Komatsu D41E,P-6 Bulldozer Shop Manual SEBM028801 PDF
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Komatsu D41E,P-6 Bulldozer Shop Manual SEBM028801 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
D41E-6 B40001 and up
D41P-6 B40001 and up
Description
Komatsu D41E,P-6 Bulldozer Shop Manual SEBM028801 – PDF DOWNLOAD
FILE DETAILS:
Komatsu D41E,P-6 Bulldozer Shop Manual SEBM028801 – PDF DOWNLOAD
Language : English
Pages : 584
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu D41E,P-6 Bulldozer Shop Manual SEBM028801 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
D41E-6 B40001 and up
D41P-6 B40001 and up
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWARD 8
GENERAL 8
HOW TO READ THE SHOP MANUAL 9
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
SPECIFICATION DRAWING 27
SPECIFICATIONS 29
WEIGHT TABLE 33
TABLE OF FUEL, COOLANT AND LUBRICANTS 35
10 STRUCTURE AND FUNCTION 38
RADIATOR, OIL COOLER 39
ENGINE CONTROL 41
POWER TRAIN 43
POWER TRAIN SYSTEM 44
POWER TRAIN HYDRAULIC PIPING DRAWING 45
DAMPER, UNIVERSAL JOINT 46
TRANSMISSION CONTROL 47
TRANSMISSION 49
TRANSMISSION CONTROL VALVE 58
STEERING, BRAKE, INCHING CONTROL 67
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 69
STEERING PPC VALVE 79
STEERING PISTON 83
PRIORITY VALVE 84
BRAKE VALVE 86
POWER TRAIN OIL FILTER 90
FINAL DRIVE 91
FRAME ASSEMBLY 93
TRACK FRAME 94
RECOIL SPRING 95
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 96
WORK EQUIPMENT CONTROL 97
HYDRAULIC TANK, FILTER 99
MAIN CONTROL VALVE 101
CLSS 112
COOLING FAN DRIVE MOTOR 125
FAN CONTROLLER 132
WORK EQUIPMENT 133
AIR CONDITIONER 134
ENGINE CONTROL SYSTEM 135
MACHINE MONITOR SYSTEM 136
COOLING FAN CONTROL SYSTEM 140
SENSORS 144
20 TESTING AND ADJUSTING 147
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 148
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 149
STANDARD VALUE TABLE FOR MACHINE MONITOR 152
TESTING AND ADJUSTING 155
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 156
ADJUSTING VALVE CLEARANCE 157
MEASURING BLOW-BY 158
TESTING AND ADJUSTING FUEL INJECTION TIMING 159
MEASURING EXHAUST COLOR 160
MEASURING ENGINE OIL PRESSURE 161
MEASUREMENT OF ENGINE SPEED 162
ADJUSTING FUEL CONTROL LINKAGE 163
ADJUSTING DECELERATOR PEDAL LINKAGE 164
ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER 166
TESTING MAIN BRAKE AND PARKING BRAKE 168
TESTING WEAR OF BRAKE LINING AND CLUTCH LINING 170
ADJUSTING BRAKE, CLUTCH LEVER ASSEMBLY AND LINING CLEARANCE 171
ADJUSTING BRAKE PEDAL LINKAGE 175
ADJUSTING INCHING PEDAL LINKAGE 176
ADJUSTING PARKING BRAKE LINKAGE 177
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE AND SAFETY LEVER LINKAGE 179
MEASURING POWER TRAIN OIL PRESSURE 180
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE 184
MEASURING AND ADJUSTING FAN MOTOR SPEED AND DRIVE CIRCUIT OIL PRESURE 185
MEASURING FAN SPEED 186
TESTING AND ADJUSTING TRACK SHOE TENSION 187
MEASURING LEAKAGE INSIDE CYLINDER 188
BLEEDING AIR FROM HYDRAULIC CYLINDER 189
PROCEDURE FOR RELEASING PARKING BRAKE 190
TESTING AND ADJUSTING “OPEN” AND “CLOSE” LOCK AND STEADY REST OF OPERATOR’S CAB DOOR 191
TROUBLESHOOTING 195
POINTS TO REMEMBER WHEN TROUBLESHOOTING 196
SEQUENCE OF EVENTS IN TROUBLESHOOTING 197
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 198
CHECKS BEFORE TROUBLESHOOTING 206
METHOD OF USING TROUBLESHOOTING CHARTS 207
TYPES AND LOCATIONS OF CONNECTORS 209
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 221
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 243
METHOD OF USING TROUBLESHOOTING CHARTS 244
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 248
S-2 ENGINE DOES NOT START 250
1) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 250
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 251
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR) 252
S-4 ENGINE STOPS DURING OPERATIONS 253
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 254
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 255
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 256
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 257
S-9 OIL BECOMES CONTAMINATED QUICKLY 258
S-10 FUEL CONSUMPTION IS EXCESSIVE 259
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 260
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 261
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 262
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 263
S-15 ABNORMAL NOISE IS MADE 264
S-16 VIBRATION IS EXCESSIVE 265
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 267
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC SYSTEM) 268
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 271
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON 276
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID MALFUNCTIONS) 278
E-3 LAMPS DO NOT LIGHT UP 281
a) HEAD LAMP 281
b) REAR LAMP 282
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO 284
E-5 WIPER DOES NOT OPERATE 286
E-6 NO WASHER FLUID IS SPRAYED OUT 290
E-7 AIR CONDITIONER HAS NO EFFECT 292
a) NO AIR COMES OUT 292
b) DOES NOT BECOME COOL 296
E-8 FAN MALFUNCTIONS 300
a) FORWARD FAN SPEED IS LOW 300
b) FORWARD FAN SPEED DOES NOT LOWER FROM MAXIMUM LEVEL (WHEN WATER TEMPERATURE IS BELOW 85 degrees C) 300
c) FAN DOES NOT REVOLVE IN REVERSE 302
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 305
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM) 306
H-1 BRAKES DO NOT WORK 308
a) WHEN INCHING PEDAL IS OPERATED 308
b) WHEN PARKING BRAKE LEVER IS AT LOCK 309
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) 310
H-3 OVERRUNS WHEN TURNING 311
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTIONAL LEVER IS OPERATED) 312
H-5 MACHINE DOES NOT MOVE OFF IN ANY SPEED RANGE 313
H-6 EXCESSIVE TIME LAG 314
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE) 314
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD) 315
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH 316
H-10 LACKS DRAWBAR PULL, TRAVEL SPEED IS SLOW 317
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND TANDEM PUMP 318
H-12 NO WORK EQUIPMENT MOVES 319
H-13 SPEED OF ALL WORK EQUIPMENT IS SLOW OR LACKS POWER 319
H-14 BLADE LIFT SPEED OR TILT SPEED IS SLOW OR LACKS POWER 320
H-15 BLADE ANGLE SPEED IS SLOW OR LACKS POWER 321
H-16 HYDRAULIC DRIFT OF BLADE LIFT, BLADE TILT IS EXCESSIVE 322
H-17 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE 322
H-18 FAN SPEED IS LOW 323
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 325
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 326
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 328
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON 329
M-2 WHEN STARTING SWITCH IS TURNED TO ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT 329
M-3 PREHEATING DISPLAY IS ABNORMAL 330
a) PREHEATING MONITOR DOES NOT LIGHT UP 330
b) PREHEATING MONITOR STAYS LIGHTED UP 330
M-4 CAUTION ITEMS LIGHT UP OR FLASH 332
a) (CHARGE) LIGHTS UP OR FLASHES 332
b) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES 333
c) (COOLANT TEMPERATURE) FLASHES 334
d) (POWER TRAIN OIL TEMPERATURE) FLASHES 335
M-5 BUZZER IS ABNORMAL 336
a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND 336
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS 336
M-6 WARNING LAMP IS ABNORMAL 337
a) CAUTION ITEM IS FLASHING BUT LAMP DOES NOT FLASH 337
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES 337
M-7 GAUGE IS ABNORMAL 338
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 338
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE 339
c) ABNORMALITY IN FUEL LEVEL GAUGE 340
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 341
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL) 342
30 DISASSEMBLY AND ASSEMBLY 344
METHOD OF USING MANUAL 346
PRECAUTIONS WHEN CARRYING OUT OPERATION 347
SPECIAL TOOL LIST 349
SKETCHES OF SPECIAL TOOLS 355
FUEL INJECTION PUMP ASSEMBLY 357
REMOVAL 357
INSTALLATION 359
ENGINE HOOD ASSEMBLY 361
REMOVAL 361
INSTALLATION 362
CYLINDER HEAD ASSEMBLY 363
REMOVAL 363
INSTALLATION 366
FUEL TANK ASSEMBLY 368
REMOVAL 368
INSTALLATION 369
RADIATOR AND OIL COOLER ASSEMBLY 370
REMOVAL 370
INSTALLATION 370
FAN DRIVE PUMP ASSEMBLY 371
REMOVAL 371
INSTALLATION 371
FAN MOTOR ASSEMBLY 372
REMOVAL 372
INSTALLATION 372
ENGINE ASSEMBLY 373
REMOVAL 373
INSTALLATION 376
RADIATOR AND RADIATOR GUARD ASSEMBLY 377
REMOVAL 377
INSTALLATION 379
DAMPER ASSEMBLY 380
REMOVAL 380
INSTALLATION 381
TRANSMISSION ASSEMBLY 383
REMOVAL 383
INSTALLATION 386
PTO ASSEMBLY 387
DISASSEMBLY 387
ASSEMBLY 388
TRANSMISSION ASSEMBLY 390
DISASSEMBLY 390
ASSEMBLY 401
STEERING CASE ASSEMBLY 413
DISASSEMBLY 413
ASSEMBLY 419
FINAL DRIVE ASSEMBLY 428
REMOVAL 428
INSTALLATION 428
DISASSEMBLY 429
ASSEMBLY 433
IDLER ASSEMBLY 438
REMOVAL 438
INSTALLATION 438
RECOIL SPRING ASSEMBLY 439
DISASSEMBLY 439
ASSEMBLY 440
IDLER ASSEMBLY 441
DISASSEMBLY 441
ASSEMBLY 442
TRACK ROLLER ASSEMBLY 445
DISASSEMBLY 445
ASSEMBLY 447
CARRIER ROLLER ASSEMBLY 449
DISASSEMBLY 449
ASSEMBLY 450
TRACK SHOE ASSEMBLY 452
REMOVAL 452
INSTALLATION 453
OVERALL DISASSEMBLY 454
OVERALL ASSEMBLY 459
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 473
ONE LINK 474
FIELD DISASSEMBLY 474
FIELD ASSEMBLY 476
MAIN CONTROL VALVE 483
ASSEMBLY 483
HYDRAULIC CYLINDER ASSEMBLY 489
DISASSEMBLY 489
ASSEMBLY 491
WORK EQUIPMENT 493
REMOVAL 493
INSTALLATION 494
DISASSEMBLY 495
ASSEMBLY 498
HYDRAULIC TANK ASSEMBLY 501
REMOVAL 501
INSTALLATION 501
ROPS ROOF, GUARD 502
REMOVAL 502
INSTALLATION 502
ROPS ASSEMBLY 503
REMOVAL 503
INSTALLATION 503
OPERATOR’S CAB ASSEMBLY 504
REMOVAL 504
INSTALLATION 506
FLOOR FRAME ASSEMBLY 510
REMOVAL 510
INSTALLATION 514
40 MAINTENANCE STANDARD 515
DAMPER, UNIVERSAL JOINT 516
HYDRAULIC+POWER TRAIN PUMP 517
TRANSMISSION 519
TRANSMISSION CONTROL VALVE 525
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 530
STEERING PPC VALVE 532
STEERING PISTON 533
PRIORITY VALVE 534
BRAKE VALVE 535
PARKING BRAKE CYLINDER 536
FINAL DRIVE 538
DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE) 540
TRACK FRAME, RECOIL SPRING 541
IDLER 542
TRACK ROLLER 544
CARRIER ROLLER 545
TRACK SHOE 546
MAIN CONTROL VALVE 552
COOLING FAN DRIVE PUMP 563
COOLING FAN DRIVE MOTOR 564
WORK EQUIPMENT CYLINDER 566
WORK EQUIPMENT 568
90 OTHERS 571
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 572
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 573
ELECTRICAL CIRCUIT DIAGRAM WITH CAB (1/2) 574
ELECTRICAL CIRCUIT DIAGRAM WITH CAB (2/2) 576
ELECTRICAL CIRCUIT DIAGRAM WITHOUT CAB (1/2) 578
ELECTRICAL CIRCUIT DIAGRAM WITHOUT CAB (2/2) 580
CAB ELECTRICAL CIRCUIT DIAGRAM 582
DESCRIPTION:
Komatsu D41E,P-6 Bulldozer Shop Manual SEBM028801 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
D41E-6 B40001 and up
D41P-6 B40001 and up
Mistakes 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 operating 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.
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.
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 components 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 carrying 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 internal 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.
G.B 18/12/24
