Shop Manual Komatsu D20A, P, S, Q-6 AND D21A, P, S, Q-6

SEBM01040604 SIMO IMTAUNTU AIL KOMATSU D20AP,S,Q-6 D21A,PS,Q-6 MACHINE MACHINE MODEL SERIAL No. MODEL SERIAL No. D20A-6 60001 and up D21A-6 60001 and up D20P-6 60001 and up D21E-6 60001 and up D20P-6A 60001 and up D21P-6 60001 and up D20PL-6 60001 and up D21P-6A 60001 and up D2OPLL-6 60001 and up D21P-6B 60001 and up D20S-6 60001 and up D21PL-6 60001 and up D200-6 60001 and up D21S-6 60001 and up D21S-6A 60001 and up D210-6 60001 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. © 020, 21-6 mount the 4D95S-W-1 engine. For details of the engine, see the 95 Series Engine Shop Manual, Printed in Japan 00-1 03-80(01)03381 aCONTENTS 10 ENGINE 12. TESTING AND ADJUSTING 13 DISASSEMBLY AND ASSEMBLY 20 POWER TRAIN 21 STRUCTURE AND FUNCTION 22 TESTING AND ADJUSTING 23 DISASSEMBLY AND ASSEMBLY 24 MAINTENANCE STANDARD 30 UNDERCARRIAGE 31 STRUCTURE AND FUNCTION 33 DISASSEMBLY AND ASSEMBLY 34 MAINTENANCE STANDARD 60 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION 62 TESTING AND ADJUSTING 63 DISASSEMBLY AND ASSEMBLY 64 MAINTENANCE STANDARD 70 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION 73 DISASSEMBLY AND ASSEMBLY . 74 MAINTENANCE STANDARD 80 ELECTRICAL SYSTEM 81 STRUCTURE AND FUNCTION No. of page 21-4 22-1 23-1 24-1 . 31-1 33-1 34-1 61-1 62-1 63-1 64-1 nea 73-1 74-1 020,21-6LIST OF REVISED PAGES ISTO REVISED PAGES. The affected pages are indicated by the use of the following marks. Its requested that necessary actions be Mark Indication Action required ‘taken to these pages according to the table below. ei © | Page to be newly added Add © | Page to be replaced | Replace (}] Page to be deletes Discard Pages having no marks are those previously revised or made additions, LIST OF REVISED PAGES Mark Page TES! | ark Page TE! | mark Page TIME | atark Page TOT | mark Page Timeof em 4 ze 4 28 21.35 2183 o2 2 274 29 21.96 21-64 oo 21 4 we 4 2110 2137 2165 B 0022 4 we 4 an 21.98 21-66 23 4 22 2139 21.87 oo 3 1 00@ | as 2140 2168 00. 4 2 aut 20a oo 5 | ma 2 245 2142 ai 00.6 | m4 @ 2146 2149 m2 4 00.7 ae a7 2144 mai 00.8 6 2 aie 2145 24 00. 8 72 2119 21.46 nes @ 0010 we 2 2120 247 26 9 oo.12 9 2 aa 2148 ar © 0013 a io 2122 2149 me 4 0-14 4 ® 2123 21-50 ze © 0015 a waz? 2124 281 2 06 wis @ 21.25 2182 nud ° 00174 waa? 21.26 2189 nai cone iis? na 2154 nas cone 2128 2158 aa aig 21.29 2156 nis 22 21.30 2157 ae 1 4 a3 es 4 2188 22.17 22004 a4 as 4 2189 22.18 i Seen a8 © 2122 21-60 ze Ret 21.6 2199 2161 nn . 265 4 a7 2134 2162 nn 20,21-6 00-2-1LIST OF REVISED PAGES Mark Page Tim®2F) mark Page Tiel | mark pone Tint | Wark Page TIME SN | Mark Pane etn 2222 T 23.38 @ © 2378 ® 23-118 2 23-156 2 nas na @ nm @) a9 2.1572 no @ 260 2 23120 @ nis 2 a1 @ aa @ zs man @ rasa 2.2 @ na @ ne mim @ m0 @ m3 2a ne 2 23.123 @ zi ® 34 @ nu @ na @ mim @ a5 2 nas @ 2852 23125 Det 26 @ nase 286 2 2318 24.2 nr ® na @ ner nag 243 28 ® nas @ mes? 218 ae 2.9 @ 249 ne 2 23.129 @ 46 210 @ 250 2 neo 2 zi 2 | 26 nu @ ner @ ne 2 | we a7 @ a2 @ ner 2 naz 2 mam 2 we 2 nia @ ns @ ne 2 a3 ® 28 nu @ ne 2 zee 2 nam 2 210 ns @ nes @ nes 23138 2 my 2 zie ne @ ne 2 nie @ | o m2 © nar @ ner @ ner 2 2197 m2 @ 23.18 @ 23.58 @ 723.98 2 23-138 @ o 2et34 @ 219 @ 259 @ no 2) mam g | o maa @ 20 60 @ 2100 2 2180 pana nan @ ne @ 2112 man Q m5 @ aw 2 ne 2 © 2102 @ ara | 2848 23-23 2 23-63 ®@ 23-103 2 23-143 @ | 24.17 Q 224 @ nes @ z108 mse aie 22 @ nes 2 21052 aus 2 rats 26 2 268 @ zai 2 | 8 26 @ 2420 227 ner 2 zi «| © mw @ 2428 228 2 nes @ 2108 2 nue zz ® 22 2 26 @ 21002 nue 2 ma no @ | 0 nn @ ao 2 2.160 2 m2 @ 201 @ an @ aan 2 4161 m2 one @ nm za @ | © a2 @ | © 225 ons nn @ zis @ | 0 ms @ un @ 2s @ 21 aim @ | o zs @ at nas ® 2375 ® zis @ | o mis2 @ a2 no ® 26D ase 2 2.454 @) a3 nar ® an @ aa @ 2.155 a aa 00.2-2 D20,21-6LIST OF REVISED PAGES Mark Page TINE! mark rage TITESH | war pape Temet] atc Page Time tT ark page Time of as oa ert e108 m4 ® ae oa 22 3 on 2 25 2 ae? os es i er 2 B68 @ ae a6 4 as 1 on 2 nr ® as 4 or es | of a0 one oe 1 ow 2 44 an ono wr e168 42 e110 es 4 e178 143 B18 oun 1 ow 2 4 B2 @ ove en ens ms @ ma 2 e119 en 2 2 46 ma ora ei 3 en 3 47 as 2 ons ou | on 2 we 8 o16 eas on 8 ant a7 3 ou e216 e202 a2 me 2 eve et oe 39 3 or-19 ee 33:10 2 61-20 @ 62419 1 4 an 3 e121 6220 | a2 ae 2 e122 en 4 e9 m3 e129 e221 oa 61-24 en 4 on wt 61.26 \fetac cay on 34.2 61.27 | 62-25 1 64.7 343 61.28 | 6226 1 48 | ues e120 | a2 3 we @ 5 2 61.30 | e228 64.10 awe ors am 4 oan a? e122 200 268 ora an ma we 2 ore na uno 6138 ei 9 3 wn 3 6126 2 2 ma m2 6127 os 2 ns un 8 61.28 os 2 6 sana 61.29 5 2 mn? 2418 e140 6 2 ovat 7 2 m1 8 ot es 2% m2 @ oe es 2 ma @ 20,21-6 00-2-3A\ IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose To prevent injury to workers, the symbols Jf and YS are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. f any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. A\ SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully 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, glasses, 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 working, 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 falling. !n 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 provide safe footing, 00-3PRECAUTIONS 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 carrying 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 negative (—) 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 prevent the component from hit ting 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 on to 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. 00-4 19. Be sure to assemble all parts again in their original 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 installing 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 particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers 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 assem- bled before taking any measurements. 24, Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD: 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 chapters for each main group of components; these chapters are further divided into the following sections. 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, 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” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any ime and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5ELECTRIC WIRE CODE eSA tie In the wiring diagrams, various colors and symbols are employed to indicat ELECTRIC WIRE CODE This wire code table will help you understand WIRING DIAGRAMS, Example: O5WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS fe the thickness of wires. Topper fomte | oeeeaaaet cabieod | curentrating Applicable circuit umber [Number Grose section | (mm) th ie Sends ‘in or " 032 088 24 12 | Starting. ighting, signal ete 02 26 on 208 34 20 | Lanting signal ete 08 05 | 032 523 46 37 | Charging and signa! 18 et | (oes 1336 10 58 | Staring Glow pig! “0 88 oso | aa79 14 136 | Stating 60 127 0.80 eae 136 178 | stating 100 27 080 1091 176 230 | staring \ CLASSIFICATION BY COLOR AND CODE Cress Ponty <2 storia | charging | Listing Signat | tastment | other Clossiiation coae ® w 7 @ v v 1 | Pama, |—— Color | Black White ed Greon Yeliow Ble Code ew wk aw ew ve ow 2 Tour | Biocka whe | wnteaned | Reds white [Greene whee | Yolow aed | Blue & white | eoae ey we Fe om va i 3 ‘Cour [BackA Yeiow| wniea Glock | Rede Back | Green& Red |volow a Black | Blues Red vation, Code aR we oy or ve Ww 4 Corr | Beckared | wnte Baie | Rede Yetow [Green Yolow [Yew & Green [Blue & Yellow cove e wy mG cy we ie 5 Color = |wnite & Yerow] fea Grecn | Green Black | Yelow save | Ble Black cous we a a vw 6 olor = Fwnite a Green | Reds ee | Green Bun [Yotiow & White 00-10WEIGHT TABLE 020AP-6 A. This weight table is guide for use when transporting or handling components. Unit:_kg Machine Model p20A-6 | D20P-6 | D20P-6A | D20PL-6 |D2OPLL-6 ae 60001 | 60001 | 60001 | 60001 | 60001 fe andup | andup | andup | andup | andup Engine and main clutch assembly 351 351 351 351 351 + Engine assembly 285 285 285 285 285 + Main clutch assembly | 66 66 66 66 66 Radiator assembly 24 24 24 24 24 Fuel tank assembly (with fuel) 129 129 129 129 129 Transmission assembly 58 58 58 58 58 Bevel gear shaft and steering clutch assembly 68 68 68 68 68 + Steering clutch assembly (each side) 19 19 19 19 19 + Brake band assembly (each side) 2 2 2 2 2 + Bevel gear shaft 5 5 5 5 5 + Bevel gear 5 5 5 5 5 ‘Steering control valve assembly 9 9 9 9 9 Final drive case (each side) 27 27 32 32 51 Sprocket (each side) 30 30 30 30 30 Main frame assembly 361 an 361 a ant + Main frame and steering case 353 403 353 403 403 + Sprocket shaft (each side) 14 14 18 18 26 Track group assembly (each side) 285 294 285 318 365 + Track frame (each side) 63 74 63 7 93 + Idler assembly (each side) 87 87 57 87 57 + Track roller assembly (each) 14 14 14 14 14 + Cartier roller assembly (each) " Ww W " WW Track shoe assembly (each side) 550 805 808 878 1280 Cross bar 87 87 67 67 91 Hydraulic tank assembly 79 79 79 79 79 Hydraulic valve assembly 10 8 10 8 8 Blade lift cylinder assembly (each side) 14 7 14 7 16 Blade tilt cylinder assembly 15 13 16 13 13 Blade angle cylinder assembly (each side) 15 - 15 - 7 00-12 20,21-6Unit: kg Machine Model D20A-6 | D20P-6 | D20P-6A | D20PL-6 | D20PLL-6 - 60001 | 60001 | 60001 | 60001 | 60001 rial No, andup | andup | andup | andup | andup Power angle and tiltdozzer assembly 385 412 + Blade 172 - 195 - - + Ustrame 146 146 Straight tiltdozer assembly 345 379 420 + Blade 173 195 212 + Straight frame (each side) - 44 - 44 46 + Blade tilt cylinder assembly 13 13, 13 + Tiltbrace 6 6 6 Radiator guard feat 98 31 98 98 Engine underguard 12 12 12 12 12 ‘Transmission underguard 16 16 16 16 16 Hood 18 18 18 18 18 Loader frame 82 70 82 70 70 Operator's seat assembly 2 21 2 21 2 Cenopy assembly 35 35 35 35 35 (60) (60) (60) (60) (60) —l * (60): D20A-6 Serial No. 61022 and up D20P-6 Serial No. 60873 and up D20P-6A Serial No. 61109 and up D20PL‘6 Serial No. 60145 and up D20PLL-6. Serial No. 60100 and up 20,21-6 00-13 @WEIGHT TABLE 021A,P-6 A This weight table is a gui fe for use when transporting or handling components. Unit: kg Machine Model 0214-6 | D21E-6 | D21P-6 |D21P-6A |D21P-6B|D21PL-6 Secihn 60001 | 60001 | 60001 | 60001 | 60001 | 60001 e andup | andup | andup | andup | andup | andup Engine and damper assembly 308 305 308 305 305 305 + Engine assembly 288 288 288 288 288 288 + Damper assembly 7 v7 7 7 7 Ww Radiator assembly 24 24 24 24 24 24 Fuel tank assembly (with fuel) 129 129 129 129 129 129 HYDOROSHIFT transmission assembly 140 190 140 140 190 140 + Modulating valve assembly 6 6 6 6 6 6 + Speed and inching valve assembly 8 6 8 8 6 8 Bevel gear shaft and steering clutch assembly | 68 68 68 68 68 68 + Steering clutch assembly (each side) 19 19 19 19 19 19 + Brake band assembly (each side) 2 2 2 2 2 2 + Bevel gear shaft 5 5 5 5 5 5 + Bevel gear 5 5 5 5 5 5 Steering control valve assembly 9 9 9 9 9 9 27 27 27 32 32 32 30 30 30 30 30 30 ‘Main frame assembly 361 361 an 361 361 ay + Main frame and steering case 353 353 403 353 353 403 + Sprocket shatt (each side) 14 14 14 18 18 18 ‘Track group assembly (each side) 285 320 294 285 320 315 + Track frame (each side) 63 7 74 63 7 7 + Idler assembly (each side) 87 57 87 57 87 87 + Track roller assembly (each) 14 14 14 14 14 14 + Carrier roller assembly (each) WW W " " W W ‘Track shoe assembly (each side) 550 619 805 805 774 878 Cross bar 87 87 57 67 67 67 00-14 020,21-6Unit: kg. Machine Model D21A-6 | D21E-6 | D21P-6 |D21P-6A | D21P-6B|D21PL-6 Seeine 60001 | 60001 | 60001 | 60001 | 60001 | 60001 andup | andup | andup | andup | andup | andup Hydraulic tank assembly 79 79 79 79 79 79 Hydraulic valve assembly 10 10 8 10 10 8 Blade lift cylinder assembly (each side) 14 14 7 14 14 7 Blade tilt cylinder assembly 18 18 13 15 15 13 Blade angle cylinder assembly (each side) 18 15 - 15 15 = Power angle and tiltdozer assembly 385 397 412 424 + Blade 172 172 - 195 195 - + U-frame 146 156 146 156 Straight titdozer assembly 345 379 + Blade 173 198 + Straight frame (each side) - - 44 - - 44 + Blade tilt cylinder assembly 13 13 + Tiltbrace 6 6 Radiator guard 31 31 98 31 31 98 Engine underguard 12 12 12 12 12 12 Transmission underguard 16 16 16 16 16 16 Hood 18 18 18 18 18 18 Loader frame 82 82 70 82 82 70 Operator's seat assembly 21 2 21 2 21 21 Canopy assembly 35 35 35 38 35 35 (60) (60) (60) (60) —___ * (60): D21A-6 Serial No, 61022 and up D2IP-6 Serial No. 60873 and up D21P-6A Serial No, 61109 and up D21PL-6 Serial No, 60158 and up 20,21-6 00-15WEIGHT TABLE 020.215, 0-6 AX This weight table is a guide for use when transporting or handling components. Unit:_kg Machine Model 208-6 | 0200-6 | 0218-6 | 0218-6A | 0210-6 Ses 60001 | 60001 | 60001 | 60001 | 60001 eae andup | andup | andup | andup | andup whee Engine and main clutch assembly 351 351 + Engine assembly 285 285 7 - = + Main clutch assembly 66 66 Engine and damper assembly 305 305 305 + Engine assembly - - 288 288 288 + Damper assembly W7 W7 7 Radiator assembly 24 24 24 24 24 Fuel tank assembly (with fuel 129 129 129 129 129 Transmission assembly 58 58 - - - HYDROSHIFT transmission assembly 140 190 140 + Modulating valve assembly - - 6 6 6 + Speed and inching valve assembly 8 6 8 Bevel gear shaft and steering clutch assembly 68 68 68 68 68 + Steering clutch assembly (each side) 19 19 19 19 19 + Brake band assembly (each side) 2 2 2 2 2 + Bevel gear shaft 5 5 5 5 + Bevel gear 5 5 5 5 Steering control valve assembly 9 9 9 9 9 Final drive case (each side) 27 32 27 27 32 Sprocket (each side) 30 30 30 30 30 Main frame assembly 361 361 361 361 361 + Main frame and steering case 3563 353 353 353 353 + Sprocket shaft (each side) 4 18 14 14 18 Track group assembly (each side) 285 285 285 320 285 + Track frame leach side) 63 63 63 7 63 + Idler assembly (each side) 87 87 87 87 57 + Track roller assembly (each) 14 14. 14 14 14 + Cartier roller assembly (each) "1 u " " " 20,21-6Unit: kg swe See = Bucket dump cylinder assembly (each side) 16 16 16 16 16 Bucket assembly (with tooth) (204 221 (204 200 221 (60) (60) (60) (60) + (60): 208-6 Serial No. 60082 and up D200-6 Serial No. 60071 and up D21S-6 Serial No. 60085 and up 210-6 Serial No. 60069 and up 020,21-6 00-17 @LIST OF LUBRICANT AND WATER resenvoin | wnpor |, ABENT TewenATinE — ae sch = SAE EWG “Transmission case SAE DEE 210206 © |r orr0 ed ee ee") | (RR) Hydraulic tank SAE 10W. ggg 21 seese\ ren 21-68 ap68 | res) tats 4 selene 00-18 D20,21-6NOTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual Change oil according to the following table if fuel sulphur content is above 0.5%. Fuel sulphur content 05 t0 1.0% Above 1.0% Change interval of oil in engine oil pan 1/2 of regular interval 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers (2 (3) When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAETOW, SAE1OW-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. Specified capacity: Total amount of oil including oil for components and oil in piping, Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 020,21-6 00-19ENGINE 12 TESTING AND ADJUSTING > PP Bb Testing and adjusting data Too list for testing and adjusting Adjusting valve clearance Measuring exhaust gas color Measuring compression pressure Measuring blow-by pressure ‘Adjusting fuel injection timing Testing and adjusting fan belt tension 12-2 12-3 12-4 12-6 12-6 12-7 12-8 12-9 ‘When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, apply the lock levers and block the tracks. ‘When working in groups, use agreed signals and do not allow unauthorized persons near the machine. ‘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. Be careful not to get caught in rotating parts 020,21-6 12-1TESTING AND ADJUSTING DATA Applicable machine model 2021-6 Engine model 40958.W-1 tem Condition Unit | Standard value | Permissible value High idling speed 2500 — 2630 Engine speed Low idling speed pm 730 — 790 Rated speed 2450 Quick acceleration Bosch 40 60 Dies oe ote Athigh idling scale 15 25 Intake valve 035 Valve clearance (at cold) mm Exhaust vave 050 Oil temperature fe Compression pressure 40-60% | K/em eo a peeon (Engine speed) ‘pm | (320 - 360) (920 — 360) ‘w-by pressur Water temperature Bree | seg else cs Athigh idling oe At high idting 35-60 2.45 (Water temperature: | Atiow idling (SAE3O) | kg/em# 10 07 Inside operating rangel| at tow igting (SAETOW) o8 7 Oil temperature Allspeed (oiin otpand | °c 80-110 120 Fuelinjection timing | 8.1.0. degree 18-17 16 Fan belt tension Deflection when pushed mm 8 (Alternator side) with a force of 6 kg 020,21-6TOOL LIST FOR TESTING AND ADJUSTING 'No.| Testing and measuring item | Fault finding too! Part No. Remarks Digital reading. 1 | Engine speed Multi-tachometer |799-203-8000] 60 — 2,000 rpm (L range) 60 — 20,000 rpm (H range) Digital temperature Water temperat 799-101-6000] : 2 | oittemperature Gouge or thermistor 1999.500-1300) °° = 1-700C temperature gauge 3 | Lubrication oil pressure Hydraulic tester 799-101-5000] 0 — 20 kg/em? Compression gauge |795-502-1590| 4 | Compression pressure 0 - 70 kg/em* Adapter 195-414-1110] 5 | Blow-by pressure Blow-by checker [799-201-1503] 0 — 500 mmH,0 6 | Vaive ci Feeler gauge 795-125-1370] 0.35, 0.50 mm Handy smoke checker|789-201-9000) p inees.o — 70s¢with standard 7 | Exhaust gas color color (Dirtiness %x 1/10 = Bosch ‘Smoke meter Commercially available scale) 020,21-6ADJUSTING VALVE CLEARANCE * Adjust clearance between valve stem and rocker arm as follows. Unit: mm Intake valve | Exhause valve Atclod 0.35 05 1. Remove the cylinder head cover. Piosso1g 2. Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of the No. 4 cylinder, bring the No. 1 cylinder into the top dead center position of the compression stroke and align the “1.4 TOP” mark on crankshaft pulley (1) with pointer (2). 3. When No. 1 cylinder is top dead center of compression stroke, adjust the valve clearance for valves marked @ in the valve arrangement chart. 4. To adjust the vaive clearance, loosen locknut (6) ‘on adjustment screw (5), insert feeler gauge A corresponding to the specified clearance between valve stem (4) and rocker arm (3), and adjust the clearance with the adjustment screw Until the thickness gauge can slide lightiy. cvingerNo ] 1 | 2] 3 | 4 5. Rotate the crankshaft in the normal direction by ram Ince wave seeeetreipesr ya etiepreniai is the remaining valves marked O. Exhaust valve 6. Aftor the clearance is properly adjusted, tighten the locknut to secure the adjustment screw. 4 3 GSD Locknut: 3.15 + 0.35 kgm Intake and exhaust valve clearances may be adjusted for each cylinder in the firing order rt by rotating the crankshaft 180° at a time in the normal direction — % Firing orderis 1-2—4—3. Et + After tightening locknut, check valve ce O 12-4 D20,21-6 oOMEASURING EXHAUST GAS COLOR AA when measuring the exhaust gos color, be careful not to touch the exhaust pipe 4 Measure the exhaust gas color while engine is warm, (Oil temperature: 60°C) 1. Insert probe A, in outlet of exhaust pipe (1) and secure to exhaust pipe with clip. 2. Connect probe hose, connector for accelerator switch and air hose to smoke meter A. ‘The pressure of air supply should be less. than 15 kg/em® 3. Connect power cable to power source. * Check that the power switch is OFF before connecting the code. 4. Loosen cap nut of suction pump and insert filter paper. 5. Turn power switch ON. 6. Accelerate engine suddenly. At the same time, depress accelerator pedal, operate relief valve and catch exhaust gas color on filter paper. 7. Lay filter paper used to catch exhaust gas color on top of unused filter papers (10 sheet or more) inside filter paper holder, and read indicated value. 20,21-6 12-5MEASURING COMPRESSION PRESSURE Special tools Part Number PartName — [a'ty A_| 795-502-1203 | Compression gauge | 1 A, | 795-414-1110 Adapter 1 B | 799-203-8000 | Trachometer | 1 A. When measuring the compression pressure, be careful not to touch the exhoust menifold a mul, or fo pot eaught rotating para 1. Adjust the valve clearance properly. For details, see ADJUSTING VALVE CLEARANCE. 2. Warm up engine. (Oil temperature: 40 — 60°C) 3. Remove nozzle holder assembly to be measured. For details, see REMOVAL OF NOZZLE HOLDER, ASSEMBLY 4. Install adapter A, to the nozzle holder mount. 5. Connect compression gauge A to the adapter Ay 6. Place the fuel control lever in NO INJECTION position, crank the engine with the starting motor, ‘and measure compression pressure. %* Read compression gauge when the pointer is stabilized, ‘* When measuring the compression pressure, ‘measure the engine speed to confirm that it is within the specified range. ‘* After measuring the compression pressure, stall nozzle holder assembly. For details, see IN- STALLATION OF NOZZLE HOLDER ASSEMBLY. 12-6 D20,21-6MEASURING BLOW-BY PRESSURE Special too! rt Number PartName [Q'ty ‘A | 799-201-1503 | Blow-by checker | 1 BL When mensuring the blow-by pressure, be Ee eens eer ar aa re mutter orto get cought in rotating parts 1. Warm up engine. (Water temperature is inside operating range.) 2. Remove head cover, install plug on blow-by suction tube (1), then install head cover. 3. Install tool A on oil filler. 4. Run engine at high idling speed, then measure blow-by pressure. 20,21-6 12-7ADJUSTING FUEL INJECTION TIMING 1. Aligh the “1.4” injection timing stamp line on crankshaft pulley (1) with pointer (2) by slowly rotating the crankshaft in the normal direction. 2. Disconnect fuel injection pipe (3) for the No. 1 cylinder. 3. Remove delivery valve holder (4), remove spring (6) and delivery valve (5) from delivery valve holder, and reassemble delivery valve holder (4), Pace he ul con ovarin FULL poi y econ 5. Loosen nuts (7) on injection pump mounting flange slot, and loosen injection pump mounting bolts (8). 6. Turn injection pump outward, operating priming Pump, slowly turn injection pump to cylinder block end, stop injection pump in the position where fuel flow out from delivery valve holder stops. % If fuel flow out does not stop when turn injection pump either directions, rotate crahk- shaft one more turn. %* If turn injection pump outward, injection timing is retard. If turn injection pump cylin der block end, injection timing is advanced, 7. Tighten injection pump mounting bolts (8) in turn, 8. Tighten nuts (7) on injection pump mounting flange slot. 9. Remove delivery valve holder (4), assemble delivery valve (6) and spring (6), install delivery valve holder (4) again. =I Delivery valve holder: 3.3 + 0.2 kam. 10. Connect fuel injection pipe (3). SED Sleeve nut: 2.4 + 0.1 kgm 12-8 020,21-6TESTING AND ADJUSTING FAN BELT TENSION TESTING FAN BELT TENSION Fen pulley Check the amount the fan belt deflects when pushed ‘Appcox. 10 mm with a force of 6 kg at a point midway between the fan pulley and the alternator pulley. Aiternator pulley ADJUSTING FAN BELT TENSION 1) Loosen mounting bolt (1) of alternator assembly and belt tension adjustment bolt (2) 2) Using a bar, raise alternator and adjust fan belt tension, Tighten adjustment bolt (2), then tighten mounting bolt (1), 20,21-6 12-9ENGINE 13 DISASSEMBLY AND ASSEMBLY STARTING 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 20,216 13-1REMOVAL OF STARTING MOTOR ASSEMBLY Ad Disconnect the cable from the negative (—) terminal ofthe battery, 1. Using transmission jack (1), remove underguard (1). Gee P1) 2. Disconnect control cable (2). (See P2) 3. Disconnect fuel hoses (3) and (4). (See P2) ‘* Fuel will come out when the hoses are dis- connected, so fit corks in the hoses, or tie them, 4. Disconnect starting motor wiring (5) and (6) (See P2) 5. Remove starting motor assembly (7). (See P3) INSTALLATION OF STARTING MOTOR ASSEMBLY 1. Fit O-ring and install starting motor assembly (7) (See P3) 2. Connect starting motor wiring (6) and (5). (See P2) 3. Connect fuel hoses (4) and (3). (See P2) 4. Connect control cable (2). (See P2) + Bend the cotter pin securely 5. Using transmission jack (1), install underguard (1). See P1) REMOVAL OF ALTERNATOR ASSEMBLY A. _ Disconnect the cable from the negative (—) terminal of the battery. Disconnect wiring (1) from alternator. (See P4) Remove mounting bolt (2) of adjustment plate, then loosen mounting bolt and nut (3), and remove fan belt, (See P4) 3. Remove mounting bolt and nut, then remove al- temator assembly (4). (See P4) INSTALLATION OF ALTERNATOR ASSEMBLY 1. Set alternator assembly (4) on bracket, and tight- ‘en mounting bolt and nut (3), and mounting bolts (2) of adjustment plate temporarily, then fit fan beltin pulley groove. (See Pa) % For details of dimensions and the procedure for adjusting the belt tension, see 12 TEST- ING AND ADJUSTING. 2. Tighten mounting bolt and nut, and mounting bolts of adjustment plate. (See P4) 3. Connect wiring (1) to alternator. (See P4) REMOVAL OF WATER PUMP ASSEMBLY 1. Loosen radiator drain valve and drain cooling water. + If the coolant contains antifreeze, dispose of itcorrectly 2. Disconnect radiator inlet hose (1) and water temperature gauge sensor (2). (See P5) 3. Remove fan guard (3), then remove fan (4), (See PS, P6) 4. Loosen mounting bolt (5) of adjustment plate, then mounting bolt and nut, and remove fan belt (6). (See P6) 5. Disconnect radiator outlet hose (7), and remove water pump assembly (8). (See P7) INSTALLATION OF WATER PUMP ASSEMBLY 1. Fit gasket and install water pump assembly (8), then connect radiator outlet hose (7), (See P7) 2. Install fan belt (6), then tighten mounting bolt and nut, and mounting bolt (5) of adjustment plate. (See P6) * For details of adjusting the fan belt tension, see 12 TESTING AND ADJUSTING. 3._ Fit fan (4) and install fan guard (3). (See P6, PS) 4. Connect water temperature gauge sensor (2) and radiator inlet hose (1). (See P5) 5. Tighten drain valve and add water through water filler to the specified level ‘* Run the engine to circulate the water through the system. Then check the water level again. 20,21-6REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. Disconnect fuel control rod (1). (See P1) 2. Disconnect fuel hoses (21, (3), and (4). (See P1, P2) 3. Disconnect fuel injection pipe (6). (See P2) 4. Remove lubrication tube (6). (See P2) 5. Remove bracket, then remove fuel injection pump assembly (7). (See P3) ‘+ For the front of the engine assembly only, sling from the top or jack up the engine from the underguard, ‘* Two pump assembly mounting bolts (8) contact the engine mount bracket, so remove the left and right mount bolts, pull out the cushion at the pump end, then lower the engine bracket and remove the mounting bolts INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY * Rotate the crankshaft in the normal direction and align the pointer with the “1,4” line on the crankshaft. ‘When doing this, if there is no match mark for aligning with the pump drive gear, rotate the ‘crankshaft one more turn, 1. Lock drive gear with bolt (Thread dia. = 8 mm, Pitch = 1.0 mm, Length = 35 mm) 2, Fit O-ring and install fuel injection pump assembly (7). (See P3) * Insert 2 pin (diameter: approx. 45 mm) through the fuel injection timing inspection hole, and check that the pin goes smoothly into the hole in the drive gear. 3. Fit gasket and connect lubrication tube (6), (See P2) 4. Connect fuel injection pipe (5). (See P2) GE Sleeve nut: 24 0.1 kgm 5. Fit gaskets and connect fuel hoses (4), (3), and (2). (See P2, P1) 6. Connect fuel control rod (1). (See P1) + Bend the cotter pin securely. For details of checking the fuel injection timing, see 12 TESTING AND ADJUSTING. 13-4 2 REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. Remove clamp (1), then disconnect fuel injection pipe (2). (See Pa) 2. Remove nut, and disconnect spill pipe (3). (See Ps) 3. Remove nozzle holder assembly (4). (See P6) When removing the nozzle holder assembly, clean around the nozzle holder assembly and fit a blind plug to prevent dust or dirt from centering. INSTALLATION OF NOZZLE HOLDER ASSEMBLY ‘+ When installing the nozzle holder assembly, check the nozzle holder mount, and clean before installing 1, Fit gasket and install nozzle holder assembly (4). (See P6) ‘* Assemble the gasket with the blue mark facing up. GE Nozzle holder: 9 + 1 kgm 2, Connect spill pipe (3). (See P5) FD Nut 4.5 +05 kgm 3. Connect fuel injection pipe (2) and secure with clamp (1). (See Pa) GBI Sleeve nut: 2.3 + 0.2 kgm 020,21-6D20,21-6 13-5REMOVAL OF CYLINDER HEAD ASSEMBLY 1. Remove air cleaner assembly (1) and exhaust muffler (2). (See P1) 2. Remove fuel filter assembly (3) from cylinder head. (See P2) 3. Disconnect fuel injection pipe (4). (See P2) 4. Disconnect spill hose (5) and heater wiring (6). (See P2) 5. Remove head cover (7), (See P2) 6. Remove water pump assembly. For details, see REMOVAL OF WATER PUMP. ASSEMBLY. 7. Remove rocker arm assembly (8). (See P3) 8. Remove push rod (81. (See P3) 9. Liftoff cylinder head assembly (10). (See P4) INSTALLATION OF CYLINDER HEAD ASSEMBLY Special tool Part No. A | 795-125-1370 PartName [Q'ty Filler gauge 1 1. Install head gasket ‘Remove all carbon and dirt from the contact surfaces of the cylinder block and cylinder head. Remove all burrs and damage, and clean out all dirt from inside the cylinder block. 2. Raise cylinder head assembly (10), set in position, and tighten head bolts in order shown in diagram on right, (See P4, F1) 7. Bolt thread, (um) seat: Anti-friction compund = Mounting bolt: Unit: kgm order [Torque Ist step 80 +10 2ndstep | 130 +10 Brdstep_ | 175 +05 10. u. Install push rod (9). (See P3) Set rocker arm assembly (8) in posit tighten mounting bolt and nut. (See P3) ‘* Check that the ball of the adjustment screw is fitted properly into the socket of the push rod Qn, then Using too! A, adjust clearance between valve and rocker lever. (See P5) © Valve clearance Intake valve 0.38 Exhaust valve 0.50 + For details of the adjustment procedure, see 12 TESTING AND ADJUSTING, Adjusting valve clearance. Install water pump assembly. For details, see INSTALLATION OF WATER PUMP ASSEMBLY. Fit O-ring and install head cover (7). (See P2) Connect heater wiring (6) and spill hose (5). (See P2) Connect fuel injection pipe (4), (See P2) GED Sleeve nut: 23 + 0.2 kgm Install fuel filter assembly (3) to cylinder head. (See P2) Fit gasket and install exhaust muffler (2) and air cleaner assembly (1). (See P1) 20,21-6020,21-6 “5 3-6-8 eo oe Intake sideREMOVAL OF RADIATOR GUARD ASSEMBLY D20,21A,£,S,0-6, D20,21P-6A,B 1. Loosen radiator drain valve and drain cooling water ‘* If the coolant contains antifreeze, dispose of it correctly 2. Disconnect radiator inlet hose (1) and outlet hose (2). (See P1, P2) 3. Remove fan guard (3), and disconnect wiring (4). (See P2) 4. Disconnect oil cooler hoses (5) and (6). (See P3) 5. Lift off radiator guard assembly (7). (See P4) kg) Radiator guard assembly: 150 kg INSTALLATION OF RADIATOR GUARD ASSEMBLY 20,214, 0-6, D20,21P-6A,B 1. Raise radiator guard assembly (7) and install (See Pa) 2. Connect oil cooler hoses (6) and (6). (See P3) 3. Connect wiring (4), and install fan guard (3). (See P2) 4. Connect radiator outlet hose (2) and inlet hose (1), (See P2,P1) 5. Tighten radiator drain valve and add water through water filler to the specified level * Run the engine to circulate the water through the system. Then check the water level again. 13-8 REMOVAL OF RADIATOR GUARD ASSEMBLY D20,21P,PL-6 1. Remove pin (1) and start engine, then retract lift cylinder piston rod fully. (See PS) # Stop the engine and operate the work equipment control lever several times to release the pressure inside the piping, 2. Loosen radiator drain valve and drain cooling water. ‘+ If the coolant contains antifreeze, dispose of it correctly, 3. Disconnect hose (2), and remove exhaust pipe and engine hood. (See P5) 4. Disconnect wiring (3) and radiator hoses (4) and. (6), and remove fan guard (6). (See P6) 5. Remove grill, and disconnect oil cooler hose (7). (See P7) 6. Liftoff radiator guard assembly (8). (See P7) ig) Radiator guard assembly: 170 kg INSTALLATION OF RADIATOR GUARD ASSEMBLY D20,21P,PL-6 1. Raise radiator guard assembly (8) and install (Seo P7) 2. Connect oil cooler hose (7), and install grill. (See P7) 3. Install fan guard (6), then connect radiator hoses (6) and (4), and wiring (3). (See P6) 4. Connect hose (2), then install engine hood and exhaust pipe. (See P5) 5. Tighten radiator drain valve and add water through water filler to the specified level * Run the engine to circulate the weter through the system. Then check the water level again. 6. Start engine and extend lift cylinder piston rod, ‘then install pin (1). (See PS) 020,21-6D20,21-6 13-9REMOVAL OF RADIATOR ASSEMBLY ‘* This shows the operation for removal of the radiator assembly when the radiator guard has been removed. * The photograph in P1 shows the 020,21 AES,0-6,D20,21P-6A,8, ‘* The photograph in P2 shows the D20, 21 PPL-6. 1, Remove radiator guard assembly, For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY. 2. Disconnect hose (1), and remove bracket (2). (See P1,P2) 3. Remove radiator assembly (3). (See P1, P2) INSTALLATION OF RADIATOR ASSEMBLY 1. Install radiator assembly (3). (See P1, P2) 2. Install bracket (2), and connect hose (1), (See P1,P2) 3. Install radiator guard assembly, For details, see INSTALLATION OF RADIATOR GUARD ASSEMBLY. REMOVAL OF RADIATOR ASSEMBLY % This shows the operation for removal of the radiator assembly when the radiator guard has not been removed. 1. Loosen radiator drain valve and drain cooling water. ‘% If the coolant contains antifreeze, dispose of it correctiy, 2. Using transmission jack 1, remove underguard (1). See P3) 3. Remove mounting bolts of oil cooler (2), and move towards front. (See Pa) 4. Disconnect radiator outlet hose (3) and inlet hose (4) at radiator end. (See PS) 5. Remove fan guard (6) and fan (6). (See P5) 6. Remove bracket (7) and mounting bolts (8). (See P6,P7) 7. Liftoff radiator assembly (9). (See P8) 13-10 o INSTALLATION OF RADIATOR ASSEMBLY 1. Raise radiator assembly (9) and install. (See P8) 2. Install mounting bolts (8) and bracket (7), (See P7,P6) 3. Install fan (6) and fan guard (6). (See PS) 4. Connect radiator inlet hose (4) and outlet hose (3). (See P5) 5. Install oil cooler (2). (See P4) 6. Using transmission jack 1), install underguard (1). See P3) 7. Tighten radiator drain valve and add water through water filler to the specified level * Run the engine to circulate the water through the system. Then check the water level again. REMOVAL OF THERMOSTAT Loosen radiator drain valve and drain cooling water * If the coolant contains antifreeze, dispose of it correctly, 2. Disconnect hose (1), and remove cover (2). (See 9, P10) 3. Remove thermostat (3). (See P10) INSTALLATION OF THERMOSTAT 1. Set thermostat (3) in mounting position, (See P10) 2. Fit gasket and install cover (2), then connect hose (1). (See P10, P9) 3. Tighten radiator drain valve and add water through water filler to the specified level ‘* Run the engine to circulate the water through the system. Then check the water level again. 020,21-6bg et ~ . a uae a 2 wig = ee kd 020.21-6 13-11REMOVAL OF ENGINE ASSEMBLY AXdisconnect the cable from the negative (—) terminal of the battery Remove drain plug and drain oil from hydraulic, tank, Hydraulic tank: Approx. 33 ¢ Using transmission jack 1, remove underguard (1). (See P1) 3. Disconnect water temperature gauge sensor wiring (2) and heater wiring (3). (See P2) 4, Remove radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY. 5. Disconnect starting motor wiring (4) and fuel control cable (6). (See P3) 6. Disconnect fuel hoses (6) and (7). (See P3) %* Fuel will come out when the hoses are dis- connected, so fit blind plugs. 7. Disconnect altenator wiring (8). (See P4) 8. Disconnect oil pressure gauge sensor wiring (9) and ground connection wiring (10). (See P4) 8. Disconnect hydraulic pump hoses (11) and (12). (See P4) 13-12 2 10. Remove universal joint assembly (13). (See PS) 11. Remove mounting bolts (14) and (15). (See PS, Pe) 12, Lift off engine assembly (16). (See P7) ‘* When raising the engine assembly, be careful of the position of the center of gravity, and check again that all wiring and piping has ‘been removed. CAP) engine assembly: 325 kg ‘Mark the positions of the left, right, front, ‘and rear engine mount cushions. 020,21-6D20,21-6 13-13 2INSTALLATION OF ENGINE ASSEMBLY Special too! Part No. PartName —_[a'ty ‘A | 790-411-1100 | Centering tool dl 1. Raise engine assembly (16), set in position, fit cushions and align mounting bolts, then lower engine. (See P1) + The spring coefficient of the front, rear, left, and right mount cushions is different, so be careful to set them correctly in the positions marked when removing. 2. Tighten mounting bolts (15) and (14) temporarily. (See P2, P3) ~~. Mounting bolt: Thread tightener (LT-2) % Tighten the mounting bolts fully after centering the engi 32) Mounting bolt: 28 + 3 kgm Measure misalignment between transmission and engine. (See P4) 1) Install tool A, and set dial gauge (2) in position. 2) Turn tool A, and measure radial runout and face runout. 4 Radial runout: Max. 1.0 mm Face runout: Max. 3.0 mm % If the measurement is not within the standard range, move the position of the engine to adjust. If the value is stil not within the standard range, change the shim thickness at the engine rear mount to adjust, 4, Install universal joint assembly (13). (See P3) 32) Mounting bolt: 3 + 0.5 kgm 7 ~ Universal joint: Grease (G2-Li) 13-14 2 5. 10. " 12. 13. Connect hydraulic pump hoses (12) and (11) (See P5) Connect ground connection wiring (10) and oil pressure gauge sensor wiring (9). (See P5) Connect alternator wiring (8). (See P5) Connect fuel hoses (7) and (6). (See P6) Connect fuel control cable (5) and starting motor wiring (4). (See P6) Install radiator guard assembly, For details, see INSTALLATION OF RADIATOR GUARD ASSEMBLY. - Connect heater wiring (3) and water temperature ‘gauge sensor wiring (2). (See P7) Using transmission jack (1). (See P8) install underguard Tighten drain plug of hydraulic tank and add hydraulic oll through oil filer to the specified level. ‘+ Run the engine to circulate the oil through the system. Then check the oil evel again. 020,21-620,21-6 13-15 2POWER TRAIN 21 STRUCTURE AND FUNCTION General (020-6) 21-2 General (D21A,P,S,0-6,D21P-6A) 21-4 General (02 1£-6, D21P-6B, D21S-6A) 21-6 Power train hydraulic system (021A, P,S,Q-6,D21P-6A) 21-8 Power train hydraulic circuit diagram (021A, P, §, 0-6, D21P-6A) 21-9 Power train hydraulic system (21-6, D21P-6B, 0215-6A) 21-10 Power train hydraulic circuit diagram (0216-6, D21P-68,021S-6A) 20-11 Main clutch (020-6) 21-12 Main clutch control (020-6) 21-17 Tramsmission (020-6) 21-18 Damper and universal joint (021A, P, S, Q-6,D21P-6A) 21-22 Damper and universal joint {021E-6,021P-6B, 021P-6) 21-23 HYDOROSHTFT transmission (021A, P,S, 0-6, D21P-6A) 21-24 HYDOROSHIFT transmission (0216-6, D21P-68,D215-6A) 21-30 ‘Transmissoion control (021A, P, S,-6,21P-6A) 21-36 Transmissoion control (021E-6,D21P-68,D21S-6A) 21-37 HYDOROSHIFT transmission hydraulic system (021A, P, S, 0-6, 021A-6A) 21-38 HYDOROSHIFT transmissoin hydraulic circuit .gram (021A, P, S, Q-6, D21P-6A) HYDOROSHIFT transmission hydraulic system (021£-6,D21P-68, D21S-6A) HYDOROSHIFT transmission hydraulic ciucuit 21-39 21-40 diagram (021E-6,021P-68, 0218-6) . 21-41 Transmission contol valve (021A,P, S,Q-6,021P-6A) (21-42 Transmission contol valve (0216-6, 021-68, 0218-64) 21-88 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 ciagrem (020-6). 21-58 Steering hydraulic system (D21-6) 21-59 Steering hydreulc circuit diagram (021-6) .. 21-69 Main clutch and steering pump (020-6) .... 21-60 Steering main relief valve (D20-6) 21-61 Steering control valve 21-62 Steering booster cylinder 21-65 Steering brake 21-68 Final drive 21-68 21-1 OGENERAL 20-6 Engine 4095S-W-1 ‘Main clutch Universal joint Transmission oaene ‘The motive power generated by diesel engine (1) is transmitted from the engine flywheel to main clutch (2). The power which is transmitted intermittently through the main clutch passes through universal joint (3) to the input shaft of transmission (4), The resulting power obtained via the gears in the transmission, which are selected in accordance with the load fluctuations, is transmitted to bevel pinion at the end of the transmission case. ‘The power which is transmitted from the engine —~ main clutch — transmission at the rear of the ma- cchine is then diverted into the left and right directions by means of the bevel pinion and bevel gear on the 4 5 6 78 9 6. Steering brake 7. Final drive 8. Sprocket 9. Track shoe Steering clutches (5) which are installed at both ends of the bevel gear shaft make and break the flow of power from the bevel gear shaft to the final drive, and are used to determine the direction in which the ‘machine is to be steered. The direction of the machine is changed by operating the steering control balve mounted at the top of the steering case in order to cut off power from the clutch at the side of the machine to which it is to be steered. The size of the tumnig radius is varied by means of steering brake (6) which is mounted on the Periphery of the brake drum of the steering clutch. Power from the steering clutch is transmitted to the final drive flange where speed reduction takes place through pinion — gear prior to rotating sprocket (8), The rotation of the sprocket drives track (9) of the undercarriage, causing the machine to travel. 020,21-6J | Ie L ee -S op jartopjarse WL .— i 4 TER Jt ' ee \ i a i ~ Teas P@NOTRONS toaFoso1a ~ Engine 40958-W-1 P,, Main clutch and steering Pump (FALO10) Main clutch P,. Hydraulic Pump (LALO25) Universal joint (O20PLL: LALO20) Transmission Steering clutch Steering brake Final drive Sprocket Track shoe 20,21-6 21-3D214, P, PL-6, D21P-6A Engine 4095S-W-1 Damper Universal joint HYDROSHIFT transmission Steering clutch opens Motive power generated by diesel engine (1) is transmitted to damper (2) which is fixed on the engine flywheel, After vibration is absorbed by the damper, the power from the engine passes from the output shaft through universal joint (3) to the input shaft of HY- DROSHIFT transmission (4). In accordance with changes in load, transmission control valve which is mounted at the top of the transmission case is ‘operated to select an appropriate speed stage. The Power which is selected by the make and break action of the speed change clutch inside the transmission passes through the output gear of transfer to bevel pinion. ‘The power which is transmitted from the engine — damper — transmission at the rear of the machine is then diverted into the left and right directions by means of the bevel pinion and bevel gear on the bevel gear. 21-4 Fl 4 5 6 78 8 6. Steering brake 7. Final drive 8. Sprocket 9. Track shoe Steering clutches (5) is installed at both ends of the bevel gear shaft make and break the flow of power from the bevel gear shaft to the final drive, and are used to change the direction of the machine. The direction of the machine is changed by operating the steering control valve mounted at the top of the steering case in order to cut off power from the clutch at the side of the machine to which it is to be steered. The size of the turning radius is varied by ‘means of steering brake (6) which is mounted on the periphery of the brake drum of the steering clutch. Power from the steering clutch is transmitted to the final drive flange where speed reduction takes place through pinion — gear prior to rotating sprocket (8). The rotation of the sprocket drives track (9) of the Undercarriage, causing the machine to travel. 020,21-6Not Cluteh | No2 Clutch | Nos citch | Nod Clutch Damper Universal joint Steering clutch Steering brake Final drive Sprocket Track shoe Sersoraens D20,21-6 Engine 4095S-W-1 HYDROSHIFT transmission loaroso14 P,, Transmission Pump. P,. Hydraulic Pump (LALO25) 21-5D21E-6, D21P-6B, D21S-6A Engine 4D95S-W-1 Damper Universal joint HYDROSHIFT transmission Steering clutch oReNe Motive power generated by diesel engine (1) is transmitted to damper (2) which is fixed on the engine flywheel ‘After vibration is absorbed by the damper, the power from the engine passes from the output shaft through universal joint (3) to the input shaft of HY- DROSHIFT transmission (4). In accordance with ‘changes in load, transmission control valve which is mounted at the top of the transmission case is operated to select an appropriate speed stage. The Power which is selected by the make and break action of the speed change clutch inside the transmission passes through the output gear of transfer to bevel pinion ‘The power which is transmitted from the engine — ‘damper — transmission at the rear of the machine is then diverted into the left and right directions by means of the bevel pinion and bevel gear on the bevel gear shaft. 21-6 4 Steering brake Final drive Sprocket Track shoe Steering clutches (6) is installed at both ends of the bevel gear shaft make and break the flow of power from the bevel gear shaft to the final drive, and are used to change the direction of the machine. The direction of the machine is changed by operating the steering control valve mounted at the top of the steering case in order to cut off power from the clutch at the side of the machine to which it is to be steered, The size of the turning radius is varied by ‘means of steering brake (6) which is mounted on the periphery of the brake drum of the steering clutch. Power from the steering clutch is transmitted to the final drive flange where speed reduction takes place through pinion — gear prior to rotating sprocket (8) The rotation of the sprocket drives track (9) of the undercarriage, causing the machine to travel. 020,21-6T No ciaten fez chen i, A Noa chten 6 = 5 9 i. Ae I | = Fio808001 Engine 4095S-W-1 P,, Transmission Pump. Damper P;. Hydraulic Pump (LALO25) Universal joint HYDROSHIFT transmission Steering clutch Steering brake Final drive Sprocket Track shoe Carourena 020,21-6 217POWER TRAIN HYDRAULIC SYSTEM D21A, P, S,0-6 D21P-6A 21-8 20,21-6POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM D21A, P, S, 0-6 D21P-6A R F 1st | qe oe 4 gs yey ee 4 21 oiscnarge: fae | 424m mn . 7 Engine a 2450 Set pressure om t—4f—=P, akgiem™ " 1 ieee toarosore 1. Transmission case 9. Oilcooler bypass valve 2. Transmission pump 10. Transmission lubrication valve 3. Modulating valve 11. Transmission lubrication 4. Quick return valve 12, Check valve 5. Speed valve 13. LH. steering valve 6. Inching valve 14, RH. steering valve 7. F-Rvalve 15. LH. steering cylinder 8. Oilcooler 16. Ri. steering cylinder 20,21-6 21-9POWER TRAIN HYDRAULIC SYSTEM D21E-6, D21P-6B, D21S-6A 6 \ R F 30 2nd 1st o o 0 o 21-10 D20,21-6POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM D21E-6, D21P-6B, D21S-6A A F 3r6 2nd 1st » MAL ‘Set pressure: sts = a 8 & UD aaa ‘atom 2 | discharge: -+ ' 4 tose f t M {Engine at 10 reson Set pre: 3kgiem’ 1 A | 1. Transmission case 9. Oil cooler bypass valve 2. Transmission pump 10. Transmission lubrication valve 3. Modulating valve 11, Transmission lubrication 4. Quick return valve 12. Check valve 5. Speed valve 13. LH. steering valve 6. Inching valve 14, RH. steering valve 7. F-Rvalve 18. LH. steering cylinder 8. Oil cooler 16. RH. steering cylinder 020,21-6 21-11MAIN CLUTCH 20-6 21-12 SSeeanonsens Flywheel Clutch plate Clutch dis Pressure plate Clutch spring Clutch cover Housing Ring gear Collar Yoke Sleeve Bearing cage Main clutch shaft Universal joint Transmission input coupling Main clutch and steering pump Drain plug Pump drive gear Nut ‘Support Lever Cover 23. 24. 25. 26. 28. 29. 30. 31 32. 33, 34, 1osF06019 Spring Oilstrainer Bracket Booster spring Lever Lever Shaft Breather Cover Oil evel gauge Oitfiler Main relief valve 20,21-6OUTLINE +The main clutch transmits and cuts the transmission of the motive force produced by the engine and sent to the transmission, ‘As a result, gear shifting operations are made ‘easy and itis possible to prevent the engine from. stalling 020,21-6 F 10306008 multiple disc, spring type with The outside circumference of the output end of main clutch shaft (13) acts as the inertia brake drum. The engaging and disengaging of the main clutch is interconnected with the operation of the inertia brake, so the operating force is increased. To reduce this operating force, booster spring (26) is installed. 21-13OPERATION OF MAIN CLUTCH + Cover (6) is fixed to flywheel (1). There are twelve springs (6) installed between the inside face of cover (6) and pressure plate (4). The tension of these springs pushes the pressure plate towards the flywheel. Lever (21) pivots about connection A with support (20). One end has connection point 8 with the pressure plate, and the other end has contact C with collar (9) Support (20) is fixed to cover (6) with a nut There is a bearing press-fitted into contact C between lever (21) and collar (9). Collar (9) slides on the outside circumference of sleeve (11) and is moved by yoke (10) connected to the main clutch pedal Disc (3) is joined to main clutch shaft (13). + Engaged When the main clutch pedal in the operator's compartment is not being operated, yoke (10) pulls collar (9) back to the right. As a result, the force moving point B of lever (21) to the right does not act on the collar. Therefore, the tension of springs (5) makes pressure plate (4) bring disc (3) and plate (2) into contact with flywheel (1) ‘When this happens, the motive force from the engine passes through the discs and is transmitted to main clutch shaft (9) + Disengaged When the main clutch pedal in the operator's ‘compartment is operated, yoke (10) pushes collar (9) and point C of lever (21) to the left. As. 2 result, point B of lever (21) pivots on point A and moves to the right. Therefore, pressure plate (4) compresses springs. (6) and relieves the contact of discs (3) and plate (2) with flywheel (1). When this happens, the motive force from the ‘engine is not transmitted to main clutch shaft (9). 21-14 F 10308008 10206008 020,21-6FUNCTION OF BOOSTER SPRING + Lever (27) rotates freely on top of the fork shaft (pivot D) because of the needle bearing At one fend itis connected to booster spring (261, and at the other end to rod (47), Lever (28) is fixed to the fork shaft (pivot D) by a key, and is connected at one end to rod (46). It is, connected to the yoke which engages and disen- ‘gages the main clutch, but rods (46) and (47) are connected to one end of lever (45), and the other end of lever (45) is connected to main clutch pedal (42) + When main clutch pedal (42) is depressed, rods (43), (44), (46), and (47) move about pivots A, 8, C and D in the direction of the arrow in the dia- ‘gram (F10306008). When this happens, the operating force of the main clutch pedal becomes slightly larger in order for lever (27) to extend booster spring (26). However, at the point where the booster spring is fully extended, in other words, when it passes the dead point, the tension of the booster spring acts as a force to rotate lever (27) clockwise. (See Fig. F10306009) This force pushes rod (47) out to the right, and because of the operating force of the main clutch pedal, it is added to the force rotating lever (45) counterclockwise. In this way, the action of the booster spring makes the operating force of the main clutch pedal lighter. 020,21-6 © Main clutch engaged A 10306007 ‘© Booster spring at dead point a Engaged ead point F 10306008 Te Engaged 1. \\ 04 point 21-15INERTIA BRAKE 13. Main clutch shaft (with brake drum) 35. Brake band 36. Rod ‘OUTLINE + Since the bulldozer is quite great in a travelling resistance, if the main clutch is disengaged and the transmission shift in a neutral position, the machine stops at the point and revolution of the output shaft is also stopped. However, even if power is discontinued the main clutch shaft con- tinues to revolve due to inertia, with the transmis sion input shaft connected with a universal joint being also revolved. If speed change is made by sliding of gears on the rotating input shaft and the stationary output shaft, such troubles as gear noise and breakage of gear chamfer portion, etc. will aise. To prevent such troubles, D20-6 is equipped with @ brake band contraction type of inertia brake on rear of main clutch 21-16 2 MH View2 soo10 37. Lever 40. Bracket 38. Lining 41, Lever 39. Return spring 42, Rod ‘The inertia brake is so constructed as to interlock with the main clutch pedal at the operator's seat and if the main clutch is thrown down, first the ‘main clutch is disengaged and if the main clutch pedal is further thrown down, the brake drum (13) fixed to the main clutch shaft is bound with the brake band (35) to prevent revolution of the main clutch shaft by inertia and ensure smooth transmission gear change. 020,21-6MAIN CLUTCH 20-6 CONTROL Main clutch pedal Lever Shaft Yoke Lever Lever Booster spring Mogaens 020,21-6 When main clutch pedal (1) in the operator's compartment is operated, shaft (3) inside the main clutch rotates, and yoke (4) moves on the seme axis to dis- engage the main clutch. At the same time, lever (5) for actuating the inertia brake rotates, so the inertia brake acts to stop the rotation of the main clutch shaft. The action of booster spring (7) makes the operating force of the main clutch pedal lighter. 21-17TRANSMISSION 20-6 21-18 eerxonsens Input coupling Seal cage ‘Transmission case Cover Gear shift lever Seat collar Main shaft Counter shaft 10, " 12, 13. 14, 15. 16. 7. 18, . Intermediate shaft Collar Cover Bearing cage Cover Breather Plunger Spring Shifter fork (1 st speed) 19, 20. 2 22 23. 24, 26. 26. 27. loarosoze Shifter fork (2nd speed) Shifter fork (3rd speed) Shifter fork shaft Shifter fork shaft Shifter fork shaft Interlock pin Interlock pin . Spring Interlock ball D20,21-6eo zommpom> Main shaft R-1t gear (14 teeth) Main shaft R-2nd gear (18 teeth) Countershaft 1 st gear (37 teeth) Countershaft 2nd gear (33 teeth) Countershaft 3rd gear (25 teeth) Intermediate shaft F-1:t gear (15 teeth) Intermediate shaft F-2nd gear (19 teeth) Intermediate shaft Forward gear (31 teeth) Intermediate shaft F-3rd gear (27 teeth) Bevel pinion (14 teeth) 020,21-6 Section8—8 OUTLINE + The transmission is a spur gear, sliding mesh, splash lubrication type with three forward and two reverse gears. Gear combina mn for each gear spe (Gear combinstion is B—H—F—c—o Forward 2nd BH G—o J Bra 8 ToeTy 1st anc Reverse ae cage 21-19POWER TRAIN Innoutral Main shaft gear (B) is constantly in mesh with intermediate shaft gear (H). As main shaft (8) is rotated by the engine, intermediate shaft (10) is rotated in the opposite direction to the main shaft. However counter shaft (9) does not rotate, because the counter shaft gear is not in mesh with those on the main shaft and intermediate shaft. Forward-1st seed [B —-H —F —C —J] Place the gear shift lever in “F-1" at the operator's ‘compartment: Slide countershaft gear (C) forward with a shifting fork to get into mesh with intermediate shaft gear (F). When the main shaft is rotated by power from the engine, the intermediate shaft rotates in the opposite direction to the main shaft, Then, intermediate shaft gear (F) rotates countershaft gear (C) in the same direction as the main shaft, and transmits power to the bevel pinion (J) Reverse-1st speed [A —-C — J] Place the gear shift lever in “R- compartment: Slide countershaft gear (C) rearward with a shifting fork to get into mesh with main shaft gear (A), t the operator's ‘When the main shaft is rotated by power from the engine, the countershaft rotates in the opposite direction to the main shaft, and transmits power to the bevel pinion (W) 21-20 020,21-6Forward-2nd speed [B —-H —@ —D—J} Place the gear shift lever in “F-2" at the operator's ‘compartment: Slide countershaft gear (0) forward with a shifting fork to get into mesh with intermediate shaft gear (G) When the main shaft is rotated by power from the engine, power is transmitted to the bevel pinion (J). Reverse-2nd speed [B —D — J] 8 ana Froaoso14s Place the gear shift lever in “R-2" at the operator's ‘compartment Slide countershaft gear (0) rearward with a shifting fork to get into mesh with main shaft gear (B) When the main shaft is rotated by power from the engine, power is transmitted to the bevel pinion (J). Forward-3rd speed [B —-H —1—E— J] Place the gear shift lever in “F-3” at the operator's compartment: Slide countershaft gear (E) forward with a shifting fork to get into mesh with intermediate shaft gear () When the main shaft is rotated by power from the engine, power is transmitted to the bevel pinion W. D20,21-6 21-21DAMPER AND UNIVERSAL JOINT D21A, P, S, 0-6 p21. Output shaft Flywheel Damper Oil filler plug Cover Output coupling Universal joint Transmission input coupling Oillevel plug Serorsens 21-22 toaFosoze OUTLINE The damper acts as a cushion to prevent the vibration of the engine from being transmitted directly to the transmission. The power from the engine is transmitted to damper (3) through flywheel (2). The power is ‘absorbed the engine vibration by damper (3), and is transmitted to shaft (1) and universal joint (7), and then is transmitted to the transmission. 20,21-6DAMPER AND UNIVERSAL JOINT D21E-6 D21P-6B D218-6A Output shaft Flywheel Damper Oil filler plug Cover Output coupting Universal joint Transmission input coupling Oillevel plug wervaneene 020,21-6 OUTLINE ‘The damper acts as cushion to prevent the vibration of the engine from being transmitted directly to the transmission The power from the engine is transmitted to damper (3) through flywheel (2). The power is absorbed the engine vibration by damper (3), and is transmitted to shaft (1) and universal joint (7), and then is transmitted to the transmission. 21-23HYDROSHIFT TRANSMISSION D21A,P,S,0-6 D21P-6A 21-24 moomp> To reverse clutch To forward clutch To 2nd speed clutch From modulation valve To 1st speed clutch Sectiona~A, 1. Oilfiler 2. Oillevel gauge 3. Input coupling 4. Sleeve 5. Cover 6. Transmission pump 7. Transmission case 8. Transfer case 9. Breather 10. Oilstrainer 020,21-6OUTLINE 3M 12 13 4 15 1G 7 18 19 2 21 22 23 24 25 2 2 BW 7 BO 8 9 Bt 11. Input shaft The D21A, P, S, Q-6 and D21P-6A bulldozer is \ \ 12. No.t clutch housing equipped with a planetary type, "2-forward and 2- 13, No.1 sun gear (28 teeth) reverse speed" transmission which is 2 combined 14, No.1 ring gear (80 teeth) structure of @ planetary gear mechenism and disc 18. No.1 planet gear (23 teeth! clutches. 16. No.1 ring gear (74 teeth) The rotational direction and the revolution of the 17. No2 sun gear (33 teeth) transmission output shaft is selected by fixing two 18. No2 planet gear (23 teeth) disc clutches out of four disc clutches by means of 19. No.2 ring gear (78 teeth) control valve operation 20. Transmission lubrication valve No.1 clutch is fixed in reverse, No.2 clutch in forward, 21. Valve spring No.3 clutch in second speed, No.4 clutch in first 22. No3 sun gear (33 teeth) speed 23. No.3 planet gear (23 teeth) Any speed can be selected from two forward speeds 24, No3 ring gear(78 teeth) and two reverse speeds by fixing either No.1 or No2 25. No4 sun gear (33 teeth) clutch and one clutch among No.3 and No.4 clutches 26, No ring gear (78 teeth) and by combining two of the above. 27. No planet geer (23 teeth) 28. Output shaft 29. No. clutch housing Speeds and oerating clutches 30. Plate 31. Transfer drive gear (18 teeth) eee oeeretnc eee 32, Pinion shaft (14 teeth) Neal 33. Transfer driven gear (49 teeth) ee) Fe 2 | eee 34, Bearing cage = — Sei neteney fret specs lo 1 and No 4 cutonos 36. Retainer even [Ecrondspoa [Nod anon’ Guchet 37. No4 carrier 38. Plate 39. No.2 and No.3 carrier Number of discs and plates on each clutch 40. No.2 and No.3 clutch housing 41, Plate teh lumber of diece | _ Number of plates 42. Tie rod pin cen Ne n ‘ " 43, Cluch spring ‘Not ee 3 3 | 44. Clutch plate No2zewten | 3 [ 3 45. Clutch Dise : (93 ele 3 46. Clutch piston SS | eee 47. No.1 carrier No etch 2 2 48. Tie rod bolt 20,21-6 21-25ACTING OF PISTON To lock ring gear (19), the discs (45) and plates (44) are brought into close contact. The clutch consists of a clutch piston (46), clutch plates (44), clutch discs (45), pins (42) and piston return springs (43) ‘The disc's internal teeth engage with the ring gear’s external teeth, The plates, whose notch on the outside diameter engage with pins (42) on housings (41) and (40), are locked against the rotating direction. Piston (46) also is locked against the rotating direction ‘@ Clutch engaged (oil pressure is acting) Oil from the control valve flows under pressure through the port in housing (40) to the piston (46). The piston presses clutch plates (44) and clutch discs (48) together, and the frictional force developed stops lutch discs (45) revolution, thus ring gear (18) meshing with the disc's internal teethis locked © Clutch disengaged (oil pressure is not acting) ‘When the supply of pressure oil from the contro! valve is shut off, piston (46) returns to the initial position by the force of piston return spring (43), thus relieving the frictional force between plates (44) and discs (45), making the ring gear (19) free. 21-26 020,21-6POWER TRAIN OF TRANSMISSION FIRST FORWARD SPEED cola fit No.2 and No clutches engaged and No.2 and No4 ring gears fixed, With No.2 and No. clutches engaged, No.2 and No ring gears (19) and (26) are fixed. When No2 ring gear (19) is fixed, the rotation of the engine is transmitted to No.2, 3 carrier (39) with reduced turning speed through input shaft (11) and No.2 sun gear (17), No.2, 3 carrier (39), then, rotates in the same direction as input shaft (11). 020,21-6 Since No.4 ring gear (26) is fixed, the rotation of No.2, 3 carrier (39) is transmitted to output shaft (28) at an increased turning speed through No.3 ring F (24) and No.4 sun gear (25) in that order. ides, the rotation is transmitted from No.3 sun r (22) to output shaft (28).) Output shaft (28) rotates in the same direction as input shaft (11). The rotation of output shaft (28) is transmitted to ‘bevel pinion (32) with reduced turning speed through drive gear (31) and tranfer driven gear (33). Bevel pinion (32) then rotates in the opposite direction to output shaft (28) 21-27SECOND FORWARD SPEED 1 \A \ No.2 and No.3 clutches engaged and No.2 and No.3 ring gears fixed, With No.2 and No.3 clutches engaged, No.2 and No.3 ring gears (19) and (24) are fixed. When No.2 ring gear (19) is fixed, the rotation of the engine is transmitted to No.2, 3 carrier (39) with duced turning speed through input shaft (11) and No.2 sun gear (17).No.2, 3 carrier (39), then, rotates in the same direction as input shaft (11) 21-28 Since No.3 ring gear (24) is fixed, the rotation of No.2, 3 carrier (39) is transmitted to output shaft (28) at an increased turning speed through No.3 sun ‘gear (22) in that order. Output shaft (28) rotates in the same direction as input shaft (11) The rotation of output shaft (28) is transmitted to bevel pinion (32) with reduced turning speed through transfer drive gear (31) and transfer driven gear (33). Bevel pinion (32) then rotates in the opposi tion to output shaft (28) 20,21-6FIRST REVERSE SPEED No.1 and No.4 clutches engaged and No.1 and No.4 ring gears fixed. With No.1 and No clutches engaged, No.1 and No. ring gears (14) and (26) are fixed. When No.1 ring gear (14) is fixed, No.1 carrier (47) meshed with No.1 ring gear (14) is also fixed. ‘The rotation of the engine is trasmitted to ring gear (16) through input shaft (11) and No. 1 sun gear (13) in the opposite direction and at reduced turning speed 020,21-6 Since ring gear (16) is meshed with No.2, 3 carrier (39), the rotation is transmitted to No.2, 3 carrier (39) The rotation of No.2, 3 carrier (39) is transmitted to output shaft (28) in the same way as in first forward speed Output shaft (28) rotates in the opposite direction to input shaft (11) The rotation of output shaft (28) is transmitted to bevel pinion (32) with reduced turning speed through transfer drive gear (31) and transfer driven gear (33) Bevel pinion (32) then rotates in the opposite direction to output shaft (28) 21-29HYDROSHIFT TRANSMISSION D21E-6 D21P-68 D218-6A Fioa0600s 1. Oilfiller 2, Oillevel gauge 3. Input coupling 4. Sleeve A. To 1st speed clutch 5. Cover B. To forward clutch 6. Transmission pump ©. To reverse clutch 7. Transmission case D. To 2nd speed clutch 8. Transfer case E. To 3rd speed clutch 9. Breather From modulation valve 10. Oilstrainer 21-30 D20,21-6Serial No. 60001 - 64855 3M 2 19 14 18 16 17 18 19 20 2 2 23 24 2 28 27 Bw 7 3 HN 8 BR 52 an 0 020,216 33 35 " 12. 13, 14, 18 16, 17. 18, 19 20. 21 22, 23. 24, 28. 26. 27. 28. 29. 30. 3 32. 33. 34. 38. 36. 37. 38. 39. 40. a. 42. 43, 44. 46, 46. 47. 48. 49. 50. 51 52. Input shaft No.1 clutch housing No.1 sun gear (24 teeth) No.1 ring gear (72 teeth) No.1 planet geer (21 teeth) No.1 ring gear (66 teeth) No2 sun gear (36 teeth) No2 ring gear (72 teeth) ‘Transmission lubrication valve Valve spring No2 planet gear (18 teeth) No sun gear (36 teeth) No planet gear (18 teeth) No3 ring gear (72 teeth No ring geer (72 teeth) No4 planet gear (18 teeth) No sun gear (36 teeth) No ring gear Output shaft No clutch housing Seat Cage Plate Transfer drive gear (21 teeth) Pinion shaft (14 teoth) ‘Transfer driven gear (37 teeth) Bearing cage Retainer Retainer No piston housing No carrier Plate No2 and No3 carrier No.2 and No.3 clutch housing Plate Tie rod pin Clutch spring Clutch plate Clutch dise Clutch piston No.t cartier Tie rod bolt OUTLINE ‘The 0216-6, D21P-6B and D21$-6A bulldozer is equipped with @ planetary type, "3-forward and 3- reverse speed” transmission which is a combined structure of a planetary gear mechanism and disc clutches. ‘The rotational direction and the revolution of the transmission output shaft is selected by fixing two disc clutches out of five disc clutches by means of control valve operation, No.1 clutch is fixed in reverse, No.2 clutch in forward, No.3 clutch in third speed, No.4 clutch in second speed, and No.5 clutch in first speed. Any speed can by selected from three forward speeds and three reverse speeds by fixing either No.1 of No.2 clutch and one clutch amoung No.3, No.4, and No. clutches and by combining two of the above ‘Speeds and operating clutch si Opersting cuteh Neutral Nog cutcn First speed N02 and Nos clutches Fomard | Second speed | No.2 and No.é clutches Third specs NO? and NO 3 chitcher ‘Neutral Nos cic Reverse | Fist speed No and No clutches ‘Second speed | No.1 and No 4 clutches ‘The speed No and No clutches Number of discs and plates on each clutch ‘ClutchNo. | _Numberofaises | _ Number of pater No. each 3 3 ‘No? extch 2 2 N03 eltch 2 2 Now clutch 7 a No. clutch 2 3 21-31 3Serial No.64856 and up OUTLINE 18 19 20 21 22 2 24 25 2% BM me 2 7 GH BB BW 3 11. Input shaft ‘The D21E-6, D21P-6B and D21S-6A bulldozer is ld / 12. No elute housing tcuipped with a planetary pe, “S-torword ond 3 | 18. No! sungeor 24 eth reverse speed” wensmiscion which fs 9 combined } 14. No.1 ring gear (72 teeth) structure of a planetary gear mechanism and disc 1B Not planet gear woth chutches / 16. No.1 ring gear (66 teeth) QM 12 19 14 15 16 " The rotational direction and the revolution of the y 17, No.2 sun gear (36 teeth) transmission output shaft is selected by fixing two 18. No.2 ring gear (72 teeth) dise clutches out of five disc clutches by means of / 19. Transmission lubrication valve control valve operation. 20. Valve spring No.t clutch is fixed in reverse, No.2 clutch in forward, 21, No2 planet gear (18 teeth! No.3 clutch in third speed, No.4 clutch in second 22. No.3 sun gear (36 teeth) speed, and No55 clutch in first speed, 23. No3 planet gear (18 teeth) ‘Any speed can by selected from three forward 24, No.3 ring gear (72 teeth) speeds and three reverse speeds by fixing either 25. Nod ring gear (72 teeth) No.1 or No.2 clutch and one clutch amoung No.3, 26. No planet gear (18 teeth) No‘, and No.5 clutches and by combining two of the 27. No sun gear (36 teeth) above 28. Nos ring gear 29, Output shaft 30. NoB cluten housing Speeds and operating clutches 31. Seat ee 32, Cage Speed Operating atch 33. Plate Neural Nog clutch 34, Transfer drive gear (21 teeth) Forward |Erstsneed Nae one crcnee 35. Pinion shaft (14 teeth! Thin spe No2 and No 3 ctutehes 36. Transfer driven gear (37 teeth) Nearer Nod auten 37. Bearing cage reverse | Fret speed No.1 end No. cutenes 38 Reta pelea 39. Retainer 40. No piston housing faiteoeaeee Number of discs and plates on each clutch 43. No.2 andNo3 carrier 444, No.2 end No.3 clutch housing ‘cunchNo. | _Numberoface | Number of plates 45, Plate No. elton 3 3 rod pin No? ela 2 2 47. Clutch spring 48. Clutch plate pesca aa ZI 49. Clutch dise No elton 2 2 ‘50. Clutch piston aac Fi ae 51. No.1 carrier 52. Tie rod bolt 52ST BS Ra 8B F 10408008-1 21-31-1 20,21-6 @POWER TRAIN OF TRANSMISSION FIRST FORWARD SPEED No.2 and No clutches engaged and No.2 ring gear fixed, No.4 carrier and No ring gear are engaged. With No2 and NoS clutches engaged, No2 ring gear (18) is fixed and No.4 carrier (41) and No.5 ring gear (28) are engaged. When No.2 ring gear (18) is fixed, the rotation of the engine is transmitted to No.2, 3 carrier (43) with reduced turning speed through input shaft (11) and No.2 sun gear (17). No.2, 3 carrier (43), then, rotates in the same direction as input shaft (1), 21-32 F 10408007 Since No.4 carrier (41) and No ring gear (28) are engaged, sun gears (22) and (27), ring gears (24) and (25), No4 carrier (41), No. ring gear (28) and No piston housing (40) are all engaged as a unit. The rotation of No.2, 3 carrier (43) is then transmitted to output shaft (29) in the same direction and at the same speed The rotation of output shaft (29) is tramsitted to bevel pinion (36) with reduced turning speed through tranfer drive gear (34) and traster driven gear (36). Bevel pinion (35) then rotates in the opposite direction to output shaft (29). 20,21-6‘SECOND FORWARD SPEED. No.1 No.2 18 No.3 No. No.5 2 p ea No.2 and No.4 clutches engaged and No.2 and No.4 ring gears fixed. With No2 and No.4 clutches engaged, No.2 and No.4 ring gears (18) and (26) are fixed. When No.2 ring gear (18) is fixed, the rotation of the engine is transmitted to No.2, 3 carrier (43) with reduced turning speed and in the same direction as in the case of first forward speed. 020,21 35 F1ososooa Sine No.4 ring gear (25) is fixed, the rotation of No.2, 3 carrier (43) is transmitted to output shaft (29) at an increased turning speed through No.3 ring gear (24) ‘and No.4 carrier (41), and No.4 sun gear (27) in that order. (Besides, the rotation is transmitted from No.3 sun ‘gear (22) to output shaft (291) Output shaft (29) rotates in the same direction as input shaft (11) ‘The rotation of output shaft (29) is transmitted to bevel pinion (35) with reduced turning speed through transfer drive gear (34) and transfer driven gear (36) Bevel pinion (35) then rotates in the opposite direction to output shaft (29) 21-33THIRD FORWARD SPEED No.2 and No.3 clutches engaged and No.2 and No.3 ring gears fixed, With No2 and No clutches engaged, No.2 and No.3 ring gears (18) and (24) are fixed ‘When No.2 ring gear (18) is fixed, the rotation of the engine is transmitted to No.2, 3 carrier (43) with re- ‘duced turning speed and in the same direction as in the case of first forward speed, 21-34 F 10406008 Since No.3 ring gear (24) is fixed, the rotation of No.2, 3 carrier (43) is transmitted to output shaft (29) at an increased turning speed thorgh No.3 sun gear (22) in that order, Output shaft (29) rotates in the same direction as input shaft (11). The rotation of output shaft (29) is transmitted to bevel pinion (35) with reduced turning speed through transfer drive gear (34) and transfer driven gear (36) Bevel pinion (36) then rotates in the opposite direction to output shaft (23). 020,21-6FIRST REVERSE SPEED Not No2 18 No.1 and No. clutches engaged and No.1 ring gear fixed, No.4 carrier and No ring gear are engaged, With No.1 and No.S clutches engaged, No.1 ring gear (14) is fixed and No carrier (41) and No ring gear (28) are engaged. When No.1 ring gear (14) is fixed, No.1 carrier (51) meshed with No.1 ring gear (14) is also fixed ‘The rotation of the engine is transmitted to ring gear (16) through input shaft (11) and No.1 sun gear (13) in the opposite direction and at @ reduced turning speed 020,21-6 F 10406010 Since ring gear (16) is meshed with No.2, 3 carrier (43), the rotation is transmitted to No.2, 3 carrier (43) ‘The rotation of No.2, 3 carrier (43) is transmitted to ‘output shaft (29) in the same way as in first forward speed Output shaft (29) rotates in the opposite direction to input shaft (11). The rotation of output shaft (29) is transmitted to bevel pinion (35) with reduced turning speed through transfer drive gear (34) and transfer driven gear (36). Bevel pinion (35) then rotates in the opposite direction to output shaft (29) 21-35TRANSMISSION CONTROL D21A, P, S,0-6 D21P-6A + Gear shift lever (1) inside the operator's compartment is connected to the spool of the speed, F-R, and inching valve assembly (4) on top of the transmission case. Inching pedal (3) is connected to the inching valve spoolin the same way. ‘When gear shift lever (1) is operated, the speed valve spool and F-R valve spool are actuated at the same time, 21-36 103F 06020 Gear shift lever Lock lever Inching pedal Speed, F-R and inching valve assembly pore The two clutches inside the transmission are en- ‘gaged, and the machine travels, When inching pedal (3) is operated, the inching valve spool is actuated, and the FORWARD or REVERSE clutch inside the transmission is partially disengaged, or is completely disengaged, This gives fine control of the machine travel speed, or stops the machine. 020,21-6TRANSMISSION CONTROL D21E-6 D21P-68 D218-6A + Gear shift lever (1) inside the operator's compartment is connected to the spool of the speed, F-R, and inching valve assembly (4) on top of the transmission case. Inching pedal (3) is connected to the inching valve spool in the same way. When gear shift lever (1) is operated, the speed, valve spool and F-R valve spool are actuated at, the same time. 20,21-6 Fioaoso! Gear shift lever Lock lever Inching pedal ‘Speed, F-R and inching valve assembly The two clutches inside the transmission are engaged. and the machine travels, ‘When inching pedal (3) is operated, the inching valve spool is actuated, and the FORWARD or REVERSE clutch inside the transmission is partially disengaged, or is completely disengaged. This gives fine contro! of the machine travel speed, or stops the machine. 21-37HYDROSHIFT TRANSMISSION HYDRAULIC SYSTEM D21A, P, S, 0-6 D21P-6A, Engine running, gear shift lever at “Neutral” position. 1 vo oe oO Eat | [ LAI fur} oe F 10206024 1 9. Oil cooler bypass valve 2. 10. Oilcooler 3. Transmission pump 11. Transmission lubrication relief valve 4. Modulating valve 12. Transmission lubrication 5. Quick return valve ‘A. To steering circuit 6. Speed valve P,_ Plug for transmission main relief pressure 7. Inching valve P, Plug for inching valve pressure 8 F-Rvalve 21-38 D20,21-6HYDROSHIFT TRANSMISSION D21A, P,S,0-6 D21P-6A HYDRAULIC CIRCUIT DIAGRAM 27 gem OUTLINE The oil in transmission case (1) is sucked by transmission pump (3) through strainer (2), and is sent to modulating valve (4) and quick return valve (6), ‘The modulating valve and quick return valve act together, and regulates the oil pressure in the circuit at 27 kg/em?, The oil flows through to the oll cooler and transmission case. 020,21-6 ‘Set pressure — 8 u }\\ Set pressure: <> (Liver ee aati 7 Engine io rom) |. f=]. Seren | The oil flowing to the quick return valve enters speed valve (6), inching valve (7) and F-R valve (3) The oil cooler bypass valve (9) is installed on transmission case. The transmission lubrication relief valve (11) is built into the transmission.HYDROSHIFT TRANSMISSION HYDRAULIC SYSTEM D21E-6, D21P-6B 218-64, En 21-40 @YO9MPEN= Transmission case Oilstrainer ‘Transmission pump Modulating valve Quick return valve ‘Speed valve Inching valve F-R valve 1@ running, gear shift lever at “Neutral position. Floaosoi2 Oil cooler bypass valve Oil cooler Transmission lubrication relief valve Transmission lubrication To steering circuit Plug for transmission main relief pressure Plug for inching valve pressure 020,21-6HYDROSHIFT TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM D21E-6 D21P-6B D21S-6A axa met VV [, ‘Set pressure ee 1 1 OUTLINE + The oil in transmission case (1) is sucked by transmission pump (3) through strainer (2), and is sent to modulating valve (4) and quick return valve (5) + The modulating valve and quick return valve act together, and regulates the oil pressure in the cit- cuit at 20 kg/cm? The oil flows through to the oil cooler and transmission case. D20,21-6 i @ sso bag ; 55.3¢/min. it ‘Set pressure: tape at yom 2450 rpm} os 2 | The oil flowing to the quick return valve enters speed valve (6), inching valve (7) and F-R valve (8). The oil cooler bypass valve (9) is installed on transmission case. The transmission lubrication relief valve (11) is built into the transmission, 21-41TRANSMISSION CONTROL VALVE D21A, P, S,0-6 D21P-6A From transmission pump To steering circuit To oil cooler Plug for main relief pressure Plug for inching valve pressure proepr 21-42 D20,21-6bree a ee al fe eee one ie ee iene ieee 20. Valve body ae pueae . oe = a = 26. Piston c 27, Stopper O76 aoc. Searanrens a 28 29 fo al oO a ee oN 20,21-6 21-43TRANSMISSION CONTROL VALVE D21E-6 D21P-6B D218-6A ko S | SOS TOOT ay From transmission pump To steering circuit To cil cooler Plug for main relief pressure Plug for inching valve pressure Prosp 21-44 OE i Toe Ke) Ol SIP he? 0D) Fiogosoi4 020,21-6Plug Speed spoo! F-R spool Plug Piston ‘Spring. Piston é 1 10. Inching valve an ; 11. Spring 12. Piston oe 0-30 2 13. Spring 14. Sleeve 15. Sleeve 16. Inching valve spoo! 17. Cover 18. Stopper 19, Load piston 20. Valve body 21. Spring 22. Spring 23. Modulating valve 24, Piston 7 25. Spring 26. Piston > S 27. Stopper of lo 2 28. Quick return valve 29. Stopper 30. Cover ‘A. From transmission pump W@NOaRENS Section 8 ‘rh er ae ¥ MY ae Sectionc—C Fiososo1s 20,21-6 21-45MODULATING VALVE OUTLINE + The modulating valve consists of 2 modulating relief valve and a quick return valve, and acts to modulates the pressure. + When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and itwillreceive an excessive shock. To prevent this, the modulating valve is installed ‘When the gear shift lever is operated to shift gear, the pressure on the piston gradually rises to the set pressure and the clutch is engaged ‘smoothiy. This allows the machine to start with- fut any shock, thereby improving the durability of the power train and at the same time providing 2 comfortable ride for the operator. + The figure on the right shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from F1 to F2, the oil from the pump passes through the speed valve spool, flows to the second clutch {and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the “filing time”, and the ol pressure during ths time is 0 kg/cm? When the circuit up to the clutch piston port is filled with ol, the oil pressure starts to rise, The time taken for the pressure to rise to the set pressure is called the “build-up time”. The filing time and. build-up time toghther are called the “modulating time” 21-46 3 Modulating graph for D21A, P, S, Q-6 and D21P-6A (igiem® Modulating ° am Modulating graph for D21E-6, D21P-68 and D218-6a, F 10306026 (ioiem adage rot eee leec oF To F 10406016 D20,21-6OPERATION 1 While traveling (Range A and D in Figs F10306026 and F10406016) The oil from the transmission pump enters port Aand chamber B. The oil passes through orifice b and goes from chamber F through the speed valve and F-R valve to fill the two sets of clutch piston ports. ‘The pressure in this circuit is always set by the action of modulating valve (23) to the following values. 27 kg/em?: D21A,P,S,0-6 andD21P-6A 20 kg/em?: 021E-6, D21P-68 and 218-64 When the pressure inside the circuit becomes higher, the modulating valve moves to the left. It ‘opens the passage between chambers B and E, 50 the oil from the pump is relieved to chamber E. If the pressure inside the circuit drops because of leakage of oil from the clutch piston or valve, the modulating valve moves to the right. This closes the passage between chambers B and E, so the oil from the pump all flows from port A. into the circuit to the clutch piston port. Immediately after shifting 9 (Range B in Figs. F10306026 and F10406016) When the gear shift lever is moved, the circuit from the transmission pump to the piston port of the clutch after gear shifting is opened and oil flows to the clutch piston port. ‘When this happens, a difference in pressure is generated between port A and chamber F be- ‘cause the oil is restricted by orifice b. Because of the pressure at port A, quick return valve (28) moves to the right. This connects chamber D ‘and drain port G and relieves the back pressure ‘on load piston (9). When this happens, modulating valve (23) is moved to the right by the tension of springs (21) and (22), and load piston (19) is returned to the left. 20,21-6 19 2 2 Tootswaler 7g 7 CET Ty ' eta a Tb F oxen 2B orn Fromoune 2 19 21 22 tootcoom 28 % ° Bc / fie als To speed A drt orm 28 ran | Fromnume 2 Fiososoza 18 21 22 Footsie 29 6 2B ome 29 Fioaoso2s 21-473. While clutch pressure is rising (Range C in Figs. F10306026 and F10406016) ‘When the oil sent under pressure from the pump fills the circuit from port A to the clutch piston ort, the oil pressure starts to rise. ‘When this happens, the difference in pressure fon both sides of orifice b is removed. Quick return valve (28) moves to the left and the passage between chamber D and drain port G is, closed. The oil flows through orifice a to chamber C and Pushes piston (26). The reaction to this makes modulating valve (23) compress springs (21) and (22) and move to the left. This opens the passage from chamber B to chamber E. At the same time, the oil passing from orifice ¢ through the chamber in the center of quick return valve (28) then passes through orifice d ‘and enters chamber D. The oll becomes the back pressure of load piston (19), compresses springs (21) and (22) and move the load piston to the right to the passage between close chambers B and E. This operation is repeated continuously to increase the load on springs (21) and (22). In this way, the hydraulic pressure inside the circuit gradually rises and finally load piston (19) comes, into contact with the valve body and cannot ‘move any further. ‘When this happens, modulating valve (23) stops in a position where the passage between chambers B and E is open, and the rise in pressure is completed, The hydraulic pressure at this point is as follows. 27 kg/cm*: D21A,P,S,0-6, and D21P-6A 20 kg/em?: D21E-6,D21P-68 and 0218-64 The oil relieved from chamber B to chamber E flows from chamber E into the oil cooler circuit. 21-48 10306030 19 21 22 Tootcoow 99 6 2 ae 29 19 21 22 Tootcockr 79 6 Fio306022 20,21-6INICHING VALVE OUTLINE +The inching valve is in the circuit between the speed valve and F-R valve. The amount that the inching pedal is operated adjusts the amount of oil (oil pressure) sent from the speed valve to the F-R valve. This changes the contact force of the FORWARD or REVERSE clutches to partially dis- engage the clutches and allow fine control of the travel speed; or it completely disengages the clutches to make it possible to stop the machine. OPERATION Inching pedal not operated ‘Spool (16) is interconnected with the inching pedal, so when the inching pedal is not being operated, itis atthe end of its stroke on the right. As a result, valve (10) is pushed to the right by sleeve (14) together with the spool The oil sent under pressure from the pump. passes through the modulating valve and speed valve and enters ports A and B. It then passes through the F-R valve and flows to the FOR- WARD or REVERSE clutch piston port. The oil passing through orifice a and entering chamber © becomes the force trying to move valve (10) to the left because of the reaction pushing piston (7). However, valve (10) is in contact with sleeve (14), so it cannot move to the left. Therefore, passage b between port A and B is kept fully open. As a result, the oil from the speed valve gradually increases in pressure because of the action of the modulating valve. it enters clutch piston port ‘and fully engages the clutch. 020,21-6 ToF-Rvsive Fioaceoss 21-49ine operation of inching pedal When the inching pedal is partly depressed, spoo! (16) moves to the lett by an amount which corresponds to the amount the pedal is depressed. When this happens, sleeve (14) moves out of contact with valve (10) and determines the tension of spring (11). n this case, ifthe oil from the speed valve fills the circuit to the clutch piston port, the oil pressure gradually rises. ‘When this happens, the oil pressure in chamber gradually moves valve (10) to the left to a position where it is in balance with the tension of spring (11). Passage b is restricted, so the pressure in the circuit from port B to the clutch port does not rise any more. ‘As a result, the clutch is partially disengaged and ‘the machine travel speed drops. 3. Inching pedal fully depressed When the inching pedal is fully depressed, spoo! (16) moves to the left from the condition in Step 2, and the tension of spring (11) becomes the ‘minimum, In this condition, the oil pressure in the circuit from port B to the clutch piston port rises slightly, and valve (10) is moved by the oll pressure in chamber C to close passage b. Therefore, the clutch is disengaged and the machine stops. If the oil pressure in the circuit beyond B drops because of oil leakage in the circuit beyond port B, the balance between the hy- ILD scene Transmasion lbcaton Transmission beatin vaive 19 oF ont» I Shgen Paz, cio h 12 ONOFF @ryEgEeNa <2 1 sotpressue: _ 9. LH. steering control valve Bkgiem 8 12. RH, steering cylinder D20,21-6 21-59MAIN CLUTCH AND STEERING PUMP 20-6 %* On the 021-6, the steering pump is common with the transmission pump. Drive ge: Bracket Gear case Cover Driven gear ‘Suction port Discharge port BPoRena 21-60 TTT OUTLINE iT ee) a \ \ 5 + The main clutch and steering pump is an FALO10, and is installed to the main clutch case. The main specifications ar aa Wesel ] Discharge Setting pressure Engine revolution oll ‘as shown below. FALOTO 23Umin a 157 kg/em? 2,450 rpm Class-CD SAE1OW 020,21-6STEERING MAIN RELIEF VALVE 020-6 Plug Piston Spring Piston Main relief valve Spring Valve body Plug Main clutch and steering pump WarvamRene From pump, To steering valve To oil cooler pep 020,21-6 Section AA, OUTLINE + The steering main relief valve is installed to the ‘main clutch case and sets the pressure in the steering circuit to 15 kg/em® The oil relieved from the main relief valve flows, to the piping type oil cooler installed to the front of the radiator. Here it is cooled and it then acts to lubricate all parts of the main clutch, OPERATION +The oil from pump (9) enters port A. One part flows to the steering circuit, and the other part passes through the orifice in viave (6) and enters the chamber inside the piston. If the pressure in the steering circuit goes above 15 kg/emt, the oil entering the chamber pushes valve (5) down. This opens the passage between ports A and C, and prevents the pressure in the Circuit from rising any further. 21-61STEERING CONTROL VALVE 5 10 Section AA OUTLINE 1. Valve stem + The steering control vaive includes @ modulation 2. Cover system which allows the hydraulic pressure to 3. Sleeve rise gradually within a range of 5.6 — 115 4. Shatt kg/em?. After modulation action finishes, the set 5. Spring pressure of the main relief valve on D40-6 rises 8. Spool to 15 kg/cm?; the set pressure of the transmis- 7. Valve body sion modulating valve on D21A,P,S,0-6 and 8. Piston D21P-6A rises to 27 kg/cm?; the set pressure of 8. Spring the transmission modulating valve on D21E-6, 10. Cover D21P-6B and D21S-6A rises to 20 kg/cm. From pump ToLH. steering cylinder To RH. steering cylinder Drain Plug for LH. steering pressure Plug for RH. steering pressure ™moo@> 21-62 D20,21-6OPERATION 1 Left and right steering levers not operated (Left and right steering clutches engaged) The oil from the pump enters ports A and B. However, steering valves (6L) and (6R) are not being operated, so the passage to chamber B and ports C and D does not open. Therefore, the oil from the pump enters ports A and B and the oil pressure in the circuit rises On the D20-6: The oil pressure is relieved from the main relief valve (set pressure: 15 kg/cm?) installed to the main clutch case. On the 021-6: The oil pressure is relieved from the transmission modulating valve (set pressure for 021A, P, S, 0-6 and D21P-6A: 27 kg/cm’, set pressure for 1D21E-6, D21P-68 andD21S-6A: 20 kg/cm’) Left steering lever partially operated {Left clutch partially engaged, right clutch engaged) When the left steering lever is pulled slightly, stem (1L) moves to the right and compresses spring (6L) Compressed spring (5L) uses this tension to move spool (6L) to the right. When this happens, the passage between chamber B and port C opens and the oil from the Pump passes through the passage inside the spool and left cylinder port. and enters chamber E When the flow of oil from the pump increases and the pressure rises, the total of the pressure of the oil entering chamber E and the tension of spring (SL) becomes larger than the tension of spring (SL) set by the stroke of the stem. When it. becomes larger than the tension of spring (SL). it moves spool (61) to the left. When this happens, the passage between chamber B and port C closes, and the pressure beyond port € does not rise any further. This action is repeated continuously until the movement of the steering lever is. stopped. During this period, the oil pressure grad- vally rises. The contact of the steering clutch is decided by the level of the pressure beyond port C (that is, by the amount that the steering lever is operated), and the radius of the tur is varied accordingly 20,21-6 Test aL lok BR OR from pumo © ton Evnasr at BL a ot Fiosososs ah gh Ne oe e a a a 21-633. Loft steoring lever fully operated (Left clutch disengaged, right clutch engaged) When the left steering lever is pulled fully, stem (1L) moves to the right from the position in Step 2. It then pushes spool (6L) directly and reaches the end ofits stroke {As a result, the oil pressure does not rise gradually as in Step 2. It increases in an almost direct line unt it reaches the set pressure of the main relief valve Therefore, the steering clutch is completely disengaged and the machine turns sharply. 4, Left and right steering levers operated When both the left and right steering levers are ‘operated, the steering valve operates in the same way as Step 2 or Step 3, and the left and right steering clutches are partially disengaged or completely disengaged. 21-64 re 7 J ie ol aL mn at ak SR BR ronH cyinaerpon BR 9A B at eat st él al at D20,21-6STEERING BOOSTER CYLINDER Sectona-A 103F060358 OUTLINE 1. Steering booster cylinder + The steering booster cylinder is installed on the 2. Spring steering case. it is actuated by the oil pressure 3. Piston from the steering control valve and operates the 4. Steering control valve release yoke of the steering clutch 5. Plate A. From steering control valve D20,21-6 21 paadSTEERING BRAKE Section AWA ‘Steering case cover Lever Lever Yoke Lever Rod Anchor Adjustment nut . Spring End 11. Brake band 12. Lining 13. Pin 14. Pin Semrsssenn 21-66 Section 8-8 Section C=C loarosoae OUTLINE ‘The steering brake is an anchor type contracting band brake which is tightened on the outside cir- ‘cumference of the brake drum (steering clutch outer drum). ‘The steering brake has two functions: sharp turning and stopping, It is used to stop the machine when the brake pedal is depressed, and to steer the machine when the steering lever is pulled to move lever (2). ‘When parking the machine, depress the brake pedal and apply the brake lock lever to hold the pedal in position, 20,21-6OPERATION + When steering to the left, pull the left steering lever and the left steering clutch is disengaged: when steering to the right, pull the right steering lever and the right steering clutch is disengaged. However, the motive force passing through the steering clutch is not completely cut, so there is dragging for a short time and the machine turns inawide circle. To adjust the radius of the turn, depress the brake pedal on the side to which the machine is, turning. This will tighten the brake band on the outer drum (brake drum) and prevent the dragging 1. Operation of brake when traveling forward When the brake pedal is depressed, lever (3) moves up and pulls up lever (5) to contract both ‘ends of the brake band to the inside. When this happens, the outer drum is rotating forward (clockwise in the diagram), so the brake band is pulled in the direction of rotation. This, tension is borne by end (10) installed by a pin to lever (5), but actually, itis borne by point A at the mount of the lever and end. Therefore, the brake band restricts the brake drum with the fulcrum at point A, and pushes ‘out point B on the other side to the right. 2. Operation of brake when traveling in reverse In the same ways as when traveling forward, when the brake pedal is depressed, both ends of the brake band are contracted to the inside When this happens, the outer drum is rotating in reverse (counterclockwise in the diagram), so the brake band is pulled in the direction of rotation, This tension is borne by mount B of rod (6) and the brake band. Therefore, the brake band restricts the brake rum with the fulcrum at point B, and pushes out point A on the other side to the left. 020,21-6 2°93 #5 &€ 7 WW AO (ees 21-67FINAL DRIVE ‘* The diagram shows the D20, D21A,P.S-6. Se@roasens 21-68 10 Lt loaFosoae OUTLINE . Final dive falnge ‘+ The final drive is a spur gear, one stage reduction, Retainer splash lubrication type. Pinion shaft (10 teeth) - Gear (71 teeth) Final drive case Ring . Sprocket |. Sprocket shaft Cover Floating seal D20,21-6POWER TRAIN 22 TESTING AND ADJUSTING ‘Standard for testing and adjusting 22-2 Testing and adjusting tool ist 22-4 Measurng oil pressure 22-6 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 When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety pins and block the tracks. When working in groups, use agreed signals and do not allow unauthorized persons near the machine. 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. > Pb b Be careful not to get caught in rotating parts. 20,21-6 22-1STANDARD FOR TESTING AND ADJUSTING Checkitam conditions unt | Stendird | Permisiie Travel of contol ever Engin owing oa 08 + Fuel contol ever Center otiever knob a mm 25-55 ~ Moin clutch peel (020) Cente of peda wom | 176 — 166 N=FI 92 — 102 : Cente offeversnob Nore mm | 97-97 Nore 7888 7 Gear cathe Bree 6 ozip-en) | Cenerotiever nod Between ech speed range | mm | 31 ~ 43 Between each speed range 30-40 on ae Conte fever knob mm ©2125, 0216-00, 0215-08) ro 52-02 + Taching pedal = ‘i GEES oo ozie-oa _ | Conerot peas mm | 103-113, 47 7 Trehing pest 7 HELE pce, o2rs.6a)_ | Comerot pea mm | tos—nia | a7 + Steering over Center of ever knob mm | 180-220 | 270 > Genter af pedal + Brake pede! 5 Operating tore 184g mm | ar—o1 6 {Glarancebatween ing ad drum) Engine. ow ising 50-70 + Fuel contol over Center oftever knob = ta Heo 6 Engine tw ing 60-100 Tiaaanacel 7 Genteraf pear oe ‘sin chute pod 120) + Engine Stopped Horii Batee! es ~ Gantr over nob i = oor sitiever 020) ee 2 | 40-60 Sa Between each speed range 25-35 + Gear sit over 0 BZIAPRSO-e. o2e-6n | Cemerotiever nod Py tee Betwoon each speed range 20-30 + Goor shit ivey 021 eae : Pies oate-ea Dars.0n | Cemerofteverkro = elses * Tachiog pear > Genterat pal a (zIAPPLS.0-6,021F-64)_| + Engine low ding to | es-1s 7Taciog pedet ~ Gentoo peg {ozietd'o21e.68, 0218.6a)_| } Engine ow ing beens + Steeinglever Center of ver knob x | 40-60 ara 7 Genter ot pagal Brae pc Engin ow ing dati enema 22.2 20,21-6coon — =] ee | ae drautic pressure + Trramision main tat oes Engine low ding levemd 2257208 : em Wziarrisasozirea | Semmens Oe Te ateate 255-285 ‘+ Transmission main z Engine low ing 170-200 pressure : eci ier (216-6, 021P-68, 216-84) Engine ful throttle 195-225 + Steering mainrebet + Oittemperature in Engine ow iting Seas pressure (020) main lateh 40 ~ 60°C Engine fl trottie 140-170 + Steering main reef pressure | + Oil temperaturein Engine low sing Po eeeee (O21APPLS.0-6,021P-68) | transmission: 40 ~ 60°¢ a Engine fl tote 255-285 + Steering main lef pressure | + Oil temperaturein Engine tow cing | 170-200 (0216-6,021P-68,0218-68) | wansmission: 40 ~ 60°C ee Engine ful torte 195-225 + Engine ful rote ‘Second forwerd speed 42 1 Engine water temperature within cates Travel speed operating range cous enaeed teeta, |e 20-8 + Machine's ontvel ground Messure te takento "Fiat everse speed a7 tavelfor 10 ~30'm after traveling 20 mas 0n Spproach travel eo + Engine ful trot Firat forward speed 27 + Engine wate temperature within operating Tenge Secong toward Travel speed + Machineis ontevel ground Secondforwerdspeed | || 4.6 (O2TABPLS.0-6,021-64) | > Measure ime tkento {ave for 10-30 matter Fretrevereeepeed 38 Kaveling 20 mas an spproach ravel Second reverse speed 58 Fest forward speed 24 + Engine ful tote Second forward speed 4a 1 Engine water temperature within opereing rng Trg yorwara ay Travel speed + Mochiveisontevelgreund TMB forwordspeed | || 78 (2ie-8,021P-68,0218.60) | Measure te taken we for 10.30 matter 268 ling 20 mas an Spprosch travel Second reverse speed 4a Third reverse speed 79 D20,21-6 22-3TESTING AND ADJUSTING TOOL LIST Check item Too! Part No. Remarks Oil temperature Thermistor kit 790-101-6000 0 - 1,000°¢ Pressure gauge: 2 | Hydraulic pressure Hydraulic tester | 799-101-5000 | 92"59 400, 600 kg/om? 1:60 — 2,000 rpm 3. | Engine speed Multi-tachometer | 799-203-8000 | Digitaldisplay 4. 69 _ 19,999 1pm ‘Commercially 4 | Operating force Push-pull scale each = 5 | Travel Scale - - 22-4 © 20,21-6MEASURING OIL PRESSURE A. 8100 the machine on evel ground and lower the work equipment to the ground A. Always remove and install plugs and pres sure gauge with the engine stopped. * When measuring the oll pressure, remove all dirt and dust from around the nipple and plug. Special too! No. | _Part No. PartName —_|Q'ty ‘A | 799-101-5000 | Hydraulic testerD | 1 1, Measuring engine oil pressure 1) Remove plug (1). 2), Install tool A (25 kg/em*) 3). Start engine and measure oll pressure. 2. Measuring transmission main relief pressure (021) 1) Remove plug (2) of transmission control valve. 2). Install toll A (60 kg/cm’) 3). Start engine and measure oil pressure. 20,21-63. Measuring inching valve oil pressure (D21) 1) Remove plug (3) of transmission control valve. 2) Install tool A (60 ka/em*) 3) Start engine, check that the oil pressure is about 0 kg/cm? when the inching pedal is fully depressed. ‘* Measure with the gear shift lever at the F1 position, 4. Measuring steering booster cylinder oil pr sure 1) Remove plug (4) of steering control valve, 2) Install tool A (60 kg/cm?) 3) Start engine and measure the oil pressure, when the steering lever is pulled, ‘%* Measure with the gear shift lever at the N position. 103006018 020,21-6MEASURING OIL TEMPERATURE A __ Stop the machine on level ground and lower the work equipment to the ground, Special tool No. | __Part No. PartName —_|a'ty ‘A | 799-101-6000 | Thermistorkit | 1 1. Measuring engine oil temperature 1) Remove oil filler cap. 2) Using tool A, measure temperature of oil in engine oll pan, 2, Measuring transmission oll temperature (D21) 1) Remove oil level gauge. 2) Using tool A, measure temperature of oil in transmission case. 3. Measuring main clutch oil temperature (020) 1) Remove oil level gauge. 2) Using tool A, measure temperature of oil in ‘main clutch case. 20,21-6 22-7TESTING TRAVEL 1. Testing travel of fuel control lever 1) Put steel tape ‘1) in contact with the center of the lever knob. 2) Pull the lever from STOP to IDLING, and from IDLING to FULL, and measure the distance the lever travels. If the measurement is not within the standard value, or if there is any abnormality when the lever is operated, adjust the linkage. For details, see 22 TESTING AND ADJUST- ING, ADJUSTING FUEL CONTROL LINKAGE. 2. Testing travel of main clutch pedal (D20-6) 1) Stop the engine, depress the main clutch pedal fully, and put steel tape ‘in contact with the tip of the pedal 2) Keep the steel tape in position, return the main clutch pedal, and measure the distance the pedal travels, ‘* If the measurement is not within the st dard value, or if there is any abnormality when the pedal is operated, adjust the linkage. For details, see 22 TESTING AND ADJUST- ING, ADJUSTING MAIN CLUTCH CONTROL LINKAGE, Testing travel of gear shift lever (020-6) 1) Stop the engine, and put steel tape @) in contact with the center of the lever knob, 2) Pull the lever from N to each position, and ‘measure the distance the lever travel 4, Testing travel of gear shift lever (021-6) 1) Stop the engine, and put steel tape (1) in contact with the center of the lever knob, 2) Pull the lever from N to each position, and ‘measure the distance the lever travels. ‘* If the measurement is not within the standard value, or if there is any abnormality When the lever is operated, adjust the linkage. For details, see 22 TESTING AND ADJUST- ING, ADJUSTING GEAR SHIFT LEVER CON- TROL LINKAGE (D21E-6, D21P-6B and 218-64), P10308020 20,21-6Testing travel of inching pedal (D21-6) 1) Stop the engine, and depress the inching pedal fully, and put steel tape ‘1) in contact with the tip of the pedal. 2) Keep the steel tape in position, return the inching pedal, and measure the distance the pedal travels. * If the measurement is not within the standard value, or if there is any abnormality when the pedal is operated, adjust the linkage. For details, see 22 TESTING AND ADJUST- ING, ADJUSTING INCHING CONTROL LINK- AGE. Testing travel of steering control lever 1). Stop the engine, and pull the lever fully, and put steel tape | in contact with the center of the lever knob. 2) Keep the steel tape in position, return the lever, and measure the distance the lever travels, ‘If the measurement is not within the standard value, or if there is any abnormality when the lever is operated, adjust the linkage. For details, see 22 TESTING AND ADJUST- ING, ADJUSTING STEERING CONTROL LINKAGE. Testing travel of brake pedal 1) Stop the engine, depress the brake pedal fully, and put steel tape 1 in contact with the tip of the pedal 2) Keep the steel tape in position, and return the brake pedal, and measure the distance the pedal travels. If the measurement is not within the standard value, or if there is any abnormality When the pedal is operated, adjust the linkage. For details, see 22 TESTING AND ADJUST- ING, ADJUSTING BRAKE CONTROL LINK- AGE. 020,21-6 22-9MEASURING OPERATING FORCE 1. Measuring operating force of fuel control lever 1) Stop the engine, and hook push-pull scale 1 on the center of the lever knob. 2) Pull the lever from IDLING to STOP, and from IDLING to FULL, and measure the operating force. 2. Measuring op pedal (020-6) 1) Stop the engine, and put push-pull scale (1 in contact with the center of the pedal. 2) Push the pedal fully, and measure the ‘operating force. force of main clutch 3. Measuring operating force of gear shift lever (020-6) 1) Stop the engine, and hook push-pull scale 1 on the center of the lever knob. 2) Pull the lever from N to each position, and measure the operating force. ‘4. Measuring operating force of gear shift lever (21-6) 1) Stop the engine, and hook push-pull scale 1) on the center of the lever knob. 2) Pull the lever from N to each position, and ‘measure the operating force. 22-10 D20,21-65. Measuring operating force of inching pedal (021-6) 1) Run the engine at low idling, and put push- pull scale 1 in contact with the center of the pedal, 2) Push the pedal fully, and measure the operating force, 6. Measuring operating force of steering le 1) Stop the engine, and hock push-pull scale 1 on the center of the lever knob. 2) Pullte lever fully, and measure the operating force 7. Measuring operating force of brake pedal 1) Run the engine at low idling, and put push- pull scale 1 in contact with the center of the pedal 2) Push the pedal fully, and measure the operating force, 020,21-6 —_— q a 10306040ADJUSTING FUEL CONTROL LEVER 1. After setting control lever (1) in notched part, set ‘engine governor lever in idling position, then connect cable (2) + Judge the position of the notched part from tthe clicking sound and difference in operating force. 2. Operate fuel control lever, set engine governor lever in high idling position, then fit stopper bolt (3) and fue! control lever (4), and tighten locknut 6), 3. Set engine governor lever in stop position, then fit stopper bolt (6) and fuel control lever, and tighten lock nut (6). ‘* Adjust governor lever to put governor lever and stopper of fuel injection pump in contact at the FULL and STOP position. 103F06201 020,21-6ADJUSTING MAIN CLUTCH CONTROL LINKAGE 1. Adjusting main clutch linkage 1) Adjust the height of stopper bolt (1) so that main clutch pedal is 178 mm from the upper 1 face of the floor plate. 2). Set the length of rods (2) and (3) to intercon- nect rods (2) and (3) Standard length Rod (2): 365.7 mm Rod (3): 342.2 mm 103F06202 2, Adjusting play of clutch pedal Loosen the locknut of rod (4), turn rod (4) and. adjust play of the main clutch pedal so that the play is 20 — 25 mm 103F06203 3. Tesing inertia brake Start the engine and run at full throttle, Depress the main clutch pedal fully, and measure the time taken for the main clutch shaft to stop. %* Standard time: 1.5 — 2.2 sec. 4, Adjusting inertia brake 1) Check the installation length of spring (5) % Standard length a: 42 mm 2) If the installation length is not within 42 mm, loosen locknut (6) and turn bolt (7) to adjust. 103F06204 20,21-6 22-13ADJUSTING INCHING CONTROL LINKAGE (021A, P, PL, S, Q-6, D21P-6A) 1, Adjust the height of stopper bolt (2) so that inch- ( ing pedal is 143 mm from the upper face of the floor plate. ‘ 2. Adjust the cable of nut (3) so that there is no slackness in the cable. 3. Depress the inching pedal fully, and adjust the inching pedal of stopper bolt (5) so that travel of inching valve spoo! (4) is 23.5 mm. Then loosen stopper bolt (5) half turn and lock in position with locknut (6). 10308208 103F06209 20,21-6ADJUSTING INCHING CONTROL LINKAGE (D21E-6, D21P-6B, D21S-6A) 1 Adjust the height of stopper bolt (1) so that inching pedal is 143 mm from the upper face of the floor plate, Adjust the length of rods (2), (3) and (4), and instal * Standard length Rod (2): 350 mm Rod (3): 265 mm Rod (4): 231 mm Depress the brake pedal, and check the travel of inching valve spool is 23.5 mm. The brake is interconnected, so adjust the clearance by rod (7) so that clearance between lever (6) and lever (6) is O mm. u 10806203 020,21-6 ce 2aimm / feo 4 10406201, ? es 10406202ADJUSTING GEAR SHIFT LEVER CONTROL LINKAGE (D21E-6, D21P-6B, 021S-6A) 1. Set speed valve spool in the N position, adjust the length of rods (1), (2) and (3), and install, * Standard length Rod (1): 398.6 mm Rod (2): 150.0 mm Rod (3): 94.0 mm 2. Set F-R valve spool in the F or R position, and adjust the lengh of rods (4), (5) and (6), and install * Standard length Rod (4): 393.6 mm Rod (6): 335.5 mm Rod (6): 126.0 mm 3. After connecting all the parts of the linkage, ‘adjust the lengh of rods (2) and (5) finely if lever (7Visin contact with guide (8) 22-16 10406204 10406205 020,21-6ADJUSTING STEERING CONTROL LINKAGE Adjust the length of stopper bolt (1) so that steering lever is 301 mm from the point a on the dashboard. 2. Adjust the length of rods (2) and (3) between the ing lever and the case and install * Standard length Rod (2): 140.2 mm Rod (3): 674.6 mm. 3. Adjust clearance b between steering valve spool and lever (5) of rod (6) and install ‘+ Standard clearance b: 0 — 0.5 mm vosF0¢205 ‘* Fit the steering lever so that it pushes against stopper (1) 4, Adjust clearance of the brake lining ‘* For details, see ADJUSTING CLEARANCE OF BRAKE LINING. 5. Check the travel of the steering lever. * Travel: 180 — 220mm Detai? 103F06206 020,21-6 22-17 3

Shop Manual Komatsu D20A, P, S, Q-6 AND D21A, P, S, Q-6

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Shop Manual Komatsu D20A, P, S, Q-6 AND D21A, P, S, Q-6

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