FUEL INJECTION PUMP Dismounting . Mounting ....... WATER PUMP Dismounting . Mounting NOZZLE HOLDER Dismounting . Mounting CYLINDER HEAD Dismout Mounting RADIATOR GUARD Dismounting . .. Mounting . . RADIATOR Dismounting . Mounting . . ENGINE (D40) Dismounting . Mounting . . ENGINE (D41) Dismounting . Mounting .. ds ee ee aed 13-56 13-59 D40-41A,P-3 13-3STARTING MOTOR DISASSEMBLY AND ASSEMBLY DISMOUNTING OF STARTING MOTOR ASSEMBLY AN Disconnect the lead frm the negative (-) terminal of the battery 1. Remove L.H. engine side cover. 2. Disconnect four wires (1). 3. Disconnect wire (2) at connector. 4. Remove starting motor assembly (3). MOUNTING OF STARTING MOTOR ASSEMBLY 1, Fit O-ring and install starting motor assembly (3). 2. Connect wire (2) at connector. 3. Connect wires (1), 4. Install L.H. engine side cover, 5. Connect lead to negative (-) terminal battery. 13-4 D40-41A,P-3 oDISASSEMBLY AND ASSEMBLY ALTERNATOR DISMOUNTING OF ALTERNATOR ASSEMBLY AN Disconnect the lead from the negative {+} terminal ofthe beter. 1, Remove LH. engine side cover. 2. Disconnect two wires (1) 3. Remove mounting bolt (2) of adjustment plate, then remove V-belt (3). 4. Remove mount bolt and nut (4), then remove alter- nator assembly (5). MOUNTING OF ALTERNATOR ASSEMBLY 1. Temporarily tighten mount bolt and nut (4) of alternator assembly (5). 2. Fit V-belt (3) in groove of alternator pulley, and Using a bar, raise alternator to adjust belt tension, ‘Belt tension: Approx. 10 mm, ‘3. Tighten mounting bolt of adjustment plate (2) 4, Tighten mount bolt and nut (4) fully. 5. Connect wires (1). 6. Install L.H. engine side cover. 7. Connect lead to negative (-) terminal of battery. D40+41A,P-3 13-5 ®ENGINE OIL COOLER DISASSEMBLY AND ASSEMBLY DISMOUNTING OF ENGINE OIL COOLER ASSEMBLY 1. Loosen radiator drain cock (1) and cooler drain ‘cock (2) and drain water, ‘If the cooling water contains antifreeze, dispose of it correctly. 2. Remove fuel injection pump assembly. For details, see DISMOUNTING FUEL INJECTION PUMP ASSEMBLY. 3. Disconnect wire (3) and remove engine oil filter as- sembly (4). 4. Disconnect corrosion resistor hose (5). 5. Remove oil pipes (6), (7) and (8). 6. Remove oil cooler assembly (9). MOUNTING OF ENGINE OIL COOLER ASSEMBLY 1. Fit gasket and install oil cooler assembly (9). 2. Fit O-rings and install oil pipes (8), (7) and (6). 3. Connect corrasion resistor hose (5). 4, Fit O-ring and install ol filter assembly (4). 5. Connect wire (3). 6. Install fuel injection pump assembly. For details, see MOUNTING FUEL INJECTION PUMP ASSEMBLY. 7. Tighten drain cocks (2) and (1), then add water to the specified level. + Run engine to circulate water through cooling 13-6 D40+41A,P-3 °DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP DISMOUNTING OF FUEL INJECTION PUMP ASSEMBLY % Tum the crankshaft in the normal direction, align pointer (2) with the injection timing line on shaft a. % If the injection timing line of the fuel injection ump is out of line, turn the crankshaft one ‘more turn to align. * Close the fuel feed cock at the bottom of the fuel tank, 1. Remove R.H. engine side cover. 2. Disconnect fuel control cable (3) 3 Disconnect fuel feed tube (4). 4, Disconnect fuel injection pump outlet hose (5). 5. Disconnect fuel injection pump inlet hose (6). 6 Remove lubrication pipe (7). 7. Disconnect lubrication pipe (8). 8. Disconnect fuel high pressure pipe (9). 9. Remove bolts (10) holding fuel injection pump and shaft. 10. Remove four mounting bolts (11) holding fuel in jection pump assembly. 11, Disconnect fuel injection pump assembly (12) from shaft and remove, D40+41A,P-3FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY MOUNTING OF FUEL INJECTION PUMP ASSEMBLY 1. Align key groove of coupling of fuel injection pump ‘assembly (12) and connect to shatt, 2. Temporarily fit mounting bolts (11) holding fuel in- sction pump assembly and tighten bolt (10) hold- ing fuel injection pump and shaft, 3) Connecting bolt: 6.2 + 0.2 kgm 3. Adjust fuel injection timing as follows. 1) Rotate crankshaft in normal direction and align pointer (2) with line on drive shaft (1). % When doing this, if the line on the coupling is not at the front, rotate one more turn, 2) Move n pump to inside or outside, and align line A on pump side with line B on coupl- ing side. 3) Hold injection pump in this position and tighten four mounting bolts (11) uniformly and. intum. * When repairing or replacing the fuel injeo- tion pump, or when there are no lines ‘marked, adjust the injection timing by the delivery method, % For details of adjustment, see TEST- ING AND ADJUSTING FUEL INJEC- TION TIMING. D40-41A,P-3DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP 4. Connect fuel high pressure pipe (9). 5. Fit gaskets to both faces and install lubrication pipe 8), 6 Fit gaskets to both faces and connect lubrication pipe (7), 7. Fit gaskets to both faces and connect fuel filter inlet hose (6) and outlet hose (5). Fit gaskets to both faces and connect fuel feed tube a. 9 Connect fuel control cable (3) ‘* Bend cotter pin securely. ‘+ After connecting cable place fuel control lever at full speed and check that itis adjusted to no injection position. 10, Install FH, engine side cover. 11. Open fuel feed cock at bottom of fuel tank, and bleed air. D40-41A,P-3,WATER PUMP DISASSEMBLY AND ASSEMBLY DISMOUNTING OF WATER PUMP ASSEMBLY 1, Loosen drain cock (1) and drain water. ‘+ If cooling water contains antifreeze, dispose of it carefully. eerie 2. Remove R.H, and LH. engine side covers. 3. Remove exhaust pipe (2), 4. Disconnect air intake hose (3), then remove hood assembly (4). 5. Remove fan guard (5). 6. Remove fan (6) and push towards radiator. 7. Remove alternator mounting bolt and nut, then re- move adjustment plate (7) and V-belt (8). 13-10DISASSEMBLY AND ASSEMBLY WATER PUMP 8, Disconnect radiator inlet hose (9). 9. Remove bracket (10), 10, Remove aeration tube (11) 11. Disconnect radiator outlet hose (12). 12, Remove bypass hose (13). 13. Remove water pump assembly (14). D40-41A,P-3 13-11 @WATER PUMP DISASSEMBLY AND ASSEMBLY MOUNTING OF WATER PUMP ASSEMBLY 1, Fit gasket and install water pump assembly (14). x Install bypass hose (13) and secure with hose band, 3. Connect radiator outlet hose (12) and secure with hose band, 4, Install aeration tube (11). 5. Install bracket (10). 6. Connect radiator inlet hose (9) and secure with hose band, 7. Fit V-belt (8) in grooves of pulley, install adjust- ment plate (7) and using a bar, raise alternator to adjust belt tension. Belt tension: Approx. 10 mm. 8 Tighten adjustment plate and alternator mount bolt and nut, 13-12 40-4143DISASSEMBLY AND ASSEMBLY WATER PUMP 9, Install fan (6). 10, Install fan guard (8). 11, Install hood assembly (4) and connect intake hose @, 12. Install exhaust pipe (2) 13, Install RH. and L.H, engine side covers, 14, Tighten drain cock. 15, Add water through water filler (15) to the specified level. % Run engine to circulate water through cooling system, Check water level again. D40-41A,P-3 13-13NOZZLE HOLDER DISASSEMBLY AND ASSEMBLY DISMOUNTING OF NOZZLE HOLDER ASSEMBLY Remove R.H. and L.H engine side covers. 2. Remove exhaust pipe (1), disconnect intake hose (2) and remove hood assembly (3). 3. Disconnect dust indicator hose (4). assembly (6). No. 8 nozzle holder assembly, remove bracket (6). 5. Remove spill tube (7). 6. Disconnect fuel injection pipe (8). 7. Remove mounting bolts (9), then remove nozzle holder assembly (10). MOUNTING OF NOZZLE HOLDER ASSEMBLY 1. Insert nozzle holder assembly (10) in mounting position and tighten mounting bolts (9). SZ) Mounting bolt of nozzle holder: 1720.2 kom %* Clean mount and be careful not to damage tip of nozzle holder. ‘% Tighten mounting bolts of nozzle holder uni- formly in turn. 2. Connect fuel injection pipe (8). SEI Sleeve nut: 2.25 + 0.25 kgm 3. Fit gasket and install spill tube (7). 4, Install air cleaner assembly (8). ‘* When No. 3 nozzle holder assembly has been re- moved, install bracket (6). 5. Connect dust indicator hose (4) 6. Install hood assembly (3), connect intake hose (2) and secure with hose band. 7. Install exhaust pipe (1) 8. Install R.H. and L.H engine side covers, 13-14 D40-41A,P-3 ®CYLINDER HEAD DISASSEMBLY AND ASSEMBLY DISMOUNTING OF CYLINDER HEAD ASSEMBLY u igh oresure pine 0 Nozze noi 5 eras Spill pipe 5 8 loaoaraps| [side covers Oi finer Hood piping utidozer [Ribbon i fier ” Fue filer ay D40+41A,P-3DISASSEMBLY AND ASSEMBLY CYLINDER HEAD D40+41A,P-3 13-17 oOCYLINDER HEAD DISASSEMBLY AND ASSEMBLY 1. Draining water Loosen radiator drain cock (1) and drain cock on cylinder block to drain water. ‘* If the coolant contains antifreeze, dispose of it correctly. 2. Side covers, hood 1) Remove right and left engine side covers. 2) Remove exhaust pipe (2). 3) Disconnect intake hose (36), release catches on. right and left, then remove hood (3). 3. Exhaust muffler, manifold assembly 1) Disconnect drain pipe (4), 2). Sling exhaust muffler and manifold assembly (6), remove mounting bolts and lift off. (Cis) Exhaust mutter, manifold assembly: 25 kg Air cleaner assembly 1) Disconnect dust indicator hose (6). 2) Loosen clamp (7) at connection of intermediate hose, 3) Remove band holding air cleaner assembly, ‘then remove air cleaner assembly (8). D40-41A,P-3DISASSEMBLY AND ASSEMBLY 4) Remove bracket (9) of air cleaner assembly. 5. Oil filter assembly 1) Disconnect wiring (10) 2) Remove oil filter assembly (11). 6. Oil filter piping 1) Remove oil filter pipes (12) and (13). 2) Remove oil filter adapter (14) 7. Ribbon heater wiring Disconnect two ribbon heater wires (18). 8. Bracket Remove bracket (16). 9. Aeration pipe Remove aeration pipe (17). D40+41A,P-3 CYLINDER HEADCYLINDER HEAD DISASSEMBLY AND ASSEMBLY 10. Wator temperature gauge wiring Disconnect water temperature gauge wiring (18), 11, Hoses 1) Disconnect thermostat outlet hose (19). 2) Remove bypass hose (20). 12. Corrosion resistor assembly 1) Disconnect hose (21) at thermostat end. 2) Disconnect connector of engine oil dipstick ‘uide, remove corrosion resistor assembly (22) and bracket as one unit and move to outside. 13. Breather tube Disconnect breather tube (23). 14, High pressure pipe Remove high pressure pipe (24). 15. Spill pipe 41) Disconnect spill hose (25). 2) Remove spill pipe (26). 116. Fuel filter assembly Remove fuel filter assembly (27) as one unit with bracket and move to outside. 13-20 oO D40+41A,P-3DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 17, Nozzle holder assembly Remove nozzle holder assembly (28). * Mark the nozzle holder assembly with a number before removing, then keep in a safe place pro- tncted from damage. % To prevent dust or dirt from entering, fit a blind plug in the hole used for mounting the nozzle holder in the cylinder head. 18. Cylinder head cover Remove cylinder head cover (29). 19, Rocker arm assembly 1) Loosen tock nuts for adjustment screws, then loosen all adjustment screws 2 to 3 turn. 2) Remove six mounting bolts (30), then remove rocket arm assembly (31). 20. Push rod Remove push rod (32). D40-414,P-3CYLINDER HEAD 21, Cylinder head assembly 1) Remove mounting bolts (33) of eylinder head assembly. 2) Remove cylinder head assembly (34) as one unit with intake manifold, CGE) Oplnder heed asembly: 70k 3) Remove cylinder head geet. 13-22 © DISASSEMBLY AND ASSEMBLY D40-41A,P-3CYLINDER HEAD MOUNTING OF CYLINDER HEAD ASSEMBLY lpaoaraps| JBultdozer 13-24 oO DISASSEMBLY AND ASSEMBLY Fuel fier ay 0 Corrosion resistor ax " Hoses ” Water perature fsuge wiring] 3 ‘Aeration Pipe 3 4 [Rocker erm ay ylinder od eover 1 Soil pipe D40+41A,P-3DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 5 Ribbon heat eewiring ie u n ‘Of fer Olt fier Hood, side Ping sy covert 1 Tir cianer ay iH ier mont | id a n secon] = tearice D40-41A,P-3 13-25 oOCYLINDER HEAD % Check that there is no dirt on the mounting surface Of the cylinder head or cylinder block. Check that there is no foreign material inside the cylinder. 1. Cylinder head assembly 1). Fiteylinder head gasket on block. 2) Raise cylinder head assembly (34), and set on ‘eylinder block using four mounting bolts as guides. 3) Tighten mounting bolts (33) as in picture be. low. ZS] Cylinder head: Tightening torque Coated with anti- | Coated with engine Order | friction compound oil Target | Range | Target | Range isttime |_ 9 a~10. 9 a~10 2ndtime| 13 | 12~14 13 [1214 3rdtime| 18 | 17.5~185 | 20 | 195-200 ‘% Order for tightening bolts of eylinder head, Install push rod (32). * Check whether ball of push rod is fitted secure: ly in socket of tappets, 13-26 DISASSEMBLY AND ASSEMBLY D40+41A,P-3,DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 3 Rocker arm assembly 1) Set rocker arm assembly (31) in position, %* Check that the ball of the adjustment screw is fitted in the socket of the push rod. * Do not let excessive force be applied to the push rod. If there is tension between the rocker arm and valve spring, loosen adjust: ment screw. 2), Tighten six mounting botts (30). 3) Adjust valve clearance, % Valve clearance (cold) Intake valve: 0.38 mm Exhaut valve: 0.65 mm % For details, see TESTING AND ADJUST. ING, ADJUSTING VALVE CLEARANCE. 4. Cylinder head cover Fit O-ring and install cylinder head cover (29). ZS) Mounting bolt: 0.94 0.1 kom 5. Nozzle holder assembly Install nozzle holder assembly (28). % Check that there is no dirt or damage inside holder sleeve or on nozzle holder contact sur face. * Coat thread of mounting bott with engine oil. % Tighten mounting bolts of nozzle holder uni- formly, 3B Mounting bolt: 1.7 + 0.2kg D40+41A,P-3CYLINDER HEAD DISASSEMBLY AND ASSEMBLY 6. Fuel filter assembly Install fuel filter assembly (27) and bracket as one unit, 7. Spill pipe 1). Fit gaskets on both faces and install spill pipe (26), 2) Connect spill hose (26). 8, High pressure pipe Install high pressure pipe (24). 9. Broather tube Fit O-ring and connect breather tube (23). 10. Corrosion resistor assembly 1) Install corrosion resistor assembly (22) and. bracket as one unit. 2) Connect hose (21), 3) Connect clamp of engi pil dipstick guide, 11, Hoses 1) Install bypass hose (20) 2) Connect thermostat outlet hose (19). 12, Water temperature gauge wiring Connect water temperature gauge wiring (18) 13-28 © D40-41A,P-3DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 18, Aeration pipe Install aeration pipe (17). 14, Bracket Install bracket (16). 15, Ribbon heater wiring Connect two ribbon heater wires (15), 16, Oil filter pipit 1) Install oil filter piping adapter (14). 2) Fit O-rings and install oil filter pipes (13) and (12). 17, Oil filter assembly 1) Fit O-ring and instal ol filter assembly (11). 2) Connect wiring (10). 18, i cleaner assembly 1) Install bracket (9) of air cleaner assembly, D40-41A,P-3 PE 227130 13-29 oOCYLINDER HEAD 2) Set air cleaner assembly (8) on bracket and secure with band, 3) Tighten clamp (7) at connection of interme- diate hose, . 4) Connect dust indicator hose (6). 19. Exhaust muffler, manifold assembly 1) Raise exhaust muffler and manifold assembly (5) and set on cylinder head. 2) Fit gasket and tighten mounting bolts, % Install gasket with mark facing out. G5 Mounting bolt: 651.0 kam 3) Install drain pipe (4). 20. Side covers, hood 1) Install hood (3). 2) Attach catches and connect intake hose (36). 3) Install right and left engine side covers. 4) Install exhaust pipe (2). 21. Refilling with water 1) Tighten radiator drain cock and drain cock on cylinder block. 2) Add water through water filler (35) to the spe- cified evel. ‘Run engine to circulate water through system, Check water level again, 13-30 ® DISASSEMBLY AND ASSEMBLY D40-41A,P-3RADIATOR GUARD DISASSEMBLY AND ASSEMBLY DISMOUNTING OF RADIATOR GUARD ASSEMBLY 2 Draining Inake hore u ator Sardscy Resistor Inet nore 1 a} Cooter versie Ping \2ario3 13-32 D40-41A,P-3 oODISASSEMBLY AND ASSEMBLY 4. Underguard Using transmission jack ( , remove underguard (1), (ie) Underguard: 50 kg 2. Draining water Loosen drain cock (2) and drain water. ‘% If the coolant contains antifreeze, dispose of it carefully. 3. Side covers Remove right and left side covers. 5. Intake hose Disconnect intake hose (4) 6. Hood Remove hood (5). 7, Piston rods Disconnect piston rods (6). 4% Place control lever on FLOAT position, retract piston rod fully, then rest blade cy hook, D40+41A,P-3 RADIATOR GUARD 13-33 ©RADIATOR GUARD DISASSEMBLY AND ASSEMBLY 8. Blade cylinder hoses Disconnect left and right blade cylinder hoses (7) and (8). 9. Wiring Disconnect horn and light wiring (9) 10, Radiator outlet hose Disconnect radiator outlet hose (10). 11, Radiator inlet hose Disconnect radiator inlet hose (11). 12. Fan guard Remove fan guard (12). D40+41A,P-3DISASSEMBLY AND ASSEMBLY 13, Cooler piping Remove cooler tubes (13) and (14). 14, Radiator guard assembly 1). Sling radiator guard assembly (16) and remove ‘mounting bolt (16). 2) Move radiator guard assembly (15) to front and remove. Radiator guard assembly: 400 kg D40-41A,P-3 RADIATOR GUARD 13-35 oRADIATOR GUARD DISASSEMBLY AND ASSEMBLY MOUNTING OF RADIATOR GUARD ASSEMBLY 2 a Underpuara ‘Goaler ping Radiator Iniet nove Wiring 1 }p40,41A,7.3|__ [Radiator Blade ovln- Bulldozer uerd easy Piston rods w Intake hose Side covers Retiling wit water learioa 13-36 D40+41A,P-3. ®DISASSEMBLY AND ASSEMBLY 11. Radiator guard assembly 1) Sling radiator guard assembly (16) and set in position. 2). Tighten mounting bolts (16) of radiator guard asvembly (15). 2. Cooler piping Fit O-rings and install cooler tubes (14) and (13). 3. Fan guard Install fan guard (12), 4. Radiator inlet hose Connect radiator inlet hose (11). D40-41A,P-3 RADIATOR GUARD = oeRADIATOR GUARD DISASSEMBLY AND ASSEMBLY 5. Radiator outlet hose Connect radiator outlet hose (10). 6. Wiring Connect horn and light wiring (9). zaps 7. Blade cylinder hoses Connect left and right blade cylinder hoses (7) and , 8, Piston rods Extend left and right piston rods (6) and connect. 13-38 D40-41A,P-3 oODISASSEMBLY AND ASSEMBLY RADIATOR GUARD 9. Hood Install hood (6. 10, Intake hose Connect intake hose (4). 11, Exhaust pipe Install exhaust pipe (3). 12, Side covers Install right and left side covers. 13. Underguard Using transmission jack @), install underguard (1). ‘Underguard mounting bolt: ‘Thread tightener (LT:2) 14, Refilling with water 1). Tighten drain cock. 2) Add water through water filler (17) to the specified level %* Rum engine to circulate water through sys- tem, Check water level again. D40-41A,P-3 13-39RADIATOR DISASSEMBLY AND ASSEMBLY DISMOUNTING OF RADIATOR ASSEMBLY paoararsl [Draining Radiator lbuitdozer wate oy 3 Hood 1 Fen guard 1. Underguard Using transmission jack @, remove underguard (1) under engine, Underguard: 50 kg 2. Draining water Loosen drain cock (2) at bottom of radiator and drain water. + If the coolant contains antifreeze, dispose of it carefully 13-40 D40+41A,P-3. @DISASSEMBLY AND ASSEMBLY 3. Hood Remove exhaust pipe (3), disconnect intake hose (4) then remove hood (6). 4, Oil cooler piping Disconnect oil cooler pipes (6) and (7). 5. Radiator outlet hose sonnect radiator outlet hose (8). 6. Radiator inlet hose Disconnect radiator inlet hose (9). 7. Fan guard Remove fan guard (10). 8. Shrouds Remove upper and lower shrouds (11). 9. Radiator assembly 1) Remove bracket (12). D40+41A,P-3 RADIATORRADIATOR 2) Remove mounting bolt (13), then sling radiator ‘assembly (14) using eye bolt @ (14 mm, 2.0). 3) Remove mounting bolts at bottom of radiator, ‘then slowly lift off radiator assembly (14). (GS) Radiator assembly: 65 kg DISASSEMBLY AND ASSEMBLY D40+41A,P-3DISASSEMBLY AND ASSEMBLY RADIATOR MOUNTING OF RADIATOR ASSEMBLY 1 3 ‘Shrouds Fan guard ‘ Hood 4 Radiator Inlet howe Josoatars| TRaaisior Fadi leuidozer ay outlet nose 1 Underguara i a 8 Refiling with water} 2arto6 1. Radiator assembly 1) Using eye bolt @ (14 mm, P= 2.0), tor assembly (14), 2). Fit rubber cushion on bottom of radiator, then slowly lower radiator assembly and set on ‘guard. 3) Tighten mounting bolts at bottom of radiator. 4) Fit bracket (12), position radiator assembly, then tighten mounting bolts (13). radia D40+41A,P-3RADIATOR 2. Shrouds Install upper and lower shrouds (11). 3. Fan guard Install fan guard (10). 4, Radiator inlet hose Connect radiator intet hose (9). 5. Radiator outlet hose Connect radiator outlet hose (8) 6. Oil cooler piping Fit O-ring and connect oil cooler pipes (7) and (6). 7. Underguard Using transmission jack @, install underguard (1) on frame. X= Mounting bolt: Thread tightener (LT:2). 8. Hood 1) Install hood (5). 2) Install exhaust pipe (3) and connect intake hose (4), 13-44 DISASSEMBLY AND ASSEMBLY D40-41A,P-3