Komatsu D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 Crawler Tractor Shop Manual PDF

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Komatsu D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 Crawler Tractor Shop Manual CEBM003100 – PDF DOWNLOAD

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Komatsu D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 Crawler Tractor Shop Manual CEBM003100 – PDF DOWNLOAD

Language : English
Pages :637
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 Crawler Tractor Shop Manual CEBM003100 – PDF DOWNLOAD

• D32E-1,P-1 P075718 and up
• D38E-1,P-1 P085799 and up
• D39E-1,P-1 P095872 and up

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

DESCRIPTION:

Komatsu D32E-1,P-1 D38E-1,P-1 D39E-1,P-1 Crawler Tractor Shop Manual CEBM003100 – PDF DOWNLOAD

• D32E-1,P-1 P075718 and up
• D38E-1,P-1 P085799 and up
• D39E-1,P-1 P095872 and up

• Human error is a contributing factor in most equipment related injuries. Haste, carelessness and lack of training are the primary causes of injuries. Most operating injuries occur because of excessive speed, loss of control, failure to observe warning signs, slipping or falling while entering or dismounting, a lack of berms on roadways or piles, lack of a ROPS or seat belt, or not watching in the direction of travel. Most maintenance injuries occur during welding or when using hammers or wrenches. The most common faults are improper work position, a slipped tool, missed aim, a broken tool, flying chips and/or no welding hood. Think before you act. A careful operator or maintenance person is the best insurance against an accident.
• Always wear proper safety equipment. Avoid wearing jewelry and loose fitting clothing; they could catch on moving parts which could result in serious injury or death. Hard hat, sturdy rough soled work shoes or safety shoes, ear protectors, reflective clothing, safety glasses and heavy gloves may be required. Consult your employer for specific safety equipment requirements.
• Each job site and application may have personal safety requirements. Carefully evaluate your particular application and machine for equipment such as warning lights, side view and rear view mirrors, back up alarms, fire extinguisher, rotating beacons and additional lights. If in doubt, contact your distributor.
• The machine should be equipped with a fully charged fire extinguisher. All personnel should be instructed in proper usage. Recharge immediately after use.
• The machine should not be serviced with anyone in the operator’s compartment unless said person is qualified to operate the machine and is assisting in the servicing. No unauthorized personnel should be allowed to operate, maintain or service this machine. Do not rush. Hurrying can lead to accidents. Do not jump on or off the machine. Keep two hands and one foot or two feet and one hand in contact with steps and grab handles and rails at all times. Place objects on machine from ground level before mounting machine.

G.B  14/12/24