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KOMATSU D32EP-1A D38EP-1A D39EP-1A CRAWLER TRACTOR SERVICE REPAIR MANUAL(CEBM004302) KOMATSU D32EP-1A – PDF DOWNLOAD
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- KOMATSU D32EP-1A D38EP-1A D39EP-1A CRAWLER TRACTOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM004302
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Description
KOMATSU D32EP-1A D38EP-1A D39EP-1A CRAWLER TRACTOR SERVICE REPAIR MANUAL(CEBM004302) KOMATSU D32EP-1A
KOMATSU D32EP-1A D38EP-1A D39EP-1A CRAWLER TRACTOR SERVICE REPAIR MANUAL(CEBM004302) KOMATSU D32EP-1A – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D32EP-1A D38EP-1A D39EP-1A CRAWLER TRACTOR SERVICE REPAIR MANUAL(CEBM004302) KOMATSU D32EP-1A
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU D32EP-1A D38EP-1A D39EP-1A CRAWLER TRACTOR SERVICE REPAIR MANUAL(CEBM004302) KOMATSU D32EP-1A
MAIN MENU................................................................ 0 COVER.................................................................... 1 CONTENTS................................................................. 2 FOREWORD................................................................. 2 SAFETY............................................................... 11 SAFETY NOTICE.................................................... 11 GENERAL.............................................................. 13 HOW TO READ THE SHOP MANUAL.......................................... 14 HOISTING INSTRUCTIONS................................................ 15 COATING MATERIALS.................................................... 16 STANDARD TIGHTENING TORQUE........................................... 18 ELECTRIC WIRE CODE................................................... 20 CONVERSION TABLES.................................................... 21 01 GENERAL............................................................... 27 VIEW OF MACHINE...................................................... 28 DIMENSIONAL DRAWINGS................................................. 29 D32E-1A.......................................................... 29 D32P-1A.......................................................... 30 D38E-1A.......................................................... 31 D38P-1A.......................................................... 32 D39E-1A.......................................................... 33 D39P-1A.......................................................... 34 SPECIFICATIONS....................................................... 35 D32E/P-1A........................................................ 35 D38E/P-1A........................................................ 37 D39E/P-1A........................................................ 39 WEIGHT TABLE......................................................... 41 USE OF FUEL, COOLANT AND LUBRICANTS.................................. 42 PROPER SELECTION................................................. 42 D32E-1A, D32P-1A, D38E-1A OR D38P-1A......................... 42 D39E-1A OR D39P-1A........................................... 42 ABBREVIATIONS................................................ 43 ENGINE OIL SPECIFICATIONS........................................ 43 NORMAL OPERATION............................................. 43 ARCTIC OPERATION............................................. 43 DRIVE TRAIN OIL SPECIFICATIONS................................... 44 TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS.... 44 EQUIPMENT SYSTEM OIL SPECIFICATIONS.............................. 44 FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPECIFICATIONS............ 44 COOLING SYSTEM................................................... 44 FUEL SYSTEM...................................................... 44 10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS........................... 45 ENGINE MOUNT......................................................... 47 ENGINE CONTROLS...................................................... 48 FUEL LINES........................................................... 49 RADIATOR, OIL COOLER................................................. 50 DRIVE TRAIN.......................................................... 51 GENERAL.......................................................... 51 OUTLINE.......................................................... 51 SCHEMATIC........................................................ 53 PIPING DIAGRAM................................................... 54 OUTLINE...................................................... 54 PRESSURE PORTS............................................... 55 TORQUE CONVERTER................................................. 56 TWO PIECE HOUSING............................................ 56 OUTLINE...................................................... 57 ONE PIECE HOUSING............................................ 58 OUTLINE...................................................... 59 TRANSMISSION CONTROL............................................. 60 OUTLINE...................................................... 60 DRIVE SHAFT...................................................... 61 TRANSMISSION MOUNTING............................................ 62 TRANSMISSION..................................................... 63 OUTLINE...................................................... 64 CLUTCH OPERATION............................................. 64 GEAR SHIFT OPERATION......................................... 65 VALVES AND MANIFOLD MOUNTING................................. 67 DIRECTIONAL (INPUT) CLUTCH SHAFT............................. 68 RANGE (OUTPUT) CLUTCH SHAFT.................................. 70 COUNTERSHAFT................................................. 72 REVERSE IDLER SHAFT.......................................... 73 PRESSURE REGULATOR VALVE..................................... 74 RANGE SELECTOR VALVE......................................... 76 RATE OF RISE VALVE........................................... 78 TASC VALVE....................................................... 81 DESCRIPTION.................................................. 82 THEORY OF OPERATION.......................................... 82 DIRECTION.................................................... 83 RANGE........................................................ 83 STEERING..................................................... 83 NEUTRAL START VALVE.............................................. 84 CHARGE AND SCAVENGE PUMP......................................... 85 SUCTION STRAINER............................................. 86 BRAKE CYLINDER VALVE............................................. 87 OPERATION.................................................... 88 STEERING DRIVE................................................... 89 OUTLINE...................................................... 91 STEERING BRAKE CYLINDER...................................... 93 STEERING CYLINDER............................................ 95 BRAKE OR STEERING SHOES...................................... 96 FINAL DRIVE...................................................... 97 DESCRIPTION.................................................. 99 UNDERCARRIAGE........................................................100 GENERAL..........................................................100 TRACK ROLLER.....................................................102 TRACK SPRING.....................................................104 TRACK ADJUSTER...................................................106 DESCRIPTION..................................................107 FRONT IDLER......................................................108 TOP IDLER........................................................110 TRACK CHAIN......................................................111 MAIN FRAME...........................................................113 EQUIPMENT HYDRAULICS.................................................114 HYDRAULIC DIAGRAM................................................114 HYDRAULIC SCHEMATIC..............................................114 DESCRIPTION......................................................115 BLADE CONTROL................................................115 RIPPER CONTROL...............................................116 WORK EQUIPMENT CONTROLS......................................117 RESERVOIR AND RETURN FILTER......................................118 PUMP.............................................................119 DESCRIPTION..................................................119 BLADE AND/OR RIPPER VALVE BANK...................................120 MAIN RELIEF VALVE............................................122 LOAD CHECK VALVE.............................................122 ANTI CAVITATION - LOAD CHECK VALVE...........................123 BLADE LIFT VALVE SECTION.....................................124 BLADE TILT VALVE SECTION.....................................126 BLADE ANGLE OR RIPPER VALVE SECTION..........................128 BLADE CYLINDERS..................................................130 BLADE LIFT AND TILT..........................................130 BLADE ANGLE..................................................131 RIPPER CYLINDERS.................................................132 CAB..................................................................133 BLADE EQUIPMENT......................................................134 C FRAME WEAR BARS................................................134 C FRAME PIN SHIMS............................................135 ANGLING FRAME................................................135 TRUNNION MOUNTING............................................137 ELECTRICAL SYSTEM....................................................139 WIRING SCHEMATIC.................................................139 ELECTRICAL COMPONENTS............................................141 DESCRIPTION..................................................141 STARTING AND CHARGING GROUP..................................141 LIGHTING GROUP...............................................141 INDICATOR GROUP..............................................141 ACCESSORY GROUP..............................................141 INSTRUMENT PANEL.................................................142 OUTLINE......................................................142 OPERATION....................................................142 GAUGE DISPLAY................................................143 SPECIAL TORQUE CHART.................................................144 20 TESTING, ADJUSTING AND TROUBLESHOOTING................................145 STANDARD VALUE TABLES FOR ENGINE.....................................146 STANDARD VALUE TABLE FOR CHASSIS.....................................149 TOOLS FOR TESTING AND ADJUSTING......................................154 ENGINE...............................................................155 EXHAUST COLOR........................................................158 BELT TENSION.........................................................159 STALL SPEEDS.........................................................160 FUEL CONTROL LINKAGE.................................................161 TASC VALVE...........................................................164 BRAKE AND DECELERATOR PEDAL..........................................165 SECONDARY BRAKE PEDAL................................................168 SAFETY LOCK LEVER....................................................169 BLADE EQUIPMENT LEVER................................................170 REAR EQUIPMENT LEVER.................................................172 DRIVE TRAIN PRESSURES................................................173 BRAKE CYLINDER RELEASE...............................................174 TRANSMISSION CLUTCH..................................................175 WORK EQUIPMENT.......................................................176 SERVICE DIAGNOSIS....................................................179 30 DISASSEMBLY AND ASSEMBLY..............................................191 METHOD OF USING MANUAL...............................................193 PRECAUTIONS WHEN CARRYING OUT OPERATION..........................197 SPECIAL TOOL LIST....................................................200 ENGINE CRANKCASE GUARD...............................................202 REMOVAL..........................................................202 INSTALLATION.....................................................202 TRANSMISSION GUARD...................................................203 REMOVAL..........................................................203 INSTALLATION.....................................................203 ENGINE HOOD..........................................................204 REMOVAL..........................................................204 INSTALLATION.....................................................204 ROPS CANOPY..........................................................205 REMOVAL..........................................................205 INSTALLATION.....................................................205 DASHBOARD............................................................206 REMOVAL..........................................................206 INSTALLATION.....................................................208 OPERATOR’S SEAT......................................................209 REMOVAL..........................................................209 INSTALLATION.....................................................209 FUEL TANK............................................................210 REMOVAL..........................................................210 INSTALLATION.....................................................212 BATTERY BOX..........................................................214 REMOVAL..........................................................214 INSTALLATION.....................................................218 BRAKE PEDAL CONNECTIONS..............................................219 GENERAL..........................................................219 BRAKE AND DECELERATOR PEDAL......................................220 BRAKE PAD........................................................225 SECONDARY BRAKE PEDAL............................................229 RADIATOR.............................................................232 REMOVAL..........................................................232 DISASSEMBLY......................................................234 REASSEMBLY.......................................................239 INSTALLATION.....................................................243 ENGINE...............................................................247 REMOVAL..........................................................247 ENGINE MOUNTING..................................................252 INSTALLATION.....................................................254 TORQUE CONVERTER.....................................................255 REMOVAL..........................................................255 INSTALLATION.....................................................258 TWO PIECE HOUSING STYLE..........................................259 ONE PIECE HOUSING STYLE..........................................279 CHARGE AND SCAVENGE PUMP.............................................292 REMOVAL..........................................................292 INSTALLATION.....................................................292 DISASSEMBLY......................................................294 REASSEMBLY.......................................................298 DRIVE SHAFT..........................................................302 SERVICE..........................................................302 TRANSMISSION.........................................................304 REMOVAL..........................................................304 MOUNTING TRANSMISSION............................................308 INSTALLATION.....................................................311 COMPLETE ASSEMBLY................................................312 DIRECTIONAL (INPUT) SHAFT........................................328 COUNTERSHAFT.....................................................342 RANGE (OUTPUT) SHAFT.............................................345 REVERSE IDLER SHAFT..............................................366 MAIN REGULATOR VALVE.............................................369 RANGE SELECTOR VALVE.............................................376 RATE OF RISE VALVE...............................................382 TASC VALVE...........................................................389 REMOVAL..........................................................389 INSTALLATION.....................................................391 DISASSEMBLY......................................................393 REASSEMBLY.......................................................401 ADJUSTMENT.......................................................409 NEUTRAL START VALVE..................................................410 REMOVAL..........................................................410 INSTALLATION.....................................................410 SERVICE..........................................................411 STEERING DRIVE.......................................................413 REMOVAL..........................................................413 INSTALLATION.....................................................415 DISASSEMBLY......................................................418 REASSEMBLY.......................................................426 BRAKE CYLINDER.......................................................444 REMOVAL OR INSTALLATION..........................................445 DISASSEMBLY......................................................445 REASSEMBLY.......................................................446 STEERING CYLINDER....................................................448 REMOVAL OR INSTALLATION..........................................448 DISASSEMBLY......................................................449 REASSEMBLY.......................................................450 BRAKE/STEERING SHOES.................................................453 REMOVAL OR INSTALLATION..........................................453 APPLY SHOES......................................................454 BACK UP SHOES....................................................455 BRAKE CYLINDER VALVE.................................................456 REMOVAL..........................................................456 INSTALLATION.....................................................457 DISASSEMBLY......................................................459 REASSEMBLY.......................................................460 FINAL DRIVE..........................................................461 REMOVAL..........................................................461 INSTALLATION.....................................................464 DISASSEMBLY......................................................466 REASSEMBLY.......................................................469 EQUIPMENT PUMP.......................................................475 REMOVAL..........................................................475 INSTALLATION.....................................................475 DISASSEMBLY......................................................477 REASSEMBLY.......................................................479 EQUIPMENT CONTROL VALVE..............................................482 REMOVAL..........................................................482 INSTALLATION.....................................................489 COMPLETE ASSEMBLY................................................490 SYSTEM RELIEF VALVE..............................................494 BLADE LIFT SECTION...............................................498 BLADE TILT SECTION...............................................504 BLADE ANGLE OR RIPPER SECTION....................................508 BLADE CYLINDERS......................................................512 REMOVAL..........................................................512 INSTALLATION.....................................................514 DISASSEMBLY......................................................515 REASSEMBLY.......................................................518 RIPPER CYLINDERS.....................................................520 REMOVAL..........................................................520 INSTALLATION.....................................................520 DISASSEMBLY......................................................521 BUSHINGS.........................................................524 REASSEMBLY.......................................................525 UNDERCARRIAGE WEAR LIMITS............................................528 SPECIFICATIONS - D32E/P-1A OR D38E/P-1A..........................528 SPECIFICATIONS - D39E/P-1A.......................................529 GENERAL..........................................................530 TRACK SHOE GROUSER HEIGHT........................................530 LINK HEIGHT......................................................530 BUSHING OUTSIDE DIAMETER.........................................530 INTERNAL PIN AND BUSHING WEAR (PITCH)............................531 FRONT IDLER FLANGE HEIGHT........................................531 TRACK ROLLER ROLLING DIAMETER....................................531 TOP IDLER ROLLING DIAMETER.......................................531 TRACK FRAME..........................................................532 REMOVAL..........................................................532 INSTALLATION.....................................................533 FRONT IDLER..........................................................534 REMOVAL..........................................................534 INSTALLATION.....................................................535 DISASSEMBLY......................................................540 CLEARANCES.......................................................544 REASSEMBLY.......................................................546 TRACK ADJUSTER.......................................................551 SERVICE..........................................................552 RECOIL SPRING........................................................556 REPLACEMENT......................................................556 TRACK ROLLER.........................................................564 REMOVAL..........................................................564 INSTALLATION.....................................................565 DISASSEMBLY......................................................566 CLEARANCES.......................................................570 REASSEMBLY.......................................................572 TOP IDLER............................................................576 REMOVAL..........................................................576 INSTALLATION.....................................................577 DISASSEMBLY......................................................579 REASSEMBLY.......................................................583 METAL TYPE FACE SEALS............................................588 SEAL INSTALLATION................................................589 FRONT CROSSBAR.......................................................591 REMOVAL..........................................................591 INSTALLATION.....................................................593 REAR RIGID BAR.......................................................595 REPLACEMENT......................................................595 TRACK FRAME ALIGNMENT................................................596 TRACK CHAIN..........................................................601 MAINTENANCE......................................................603 REMOVAL..........................................................603 INSTALLATION.....................................................604 COMPLETE CHAIN REBUILD...........................................604 SINGLE JOINT REBUILD.............................................606 MOUNTED EQUIPMENT....................................................610 C FRAME RUB BARS.................................................610 ANGLING FRAME....................................................611 C FRAME PIN SHIMS................................................613 C FRAME BUSHINGS.................................................614 BLADE BUSHINGS...................................................615 90 OTHERS................................................................617 DRIVE TRAIN SCHEMATIC................................................618 ELECTRICAL WIRING DIAGRAM............................................619
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]
