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KOMATSU D32EP-1 D38EP-1 D39EP-1 BULLDOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU D32EP-1 D38EP-1 D39EP-1 BULLDOZER SERVICE REPAIR MANUAL
- Publication Number:CEBM000301
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Description
KOMATSU D32EP-1 D38EP-1 D39EP-1 BULLDOZER SERVICE REPAIR MANUAL
KOMATSU D32EP-1 D38EP-1 D39EP-1 BULLDOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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KOMATSU D32EP-1 D38EP-1 D39EP-1 BULLDOZER SERVICE REPAIR MANUAL
- 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 D32EP-1 D38EP-1 D39EP-1 BULLDOZER SERVICE REPAIR MANUAL
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
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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