Shop Manual for Komatsu D32E-1, D32P-1, D38E-1, D38P-1, D39E-1, D39P-1 Crawler Tractor 1998

Komatsu D32E-1, D32P-1, D38E-1, D38P-1, D39E-1, D39P-1 Shop Manual - 1998

This shop manual provides factory-grade technical intelligence for the maintenance and structural repair of specific Komatsu crawler tractors. It includes high-precision tolerances, pressure settings, and lubricant specifications to ensure peak machine reliability. A vital procedure for field uptime is the specific track adjuster pressure relief sequence, which requires opening the valve exactly 1/2 to 1 turn to safely bleed cylinder pressure before component disassembly.

Technical Applicability & Serial Ranges

Series 1 (D32 Configuration)

• Komatsu D32E-1: Serial P075718 and up
• Komatsu D32P-1: Serial P075718 and up

Series 1 (D38 Configuration)

• Komatsu D38E-1: Serial P085799 and up
• Komatsu D38P-1: Serial P085799 and up

Series 1 (D39 Configuration)

• Komatsu D39E-1: Serial P095872 and up
• Komatsu D39P-1: Serial P095872 and up

Operational Parameters & Service ROI

• Detailed torque sequences for critical joints prevent fastener fatigue and structural failure under heavy drawbar loads.
• Precise hydraulic relief valve settings ensure the work equipment operates within safe structural limits while maintaining breakout force.
• Accurate fluid capacity data for rebuilt rollers and idlers prevents premature undercarriage wear and overheating.

Technical Documentation Metadata

• Print Number: CEBM003100
• Page Count: 636 Pages
• Publication Date: November 1998
• System Language: US English

Technical Depth & Factory Benchmarks

System calibration is supported by specific standard value tables for engine and drive train performance. The manual defines main pressure regulator valve settings between 1792 and 1930 kPa (260 to 280 psi) to ensure crisp transmission engagement. Cooling system integrity is benchmarked by a radiator cap maximum pressure of 45 to 55 kPa (6.5 to 8 psi), maintaining stable operating temperatures during high-load pioneering operations.

System Architecture & Visual Aids

Internal workflows are illustrated through complex drive train schematics and exploded views of the power shift transmission and steering drive. Sectional diagrams detail the multi-disc clutch configurations and planetary gear arrangements essential for overhauling the final drive and sprocket assemblies.

Table of Contents

• Section 1: Introduction (Safety, Service Information, Loctite Usage)
• Section 2: Miscellaneous (Dimensions, Specifications, Capacities, Torques)
• Section 4: Brakes (Pedal, Support Bracket, Brake Pad)
• Section 6: Cooling (Radiator, Fans, Service Diagnosis)
• Section 7: Drive Train (Torque Converter, Transmission, Steering Drive, Sprocket Drive)
• Section 8: Electrical (Wiring Diagrams, Specifications)
• Section 10: Hydraulics (Pumps, Motors, Control Valves, Cylinders)
• Section 12: Engine (Removal, Installation, Standard Values)
• Section 14: Undercarriage (Wear Limits, Idlers, Track Adjuster, Rollers)
• Section 15: Track Chain (Split Link Type)
• Section 17: Mounted Equipment (C-Frame, Blade Bushings, Ripper)

Operational Limits & Specifications

• Engine Lubrication: SAE 15W-40 (E01) for ambient temperatures above -15°C; 9.5 liters (2.5 gal) capacity.
• Final Drive Lubricant: SAE 85W-140 or 80W-90 (MPL) depending on chassis size.
• Transmission Fluid: Komatsu HDTF (C-4/TO-4) strictly without viscosity index improvers.
• Grease Specification: Multigrade Lithium with 3% Molybdenum Disulfide (MoS2) for pivot points.
• Torque Sequence: ROPS mounting bolts require 822 ± 47 Nm (605 ± 35 lbf ft) for certified structural integrity.