1990–1997 Komatsu D32E-1, D32P-1, D38E-1, D38P-1, D39E-1, D39P-1 Bulldozer Chassis Shop Manual (P/N CEBM000301)

Komatsu chassis shop manual CEBM000301, March 1997, covers the 1990–1997 D32E-1, D32P-1, D38E-1, D38P-1, D39E-1, and D39P-1 bulldozers. Serial coverage starts at P075501 for D32, P085501 for D38, and P095501 for D39 machines.

Text search and diagram navigation: Most service pages have searchable OCR text, but some pages and foldout diagrams are not searchable. Embedded bookmarks lead to sections and individual components. Small wiring labels are readable when enlarged.

• Powershift drivetrain: Torque converter overhaul, transmission clutch repair, shaft endplay adjustment, and pressure and stall testing.

• Steering and final drives: Planetary steering drive overhaul, brake adjustment, steering cylinder repair, and separate final-drive procedures for different models.

• Equipment hydraulics: Charge and scavenge pumps, equipment pump, control valves, blade and ripper cylinders, and hydraulic performance tests.

• Undercarriage and tracks: Wear inspection, roller and idler rebuilding, track frame alignment, split-link connections, and track joint repair.

• Cooling and engine work: Radiator core and tank overhaul, engine removal and installation, throttle linkage adjustment, and engine test specifications.

• Electrical reference: System specifications and wiring connections for starting, charging, lighting, instruments, and accessories.

Written for service personnel responsible for machine overhaul and repair, this manual assumes access to workshop lifting equipment, presses, and dedicated service tools.

Torque Converter and Powershift Transmission

Drivetrain descriptions follow power from the engine flex plate through the torque converter and transmission to the steering drive. Converter repair covers the rear housing, impeller, turbine, stator, bearings, and related clearance checks.

Transmission procedures address directional and range clutch assemblies, shaft endplay, and shim selection. The Cross Section View of Transmission supports component identification during teardown.

Main pressure regulator, range selector, rate of rise, and transmission/steering control valves receive separate treatment. Spring tables list free length, test load, and working coils for inspection.

The Drive Train Schematic maps hydraulic connections. Test tables cover main, converter, and transmission lubrication pressures in neutral and stall conditions, alongside clutch-pressure and stall-speed checks. Tool references include pressure test kit DR04-309 and transmission tool kit DR04-721.

Steering Brakes and Model-Specific Final Drives

Steering coverage extends to planet gear carriers, brake shoes, steering cylinder seal replacement, and the brake cylinder valve. Bearing preload, gear backlash, and tooth-contact checks accompany assembly and adjustment procedures.

Final drives use single-reduction gearing, with separate procedures for D32/D38 and D39 machines and E/P configuration differences. The Cross Section View of Final Drive shows the assemblies; inspection and assembly instructions address sprocket carrier bearings and metal-type face seals.

Assembly cautions explain how tightening the carrier-shaft bolt with the bottom cover removed can distort the final-drive housing.

Blade, Ripper, and Pump Hydraulics

The Hydraulic System diagram distinguishes the three-spool control arrangement for the six-way blade from the four-spool arrangement with a ripper. Valve sections cover relief, load-check, anti-cavitation, and blade-float functions.

The cylinder drift test helps separate piston-packing leakage from control-valve spool leakage before choosing which assembly needs repair. Piston-packing tests, cylinder time-cycle checks, and relief-pressure tests add further diagnostic detail.

Pump chapters distinguish the dual-element charge/scavenge pump from the equipment pump. Inspection instructions separate seal-kit repairs from internal damage requiring complete pump replacement.

Undercarriage, Track Chains, and Mounted Equipment

Wear Limit Checks charts distinguish dry-sealed and lubricated tracks and cover pins, bushings, links, idlers, rollers, and grousers. Repair procedures extend to top idlers, track rollers, track adjusters, springs, frame alignment, and front crossbars.

Split-link connection procedures are separate from pressed track-joint repairs. The latter reference portable press DR11-802-2; track-chain assembly cautions identify excessive pressing force as a cause of spacer damage.

Mounted-equipment coverage includes C-frame rub bars, angling-frame wear plates, and blade and cylinder-pin bushings, with model-specific shimming differences.

Radiator Repair and Engine Service Scope

Cooling-system instructions cover radiator removal, core and tank disassembly, gasket replacement, reassembly, and service diagnosis. Blower and reversible-fan arrangements are identified.

For the 4D102-1 and S4D102-1 engines, this chassis manual provides removal and installation procedures, mountings, throttle/decelerator adjustments, and operating test data. Internal engine overhaul requires the separate Engine Shop Manual, SEBM010002, which is not included.

Electrical Diagrams and Coverage

The Wiring Diagram identifies component connections, connector terminals, and wire colors. Electrical coverage is limited to specifications, circuit descriptions, and this diagram; it does not provide a dedicated electrical troubleshooting or component-overhaul chapter.

Torque Tables, Capacities, and Inspection Data

Reference tables supply inch and metric fastener torques, component clearances, mounting torques, and fluid capacities across the three machine series.

The manual's safety instructions address pressurized systems, heavy components, and crushing hazards associated with shop work.

English PDF and Included Pages

The manual is supplied as a printable 629-page PDF in English: 618 section pages, 10 front-matter pages, and one manual-revision form. The total already includes the cover, revision records, publication/order pages, indexes, foldout diagrams, and blank pages.