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D39P-1
Komatsu D39P-1 Shop Manual
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SAFETY PRECAUTIONS
INTRODUCTION
1 - 9
1.
General Caution
4.
Track Adjuster Caution
(737 994 C3)
(655 434 C2)
2.
Door Caution
(667 460 C2)
3.
Instructional Caution
(628 135 C4)
5.
Pressurized Reservoir
(2754 473 R3)
6.
Safety Caution
(1120 363 C2)
7.
ROPS Caution
(737 993 C3)
14
16
Table of Contents
SECTION INDEX
5
INDEX TO SECTIONS
6
SECTION 1 - INTRODUCTION
7
SAFETY PRECAUTIONS
8
GENERAL
8
BEFORE STARTING THE ENGINE
8
OPERATION
9
MAINTENANCE
10
SHUTDOWN
12
SAFETY PRODUCT GRAPHICS AND LOCATION
14
SERVICE INFORMATION
16
GENERAL
16
PIN AND SERIAL NUMBERS
16
SERVICE TOOLS AND PARTS
17
INSPECTION AND REPAIR
17
LOCTITE USAGE
18
SURFACE PREPARATION
18
APPLICATION
18
SETTING TIME (BEFORE PLACING IN OPERATION)
19
REMOVAL
19
APPLICATIONS AT LOW TEMPERATURES
19
SECTION 2 - MISCELLANEOUS
20
DIMENSIONS
21
D32E-1 DIMENSIONS
21
D32P-1 DIMENSIONS
22
D38E-1 DIMENSIONS
23
D38P-1 DIMENSIONS
24
D39E-1 DIMENSIONS
25
D39P-1 DIMENSIONS
26
SPECIFICATIONS
27
D32E-1, D32P-1 SPECIFICATIONS
27
D38E-1, D38P-1 SPECIFICATIONS
28
D39E-1, D39P-1 SPECIFICATIONS
29
CAPACITIES AND LUBRICANTS
30
SPECIAL TORQUES
32
STANDARD TORQUES
34
INTRODUCTION OF TOOLS
34
BOLT IDENTIFICATION CHART
35
GRADE 5 AND 8 NON-PHOSPHATE HARDWARE
36
GRADE 8 PHOSPHATE HARDWARE
37
STANDARD METRIC FASTENERS
37
HOSE CLAMPS
38
SPLIT FLANGE CONNECTIONS
38
SECTION 4 - BRAKES
39
GENERAL
40
DESCRIPTION
41
SPECIFICATIONS
41
BRAKE AND DECELERATOR PEDAL
42
REMOVAL
43
SERVICE
43
INSTALLATION
47
BRAKE PAD
48
REMOVAL
50
SERVICE
51
INSTALLATION
56
BRAKE SUPPORT BRACKET
59
SECTION 6 - COOLING
61
GENERAL
62
DESCRIPTION
62
OPERATION
62
SPECIFICATIONS
62
SERVICE DIAGNOSIS
63
RADIATOR - D32E-1 & D32P-1
64
RADIATOR - D38E/P-1 & D39E/P-1
65
REMOVAL
67
DISASSEMBLY
71
REASSEMBLY
76
INSTALLATION
80
SECTION 7 - DRIVE TRAIN
86
GENERAL
87
SPECIFICATIONS
87
DRIVE TRAIN SCHEMATIC
88
DESCRIPTION
90
OPERATION
90
PRESSURES
92
BRAKE CYLINDER RELEASE
93
TRANSMISSION CLUTCH
93
STALL SPEEDS
94
SECTION 7B - TORQUE CONVERTER
95
GENERAL
96
DESCRIPTION
96
OPERATION
96
SPECIAL TOOLS
96
SPECIFICATIONS
98
SERVICE DIAGNOSIS
98
REMOVAL
99
DISASSEMBLY
107
COMPLETE ASSEMBLY
107
CONVERTER ASSEMBLY
111
REAR HOUSING
115
REASSEMBLY
118
REAR HOUSING
118
CONVERTER ASSEMBLY
122
COMPLETE ASSEMBLY
126
INSTALLATION
133
SECTION 7C - TRANSMISSION
140
GENERAL
141
DESCRIPTION
142
OPERATION
142
SPECIFICATIONS
144
REMOVAL
145
COMPLETE ASSEMBLY
161
DISASSEMBLY
162
REASSEMBLY
167
DIRECTIONAL (INPUT) SHAFT
177
GENERAL
177
SPRING CRITERION
179
DISASSEMBLY
179
REASSEMBLY
184
COUNTERSHAFT
193
GENERAL
193
DISASSEMBLY
194
REASSEMBLY
194
RANGE (OUTPUT) SHAFT
196
GENERAL
196
SPRING CRITERION
198
DISASSEMBLY
198
REASSEMBLY
205
REVERSE IDLER SHAFT
219
GENERAL
219
DISASSEMBLY
220
REASSEMBLY
220
MAIN REGULATOR VALVE
222
DESCRIPTION
223
THEORY OF OPERATION
223
SPECIFICATIONS
224
DISASSEMBLY
224
REASSEMBLY
227
RANGE SELECTOR VALVE
231
DESCRIPTION
232
THEORY OF OPERATION
232
SPECIFICATIONS
233
DISASSEMBLY
233
REASSEMBLY
235
RATE OF RISE VALVE
238
SPECIFICATIONS
243
DISASSEMBLY
244
REASSEMBLY
246
INSTALLATION
250
TRANSMISSION/STEERING VALVE
268
DESCRIPTION
270
THEORY OF OPERATION
270
SPECIFICATIONS
271
REMOVAL
272
DISASSEMBLY
274
REASSEMBLY
282
ADJUSTMENT
290
INSTALLATION
291
DRIVE SHAFT
294
SPECIFICATIONS
294
SERVICE
295
SECTION 7E - STEERING DRIVE
297
GENERAL
298
DESCRIPTION
298
OPERATION
298
SPECIFICATIONS
299
REMOVAL
300
DISASSEMBLY
310
BRAKE CYLINDER
320
SPECIFICATIONS
322
DISASSEMBLY
322
REASSEMBLY
324
STEERING CYLINDER
326
DESCRIPTION
327
DISASSEMBLY
327
REASSEMBLY
329
MOUNTING PLATE
331
SERVICE
332
BRAKE/STEERING SHOES
334
SPECIFICATIONS
336
SERVICE
336
BEARING CARRIER
339
SERVICE
339
PLANET GEAR CARRIER
342
SERVICE
342
REASSEMBLY
344
INSTALLATION
363
BRAKE ADJUSTMENT
374
BRAKE CYLINDER VALVE
377
GENERAL
377
SPECIFICATIONS
378
OPERATION
378
REMOVAL
379
DISASSEMBLY
381
REASSEMBLY
382
INSTALLATION
383
SECTION 7F - FINAL DRIVE
385
GENERAL
386
DESCRIPTION
387
OPERATION
387
SPECIFICATION
387
SERVICE DIAGNOSIS
388
REMOVAL
389
DISASSEMBLY
391
D32E-1, D32P-1, D38E-1 OR D38P-1
392
D39E-1 OR D39P-1
395
REASSEMBLY
400
D32E-1, D32P-1, D38E-1 OR D38P-1
401
D39E-1 OR D39P-1
404
METAL TYPE FACE SEALS
408
SEAL INSPECTION
408
SEAL INSTALLATION
409
INSTALLATION
410
SECTION 8 - ELECTRICAL
412
GENERAL
413
DESCRIPTION
413
SPECIFICATIONS
413
SPECIAL TOOLS
413
TORQUE DATA
413
WIRING DIAGRAM
414
SECTION 10 - HYDRAULICS
416
GENERAL
417
DESCRIPTION
418
OPERATION
418
SPECIFICATIONS
419
SPECIAL TOOLS
419
WORK EQUIPMENT
420
BLADE EQUIPMENT LEVER
423
REAR EQUIPMENT LEVER
424
SECTION 10A - PUMPS
425
CHARGE AND SCAVENGE PUMP
426
GENERAL
427
REMOVAL
428
DISASSEMBLY
429
INSPECTION
433
REASSEMBLY
433
INSTALLATION
437
EQUIPMENT PUMP
438
GENERAL
439
REMOVAL
440
DISASSEMBLY
441
INSPECTION
443
REASSEMBLY
443
INSTALLATION
445
SECTION 10B - CONTROL VALVE
447
REMOVAL
448
COMPLETE ASSEMBLY
456
DISASSEMBLY
456
REASSEMBLY
459
SYSTEM RELIEF VALVE
461
DISASSEMBLY
463
REASSEMBLY
464
BLADE LIFT SECTION
466
DISASSEMBLY
469
REASSEMBLY
470
BLADE TILT SECTION
475
DISASSEMBLY
477
REASSEMBLY
477
BLADE ANGLE OR RIPPER SECTION
480
DISASSEMBLY
480
REASSEMBLY
480
INSTALLATION
485
SECTION 10C - CYLINDERS
492
BLADE EQUIPMENT
493
SPECIFICATIONS
494
REMOVAL
494
DISASSEMBLY
496
REASSEMBLY
499
INSTALLATION
501
RIPPER
503
SPECIFICATIONS
504
REMOVAL
504
DISASSEMBLY
505
BUSHINGS
507
REASSEMBLY
508
SECTION 12 - POWER
511
ENGINE
512
STANDARD VALUE TABLE FOR ENGINE
512
D32E AND D32P
512
D38E AND D38P
513
D39E AND D39P
514
REMOVAL
515
INSTALLATION
527
THROTTLE
538
ADJUSTMENT
538
FUEL CONTROL LINKAGE
541
SECTION 14 - UNDERCARRIAGE
542
GENERAL
543
DESCRIPTION
544
FRONT IDLER
544
TRACK ADJUSTER
544
TRACK SPRING
544
TRACK TOP IDLER
544
TRACK ROLLER
544
FRONT CROSSBAR
544
REAR RIGID BAR
544
MAINTENANCE
544
SERVICE DIAGNOSIS
545
WEAR LIMIT CHECKS
547
SPECIFICATIONS
547
GENERAL
549
TRACK SHOE GROUSER HEIGHT
549
LINK HEIGHT
549
BUSHING OUTSIDE DIAMETER
549
INTERNAL PIN AND BUSHING WEAR (PITCH)
550
FRONT IDLER FLANGE HEIGHT
550
TRACK ROLLER ROLLING DIAMETER
550
TOP IDLER ROLLING DIAMETER
550
FRONT IDLER
551
SPECIFICATIONS
552
REMOVAL
553
DISASSEMBLY
553
CLEARANCES
557
REASSEMBLY
559
INSTALLATION
563
TRACK ADJUSTER
568
SPECIFICATIONS
569
SERVICE
569
TOP IDLER
573
SPECIFICATIONS
574
REMOVAL
574
DISASSEMBLY
575
REASSEMBLY
578
INSTALLATION
581
TRACK ROLLER
583
SPECIFICATIONS
584
REMOVAL
584
DISASSEMBLY
585
CLEARANCES
588
REASSEMBLY
590
INSTALLATION
593
METAL TYPE FACE SEALS
594
SEAL INSPECTION
594
SEAL INSTALLATION
595
TRACK FRAME
597
REMOVAL
597
INSTALLATION
598
TRACK SPRING
599
SPECIFICATIONS
600
SPECIAL TOOLS
600
REPLACEMENT
601
FRONT CROSSBAR
608
REMOVAL
608
INSTALLATION
609
REAR RIGID BAR
612
REPLACEMENT
612
TRACK FRAME ALIGNMENT
613
SECTION 15 - TRACK CHAIN
617
SPLIT LINK TYPE CHAINS
618
SPECIFICATIONS
620
DESCRIPTION
621
MAINTENANCE
621
REMOVAL
622
INSTALLATION
622
COMPLETE CHAIN REBUILD
622
SINGLE TRACK CHAIN JOINT REBUILD
624
SECTION 17 - MOUNTED EQUIPMENT
628
C FRAME RUB BARS
629
MOUNTING
629
ANGLING FRAME
631
BUSHING REPLACEMENT
631
SPECIFICATIONS
632
ADJUSTING
632
C FRAME PIN
633
PIN SHIMS
633
C FRAME
634
BUSHING REPLACEMENT
634
BLADE BUSHINGS
635
BUSHING REPLACEMENT
635
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Komatsu D39P-1 Specifications
General
Brand
Komatsu
Model
D39P-1
Category
Excavators
Language
English
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