Komatsu D39E-1 D39P-1 Crawler Tractor Service Manual

Shop Manual CEBM000301 D32E/h D38E/P=l D39E/h BULLDOZER D32E/P-1 - PO75501 SERIAL NUMBERS D38E/P4 n PO85501 andup D39E/P-1 - PO95501 This’rnaterial is proprietary to Komatsu America international Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. 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. March 1997 Copyright 1997 Komatsu America International Company

The affected pages are indicated by using the follow- 1 Mark I Indication I Action ing marks. It is requested that necessary actions be taken to these pages according to the table below. 0 New page to be added Add I . I Page to be replaced I Replace I 0 I Page to be deleted I Discard Pages without marks were previous additions or revised pages. LIST OF ORIGINAL, NEW AND REVISED PAGES CEBM00030’ VlARK PAGE REV MARK PAGE REV MARK PAGE REV MARK PAGE REV 0 O-l 0 l 2-20 0 . 7B-5 0 (7B-51) l o-2 0 0 7B-6 0 (7B-52) 0 o-3 0 . 6-l 0 . 7B-7 0 (7B-53) 0 o-4 0 l 6-2 0 . 7B-8 0 (7B-54) 0 o-5 0 l 6-3 0 . 7B-9 0 (7B-55) 0 O-6 0 . 6-4 0 . 7B-10 0 (7B-56) 0 o-7 0 l 6-5 0 . 7B-11 0 0 O-8 0 l 6-6 0 0 7B-12 0 0 7c-1 0 0 o-9 0 l 6-7 0 l 7B-13 0 0 7C-2 0 0 O-l 0 0 l 6-8 0 . 7B-14 0 0 7c-3 0 0 6-9 0 . 7B-15 0 0 7c-4 0 l-l 0 6-l 0 0 . 7B-16 0 a 7c-5 0 l-2 l 6-l 1 0 . 7B-17 0 . 7C-6 0 l-3 l 6-12 0 0 7B-18 0 0 7c-7 0 1-4 0 6-l 3 0 . 7B-19 0 0 7C-8 0 l-5 l 6-14 0 . 7B-20 0 . 7c-9 0 1-6 0 6-l 5 0 . 7B-21 0 . 7c-10 0 l-7 0 6-16 0 . 7B-22 0 0 7c-11 0 l-8 0 6-17 0 l 7B-23 0 0 7C-12 0 l-9 0 6-l 8 0 0 7B-24 0 0 7c-13 0 I-IO a 6-l 9 0 l 7B-25 0 0 7c-14 0 I-II 0 6-20 0 . 7B-26 0 0 7c-15 0 1-12 0 6-21 0 . 7B-27 0 . 7C-16 0 1-13 l 6-22 0 0 7B-28 0 0 7c-17 0 1-14 0 6-23 0 . 78-29 0 0 7C-18 0 0 6-24 0 . 78-30 0 0 7c-19 0 0 2-l 0 (6-25) l 7B-31 0 0 7C-20 0 l 2-2 0 (6-26) 0 7B-32 0 . 7C-21 0 0 2-3 0 (6-27) 0 78-33 0 l 7C-22 0 0 2-4 0 (6-28) 0 7B-34 0 . 7C-23 0 0 2-5 0 (6-29) 0 7B-35 0 l 7C-24 0 0 2-6 0 (6-30) a 7B-36 0 a 7C-25 0 0 2-7 0 0 7B-37 0 0 7C-26 0 0 2-8 0 l 7-l 0 . 7B-38 0 0 7C-27 0 l 2-9 0 . 7-2 0 . 7B-39 0 . 7C-28 0 0 2-l 0 0 l 7-3 0 . 7B-40 0 a 7c-29 0 0 2-l 1 0 l 7-4 0 . 78-41 0 . 7c-30 0 0 2-l 2 0 . 7-5 0 l 7B-42 0 . 7c-31 0 0 2-l 2 0 l 7-6 0 . 78-43 0 0 7C-32 0 0 2-l 3 0 o 7-7 0 . 7B-44 0 . 7c-33 0 0 2-14 0 o 7-8 0 . 78-45 0 0 7c-34 0 0 2-l 5 0 0 7B-46 0 . 7c-35 0 0 2-16 0 . 7B-1 0 (7B-47) 0 7C-36 0 0 2-17 0 . 7B-2 0 (7B-48) 0 7c-37 0 0 2-l 8 0 . 7B-3 0 (7B-49) l 76-38 0 l 2-l 9 0 . 7B-4 0 (7B-50) 0 76-39 0 o-3 0

CEBM000301 LIST OF ORIGINAL, NEW AND REVISED PAGES AARK PAGE REV dlARK PAGE REV VlARK PAGE REV vlARK PAGE REV 7c-40 7c-41 7C-42 7c-43 7c-44 7c-45 7C-46 7c-47 7C-48 7c-49 7c-50 7c-51 76-52 7c-53 7c-54 7c-55 7C-56 7c-57 7C-58 7c-59 7C-60 7C-61 7C-62 7C-63 7C-64 7C-65 7C-66 7C-67 7C-68 7C-69 7c-70 7c-71 7C-72 7c-73 76-74 76-75 76-76 7c-77 7C-78 7c-79 7C-80 7C-81 7C-82 7C-83 76-84 7C-85 7C-86 7C-87 7C-88 7C-89 7c-90 7c-91 76-92 7c-93 7c-94 7C-96 7c-97 7C-98 7c-99 7c-100 7c-101 7c-102 7c-103 7c-104 7c-105 7C-106 7c-107 7C-108 7c-109 7c-110 7c-111 7c-112 7c-113 7c-114 7c-115 7C-116 7c-117 7C-118 7c-119 7c-120 7C-121 7C-122 7C-123 7C-124 7C-125 7C-126 7C-127 7C-128 7c-129 7c-130 7c-131 7C-132 7c-133 7c-134 7c-135 7C-136 7c-137 7C-138 7c-139 7c-140 7c-141 7C-142 7c-143 7c-144 7c-145 7C-146 7c-147 7C-148 7c-149 7c-150 7c-151 7C-152 7c-153 7c-154 7c-155 7C-156 7c-157 7C-158 (7C-159) (7C-160) (7C-161) (7C-162) (7C-163) (7C-164) (7C-165) (7C-166) (7C-167) (7C-168) 7E-1 7E-2 7E-3 7E-4 7E-5 7E-6 7E-7 7E-8 7E-9 7E-10 7E-11 7E-12 7E-13 7E-14 7E-15 7E-16 7E-17 7E-18 7E-19 7E-20 7E-21 7E-22 7E-23 7E-24 7E-25 7E-26 7E-27 7E-28 7E-29 7E-30 7E-31 7E-32 7E-33 7E-34 7E-35 7E-36 7E-37 7E-38 0 7E-39 7E-40 7E-41 7E-42 7E-43 7E-44 7E-45 7E-46 7E-47 7E-48 7E-49 7E-50 7E-51 7E-52 7E-53 7G54 7E-55 7E-56 7E-57 7E-58 7E-59 7E-60 7E-61 7E-62 7E-63 7E-64 7E-65 7E-66 7E-67 7E-68 7E-69 7E-70 7E-71 7E-72 7E-73 7E-74 7E-75 7E-76 7E-77 7E-78 7E-79 7E-80 7E-81 7E-82 7E-83 7E-84 7E-85 7E-86 7E-87 7E-88 7F-1 7F-2 7F-3 7F-4 7F-5 w o-4 0

LIST OF ORIGINAL, NEW AND REVISED PAGES CEBM000301 ilARK PAGE REV ilARK PAGE REV vlARK PAGE REV 7F-6 7F-7 7F-8 7F-9 7F-10 7F-11 7F-12 7F-13 7F-14 7F-15 7F-16 7F-17 7F-18 7F-19 7F-20 7F-21 7F-22 7F-23 7F-24 7F-25 7F-26 7F-27 7F-28 (7F-29) (7F-30) (7F-31) (7F-32) (7F-33) (7F-34) (7F-35) (7F-36) (7F-37) (7F-38) (7F-39) (7F-40) (7F-41) (7F-42) (7F-43) (7F-44) 8-l 8-2 8-3 8-4 IO-I IO-2 IO-3 IO-4 IO-5 IO-6 IO-7 IO-8 IO-9 IO-10 IOA-I lOA- lOA- lOA- lOA- lOA- lOA- lOA- lOA- IOA-IO IOA-II lOA- lOA- lOA- lOA- lOA- lOA- lOA- lOA- lOA- lOA- lOA- (IOA-23) (IOA-24) (IOA-25) (IOA-26) (IOA-27) (IOA-28) (IOA-29) (IOA-30) (IOA-31) (IOA-32) (IOA-33) (IOA-34) 0 108-l 0 108-2 0 108-3 0 lOB-4 0 IOB-5 0 IOB-6 0 IOB-7 0 IOB-8 0 IOB-9 0 IOB-10 0 IOB-11 0 108-12 0 IOB-13 0 108-14 0 IOB-15 0 IOB-16 0 IOB-17 0 IOB-18 0 108-19 0 IOB-20 0 IOB-21 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 a l 0 0 0 l l 0 0 0 0 0 l 0 0 0 0 0 0 IOB-22 IOB-23 IOB-24 IOB-25 IOB-26 IOB-27 108-28 IOB-29 IOB-30 IOB-31 IOB-32 IOB-33 IOB-34 IOB-35 IOB-36 IOB-37 IOB-38 IOB-39 lOB-40 IOB-41 108-42 108-43 lOB-44 lOB-45 IOB-46 IOC-1 IOC-2 IOC-3 lOC-4 IOC-5 IOC-6 IOC-7 IOC-8 IOC-9 IOC-10 IOC-11 IOC-12 IOC-13 IOC-14 IOC-15 IOC-16 IOC-17 IOC-18 IOC-19 IOC-20 (IOC-21) (IOC-22) (IOC-23) (IOC-24) (IOC-25) (IOC-26) 12-1 12-2 12-3 0 14-26 i/ARK PAGE REV 12-4 12-5 12-6 12-7 12-8 12-9 12-10 12-11 12-12 12-13 12-14 12-15 12-16 12-17 12-18 12-19 12-20 12-21 12-22 12-23 12-24 12-25 12-26 12-27 12-28 12-29 12-30 12-31 12-32 14-1 14-2 14-3 14-4 14-5 14-6 14-7 14-8 14-9 14-10 14-11 14-12 14-13 14-14 14-15 14-16 14-17 14-18 14-19 14-20 14-21 14-22 14-23 14-24 14-25

CEBM000301 LIST OF ORIGINAL, NEW AND REVISED PAGES IARK PAGE REV 14-27 14-28 14-29 14-30 14-31 14-32 14-33 14-34 14-35 14-36 14-37 14-38 14-39 14-40 14-41 14-42 14-43 14-44 14-45 14-46 14-47 14-48 14-49 14-50 14-51 14-52 14-53 14-54 14-55 14-56 14-57 14-58 14-59 14-60 14-61 14-62 14-63 14-64 14-65 14-66 14-67 14-68 14-69 14-70 14-71 14-72 14-73 14-74 14-75 14-76 /lARK PAGE REV IARK PAGE REV IARK PAGE REV 15-6 15-7 15-8 15-9 15-10 15-I 1 15-12 17-1 0 17-2 0 17-3 0 17-4 0 17-5 0 17-6 0 17-7 0 17-8 0 15-l 15-2 15-3 15-4 15-5 O-6 0

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 PARTS BOOK - PAPER: ENGINE AND CHASSIS - D32E-1 & D32P-1 ENGINE AND CHASSIS - D38E-1 & D38P-1 ENGINE AND CHASSIS - D39E-1 & D39P-1 PARTS BOOK - MICROFICHE: ENGINE AND CHASSIS - D32E-1 & D32P-1 ENGINE AND CHASSIS - D38E-1 & D38P-1 ENGINE AND CHASSIS - D39E-1 & D39P-1 OPERATION AND MAINTENANCE MANUAL: CHASSIS . . . . . . . . . . . . . . . SHOP MANUAL: CHASSIS ........................... SUPPLEMENT ONLY ............. ENGINE ............................ SAFETY MANUAL ......................... . . . . . . . . . . . . . . . . . . . . . FORM NUMBER BEPBOOI 000 BEPBOOI 100 BEPB001200 BEPMOOI 000 BEPMOOI 100 BEPMOOI 200 CEAM000700 CEBM000301 CEBM000301 S SEBMOI 0002 CLT80-1 PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBU- TORS, 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 KDCSID IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.

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 SHIP TO COMPANY NAME c ATTN. TYPE or PRINT ONLY STREET ADDRESS CITY, STATE, ZIP CODE . COUNTRY I 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. PARTS BOOK PUBLICATION s M_;;;;;he DESCRIPTION MoDEL NUMBER SERIAL NUMBER KDC91D 081696 CURRENT PRICES WILL BE CHARGED

This shop manual includes information for locations, 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. INTRODUCTION - SECTION 1 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 IOA CONTROL VALVE - SECTION IOB CYLINDERS - SECTION IOC - SECTION 11 POWER - SECTION 12 - SECTION 13 UNDERCARRIAGE - SECTION 14 TRACK CHAIN - SECTION 15 MOUNTED EQUIPMENT - SECTION 17 o-9 0

INDEX TO SECTIONS SECTION 1 - INTRODUCTION SECTION 7F - FINAL DRIVE SAFETY PRECAUTIONS ........... SERVICE INFORMATION .......... LOCTITE USAGE ................. SECTION 2 - MISCELLANEOUS . . . . . . . 2 . . 10 . . 12 DIMENSIONS .................... SPECIFICATIONS ................ CAPACITIES AND LUBES .......... SPECIAL TORQUES .............. STANDARD TORQUES ............ SECTION 6 -COOLING . . . . . . . 2 . . 8 . 11 . 13 . 15 GENERAL ....................... REMOVAL ....................... DISASSEMBLY ................... REASSEMBLY ................... METAL TYPE FACE SEALS ......... INSTALLATION ................... SECTION 8 - ELECTRICAL GENERAL ........................ WIRING DIAGRAM ................ SECTION 10 - HYDRAULICS GENERAL ....................... SERVICE DIAGNOSIS ............. RADIATOR ...................... SECTION 7 - DRIVE TRAIN . . . . . . . 2 . . 3 . . 4 . . GENERAL ....................... SECTION 78 - TORQUE CONVERTER . . 2 GENERAL ....................... SECTION IOA - PUMP AND MOTORS CHARGE AND SCAVENGE PUMP ... EQUIPMENT PUMP ............... SECTION IOB - CONTROL VALVE GENERAL ....................... REMOVAL ....................... DISASSEMBLY ................... REASSEMBLY ................... INSTALLATION ................... SECTION 7C - TRANSMISSION . . . . . . 2 . . 5 . 13 . 24 . 39 . . GENERAL ....................... REMOVAL ....................... COMPLETE ASSEMBLY ........... DIRECTIONAL (INPUT) SHAFT ...... COUNTERSHAFT ................. RANGE (OUTPUT) SHAFT. ......... REVERSE IDLER SHAFT ........... MAIN REGULATOR VALVE ......... RANGE SELECTOR VALVE ......... RATE OF RISE VALVE ............. INSTALLATION ................... TRANSISTEERING VALVE ......... DRIVE SHAFT ................... SECTION 7E - STEERING DRIVE . . . . . REMOVAL ....................... COMPLETE ASSEMBLY ........... SYSTEM RELIEF VALVE ........... BLADE LIFT SECTION ............. BLADE TILT SECTION ............. BLADE ANGLE OR RIPPER SECTION INSTALLATION ................... SECTION IOC - CYLINDERS . . . . . . BLADE ......................... RIPPER ......................... SECTION 14 -SUSPENSION . . . . . . . . . . . . . . . . . . 2 . 6 . 22 . 38 . 54 . 57 . 80 . 83 . 92 . 99 111 129 155 . . . . . . . . . . GENERAL ....................... REMOVAL ....................... DISASSEMBLY ................... BRAKE CYLINDER ................ STEERING CYLINDER ............. MOUNTING PLATE ............... BRAKE/STEERING SHOES ......... BEARING CARRIER ............... PLANET GEAR CARRIER .......... REASSEMBLY ................... INSTALLATION ................... BRAKE ADJUSTMENT ............. BRAKE CYLINDER VALVE ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . 4 . 14 . 24 . 30 . 35 . 38 . 43 46 48 . 67 78 . 81 . GENERAL ....................... SERVICE DIAGNOSIS ............. WEAR LIMIT CHECKS ............. FRONT IDLER ................... TRACK ADJUSTER ............... TOP IDLER ...................... TRACK ROLLER .................. METAL TYPE FACE SEALS ......... TRACK FRAME .................. TRACK SPRING .................. FRONT CROSSBAR ............... REAR RIGID BAR ................. TRACK FRAME ALIGNMENT. ....... SECTION 15 -TRACK CHAIN SPLIT LINK TYPE CHAINS ......... SECTION 17 - MOUNTED EQUIPMENT C FRAME PIN .................... C FRAME RUB BARS .............. ANGLING FRAME ................ C FRAME ....................... BLADE BUSHINGS ................ . 2 . 5 . 7 16 24 26 . . . . . . . . . . . . . . 2 . 3 . 2 . 2 14 . . . . . . . : .I0 2 15 . 20 . 29 34 39 . . . . . . . . . . . . . . . 2 12 . 2 . 4 . 6 10 27 32 40 53 56 58 67 71 72 . 2 . . 2 . . 3 . 5 . . 7 . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-IO 0

Komatsu D39E-1 D39P-1 Crawler Tractor Service Manual

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