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KOMATSU PLUS D32EP-1A, D38EP-1A, D39EP-1A CRAWLER TRACTOR OPERATION & MAINTENANCE MANUAL (CEAM004300) – PDF DOWNLOAD
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- KOMATSU PLUS D32EP-1A, D38EP-1A, D39EP-1A CRAWLER TRACTOR OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:CEAM004300
- SERIAL NUMBER:
D32E/P-1A – P076093 and up
D38E/P-1A – P086239 and up
D39E/P-1A – P096338 and up
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Description
KOMATSU PLUS D32EP-1A, D38EP-1A, D39EP-1A CRAWLER TRACTOR OPERATION & MAINTENANCE MANUAL (CEAM004300)
KOMATSU PLUS D32EP-1A, D38EP-1A, D39EP-1A CRAWLER TRACTOR OPERATION & MAINTENANCE MANUAL (CEAM004300) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PLUS D32EP-1A, D38EP-1A, D39EP-1A CRAWLER TRACTOR OPERATION & MAINTENANCE MANUAL (CEAM004300)
- 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 local 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 local distributor for the latest available information on your machine or for questions regarding information in this manual.Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.
- If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your distributor.
TABLE OF CONTENTS:
KOMATSU PLUS D32EP-1A, D38EP-1A, D39EP-1A CRAWLER TRACTOR OPERATION & MAINTENANCE MANUAL (CEAM004300)
MAIN MENU........................................................................... 0 COVER............................................................................... 1 INTRODUCTION........................................................................ 6 FORWARD......................................................................... 7 SAFETY INFORMATION.............................................................. 7 INTRODUCTION.................................................................... 8 INTENDED USE................................................................ 8 FEATURES.................................................................... 8 BREAKING IN THE MACHINE..................................................... 8 LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTION..................... 9 P.I.N. PLATE LOCATION....................................................... 9 ENGINE SERIAL NO. PLATE LOCATION............................................ 9 TABLE OF CONTENTS........................................................... 10 TABLE OF CONTENTS............................................................... 10 SAFETY.............................................................................. 16 WARNING LABELS.................................................................. 17 GENERAL PRECAUTIONS............................................................. 21 SAFETY RULES................................................................ 21 SAFETY FEATURES............................................................. 21 UNATHORIZED MODIFICATION.................................................... 21 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................... 21 ALWAYS APPLY LOCK WHEN LEAVING OPERATIORS SEAT.............................. 21 MOUNTING AND DISMOUNTING.................................................... 22 FIRE PREVENTION FOR FUEL AND OIL............................................ 22 CRUSHING OR CUTTING PREVENTION.............................................. 22 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES.............................. 22 ASBESTOS DUST HAZARD PREVENTION............................................. 23 FIRE EXTINGUISHER AND FIRST AID KIT......................................... 23 PRECAUTIONS FOR ATTACHMENTS................................................. 23 PRECAUTIONS FOR ROPS CANOPY OR CAB.......................................... 23 PRECAUTIONS DURING OPERATION.................................................... 24 BEFORE STARTING ENGINE...................................................... 24 SAFETY AT WORK SITE......................................................... 24 FIRE PREVENTION............................................................. 24 IN OPERATORS COMPARTMENT.................................................... 24 VENTILATION FOR ENCLOSED AREAS.............................................. 24 PRECAUTIONS FOR MIRROR AND LIGHTS........................................... 24 OPERATING MACHINE............................................................... 25 WHEN STARTING ENGINE........................................................ 25 PRECAUTIONS WHEN MOVING FORWARD OR BACKWARD................................. 25 VISIBILITY.................................................................. 25 TRAVELING ON SLOPES......................................................... 25 OPERATE CAREFULLY ON SNOW................................................... 26 WORKING ON LOOSE GROUND..................................................... 26 PARKING THE MACHINE......................................................... 26 TRANSPORTATION.................................................................. 27 LOADING AND UNLOADING....................................................... 27 SHIPPING.................................................................... 27 PRECAUTIONS WHEN FIXING ROPE AND RAISING MACHINE............................ 28 BATTERY..................................................................... 29 BATTERY HAZARD PREVENTION............................................... 29 STARTING WITH BOOSTER CABLES............................................ 29 TOWING...................................................................... 30 PRECAUTIONS FOR MAINTENANCE..................................................... 31 BEFORE CARRYING OUT MAINTENANCE............................................. 31 WARNING TAG............................................................. 31 PROPER TOOLS............................................................ 31 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.............. 31 RULES TO FOLLOW WHEN ADDING FUEL OR OIL......................................... 31 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................... 32 RADIATOR COOLANT LEVEL ......................................................... 32 USE OF LIGHTING................................................................. 32 DURING MAINTENANCE.............................................................. 33 PERSONNEL................................................................... 33 ATTACHMENTS................................................................. 33 WORK UNDER THE MACHINE...................................................... 33 KEEP THE MACHINE CLEAN...................................................... 33 HANDLING HIGH PRESSURE HOSES................................................ 33 PRECAUTION WITH BATTERY..................................................... 33 PRECAUTION WITH HIGH PRESSURE OIL........................................... 34 PRECAUTION WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR PRESSURE.... 34 PRECAUTION WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION.......... 34 ROTATING FAN AND BELT....................................................... 34 WASTE MATERIALS............................................................. 34 OPERATION.......................................................................... 36 GENERAL VIEW.................................................................... 37 GENERAL VIEW OF MACHINE..................................................... 37 GENERAL VIEW OF CONTROLS AND GAUGES......................................... 38 UNIVERSAL SYMBOLS........................................................... 39 EXPLANATIONS OF COMPONENTS...................................................... 40 GENERAL..................................................................... 40 GAUGES AND WARNING LIGHTS................................................... 40 HOURMETER............................................................... 41 TRANSMISSION OIL FILTER WARNING LIGHT................................... 41 ENGINE COOLANT TEMPERATURE GAUGE....................................... 41 ENGINE OIL PRESSURE GAUGE............................................... 42 ILLUMINATION LAMP....................................................... 42 VOLTMETER............................................................... 42 DRIVE TRAIN OIL TEMPERATURE GAUGE....................................... 42 HYDRAULIC OIL FILTER LIGHT.............................................. 43 AIR CLEANER SERVICE LIGHT............................................... 43 FUEL GAUGE.............................................................. 43 GEAR RANGE INDICATOR.................................................... 43 TRANSMISSION PRESSURE WARNING LIGHT..................................... 43 SWITCHES........................................................................ 44 START KEY SWITCH............................................................ 44 WORK LIGHT SWITCH........................................................... 45 HORN SWITCH................................................................. 45 ETHER START SWITCH.......................................................... 45 ELECTRIAL SYSTEM MASTER SWITCH.............................................. 45 CAB SWITCHES................................................................ 46 SEAT, SEAT BELT AND ARM RESTS................................................... 48 SEAT........................................................................ 48 SEAT BELT................................................................... 48 ARM REST.................................................................... 48 CONTROL LEVERS AND PEDALS....................................................... 49 FUEL CONTROL LEVER.......................................................... 49 TRANSMISSION STEERING LEVER................................................. 49 SAFETY LOCK LEVER........................................................... 50 LEFT PEDAL SECONDARY BRAKE.................................................. 51 BRAKE AND DECELERATOR PEDAL................................................. 51 BRAKE PEDAL LOCK............................................................ 51 BLADE CONTROL LEVER......................................................... 52 RIPPER CONTROL LEVER........................................................ 54 CAB CONTROLS................................................................ 55 LOCKING FUEL CAP................................................................ 56 OPENING..................................................................... 56 CLOSING..................................................................... 56 OPERATION....................................................................... 57 CHECKS BEFORE STARTING ENGINE............................................... 57 WALK AROUND CHECK....................................................... 57 CHECK BEFORE STARTING................................................... 58 OPERATIONS AND CHECKS BEFORE STARTING ENGINE............................ 63 STARTING ENGINE................................................................. 65 NORMAL STARTING............................................................. 65 COLD WEATHER STARTING....................................................... 67 OPERATIONS AND CHECKS AFTER ENGINE STARTS....................................... 69 MOVING MACHINE.................................................................. 71 SHIFTING GEAR................................................................... 73 SHIFTING BETWEEN FORWARD AND REVERSE............................................ 74 STEERING MACHINE................................................................ 75 NORMAL STARTING............................................................. 75 TURNING WHILE DESCENDING A SLOPE............................................ 76 STOPPING MACHINE................................................................ 77 PRECAUTIONS FOR OPERATION....................................................... 79 METHOD FOR USING STEERING CLUTCH............................................ 79 PERMISSIBLE WATER DEPTH..................................................... 79 WHEN TRAVELING UP OR DOWN HILLS............................................. 79 ON SLOPES................................................................... 79 WORK POSSIBLE USING BULLDOZER................................................... 80 DOZING...................................................................... 80 SMOOTHING................................................................... 80 CUTTING INTO HARD/FROZEN GROUND OR DITCHING................................. 80 PARKING MACHINE................................................................. 81 CHECK AFTER FINISHING WORK...................................................... 83 STOPPING ENGINE................................................................. 84 CHECKS AFTER STOPPING ENGINE.................................................... 86 LOCKING......................................................................... 87 ROPS CANOPY................................................................. 87 ROPS CAB.................................................................... 87 TIPS FOR LONGER UNDERCARRIAGE LIFE.............................................. 89 OPERATION METHOD............................................................ 89 INSPECTION AND ADJUSTMENT................................................... 90 INSPECTION AND REPAIR....................................................... 90 TRANSPORTATION.................................................................. 92 LOADING, UNLOADING WORK..................................................... 92 PRECAUTIONS FOR LOADING..................................................... 92 PRECAUTIONS FOR TRANSPORTATION.............................................. 93 COLD WEATHER OPERATIONS......................................................... 94 PRECAUTIONS FOR LOW TEMPERATURE............................................. 94 FUEL AND LUBRICANTS..................................................... 94 COOLANT................................................................. 94 BATTERY................................................................. 94 AFTER COMPLETION OF WORK.................................................... 95 AFTER COLD WEATHER.......................................................... 95 LONG TERM STORAGE............................................................... 96 BEFORE STORAGE.............................................................. 96 DURING STORAGE.............................................................. 96 ATER STORAGE................................................................ 96 TROUBLESHOOTING................................................................. 97 AFTER RUNNING OUT OF FUEL................................................... 97 IF BATTERY IS DISCHARGED ................................................... 97 STARTING ENGINE WITH BOOSTER CABLE...................................... 97 OTHER TROUBLE............................................................... 99 ELECTRICAL SYSTEM....................................................... 99 CHASSIS................................................................. 99 ENGINE..................................................................100 METHODS OF TOWING MACHINE.......................................................101 MAINTENANCE.........................................................................102 GUIDES TO MAINTENANCE...........................................................103 OUTLINES OF SERVICE.............................................................105 OUTLINE OF OIL, FUEL, COOLANT...............................................105 OIL ....................................................................105 FUEL....................................................................105 COOLANT.................................................................106 GREASE..................................................................106 STORING OIL AND FUEL....................................................106 FILTERS.................................................................106 RELATING TO ELECTRICAL SYSTEM...........................................106 WEAR PARTS LIST.................................................................107 USE OF FUEL, COOLANT AND LUBRICANTS.............................................108 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................108 D32E-1, D32P-1, D38E-1 OR D38P-1........................................108 D39E-1 OR D39P-1........................................................109 ABBREVIATIONS...........................................................109 ENGINE OIL SPECIFICATIONS.......................................................110 NORMAL OPERATION ...........................................................110 ARCTIC OPERATION............................................................110 DRIVE TRAIN OIL SPECIFICATIONS..................................................111 TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS...................111 EQUIPMENT SYSTEM OIL SPECIFICATIONS.............................................111 FINAL DRIVE OIL SPECIFICATIONS..................................................111 COOLING SYSTEM..................................................................112 GENERAL.....................................................................112 WATER.......................................................................112 ANTIFREEZE..................................................................112 INHIBITORS / CONDITIONERS...................................................113 FUEL SYSTEM.....................................................................115 GENERAL.....................................................................115 DIESEL FUEL SPECIFICATIONS..................................................115 STANDARD TIGHTENING TORQUES.....................................................116 INTRODUCTION OF NECESSARY TOOLS.............................................116 BOLT IDENTIFICATION CHART...................................................117 GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE.............................118 GRADE 8 PHOSPHATE COATED HARDWARE.......................................119 STANDARD METRIC FASTENERS ..............................................119 HYDRAULIC TUBES AND FITTINGS............................................120 HOSE CLAMPS.............................................................120 SPLIT FLANGE CONNECTIONS................................................120 PERIODIC REPLACEMENT OF CRITICAL PARTS..........................................121 MAINTENANCE SCHEDULE CHART......................................................124 SERVICE PROCEDURE...............................................................127 INITIAL 10 HOURS SERVICE....................................................127 BLADE CUTTING EDGE HARDWARE.............................................127 TRACK SHOE BOLT TORQUE..................................................127 EVERY 50 HOURS SERVICE..........................................................128 REPLACING DRIVE TRAIN PRESSURE FILTER.......................................128 SERVICING THE DRIVE TRAIN PRESSURE FILTER...................................129 TRACK TENSION AND ADJUSTMENT................................................130 EVERY 10 HOURS SERVICE..........................................................132 CHECK RADIATOR COOLANT LEVEL................................................132 CHECK ENGINE CRANKCASE OIL LEVEL............................................132 CHECK EQUIPMENT SYSTEM HYDRAULIC OIL LEVEL..................................133 FILL FUEL TANK..............................................................133 DRAIN FUEL FILTER WATER SEPARATOR...........................................134 OPEN FUEL SHUT OFF VALVE....................................................134 CLEAN PRE-CLEANER HOOD......................................................134 CHECK BRAKE PEDAL TRAVEL....................................................135 PERFORM GROUND LEVEL INSPECTION.............................................135 EVERY 50 HOURS SERVICE..........................................................137 CHECK OIL LEVEL IN DRIVE TRAIN..............................................137 LUBRICATION.................................................................137 EVERY 100 HOURS.................................................................138 BLADE CUTTING EDGE HARDWARE.................................................138 EVERY 250 HOURS SERVICE.........................................................139 REPLACE ENGINE OIL FILTER...................................................139 CHANGE ENGINE CRANKCASE OIL ................................................139 CHECKING FINAL DRIVE OIL LEVEL..............................................140 REPLACE FUEL FILTER WATER SEPARATOR.........................................141 CHECK ENGINE DRIVE BELT FOR WEAR............................................142 CHECK OPERATION OF THE DECELERATOR..........................................142 REVERSE REVERSIBLE FAN BLADES...............................................142 EVERY 500 HOURS SERVICE.........................................................143 CHECK ROPS MOUNTING BOT NUT TORQUE..........................................143 CHECK TRACK SHOE BOLT NUT TORQUE............................................143 INSPECT MOUNTED EQUIPMENT...................................................143 RADIATOR LEAKS..............................................................143 OUTSIDE OF RADIATOR CORE....................................................143 EVERY 1000 HOURS SERVICE........................................................144 SERVICE THE DRIVE TRAIN SUCTION STRAINER....................................144 CHANGING DRIVE TRAIN SYSTEM OIL.............................................145 DRAIN, FLUSH AND REFILL FINAL DRIVE OIL.....................................145 REPLACE DRIVE TRAIN SYSTEM BREATHER.........................................146 REPLACING DRIVE TRAIN PRESSURE FILTER.......................................146 REPLACE HYDRAULIC SYSTEM RETURN FILTER......................................147 CLEAN NEUTRAL VALVE INLET STRAINER..........................................148 LUBRICATE VALVE CAM PLATE...................................................149 CHECK TORQUE OF SPROCKET MOUNTING BOLTS.....................................149 LUBRICATION.................................................................149 EVERY 2000 HOURS SERVICE........................................................151 DRAIN, FLUSH AND REFILL COOLING SYSTEM......................................151 CLEAN HYDRAULIC SUCTION STRAINER............................................152 CLEAN HYDRAULIC RESERVOIR RELIEF VALVE......................................152 CHANGE HYDRAULIC SYSTEM FLUID...............................................153 PERIODIC........................................................................154 CLEAN AIR CLEANER ELEMENTS..................................................154 CLEAN FUEL TANK STRAINER....................................................158 DRAIN FUEL TANK SEDIMENT BOWL...............................................158 REPLACE IN LINE FUEL STRAINER...............................................158 SEAT BELT...................................................................159 CHECK HOSE CLAMP TORQUE.....................................................159 WHEN REQUIRED...................................................................160 FAN BELT....................................................................160 ELECTRICAL SYSTEM...........................................................160 ETHER START.................................................................165 VENTING THE FUEL SYSTEM.....................................................167 ANGLING FRAME TO BLADE......................................................167 REVERSE OR REPLACE END BITS AND CUTTING EDGES...............................168 TRACK TENSION AND ADJUSTMENT................................................169 ADJUST FRONT IDLER CLEARANCE................................................171 CLEAN OR REPLACE CAB FRESH AIR FILTER.......................................171 GREASE CAB DOOR HINGES......................................................171 WIPER WASHER FLUID LEVEL....................................................172 SEASONAL PREPARATION............................................................173 GENERAL.....................................................................173 OUTSIDE SOURCE OF HEAT......................................................173 LUBRICATION.................................................................173 FUEL SYSTEM.................................................................173 COOLING SYSTEM..............................................................173 ELECTRICAL SYSTEM...........................................................174 TURBOCHARGER: D38E/P-1 AND D39E/P-1.............................................175 PRECAUTIONS.................................................................175 PRIMING.....................................................................176 SPECIFICATIONS......................................................................178 SPECIFICATIONS..................................................................179 D32E-1,D32P-1 SPECIFICATIONS................................................179 D38E-1, D38P-1 SPECIFICATIONS...............................................180 D39E-1, D39P-1 SPECIFICATIONS...............................................181 D32E-1 DIMENSIONS...........................................................182 D32P-1 DIMENSIONS...........................................................183 D38E-1 DIMENSIONS...........................................................184 D38P-1 DIMENSIONS...........................................................185 D39E-1 DIMENSIONS...........................................................186 D39P-1 DIMENSIONS...........................................................187 OPTIONS, ATTACHMENTS................................................................188 PRECAUTIONS RELATED TO SAFETY...................................................189
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⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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