Komatsu Bulldozer D41E-6 D41P-6 Shop Manual SEBM028803 – PDF DOWNLOAD

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Komatsu Bulldozer D41E-6 D41P-6 Shop Manual SEBM028803 – PDF DOWNLOAD

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Komatsu Bulldozer D41E-6 D41P-6 Shop Manual SEBM028803 – PDF DOWNLOAD

Language : English
Pages :607
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer D41E-6 D41P-6 Shop Manual SEBM028803 – PDF DOWNLOAD

MACHINE MODEL
D41E-6 D41P-6
SERIAL NUMBER
B40001 and up B40001 and up

• 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 judge- ments. 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 the following chapters; these chapters are fur- ther divided into the each main group of components.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte- nance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each com- ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu Bulldozer D41E-6 D41P-6 Shop Manual SEBM028803 – PDF DOWNLOAD

MACHINE MODEL
D41E-6 D41P-6
SERIAL NUMBER
B40001 and up B40001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 7
SAFETY NOTICE 7
FOREWARD 9
GENERAL 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 12
COATING MATERIALS 14
STANDARD TIGHTENING TORQUE 16
ELECTRIC WIRE CODE 19
CONVERSION TABLE 20
UNITS 26
01 GENERAL 27
SPECIFICATION DRAWING 28
SPECIFICATIONS 30
WEIGHT TABLE 34
TABLE OF FUEL, COOLANT AND LUBRICANTS 36
10 STRUCTURE AND FUNCTION 39
RADIATOR, OIL COOLER 40
ENGINE CONTROL 42
POWER TRAIN 44
POWER TRAIN SYSTEM 45
POWER TRAIN HYDRAULIC PIPING DRAWING 46
DAMPER, UNIVERSAL JOINT 47
TRANSMISSION CONTROL 48
TRANSMISSION 50
TRANSMISSION CONTROL VALVE 59
STEERING, BRAKE, INCHING CONTROL 68
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 70
STEERING PPC VALVE 80
STEERING PISTON 84
PRIORITY VALVE 85
BRAKE VALVE 87
POWER TRAIN OIL FILTER 91
FINAL DRIVE 92
FRAME ASSEMBLY 94
TRACK FRAME 95
RECOIL SPRING 96
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 97
WORK EQUIPMENT CONTROL 98
HYDRAULIC TANK, FILTER100
MAIN CONTROL VALVE102
CLSS113
COOLING FAN DRIVE MOTOR126
FAN CONTROLLER133
WORK EQUIPMENT134
AIR CONDITIONER135
ENGINE CONTROL SYSTEM136
MACHINE MONITOR SYSTEM137
COOLING FAN CONTROL SYSTEM141
SENSORS145
20 TESTING AND ADJUSTING148
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS149
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS150
STANDARD VALUE TABLE FOR MACHINE MONITOR153
TESTING AND ADJUSTING156
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING157
ADJUSTING VALVE CLEARANCE158
MEASURING BLOW-BY159
TESTING AND ADJUSTING FUEL INJECTION TIMING160
MEASURING EXHAUST COLOR161
MEASURING ENGINE OIL PRESSURE162
MEASUREMENT OF ENGINE SPEED163
ADJUSTING FUEL CONTROL LINKAGE164
ADJUSTING DECELERATOR PEDAL LINKAGE165
ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER167
TESTING MAIN BRAKE AND PARKING BRAKE169
TESTING WEAR OF BRAKE LINING AND CLUTCH LINING171
ADJUSTING BRAKE, CLUTCH LEVER ASSEMBLY AND LINING CLEARANCE172
ADJUSTING BRAKE PEDAL LINKAGE176
ADJUSTING INCHING PEDAL LINKAGE177
ADJUSTING PARKING BRAKE LINKAGE178
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE AND SAFETY LEVER LINKAGE180
MEASURING POWER TRAIN OIL PRESSURE181
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE185
MEASURING AND ADJUSTING FAN MOTOR SPEED AND DRIVE CIRCUIT OIL PRESURE186
MEASURING FAN SPEED187
TESTING AND ADJUSTING TRACK SHOE TENSION188
MEASURING LEAKAGE INSIDE CYLINDER189
BLEEDING AIR FROM HYDRAULIC CYLINDER190
PROCEDURE FOR RELEASING PARKING BRAKE191
TESTING AND ADJUSTING “OPEN” AND “CLOSE” LOCK AND STEADY REST OF OPERATOR’S CAB DOOR192
TROUBLESHOOTING198
POINTS TO REMEMBER WHEN TROUBLESHOOTING199
SEQUENCE OF EVENTS IN TROUBLESHOOTING200
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE201
CHECKS BEFORE TROUBLESHOOTING209
METHOD OF USING TROUBLESHOOTING CHARTS210
TYPES AND LOCATIONS OF CONNECTORS212
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS224
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)250
METHOD OF USING TROUBLESHOOTING CHARTS251
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)255
S-2 ENGINE DOES NOT START257
1) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)257
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)258
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)259
S-4 ENGINE STOPS DURING OPERATIONS260
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)261
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)262
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)263
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)264
S-9 OIL BECOMES CONTAMINATED QUICKLY265
S-10 FUEL CONSUMPTION IS EXCESSIVE266
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN267
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)268
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)269
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)270
S-15 ABNORMAL NOISE IS MADE271
S-16 VIBRATION IS EXCESSIVE272
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)274
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC SYSTEM)275
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM278
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON283
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID MALFUNCTIONS)285
E-3 LAMPS DO NOT LIGHT UP288
a) HEAD LAMP288
b) REAR LAMP289
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO291
E-5 WIPER DOES NOT OPERATE293
E-6 NO WASHER FLUID IS SPRAYED OUT297
E-7 AIR CONDITIONER HAS NO EFFECT299
a) NO AIR COMES OUT299
b) DOES NOT BECOME COOL303
E-8 FAN MALFUNCTIONS307
a) FORWARD FAN SPEED IS LOW307
b) FORWARD FAN SPEED DOES NOT LOWER FROM MAXIMUM LEVEL (WHEN WATER TEMPERATURE IS BELOW 85 degrees C)307
c) FAN DOES NOT REVOLVE IN REVERSE309
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)312
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)313
H-1 BRAKES DO NOT WORK315
a) WHEN INCHING PEDAL IS OPERATED315
b) WHEN PARKING BRAKE LEVER IS AT LOCK316
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE)317
H-3 OVERRUNS WHEN TURNING318
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTIONAL LEVER IS OPERATED)319
H-5 MACHINE DOES NOT MOVE OFF IN ANY SPEED RANGE320
H-6 EXCESSIVE TIME LAG321
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)321
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)322
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH323
H-10 LACKS DRAWBAR PULL, TRAVEL SPEED IS SLOW324
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND TANDEM PUMP325
H-12 NO WORK EQUIPMENT MOVES326
H-13 SPEED OF ALL WORK EQUIPMENT IS SLOW OR LACKS POWER326
H-14 BLADE LIFT SPEED OR TILT SPEED IS SLOW OR LACKS POWER327
H-15 BLADE ANGLE SPEED IS SLOW OR LACKS POWER328
H-16 HYDRAULIC DRIFT OF BLADE LIFT, BLADE TILT IS EXCESSIVE329
H-17 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE329
H-18 FAN SPEED IS LOW330
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)332
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)333
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM335
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON336
M-2 WHEN STARTING SWITCH IS TURNED TO ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT336
M-3 PREHEATING DISPLAY IS ABNORMAL337
a) PREHEATING MONITOR DOES NOT LIGHT UP337
b) PREHEATING MONITOR STAYS LIGHTED UP337
M-4 CAUTION ITEMS LIGHT UP OR FLASH339
a) (CHARGE) LIGHTS UP OR FLASHES339
b) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES340
c) (COOLANT TEMPERATURE) FLASHES341
d) (POWER TRAIN OIL TEMPERATURE) FLASHES342
M-5 BUZZER IS ABNORMAL343
a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND343
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS343
M-6 WARNING LAMP IS ABNORMAL344
a) CAUTION ITEM IS FLASHING BUT LAMP DOES NOT FLASH344
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES344
M-7 GAUGE IS ABNORMAL345
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE345
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE346
c) ABNORMALITY IN FUEL LEVEL GAUGE347
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED348
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)349
30 DISASSEMBLY AND ASSEMBLY351
METHOD OF USING MANUAL353
PRECAUTIONS WHEN CARRYING OUT OPERATION354
SPECIAL TOOL LIST356
SKETCHES OF SPECIAL TOOLS362
FUEL INJECTION PUMP ASSEMBLY364
REMOVAL364
INSTALLATION366
ENGINE HOOD ASSEMBLY368
REMOVAL368
INSTALLATION369
CYLINDER HEAD ASSEMBLY370
REMOVAL370
INSTALLATION373
FUEL TANK ASSEMBLY375
REMOVAL375
INSTALLATION376
RADIATOR AND OIL COOLER ASSEMBLY377
REMOVAL377
INSTALLATION377
FAN DRIVE PUMP ASSEMBLY378
REMOVAL378
INSTALLATION378
FAN MOTOR ASSEMBLY379
REMOVAL379
INSTALLATION379
ENGINE ASSEMBLY380
REMOVAL380
INSTALLATION383
RADIATOR AND RADIATOR GUARD ASSEMBLY384
REMOVAL384
INSTALLATION386
DAMPER ASSEMBLY387
REMOVAL387
INSTALLATION388
TRANSMISSION ASSEMBLY390
REMOVAL390
INSTALLATION393
PTO ASSEMBLY394
DISASSEMBLY394
ASSEMBLY395
TRANSMISSION ASSEMBLY397
DISASSEMBLY397
ASSEMBLY409
STEERING CASE ASSEMBLY423
DISASSEMBLY423
ASSEMBLY429
FINAL DRIVE ASSEMBLY438
REMOVAL438
INSTALLATION438
DISASSEMBLY439
ASSEMBLY443
IDLER ASSEMBLY448
REMOVAL448
INSTALLATION448
RECOIL SPRING ASSEMBLY449
DISASSEMBLY449
ASSEMBLY450
IDLER ASSEMBLY451
DISASSEMBLY451
ASSEMBLY452
TRACK ROLLER ASSEMBLY455
DISASSEMBLY455
ASSEMBLY457
CARRIER ROLLER ASSEMBLY459
DISASSEMBLY459
ASSEMBLY460
TRACK SHOE ASSEMBLY462
REMOVAL462
INSTALLATION463
OVERALL DISASSEMBLY464
OVERALL ASSEMBLY469
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS483
ONE LINK484
FIELD DISASSEMBLY484
FIELD ASSEMBLY486
MAIN CONTROL VALVE493
ASSEMBLY493
HYDRAULIC CYLINDER ASSEMBLY499
DISASSEMBLY499
ASSEMBLY501
WORK EQUIPMENT503
REMOVAL503
INSTALLATION504
DISASSEMBLY505
ASSEMBLY508
HYDRAULIC TANK ASSEMBLY511
REMOVAL511
INSTALLATION511
ROPS ROOF, GUARD512
REMOVAL512
INSTALLATION512
ROPS ASSEMBLY513
REMOVAL513
INSTALLATION513
OPERATOR’S CAB ASSEMBLY514
REMOVAL514
INSTALLATION516
FLOOR FRAME ASSEMBLY522
REMOVAL522
INSTALLATION526
40 MAINTENANCE STANDARD538
DAMPER, UNIVERSAL JOINT539
HYDRAULIC+POWER TRAIN PUMP540
TRANSMISSION542
TRANSMISSION CONTROL VALVE548
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE553
STEERING PPC VALVE555
STEERING PISTON556
PRIORITY VALVE557
BRAKE VALVE558
PARKING BRAKE CYLINDER559
FINAL DRIVE561
DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE)563
TRACK FRAME, RECOIL SPRING564
IDLER565
TRACK ROLLER567
CARRIER ROLLER568
TRACK SHOE569
MAIN CONTROL VALVE575
COOLING FAN DRIVE PUMP586
COOLING FAN DRIVE MOTOR587
WORK EQUIPMENT CYLINDER589
WORK EQUIPMENT591
90 OTHERS594
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM595
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM596
ELECTRICAL CIRCUIT DIAGRAM WITH CAB (1/2)597
ELECTRICAL CIRCUIT DIAGRAM WITH CAB (2/2)599
ELECTRICAL CIRCUIT DIAGRAM WITHOUT CAB (1/2)601
ELECTRICAL CIRCUIT DIAGRAM WITHOUT CAB (2/2)603
CAB ELECTRICAL CIRCUIT DIAGRAM605

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24