Komatsu D21A, P-8 Shop Manual SEBM033602 – PDF DOWNLOAD

Description

Komatsu D21A, P-8 Shop Manual SEBM033602 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D21A, P-8 Shop Manual SEBM033602 – PDF DOWNLOAD

Language : English
Pages :380
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D21A P-8 Shop Manual SEBM033602 – PDF DOWNLOAD

MACHINE MODEL SERIAL No.
D21A, P-8 83001 and up

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu D21A, P-8 Shop Manual SEBM033602 – PDF DOWNLOAD

MACHINE MODEL SERIAL No.
D21A, P-8 83001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWORD 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 TIGHTING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
SPECIFICATION DRAWINGS 27
SPECIFICATIONS 28
WEIGHT TABLE 32
FUEL, COOLANT AND LUBRICANTS 34
10 STRUCTURE AND FUNCTION 36
ENGINE CONTROL 37
POWER TRAIN SYSTEM 39
POWER TRAIN SKELETON 40
POWER TRAIN HYDRAULIC PIPING 42
DAMPER AND UNIVERSAL JOINT 43
TRANSMISSION CONTROL 44
TRANSMISSION PUMP 46
HYDROSHIFT TRANSMISSION 48
TRANSMISSION CONTROL VALVE 60
STEERING CLUTCH AND BRAKE CONTROL 69
STEERING CYLINDER 71
BRAKE CYLINDER 72
PPC VALVE 73
BEVEL GEAR SHAFT AND STEERING CLUTCH 79
STEERING BRAKE 82
FINAL DRIVE 84
TRACK FRAME 85
MAIN FRAME AND SUSPENSION 87
HYDRAULIC PIPING 88
HYDRAULIC CONTROL 89
HYDRAULIC TANK AND FILTER 90
HYDRAULIC CONTROL VALVE 91
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT 95
POWER ANGLE AND POWER TILTDOZER101
ENGINE CONTROL103
MONITOR SYSTEM105
SENSORS106
20 TESTING AND ADJUSTING109
STANDARD VALUE TABLE FOR ENGINE110
STANDARD VALUE TABLE FOR CHASSIS111
TESTING AND ADJUSTING115
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS116
MEASURING ENGINE SPEED117
MEASURING OF EXHAUST GAS COLOR118
ADJUSTING VALVE CLEARANCE119
MEASURING COMPRESSION PRESSURE121
TESTING AND ADJUSTING FUEL INJECTION TIMING122
BLEEDING AIR FROM FUEL CIRCUIT124
MEASURING ENGINE OIL PRESSURE125
TESTING AND ADJUSTING FAN BELT TENSION126
ADJUSTING FUEL CONTROL LINKAGE127
MEASURING POWER TRAIN OIL PRESSURE129
ADJUSTING PPC VALVE130
BLEEDING AIR FROM STEERING CIRCUIT130
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE131
BLEEDING AIR FROM HYDRAULIC CYLINDERS132
BLEEDING AIR FROM ANGLE CYLINDER CIRCUIT133
ADJUSTING FUEL CONTROL LEVER134
ADJUSTING TRAVEL OF INCHING PEDAL135
ADJUSTING BRAKE PEDAL, BRAKE CYLINDER136
ADJUSTING BRAKE LINING CLEARANCE137
TROUBLESHOOTING139
POINTS TO REMEMBER WHEN TROUBLESHOOTING140
SEQUENCE OF EVENTS IN TROUBLESHOOTING141
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE142
CHECKS BEFORE TROUBLESHOOTING150
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING153
TYPES AND LOCATIONS OF CONNECTORS154
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS156
T-BRANCH BOX AND T-BRANCH TABLE178
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)181
BEFORE CARRYING OUT TROUBLESHOOTING IN E MODE182
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE183
E-1 THE ENGINE DOES NOT START184
E-2 THE ENGINE DOES NOT STOP190
E-3 THE HEATER SIGNAL IS NOT HEATER RED, OR THE HEATER DOES NOT BECOME HOT EVEN IF THE HEATER SIGNAL IS HEATED RED192
E-4 THE BATTERY IS NOT CHARGED NORMALLY (CAUTION LAMP LIGHTS UP)194
E-5 THE HORN DOES NOT SOUND195
E-6 THE HEADLAMP (REAR LAMP) DOES NOT LIGHT UP196
E-7 THE COOLANT TEMPERATURE GAUGE IS ABNORMAL198
E-8 THE FUEL LEVEL GAUGE IS ABNORMAL199
E-9 THE BACKUP BUZZER DOES NOT SOUND200
E-10 THE SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING201
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)203
METHOD OF USING TROUBLESHOOTING CHART204
H-1 MACHINE DOES NOT START206
H-2 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW207
H-3 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR CHECKS BEFORE TROUBLESHOOTING208
H-4 STEERING DOES NOT WORK PROPERLY209
H-5 MACHINE MOVES WHEN ENGINE IS STARTED210
H-6 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING GEAR210
H-7 LEVEL OF OIL IN TRANSMISSION CASE OR BEVEL GEAR CASE CHANGES210
H-8 LACK OF BLADE LIFTING FORCE, SPEED211
H-9 IMPOSSIBLE TO RAISE BLADE OR PUSH UP CHASSIS212
H-10 EXCESSIVE HYDRAULIC DRIFT OF BLADE213
H-11 BLADE MOVES UP AND DOWN DURING LEVELING OPERATIONS (CONTROL LEVER AT HOLD)213
H-12 BLADE GOES DOWN213
H-13 BLADE TILT LACKS POWER, SPEED, IMPOSSIBLE TO PUSH UP CHASSIS WITH TILT214
H-14 BLADE CANNOT BE TILTED215
H-15 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT216
H-16 BLADE ANGLE LACKS POWER, SPEED (APPLICABLE TO POWER ANGLE, POWER TILT DOZER)217
H-17 BLADE CANNOT BE ANGLED (APPLICABLE TO POWER ANGLE TILTDOZER)218
H-18 WHEN BLADE IS ANGLED, BLADE RETURNS TO STRAIGHT POSITION OR SHAKES DURING OPERATIONS (CONTROL LEVER AT HOLD)219
H-19 WORK EQUIPMENT CONTROL LEVERS ARE HEAVY220
TROUBLESHOOTING OF ENGINE (S MODE)221
METHOD OF USING MATRIX TROUBLESHOOTING CHART222
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)226
S-2 ENGINE DOES NOT START227
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)230
S-4 ENGINE STOPS DURING OPERATIONS231
S-5 ENGINE DOES NOT ROTATE SMOOTHLY232
S-6 ENGINE LACKS OUTPUT (NO POWER)233
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)234
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)235
S-9 OIL BECOMES CONTAMINATED QUICKLY236
S-10 FUEL CONSUMPTION IS EXCESSIVE237
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN238
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)239
S-13 OIL LEVEL RISES240
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)241
S-15 ABNORMAL NOISE IS MADE242
S-16 VIBRATION IS EXCESSIVE243
30 DISASSEMBLY AND ASSEMBLY244
METHOD OF USING MANUAL245
PRECAUTION WHEN CARRYING OUT OPERATION246
FUEL INJECTION PUMP249
REMOVAL249
INSTALLATION250
RADIATOR GUARD251
REMOVAL251
INSTALLATION252
ENGINE253
REMOVAL253
INSTALLATION255
HYDROSHIFT TRANSMISSION256
DISASSEMBLY256
ASSEMBLY271
MODULATING VALVE288
ASSEMBLY288
SELECTOR AND INCHING VALVE290
ASSEMBLY290
STEERING PPC VALVE292
ASSEMBLY292
STEERING CLUTCH293
REMOVAL293
INSTALLATION295
DISASSEMBLY296
ASSEMBLY298
BEVEL GEAR SHAFT AND BEVEL GEAR301
REMOVAL301
INSTALLATION305
FINAL DRIVE311
REMOVAL AND INSTALLATION311
FINAL DRIVE FIRST PINION312
REMOVAL312
INSTALLATION313
FINAL DRIVE315
DISASSEMBLY315
ASSEMBLY318
POWER TRAIN OIL COOLER322
REMOVAL AND INSTALLATION322
RECOIL SPRING323
REMOVAL AND INSTALLATION323
DISASSEMBLY AND ASSEMBLY324
TRACK SHOE325
REMOVAL AND INSTALLATION325
HYDRAULIC CONTROL VALVE326
ASSEMBLY326
HYDRAULIC CYLINDER328
ASSEMBLY328
BLADE330
REMOVAL AND INSTALLATION330
40 MAINTENANCE STANDARD332
DAMPER AND UNIVERSAL JOINT333
HYDROSHIFT TRANSMISSION335
TRANSMISSION CONTROL VALVE339
TRANSMISSION AND STEERING PUMP343
PPC VALVE344
STEERING CYLINDER345
BEVEL GEAR SHAFT346
STEERING CLUTCH347
STEERING BRAKE349
FINAL DRIVE351
TRACK FRAME353
IDLER CUSHION355
IDLER357
TRACK ROLLER359
CARRIER ROLLER360
TRACK SHOE (LUBRICATED TRACK LINK)361
RUBBER CRAWLER363
HYDRAULIC PUMP364
HYDRAULIC CONTROL VALVE365
HYDRAULIC CYLINDER367
POWER ANGLE AND POWER TILTDOZER369
90 OTHERS372
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM373
POWER TRAIN HYDRAULIC SYSTEM374
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM375
POWER TRAIN HYDRAULIC SYSTEM376
HYDRAULIC CIRCUIT DIAGRAM377
HYDRAULIC CIRCUIT SYSTEM378
ELECTRICAL WIRING DIAGRAM379
CAB AND AIR CONDITIONER ELECTRICAL CIRCUIT380

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24