Komatsu D32/EP-1A D38/EP-1A D39E/P-1A Crawler Tractor Shop Manual PDF

Description

Komatsu D32/EP-1A D38/EP-1A D39/EP-1A Crawler Tractor Shop Manual CEBM004302 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D32/EP-1A D38/EP-1A D39/EP-1A Crawler Tractor Shop Manual CEBM004302 – PDF DOWNLOAD

Language : English
Pages : 620
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D32/EP-1A D38/EP-1A D39/EP-1A Crawler Tractor Shop Manual CEBM004302 – PDF DOWNLOAD

• SERIAL NUMBERS
• D32E/P-1A – P076093  and up
• D38E/P-1A – P086239  and up
• D39E/P-1A – P096338  and up

MAIN MENU 0
COVER 1
CONTENTS 2
FOREWORD 2
SAFETY 11
SAFETY NOTICE 11
GENERAL 13
HOW TO READ THE SHOP MANUAL 14
HOISTING INSTRUCTIONS 15
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 20
CONVERSION TABLES 21
01 GENERAL 27
VIEW OF MACHINE 28
DIMENSIONAL DRAWINGS 29
D32E-1A 29
D32P-1A 30
D38E-1A 31
D38P-1A 32
D39E-1A 33
D39P-1A 34
SPECIFICATIONS 35
D32E/P-1A 35
D38E/P-1A 37
D39E/P-1A 39
WEIGHT TABLE 41
USE OF FUEL, COOLANT AND LUBRICANTS 42
PROPER SELECTION 42
D32E-1A, D32P-1A, D38E-1A OR D38P-1A 42
D39E-1A OR D39P-1A 42
ABBREVIATIONS 43
ENGINE OIL SPECIFICATIONS 43
NORMAL OPERATION 43
ARCTIC OPERATION 43
DRIVE TRAIN OIL SPECIFICATIONS 44
TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS 44
EQUIPMENT SYSTEM OIL SPECIFICATIONS 44
FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPECIFICATIONS 44
COOLING SYSTEM 44
FUEL SYSTEM 44
10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS 45
ENGINE MOUNT 47
ENGINE CONTROLS 48
FUEL LINES 49
RADIATOR, OIL COOLER 50
DRIVE TRAIN 51
GENERAL 51
OUTLINE 51
SCHEMATIC 53
PIPING DIAGRAM 54
OUTLINE 54
PRESSURE PORTS 55
TORQUE CONVERTER 56
TWO PIECE HOUSING 56
OUTLINE 57
ONE PIECE HOUSING 58
OUTLINE 59
TRANSMISSION CONTROL 60
OUTLINE 60
DRIVE SHAFT 61
TRANSMISSION MOUNTING 62
TRANSMISSION 63
OUTLINE 64
CLUTCH OPERATION 64
GEAR SHIFT OPERATION 65
VALVES AND MANIFOLD MOUNTING 67
DIRECTIONAL (INPUT) CLUTCH SHAFT 68
RANGE (OUTPUT) CLUTCH SHAFT 70
COUNTERSHAFT 72
REVERSE IDLER SHAFT 73
PRESSURE REGULATOR VALVE 74
RANGE SELECTOR VALVE 76
RATE OF RISE VALVE 78
TASC VALVE 81
DESCRIPTION 82
THEORY OF OPERATION 82
DIRECTION 83
RANGE 83
STEERING 83
NEUTRAL START VALVE 84
CHARGE AND SCAVENGE PUMP 85
SUCTION STRAINER 86
BRAKE CYLINDER VALVE 87
OPERATION 88
STEERING DRIVE 89
OUTLINE 91
STEERING BRAKE CYLINDER 93
STEERING CYLINDER 95
BRAKE OR STEERING SHOES 96
FINAL DRIVE 97
DESCRIPTION 99
UNDERCARRIAGE 100
GENERAL 100
TRACK ROLLER 102
TRACK SPRING 104
TRACK ADJUSTER 106
DESCRIPTION 107
FRONT IDLER 108
TOP IDLER 110
TRACK CHAIN 111
MAIN FRAME 113
EQUIPMENT HYDRAULICS 114
HYDRAULIC DIAGRAM 114
HYDRAULIC SCHEMATIC 114
DESCRIPTION 115
BLADE CONTROL 115
RIPPER CONTROL 116
WORK EQUIPMENT CONTROLS 117
RESERVOIR AND RETURN FILTER 118
PUMP 119
DESCRIPTION 119
BLADE AND/OR RIPPER VALVE BANK 120
MAIN RELIEF VALVE 122
LOAD CHECK VALVE 122
ANTI CAVITATION – LOAD CHECK VALVE 123
BLADE LIFT VALVE SECTION 124
BLADE TILT VALVE SECTION 126
BLADE ANGLE OR RIPPER VALVE SECTION 128
BLADE CYLINDERS 130
BLADE LIFT AND TILT 130
BLADE ANGLE 131
RIPPER CYLINDERS 132
CAB 133
BLADE EQUIPMENT 134
C FRAME WEAR BARS 134
C FRAME PIN SHIMS 135
ANGLING FRAME 135
TRUNNION MOUNTING 137
ELECTRICAL SYSTEM 139
WIRING SCHEMATIC 139
ELECTRICAL COMPONENTS 141
DESCRIPTION 141
STARTING AND CHARGING GROUP 141
LIGHTING GROUP 141
INDICATOR GROUP 141
ACCESSORY GROUP 141
INSTRUMENT PANEL 142
OUTLINE 142
OPERATION 142
GAUGE DISPLAY 143
SPECIAL TORQUE CHART 144
20 TESTING, ADJUSTING AND TROUBLESHOOTING 145
STANDARD VALUE TABLES FOR ENGINE 146
STANDARD VALUE TABLE FOR CHASSIS 149
TOOLS FOR TESTING AND ADJUSTING 154
ENGINE 155
EXHAUST COLOR 158
BELT TENSION 159
STALL SPEEDS 160
FUEL CONTROL LINKAGE 161
TASC VALVE 164
BRAKE AND DECELERATOR PEDAL 165
SECONDARY BRAKE PEDAL 168
SAFETY LOCK LEVER 169
BLADE EQUIPMENT LEVER 170
REAR EQUIPMENT LEVER 172
DRIVE TRAIN PRESSURES 173
BRAKE CYLINDER RELEASE 174
TRANSMISSION CLUTCH 175
WORK EQUIPMENT 176
SERVICE DIAGNOSIS 179
30 DISASSEMBLY AND ASSEMBLY 191
METHOD OF USING MANUAL 193
PRECAUTIONS WHEN CARRYING OUT OPERATION 197
SPECIAL TOOL LIST 200
ENGINE CRANKCASE GUARD 202
REMOVAL 202
INSTALLATION 202
TRANSMISSION GUARD 203
REMOVAL 203
INSTALLATION 203
ENGINE HOOD 204
REMOVAL 204
INSTALLATION 204
ROPS CANOPY 205
REMOVAL 205
INSTALLATION 205
DASHBOARD 206
REMOVAL 206
INSTALLATION 208
OPERATOR’S SEAT 209
REMOVAL 209
INSTALLATION 209
FUEL TANK 210
REMOVAL 210
INSTALLATION 212
BATTERY BOX 214
REMOVAL 214
INSTALLATION 218
BRAKE PEDAL CONNECTIONS 219
GENERAL 219
BRAKE AND DECELERATOR PEDAL 220
BRAKE PAD 225
SECONDARY BRAKE PEDAL 229
RADIATOR 232
REMOVAL 232
DISASSEMBLY 234
REASSEMBLY 239
INSTALLATION 243
ENGINE 247
REMOVAL 247
ENGINE MOUNTING 252
INSTALLATION 254
TORQUE CONVERTER 255
REMOVAL 255
INSTALLATION 258
TWO PIECE HOUSING STYLE 259
ONE PIECE HOUSING STYLE 279
CHARGE AND SCAVENGE PUMP 292
REMOVAL 292
INSTALLATION 292
DISASSEMBLY 294
REASSEMBLY 298
DRIVE SHAFT 302
SERVICE 302
TRANSMISSION 304
REMOVAL 304
MOUNTING TRANSMISSION 308
INSTALLATION 311
COMPLETE ASSEMBLY 312
DIRECTIONAL (INPUT) SHAFT 328
COUNTERSHAFT 342
RANGE (OUTPUT) SHAFT 345
REVERSE IDLER SHAFT 366
MAIN REGULATOR VALVE 369
RANGE SELECTOR VALVE 376
RATE OF RISE VALVE 382
TASC VALVE 389
REMOVAL 389
INSTALLATION 391
DISASSEMBLY 393
REASSEMBLY 401
ADJUSTMENT 409
NEUTRAL START VALVE 410
REMOVAL 410
INSTALLATION 410
SERVICE 411
STEERING DRIVE 413
REMOVAL 413
INSTALLATION 415
DISASSEMBLY 418
REASSEMBLY 426
BRAKE CYLINDER 444
REMOVAL OR INSTALLATION 445
DISASSEMBLY 445
REASSEMBLY 446
STEERING CYLINDER 448
REMOVAL OR INSTALLATION 448
DISASSEMBLY 449
REASSEMBLY 450
BRAKE/STEERING SHOES 453
REMOVAL OR INSTALLATION 453
APPLY SHOES 454
BACK UP SHOES 455
BRAKE CYLINDER VALVE 456
REMOVAL 456
INSTALLATION 457
DISASSEMBLY 459
REASSEMBLY 460
FINAL DRIVE 461
REMOVAL 461
INSTALLATION 464
DISASSEMBLY 466
REASSEMBLY 469
EQUIPMENT PUMP 475
REMOVAL 475
INSTALLATION 475
DISASSEMBLY 477
REASSEMBLY 479
EQUIPMENT CONTROL VALVE 482
REMOVAL 482
INSTALLATION 489
COMPLETE ASSEMBLY 490
SYSTEM RELIEF VALVE 494
BLADE LIFT SECTION 498
BLADE TILT SECTION 504
BLADE ANGLE OR RIPPER SECTION 508
BLADE CYLINDERS 512
REMOVAL 512
INSTALLATION 514
DISASSEMBLY 515
REASSEMBLY 518
RIPPER CYLINDERS 520
REMOVAL 520
INSTALLATION 520
DISASSEMBLY 521
BUSHINGS 524
REASSEMBLY 525
UNDERCARRIAGE WEAR LIMITS 528
SPECIFICATIONS – D32E/P-1A OR D38E/P-1A 528
SPECIFICATIONS – D39E/P-1A 529
GENERAL 530
TRACK SHOE GROUSER HEIGHT 530
LINK HEIGHT 530
BUSHING OUTSIDE DIAMETER 530
INTERNAL PIN AND BUSHING WEAR (PITCH) 531
FRONT IDLER FLANGE HEIGHT 531
TRACK ROLLER ROLLING DIAMETER 531
TOP IDLER ROLLING DIAMETER 531
TRACK FRAME 532
REMOVAL 532
INSTALLATION 533
FRONT IDLER 534
REMOVAL 534
INSTALLATION 535
DISASSEMBLY 540
CLEARANCES 544
REASSEMBLY 546
TRACK ADJUSTER 551
SERVICE 552
RECOIL SPRING 556
REPLACEMENT 556
TRACK ROLLER 564
REMOVAL 564
INSTALLATION 565
DISASSEMBLY 566
CLEARANCES 570
REASSEMBLY 572
TOP IDLER 576
REMOVAL 576
INSTALLATION 577
DISASSEMBLY 579
REASSEMBLY 583
METAL TYPE FACE SEALS 588
SEAL INSTALLATION 589
FRONT CROSSBAR 591
REMOVAL 591
INSTALLATION 593
REAR RIGID BAR 595
REPLACEMENT 595
TRACK FRAME ALIGNMENT 596
TRACK CHAIN 601
MAINTENANCE 603
REMOVAL 603
INSTALLATION 604
COMPLETE CHAIN REBUILD 604
SINGLE JOINT REBUILD 606
MOUNTED EQUIPMENT 610
C FRAME RUB BARS 610
ANGLING FRAME 611
C FRAME PIN SHIMS 613
C FRAME BUSHINGS 614
BLADE BUSHINGS 615
90 OTHERS 617
DRIVE TRAIN SCHEMATIC 618
ELECTRICAL WIRING DIAGRAM 619

DESCRIPTION:

Komatsu D32/EP-1A D38/EP-1A D39/EP-1A Crawler Tractor Shop Manual CEBM004302 – PDF DOWNLOAD

• SERIAL NUMBERS
• D32E/P-1A – P076093  and up
• D38E/P-1A – P086239  and up
• D39E/P-1A – P096338  and up

GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding
of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand
the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
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, ADJUSTING AND TROUBLESHOOTING:
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.

G.B  16/12/24