-
KOM-S-D20AP+
KKoommaattssuuService Manual
D20A, P, S, Q-6,D21A, P, S & Q-6
Volume 1 of 2
THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE
AUTHORIZATION OF KOMATSU OR IT’S SUCCESSORS. KOMATSU AND IT’S
SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS
MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE
OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE
PRODUCTS OF OTHERS.
Serv
ice
Man
ual
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CONTENTS
No. of page
10 ENGINE 1 2 TESTING AND ADJUSTING
................................................ . 1 3 DISASSEMBLY
AND ASSEMBLY ........................................... .
12-1 13-1
20 POWER TRAIN 21 STRUCTURE AND FUNCTION . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 21-1 22 TESTING AND ADJUSTING
................................................. 22-1 23
DISASSEMBLY AND ASSEMBLY
............................................ 23-1 24 MAINTENANCE
STANDARD ............................................... . 24-1
30 UNDERCARRIAGE 31 STRUCTURE AND FUNCTION
.............................................. . 31-1 33
DISASSEMBLY AND ASSEMBLY
............................................ 33-1 34 MAINTENANCE
STANDARD ............................................... . 34-1
60 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .. 61-1. 62 TESTING AND ADJUSTING ......................... . .
. . . . . . . . . . . . . . . . . . . . .. 62-1 63 DISASSEMBLY AND
ASSEMBLY ............................................ 63-1 64
MAINTENANCE STANDARD
............................................... . 64-1
70 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION :. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 71-1 73 DISASSEMBLY AND ASSEMBLY
............................................ 73-1 74 MAINTENANCE
STANDARD ................................................ 74-1
80 ELECTRICAL SYSTEM
00-2 ®
81 STRUCTURE AND FUNCTION ........................ . . . . . . .
. . . . . . . . . . . . . . .. 81-1
020,21-6
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ENGINE .2 TESTING AND AD~USTING
Testing and adjusting data. . . . . . . . . . . . . . . .. 12- 2
Tool list for testing and adjusting. . . . . . . . . .. 12- 3
Adjusting valve clearance .................. 12- 4 Measuring
exhaust gas color. . . . . . . . . . . . . .. 12- 5 Measuring
compression pressure. . . . . . . . . .. 12- 6 Measuring blow-by
pressure.. . . . . . . . . .. . .. 12- 7 Adjusting fuel injection
timing. . . . . . . . . . . . .. 12- 8 Testing and adjusting fan
belt tension. . . . . .. 12- 9
A When carrying out testing, adjusting or troubleshooting, stop
the machine on level ground, apply the lock levers and block the
tracks.
A When working in groups, use agreed signals and do not allow
unauthorized persons near the machine. A When checking the water
level in the radiator, wait for the water to cool. Do not remove
the radiator cap
while the water is hot. Boiling water may spurt out.
A Be careful not to get caught in rotating parts.
020,21-6 12-1 CD
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ENGINE 13 DISASSEMBLY AND ASSEMBLY
020.21-6
8T ARTING MOTOR Removal and Installation. . . . . . . . . . . .
. .. 13- 2
ALTERNATOR Removal and Installation ............. " 13- 2
WATER PUMP Removal and Installation. . . . . . . . . . . . . ..
13- 2
FUEL INJECTION PUMP Removal and Installation. . . . . . . . . .
. . . .. 13- 4
NOZZLE HOLDER Removal and Installation. . . . . . . . . . . . .
.. 13- 4
CYLINDER HEAD Removal and Installation. . . . . . . . . . . . .
.. 13- 6
RADIATOR GUARD Removal and Installation. . . . . . . . . . . . .
.. 13- 8
RADIATOR Removal and Installation. . . . . . . . . . . . . ..
13-10
THERMOSTAT Removal and Installation . . . . . . . . . . . . . ..
13-10
ENGINE Removal . . . . . . . . . . . . . . . . . . . . . . . . .
. . .. 13-12 Installation ........................... 13-14
13-1 ;2
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POWER TRAIN %1 STRUCTURE AND FUNCTION
General (020-6) ........... . . . . . . . . . . . . . .. 21- 2
General(021A,P,S,Q-6,021P-6A) ......... 21- 4 General (021 E-6, 021
P-6B, 021 S-6A) ..... 21- 6 Power train hydraulic system
(021A,P,S,Q-6,021P-6A) ........... 21- 8 Power train hydraulic
circuit diagram
(021 A, P, S, Q-6, 021 P-6A) ........... 21- 9 Power train
hydraulic system
(021E-6,021P-6B,021S-6A) ......... 21-10 Power train hydraulic
circuit diagram
(021 E-6, 021 P-6B, 021 S-6A) . . . . . . . .. 21 -11 Main
clutch (020-6) ...................... 21-12 Main clutch control
(020-6) ............... 21-17 Tramsmission (020-6)
.................... 21-18 Oamper and universal joint
(021A,P,S,Q-6,021P-6A) ........... 21-22 Oamper and universal
joint
(021 E-6, 021 P-6B, 021 P-6A) ... . . . . .. 21-23 HYOOROSHTFT
transmission
(021A, P, S, Q-6, 021 P-6A) ........... 21-24 HYOOROSHIFT
transmission
(021 E-6, 021 P-6B, 021 S-6A) . . . . . . . .. 21-30
Transmissoion control
(021 A, P, S, Q-6, 021 P-6A) ........... 21-36 Transmissoion
control
(021 E-6, 021 P-6B, 021 S-6A) ......... 21-37 HYOOROSHIFT
transmission hydraulic system
(021A,P,S,Q-6,021A-6A) ........... 21-38
020,21-6
HYOOROSHIFT transmissoin hydraulic circuit diagram (021 A, P, S,
Q-6, 021 P-6A) ... 21-39
HYOOROSHIFT transmission hydraulic system (021 E-6, 021 P-6B,
021 S-6A) . . . . . . . .. 21-40
HYOOROSHIFT transmission hydraulic ciucuit diagram (021 E-6, 021
P-6B, 021 S-6A). 21 -41
Transmission control valve (021A,P,S,Q-6,021P-6A) ...........
21-42
Transmission control valve (021 E-6, 021 P-6B, 021 S-6A) . . . .
. . . .. 21-44
Transmission pump (021-6) ............... 21-51 Bevel gear shaft
and steering clutch ........ 21-52 Steering control
.......................... 21-55 Steering hydraulic piping (020-6)
.......... 21-56 Steering hydraulic piping (021 -6) ..........
21-57 Steering hydraulic system (020-6) ......... 21-58 Steering
hydraulic circuit diagram (020-6) .. 21-58 Steering hydraulic
system (021 -6) ......... 21 -59 Steering hydraulic circuit diagram
(021-6) .. 21-59 Main clutch and steering pump (020-6) ..... 21-60
Steering main relief valve (020-6) .......... 21 -61 Steering
control valve ....... . . . . . . . . . . . . .. 21-62 Steering
booster cylinder .................. 21-65 Steering brake
.............. , ............ , 21-66 Final drive. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .. 21 -68
21-1 J:!
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POWER TRAIN Z2 TESTING AND AD~USTING
Standard for testing and adjusting. . . . . . . . .. 22- 2
Testing and adjusting tool list ~ ....... , ..... 22- 4 Measurng
oil pressure . . . . . . . . . . . . . . . . . . . .. 22- 5
Measuring oil temperature ................. 22- 7 Testing travel
............................ 22- 8 Measuring operating force
............... " 22-10 Adjusting fuel control lever
................ 22-12 Adjusting main clutch control linkage
•...... 22-13 Adjusting inching control linkage ........... 22-14
Adjusting gear shift lever control linkage .... 22-16 Adjusting
steering control linkage .......... 22-17 Adjusting brake control
linkage . . . . . . . . . . . .. 22-18 Troubleshooting. . . . . . .
. . .. . . . . . . . . . . . . . .. 22-19
A When carrying out testing, adjusting or troubleshooting, stop
the machine on level ground, install the safety pins and block the
tracks.
A When working in groups, use agreed signals and do not allow
unauthorized persons near the machine. A When checking the water
level in the radiator, wait for the water to cool. Do not remove
the radiator cap
while the water is hot. Boiling water may spurt out.
A Be careful not to get caught in rotating parts.
020,21-6 22-1 CD
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POWER TRAIN 23 DISASSEMBLY AND ASSEMBLY
MAIN CLUTCH (D20-6) Removal and Installation. . . . . . . . . .
. . . .. 23- 2 Disassembly. . . . . . . . . . . . . . . . . . . . .
. . . .. 23- 4 Assembly .......................... ~. 23-10
TRANSMISSION (D20-6) Removal and Installation. . . . . . . . . .
. . . .. 23-16 Disassembly. . . . . . . . . . . . . . . . . . . . .
. . . .. 23-18 Assembly ...................... . . . . .. 23-24
DAMPER (D21 -6) Removal and Installation. . . . . . . . . . . .
. .. 23-32
HYDROSHIFT TRANSMISSION (D21 -6) Removal
............................. 23-34 Installation
........................... 23-38 Disassembly
(D21 A,P,S,Q-6, D21 P-6A) ........ 23-42 Assembly
(D21 A,P,S,Q-6, D21 P-6A) 23-58 Disassembly
(021 E-6, D21 P"-6B, D21 S-6A) . . . .. 23-76 Assembly
(D21 E-6, D21 P-6B, D21 S-6A) . . . .. 23-90
TRANSMISSION PUMP (D21-6) Removal ............................
23-106 Installation .......................... 23-110
MODULATING VALVE (D21-6) Removal and Installation . . . . . . .
. . . . . .. 23-114 Disassembly and Assembly ........... 23-116
SELECTOR AND INCHING VALVE (D21 -6) Removal and Installation
......... . . . .. 23-114 Disassembly and Assembly ...........
23-118
D20,21-6
STEERING PUMP (D20-6) Removal and Installation . . . . . . . . .
. . . .. 23-120
STEERING MAIN RELIEF VALVE (D20-6) Removal and Installation . .
. . . . . . . . . . .. 23-1 20
STEERING VALVE Removal and Installation .............. 23-122
Disassembly and Assembly ........... 23-122
STEERIGN CLUTCH Removal ............................ 23-1 24
Installation .......................... 23-128 Disassembly
......................... 23-132 Assembly
........................... 23-134
BEVEL GEAR SHAFT AND BEVEL GEAR Removal
............................ 23-138 Installation
.......................... 23-142
FINAL DRIVE Removal and Installation .............. 23-150
FINAL DRIVE FIRST PINION Removal and Installation: .............
23-152
FINAL DRIVE Disassembly. . . . . . . . . . . . . . . . . . . . .
. . .. 23-154 Assembly ........................... 23-158
23-1 ~
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POWER TRAIN 24 MAINTENANCE STANDARD
Main clutch (020-6) ...................... 24- 2 Main clutch and
steering pump (020-6) ..... 24- 5 Transmisson (020-6)
................... " 24- 6 Oamper and universal joint (021-6) . .
. . . . . .. 24- 9 HYOOROSHIFT transmission
(021A, P, S, 0-6, 021 P-6A) ........... 24-10 HYOOROSHIFT
transmission .
(021 E-6, 021 P-6B, 021 S-6A) . . . . . . . .. 24-12
Transmission control valve
(021A,P,S,O-6,021P-6A) ........... 24-14 Transmission control
valve
(021 E-6, 021 P-6B, 021 S-6A) . . . . . . . .. 24-16
Transmission and steering pump (021-6) .,. 24-18 Bevel gear shaft
.......................... 24-1 9 Steering clutch
........................... 24-20 Steering main relief valve
(020-6) .......... 24-22 Steering control valve
..................... 24-23 Steering booster cylinder ....... . . .
. . . . . . . .. 24-24 Steering brake. . . . . . . . . . . . . . .
. . . . . . . . . . . .. 24-25 Final drive. .. . .. . . .. . .. .
.. .. . . .. .. . . . .. ... 24-26
020,21-6 24-1
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UNDERCARRIAGE 3I STRUCTURE AND FUNCTION
D20.21-6
Track (dry type track link) (020,21 A, E, P-6)
.................... 31- 2
Track (lubricated track link) (021, 21A, E, P-6)
.................... 31- 3
Track (dry type track link) (020,215,0-6) ......................
31- 4
Track (lubricated track link) (020,215,0-6)
...................... 31- 5
Track group (020, 21A, P, 5, Q-6, 020, 21 P-6A} .... 31- 6
Track group (021 E-6, 021 P-6B, 021 5-6A, 020,21 Pl-6, 021
PLl-6) . . . . . . . . . . . . .. 31- 7
Idler .................................... . Idler cushion
............................ . Track roller
.............................. . Carrier roller
............................. . Main frame and suspension
............... .
31- 8 31- 9 31-10 31-10 31-11
31-1
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UNDERCARRIAGE 33 DISASSEMBLY AND ASSEMBLY
020,21-6
TRACK FRAME Removal and Installation. . . . . . . . . .. . . ..
33- 2
RECOIL SPRING Removal and Installation .. . . . . . . . . . . .
.. 33- 4 Disassembly and Assembly ............ 33- 6
IDLER Removal and Installation. . . . . . . . . . . . . .. 33-
6
CARRIER ROLLER Removal and Installation. . . . . . . . . . . . .
.. 33- 8
TRACK SHOE (020,21,A,E,S,Q-6, 020,21 P-6A,B) Removal and
Installation. .. . . . . . . . . . . .. 33-1 ° (020,21 P,PL-6)
Removal and Installation .. . . . . . . . . . . . . .. 33-12
33-1 ®
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UNDERCARRIAGE 34 MAINTENANCE STANDARD
Track (dry type track link) (020. 021 A. E. P-6) ..............
, . . .. 34- 2
Track (lubricated track link) (020. 21 A. E. P-6) ..............
... . . .. 34- 4
Track (dry type track link) (020. 21 S. Q-6)
....................... 34- 6
Track Uubricated track link) (020. 21 S. Q-6)
...................... 34- 8
Track frame .............................. 34-10 Idler cushion
............................. 34-11 Idler .... . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .. 34-1 2 Track roller
............................... 34-14 Carrier roller ... ,
.......... , . . . . . . . . . . . . . .. 34-1 5
D20,21-6 34-1
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HYDRAULIC SYSTEM 61: STRUCTURE AND FUNCTION
Hydraulic piping (020,21 A, E-6, 020, 21 P-6A, Bl
Hydraulic control (020,21 A, E-6, 020, 21 P-6A, Bl
Hydraulic circuit system (020,21 A, E-6, 020, 21 P-6A, Bl
Hydraulic circuit diagram (020,21 A, E-6, 020, 21 P-6A, Bl
Hydraulic piping (020,21 P, PL, PLL-6l ..... . Hydraulic control
(020, 21 P, PL, PLL-6l .... . Hydraulic circuit system
(020,21 p, PL, PLL-6l ................ . Hydraulic circuit
diagram
(020,21 P, PL, PLL-6l ................ . Hydraulic piping
(020,21 S, 0-6, 021 S-6Al ........... . Hydraulic control
(020,21 S, 0-6, 021 S-6Al ........... . Hydraulic circuit
system
(020, 21S, 0-6, 021A-6Al ........... . Hydraulic circuit
diagram
(020,21 S, 0-6, 021 S-6Al ........... . Hydraulic tank and
filter .................. . Hydraulic pump
.......................... . Hydraulic control valve
61- 2
61- 3
61- 4
61- 5 61- 6 61- 7
61- 8
61- 9
61-10
61-11
61-12
61-13 61-14 61-15
(020, 21A, E-6, 020, 21 P-6A, B) ...... 61-16 Hydraulic control
valve
(020, 21P,PL,PLL-6} ................. 61-18 Hydraulic control
valve
(020, 21S, 0-6, 021S-6A} ............ 61-20 Hydraulic lever
operation (020, 21A, E, P-6). 61-26 Hydraulic lever operation
(020,21 S, 0-6) .. , 61-32 Hydraulic cylinder
(020,21 A, E-6, 020,21 P-6A, B) ...... 61-36 Hydraulic cylinder
(020, 21 P, PL, PLL-6) .... 61-38 Hydraulic cylinder
(020,21 S, 0-6, 021 S-6Al ............ 61-40
020,21 -6 6 1 -1
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HYDRAULIC PIPING
020, 21 A-6, 021 E-6, 020, 21P-6A, 021P-68
5
OUTLINE The oil in hydraulic tank (1) is sucked up by hy-draulic
pump (2) installed to the engine, and is sent to hydraulic control
valve (3). The hydraulic control valve sets the pressure in the
circuit to 155 kg/cm2.lt switches the flow of oil to lift cylinder
(4), angle cylinder (5), or tilt cylinder (6) to operate the blade
according to the movement of the work equipment control lever. If
the hydraulic control valve is at the "HOLD" po-sition, the oil
enters hydraulic filter (7) installed to the hydraulic tank and
returns to the hydraulic tank.
61-2
I03F06041
1 . Hydraulic tank 2. Hydraulic pump 3. Hydraulic control valve
4. Blade lift cylinder 5. Blade angle cylinder 6. Blade tilt
cylinder 7. Hydraulic filter
The hydraulic filter is a cartridge type with a filtering
preCision of 10 J.l, and a maximum filter-irig rate of 1 OOX~/min,
and the normal pressure is set to 1 .5 kg/ cm2• The total capacity
of the hydraulic tank is 33 liters, with the amount of oil inside
the tank set to 20 litres.
020,21-6
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HYDRAULIC SYSTEM 62- TESTING AND AD'--'USTING
Standard for testing and adjusting . . . . . . . . .. 62- 2
Testing and adjusting tool list .............. 62- 3 Measuring and
adjusting oil pressure. . . . . . .. 62- 4 Measuring oil
temperature ..... . . . . . . . . . . .. 62- 5 Bleeding air from
angle
cylinder head circuit. . . . . . . . . . . . . . . . . .. 62- 5
Testing travel ............................ 62- 6 Measuring
operating force ................. 62- 6 Testing performance of work
equipment .... 62- 7 Measuring hydraulic drift of
work equipment ...................... 62- 9 Troubleshooting. . .
. . . . . . . . . . . . . . . . . . . . . .. 62-11
A When carrying out testing, adjusting or troubleshooting, stop
the machine on level ground, install the safety pins and block the
tracks.
A When working in groups, use agreed signals and do not allow
unauthorized persons near the machil)e. A When checking the water
level in the radiator, wait for the water to cool. Do not remove
the radiator cap
while the water is hot Boiling water may spurt out.
A Be careful not to get caught in rotating parts. A Bleeding air
from hydraulic cylinder.
After replacing or installing hydraulic cylinders or hydraulic
piping, bleed the air from the hydraulic cylin-ders as follows: 1.
Start the engine and run at idling for about 5 minutes. 2. Run the
engine at low idling, and raise and lower the work equipment 4 - 5
times.
* Stop the piston rod about 100 mm from the end of the stroke.
Never operate it to the relief position.
3. Run the engine at full throttle and repeat the above
procedure. Then run the engine at low idling and operate the piston
rod to the end of the stroke to relieve the circuit.
020,21-6 62-1 ,.
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HYDRAULIC SYSTEM 63 OISASSEMBL Y AND ASSEMBLY
020,21-6
HYDRAULIC PUMP Removal and Installation. . . . . . . . . . . . .
.. 63- 2
HYDRAULIC CONTROL VALVE Removal and Installation. . . . . . . .
. . . . . .. 63- 2 Disassembly
(020,21 A,E-6, 020,21 P-6A,B) Assembly
(020,21 A,E-6, 020,21 P-6A,B) Disassembly
(020,21 P,PL-6) Assembly
63- 4
63- 6
63- 8
(020,21 P,PL-6) .................. 63-1 ° Disassembly (020,21
S,0-6) ... . . . . . . .. 63-12 Assembly (020,21 S,0-6)
............. 63-14
BLADE LIFT CYLINDER Removal and Installation. . . . . . . . . .
. . . .. 63-16
BLADE ANGLE CYLINDER Removal and Installation. . . . . . . . . .
. . . .. 63-16
BLADE TILT CYLINDER Removal and Installation. . . . . . . . . .
. . . .. 63-1 B
BUCKET LIFT CYLINDER Removal and Installation ............. ;.
63-20
BUCKET DUMP CYLINDER Removal and Installation. . . . . . . . . .
. . . .. 63-20
HYDRAULIC CYLINDER Disassembly. . . . . . . . . . . . . . . . .
. . . . . . . .. 63-22 Assembly. . . . . . . . . . . . . . . . . .
. . . . . . . . .. 63-24
63-1 C~)
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HYDRAULIC SYSTEM 64 MAINTENANCE STANDARD
Hydraulic control velve (020,21A,E-6, 020, 21 P-SA, B) .......
34- 2
Hydraulic control valve (020,21 P, PL, PLL-61 ............ ~ . .
.. 34- 4
Hydraulic control valve (020, 21 S, 0-6, 021 S-6A) .............
34- 6
Hydraulic cylinder (020, 21 A, E, P-61 ....... 34- 8 Hydraulic
cylinder
(020,21 S, 0-6, 021 S-SA) ............ 34-10 Hydraulic pump. . .
. . . . . . . . . . . . . . . . . . . . . . .. 34-11
020,21-6 64-1
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WORK EQUIPMENT 71. STRUCTURE AND FUNCTION
D20,21-6
Power angle and·tiltdozer (020, 21 A, E-6, 020, 21 P-6A, B) .. .
.. .. 71- 2
Strainght tiltdozer (020, 21 P, PL, PLL-6) ... 71- 4 Bucket and
link (020,21S,Q-6,021S-6A) .71- 6
71-1
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WORK EQUIPMENT 73 DISASSEMBLY AND ASSEMBLY
020,21-6
WORK EQUIPMENT Removal and Installation ........... ; . . ..
73-2
BLADE Removal and Installation ........... : . . .. 73-4
WORK EQUIPMENT Removal and Installation ....... ,. . . . ....
73-6
BUCKET Removal and Installation.. . . . . . . . . .. . . ..
73-6
73-1 ~
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WORK EQUIPMENT 74 MAINTENANCE STANDARD
D20,21-6
Power angle and tiltdozer (020,21A,E-6,020, 21P-6A,Bl ..•... 74-
2
5trainghttiltdozer (020, 21 P, PL, PLL-6l .... 74- 4 Bucket and
link (020,215, 0-6, D215-6Al . 74- 6
74-1
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ELECTRICAL SYSTEM 81 STRUCTURE AND FUNCTION
Wiring dyagram .......................... 81 - 2
020.21-6 81-1
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kom-s-d20ap+ vol1