2005 Komatsu D41E-6 and D41P-6 Bulldozer Service & Repair Manual (P/N SEBM007009)

This Komatsu chassis shop manual covers the 2005 D41E-6 and D41P-6 bulldozers, serial numbers B20001–B40000 and 50001 and up. Publication SEBM007009, with a June 2005 printing date, combines system explanations, testing and adjustment procedures, component repair instructions, and maintenance standards.

• Engine service: Valve-clearance adjustment, injection-timing checks, blow-by measurement, cylinder-head removal and installation, and removal of the engine and fuel injection pump.

• Power train repair: Transmission and PTO teardown, steering-case assembly, final-drive overhaul, and testing of modulating, inching, steering, and brake circuits.

• Blade hydraulics: Pump removal, main control valve rebuilding, hydraulic cylinder disassembly and assembly, internal-leakage testing, pressure adjustment, and cylinder bleeding.

• Undercarriage work: Idler, recoil spring, track roller, carrier roller, and track shoe service, including lubricated-track and grease-filled-track assembly procedures.

• Electrical troubleshooting: Engine electrical and machine monitor fault charts, connector arrangement diagrams, pin-number tables, terminal service, and wiring harness repair.

• Cab and air conditioning: Cab, canopy, ROPS roof, and floor-frame removal; bonded-glass replacement; compressor and condenser service; and refrigerant charging references.

Written for service workshop personnel, this manual assumes familiarity with mechanical repairs and access to lifting equipment, test instruments, and the specified special tools.

Engine Service and Repair Scope

The S6D102-1 sections cover fuel-control and decelerator linkage adjustment, engine stop solenoid adjustment, and troubleshooting for starting problems, low output, abnormal exhaust smoke, oil-pressure complaints, and overheating.

Removal and installation procedures extend to the turbocharger, water pump, thermostat, nozzle holders, radiator, and oil coolers. Cylinder-head removal and installation are included, but internal engine overhaul requires the separate 102 Series Engine Shop Manual, which is referenced on the cover.

Transmission, Steering, and Brake Repair

Transmission coverage includes clutch packs, planetary carriers, shafts, bearings, and the PTO. The steering-case procedures address bevel-gear tooth contact, backlash, and clutch and brake assembly. Final-drive sections distinguish earlier and later construction and include bearing-preload checks.

The No. 2 forward-clutch procedures identify different spring arrangements by serial number, including nonconsecutive D41E-6 groups. Those distinctions help match the clutch assembly procedure to the machine before selecting replacement components.

Brake adjustment caution: The manual explains how using the assembly adjustment screw to compensate for worn brake linings can restore main-brake action while causing the parking brake to lose its braking effect.

Blade Hydraulics and Undercarriage

The hydraulic sections explain the Closed Center Load Sensing System (CLSS), pressure compensation, the unload valve, priority valve, and main relief valve. Cylinder-leakage tests help distinguish cylinder faults from control-valve leakage when blade drift exceeds the standard.

Structure and maintenance-standard sections also show the D41E-6 four-spool valve for blade lift, tilt, angle, and ripper control. This valve documentation does not constitute a separate ripper overhaul manual.

Undercarriage coverage includes recoil spring and idler variants, track-link press work, seal handling, and field replacement of individual links. The overall track-disassembly procedure specifically addresses lubricated track; assembly instructions distinguish lubricated and grease-filled configurations.

Electrical Diagrams and Cab Systems

Diagnostic references include power train hydraulic circuit diagrams, work equipment hydraulic circuit diagrams, actual electric wiring diagrams, connector arrangement diagrams, and machine monitor system diagrams. Electrical fault charts separate earlier and later serial groups for starting, lighting, engine stopping, and monitor complaints.

Circuit-sheet coverage: The full-machine and cab circuit sheets at the end cover B20001–B40000 and 50001–50200. The 50201-up cab sheets listed as 90-11-2, 90-11-4, and 90-17 are absent from this PDF. System-specific troubleshooting diagrams address later serial groups.

Cab procedures include door-lock adjustment, sealing, and bonded-glass installation. Air-conditioning coverage combines electrical fault tracing with compressor and condenser removal and installation.

Workshop Reference Tables

Reference data includes metric fastener, flared-nut, and O-ring boss joint torque tables; fluid capacities; ambient-temperature viscosity charts; conversion tables; and component wear limits. Assembly-weight tables cover final drives, track frames, and blade equipment for planning lifting work.

Tool references include hydraulic tester 799-101-5002 and blow-by pressure gauge 799-201-1504. The safety sections address machine blocking, residual hydraulic pressure, and handling heavy assemblies.

Examples of Track Clearance and Hydraulic Test Data

These examples represent a small selection of the inspection and test data in the manual.

The track-tension section specifies a 20–30 mm clearance from the center grouser to a straightedge spanning the idler and carrier roller, with the machine on level ground.

The cylinder-leakage test specifies 45–55°C hydraulic oil temperature for the checks used to distinguish internal cylinder leakage from a control-valve fault.

PDF Search, Bookmarks, and Circuit Detail

Search and navigation: The file is partially searchable; some repair and diagram pages have no searchable text. Embedded bookmarks cover the main chapters and many components, although steering PPC valve teardown and assembly entries are grouped under Main Relief Valve. Small wire codes and connector numbers on dense circuit sheets require zooming.

Supplied as one printable, 677-page PDF in English. The total includes 25 pages of original front matter, including the cover, contents, three revised-page lists, safety information, and introductory reference material.