![DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
D21A, P-830-7-1
(4)
4
3 Mounting bolt of mount bracket:
59 – 74 Nm {6 – 7 kgm}
5
fl Check the distinguishing marks on the front and
rear engine mount rubbers when installing.
• Front: [ZZ ]embossed mark
• Rear: Round blue paint mark
2 Thread of engine mount mounting bolt:
Thread tightener (LT-2)
3 Engine mount mounting bolt:
277 ±31.9 Nm (28.25 ±3.25 kgm)](https://image.slidesharecdn.com/komatsud21ap-8dozerbulldozerservicerepairmanualsn83001andup-200727065901/85/Komatsu-d21-a-p-8-dozer-bulldozer-service-repair-manual-sn-83001-and-up-8-320.jpg)
![D21A, P-830-12
(1)
DISASSEMBLY AND ASSEMBLY ENGINE
INSTALLATION OF ENGINE
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1
fl Bleed the air from fuel circuit.
fl For details, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.
2
fl Adjust the cable.
For details, see TESTING AND ADJUSTING,
Adjusting fuel control cable.
3
3 Universal joint mounting bolt:
30.1 ± 3.4 Nm (3.15 ± 0.35 kgm)
4
fl Check the distinguishing marks on the front
and rear engine mount rubbers when install-
ing.
• Front: [ZZ] embossed mark
• Rear: Round blue paint mark
2 Thread of engine mount mounting bolt:
Thread tightener (LT-2)
3 Engine mount mounting bolt:
277 ± 31.9 Nm (28.25 ± 3.25 kgm)
• Refilling with coolant
fl Add coolant through coolant filler to the speci-
fied level.
fl Run the engine to circulate the coolant through
the system. Then check the coolant level again.
• Refilling with oil (transmission case, hydraulic
tank)
Add engine oil through oil filler to the specified
level.
fl Run the engine to circulate the oil through
the system. Then check the oil level again.](https://image.slidesharecdn.com/komatsud21ap-8dozerbulldozerservicerepairmanualsn83001andup-200727065901/85/Komatsu-d21-a-p-8-dozer-bulldozer-service-repair-manual-sn-83001-and-up-13-320.jpg)
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)
- 1. SEBM033605 © 2008 1 All Rights Reserved Printed in Japan 02-08 (01) 1 00-1 (5) MACHINE MODEL SERIAL No. D21A, P-8 83001 and up • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • D21-8 mount the 4D94LE-2 engine. For details of the engine, see the 94E, 98E Series Engine Shop Manual.
- 2. 00-2 D21A, P-8 CONTENTS No. of page 01 GENERAL ......................................................................... 01-1 10 STRUCTURE AND FUNCTION ....................................... 10-1 20 TESTING AND ADJUSTING........................................... 20-1 30 DISASSEMBLY AND ASSEMBLY .................................. 30-1 40 MAINTENANCE STANDARD.......................................... 40-1 90 OTHERS............................................................................ 90-1 (2)
- 3. SAFETY SAFETY NOTICE 00-3 SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any danger- ous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual care- fully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while work- ing. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from fall- ing. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to pro- vide safe footing.
- 4. SAFETY SAFETY NOTICE 00-4 PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carry- ing out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the nega- tive (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to pre- vent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 19.Be sure to assemble all parts again in their origi- nal places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when install- ing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be par- ticularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fin- gers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
- 5. FOREWORD GENERAL 00-5 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 judge- ments. 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 fur- ther 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 under- standing of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte- nance 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 com- ponent, 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. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
- 6. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Remove the radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY. 2. Remove the right front engine mount and mount bracket. 4 5 3. Loosen the fan belt and remove fan (1). 4. Before removing fuel injection pump (2), remove the cover in front of the timing gear case. Using paint, make match marks on the meshing parts of pump drive gear (3) and idle gear (4). 5. Accurately record the relative positions of stamped line (5) of the fuel injection pump body and stamped line (6) of the gear case with mark-off lines (7), etc. 6. Remove fuel high pressure injection pipe (8). 1 7. Disconnect fuel hoses (9) and (10) and engine stop solenoid connector (SO1). D21A, P-830-6 (4)
- 7. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP 8. Remove lubrication tube (11) and 3 fuel injection pump mounting nuts (12). 9. Remove nut (13) from the fuel injection pump drive shaft end. 2 fl Take care not to drop the nut in the case. fl Never loosen mounting bolt (14) of pump drive gear (3) and flange. (If the relative positions of the flange and fuel injection pump drive gear change, it be- comes very difficult to adjust the fuel injec- tion timing.) 10. Using a puller, push the fuel injection pump drive shaft out of the gear and remove fuel injection pump assembly (2). 3 INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY fl Carry out installation in the reverse order to re- moval. 1 fl For installation of the fuel high-pressure injection pipe, see the illustration at right. 2 3 Nut at shaft end: 113 – 123 Nm {11.5 – 12.5 kgm} 3 fl Install the fuel injection pump temporarily and tighten the nut at the shaft end first. fl Adjust the fuel injection angle. For details, see TESTING AND ADJUSTING, Testing and adjust- ing fuel injection timing. D21A, P-8 30-7 (4)
- 8. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP D21A, P-830-7-1 (4) 4 3 Mounting bolt of mount bracket: 59 – 74 Nm {6 – 7 kgm} 5 fl Check the distinguishing marks on the front and rear engine mount rubbers when installing. • Front: [ZZ ]embossed mark • Rear: Round blue paint mark 2 Thread of engine mount mounting bolt: Thread tightener (LT-2) 3 Engine mount mounting bolt: 277 ±31.9 Nm (28.25 ±3.25 kgm)
- 9. D21A, P-830-8 (1) DISASSEMBLY AND ASSEMBLY RADIATOR GUARD REMOVAL OF RADIATOR GUARD ASSEMBLY 1. Drain coolant. 2. Remove left and right engine side covers (3), en- gine hood (4), and radiator grill (5). 3. Disconnect oil cooler hoses (7) from power train oil cooler (6). fl After disconnecting, install blind plugs to pre- vent the oil from leaking. 4. Disconnect radiator hoses (8) and (9), and front lamp wiring harness (10). 5. Remove fan guard (11) and fan (12). 6. Disconnect the clamp of fuel hose (14) from the radiator guard. 7. Disconnect headlamp wiring harness (10).
- 10. D21A, P-8 30-9 (1) 8. Install wires to the radiator upper bracket and lift off radiator guard assembly (13). 4 Radiator guard assembly: 65 kg DISASSEMBLY AND ASSEMBLY RADIATOR GUARD INSTALLATION OF RADIATOR GUARD ASSEMBLY • Carry out installation in the reverse order to re- moval. • Refilling with coolant fl Add coolant through coolant filler to the speci- fied level. fl Run the engine to circulate the coolant through the system. Then check the coolant level again. • Refilling with oil (transmission case) fl Add engine oil through oil filler to the speci- fied level. fl Run the engine to circulate the oil through the system. Then check the oil level again.
- 11. D21A, P-830-10 (1) DISASSEMBLY AND ASSEMBLY ENGINE REMOVAL OF ENGINE ASSEMBLY Disconnect the cable from the negative (–) termi- nal of the battery. 1. Remove the radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY. 2. Remove the cover and drain the hydraulic oil. 6 Hydraulic tank: Approx. 21 ¬ 3. Disconnect alternator wiring harness (1) and start- ing motor wiring harness (2). 4. Disconnect air heater relay wiring harnesses (3) (HE1) and (4) (HE2). 5. Disconnect ground wiring harness (5). 6. Disconnect fuel hoses (6) and (7). 1 fl Plug the hoses to stop the fuel from leaking out. 7. Disconnect fuel control rod (8). 2
- 12. D21A, P-8 30-11 (1) DISASSEMBLY AND ASSEMBLY ENGINE 8. Disconnect engine oil pressure sensor connector (9), engine stop solenoid connector (10), and dust indicator connector (11). 9. Disconnect work equipment pump suction hose (12) from the rear of the fuel injection pump. 10. Remove the floor plate and disconnect work equipment pump outlet hose (13) from the top of the right rear engine mount. 11. Disconnect universal joint (14) from the damper end. 3 12. Remove the engine mounting bolts and lift off engine assembly (15). 4 4 Engine assembly: 300 kg fl When removing the engine assembly, take care of the center of gravity and check that all the pipes and wires are disconnected. fl When storing the engine mount rubbers, make marks of the front and rear sides on them.
- 13. D21A, P-830-12 (1) DISASSEMBLY AND ASSEMBLY ENGINE INSTALLATION OF ENGINE ASSEMBLY • Carry out installation in the reverse order to re- moval. 1 fl Bleed the air from fuel circuit. fl For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit. 2 fl Adjust the cable. For details, see TESTING AND ADJUSTING, Adjusting fuel control cable. 3 3 Universal joint mounting bolt: 30.1 ± 3.4 Nm (3.15 ± 0.35 kgm) 4 fl Check the distinguishing marks on the front and rear engine mount rubbers when install- ing. • Front: [ZZ] embossed mark • Rear: Round blue paint mark 2 Thread of engine mount mounting bolt: Thread tightener (LT-2) 3 Engine mount mounting bolt: 277 ± 31.9 Nm (28.25 ± 3.25 kgm) • Refilling with coolant fl Add coolant through coolant filler to the speci- fied level. fl Run the engine to circulate the coolant through the system. Then check the coolant level again. • Refilling with oil (transmission case, hydraulic tank) Add engine oil through oil filler to the specified level. fl Run the engine to circulate the oil through the system. Then check the oil level again.
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