Komatsu D32E/P-1 D38E/P-1 D39E/P-1 Bulldozer Shop Manual CEBM000301 PDF

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Komatsu D32E/P-1 D38E/P-1 D39E/P-1 Bulldozer Shop Manual CEBM000301 – PDF DOWNLOAD

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Komatsu D32E/P-1 D38E/P-1 D39E/P-1 Bulldozer Shop Manual CEBM000301 – PDF DOWNLOAD 

Language : English
Pages : 629
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu D32E/P-1 D38E/P-1 D39E/P-1 Bulldozer Shop Manual CEBM000301 – PDF DOWNLOAD 

D32E/P-1 – PO75501 andup
D38E/P4 n PO85501 andup
D39E/P-1 – PO95501 andup

GENERAL:

• 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.

Electrical system is 12 volt negative ground. When using jumper cables, precautions must be taken to minimize
chances of injury or damage to electrical parts.

1. Attach one end of jumper cable to positive terminal of booster battery and other end to positive terminal of machine
battery.
2. Attach one end of second cable to negative terminal of booster battery and other end to machine’s frame away
from the battery.
3. To remove cables, reverse above sequence exactly to avoid sparks near the battery. A frozen battery can explode
when the booster cables are attached.

NEVER check battery charge by placing a metal object across the battery posts. The sparks could cause an explosion.
Use a voltmeter for checking battery state of charge.

TABLE OF CONTENTS:

Komatsu D32E/P-1 D38E/P-1 D39E/P-1 Bulldozer Shop Manual CEBM000301 – PDF DOWNLOAD

D32E/P-1 – PO75501 andup
D38E/P4 n PO85501 andup
D39E/P-1 – PO95501 andup

MAIN MENU 0
SECTION INDEX 9
INDEX TO SECTIONS 10
SECTION 1 – INTRODUCTION 11
SAFETY PRECAUTIONS 12
GENERAL 12
BEFORE STARTING THE ENGINE 12
OPERATION 13
MAINTENANCE 15
SHUTDOWN 17
SAFETY PRODUCT GRAPHICS AND LOCATION 18
SERVICE INFORMATION 20
GENERAL 20
PIN AND SERIAL NUMBERS 20
SERVICE TOOL AND PARTS 21
INSPECTION AND REPAIR 21
LOCTITE USAGE 22
SURFACE PREPARATION 22
APPLICATION 22
SETTING TIME 23
REMOVAL 23
APPLICATIONS AT LOW TEMPERATURES 23
SECTION 2 – MISCELLANEOUS 25
DIMENSIONS 26
D32E-1 DIMENSIONS 26
D32P-1 DIMENSIONS 27
D38E-1 DIMENSIONS 28
D38P-1 DIMENSIONS 29
D39E-1 DIMENSIONS 30
D39P-1 DIMENSIONS 31
SPECIFICATIONS 32
D32E-1, D32P-1 SPECIFICATIONS 32
D38E-1, D38P-1 SPECIFICATIONS 33
D39E-1, D39P-1 SPECIFICATIONS 34
CAPACITIES AND LUBRICANTS 35
CAPACITIES AND LUBRICANTS 35
SPECIAL TORQUES 37
STANDARD TORQUES 39
INTRODUCTION OF TOOLS 39
BOLT IDENTIFICATION CHART 40
GRADE 5 AND 8 NON-PHOSPHATE HARDWARE 41
GRADE 8 PHOSPHATE COATED HARDWARE 42
STANDARD METRIC FASTENERS 42
HOSE CLAMPS 43
SPLIT FLANGE CONNECTIONS 43
SECTION 6 – COOLING 45
GENERAL 46
DESCRIPTION 46
OPERATION 46
SPECIFICATIONS 46
SERVICE DIAGNOSIS 47
RADIATOR 48
REMOVAL 50
DISASSEMBLY 55
REASSEMBLY 59
INSTALLATION 63
SECTION 7 – DRIVE TRAIN 69
GENERAL 70
SPECIFICATIONS 70
DRIVE TRAIN SCHEMATIC 71
DESCRIPTION 73
OPERATION 73
PRESSURES 75
BRAKE CYLINDER RELEASE 76
TRANSMISSION CLUTCH 76
STALL SPEEDS 77
SECTION 7B – TORQUE CONVERTER 79
GENERAL 80
DESCRIPTION 80
OPERATION 80
SPECIAL TOOLS 80
SPECIFICATIONS 82
SERVICE DIAGNOSIS 82
REMOVAL 83
DISASSEMBLY 91
COMPLETE ASSEMBLY 91
CONVERTER ASSEMBLY 95
REAR HOUSING 99
REASSEMBLY 102
REAR HOUSING 102
CONVERTER ASSEMBLY 106
COMPLETE ASSEMBLY 110
INSTALLATION 117
SECTION 7C – TRANSMISSION 125
GENERAL 126
DESCRIPTION 127
OPERATION 127
SPECIFICATIONS 129
REMOVAL 130
COMPLETE ASSEMBLY 146
DISASSEMBLY 147
REASSEMBLY 152
DIRECTIONAL (INPUT) SHAFT 162
GENERAL 162
PISTON RETURN SPRING CRITERION 164
DISASSEMBLY 164
REASSEMBLY 169
COUNTERSHAFT 178
GENERAL 178
DISASSEMBLY 179
REASSEMBLY 179
RANGE (OUTPUT) SHAFT 181
GENERAL 181
PISTON RETURN SPRING CRITERION 183
DISASSEMBLY 183
REASSEMBLY 190
REVERSE IDLER SHAFT 204
GENERAL 204
DISASSEMBLY 205
REASSEMBLY 205
MAIN REGULATOR VALVE 207
DESCRIPTION 208
THEORY OF OPERATION 208
SPECIFICATIONS 209
DISASSEMBLY 209
REASSEMBLY 212
RANGE SELECTOR VALVE 216
DESCRIPTION 217
THEORY OF OPERATION 217
SPECIFICATIONS 218
DISASSEMBLY 218
REASSEMBLY 220
RATE OF RISE VALVE 223
SPECIFICATIONS 228
DISASSEMBLY 229
REASSEMBLY 231
INSTALLATION 235
TRANSMISSION/ISTEERING VALVE 253
DESCRIPTION 255
THEORY OF OPERATION 255
SPECIFICATIONS 256
REMOVAL 257
DISASSEMBLY 259
REASSEMBLY 267
ADJUSTMENT 275
INSTALLATION 276
DRIVE SHAFT 279
SPECIFICATIONS 279
SERVICE 280
SECTION 7E – STEERING DRIVE 283
GENERAL 284
DESCRIPTION 284
OPERATION 284
SPECIFICATIONS 285
REMOVAL 286
DISASSEMBLY 296
BRAKE CYLINDER 306
SPECIFICATIONS 308
DISASSEMBLY 308
REASSEMBLY 310
STEERING CYLINDER 312
DESCRIPTION 313
DISASSEMBLY 313
REASSEMBLY 315
MOUNTING PLATE 317
SERVICE 318
BRAKE/STEERING SHOES 320
SPECIFICATIONS 322
SERVICE 322
BEARING CARRIER 325
SERVICE 325
PLANET GEAR CARRIER 328
SERVICE 328
REASSEMBLY 330
INSTALLATION 349
BRAKE ADJUSTMENT 360
BRAKE CYLINDER VALVE 363
GENERAL 363
SPECIFICATIONS 364
OPERATION 364
REMOVAL 365
DISASSEMBLY 367
REASSEMBLY 368
INSTALLATION 369
SECTION 7F – FINAL DRIVE 371
GENERAL 372
DESCRIPTION AND OPERATION 373
SPECIFICATION 373
SERVICE DIAGNOSIS 374
REMOVAL 375
DISASSEMBLY 377
D32E-1, D32P-1, D38E-1 OR D38P-1 378
D39E-1 OR D39P-1 381
REASSEMBLY 386
D32E-1, D32P-1, D38E-1 OR D38P-1 387
D39E-1 OR D39P-1 390
METAL TYPE FACE SEALS 394
SEAL INSPECTION 394
SEAL INSTALLATION 395
INSTALLATION 396
SECTION 8 – ELECTRICAL 399
GENERAL 400
DESCRIPTION 400
SPECIFICATIONS 400
SPECIAL TOOLS 400
TORQUE DATA 400
WIRING DIAGRAM 401
SECTION 10 – HYDRAULICS 403
GENERAL 404
DESCRIPTION 405
OPERATION 405
SPECIFICATIONS 406
SPECIAL TOOLS 406
WORK EQUIPMENT 407
BLADE EQUIPMENT LEVER 410
REAR EQUIPMENT LEVER 411
SECTION 10A – PUMP AND MOTORS 413
CHARGE AND SCAVENGE PUMP 414
GENERAL 415
REMOVAL 416
DISASSEMBLY 417
INSPECTION 421
REASSEMBLY 421
INSTALLATION 425
EQUIPMENT PUMP 426
GENERAL 427
REMOVAL 428
DISASSEMBLY 429
INSPECTION 431
REASSEMBLY 431
INSTALLATION 433
SECTION 10B – CONTROL VALVE 435
REMOVAL 436
COMPLETE ASSEMBLY 444
DISASSEMBLY 444
REASSEMBLY 447
SYSTEM RELIEF VALVE 449
DISASSEMBLY 451
REASSEMBLY 452
BLADE LIFT SECTION 454
DISASSEMBLY 457
REASSEMBLY 458
BLADE TILT SECTION 463
DISASSEMBLY 465
REASSEMBLY 465
BLADE ANGLE OR RIPPER SECTION 468
DISASSEMBLY 468
REASSEMBLY 468
INSTALLATION 473
SECTION 10C – CYLINDERS 481
BLADE EQUIPMENT 482
SPECIFICATIONS 483
REMOVAL 483
DISASSEMBLY 485
REASSEMBLY 488
INSTALLATION 490
RIPPER 492
SPECIFICATIONS 493
REMOVAL 493
DISASSEMBLY 494
BUSHINGS 496
REASSEMBLY 497
INSTALLATION 500
SECTION 12 – POWER 501
ENGINE 502
STANDARD VALUE TABLE FOR ENGINE D32E AND D32P 502
STANDARD VALUE TABLE FOR ENGINE D38E AND D38P 503
STANDARD VALUE TABLE FOR ENGINE D39E AND D39P 504
REMOVAL 505
INSTALLATION 517
THROTTLE 528
ADJUSTMENT 528
FUEL CONTROL LINKAGE 531
SECTION 14 – SUSPENSION 533
GENERAL 534
DESCRIPTION 535
FRONT IDLER 535
TRACK ADJUSTER 535
TRACK SPRING 535
TRACK TOP IDLER 535
TRACK ROLLER 535
FRONT CROSSBAR 535
REAR RIGID BAR 535
MAINTENANCE 535
SERVICE DIAGNOSIS 536
WEAR LIMIT CHECKS 538
SPECIFICATIONS 538
GENERAL 540
TRACK SHOE GROUSER HEIGHT 540
LINK HEIGHT 540
BUSHING OUTSIDE DIAMETER 540
INTERNAL PIN AND BUSHING WEAR (PITCH) 541
FRONT IDLER FLANGE HEIGHT 541
TRACK ROLLER ROLLING DIAMETER 541
TOP IDLER ROLLING DIAMETER 541
FRONT IDLER 542
SPECIFICATIONS 543
REMOVAL 544
DISASSEMBLY 544
CLEARANCES 548
REASSEMBLY 550
INSTALLATION 554
TRACK ADJUSTER 559
SPECIFICATIONS 560
SERVICE 560
TOP IDLER 564
SPECIFICATIONS 565
REMOVAL 565
DISASSEMBLY 566
REASSEMBLY 569
INSTALLATION 572
TRACK ROLLER 574
SPECIFICATIONS 575
REMOVAL 575
DISASSEMBLY 576
CLEARANCES 579
REASSEMBLY 581
INSTALLATION 584
METAL TYPE FACE SEALS 585
SEAL INSPECTION 585
SEAL INSTALLATION 586
TRACK FRAME 588
REMOVAL 588
INSTALLATION 589
TRACK SPRING 590
SPECIFICATIONS 591
SPECIAL TOOLS 591
REPLACEMENT 592
FRONT CROSSBAR 599
REMOVAL 599
INSTALLATION 600
REAR RIGID BAR 603
REPLACEMENT 603
TRACK FRAME ALIGNMENT 604
SECTION 15 – TRACK CHAIN 609
SPLIT LINK TYPE CHAINS 610
SPECIFICATIONS 612
DESCRIPTION 613
MAINTENANCE 613
REMOVAL 614
INSTALLATION 614
COMPLETE CHAIN REBUILD 614
SINGLE TRACK CHAIN JOINT REBUILD 616
SECTION 17 – MOUNTED EQUIPMENT 621
C FRAME RUB BARS 622
MOUNTING 622
ANGLING FRAME 624
BUSHING REPLACEMENT 624
SPECIFICATIONS 625
ADJUSTING 625
C FRAME PIN 626
PIN SHIMS 626
C FRAME 627
BUSHING REPLACEMENT 627
BLADE BUSHINGS 628
BUSHING REPLACEMENT 628

S.V 14/12/24