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KOMATSU D21A,P,PL-8 SHOP MANUAL SEN06706-03 – PDF DOWNLOAD
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Description
KOMATSU D21A,P,PL-8 SHOP MANUAL SEN06706-03 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D21A,P,PL-8 SHOP MANUAL SEN06706-03 – PDF DOWNLOAD
Language : English
Pages : 466
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D21A,P,PL-8 SHOP MANUAL SEN06706-03 – PDF DOWNLOAD
COVER............................................................................................................................. 1 CONTENTS.......................................................................................................................... 2 01 GENERAL........................................................................................................................ 23 SPECIFICATION DRAWINGS........................................................................................................ 24 SPECIFICATIONS................................................................................................................ 26 WEIGHT TABLE.................................................................................................................. 30 FUEL, COOLANT AND LUBRICANTS.................................................................................................. 32 10 STRUCTURE AND FUNCTION......................................................................................................... 33 ENGINE CONTROL................................................................................................................ 34 POWER TRAIN SYSTEM............................................................................................................ 36 POWER TRAIN SKELETON.......................................................................................................... 37 POWER TRAIN HYDRAULIC PIPING.................................................................................................. 39 DAMPER AND UNIVERSAL JOINT.................................................................................................... 40 TRANSMISSION CONTROL.......................................................................................................... 41 TRANSMISSION PUMP............................................................................................................. 43 HYDROSHIFT TRANSMISSION....................................................................................................... 45 TRANSMISSION CONTROL VALVE.................................................................................................... 57 STEERING CLUTCH AND BRAKE CONTROL............................................................................................. 66 STEERING CYLINDER............................................................................................................. 68 BRAKE CYLINDER................................................................................................................ 69 PPC VALVE..................................................................................................................... 70 BEVEL GEAR SHAFT AND STEERING CLUTCH.......................................................................................... 76 STEERING BRAKE................................................................................................................ 79 FINAL DRIVE................................................................................................................... 81 TRACK FRAME................................................................................................................... 82 MAIN FRAME AND SUSPENSION..................................................................................................... 84 HYDRAULIC PIPING.............................................................................................................. 85 HYDRAULIC CONTROL............................................................................................................. 88 HYDRAULIC TANK AND FILTER..................................................................................................... 89 HYDRAULIC CONTROL VALVE....................................................................................................... 90 OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT................................................................................... 98 POWER ANGLE AND POWER TILTDOZER...............................................................................................104 STRAIGHT TILTDOZER............................................................................................................105 ENGINE CONTROL................................................................................................................106 MONITOR SYSTEM................................................................................................................108 SENSORS.......................................................................................................................109 20 TESTING AND ADJUSTING..........................................................................................................113 STANDARD VALUE TABLE FOR ENGINE...............................................................................................114 STANDARD VALUE TABLE FOR CHASSIS..............................................................................................115 TESTING AND ADJUSTING.........................................................................................................119 LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS.....................................................................120 MEASURING ENGINE SPEED....................................................................................................121 MEASUREMENT OF EXHAUST GAS COLOR..........................................................................................122 ADJUSTING VALVE CLEARANCE.................................................................................................123 MEASURING COMPRESSION PRESSURE............................................................................................125 TESTING AND ADJUSTING FUEL INJECTION TIMING...............................................................................126 BLEEDING AIR FROM FUEL CIRCUIT............................................................................................128 MEASURING ENGINE OIL PRESSURE.............................................................................................129 TESTING AND ADJUSTING FAN BELT TENSION....................................................................................130 ADJUSTING FUEL CONTROL LINKAGE............................................................................................131 MEASURING POWER TRAIN OIL PRESSURE........................................................................................133 ADJUSTING PPC VALVE.......................................................................................................134 BLEEDING AIR FROM STEERING CIRCUIT........................................................................................134 MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE...............................................................135 BLEEDING AIR FROM HYDRAULIC CYLINDERS.....................................................................................136 BLEEDING AIR FROM ANGLE CYLINDERS CIRCUIT.................................................................................137 ADJUSTING FUEL CONTROL LEVER..............................................................................................138 ADJUSTING TRAVEL OF INCHING PEDAL.........................................................................................139 ADJUSTING STEERING CONTROL LINKAGE........................................................................................140 ADJUSTING BRAKE PEDAL, BRAKE CYLINDER.....................................................................................142 ADJUSTING BRAKE LINING CLEARANCE..........................................................................................143 TROUBLESHOOTING...............................................................................................................145 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................146 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................147 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................................148 CHECKS BEFORE TROUBLESHOOTING.............................................................................................156 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..............................................................................159 TYPES AND LOCATIONS OF CONNECTORS.........................................................................................160 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................162 T-BRANCH BOX AND T-BRANCH TABLE...........................................................................................185 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).............................................................................187 BEFORE CARRYING OUT TROUBLESHOOTING IN E-MODE.........................................................................188 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................189 E-1 THE ENGINE DOES NOT START.........................................................................................190 E-2 THE ENGINE DOES NOT STOP..........................................................................................196 E-3 THE HEATER SIGNAL IS NOT HEATED RED, OR THE HEATER DOES NOT BECOME HOT EVEN IF THE HEATER SIGNAL IS HEATED RED....198 E-4 THE BATTERY IS NOT CHARGED NORMALLY (CAUTION LAMP LIGHTS UP)......................................................200 E-5 THE HORN DOES NOT SOUND...........................................................................................201 E-6 THE HEADLAMP (REAR LAMP) DOES NOT LIGHT UP........................................................................202 E-7 THE COOLANT TEMPERATURE GAUGE IS ABNORMAL.........................................................................204 E-8 THE FUEL LEVEL GAUGE IS ABNORMAL..................................................................................205 E-9 THE BACKUP BUZZER DOES NOT SOUND..................................................................................206 E-10 THE SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING.......................................................207 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..................................................................209 METHOD OF USING TROUBLESHOOTING CHART.................................................................................210 H-1 MACHINE DOES NOT MOVE.............................................................................................212 H-2 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW........................................................................213 H-3 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR CHECKS BEFORE TROUBLESHOOTING...................................214 H-4 STEERING DOES NOT WORK PROPERTY...................................................................................215 H-5 MACHINE MOVES WHEN ENGINE IS STARTED..............................................................................216 H-6 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING GEAR....................................................................216 H-7 LEVEL OF OIL IN TRANSMISSION CASE OR BEVEL GEAR CASE CHANGES......................................................216 H-8 LACK OF BLADE LIFTING FORCE, SPEED................................................................................217 H-9 IMPOSSIBLE TO RAISE BLADE OR PUSH UP CHASSIS......................................................................218 H-10 EXCESSIVE HYDRAULIC DRIFT OF BLADE...............................................................................219 H-11 BLADE MOVES UP AND DOWN DURING LEVELING OPERATIONS (CONTROL LEVER AT HOLD) ......................................219 H-12 BLADE GOES DOWN..................................................................................................219 H-13 BLADE TILT LACKS POWER, SPEED, IMPOSSIBLE TO PUSH UP CHASSIS WITH TILT...........................................220 H-14 BLADE CANNOT BE TILTED...........................................................................................221 H-15 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT..........................................................................222 H-16 BLADE ANGLE LACKS POWER, SPEED (APPLICABLE TO POWER ANGLE, POWER TILT DOZER).....................................223 H-17 BLADE CANNOT BE ANGLED (APPLICABLE TO POWER ANGLE TILTDOZER).....................................................224 H-18 WHEN BLADE IS ANGLED, BLADE RETURNS TO STRAIGHT POSITION OR SHAKES DURING OPERATIONS (CONTROL LEVER AT HOLD).....225 H-19 WORK EQUIPMENT CONTROL LEVERS ARE HEAVY..........................................................................226 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................................227 METHOD OF USING MATRIX TROUBLESHOOTING CHART..........................................................................228 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................................................232 S-2 ENGINE DOES NOT START.............................................................................................233 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..............................................................236 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................237 S-5 ENGINE DOES NT ROTATE SMOOTHLY....................................................................................238 S-6 ENGINE LACKS OUTPUT (NO POWER)....................................................................................239 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)......................................................................240 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).............................................................241 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................242 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................243 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN............................................244 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...............................................................245 S-13 OIL LEVEL RISES..................................................................................................246 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................247 S-15 ABNORMAL NOISE IS MADE...........................................................................................248 S-16 VIBRATION IS EXCESSIVE...........................................................................................249 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................251 METHOD OF USING MANUAL........................................................................................................252 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................253 FUEL INJECTION PUMP...........................................................................................................256 REMOVAL...................................................................................................................256 INSTALLATION..............................................................................................................257 RADIATOR GUARD................................................................................................................259 REMOVAL...................................................................................................................259 INSTALLATION..............................................................................................................260 ENGINE........................................................................................................................261 REMOVAL...................................................................................................................261 INSTALLATION..............................................................................................................263 HYDROSHIFT TRANSMISSION.......................................................................................................264 DISASSEMBLY...............................................................................................................264 ASSEMBLY..................................................................................................................279 MODULATING VALVE..............................................................................................................296 ASSEMBLY..................................................................................................................296 SELECTOR AND INCHING VALVE....................................................................................................298 ASSEMBLY..................................................................................................................298 STEERING PPC VALVE............................................................................................................300 ASSEMBLY..................................................................................................................300 STEERING CLUTCH...............................................................................................................301 REMOVAL...................................................................................................................301 INSTALLATION..............................................................................................................303 DISASSEMBLY...............................................................................................................304 ASSEMBLY..................................................................................................................306 BEVEL GEAR SHAFT AND BEVEL GEAR...............................................................................................309 REMOVAL...................................................................................................................309 INSTALLATION..............................................................................................................313 FINAL DRIVE...................................................................................................................323 REMOVAL AND INSTALLATION..................................................................................................323 FINAL DRIVE FIRST PINION......................................................................................................324 REMOVAL...................................................................................................................324 INSTALLATION..............................................................................................................325 FINAL DRIVE...................................................................................................................327 DISASSEMBLY...............................................................................................................327 ASSEMBLY..................................................................................................................330 POWER TRAIN OIL COOLER........................................................................................................334 REMOVAL AND INSTALLATION..................................................................................................334 RECOIL SPRING.................................................................................................................335 REMOVAL AND INSTALLATION..................................................................................................335 DISASSEMBLY AND ASSEMBLY..................................................................................................337 TRACK SHOE....................................................................................................................338 REMOVAL AND INSTALLATION..................................................................................................338 HYDRAULIC CONTROL VALVE.......................................................................................................339 ASSEMBLY..................................................................................................................339 HYDRAULIC CYLINDER............................................................................................................341 ASSEMBLY..................................................................................................................341 BLADE.........................................................................................................................343 REMOVAL AND INSTALLATION..................................................................................................343 40 MAINTENANCE STANDARD...........................................................................................................345 DAMPER AND UNIVERSAL JOINT....................................................................................................346 HYDROSHIFT TRANSMISSION.......................................................................................................348 TRANSMISSION CONTROL VALVE....................................................................................................352 TRANSMISSION AND STEERING PUMP................................................................................................356 PPC VALVE.....................................................................................................................357 STEERING CYLINDER.............................................................................................................358 BEVEL GEAR SHAFT..............................................................................................................359 STEERING CLUTCH...............................................................................................................360 STEERING BRAKE................................................................................................................362 FINAL DRAIVE..................................................................................................................364 TRACK FRAME...................................................................................................................366 IDLER CUSHION.................................................................................................................368 IDLER.........................................................................................................................370 TRACK ROLLER..................................................................................................................372 CARRIER ROLLER................................................................................................................373 TRACK SHOE (LUBRICATED TRACK LINK)............................................................................................374 RUBBER CRAWLER................................................................................................................376 HYDRAULIC PUMP................................................................................................................377 HYDRAULIC CONTROL VALVE.......................................................................................................378 HYDRAULIC CYLINDER............................................................................................................382 POWER ANGLE AND POWER TILTDOZER...............................................................................................384 STRAIGHT TILTDOZER............................................................................................................386 90 OTHERS.........................................................................................................................389 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (F2, R2 TRANSMISSION)...................................................................391 POWER TRAIN HYDRAULIC SYSTEM (F2, R2 TRANSMISSION)............................................................................393 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (F3, R3 TRANSMISSION)...................................................................395 POWER TRAIN HYDRAULIC SYSTEM (F3, R3 TRANSMISSION)............................................................................397 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................399 HYDRAULIC CIRCUIT SYSTEM......................................................................................................401 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM......................................................................................403 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.......................................................................................405 ELECTRICAL WIRING DIAGRAM.....................................................................................................407 CAB AND AIR CONDITIONER ELECTRICAL CIRCUIT....................................................................................409 TRIMMING DOZER................................................................................................................411 CONTENTS..................................................................................................................412 OUTLINE...................................................................................................................413 SPECIFICATION DRAWINGS................................................................................................413 SPECIFICATIONS........................................................................................................414 WEIGHT TABLE..........................................................................................................418 FUEL,COOLANT AND LUBRICANTS...........................................................................................420 STRUCTURE AND FUNCTION....................................................................................................422 POWER TRAIN SKELETON..................................................................................................422 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.................................................................................423 TRANSMISSION CONTROL..................................................................................................426 HYDROSHIFT TRANSMISSION...............................................................................................427 TRANSMISSION CONTROL VALVE............................................................................................430 TRACK FRAME...........................................................................................................432 HYDRAULIC PIPING DIAGRAM OF WORK EQUIPMENT............................................................................433 HYDRAULIC CIRCUIT OF WORK EQUIPMENT...................................................................................434 WORK EQUIPMENT CONTROL................................................................................................435 WORK EQUIPMENT CONTROL VALVE..........................................................................................436 TRIMMING DOZER........................................................................................................442 ELECTRICAL WIRING DIAGRAM.............................................................................................443 MONITOR SYSTEM........................................................................................................445 MAINTENANCE STANDARD......................................................................................................446 HYDROSHIFT TRANSMISSION...............................................................................................446 TRANSMISSION CONTROL VALVE............................................................................................448 TRACK FRAME...........................................................................................................450 IDLER CUSHION.........................................................................................................451 IDLER.................................................................................................................452 TRACK ROLLER..........................................................................................................454 CARRIER ROLLER........................................................................................................455 TRACK SHOE (DRY TYPE).................................................................................................456 RUBBER CRAWLER........................................................................................................459 WORK EQUIPMENT CONTROL VALVE..........................................................................................460 WORK EQUIPMENT CYLINDER...............................................................................................462 TRIMMING DOZER........................................................................................................464
DESCRIPTION:
KOMATSU D21A,P,PL-8 SHOP MANUAL SEN06706-03 – PDF DOWNLOAD
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.
S.S 25/12/24
