KOMATSU D32E/P-1 D38E/P-1 D39E/P-1 BULLDOZER Operation & Maintenance Manual (CEAM002700) – PDF DOWNLOAD

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KOMATSU D32E/P-1 D38E/P-1 D39E/P-1 BULLDOZER Operation & Maintenance Manual (CEAM002700)

KOMATSU D32E/P-1 D38E/P-1 D39E/P-1 BULLDOZER OPERATION & MAINTENANCE MANUAL (CEAM002700) – PDF DOWNLOAD:

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KOMATSU D32E/P-1 D38E/P-1 D39E/P-1 BULLDOZER Operation & Maintenance Manual (CEAM002700)

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
• If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information on your machine or for uestions regarding information in this manual.

TABLE OF CONTENTS:

KOMATSU D32E/P-1 D38E/P-1 D39E/P-1 BULLDOZER Operation & Maintenance Manual (CEAM002700)

MAIN MENU........................................................................  0
INTRODUCTION ....................................................................  5
	1. FORWARD ..................................................................  6
	2. SAFETY INFORMATION .......................................................  7
	3. INTRODUCTION .............................................................  8
		3.1 INTENDED USE ........................................................  8
		3.2 FEATURES ............................................................  8
		3.3 BREAKING IN THE MACHINE .............................................  8
	4. LOCATION OF PLATES, TABLE TO  ENTER P.I.N. AND DISTRIBUTOR ...............  9
		4.1 P.I.N. PLATE LOCATION ...............................................  9
		4.2 ENGINE SERIAL NO. PLATE LOCATION ....................................  9
		4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR ..............................  9
	5. TABLE OF CONTENTS ........................................................ 10
SAFETY .......................................................................... 15
	6. GENERAL PRECAUTIONS ...................................................... 16
	7. PRECAUTIONS DURING OPERATION ............................................. 21
		7.1 BEFORE STARTING ENGINE .............................................. 21
		7.2 OPERATING MACHINE ................................................... 23
		7.3 TRANSPORTATION....................................................... 26
		7.4 BATTERY ............................................................. 28
		7.5 TOWING .............................................................. 29
	8. PRECAUTIONS FOR MAINTENANCE .............................................. 30
		8.1 BEFORE CARRYING OUT MAINTENANCE ..................................... 30
		8.2 DURING MAINTENANCE .................................................. 32
	9. POSITION FOR ATTACHING SAFETY LABELS...................................... 35
OPERATION ....................................................................... 37
	10. GENERAL VIEW............................................................. 38
		10.1 GENERAL VIEW OF MACHINES ........................................... 38
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES ................................ 39
		10.3 UNIVERSAL SYMBOLS .................................................. 40
	11. EXPLANATIONS OF COMPONENTS .............................................. 41
		11.1 GENERAL ............................................................ 41
		11.2 GAUGES AND WARNING LIGHTS .......................................... 41
			11.2.1 HOURMETER .................................................... 42
			11.2.2 TRANSMISSION OIL FILTER WARNING LIGHT ........................ 42
			11.2.3 ENGINE COOLANT TEMPERATURE GAUGE ............................. 42
			11.2.4 ENGINE OIL PRESSURE GAUGE .................................... 43
			11.2.5 ILLUMINATION LAMP ............................................ 43
			11.2.6 VOLTMETER .................................................... 43
			11.2.7 DRIVE TRAIN OIL TEMPERATURE GAUGE ............................ 43
			11.2.8 HYDRAULIC OIL FILTER LIGHT ................................... 44
			11.2.9 AIR CLEANER SERVICE LIGHT .................................... 44
			11.2.10 FUEL GAUGE .................................................. 44
			11.2.11 GEAR RANGE INDICATOR ........................................ 44
			11.2.12 TRANSMISSION PRESSURE WARNING LIGHT ......................... 44
		11.3 SWITCHES ........................................................... 45
			11.3.1 START KEY SWITCH ............................................. 45
			11.3.2 WORK LIGHT SWITCH ............................................ 46
			11.3.3 HORN SWITCH .................................................. 46
			11.3.4 ETHER START SWITCH ........................................... 46
			11.3.5 ELECTRICAL SYSTEM MASTER SWITCH .............................. 46
			11.3.6 CAB SWITCHES ................................................. 47
		11.4 SEAT, SEAT BELT AND ARM RESTS ...................................... 49
			11.4.1 SEAT WITH ADJUSTABLE SEAT BELT ............................... 49
			11.4.2 SEAT WITH RETRACTABLE SEAT BELT .............................. 49
			11.4.3 SEAT BELT .................................................... 49
			11.4.4 ARM RESTS..................................................... 50
		11.5 CONTROL LEVERS AND PEDALS .......................................... 51
			11.5.1 FUEL CONTROL LEVER ........................................... 51
			11.5.2 TRANSMISSION STEERING LEVER .................................. 51
			11.5.3 SAFETY LOCK LEVER............................................. 52
			11.5.4 LEFT PEDAL SECONDARY BRAKE.................................... 52
			11.5.5 BRAKE AND DECELERATOR PEDAL .................................. 53
			11.5.6 BRAKE PEDAL LOCK ............................................. 53
			11.5.7 BLADE CONTROL LEVER........................................... 53
			11.5.8 RIPPER CONTROL LEVER.......................................... 56
			11.5.9 CAB CONTROLS.................................................. 57
	12. OPERATION................................................................ 58
		12.1 CHECKS BEFORE STARTING ENGINE ...................................... 58
			12.1.1 WALK AROUND CHECK ............................................ 58
			12.1.2 CHECK BEFORE STARTING ........................................ 59
			12.1.3 OPERATIONS AND CHECKS BEFORE STARTING  ENGINE ................ 64
		12.2 STARTING ENGINE .................................................... 66
			12.2.1 NORMAL STARTING .............................................. 66
			12.2.2 COLD WEATHER STARTING ........................................ 68
		12.3 OPERATIONS AND CHECKS AFTER ENGINE  STARTS ......................... 70
		12.4 MOVING MACHINE ..................................................... 72
		12.5 SHIFTING GEAR ...................................................... 74
		12.6 SHIFTING BETWEEN FORWARD AND REVERSE ............................... 75
		12.7 STEERING MACHINE ................................................... 77
			12.7.1 NORMAL TURNING................................................ 77
			12.7.2 TURNING WHILE DESCENDING A SLOPE.............................. 78
		12.8 STOPPING MACHINE ................................................... 79
		12.9 PRECAUTIONS FOR OPERATION .......................................... 80
			12.9.1 METHOD FOR USING STEERING CLUTCH.............................. 80
			12.9.2 PERMISSIBLE WATER DEPTH....................................... 80
			12.9.3 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS................... 81
			12.9.4 PRECAUTIONS ON SLOPES......................................... 81
		12.10 WORK POSSIBLE USING BULLDOZER ..................................... 81
			12.10.1 DOZING ...................................................... 81
			12.10.2 SMOOTHING.................................................... 81
			12.10.3 CUTTING INTO HARD/ FROZEN GROUND OR DITCH ING ............... 82
		12.11 PARKING MACHINE ................................................... 83
		12.12 CHECK AFTER FINISHING WORK......................................... 84
		12.13 STOPPING ENGINE ................................................... 85
		12.14 CHECK AFTER STOPPING ENGINE ....................................... 86
		12.15 LOCKING ........................................................... 87
			12.15.1 ROPS CANOPY ................................................. 87
			12.15.2 ROPS CAB .................................................... 87
		12.16 TIPS FOR LONGER UNDERCARRIAGE LIFE ................................ 88
			12.16.1 OPERATION METHOD ............................................ 88
			12.16.2 INSPECTION AND ADJUSTMENT ................................... 89
			12.16.3 INSPECTION AND REPAIR ....................................... 89
	13. TRANSPORTATION........................................................... 91
		13.1 LOADING, UNLOADING WORK ............................................ 91
		13.2 PRECAUTIONS FOR LOADING ............................................ 91
		13.3 PRECAUTIONS FOR TRANSPORTATION ..................................... 92
	14. COLD WEATHER OPERATIONS ................................................. 93
		14.1 PRECAUTIONS FOR LOW TEMPERATURE .................................... 93
			14.1.1 FUEL AND LUBRICANTS .......................................... 93
			14.1.2 COOLANT....................................................... 93
			14.1.3 BATTERY ...................................................... 93
		14.2 AFTER COMPLETION OF WORK ........................................... 94
		14.3 AFTER COLD WEATHER ................................................. 94
	15. LONG TERM STORAGE (MORE THAN ONE MONTH).................................. 95
		15.1 BEFORE STORAGE ..................................................... 95
		15.2 DURING STORAGE ..................................................... 95
		15.3 AFTER STORAGE ...................................................... 95
	16. TROUBLESHOOTING.......................................................... 96
		16.1 AFTER RUNNING OUT OF FUEL .......................................... 96
		16.2 IF BATTERY IS DISCHARGED ........................................... 96
			16.2.1 STARTING ENGINE WITH BOOSTER CABLE ........................... 96
		16.3 OTHER TROUBLE ...................................................... 98
			16.3.1 ELECTRICAL SYSTEM ............................................ 98
			16.3.2 CHASSIS....................................................... 98
			16.3.3 ENGINE........................................................ 99
		16.4 METHODS OF TOWING MACHINE...........................................100
MAINTENANCE .....................................................................101
	17. GUIDES TO MAINTENANCE ...................................................102
	18. OUTLINES OF SERVICE .....................................................104
		18.1 OUTLINE OF OIL, FUEL, COOLANT ......................................104
			18.1.1 OIL ..........................................................104
			18.1.2 FUEL .........................................................104
			18.1.3 COOLANT ......................................................105
			18.1.4 GREASE .......................................................105
			18.1.5 STORING OIL AND FUEL .........................................105
			18.1.6 FILTERS.......................................................105
		18.2 RELATING TO ELECTRICAL SYSTEM ......................................106
	19. WEAR PARTS LIST..........................................................107
	20. USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT  TEMPERATURE ....108
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANT ....................108
			20.1.1 D32E-1, D32P-1, D38E-1 OR D38P-1..............................108
			20.1.2 D39E-1 OR D39P-1 .............................................109
			20.1.3 ABBREVIATIONS ................................................110
		20.2 COOLING SYSTEM .....................................................111
			20.2.1 GENERAL ......................................................111
			20.2.2 WATER ........................................................111
			20.2.3 ANTIFREEZE....................................................112
			20.2.4 INHIBITORS/CONDITIONERS ......................................113
		20.3 FUEL SYSTEM ........................................................114
			20.3.1 GENERAL ......................................................114
			20.3.2 DIESEL FUEL SPECIFICATIONS ...................................114
	21. STANDARD TIGHTENING TORQUES .............................................115
		21.1 INTRODUCTION OF NECESSARY TOOLS ....................................115
		21.2 BOLT IDENTIFICATION CHART ..........................................116
			21.2.1 GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE ..................117
			21.2.2 GRADE 8 PHOSPHATE COATED HARDWARE ............................118
			21.2.3 STANDARD METRIC FASTENERS ....................................118
		21.3 HYDRAULIC TUBES AND FITTINGS .......................................119
		21.4 HOSE CLAMPS ........................................................119
		21.5 SPLIT FLANGE CONNECTIONS............................................119
	22. PERIODIC REPLACEMENT OF CRITICAL PARTS ..................................120
	23. MAINTENANCE SCHEDULE CHART ..............................................123
	24. SERVICE PROCEDURE .......................................................126
		24.1 INITIAL 10 HOURS SERVICE ...........................................126
			24.1.1 BLADE CUTTING EDGE HARDWARE ..................................126
			24.1.2 TRACK SHOE BOLT TORQUE .......................................126
		24.2 INITIAL 50 HOURS SERVICE............................................127
			24.2.1 REPLACING DRIVE TRAIN PRESSURE FILTER.........................127
			24.2.2 SERVICING THE DRIVE TRAIN SUCTION STRAINER....................128
			24.2.3 TRACK TENSION AND ADJUSTMENT .................................129
		24.3 EVERY 10 HOURS SERVICE (CHECK BEFORE  STARTING) ....................131
			24.3.1 CHECK RADIATOR COOLANT LEVEL .................................131
			24.3.2 CHECK ENGINE CRANKCASE OIL LEVEL .............................131
			24.3.3 CHECK EQUIPMENT SYSTEM HYDRAULIC OIL LEVEL ...................132
			24.3.4 FILL FUEL TANK ...............................................132
			24.3.5 DRAIN FUEL FILTER WATER SEPARATOR ............................133
			24.3.6 OPEN FUEL SHUT OFF VALVE .....................................133
			24.3.7 CLEAN PRE-CLEANER HOOD .......................................133
			24.3.8 CHECK BRAKE PEDAL TRAVEL .....................................134
			24.3.9 PERFORM GROUND LEVEL INSPECTION ..............................134
		24.4 EVERY 50 HOURS SERVICE .............................................136
			24.4.1 CHECK OIL LEVEL IN DRIVE TRAIN ...............................136
			24.4.2 LUBRICATION ..................................................136
		24.5 EVERY 100 HOURS ....................................................137
			24.5.1 BLADE CUTTING EDGE HARDWARE ..................................137
		24.6 EVERY 250 HOURS SERVICE ............................................138
			24.6.1 REPLACE ENGINE OIL FILTER ....................................138
			24.6.2 CHANGE ENGINE CRANKCASE OIL ..................................139
			24.6.3 CHECKING FINAL DRIVE OIL LEVEL ...............................139
			24.6.4 REPLACE FUEL FILTER WATER SEPARATOR ..........................140
			24.6.5 CHECK ENGINE DRIVE BELT FOR WEAR .............................141
			24.6.6 CHECK OPERATION OF THE DECELERATOR ...........................141
			24.6.7 REVERSE REVERSIBLE FAN BLADES ................................141
		24.7 EVERY 500 HOURS SERVICE ............................................142
			24.7.1 CHECK HOSE CLAMP TORQUE ......................................142
			24.7.2 CHECK ROPS MOUNTING BOLT NUT TORQUE ..........................142
			24.7.3 CHECK TRACK SHOE BOLT TORQUE .................................142
			24.7.4 INSPECT MOUNTED EQUIPMENT ....................................142
			24.7.5 RADIATOR LEAKS ...............................................142
			24.7.6 OUTSIDE OF RADIATOR CORE .....................................142
		24.8 EVERY 1000 HOURS SERVICE ...........................................143
			24.8.1 SERVICE THE DRIVE TRAIN SUCTION STRAINER .....................143
			24.8.2 CHANGING DRIVE TRAIN SYSTEM OIL...............................144
			24.8.3 DRAIN, FLUSH AND REFILL FINAL DRIVE OIL.......................144
			24.8.4 REPLACE DRIVE TRAIN SYSTEM BREATHER...........................144
			24.8.5 REPLACING DRIVE TRAIN PRESSURE FILTER ........................145
			24.8.6 REPLACE HYDRAULIC SYSTEM RETURN FILTER .......................146
			24.8.7 CLEAN NEUTRAL VALVE INLET STRAINER ...........................147
			24.8.8 LUBRICATE VALVE CAM PLATE ....................................147
			24.8.9 CHECK TORQUE OF SPROCKET MOUNTING BOLTS ......................147
		24.9 EVERY 2000 HOURS SERVICE ...........................................148
			24.9.1 DRAIN, FLUSH AND REFILL COOLING SYSTEM .......................148
			24.9.2 CLEAN HYDRAULIC SUCTION STRAINER .............................149
			24.9.3 CLEAN HYDRAULIC RESERVOIR RELIEF VALVE .......................149
			24.9.4 CHANGE HYDRAULIC SYSTEM FLUID ................................150
		24.10 PERIODIC ..........................................................151
			24.10.1 CLEAN AIR CLEANER ELEMENTS ..................................151
			24.10.2 CLEAN FUEL TANK STRAINER ....................................155
			24.10.3 DRAIN FUEL TANK SEDIMENT BOWL ...............................155
			24.10.4 REPLACE IN-LINE FUEL STRAINER ...............................156
			24.10.5 LUBRICATE ...................................................156
			24.10.6 SEAT BELT ...................................................157
		24.11 WHEN REQUIRED .....................................................158
			24.11.1 FAN BELT ....................................................158
			24.11.2 ELECTRICAL SYSTEM............................................158
			24.11.3 ETHER START..................................................163
			24.11.4 VENTING THE FUEL SYSTEM .....................................165
			24.11.5 ANGLING FRAME TO BLADE ......................................165
			24.11.6 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES ..........166
			24.11.7 TRACK TENSION AND ADJUSTMENT ................................167
			24.11.8 ADJUST FRONT IDLER CLEARANCE.................................169
			24.11.9 CLEAN OR REPLACE CAB FRESH AIR FILTER........................169
			24.11.10 GREASE CAB DOOR HINGES .....................................169
			24.11.11 WIPER WASHER FLUID LEVEL ...................................170
		24.12 SEASONAL PREPARATION ..............................................171
			24.12.1 GENERAL .....................................................171
			24.12.2 OUTSIDE SOURCE OF HEAT ......................................171
			24.12.3 LUBRICATION .................................................171
			24.12.4 FUEL SYSTEM..................................................171
			24.12.5 COOLING SYSTEM ..............................................171
			24.12.6 ELECTRICAL SYSTEM............................................172
		24.13 TURBOCHARGER: D38E-1, D38P-1, D39E-1 AND D39P-1 ...................173
			24.13.1 PRECAUTIONS..................................................173
			24.13.2 PRIMING......................................................174
SPECIFICATIONS ..................................................................175
	25. SPECIFICATIONS ..........................................................176
		25.1 D32E-1, D32P-1 SPECIFICATIONS ......................................176
		25.2 D38E-1, D38P-1 SPECIFICATIONS ......................................177
		25.3 D39E-1, D39P-1 SPECIFICATIONS ......................................178
		25.4 D32E-1 DIMENSIONS ..................................................179
		25.5 D32P-1 DIMENSIONS ..................................................180
		25.6 D38E-1 DIMENSIONS ..................................................181
		25.7 D38P-1 DIMENSIONS ..................................................182
		25.8 D39E-1 DIMENSIONS ..................................................183
		25.9 D39P-1 DIMENSIONS ..................................................184
OPTIONS, ATTACHMENTS ............................................................185
	26. PRECAUTIONS RELATED TO SAFETY ...........................................186

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