KOMATSU D21A-8E0 D21P-8E0 BULLDOZER SERVICE REPAIR MANUAL (SN:90001 & UP) KOMATSU D21A-8E0 D21P-8E0 – PDF DOWNLOAD

Description

KOMATSU D21A-8E0 D21P-8E0 BULLDOZER SERVICE REPAIR MANUAL (SN:90001 & UP) KOMATSU D21A-8E0 D21P-8E0

KOMATSU D21A-8E0 D21P-8E0 BULLDOZER SERVICE REPAIR MANUAL (SN:90001 & UP) KOMATSU D21A-8E0 D21P-8E0 – PDF DOWNLOAD:

IMAGE PREVIEW:

DESCRIPTION:

KOMATSU D21A-8E0 D21P-8E0 BULLDOZER SERVICE REPAIR MANUAL (SN:90001 & UP) KOMATSU D21A-8E0 D21P-8E0

This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume:This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume:This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

KOMATSU D21A-8E0 D21P-8E0 BULLDOZER SERVICE REPAIR MANUAL (SN:90001 & UP) KOMATSU D21A-8E0 D21P-8E0

COVER
........................................................................................................................  1
00 Index and foreword.........................................................................................................  0
	100 Index.................................................................................................................  3
		Composition of shop manual............................................................................................  4
		Table of contents.....................................................................................................  6
	200 Foreword and general information...................................................................................... 11
		Safety notice......................................................................................................... 12
		How to read the shop manual........................................................................................... 17
		Explanation of terms for maintenance standard......................................................................... 19
		Handling of electric equipment and hydraulic component................................................................ 21
		Handling of connectors newly used for engines......................................................................... 30
		How to read electric wire code........................................................................................ 33
		Precautions when carrying out operation............................................................................... 36
		Method of disassembling and connecting push-pull type coupler......................................................... 39
		Standard tightening torque table...................................................................................... 42
		Conversion table...................................................................................................... 46
01 Specification..............................................................................................................  0
	100 Specification and technical data...................................................................................... 53
		Specification dimension drawing....................................................................................... 55
		Specifications........................................................................................................ 56
		Weight table.......................................................................................................... 62
		Table of fuel, coolant and lubricant.................................................................................. 64
10 Structure, function and maintenance standard...............................................................................  0
	100 Engine and cooling system............................................................................................. 67
		Engine control........................................................................................................ 68
	210 Power train, Part 1................................................................................................... 71
		Power train system.................................................................................................... 72
		Power train skeleton.................................................................................................. 73
		Damper and universal joint............................................................................................ 75
		Power train hydraulic piping drawing.................................................................................. 77
		Transmission control.................................................................................................. 78
		Steering clutch and brake control..................................................................................... 82
		Transmission.......................................................................................................... 85
		Transmission control valve............................................................................................104
	220 Power train, Part 2...................................................................................................119
		Bevel gear shaft, steering clutch and steering brake..................................................................120
		Final drive...........................................................................................................129
		Sprocket..............................................................................................................132
		Steering cylinder.....................................................................................................133
		Brake cylinder........................................................................................................135
	300 Undercarriage and frame...............................................................................................137
		Main frame and suspension.............................................................................................139
		Track frame...........................................................................................................140
		Idler cushion.........................................................................................................144
		Idler.................................................................................................................146
		Track roller..........................................................................................................148
		Carrier roller........................................................................................................149
		Track shoe............................................................................................................150
	400 Hydraulic system......................................................................................................157
		Work equipment hydraulic piping diagram...............................................................................158
		Work equipment control................................................................................................159
		Hydraulic tank and filter.............................................................................................160
		Power train and steering pump.........................................................................................161
		Work equipment pump...................................................................................................163
		Control valve.........................................................................................................164
		Operation of work equipment control circuit...........................................................................170
		PPC valve.............................................................................................................176
	500 Work equipment........................................................................................................185
		Blade.................................................................................................................187
		Hydraulic cylinder....................................................................................................190
	600 Electrical system.....................................................................................................193
		Monitor system........................................................................................................194
		Engine control........................................................................................................195
		KOMTRAX system........................................................................................................197
		Sensor................................................................................................................199
20 Standard value table.......................................................................................................  0
	100 Standard service value table..........................................................................................203
		Standard value table for engine.......................................................................................204
		Standard value table for chassis......................................................................................205
30 Testing and adjusting......................................................................................................  0
	100 Testing and adjusting.................................................................................................211
		List of testing, adjusting, and troubleshooting tools.................................................................212
		Measuring engine speed................................................................................................213
		Measuring exhaust gas color...........................................................................................214
		Adjusting valve clearance.............................................................................................215
		Measuring compression pressure........................................................................................217
		Testing and adjusting fuel injection timing...........................................................................218
		Bleeding air from fuel circuit........................................................................................220
		Measuring engine oil pressure.........................................................................................220
		Testing and adjusting fan belt tension................................................................................221
		Replacing fan belt....................................................................................................221
		Adjusting fuel control linkage........................................................................................222
		Measuring power train oil pressure....................................................................................224
		Adjusting PPC valve...................................................................................................225
		Bleeding air from steering circuit....................................................................................225
		Measuring and adjusting work equipment main relief pressure...........................................................226
		Bleeding air from hydraulic cylinders.................................................................................227
		Bleeding air from angle cylinder circuit..............................................................................228
		Adjusting fuel control lever..........................................................................................229
		Adjusting travel of inching pedal.....................................................................................230
		Adjusting brake pedal, brake cylinder.................................................................................231
		Adjusting brake lining clearance......................................................................................233
40 Troubleshooting............................................................................................................  0
	100 General Information on troubleshooting................................................................................235
		Points to remember when troubleshooting...............................................................................236
		Sequence of events in troubleshooting.................................................................................237
		Checks before troubleshooting.........................................................................................238
		Classification and steps for troubleshooting..........................................................................240
		Types and locations of connectors.....................................................................................241
		Connection table for connector pin numbers............................................................................243
		T-branch box and T-branch adapter table...............................................................................279
	200 Troubleshooting of electrical system (E-mode).........................................................................283
		Before carrying out troubleshooting in E-MODE.........................................................................284
		Information contained in troubleshooting table........................................................................285
		E-1 Engine does not start.............................................................................................286
		E-2 The engine does not stop..........................................................................................292
		E-3 The heater signal is not heated red, or the heater does not become hot even if the heater signal is heated red....294
		E-4 The battery is not charged normally (caution lamp lights up)......................................................296
		E-5 The horn does not sound...........................................................................................297
		E-6 The headlamp (rear lamp) does not light up........................................................................298
		E-7 The coolant temperature gauge is abnormal.........................................................................300
		E-8 The fuel level gauge is abnormal..................................................................................302
		E-9 The backup buzzer does not sound..................................................................................304
		E-10 The service meter does not operate while engine is running.......................................................305
		E-11 KOMTRAX system does not operate normally.........................................................................306
	300 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................309
		Method of using troubleshooting chart.................................................................................310
		H-1 Machine does not start............................................................................................312
		H-2 Drawbar pull is weak, travel speed is slow........................................................................313
		H-3 Excessive time lag when starting or shifting gear checks before troubleshooting...................................314
		H-4 Steering does not work properly...................................................................................315
		H-5 Machine moves when engine is started..............................................................................316
		H-6 Excessive shock when starting or shifting gear....................................................................316
		H-7 Level of oil in transmission case or bevel gear case changes......................................................316
		H-8 Lack of blade lifting force, speed................................................................................317
		H-9 Impossible to raise blade or push up chassis......................................................................318
		H-10 Excessive hydraulic drift of blade...............................................................................319
		H-11 Blade moves up and down during leveling operations (control lever at HOLD).......................................319
		H-12 Blade goes down..................................................................................................319
		H-13 Blade tilt lacks power, speed, impossible to push up chassis with tilt...........................................320
		H-14 Blade cannot be tilted...........................................................................................321
		H-15 Excessive hydraulic drift of blade tilt..........................................................................322
		H-16 Blade angle lacks power, speed (applicable to power angle, power tilt dozer).....................................323
		H-17 Blade cannot be angled (applicable to power angle tiltdozer).....................................................324
		H-18 When blade is angled, blade returns to straight position or shakes during operations (control lever at HOLD).....325
		H-19 Work equipment control levers are heavy..........................................................................326
	400 Troubleshooting of engine (S-mode)....................................................................................329
		Method of using matrix troubleshooting chart..........................................................................330
		S-1 Starting performance is poor (Starting always takes time).........................................................334
		S-2 Engine does not start.............................................................................................335
		S-3 Engine does not pick up smoothly (Follow-up is poor)..............................................................338
		S-4 Engine stops during operations....................................................................................339
		S-5 Engine does not rotate smoothly...................................................................................340
		S-6 Engine lacks output (no power)....................................................................................341
		S-7 Exhaust gas is black (incomplete combustion)......................................................................342
		S-8 Oil consumption is excessive (or exhaust gas is blue).............................................................343
		S-9 Oil becomes contaminated quickly..................................................................................344
		S-10 Fuel consumption is excessive....................................................................................345
		S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down............................................346
		S-12 Oil pressure lamp lights up (drop in oil pressure)...............................................................347
		S-13 Oil level rises..................................................................................................348
		S-14 Coolant temperature becomes too high (overheating)...............................................................349
		S-15 Abnormal noise is made...........................................................................................350
		S-16 Vibration is excessive...........................................................................................351
50 Disassembly and assembly...................................................................................................  0
	100 General information on disassembly and assembly.......................................................................353
		How to read this manual...............................................................................................354
		Coating materials list................................................................................................356
		Special tools list....................................................................................................359
	200 Engine and cooling system.............................................................................................363
		Removal and installation of fuel injection pump assembly..............................................................364
		Removal and installation of radiator guard assembly...................................................................366
		Removal and installation of engine assembly...........................................................................368
	310 Power train, Part 1...................................................................................................373
		Disassembly and assembly of hydroshift transmission assembly..........................................................374
		Disassembly and assembly of modulating valve assembly.................................................................397
		Disassembly and assembly of selector and inching valve assembly.......................................................398
	320 Power train, Part 2...................................................................................................401
		Disassembly and assembly of steering PPC valve assembly...............................................................402
		Removal and installation of steering clutch assembly..................................................................403
		Disassembly and assembly of steering clutch assembly..................................................................406
		Removal and installation of bevel gear shaft and bevel gear assembly..................................................410
		Removal and installation of final drive assembly......................................................................417
		Removal and installation of final drive first pinion assembly.........................................................418
		Disassembly and assembly of final drive assembly......................................................................421
	400 Undercarriage and frame...............................................................................................427
		Removal and installation of power train oil cooler assembly...........................................................428
		Removal and installation of recoil spring assembly....................................................................429
		Disassembly and assembly of recoil spring assembly....................................................................430
		Expansion and installation of track shoe assembly.....................................................................431
	500 Hydraulic system......................................................................................................433
		Disassembly and assembly of hydraulic control valve assembly..........................................................434
		Disassembly and assembly of hydraulic cylinder assembly...............................................................436
	600 Work equipment........................................................................................................439
		Removal and installation of blade.....................................................................................440
	700 Electric system.......................................................................................................443
		Removal and installation of KOMTRAX terminal assembly.................................................................444
90 Diagrams and drawings......................................................................................................  0
	100 Hydraulic diagrams and drawings.......................................................................................447
		Power train hydraulic circuit diagram.................................................................................449
		Work equipment hydraulic circuit diagram..............................................................................453
	200 Electrical diagrams and drawings......................................................................................457
		Electrical circuit diagram............................................................................................459
		Cab and air conditioner electrical circuit diagram....................................................................460

PLEASE NOTE:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]