Komatsu D21A-8E0, D21P-8E0 Bulldozer Service Manual
462 pages · Publication SEN03320-05
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What's inside
From the manual's own table of contents: 38 sections, 220 entries. See sample pages (PDF, 662 KB)
Show all 38 sections
Index and foreword13 topics
- Index
- Composition of shop manual
- Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
Specification5 topics
- Specification and technical data
- Specification dimension drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricant
Structure, function and maintenance standard41 topics
- Engine and cooling system
- Engine control
- Power train, Part 1
- Power train system
- Power train skeleton
- Damper and universal joint
- Power train hydraulic piping drawing
- Transmission control
- Steering clutch and brake control
- Transmission
- Transmission control valve
- Power train, Part 2
- Bevel gear shaft, steering clutch and steering brake
- Final drive
- Sprocket
- Steering cylinder
- Brake cylinder
- Undercarriage and frame
- Main frame and suspension
- Track frame
- Idler cushion
- Idler
- Track roller
- Carrier roller
- Track shoe
- Hydraulic system
- Work equipment hydraulic piping diagram
- Work equipment control
- Hydraulic tank and filter
- Power train and steering pump
- Work equipment pump
- Control valve
- Operation of work equipment control circuit
- PPC valve
- Work equipment
- Blade
- Hydraulic cylinder
- Electrical system
- Monitor system
- KOMTRAX system
- Sensor
Standard value table3 topics
- Standard service value table
- Standard value table for engine
- Standard value table for chassis
Testing and adjusting21 topics
- List of testing, adjusting, and troubleshooting tools
- Measuring engine speed
- Measuring exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Testing and adjusting fuel injection timing
- Bleeding air from fuel circuit
- Measuring engine oil pressure
- Testing and adjusting fan belt tension
- Replacing fan belt
- Adjusting fuel control linkage
- Measuring power train oil pressure
- Adjusting PPC valve
- Bleeding air from steering circuit
- Measuring and adjusting work equipment main relief pressure
- Bleeding air from hydraulic cylinders
- Bleeding air from angle cylinder circuit
- Adjusting fuel control lever
- Adjusting travel of inching pedal
- Adjusting brake pedal, brake cylinder
- Adjusting brake lining clearance
Troubleshooting61 topics
- General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Classification and steps for troubleshooting
- Types and locations of connectors
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Troubleshooting of electrical system (E-mode)
- Before carrying out troubleshooting in E-MODE
- Information contained in troubleshooting table
- E-1 The engine does not start
- E-2 The engine does not stop
- heated red
- E-4 The battery is not charged normally (caution lamp lights up)
- E-5 The horn does not sound
- E-6 The headlamp (rear lamp) does not light up
- E-7 The coolant temperature gauge is abnormal
- E-8 The fuel level gauge is abnormal
- E-9 The backup buzzer does not sound
- E-10 The service meter does not operate while engine is running
- E-11 KOMTRAX system does not operate normally
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Method of using troubleshooting chart
- H-1 Machine does not start
- H-2 Drawbar pull is weak, travel speed is slow
- H-3 Excessive time lag when starting or shifting gear checks before troubleshooting
- H-4 Steering does not work properly
- H-5 Machine moves when engine is started
- H-6 Excessive shock when starting or shifting gear
- H-7 Level of oil in transmission case or bevel gear case changes
- H-8 Lack of blade lifting force, speed
- H-9 Impossible to raise blade or push up chassis
- H-10 Excessive hydraulic drift of blade
- H-11 Blade moves up and down during leveling operations (control lever at HOLD)
- H-12 Blade goes down
- H-13 Blade tilt lacks power, speed, impossible to push up chassis with tilt
- H-14 Blade cannot be tilted
- H-15 Excessive hydraulic drift of blade tilt
- H-16 Blade angle lacks power, speed (applicable to power angle, power tilt dozer)
- H-17 Blade cannot be angled (applicable to power angle tiltdozer)
- (control lever at HOLD)
- H-19 Work equipment control levers are heavy
- Troubleshooting of engine (S-mode)
- Method of using matrix troubleshooting chart
- S-1 Starting performance is poor (Starting always takes time)
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly (Follow-up is poor)
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly
- S-6 Engine lacks output (no power)
- S-7 Exhaust gas is black (incomplete combustion)
- S-8 Oil consumption is excessive (or exhaust gas is blue)
- S-9 Oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
- S-12 Oil pressure lamp lights up (drop in oil pressure)
- S-13 Oil level rises
- S-14 Coolant temperature becomes too high (overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
Disassembly and assembly32 topics
- General information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Engine and cooling system
- Removal and installation of fuel injection pump assembly
- Removal and installation of radiator guard assembly
- Removal and installation of engine assembly
- Power train, Part 1
- Disassembly and assembly of hydroshift transmission assembly
- Disassembly and assembly of modulating valve assembly
- Disassembly and assembly of selector and inching valve assembly
- Power train, Part 2
- Disassembly and assembly of steering PPC valve assembly
- Removal and installation of steering clutch assembly
- Disassembly and assembly of steering clutch assembly
- Removal and installation of bevel gear shaft and bevel gear assembly
- Removal and installation of final drive assembly
- Removal and installation of final drive first pinion assembly
- Disassembly and assembly of final drive assembly
- Undercarriage and frame
- Removal and installation of power train oil cooler assembly
- Removal and installation of recoil spring assembly
- Disassembly and assembly of recoil spring assembly
- Expansion and installation of track shoe assembly
- Hydraulic system
- Disassembly and assembly of hydraulic control valve assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Work equipment
- Removal and installation of blade
- Electrical system
- Removal and installation of KOMTRAX terminal assembly
Diagrams and drawings6 topics
- Hydraulic diagrams and drawings
- Power train hydraulic circuit diagram
- Work equipment hydraulic circuit diagram
- Electrical diagrams and drawings
- Electrical circuit diagram
- Cab and air conditioner electrical circuit diagram
Inside this manual
Real pages from this service manual (462 pages). Open the sample pages (PDF, 662 KB)
- Specifications, page 56: 100 Specification and technical data
- Troubleshooting, page 287: 200 Troubleshooting of electrical system (E-mode)
- Diagram, page 308: 200 Troubleshooting of electrical system (E-mode)
- Foldout diagram, page 459: Electrical circuit diagram
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the D21A-8E0, D21P-8E0 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 462 pages
Quantity one is the manual described above.
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Other editions and similar models
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