Complete service repair manual for Komatsu Bulldozers D40-, D41-, D45- series, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Komatsu Bulldozers D40-, D41-, D45- series workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
D40,45.1BE-2 – Bulldozer/Dozer Shovel D40A,P-1 & D45A,P,S-1 Shop Manual (SN1501&up).pdf
SEBM0125B04 – Bulldozer D41S,Q-3 Shop Manual (SN60001&up).pdf
SEBM007009 – Bulldozer D41E,P-6 Shop Manual.pdf
SEBM007009 – Bulldozer D41E,P-6 Shop Manual (SN-B20001_50001&up).pdf
SEBM028801 – Bulldozer D41E-6, D41P-6 Shop Manual.pdf
SEBM028803 – Bulldozer D41E,P-6 Shop Manual (SN-B40001&up).pdf
PRODUCT DETAILS:
Total Pages: 4,018 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
01 GENERAL .. 01-1
10 STRUCTURE AND FUNCTION .. 10-1
20 TESTING AND ADJUSTING .. 20-1
30 DISASSEMBLY AND ASSEMBLY … 30-1
40 MAINTENANCE STANDARD… 40-1
90 OTHERS .. 90-1
D40,45.1BE-2 – Bulldozer_Dozer Shovel D40A,P-1 & D45A,P,S-1 Shop Manual (SN1501&up)…..2
SEBM007009 – Bulldozer D41E,P-6 Shop Manual (SN-B20001_50001&up)…..968
COVER…..968
CONTENTS…..969
01 GENERAL…..993
GENERAL ASSEMBLY DRAWING…..994
SPECIFICATIONS…..996
WEIGHT TABLE…..1000
TABLE OF FUEL, COOLANT AND LUBRICANTS…..1002
10 STRUCTURE AND FUNCTION…..1004
RADIATOR, OIL COOLER…..1005
ENGINE CONTROL…..1007
POWER TRAIN…..1008
POWER TRAIN SYSTEM…..1009
POWER TRAIN HYDRAULIC PIPING DIAGRAM…..1010
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…..1012
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..1013
DAMPER, UNIVERSAL JOINT…..1014
TRANSMISSION CONTROL…..1015
TRANSMISSION…..1016
TRANSMISSION CONTROL VALVE…..1025
STEERING, BRAKE, INCHING CONTROL…..1034
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE…..1037
STEERING PPC VALVE…..1057
STEERING PISTON…..1061
PRIORITY VALVE…..1062
BRAKE VALVE…..1064
POWER TRAIN OIL FILTER…..1068
FINAL DRIVE…..1069
FRAME ASSEMBLY…..1073
TRACK FRAME…..1074
RECOIL SPRING…..1075
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…..1076
WORK EQUIPMENT CONTROL…..1077
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…..1079
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…..1080
HYDRAULIC TANK, FILTER…..1081
MAIN CONTROL VALVE…..1083
CLSS…..1093
WORK EQUIPMENT…..1105
AIR CONDITINER…..1106
ACTUAL ELECTRIC WIRING DIAGRAM…..1108
ELECTRICAL CIRCUIT DIAGRAM…..1109
ENGINE CONTROL SYSTEM…..1112
MACHINE MONITOR SYSTEM…..1113
SENSORS…..1117
20 TESTING AND ADJUSTING…..1120
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…..1121
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…..1122
STANDARD VALUE TABLE FOR MACHINE MONITOR…..1125
TESTING AND ADJUSTING…..1128
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…..1129
ADJUSTING VALVE CLEARANCE…..1130
MEASURING BLOW-BY…..1131
TESTING AND ADJUSTNG FUEL INJECTION TIMING…..1132
MEASURING EXHAUST COLOR…..1133
MEASURING ENGINE OIL PRESSURE…..1134
MEASURING ENGINE SPEED…..1135
ADJUSTING FUEL CONTROL LINKAGE…..1136
ADJUSTING DECELERATOR PEDAL LINKAGE…..1137
ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER…..1150
TESTING MAIN BRAKE AND PARKING BRAKE…..1154
TESTING WEAR OF BRAKE LINING AND CLUTCH LINING…..1156
ADJUSTING BRAKE, CLUTCH LEVER ASSEMBLY AND LINING CLEARANCE…..1157
ADJUSTING BRAKE PEDAL LINKAGE…..1161
ADJUSTING INCHING PEDAL LINKAGE…..1162
ADJUSTING PARKING BRAKE LINKAGE…..1163
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE AND SAFETY LEVER LINKAGE…..1165
MEASURING POWER TRAIN OIL PRESSURE…..1166
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE…..1170
TESTING AND ADJUSTING TRACK SHOE TENSION…..1171
MEASURING LEAKAGE INSIDE CYLINDER…..1172
BLEEDING AIR FROM HYDRAULIC CYLINDER…..1173
PROCEDURE FOR RELEASING PARKING BRAKE…..1174
TESTING AND ADJUSTING OPERATOR'S CAB…..1175
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATOR'S CAB DOOR…..1176
TROUBLESHOOTING…..1178
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..1179
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..1180
POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..1181
CHECK BEFORE TROUBLESHOOTING…..1189
METHOD OF USING TROUBLESHOOTING CHARTS…..1190
CONNECTOR TYPES AND MOUNTING LOCATIONS…..1192
CONNECTOR ARRENGEMENT DIAGRAM…..1194
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..1200
T-ADAPTER TABLE…..1223
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…..1226
MERHOD OF USING TROUBLESHOOTING CHARTS…..1227
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..1231
S-2 ENGINE DOES NOT START…..1233
1) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)…..1233
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…..1234
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…..1235
S-4 ENGINE STOPS DURING OPERATIONS…..1236
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..1237
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) …..1238
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..1239
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..1240
S-9 OIL BECOMES CONTAMINATED QUICKLY…..1241
S-10 FUEL CONSUMPTION IS EXCESSIVE…..1242
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..1243
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..1244
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..1245
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..1246
S-15 ABNORMAL NOISE IS MADE…..1247
S-16 VIBRATION IS EXCESSIVE…..1248
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…..1249
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…..1250
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM…..1251
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON …..1256
E-2 ENGINE DOES NOT START (DEFECTIVE OPERATION OF ENGINE STOP SOLENOID)…..1260
E-3 LAMPS DO NO LIGHT UP…..1261
a) FRONT LAMPS…..1261
b) REAR LAMPS…..1264
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO…..1266
E-5 CAB WIPER DOES NOT WORK…..1270
E-6 NO WASHER FLUID ID SPRAYED OUT…..1274
E-7 AIR CONDITIONER HAS NO EFFECT…..1278
a) NO AIR COMES OUT…..1278
b) DOES MOT BECOME COOL…..1282
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)…..1286
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)…..1287
H-1 BRAKES DOES NOT WORK…..1289
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE)…..1291
H-3 OVERTURNS WHEN TURING…..1292
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTIONAL LEVER IS OPERATED)…..1293
H-5 MACHINE DOES NOT MOVE OFF IN ANY SPEED RANGE…..1294
H-6 EXCESSIVE TIME LAG…..1295
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)…..1295
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)…..1296
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH…..1297
H-10 LACKS DRAWBAR PULL, TRAVEL SPEED IS SLOW…..1298
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC PUMP…..1299
H-12 NO WORK EQUIPMENT MOVES…..1300
H-13 SPEED OF ALL WORK EQUIPMENT IS SLOW OR LACKS POWER…..1300
H-14 BLADE LIFT SPEED OR TILT SPEED IS SLOW OR LACKS POWER…..1301
H-15 BLADE ANGLE SPEED IS SLOW OR LACKS POWER…..1302
H-16 HYDRAULIC DRIFT OF BLADE LIFT, BLADE TILT IS EXCESSIVE…..1303
H-17 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE…..1303
TROUBLESHOOTING OF MACHING MONITOR SYSTEM (M MODE)…..1304
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…..1305
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM…..1306
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON …..1310
M-2 WHEN STARTING SWITCH IS TURNED TO ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT…..1310
M-3 PREHEATING DISPLAY IS ABNORMAL…..1311
a) PREHEATING MONITOR DOES NOT LIGHT UP…..1311
b) PREHEATING MONITOR STAYS LIGHTED UP…..1311
M-4 CAUTION ITEMS LIGHT UP OR FLASH…..1315
a) (CHARGE) LIGHTS UP OR FLASHES…..1315
b) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED, (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES…..1316
c) (COOLANT TEMPERATURE) FLASHES…..1317
d) (POWER TRAIN OIL TEMPERATURE) FLASHES…..1318
M-5 BUZZER IS ABNORMAL…..1323
a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND…..1323
b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS…..1323
M-6 WARNING LAMP IS ABNORMAL…..1324
a) CAUTION ITEM IS FLASHES BUT LAMP DOES NOT FLASH…..1324
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES…..1324
M-7 GAUGE IS ABNORMAL …..1325
a) ABNORMAILTY IN ENGINE COOLANT TEMPERATURE GAUGE…..1325
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE…..1327
c) ABNORMALITY IN FUEL LEVEL GAUGE…..1328
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED…..1329
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)…..1330
30 DISASSEMBLY AND ASSEMBLY…..1331
METHOD OF USING MANUAL…..1334
PRECAUTIONS WHEN CARRYING OUT OPERATION…..1335
SPECIAL TOOL LIST…..1337
SKETCHES OF SPECIAL TOOLS…..1342
STARTING MOTOR…..1344
REMOVAL…..1344
INSTALLATION…..1344
ALTERNATOR…..1345
REMOVAL…..1345
INSTALLATION…..1345
ENGINE OIL COOLER CORE…..1346
REMOVAL…..1346
INSTALLATION…..1346
FUEL INJECTION PUMP ASSEMBLY…..1347
REMOVAL…..1347
INSTALLATION…..1351
WATER PUM …..1353
REMOVAL…..1353
INSTALLATION…..1353
TURBOCHARGER…..1354
REMOVAL…..1354
INATALLATION…..1354
NOZZLE HOLDER …..1355
REMOVAL…..1355
INSTALLATION…..1355
THERMOSTAL…..1356
REMOVAL…..1356
INSTALLATION…..1356
ENGINE HOOD…..1357
REMOVAL…..1357
INSTALLATION…..1357
CYLINDRER HEAD…..1358
REMOVAL…..1358
INSTALLATION…..1362
FUEL TANK…..1364
REMOVAL…..1364
INSTALLATION…..1365
RADIATOR,OIL COOLER…..1366
REMOVAL…..1366
INSTALLATION…..1367
HYDRAULIC…..1368
REMOVAL…..1368
INSTALLATION…..1368
ENGINE…..1369
REMOVAL…..1369
INSTALLATION…..1373
RADIATOR, GUARD…..1374
REMOVAL…..1374
INSTALLATION…..1375
DAMPER…..1376
REMOVAL…..1376
INSTALLATION…..1377
TRANSMISSION…..1379
REMOVAL…..1379
INSTALLATION…..1382
PTO…..1383
DISASSEMBLY…..1383
ASSEMBLY…..1384
TRANSMISSION…..1386
DISASSEMBLY…..1386
ASSEMBLY…..1398
STEERING CASE…..1411
DISASSEMBLY…..1411
ASSEMBLY…..1417
PROIRITY VALVE…..1426
REMOVAL…..1426
INSTALLATION…..1426
DISASSEMBLY…..1427
ASSEMBLY…..1427
BRAKE CONTROL VALVE…..1428
REMOVAL…..1428
INSTALLATION…..1428
DISASSEMBLY…..1429
ASSEMBLY…..1431
TRANSMISSION SHIFT VALVE…..1434
REMOVAL…..1434
INSTALLATION…..1434
DISASSEMBLY…..1435
ASSEMBLY…..1437
TRANSMISSION PRESSURE VALVE…..1440
REMOVAL…..1440
INSTALLATION…..1440
DISASSEMBLY…..1441
ASSEMBLY…..1442
STEERING PISTON…..1443
REMOVAL…..1443
INSTALLATION…..1443
DISASSEMBLY…..1444
ASSEMBLY…..1444
PARKING BRAKE CYLINDER…..1445
REMOVAL…..1445
INSTALLATION…..1446
DISASSEMBLY…..1447
ASSEMBLY…..1448
FINAL DRIVE…..1449
REMOVAL…..1449
INSTALATION…..1449
DISASSEMBLY…..1450
ASSEMBLY…..1454
IDLER, RECOIL SPRING…..1468
REMOVAL…..1468
INSTALLATION…..1468
DISASSEMBLY…..1469
ASSEMBLY…..1470
IDLER…..1471
DISASSEMBLY…..1471
ASSEMBLY…..1472
TRACK ROLLER…..1480
REMOVAL…..1480
INSTALLATION…..1480
DISASSEMBLY…..1481
ASSEMBLY…..1482
CARRIER ROLLER…..1484
REMOVAL…..1484
INSTALLATION…..1484
DISASSEMBLY…..1485
ASSEMBLY…..1486
TRACK SHOE…..1488
REMOVAL…..1488
INSTALLATION…..1489
OVERALL DISASSEMBLY…..1490
OVERALL ASSEMBLY…..1495
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…..1509
ONE LINK…..1510
FIELD DISASSEMBLY…..1510
FIELD ASSEMBLY…..1512
HYDRAULIC PUMP…..1518
REMOVAL…..1518
INSTALLATION…..1519
MAIN CONTROL VALVE…..1520
REMOVAL…..1520
INSTALLATION…..1521
DISASSEMBLY…..1522
ASSEMBLY…..1527
MAIN RELIEF VALVE …..1533
REMOVAL…..1533
INSTALLATION…..1533
DISASSEMBLY…..1535
ASSEMBLY…..1536
BLADE ANGLE CYLINDER…..1538
REMOVAL…..1538
INSTALLATION…..1538
BLADE LIFT CYLINDER…..1539
REMOVAL…..1539
INSTALLATION…..1539
BLADE TILT CYLINDER…..1540
INSTALLATION…..1540
HYDRAULIC CYLINDER…..1541
DISSASSEMBLY…..1541
ASSEMBLY…..1543
WORK EQUIPMENT…..1545
REMOVAL…..1545
INSTALLATION…..1546
DISASSEMBLY…..1547
ASSEMBLY…..1550
HYDRAULIC…..1553
REMAOVAL…..1553
INSTALLATION…..1553
ROPS ROOF, GUARD…..1554
REMOVAL…..1554
INSTALLATION…..1554
CANOPY…..1555
REMOVAL…..1555
INSTALLATION…..1555
OPERATOR CAB…..1556
REMOVAL…..1556
INSTALLATION…..1558
OPERATOR CAB GLASS (STUCK GLASS)…..1561
REMOVAL…..1562
INSTALLATION…..1563
FLOOR FRAME…..1569
REMOVAL…..1569
INSTALLATION…..1573
AIR CONDITIONER COMPRESSOR…..1574
REMOVAL…..1574
INSTALLATION…..1575
AIR CONDITIONER CONDENSER…..1576
REMOVAL…..1576
INSTALLATION…..1577
MONITOR…..1578
REMOVAL…..1578
INSTALLATION…..1578
DT CONNECTOR PIN…..1579
REMOVEL…..1579
INSTALLATION…..1580
DH CONNECTOR PIN…..1581
REMOVAL…..1581
INSTALLATION…..1581
REPAIR PROCEDURE FOR WIRING HARNESS…..1582
40 MAINTENANCE STANDARD…..1583
DAMPER, UNIVERSAL JOINT…..1584
HYDRAULIC+POWER TRAIN PUMP…..1585
TRANSMISSION…..1586
TRANISMISSION CONTROL VALVE…..1591
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE…..1596
STEERING PPC VALVE…..1600
STEERING PISTON…..1601
PRIORITY VALVE…..1602
BRAKE VALVE…..1603
PARKING BRAKE CYLINDER…..1604
FINAL DRIVE…..1605
TRACK FRAME, RECOIL SPRING…..1609
IDLER…..1610
TRACK ROLLER…..1613
CARRIER ROLLER…..1614
TRACK SHOE…..1615
MAIN CONTROL VALVE…..1621
WORK EQUIPMENT CYLINDER…..1631
WORK EQUIPMENT…..1633
90 OTHERS…..1636
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…..1637
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..1638
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…..1639
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…..1640
ACTUAL ELECTRIC WIRING DIAGRAM…..1641
ELECTRICAL CIRCUIT DIAGRAM…..1642
WITH CAB (SERIAL NO.:B20001-B40000, 50001-50200)…..1642
WITHOUT CAB (SERIAL NO.:B20001-B40000, 50001-50200)…..1643
CAB ELECERICAL CIRCUIT DIAGRAM (SERIAL NO.:B20001-B40000, 50001-50200)…..1644
SEBM007009 – Bulldozer D41E,P-6 Shop Manual…..1645
COVER…..1645
CONTENTS…..1646
SAFETY…..1651
FOREWORD…..1653
GENERAL…..1653
HOW TO READ THE SHOPMANUAL…..1654
HOISTING INSTRUCTION…..1655
METHOD OF DISASSEMBLING, CONNECTION PUSH-PULL TYPE COUPLER…..1656
COATING MATERIALS…..1658
STANDARD TIGHTENING TORQUE…..1660
ELECTRIC WIRE CODE…..1663
CONVERSION TABLE…..1664
UNITS…..1670
01 GENERAL…..1671
GENERAL ASSEMBLY DRAWING…..1672
SPECIFICATIONS…..1674
WEIGHT TABLE…..1686
TABLE OF FUEL, COOLANT AND LUBRICANTS…..1692
10 STRUCTURE AND FUNCTION…..1695
RADIATOR, OIL COOLER…..1696
ENGINE CONTROL…..1698
POWER TRAIN…..1700
POWER TRAIN SYSTEM…..1701
POWER TRAIN HYDRUALIC PIPING DRAWING…..1702
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…..1704
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..1705
DAMPER, UNIVERSAL JOINT…..1706
TRANSMISSION CONTROL…..1707
TRANSMISSION…..1709
TRANSMISSION CONTROL VALVE…..1718
STEERING, BRAKE, INCHING CONTROL…..1727
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE…..1730
STEERING PPC VALVE…..1750
STEERING PISTON…..1755
PRIORITY VALVE…..1756
BRAKE VALVE…..1758
POWER TRAIN OIL FILTER…..1762
FINAL DRIVE…..1763
FRAME ASSEMBLY…..1767
TRACK FRAME…..1768
RECOIL SPRING…..1770
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM…..1771
WORK EQUIPMENT CONTROL…..1772
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…..1774
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…..1775
HYDRAULIC TANK, FILTER…..1776
MAIN CONTROL VALVE…..1778
CLSS…..1789
WORK EQUIPMENT…..1801
AIR CONDITIONER…..1803
ACTUAL ELECTRIC WIRING DIAGRAM…..1804
ELECTRICAL CIRCUIT DIAGRAM…..1806
ENGINE CONTROL SYSTEM…..1810
MACHINE MONITOR SYSTEM…..1811
SENSORS…..1815
20 TESTING AN ADJUSTING…..1818
STANDARD VALUE TABLE FOR ENGINE RELATE PARTS…..1819
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…..1820
STANDARD VALUE TABLE FOR MACHINE MONITOR…..1823
TESTING AND ADJUSTING…..1826
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…..1827
ADJUSTING VALVE CLEARANCE…..1828
MEASURING BLOW-BY…..1829
TESTING AND ADJUSTING FUEL INJECTION TIMING…..1830
MEASURING EXHAUST COLOR…..1831
MEASURING ENGINE OIL PRESSURE…..1832
MEASURING ENGINE SPEED…..1833
ADJUSTING FUEL CONTROL LINKAGE…..1834
ADJUSTING DECELERATOR PEDAL LINKAGE…..1835
ADJUSTING ENGINE STOP SOLENOID…..1838
ADJUSTING STEERING, DIRECTIONAL, GEAR SHIFT LEVER…..1848
TESTING MAIN BRAKE AND PARKING BRAKE…..1852
TESTING WEAR OF BRAKE LINING AND CLUTCH LINING…..1854
ADJUSTING BRAKE, CLUTCH LEVER ASSEMBLY AND LINING CLEARANCE…..1855
ADJUSTING BRAKE PEDAL LINKAGE…..1859
ADJUSTING INCHING PEDAL LINKAGE…..1860
ADJUSTING PARKING BRAKE LINKAGE…..1861
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE AND SAFETY LEVER LINKAGE…..1863
MEASURING POWER TRAIN OIL PRESSURE…..1864
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE…..1868
TESTING AND ADJUSTING TRACK SHOE TENSION…..1869
MEASURING LEAKAGE INSIDE CYLINDER…..1870
BLEEDING AIR FROM HYDRAULIC CYLINDER…..1871
PROCEDURE FOR RELEASING PARKING BRAKE…..1872
TESTING AND ADJUSTING OPERATOR'S CAB…..1873
TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATOR'S CAB DOOR…..1874
TROUBLESHOOTING…..1876
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..1877
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..1878
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..1879
CHECKS BEFORE TROUBLESHOOTING…..1887
METHOD OF USING TROUBLESHOOTING CHARTS…..1888
CONNECTOR TYPES AND MOUNTING LOCATIONS…..1891
CONNECTOR ARRANGEMENT DIAGRAM…..1893
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..1899
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…..1926
METHOD OF USING TROUBLESHOOTING CHARTS…..1927
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..1931
S-2 ENGINE DOES NOT START…..1933
1) ENGINE TURNS BUT NOT EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…..1933
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUIE IS BEING INJECTED)…..1934
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…..1935
S-4 ENGINE STOPS DURING OPERATIONS…..1936
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING…..1937
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..1938
S-7 EXHAUST SMOKE IS BLACK …..1939
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE…..1940
S-9 OIL BECOMES CONTAMINATED QUICKLY…..1941
S-10 FUEL CONSUMPTION IS EXCESSIVE…..1942
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..1943
S-12 OIL PRESSURE CAUSTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..1944
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..1945
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..1946
S-15 ABNORMAL NOISE IS MADE…..1947
S-16 VIBRATION IS EXCESSIVE…..1948
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…..1950
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC SYSTEM)…..1951
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM…..1952
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON…..1957
E-2 ENGINE DOES NOT START (DEFECTIVE OPERATION OF ENGINE STOP SOLENOID)…..1961
E-3 LAMPS DO NOT LIGHT UP…..1963
A) FRONT LAMPS…..1963
B) REAR LAMPS…..1964
E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO…..1967
E-5 CAB WIPER DOES NOT WORK…..1971
E-6 NO WASHER FLUID IS SPRAYED OUT…..1975
E-7 AIR CONDITIONER HAS NOT EFFECT…..1979
A) NO AIR COMES OUT…..1979
B) DOES NOT BECOME COOL…..1983
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…..1988
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)…..1989
H-1 BRAKES DO NOT WORK…..1991
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE)…..1993
H-3 OVERRUNS WHEN TURNING…..1994
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTION LEVER IS OPERATED)…..1995
H-5 MACHINE DOES NOT MOVE OFF IN ANY SPEED RANGE…..1996
H-6 EXCESSIVE TIME LAG…..1997
H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)…..1997
H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)…..1998
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH…..1999
H-10 LACKS DRAWBAR PULL, TRAVEL SPEED IS SLOW…..2000
H-11 ABNORMAL NOISE IS GENERATER FROM AROUND TANDEM PUMP…..2001
H-12 NO WORK EQUIPMENT MOVES…..2002
H-13 SPEED OF ALL WORK EQUIPMENT IS SLOW OR LACKS POWER…..2002
H-14 BLADE LIFT SPEED OR TILT SPEED IS SLOW OR LACKS POWER…..2003
H-15 BLADE ANGLE SPEED IS SLOW OR LACKS POWER…..2004
H-16 HYDRAULIC DRIFT OF BLADE LIFT, BLADE TILT IS EXCESSIVE…..2005
H-17 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE…..2005
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…..2006
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…..2007
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM…..2008
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON…..2012
M-2 WHEN STARTING SWITCH IS TURNED TO ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT…..2012
M-3 PREHEATING DISPLAY IS ABNORMAL…..2013
A) PREHEATING MONITOR DOES NOT LIGHT UP…..2013
B) PREHEATING MONITOR STAYS LIT UP…..2013
M-4 CAUTION ITEMS LIGHT UP OR FLASH…..2017
A) RELATED ELECTRICAL CIRCUIT DIAGRAM…..2017
B) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES…..2018
C) (COOLANT TEMPERATURE) FLASHES…..2019
D) (POWER TRAIN OIL TEMPERATURE) FLASHES…..2020
M-5 BUZZER IS ABNORMAL…..2025
A) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND…..2025
B) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS…..2025
M-6 WARNING LAMP IS ABNORMAL…..2026
A) CAUTION ITEM IS FLASHING BUT LAMP DOES NOT FLASH…..2026
B) MONITOR DIAPLAY IS NORMAL BUT LAMP FLASHES…..2026
M-7 GAUGE IS ABNORMAL…..2027
A) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE…..2027
B) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE…..2030
C) ABNORMALITY IN FUEL LEVEL GAUGE…..2031
M-8 SERVICE METER DOES NOT MOVE AFTE ENGINE IS STARTED …..2032
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FORNT LAMPS ARE NORMAL)…..2033
30 DISASSEMBLY AND ASSEMBLY…..2034
METHOD OF USING MANUAL…..2037
PRECAUTIONS WHEN CARRYING OUT OPERATION…..2038
SPECIAL TOOL LIST…..2040
SKETCHES OF SPECIAL TOOLS…..2046
STARTING MOTOR…..2048
REMOVAL…..2048
INSTALLATION…..2048
ALTERNATOR …..2049
REMOVAL…..2049
INSTALLATION…..2049
ENGINE OIL COOLER CORE…..2050
REMOVAL…..2050
INSTALLATION…..2050
FUEL INJECTION PUMP…..2051
REMOVAL…..2051
INSTALLATION…..2055
WATER PUMP…..2057
REMOVAL …..2057
INSTALLATION…..2057
TURBOCHARGER…..2058
REMOVAL…..2058
INSTALLATION…..2058
NOZZLE HOLDER…..2059
REMOVAL …..2059
INSTALLATION…..2059
THERMOSTAT…..2060
REMOVAL…..2060
INSTALLATION…..2060
ENGINE HOOD…..2061
REMOVAL…..2061
INSTALLATION…..2061
CYLINDER HEAD…..2062
REMOVAL…..2062
INSTALLATION…..2066
FUEL TANK…..2068
REMOVAL…..2068
INSTALLATION…..2069
RADIATOR, OIL COOLER…..2070
REMOVAL…..2070
INSTALLATION…..2071
HYDRAULIC COOLER…..2072
REMOVAL…..2072
INSTALLATION…..2072
ENGINE …..2073
REMOVAL…..2073
INSTALLATION…..2077
RADIATOR, GUARD…..2078
REMOVAL…..2078
INSTALLATION…..2079
DAMPER …..2080
REMOVAL…..2080
INSTALLATION…..2081
TRANSMISSION…..2083
REMOVAL…..2083
INSTALLATION…..2086
PTO…..2087
DISASSEMBLY…..2087
ASSEMBLY…..2088
TRANSMISSION…..2090
DISASSEMBLY…..2090
ASSEMBLY…..2102
STEERING CASE…..2115
DISASSEMBLY…..2115
ASSEMBLY…..2121
PRIORITY VALVE…..2130
REMOVAL…..2130
INSTALLATION…..2130
DISASSEMBLY…..2131
ASSEMBLY…..2131
BRAKE CONTROL VALVE…..2132
REMOVAL…..2132
INSTALLATION…..2132
DISASSEMBLY…..2134
ASSEMBLY…..2136
TRANSMISSION SHIFT VALVE…..2139
REMOVAL…..2139
INSTALLATION…..2139
DISASSEMBLY…..2140
ASSEMBLY…..2142
TRANSMISSION PRESSURE VALVE…..2146
REMOVAL…..2146
INSTALLATION…..2146
DISASSEMBLY…..2148
ASSEMBLY…..2149
STEERING PISTON …..2150
REMOVAL…..2150
INSTALLATION…..2150
DISASSEMBLY…..2151
ASSEMBLY…..2151
PARKING BRAKE CYLINDER…..2152
REMOVAL…..2152
INSTALLATION…..2153
DISASSEMBLY…..2154
ASSEMBLY…..2155
FINAL DRIVE…..2156
REMOVAL …..2156
INSTALLATION…..2156
DISASSEMBLY…..2157
ASSEMBLY…..2161
IDLER, RECOIL SPRING…..2176
REMOVAL…..2176
INSTALLATION…..2176
RECOIL SPRING…..2177
DISASSEMBLY…..2177
ASSEMBLY…..2178
IDLER…..2179
DISASSEMBLY…..2179
ASSEMBLY…..2180
TRACK ROLLER …..2188
REMOVAL…..2188
INSTALLATION…..2188
DISASSEMBLY…..2189
ASSEMBLY…..2190
CARRIER ROLLER…..2192
REMOVAL…..2192
INSTALLATION…..2192
DISASSEMBLY…..2193
ASSEMBLY…..2194
TRACK SHOE…..2196
REMOVAL…..2196
INSTALLATION…..2197
OVERALL DISASSEMBLY…..2198
OVERALL ASSEMBLY…..2203
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…..2217
ONE LINK…..2218
FIELD DISASSEMBLY…..2218
FIELD ASSEMBLY…..2220
HYDRAULIC PUMP…..2226
REMOVAL…..2226
INSTALLATION…..2227
MAIN CONTROL VALVE…..2228
REMOVAL…..2228
INSTALLATION…..2229
DISASSEMBLY…..2230
ASSEMBLY…..2236
MAIN RELIEF VALVE…..2242
REMOVAL…..2242
INSTALLATION…..2242
STEERING PPC VALVE…..2243
REMOVAL…..2243
INSTALLATION…..2243
DISASSEMBLY…..2244
ASSEMBLY…..2245
BLADE ANGLE CYLINDER…..2247
REMOVAL…..2247
INSTALLATION…..2247
BLADE LIFT CYLINDER…..2248
REMOVAL…..2248
INSTALLATION…..2248
BLADE TILT CYLINDER…..2249
REMOVAL…..2249
INSTALLATION…..2249
HYDRAULIC CYLINDER…..2250
DISASSEMBLY…..2250
ASSEMBLY…..2252
WORK EQUIPMENT…..2254
REMOVAL…..2254
INSTALLATION…..2255
DISASSEMBLY…..2256
ASSEMBLY…..2259
HYDRAULIC TANK…..2262
REMOVAL…..2262
INSTALLATION…..2262
ROPS ROOF, GUARD…..2263
REMOVAL…..2263
INSTALLATION…..2263
CANOPY…..2264
REMOVAL…..2264
INSTALLATION…..2264
OPERATOR'S CAB…..2265
REMOVAL…..2265
INSTALLATION…..2267
OPERATOR'S CAB GLASS (STUCK GLASS)…..2270
REMOVAL…..2271
INSTALLATION…..2272
FLOOR FRAME…..2278
REMOVAL…..2278
INSTALLATION…..2282
AIR CONDITIONER COMPRESSOR…..2283
REMOVAL…..2283
INSTALLATION…..2284
AIR CONDITIONER CONDENSER…..2285
REMOVAL…..2285
INSTALLATION…..2286
MONITOR…..2287
REMOVAL…..2287
INSTALLATION…..2287
DT CONNECTOR PIN…..2288
REMOVAL…..2288
INSTALLATION…..2289
HD CONNECTOR PINS…..2290
REMOVAL…..2290
INSTALLATION…..2290
REPAIR PROCEDURE FOR WIRING HARNESS…..2291
40 MAINTENANCE STANDARD…..2292
DAMPER, UNIVERSAL JOINT…..2293
HYDRAULIC + POWER TRAIN PUMP…..2294
TRANSMISSION…..2296
TRANSMISSION CONTROL VALVE…..2302
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE…..2307
STEERING PPC VALVE…..2311
STEERING PISTON…..2312
PRIORITY VALVE…..2313
BRAKE VALVE…..2314
PARKING BRAKE CYLINDER…..2315
FINAL DRIVE…..2317
TRACK FRAME, RECOIL SPRING…..2321
IDLER…..2322
TRACK ROLLER…..2325
CARRIER ROLLER…..2328
TRACK SHOE…..2329
MAIN CONTROL VALVE…..2339
WORK EQUIPMENT CYLINDER…..2351
WORK EQUIPMENT…..2353
90 OTHERS…..2356
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…..2357
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..2358
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM…..2360
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM…..2361
ACTUAL ELECTRIC WIRING DIAGRAM…..2362
ELECTRIC CIRCUIT DIAGRAM…..2363
WITH CAB (SERIAL NO.: B20001-50200)…..2363
WITH CAB (1/2) (SERIAL NO.: 50201 AND UP)…..2364
WITH CAB (2/2) (SERIAL NO.: 50201 AND UP)…..2365
WITHOUT CAB (SERIAL NO.: B20001 – 50200)…..2366
CAB ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO.: B20001 – 50200 AND UP)…..2367
CAB ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO.: B20001 – 50201 AND UP)…..2368
SEBM0125B04 – Bulldozer D41S,Q-3 Shop Manual (SN60001&up)…..2370
SEBM028801 – Bulldozer D41E-6, D41P-6 Shop Manual…..2826
SEBM028803 – Bulldozer D41E,P-6 Shop Manual (SN-B40001&up)…..3412
Komatsu Bulldozers D40-, D41-, D45- series Repair Service Manuals