KOMATSU D32E-1A, D32P-1A, D38E-1A, D38P-1A, D39E-1A, D39P-1A Crawler Tractor Service Repair Manual + Operation & Maintenance MAN

SHOP MANUAL CEBM003100 CRAWLER TRACTOR SERIAL NUMBERS D32E-1,P-1 P075718 and up D38E-1,P-1 P085799 and up D39E-1,P-1 P095872 and up This material is proprietary to Komatsu and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. NOV 98 COPYRIGHT 1998 KOMATSU AMERICA INTERNATIONAL COMPANY

PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION AND SHOP MANUALS IN FOREIGN LANGUAGES. THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THESE PARTICULAR MACHINES. DESCRIPTION FORM NUMBER PARTS BOOK - PAPER: ENGINE AND CHASSIS - D32E-1 & D32P-1 ................................ BEPB004300 ENGINE AND CHASSIS - D38E-1 & D38P-1 ................................ BEPB004400 ENGINE AND CHASSIS - D39E-1 & D39P-1 ................................ BEPB004500 PARTS BOOK - MICROFICHE: ENGINE AND CHASSIS - D32E-1 & D32P-1 ................................ BEPM004300 ENGINE AND CHASSIS - D38E-1 & D38P-1 ................................ BEPM004400 ENGINE AND CHASSIS - D39E-1 & D39P-1 ................................ BEPM004500 OPERATION AND MAINTENANCE MANUAL: CHASSIS ............................................................. CEAM002700 SHOP MANUAL: CHASSIS ............................................................. CEBM003100 ENGINE .............................................................. SEBM010002 SAFETY MANUAL .......................................................... CLT80-1 PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE PARTS INVENTORY PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.

PURCHASE ORDER NO. ORDER DATE REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO < Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME ATTN. STREET ADDRESS CITY, STATE, ZIP CODE COUNTRY SHIP TO < TYPE or PRINT ONLY < PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER PARTS BOOK M-Microfiche PUBLICATION DESCRIPTION KDC91D 081696 CURRENT PRICES WILL BE CHARGED

SECTION INDEX This shop manual includes information for locations, INTRODUCTION — SECTION 1 specifications, service/special tools, tolerances, pressures, lubricants and sealants, special torques, tests and adjust- ments, assembly tips and service bulletin references for various components of the machine. This shop manual is divided into major sections. These sections are indexed by title and divided by individual section index tab. To use this shop manual, locate the section required and turn to that section index tab. MISCELLANEOUS — SECTION 2 — SECTION 4 — SECTION 5 COOLING — SECTION 6 DRIVE TRAIN — SECTION 7 TORQUE CONVERTER — SECTION 7B TRANSMISSION — SECTION 7C STEERING DRIVE — SECTION 7E SPROCKET DRIVE — SECTION 7F ELECTRICAL — SECTION 8 — SECTION 9 HYDRAULICS — SECTION 10 PUMPS AND MOTORS — SECTION 10A CONTROL VALVE — SECTION 10B CYLINDERS — SECTION 10C — SECTION 11 POWER — SECTION 12 — SECTION 13 UNDERCARRIAGE — SECTION 14 TRACK CHAIN — SECTION 15 MOUNTED EQUIPMENT — SECTION 17

INDEX TO SECTIONS SECTION 1 - INTRODUCTION SAFETY PRECAUTIONS ......................... 2 SERVICE INFORMATION ........................ 10 LOCTITE USAGE .............................. 12 SECTION 2 - MISCELLANEOUS DIMENSIONS .................................. 2 SPECIFICATIONS ............................... 8 CAPACITIES AND LUBES ....................... 11 SPECIAL TORQUES ............................ 13 STANDARD TORQUES ......................... 15 SECTION 4 - BRAKES GENERAL ..................................... 2 BRAKE PEDAL ................................. 4 BRAKE SUPPORT BRACKET .................... 13 BRAKE PAD .................................. 25 SECTION 6 - COOLING GENERAL ..................................... 2 SERVICE DIAGNOSIS ........................... 3 RADIATOR ..................................... 4 SECTION 7 - DRIVE TRAIN GENERAL ..................................... 2 SECTION 7B - TORQUE CONVERTER GENERAL ..................................... 2 REMOVAL ..................................... 5 DISASSEMBLY ................................ 13 REASSEMBLY ................................. 24 INSTALLATION ................................ 39 SECTION 7C - TRANSMISSION GENERAL ..................................... 2 REMOVAL ..................................... 6 COMPLETE ASSEMBLY ........................ 22 DIRECTIONAL (INPUT) SHAFT ................... 38 COUNTERSHAFT .............................. 54 RANGE (OUTPUT) SHAFT ...................... 57 REVERSE IDLER SHAFT ........................ 80 MAIN REGULATOR VALVE ...................... 83 RANGE SELECTOR VALVE ..................... 92 RATE OF RISE VALVE .......................... 99 INSTALLATION .............................. 111 TRANS/STEERING VALVE .................... 129 DRIVE SHAFT ............................... 155 SECTION 7E - STEERING DRIVE GENERAL ..................................... 2 REMOVAL ..................................... 4 DISASSEMBLY ................................ 14 BRAKE CYLINDER ............................. 24 STEERING CYLINDER .......................... 30 MOUNTING PLATE ............................. 35 BRAKE/STEERING SHOES ...................... 38 BEARING CARRIER ............................ 43 PLANET GEAR CARRIER ....................... 46 REASSEMBLY ................................. 48 INSTALLATION ................................ 67 BRAKE ADJUSTMENT .......................... 78 BRAKE CYLINDER VALVE ...................... 81 SECTION 7F - FINAL DRIVE GENERAL .................................... 2 REMOVAL .................................... 5 DISASSEMBLY ................................ 7 REASSEMBLY ................................. 16 METAL TYPE FACE SEALS ...................... 24 INSTALLATION ................................ 26 SECTION 8 - ELECTRICAL GENERAL .................................... 2 WIRING DIAGRAM ............................. 3 SECTION 10 - HYDRAULICS GENERAL .................................... 2 SECTION 10A - PUMP AND MOTORS CHARGE AND SCAVENGE PUMP ................ 2 EQUIPMENT PUMP ............................ 14 SECTION 10B - CONTROL VALVE REMOVAL ..................................... 2 COMPLETE ASSEMBLY ........................ 10 SYSTEM RELIEF VALVE ........................ 15 BLADE LIFT SECTION .......................... 20 BLADE TILT SECTION .......................... 29 BLADE ANGLE OR RIPPER SECTION ............. 34 INSTALLATION ................................ 39 SECTION 10C - CYLINDERS BLADE ....................................... 2 RIPPER ...................................... 12 SECTION 12 - ENGINE STANDARD VALUE TABLE ...................... 2 REMOVAL ..................................... 5 INSTALLATION ................................ 17 SECTION 14 - SUSPENSION GENERAL .................................... 2 SERVICE DIAGNOSIS .......................... 4 WEAR LIMIT CHECKS .......................... 6 FRONT IDLER ................................. 10 TRACK ADJUSTER ............................ 27 TOP IDLER ................................... 32 TRACK ROLLER ............................... 40 METAL TYPE FACE SEALS ...................... 53 TRACK FRAME ................................ 56 TRACK SPRING ............................... 58 FRONT CROSSBAR ............................ 67 REAR RIGID BAR .............................. 71 TRACK FRAME ALIGNMENT .................... 72 SECTION 15 - TRACK CHAIN SPLIT LINK TYPE CHAINS ....................... 2 SECTION 17 - MOUNTED EQUIPMENT C FRAME PIN .................................. 2 C FRAME RUB BARS ............................ 3 ANGLING FRAME ............................... 5 C FRAME ...................................... 7 BLADE BUSHINGS .............................. 8

1 - 1 INTRODUCTION SECTION 1 SAFETY PRECAUTIONS ............................... 2 GENERAL ......................................... 2 BEFORE STARTING THE ENGINE ..................... 2 OPERATION ....................................... 3 MAINTENANCE ..................................... 5 SHUTDOWN ....................................... 7 SAFETY PRODUCT GRAPHICS AND LOCATION ......... 8 SERVICE INFORMATION ............................. 10 GENERAL ........................................ 10 PIN AND SERIAL NUMBERS ......................... 10 SERVICE TOOLS AND PARTS ....................... 11 INSPECTION AND REPAIR .......................... 11 LOCTITE USAGE .................................... 12 SURFACE PREPARATION ........................... 12 APPLICATION ..................................... 12 SETTING TIME .................................... 13 REMOVAL ........................................ 13 APPLICATIONS AT LOW TEMPERATURES ............ 13 WARNING Refer to, read and follow all safety precautions in this SECTION. Failure to do so may result in serious injury or death.

1 - 2 INTRODUCTION SAFETY PRECAUTIONS AVOID ACCIDENTS WORK SAFETY -- FOLLOW THESE RULES A CAREFUL MECHANIC IS THE BEST INSURANCE AGAINST AN ACCIDENT THIS SYMBOL IS USED THROUGHOUT THIS SHOP MANUAL TO CALL YOUR ATTENTION TO INSTRUCTIONS CONCERNING PERSONAL SAFETY. OBSERVE AND FOLLOW THESE INSTRUCTIONS. BE CERTAIN ANYONE OPERATING OR SERVICING THIS MACHINE IS AWARE OF THESE RULES. FAILURE TO FOLLOW THESE RULES MAY RESULT IN INJURY OR DEATH. 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. BEFORE STARTING THE ENGINE 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

SAFETY PRECAUTIONS INTRODUCTION 1 - 3 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. OPERATION Before starting the engine, be sure you understand all control functions. Only one person, the operator, should be permitted to ride on the machine when it is in operation. Never haul passengers. Perform an operational check of the machine in a safe area before putting it to work. Check all controls, including the brake pedal, steering pedals and transmission selector. Check all gauges, warning lights and safety devices. Correct any malfunctions. Always sit in the operator's seat before operating any controls. Keep operating controls, hands and shoes free of grease, water and mud to insure positive control functions. The machine is ROPS equipped, for your personal protection, wear your seat belt. In the event of a rollover, stay with the machine. Experience has shown this will reduce the seriousness or chance of injury. Before driving the machine, adjust the seat and fasten the seat belt. Adjust the seat belt to fit snugly and flow around the hips to lessen the chance and severity of injury in the event of an accident. Never wear the seat belt across the abdomen. Check overhead clearance carefully before operating the machine in areas with low overhead clearance, such as guy wires, power lines, bridges, low hanging tree branches and building entrances or exits. These overhead obstructions could cause an accident. Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases. Once the engine is operating, move the machine outdoors as soon as possible. Exhaust gases are dangerous and cause unconsciousness and death. Never operate the engine at more than the regular governed speed shown in the OPERATION & MAINTENANCE MANUAL. Excessive speeds are harmful and dangerous. After starting the engine, but before moving the machine, warn nearby personnel by giving a couple of short horn blasts. When operating the machine, look in the intended direction of travel to be sure personnel or allied equipment does not interfere with the machine work pattern. Never try to get on or off the machine while it is moving. A serious injury or death could result. Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard and under certain conditions an explosion which could result in personal injury or death. Never remove the fuel tank filler caps or refill the fuel tanks while the engine is running or hot or when the machine is indoors. Fumes are dangerous, a spark or flame could result in a fire or explosion. Avoid sidehill travel whenever possible. Drive straight up and down the slope. If the machine starts slipping sideways on a grade, turn downhill immediately. Be careful and alert when operating sideways on a steep slope as a rollover and serious injuries could result. There is no substitute for good judgement when working the machine on a slope. If possible avoid crossing obstacles such as ridges, rocks or logs. If you can't avoid them, reduce speed and ease over the obstacle at an angle.

INTRODUCTION SAFETY PRECAUTIONS 1 - 4 A machine's weight and the vibration it creates can cause the edge of a high wall to collapse. Keep your machine back from the edges of banks and excavations. Operating in rough virgin terrain with such hazards as trees, logs, large rocks and brush is called pioneering. Be sure you know the operating techniques required. Danger from falling branches and upturning roots is acute in pioneering. When pushing over trees, the machine must be equipped with proper overhead guards. Never allow the machine to climb up the root structure, especially when the tree is being felled. Use extreme care when pushing over any tree with dead branches. If engine has a tendency to stall for any reason under load or at idle, report this condition immediately. Do not operate the machine until the condition has been corrected. Periodically check the engine exhaust system for leaks. Exhaust gases are dangerous to the operator. Use common sense, care and good judgement to avoid accidents. Operate at speeds slow enough to insure complete control of the machine. Travel slowly in congested areas or on rough ground, slopes or near drop offs or on snow, ice or slippery surfaces. Maintain a safe distance between your machine and other vehicles according to the condition of the road and load. Keep the machine as close to the side of the road as is possible to provide for oncoming or passing vehicles. Observe instruments and warning lights frequently. Report any defects or unusual noises in machine during operation. Be alert to the location of other personnel. Do not operate if exposed personnel enter the immediate work area. Warn all ground persons to leave the area of the machine. Do not operate the machine in a condition of extreme fatigue or illness. Be especially careful at the end of a work shift. Keep your work area as smooth as possible and free of obstructions. When pulling or towing with a chain or cable, take up the slack carefully. A sudden jerk could snap the chain or cable causing it to whip dangerously. Do not pull or tow unless the operator compartment is guarded for a whipping chain or cable. Clear personnel from the area. Be sure chains or cables and their anchor points are strong enough to handle the expected load. Inspect carefully for flaws before using. Always wear gloves when handling chains or cables. Avoid kinking the chain or cable. Do not pull with a kinked chain or cable as the high stress could cause a failure in the kinked area. Use only designated towing or pulling attachment points. Be sure pins are attached securely before pulling. Stand clear of chains or cables under load. Where noise exposure exceeds 90 dBA for 8 hours, wear authorized ear protective equipment. Keep engine exhaust system and exhaust manifold clear of combustible material for your personal protection. Know the locations of underground cables, water mains, gas lines, etc. A ruptured gas line or cut electrical cable could result in personal injury or death. Never use the mounted equipment as a brake except in an emergency. Do not adjust the seat position while the machine is in motion. A loss of control may result. Completely stop the machine, apply and lock the parking brake and then adjust the seat. During operation always carry ripper in full raised position when not in use and lower to ground when parked. Keep head, body, feet, hands and fingers away from the blade and ripper when they are in a raised position. Carry the blade low for maximum stability and visibility. Never leave the machine unattended while the engine is operating. When parking the machine, be sure all mounted equipment is lowered completely to minimize damage or injury possibilities. Do not allow the hydraulic system to support the mounted equipment when leaving the machine unattended. When leaving the machine unattended for any length of time, make sure the transmission/steering lever is positioned and locked in neutral (N), the blade and rear mounted equipment are completely lowered, the engine is stopped and the electrical master switch is locked in the OFF position. Never hold the hydraulic controls in their extreme position after the equipment has reached its maximum travel. This could cause overheating of the hydraulic system. MAINTENANCE Lower the blade to the ground or hold up with blocking, safety bar or hoist. Lower all equipment to the ground. Shift all controls to NEUTRAL position. Lock the transmission selector in NEUTRAL to neutralize the transmission and apply

KOMATSU D32E-1A, D32P-1A, D38E-1A, D38P-1A, D39E-1A, D39P-1A Crawler Tractor Service Repair Manual + Operation & Maintenance MAN

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