KOMATSU D21A,P-8 SERVICE REPAIR MANUAL (SN:83001 & UP) – PDF Download

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KOMATSU D21A,P-8 SERVICE REPAIR MANUAL (SN:83001 & UP)

KOMATSU D21A,P-8 SERVICE REPAIR MANUAL (SN:83001 & UP) – PDF DOWNLOAD:

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KOMATSU D21A,P-8 SERVICE REPAIR MANUAL (SN:83001 & UP)

• 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 SERVICE REPAIR MANUAL (SN:83001 & UP)

COVER.............................................................................................................................  1
CONTENTS..........................................................................................................................  2
01 GENERAL........................................................................................................................ 26
	SPECIFICATION DRAWINGS........................................................................................................ 27
	SPECIFICATIONS................................................................................................................ 28
	WEIGHT TABLE.................................................................................................................. 32
	FUEL, COOLANT AND LUBRICANTS.................................................................................................. 34
10 STRUCTURE AND FUNCTION......................................................................................................... 35
	ENGINE CONTROL................................................................................................................ 36
	POWER TRAIN SYSTEM............................................................................................................ 38
	POWER TRAIN SKELETON.......................................................................................................... 39
	POWER TRAIN HYDRAULIC PIPING.................................................................................................. 41
	DAMPER AND UNIVERSAL JOINT.................................................................................................... 42
	TRANSMISSION CONTROL.......................................................................................................... 43
	TRANSMISSION PUMP............................................................................................................. 45
	HYDROSHIFT TRANSMISSION....................................................................................................... 46
	TRANSMISSION CONTROL VALVE.................................................................................................... 58
	STEERING CLUTCH AND BRAKE CONTROL............................................................................................. 67
	STEERING CYLINDER............................................................................................................. 68
	BRAKE CYLINDER................................................................................................................ 69
	PPC VALVE..................................................................................................................... 70
	BEVEL GEAR SHAFT AND STEERING CLUTCH.......................................................................................... 76
	STEERING BRAKE................................................................................................................ 78
	FINAL DRIVE................................................................................................................... 80
	TRACK FRAME................................................................................................................... 81
	MAIN FRAME AND SUSPENSION..................................................................................................... 83
	HYDRAULIC PIPING.............................................................................................................. 84
	HYDRAULIC CONTROL............................................................................................................. 85
	HYDRAULIC TANK AND FILTER..................................................................................................... 86
	HYDRAULIC CONTROL VALVE....................................................................................................... 87
	OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT................................................................................... 91
	POWER ANGLE AND POWER TILTDOZER............................................................................................... 97
	ENGINE CONTROL................................................................................................................ 98
	MONITOR SYSTEM................................................................................................................100
	SENSORS.......................................................................................................................101
20 TESTING AND ADJUSTING..........................................................................................................104
	STANDARD VALUE TABLE FOR ENGINE...............................................................................................105
	STANDARD VALUE TABLE FOR CHASSIS..............................................................................................106
	TESTING AND ADJUSTING.........................................................................................................110
		LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS.....................................................................111
		MEASURING ENGINE SPEED....................................................................................................112
		MEASUREMENT OF EXHAUST GAS COLOR..........................................................................................113
		ADJUSTING VALVE CLEARANCE.................................................................................................114
		MEASURING COMPRESSION PRESSURE............................................................................................116
		TESTING AND ADJUSTING FUEL INJECTION TIMING...............................................................................117
		BLEEDING AIR FROM FUEL CIRCUIT............................................................................................119
		MEASURING ENGINE OIL PRESSURE.............................................................................................120
		TESTING AND ADJUSTING FAN BELT TENSION....................................................................................121
		ADJUSTING FUEL CONTROL LINKAGE............................................................................................122
		MEASURING POWER TRAIN OIL PRESSURE........................................................................................124
		ADJUSTING PPC VALVE.......................................................................................................125
		BLEEDING AIR FROM STEERING CIRCUIT........................................................................................125
		MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE...............................................................126
		BLEEDING AIR FROM HYDRAULIC CYLINDERS.....................................................................................127
		BLEEDING AIR FROM ANGLE CYLINDERS CIRCUIT.................................................................................128
		ADJUSTING FUEL CONTROL LEVER..............................................................................................129
		ADJUSTING TRAVEL OF INCHING PEDAL.........................................................................................130
		ADJUSTING BRAKE PEDAL, BRAKE CYLINDER.....................................................................................131
		ADJUSTING BRAKE LINING CLEARANCE..........................................................................................132
	TROUBLESHOOTING...............................................................................................................133
		POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................134
		SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................135
		POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................................136
		CHECKS BEFORE TROUBLESHOOTING.............................................................................................144
		CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..............................................................................147
		TYPES AND LOCATIONS OF CONNECTORS.........................................................................................148
		CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................150
		T-BRANCH BOX AND T-BRANCH TABLE...........................................................................................173
		TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).............................................................................175
			BEFORE CARRYING OUT TROUBLESHOOTING IN E-MODE.........................................................................176
			INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................177
			E-1 THE ENGINE DOES NOT START.........................................................................................178
			E-2 THE ENGINE DOES NOT STOP..........................................................................................183
			E-3 THE HEATER SIGNAL IS NOT HEATED RED, OR THE HEATER DOES NOT BECOME HOT EVEN IF THE HEATER SIGNAL IS HEATED RED....185
			E-4 THE BATTERY IS NOT CHARGED NORMALLY (CAUTION LAMP LIGHTS UP)......................................................187
			E-5 THE HORN DOES NOT SOUND...........................................................................................188
			E-6 THE HEADLAMP (REAR LAMP) DOES NOT LIGHT UP........................................................................189
			E-7 THE COOLANT TEMPERATURE GAUGE IS ABNORMAL.........................................................................191
			E-8 THE FUEL LEVEL GAUGE IS ABNORMAL..................................................................................192
			E-9 THE BACKUP BUZZER DOES NOT SOUND..................................................................................193
			E-10 THE SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING.......................................................194
		TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..................................................................195
			METHOD OF USING TROUBLESHOOTING CHART.................................................................................196
			H-1 MACHINE DOES NOT MOVE.............................................................................................198
			H-2 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW........................................................................199
			H-3 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR CHECKS BEFORE TROUBLESHOOTING...................................200
			H-4 STEERING DOES NOT WORK PROPERTY...................................................................................201
			H-5 MACHINE MOVES WHEN ENGINE IS STARTED..............................................................................202
			H-6 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING GEAR....................................................................202
			H-7 LEVEL OF OIL IN TRANSMISSION CASE OR BEVEL GEAR CASE CHANGES......................................................202
			H-8 LACK OF BLADE LIFTING FORCE, SPEED................................................................................203
			H-9 IMPOSSIBLE TO RAISE BLADE OR PUSH UP CHASSIS......................................................................204
			H-10 EXCESSIVE HYDRAULIC DRIFT OF BLADE...............................................................................205
			H-11 BLADE MOVES UP AND DOWN DURING LEVELING OPERATIONS (CONTROL LEVER AT HOLD) ......................................205
			H-12 BLADE GOES DOWN..................................................................................................205
			H-13 BLADE TILT LACKS POWER, SPEED, IMPOSSIBLE TO PUSH UP CHASSIS WITH TILT...........................................206
			H-14 BLADE CANNOT BE TILTED...........................................................................................207
			H-15 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT..........................................................................208
			H-16 BLADE ANGLE LACKS POWER, SPEED (APPLICABLE TO POWER ANGLE, POWER TILT DOZER).....................................209
			H-17 BLADE CANNOT BE ANGLED (APPLICABLE TO POWER ANGLE TILTDOZER).....................................................210
			H-18 WHEN BLADE IS ANGLED, BLADE RETURNS TO STRAIGHT POSITION OR SHAKES DURING OPERATIONS (CONTROL LEVER AT HOLD).....211
			H-19 WORK EQUIPMENT CONTROL LEVERS ARE HEAVY..........................................................................212
		TROUBLESHOOTING OF ENGINE (S MODE)........................................................................................213
			METHOD OF USING MATRIX TROUBLESHOOTING CHART..........................................................................214
			S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................................................218
			S-2 ENGINE DOES NOT START.............................................................................................219
			S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..............................................................222
			S-4 ENGINE STOPS DURING OPERATIONS....................................................................................223
			S-5 ENGINE DOES NT ROTATE SMOOTHLY....................................................................................224
			S-6 ENGINE LACKS OUTPUT (NO POWER)....................................................................................225
			S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)......................................................................226
			S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).............................................................227
			S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................228
			S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................229
			S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN............................................230
			S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...............................................................231
			S-13 OIL LEVEL RISES..................................................................................................232
			S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................233
			S-15 ABNORMAL NOISE IS MADE...........................................................................................234
			S-16 VIBRATION IS EXCESSIVE...........................................................................................235
30 DISASSEMBLY AND ASSEMBLY.......................................................................................................236
	METHOD OF USING MANUAL........................................................................................................237
	PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................238
	FUEL INJECTION PUMP...........................................................................................................241
		REMOVAL...................................................................................................................241
		INSTALLATION..............................................................................................................242
	RADIATOR GUARD................................................................................................................244
		REMOVAL...................................................................................................................244
		INSTALLATION..............................................................................................................245
	ENGINE........................................................................................................................246
		REMOVAL...................................................................................................................246
		INSTALLATION..............................................................................................................248
	HYDROSHIFT TRANSMISSION.......................................................................................................249
		DISASSEMBLY...............................................................................................................249
		ASSEMBLY..................................................................................................................264
	MODULATING VALVE..............................................................................................................281
		ASSEMBLY..................................................................................................................281
	SELECTOR AND INCHING VALVE....................................................................................................283
		ASSEMBLY..................................................................................................................283
	STEERING PPC VALVE............................................................................................................285
		ASSEMBLY..................................................................................................................285
	STEERING CLUTCH...............................................................................................................286
		REMOVAL...................................................................................................................286
		INSTALLATION..............................................................................................................288
		DISASSEMBLY...............................................................................................................289
		ASSEMBLY..................................................................................................................291
	BEVEL GEAR SHAFT AND BEVEL GEAR...............................................................................................294
		REMOVAL...................................................................................................................294
		INSTALLATION..............................................................................................................298
	FINAL DRIVE...................................................................................................................304
		REMOVAL AND INSTALLATION..................................................................................................304
	FINAL DRIVE FIRST PINION......................................................................................................305
		REMOVAL...................................................................................................................305
		INSTALLATION..............................................................................................................306
	FINAL DRIVE...................................................................................................................308
		DISASSEMBLY...............................................................................................................308
		ASSEMBLY..................................................................................................................311
	POWER TRAIN OIL COOLER........................................................................................................315
		REMOVAL AND INSTALLATION..................................................................................................315
	RECOIL SPRING.................................................................................................................316
		REMOVAL AND INSTALLATION..................................................................................................316
		DISASSEMBLY AND ASSEMBLY..................................................................................................317
	TRACK SHOE....................................................................................................................318
		REMOVAL AND INSTALLATION..................................................................................................318
	HYDRAULIC CONTROL VALVE.......................................................................................................319
		ASSEMBLY..................................................................................................................319
	HYDRAULIC CYLINDER............................................................................................................321
		ASSEMBLY..................................................................................................................321
	BLADE.........................................................................................................................323
		REMOVAL AND INSTALLATION..................................................................................................323
40 MAINTENANCE STANDARD...........................................................................................................324
	DAMPER AND UNIVERSAL JOINT....................................................................................................325
	HYDROSHIFT TRANSMISSION.......................................................................................................326
	TRANSMISSION CONTROL VALVE....................................................................................................330
	TRANSMISSION AND STEERING PUMP................................................................................................334
	PPC VALVE.....................................................................................................................335
	STEERING CYLINDER.............................................................................................................336
	BEVEL GEAR SHAFT..............................................................................................................337
	STEERING CLUTCH...............................................................................................................338
	STEERING BRAKE................................................................................................................340
	FINAL DRAIVE..................................................................................................................341
	TRACK FRAME...................................................................................................................343
	IDLER CUSHION.................................................................................................................345
	IDLER.........................................................................................................................346
	TRACK ROLLER..................................................................................................................348
	CARRIER ROLLER................................................................................................................349
	TRACK SHOE (LUBRICATED TRACK LINK)............................................................................................350
	RUBBER CRAWLER................................................................................................................352
	HYDRAULIC PUMP................................................................................................................353
	HYDRAULIC CONTROL VALVE.......................................................................................................354
	HYDRAULIC CYLINDER............................................................................................................356
	POWER ANGLE AND POWER TILTDOZER...............................................................................................358
90 OTHERS.........................................................................................................................360
	POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (F2, R2 TRANSMISSION)...................................................................361
	POWER TRAIN HYDRAULIC SYSTEM (F2, R2 TRANSMISSION)............................................................................362
	POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (F3, R3 TRANSMISSION)...................................................................363
	POWER TRAIN HYDRAULIC SYSTEM (F3, R3 TRANSMISSION)............................................................................364
	HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................365
	HYDRAULIC CIRCUIT SYSTEM......................................................................................................366
	ELECTRICAL WIRING DIAGRAM.....................................................................................................367
	CAB AND AIR CONDITIONER ELECTRICAL CIRCUIT....................................................................................368
	TRIMMING DOZER................................................................................................................369
		CONTENTS..................................................................................................................370
		OUTLINE...................................................................................................................371
			SPECIFICATION DRAWINGS................................................................................................371
			SPECIFICATIONS........................................................................................................372
			WEIGHT TABLE..........................................................................................................376
			FUEL,COOLANT AND LUBRICANTS...........................................................................................378
		STRUCTURE AND FUNCTION....................................................................................................379
			POWER TRAIN SKELETON..................................................................................................379
			POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.................................................................................380
			TRANSMISSION CONTROL..................................................................................................381
			HYDROSHIFT TRANSMISSION...............................................................................................382
			TRANSMISSION CONTROL VALVE............................................................................................385
			TRACK FRAME...........................................................................................................387
			HYDRAULIC PIPING DIAGRAM OF WORK EQUIPMENT............................................................................388
			HYDRAULIC CIRCUIT OF WORK EQUIPMENT...................................................................................389
			WORK EQUIPMENT CONTROL................................................................................................390
			WORK EQUIPMENT CONTROL VALVE..........................................................................................391
			TRIMMING DOZER........................................................................................................397
			ELECTRICAL WIRING DIAGRAM.............................................................................................398
			MONITOR SYSTEM........................................................................................................399
		MAINTENANCE STANDARD......................................................................................................400
			HYDROSHIFT TRANSMISSION...............................................................................................400
			TRANSMISSION CONTROL VALVE............................................................................................402
			TRACK FRAME...........................................................................................................404
			IDLER CUSHION.........................................................................................................405
			IDLER.................................................................................................................406
			TRACK ROLLER..........................................................................................................408
			CARRIER ROLLER........................................................................................................409
			TRACK SHOE (DRY TYPE).................................................................................................410
			RUBBER CRAWLER........................................................................................................413
			WORK EQUIPMENT CONTROL VALVE..........................................................................................414
			WORK EQUIPMENT CYLINDER...............................................................................................416
			TRIMMING DOZER........................................................................................................417

PLEASE NOTE:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]