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KOMATSU D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 CRAWLER TRACTOR SERVICE REPAIR MANUAL (CEBM003100) – PDF DOWNLOAD
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- KOMATSU D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 CRAWLER TRACTOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM003100
- SERIAL NUMBERS:D32E-1,P-1 P075718 and up
D38E-1,P-1 P085799 and up
D39E-1,P-1 P095872 and up
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KOMATSU D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 CRAWLER TRACTOR SERVICE REPAIR MANUAL (CEBM003100)
KOMATSU D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 CRAWLER TRACTOR SERVICE REPAIR MANUAL (CEBM003100) – PDF DOWNLOAD:
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KOMATSU D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 CRAWLER TRACTOR SERVICE REPAIR MANUAL (CEBM003100)
- Always place the transmission/steering lever in neutral and apply the neutral safety lock and lock the parking brake before starting. The operator must be alert, physically fit and free from the influences of alcohol, drugs or medications that might affect his eyesight, hearing, reactions or judgement. Observe and know the use of alternate exits from the operator compartment.
- Safety must always be the operator’s most important concern. He must refuse to operate when he knows it is unsafe and consult his supervisor when safety is in doubt. The best safety device is a safe operator. Do not use controls or hoses as hand holds when climbing on or off the machine. Hoses and controls can move and do not provide solid support.
- Movement of the controls may cause inadvertent and unexpected movement of the machine or its equipment. Follow all machine mounted safety signs before starting, operating, maintaining or servicing the machine. Be sure the area of the operator’s compartment, all mounting steps and grab handles are free of oil, grease, loose objects, ice and mud to lessen the possibility of slipping.
- Remove or secure all maintenance and personal items so they will not interfere with the operator or jam the controls. Perform a visual check of the machine before starting the engine. Look for such things as improper fluid levels, oil leaks, and loose, damaged or missing parts. Do not start the engine until any unsafe conditions are corrected.
- Secure all caps and filler plugs. Know and understand the traffic flow patterns of your job and obey flagman, signs and signals. Check work area for hazardous conditions. Be alert for soft ground conditions, especially when working on slopes, near drop offs or excavations or fill material, which could lead to sudden tipping of the machine. At night and times of poor visibility, carefully check the work area before moving in with the machine.
- Use all lights provided. Before entering the operator’s compartment, clear the immediate area surrounding the machine of personnel and obstructions. Walk completely around the machine. After entering the operator’s compartment, sound the horn to clear the immediate area of the machine. Due to the danger of fire and explosion, never check or fill fuel tank or batteries near lighted smoking materials or open flame or sparks.
TABLE OF CONTENTS:
KOMATSU D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 CRAWLER TRACTOR SERVICE REPAIR MANUAL (CEBM003100)
MAIN MENU............................................. 0 SECTION INDEX......................................... 5 INDEX TO SECTIONS..................................... 6 SECTION 1 - INTRODUCTION.............................. 7 SAFETY PRECAUTIONS................................ 8 GENERAL....................................... 8 BEFORE STARTING THE ENGINE.................... 8 OPERATION..................................... 9 MAINTENANCE................................... 10 SHUTDOWN...................................... 12 SAFETY PRODUCT GRAPHICS AND LOCATION.......... 14 SERVICE INFORMATION............................... 16 GENERAL....................................... 16 PIN AND SERIAL NUMBERS........................ 16 SERVICE TOOLS AND PARTS....................... 17 INSPECTION AND REPAIR......................... 17 LOCTITE USAGE..................................... 18 SURFACE PREPARATION........................... 18 APPLICATION................................... 18 SETTING TIME (BEFORE PLACING IN OPERATION).... 19 REMOVAL....................................... 19 APPLICATIONS AT LOW TEMPERATURES.............. 19 SECTION 2 - MISCELLANEOUS............................. 20 DIMENSIONS........................................ 21 D32E-1 DIMENSIONS............................. 21 D32P-1 DIMENSIONS............................. 22 D38E-1 DIMENSIONS............................. 23 D38P-1 DIMENSIONS............................. 24 D39E-1 DIMENSIONS............................. 25 D39P-1 DIMENSIONS............................. 26 SPECIFICATIONS.................................... 27 D32E-1, D32P-1 SPECIFICATIONS................. 27 D38E-1, D38P-1 SPECIFICATIONS................. 28 D39E-1, D39P-1 SPECIFICATIONS................. 29 CAPACITIES AND LUBRICANTS......................... 30 SPECIAL TORQUES................................... 32 STANDARD TORQUES.................................. 34 INTRODUCTION OF TOOLS......................... 34 BOLT IDENTIFICATION CHART..................... 35 GRADE 5 AND 8 NON-PHOSPHATE HARDWARE.......... 36 GRADE 8 PHOSPHATE HARDWARE.................... 37 STANDARD METRIC FASTENERS..................... 37 HOSE CLAMPS................................... 38 SPLIT FLANGE CONNECTIONS...................... 38 SECTION 4 - BRAKES.................................... 39 GENERAL........................................... 40 DESCRIPTION................................... 41 SPECIFICATIONS................................ 41 BRAKE AND DECELERATOR PEDAL....................... 42 REMOVAL....................................... 43 SERVICE....................................... 43 INSTALLATION.................................. 47 BRAKE PAD......................................... 48 REMOVAL....................................... 50 SERVICE....................................... 51 INSTALLATION.................................. 56 BRAKE SUPPORT BRACKET............................. 59 SECTION 6 - COOLING................................... 61 GENERAL........................................... 62 DESCRIPTION................................... 62 OPERATION..................................... 62 SPECIFICATIONS................................ 62 SERVICE DIAGNOSIS................................. 63 RADIATOR - D32E-1 & D32P-1........................ 64 RADIATOR - D38E/P-1 & D39E/P-1.................... 65 REMOVAL....................................... 67 DISASSEMBLY................................... 71 REASSEMBLY.................................... 76 INSTALLATION.................................. 80 SECTION 7 - DRIVE TRAIN............................... 86 GENERAL........................................... 87 SPECIFICATIONS................................ 87 DRIVE TRAIN SCHEMATIC......................... 88 DESCRIPTION................................... 90 OPERATION..................................... 90 PRESSURES..................................... 92 BRAKE CYLINDER RELEASE........................ 93 TRANSMISSION CLUTCH........................... 93 STALL SPEEDS.................................. 94 SECTION 7B - TORQUE CONVERTER......................... 95 GENERAL........................................... 96 DESCRIPTION................................... 96 OPERATION..................................... 96 SPECIAL TOOLS................................. 96 SPECIFICATIONS................................ 98 SERVICE DIAGNOSIS............................. 98 REMOVAL........................................... 99 DISASSEMBLY.......................................107 COMPLETE ASSEMBLY.............................107 CONVERTER ASSEMBLY............................111 REAR HOUSING..................................115 REASSEMBLY........................................118 REAR HOUSING..................................118 CONVERTER ASSEMBLY............................122 COMPLETE ASSEMBLY.............................126 INSTALLATION......................................133 SECTION 7C - TRANSMISSION.............................140 GENERAL...........................................141 DESCRIPTION...................................142 OPERATION.....................................142 SPECIFICATIONS................................144 REMOVAL...........................................145 COMPLETE ASSEMBLY.................................161 DISASSEMBLY...................................162 REASSEMBLY....................................167 DIRECTIONAL (INPUT) SHAFT.........................177 GENERAL.......................................177 SPRING CRITERION..............................179 DISASSEMBLY...................................179 REASSEMBLY....................................184 COUNTERSHAFT......................................193 GENERAL.......................................193 DISASSEMBLY...................................194 REASSEMBLY....................................194 RANGE (OUTPUT) SHAFT..............................196 GENERAL.......................................196 SPRING CRITERION..............................198 DISASSEMBLY...................................198 REASSEMBLY....................................205 REVERSE IDLER SHAFT...............................219 GENERAL.......................................219 DISASSEMBLY...................................220 REASSEMBLY....................................220 MAIN REGULATOR VALVE..............................222 DESCRIPTION...................................223 THEORY OF OPERATION...........................223 SPECIFICATIONS................................224 DISASSEMBLY...................................224 REASSEMBLY....................................227 RANGE SELECTOR VALVE..............................231 DESCRIPTION...................................232 THEORY OF OPERATION...........................232 SPECIFICATIONS................................233 DISASSEMBLY...................................233 REASSEMBLY....................................235 RATE OF RISE VALVE................................238 SPECIFICATIONS................................243 DISASSEMBLY...................................244 REASSEMBLY....................................246 INSTALLATION......................................250 TRANSMISSION/STEERING VALVE.......................268 DESCRIPTION...................................270 THEORY OF OPERATION...........................270 SPECIFICATIONS................................271 REMOVAL.......................................272 DISASSEMBLY...................................274 REASSEMBLY....................................282 ADJUSTMENT....................................290 INSTALLATION..................................291 DRIVE SHAFT.......................................294 SPECIFICATIONS................................294 SERVICE.......................................295 SECTION 7E - STEERING DRIVE...........................297 GENERAL...........................................298 DESCRIPTION...................................298 OPERATION.....................................298 SPECIFICATIONS................................299 REMOVAL...........................................300 DISASSEMBLY.......................................310 BRAKE CYLINDER....................................320 SPECIFICATIONS................................322 DISASSEMBLY...................................322 REASSEMBLY....................................324 STEERING CYLINDER.................................326 DESCRIPTION...................................327 DISASSEMBLY...................................327 REASSEMBLY....................................329 MOUNTING PLATE....................................331 SERVICE.......................................332 BRAKE/STEERING SHOES..............................334 SPECIFICATIONS................................336 SERVICE.......................................336 BEARING CARRIER...................................339 SERVICE.......................................339 PLANET GEAR CARRIER...............................342 SERVICE.......................................342 REASSEMBLY........................................344 INSTALLATION......................................363 BRAKE ADJUSTMENT..................................374 BRAKE CYLINDER VALVE..............................377 GENERAL.......................................377 SPECIFICATIONS................................378 OPERATION.....................................378 REMOVAL.......................................379 DISASSEMBLY...................................381 REASSEMBLY....................................382 INSTALLATION..................................383 SECTION 7F - FINAL DRIVE..............................385 GENERAL...........................................386 DESCRIPTION...................................387 OPERATION.....................................387 SPECIFICATION.................................387 SERVICE DIAGNOSIS.............................388 REMOVAL...........................................389 DISASSEMBLY.......................................391 D32E-1, D32P-1, D38E-1 OR D38P-1..............392 D39E-1 OR D39P-1..............................395 REASSEMBLY........................................400 D32E-1, D32P-1, D38E-1 OR D38P-1..............401 D39E-1 OR D39P-1..............................404 METAL TYPE FACE SEALS.............................408 SEAL INSPECTION...............................408 SEAL INSTALLATION.............................409 INSTALLATION......................................410 SECTION 8 - ELECTRICAL................................412 GENERAL...........................................413 DESCRIPTION...................................413 SPECIFICATIONS................................413 SPECIAL TOOLS.................................413 TORQUE DATA...................................413 WIRING DIAGRAM....................................414 SECTION 10 - HYDRAULICS...............................416 GENERAL...........................................417 DESCRIPTION...................................418 OPERATION.....................................418 SPECIFICATIONS................................419 SPECIAL TOOLS.................................419 WORK EQUIPMENT................................420 BLADE EQUIPMENT LEVER.........................423 REAR EQUIPMENT LEVER..........................424 SECTION 10A - PUMPS...................................425 CHARGE AND SCAVENGE PUMP..........................426 GENERAL.......................................427 REMOVAL.......................................428 DISASSEMBLY...................................429 INSPECTION....................................433 REASSEMBLY....................................433 INSTALLATION..................................437 EQUIPMENT PUMP....................................438 GENERAL.......................................439 REMOVAL.......................................440 DISASSEMBLY...................................441 INSPECTION....................................443 REASSEMBLY....................................443 INSTALLATION..................................445 SECTION 10B - CONTROL VALVE...........................447 REMOVAL...........................................448 COMPLETE ASSEMBLY.................................456 DISASSEMBLY...................................456 REASSEMBLY....................................459 SYSTEM RELIEF VALVE...............................461 DISASSEMBLY...................................463 REASSEMBLY....................................464 BLADE LIFT SECTION................................466 DISASSEMBLY...................................469 REASSEMBLY....................................470 BLADE TILT SECTION................................475 DISASSEMBLY...................................477 REASSEMBLY....................................477 BLADE ANGLE OR RIPPER SECTION.....................480 DISASSEMBLY...................................480 REASSEMBLY....................................480 INSTALLATION......................................485 SECTION 10C - CYLINDERS...............................492 BLADE EQUIPMENT...................................493 SPECIFICATIONS................................494 REMOVAL.......................................494 DISASSEMBLY...................................496 REASSEMBLY....................................499 INSTALLATION..................................501 RIPPER............................................503 SPECIFICATIONS................................504 REMOVAL.......................................504 DISASSEMBLY...................................505 BUSHINGS......................................507 REASSEMBLY....................................508 SECTION 12 - POWER....................................511 ENGINE............................................512 STANDARD VALUE TABLE FOR ENGINE ..............512 D32E AND D32P.............................512 D38E AND D38P.............................513 D39E AND D39P.............................514 REMOVAL.......................................515 INSTALLATION..................................527 THROTTLE..........................................538 ADJUSTMENT....................................538 FUEL CONTROL LINKAGE..........................541 SECTION 14 - UNDERCARRIAGE............................542 GENERAL...........................................543 DESCRIPTION...................................544 FRONT IDLER...................................544 TRACK ADJUSTER................................544 TRACK SPRING..................................544 TRACK TOP IDLER...............................544 TRACK ROLLER..................................544 FRONT CROSSBAR................................544 REAR RIGID BAR................................544 MAINTENANCE...................................544 SERVICE DIAGNOSIS.................................545 WEAR LIMIT CHECKS.................................547 SPECIFICATIONS................................547 GENERAL.......................................549 TRACK SHOE GROUSER HEIGHT.....................549 LINK HEIGHT...................................549 BUSHING OUTSIDE DIAMETER......................549 INTERNAL PIN AND BUSHING WEAR (PITCH).........550 FRONT IDLER FLANGE HEIGHT.....................550 TRACK ROLLER ROLLING DIAMETER.................550 TOP IDLER ROLLING DIAMETER....................550 FRONT IDLER.......................................551 SPECIFICATIONS................................552 REMOVAL.......................................553 DISASSEMBLY...................................553 CLEARANCES....................................557 REASSEMBLY....................................559 INSTALLATION..................................563 TRACK ADJUSTER....................................568 SPECIFICATIONS................................569 SERVICE.......................................569 TOP IDLER.........................................573 SPECIFICATIONS................................574 REMOVAL.......................................574 DISASSEMBLY...................................575 REASSEMBLY....................................578 INSTALLATION..................................581 TRACK ROLLER......................................583 SPECIFICATIONS................................584 REMOVAL.......................................584 DISASSEMBLY...................................585 CLEARANCES....................................588 REASSEMBLY....................................590 INSTALLATION..................................593 METAL TYPE FACE SEALS.............................594 SEAL INSPECTION...............................594 SEAL INSTALLATION.............................595 TRACK FRAME.......................................597 REMOVAL.......................................597 INSTALLATION..................................598 TRACK SPRING......................................599 SPECIFICATIONS................................600 SPECIAL TOOLS.................................600 REPLACEMENT...................................601 FRONT CROSSBAR....................................608 REMOVAL.......................................608 INSTALLATION..................................609 REAR RIGID BAR....................................612 REPLACEMENT...................................612 TRACK FRAME ALIGNMENT.............................613 SECTION 15 - TRACK CHAIN..............................617 SPLIT LINK TYPE CHAINS............................618 SPECIFICATIONS................................620 DESCRIPTION...................................621 MAINTENANCE...................................621 REMOVAL.......................................622 INSTALLATION..................................622 COMPLETE CHAIN REBUILD........................622 SINGLE TRACK CHAIN JOINT REBUILD..............624 SECTION 17 - MOUNTED EQUIPMENT........................628 C FRAME RUB BARS..................................629 MOUNTING......................................629 ANGLING FRAME.....................................631 BUSHING REPLACEMENT...........................631 SPECIFICATIONS................................632 ADJUSTING.....................................632 C FRAME PIN.......................................633 PIN SHIMS.....................................633 C FRAME...........................................634 BUSHING REPLACEMENT...........................634 BLADE BUSHINGS....................................635 BUSHING REPLACEMENT...........................635
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