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

Description

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

FILE DETAILS:

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

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

MACHINE MODEL       SERIAL NUMBER
D41E-6                           B40001 and up
D41P-6                           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, FILTER 100
MAIN CONTROL VALVE 102
CLSS 113
COOLING FAN DRIVE MOTOR 126
FAN CONTROLLER 133
WORK EQUIPMENT 134
AIR CONDITIONER 135
ENGINE CONTROL SYSTEM 136
MACHINE MONITOR SYSTEM 137
COOLING FAN CONTROL SYSTEM 141
SENSORS 145
20 TESTING AND ADJUSTING 148
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 149
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 150
STANDARD VALUE TABLE FOR MACHINE MONITOR 153
TESTING AND ADJUSTING 156
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 157
ADJUSTING VALVE CLEARANCE 158
MEASURING BLOW-BY 159
TESTING AND ADJUSTING FUEL INJECTION TIMING 160
MEASURING EXHAUST COLOR 161
MEASURING ENGINE OIL PRESSURE 162
MEASUREMENT OF ENGINE SPEED 163
ADJUSTING FUEL CONTROL LINKAGE 164
ADJUSTING DECELERATOR PEDAL LINKAGE 165
ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER 167
TESTING MAIN BRAKE AND PARKING BRAKE 169
TESTING WEAR OF BRAKE LINING AND CLUTCH LINING 171
ADJUSTING BRAKE, CLUTCH LEVER ASSEMBLY AND LINING CLEARANCE 172
ADJUSTING BRAKE PEDAL LINKAGE 176
ADJUSTING INCHING PEDAL LINKAGE 177
ADJUSTING PARKING BRAKE LINKAGE 178
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE AND SAFETY LEVER LINKAGE 180
MEASURING POWER TRAIN OIL PRESSURE 181
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE 185
MEASURING AND ADJUSTING FAN MOTOR SPEED AND DRIVE CIRCUIT OIL PRESURE 186
MEASURING FAN SPEED 187
TESTING AND ADJUSTING TRACK SHOE TENSION 188
MEASURING LEAKAGE INSIDE CYLINDER 189
BLEEDING AIR FROM HYDRAULIC CYLINDER 190
PROCEDURE FOR RELEASING PARKING BRAKE 191
TESTING AND ADJUSTING “OPEN” AND “CLOSE” LOCK AND STEADY REST OF OPERATOR’S CAB DOOR 192
TROUBLESHOOTING 198
POINTS TO REMEMBER WHEN TROUBLESHOOTING 199
SEQUENCE OF EVENTS IN TROUBLESHOOTING 200
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 201
CHECKS BEFORE TROUBLESHOOTING 209
METHOD OF USING TROUBLESHOOTING CHARTS 210
TYPES AND LOCATIONS OF CONNECTORS 212
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 224
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 250
METHOD OF USING TROUBLESHOOTING CHARTS 251
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 255
S-2 ENGINE DOES NOT START 257
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 OPERATIONS 260
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 QUICKLY 265
S-10 FUEL CONSUMPTION IS EXCESSIVE 266
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 267
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 MADE 271
S-16 VIBRATION IS EXCESSIVE 272
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 274
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC SYSTEM) 275
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 278
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON 283
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID MALFUNCTIONS) 285
E-3 LAMPS DO NOT LIGHT UP 288
a) HEAD LAMP 288
b) REAR LAMP 289
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO 291
E-5 WIPER DOES NOT OPERATE 293
E-6 NO WASHER FLUID IS SPRAYED OUT 297
E-7 AIR CONDITIONER HAS NO EFFECT 299
a) NO AIR COMES OUT 299
b) DOES NOT BECOME COOL 303
E-8 FAN MALFUNCTIONS 307
a) FORWARD FAN SPEED IS LOW 307
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 REVERSE 309
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 312
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM) 313
H-1 BRAKES DO NOT WORK 315
a) WHEN INCHING PEDAL IS OPERATED 315
b) WHEN PARKING BRAKE LEVER IS AT LOCK 316
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) 317
H-3 OVERRUNS WHEN TURNING 318
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 RANGE 320
H-6 EXCESSIVE TIME LAG 321
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 HIGH 323
H-10 LACKS DRAWBAR PULL, TRAVEL SPEED IS SLOW 324
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND TANDEM PUMP 325
H-12 NO WORK EQUIPMENT MOVES 326
H-13 SPEED OF ALL WORK EQUIPMENT IS SLOW OR LACKS POWER 326
H-14 BLADE LIFT SPEED OR TILT SPEED IS SLOW OR LACKS POWER 327
H-15 BLADE ANGLE SPEED IS SLOW OR LACKS POWER 328
H-16 HYDRAULIC DRIFT OF BLADE LIFT, BLADE TILT IS EXCESSIVE 329
H-17 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE 329
H-18 FAN SPEED IS LOW 330
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 332
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 333
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 335
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON 336
M-2 WHEN STARTING SWITCH IS TURNED TO ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT 336
M-3 PREHEATING DISPLAY IS ABNORMAL 337
a) PREHEATING MONITOR DOES NOT LIGHT UP 337
b) PREHEATING MONITOR STAYS LIGHTED UP 337
M-4 CAUTION ITEMS LIGHT UP OR FLASH 339
a) (CHARGE) LIGHTS UP OR FLASHES 339
b) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES 340
c) (COOLANT TEMPERATURE) FLASHES 341
d) (POWER TRAIN OIL TEMPERATURE) FLASHES 342
M-5 BUZZER IS ABNORMAL 343
a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND 343
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS 343
M-6 WARNING LAMP IS ABNORMAL 344
a) CAUTION ITEM IS FLASHING BUT LAMP DOES NOT FLASH 344
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES 344
M-7 GAUGE IS ABNORMAL 345
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 345
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE 346
c) ABNORMALITY IN FUEL LEVEL GAUGE 347
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 348
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL) 349
30 DISASSEMBLY AND ASSEMBLY 351
METHOD OF USING MANUAL 353
PRECAUTIONS WHEN CARRYING OUT OPERATION 354
SPECIAL TOOL LIST 356
SKETCHES OF SPECIAL TOOLS 362
FUEL INJECTION PUMP ASSEMBLY 364
REMOVAL 364
INSTALLATION 366
ENGINE HOOD ASSEMBLY 368
REMOVAL 368
INSTALLATION 369
CYLINDER HEAD ASSEMBLY 370
REMOVAL 370
INSTALLATION 373
FUEL TANK ASSEMBLY 375
REMOVAL 375
INSTALLATION 376
RADIATOR AND OIL COOLER ASSEMBLY 377
REMOVAL 377
INSTALLATION 377
FAN DRIVE PUMP ASSEMBLY 378
REMOVAL 378
INSTALLATION 378
FAN MOTOR ASSEMBLY 379
REMOVAL 379
INSTALLATION 379
ENGINE ASSEMBLY 380
REMOVAL 380
INSTALLATION 383
RADIATOR AND RADIATOR GUARD ASSEMBLY 384
REMOVAL 384
INSTALLATION 386
DAMPER ASSEMBLY 387
REMOVAL 387
INSTALLATION 388
TRANSMISSION ASSEMBLY 390
REMOVAL 390
INSTALLATION 393
PTO ASSEMBLY 394
DISASSEMBLY 394
ASSEMBLY 395
TRANSMISSION ASSEMBLY 397
DISASSEMBLY 397
ASSEMBLY 409
STEERING CASE ASSEMBLY 423
DISASSEMBLY 423
ASSEMBLY 429
FINAL DRIVE ASSEMBLY 438
REMOVAL 438
INSTALLATION 438
DISASSEMBLY 439
ASSEMBLY 443
IDLER ASSEMBLY 448
REMOVAL 448
INSTALLATION 448
RECOIL SPRING ASSEMBLY 449
DISASSEMBLY 449
ASSEMBLY 450
IDLER ASSEMBLY 451
DISASSEMBLY 451
ASSEMBLY 452
TRACK ROLLER ASSEMBLY 455
DISASSEMBLY 455
ASSEMBLY 457
CARRIER ROLLER ASSEMBLY 459
DISASSEMBLY 459
ASSEMBLY 460
TRACK SHOE ASSEMBLY 462
REMOVAL 462
INSTALLATION 463
OVERALL DISASSEMBLY 464
OVERALL ASSEMBLY 469
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 483
ONE LINK 484
FIELD DISASSEMBLY 484
FIELD ASSEMBLY 486
MAIN CONTROL VALVE 493
ASSEMBLY 493
HYDRAULIC CYLINDER ASSEMBLY 499
DISASSEMBLY 499
ASSEMBLY 501
WORK EQUIPMENT 503
REMOVAL 503
INSTALLATION 504
DISASSEMBLY 505
ASSEMBLY 508
HYDRAULIC TANK ASSEMBLY 511
REMOVAL 511
INSTALLATION 511
ROPS ROOF, GUARD 512
REMOVAL 512
INSTALLATION 512
ROPS ASSEMBLY 513
REMOVAL 513
INSTALLATION 513
OPERATOR’S CAB ASSEMBLY 514
REMOVAL 514
INSTALLATION 516
FLOOR FRAME ASSEMBLY 522
REMOVAL 522
INSTALLATION 526
40 MAINTENANCE STANDARD 538
DAMPER, UNIVERSAL JOINT 539
HYDRAULIC+POWER TRAIN PUMP 540
TRANSMISSION 542
TRANSMISSION CONTROL VALVE 548
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 553
STEERING PPC VALVE 555
STEERING PISTON 556
PRIORITY VALVE 557
BRAKE VALVE 558
PARKING BRAKE CYLINDER 559
FINAL DRIVE 561
DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE) 563
TRACK FRAME, RECOIL SPRING 564
IDLER 565
TRACK ROLLER 567
CARRIER ROLLER 568
TRACK SHOE 569
MAIN CONTROL VALVE 575
COOLING FAN DRIVE PUMP 586
COOLING FAN DRIVE MOTOR 587
WORK EQUIPMENT CYLINDER 589
WORK EQUIPMENT 591
90 OTHERS 594
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 595
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 596
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 DIAGRAM 605

DESCRIPTION:

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

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

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 24/12/24