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Komatsu Bulldozer D21A-8 D21P-8 Operation & Maintenance Manual SN 83001 and up – PDF DOWNLOAD
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Komatsu Bulldozer D21A-8 D21P-8 Operation & Maintenance Manual
Book Code : TEN00016-01
SERIAL NUMBERS
- D21A-83001 and up
- D21P-83001 and up
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Description
Komatsu Bulldozer D21A-8 D21P-8 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D21A-8 D21P-8 Operation & Maintenance Manual
Size : 4.20 MB
Format : PDF
Language : English
Number of Pages : 207 pages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: D21A-8 D21P-8
Serial: 83001 and up
KOMATSU BULLDOZER D21A-8 D21P-8 OPERATION & MAINTENANCE MANUAL SN 83001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D21A-8 D21P-8 Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Bulldozer D21A-8 D21P-8 Operation & Maintenance Manual
COVER............................................................................... 1 FOREWORD............................................................................ 2 FOREWORD........................................................................ 3 SAFETY INFORMATION.............................................................. 6 INTRODUCTION.................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................ 8 NECESSARY INFORMATION........................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................ 9 ENGINE SERIAL NO. PLATE..................................................... 9 EMISSION CONTROL INFORMATION LABEL.......................................... 10 POSITION OF SERVICE METER................................................... 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR................................... 11 CONTENTS............................................................................ 12 SAFETY.............................................................................. 16 SAFETY.......................................................................... 17 SAFETY LABELS................................................................... 19 POSITIONS OF SAFETY PICTOGRAMS.............................................. 19 SAFETY LABELS............................................................... 20 GENERAL PRECAUTIONS............................................................. 23 SAFETY RULES................................................................ 23 IF PROBLEMS ARE FOUND....................................................... 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT......................................... 23 SAFETY FEATURES............................................................. 23 KEEP MACHINE CLEAN.......................................................... 24 INSIDE OPERATOR'S COMPARTMENT............................................... 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................. 24 HANDRAILS AND STEPS......................................................... 25 MOUNTING AND DISMOUNTING.................................................... 26 NO PEOPLE ON ATTACHMENTS.................................................... 26 CRUSHING OR CUTTING PREVENTION.............................................. 26 PREVENTION OF BURNS......................................................... 26 FIRE PREVENTION............................................................. 27 ACTION IF FIRE OCCURS....................................................... 28 WINDOW WASHER LIQUID........................................................ 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................ 28 PRECAUTIONS FOR ATTACHMENTS................................................. 28 UNAUTHORIZED MODIFICATION................................................... 28 SAFETY AT WORKSITE.......................................................... 29 WORKING ON LOOSE GROUND..................................................... 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................... 29 ENSURE GOOD VISIBILITY...................................................... 30 VENTILATION FOR ENCLOSED AREAS.............................................. 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................... 30 EMERGENCY EXIT FROM OPERATOR'S CAB.......................................... 30 BE CAREFUL ABOUT ASBESTOS DUST.............................................. 30 PRECAUTIONS FOR OPERATION....................................................... 31 STARTING ENGINE............................................................. 31 CHECKS BEFORE STARTING ENGINE........................................... 31 PRECAUTIONS WHEN STARTING............................................... 31 PRECAUTIONS IN COLD AREAS............................................... 32 OPERATION................................................................... 33 CHECKS BEFORE OPERATION................................................. 33 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................... 33 PRECAUTIONS WHEN TRAVELING.............................................. 33 TRAVELING ON SLOPES..................................................... 34 USING BRAKES............................................................ 34 OPERATE CAREFULLY ON SNOW............................................... 35 PARKING MACHINE......................................................... 35 TRANSPORTATION.............................................................. 37 LOADING AND UNLOADING................................................... 37 SHIPPING................................................................ 37 BATTERY..................................................................... 38 BATTERY HAZARD PREVENTION............................................... 38 STARTING WITH BOOSTER CABLE............................................. 39 TOWING...................................................................... 40 WHEN TOWING............................................................. 40 PRECAUTIONS FOR MAINTENANCE..................................................... 41 WARNING TAG................................................................. 41 KEEP WORK PLACE CLEAN AND TIDY.............................................. 41 APPOINT LEADER WHEN WORKING WITH OTHERS..................................... 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.................. 42 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................... 43 PROPER TOOLS................................................................ 44 NO UNAUTHORIZED PERSONNEL INTO AREA......................................... 44 ATTACHMENTS................................................................. 44 WORK UNDER THE MACHINE...................................................... 44 NOISE....................................................................... 44 PRECAUTIONS WHEN USING HAMMER............................................... 45 REPAIR WELDING.............................................................. 45 REMOVING BATTERY TERMINAL................................................... 45 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......... 45 DO NOT DISASSEMBLE RECOIL SPRING............................................ 45 PRECAUTION WITH HIGH-PRESSURE OIL........................................... 46 HANDLING HIGH-PRESSURE HOSES................................................ 46 WASTE MATERIAL.............................................................. 46 MAINTENANCE FOR AIR CONDITIONER............................................. 46 COMPRESSED AIR.............................................................. 47 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................... 47 OPERATION........................................................................... 48 GENERAL VIEW.................................................................... 49 GENERAL VIEW OF MACHINE..................................................... 49 GENERAL VIEW OF CONTROLS AND GAUGES......................................... 50 EXPLANATION OF COMPONENTS....................................................... 51 FRONT PANEL................................................................. 51 SWITCHES.................................................................... 57 CONTROL LEVERS AND PEDALS................................................... 59 FUSE........................................................................ 65 FUSIBLE LINK................................................................ 65 DOOR POCKET................................................................. 66 OPERATION....................................................................... 67 CHECK BEFORE STARTING ENGINE, ADJUST........................................ 67 STARTING ENGINE............................................................. 79 OPERATIONS AND CHECKS AFTER STARTING ENGINE................................. 82 STOPPING ENGINE............................................................. 84 MACHINE OPERATION........................................................... 85 SHIFTING GEARS.............................................................. 89 SHIFTING BETWEEN FORWARD AND REVERSE........................................ 90 STEERING MACHINE............................................................ 91 PRECAUTIONS FOR OPERATION................................................... 95 WORK POSSIBLE USING BULLDOZER............................................... 96 PARKING MACHINE............................................................. 98 CHECK AFTER FINISHING WORK..................................................100 LOCKING.....................................................................100 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................101 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)...................................104 TRANSPORTATION..................................................................109 TRANSPORTATION MEANS........................................................109 LOADING, UNLOADING WORK.....................................................109 LIFTING MACHINE.............................................................112 COLD WEATHER OPERATION..........................................................113 PRECAUTIONS FOR LOW TEMPERATURE.............................................113 AFTER COMPLETION OF WORK....................................................115 AFTER COLD WEATHER..........................................................115 LONG-TERM STORAGE...............................................................116 BEFORE STORAGE..............................................................116 DURING STORAGE..............................................................116 AFTER STORAGE...............................................................116 TROUBLESHOOTING.................................................................117 AFTER RUNNING OUT OF FUEL...................................................117 MACHINE TOWING METHOD.......................................................117 IF BATTERY IS DISCHARGED....................................................118 OTHER TROUBLE...............................................................121 MAINTENANCE.........................................................................124 GUIDE TO MAINTENANCE............................................................125 OUTLINE OF SERVICE..............................................................127 OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....................127 RELATING TO ELECTRIC SYSTEM.................................................129 WEAR PARTS LIST.................................................................130 WEAR PARTS LIST.............................................................130 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............131 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................131 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................135 TORQUE LIST.................................................................135 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................136 SAFETY CRITICAL PARTS.......................................................136 MAINTENANCE SCHEDULE CHART......................................................137 MAINTENANCE SCHEDULE CHART..................................................137 SERVICE PROCEDURE...............................................................139 INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)...................139 WHEN REQUIRED...............................................................140 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................140 CLEAN INSIDE OF COOLING SYSTEM..........................................143 CLEAN WATER SEPARATOR ELEMENT...........................................145 CHECK AND ADJUST STEEL SHOE TENSION.....................................146 CHECK AND TIGHTEN TRACK STEEL SHOE BOLTS................................148 CHECK AND REPLACE RUBBER SHOES..........................................149 CHECK AND ADJUST RUBBER SHOE TENSION....................................151 REPLACE RUBBER SHOES....................................................153 REVERSE AND REPLACE END BITS AND CUTTING EDGES..........................156 BLEED AIR FROM HEAD END OF ANGLE CIRCUIT................................157 ADJUST BRAKE PEDAL (TEST, ADJUST STEERING BRAKE)........................158 ADJUST IDLER CLEARANCE..................................................160 CHECK BEFORE STARTING.......................................................161 EVERY 50 HOURS SERVICE......................................................162 DRAIN WATER, SEDIMENT FROM FUEL TANK....................................162 EVERY 250 HOURS SERVICE.....................................................163 LUBRICATING.............................................................163 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................165 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............................165 CHECK LEVEL OF BATTERY ELECTROLYTE......................................166 CHECK FAN BELT TENSION, ADJUST..........................................168 EVERY 500 HOURS SERVICE.....................................................169 REPLACE FUEL FILTER CARTRIDGE...........................................169 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......171 CLEAN, CHECK RADIATOR FINS..............................................172 CLEAN BREATHER..........................................................172 EVERY 1000 HOURS SERVICE....................................................173 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................173 CHANGE OIL IN BEVEL GEAR CASE, TRANSFER CASE............................173 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER.........................175 CHANGE OIL IN FINAL DRIVE CASE..........................................176 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER CARTRIDGE....177 CHECK OIL IN UNDERCARRIAGE COMPONENTS...................................177 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................177 EVERY 2000 HOURS SERVICE....................................................178 CHECK ALTERNATOR, STARTING MOTOR........................................178 EVERY 4000 HOURS SERVICE....................................................179 CHECK WATER PUMP........................................................179 SPECIFICATIONS......................................................................180 SPECIFICATIONS..................................................................181 ATTACHMENTS, OPTIONS................................................................182 GENERAL PRECAUTIONS.............................................................183 PRECAUTIONS RELATED TO SAFETY...............................................183 DECELERATOR PEDAL...............................................................184 SUSPENSION SEAT.................................................................185 ADJUSTMENT..................................................................185 SEAT BELT...................................................................185 HANDLING TRIMMING DOZER.........................................................187 GENERAL VIEW................................................................187 EXPLANATION OF COMPONENTS...................................................188 OPERATION...................................................................191 MAINTENANCE.................................................................193 SPECIFICATIONS..............................................................201 WEAR PARTS LIST.............................................................202 INDEX...............................................................................204
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