Komatsu D38E-1 D38P-1 Crawler Tractor Workshop Service Manua

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🏷️ Basic Information Identification Make: Komatsu Model: D38E-1 / D38P-1 Crawler Tractor Product Type: Workshop Service Repair Manual Engine Type Designation: Crawler Tractor Codes Serial Number Applicability D38E: P085799 and...

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Typ: Crawler Tractor

Anbieter:

Art.-Nr: 26091

Stichworte: Crawler Tractor D38E-1 D38P-1 Engines Komatsu Misc

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Komatsu

Model:

D38E-1 / D38P-1 Crawler Tractor

Product Type:

Workshop Service Repair Manual

Engine Type Designation:

Crawler Tractor

Codes

Serial Number Applicability D38E:

P085799 and up

Serial Number Applicability D38P:

P085799 and up

👋 Introduction

Market Position

Equipment Class:

Medium-sized crawler tractor, suitable for a range of construction, earthmoving, and land clearing applications

Competitive Analysis

Key Competitors:

Caterpillar D5, John Deere 650J, Case IH CX100, Volvo EC140B

Key Features

Power And Performance:

Designed for robust performance and reliability in demanding conditions

Operator Comfort:

Focus on operator efficiency and comfort through ergonomic design (typical for Komatsu)

Durability:

Built with Komatsu's reputation for robust construction and long service life

📋 Manual Details

Coverage Areas

Manual Coverage:

Comprehensive workshop service and repair for Komatsu D38E-1 and D38P-1 Crawler Tractors

Page Count

Page Count Estimated:

Extensive (exact number not specified, but described as 'COMPLETE offic...')

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English (assumed based on common industry standards for Komatsu manuals of this era and description)

Format

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, fuel system, cooling system, lubrication system, exhaust system, transmission, final drives, driveline components

Undercarriage:

Track frame, idlers, track rollers, carrier rollers, sprockets, recoil system, suspension

Hydraulic System:

Hydraulic pump, control valves, cylinders, hoses, filters, hydraulic fluid specifications and maintenance

Electrical System:

Starting system, charging system, battery, wiring diagrams, lighting, gauges, operator controls

Operator Station:

Seating, controls, instrumentation, safety features, ROPS (Roll-Over Protective Structure) / FOPS (Falling-Object Protective Structure) if applicable

Blades And Attachments:

Dozer blade operation, adjustments, hydraulic control for blade angle, pitch, and tilt; ripper operation and maintenance

Procedures Included

Scheduled Maintenance:

Oil change intervals, filter replacement schedules, greasing points and intervals, track adjustment procedures

Troubleshooting:

Diagnostic procedures for common issues, fault codes, symptom-based troubleshooting guides

Repair Disassembly Reassembly:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation

Torquing Specifications:

Critical fastener torque values for all major components and assemblies

Adjustment Procedures:

Calibration and adjustment of hydraulic systems, braking systems, engine components, and controls

Safety Precautions:

Essential safety guidelines for operating, maintaining, and repairing the equipment

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic information, including troubleshooting flowcharts and component testing procedures

Rebuild Instructions:

Detailed instructions for complete overhaul and rebuilding of major components like engine, transmission, and hydraulic systems

Specifications Data:

Comprehensive technical data, including measurements, tolerances, capacities, and performance specifications

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - assumed for download

Print Quality

Print Readability:

High resolution, optimized for clear viewing and printing of diagrams and text

Binding Type

Binding:

N/A (Digital download, no physical binding)

Paper Type

Paper Type:

N/A (Digital download, no physical paper type)

Searchability

Text Search:

Likely searchable text within the PDF document for efficient information retrieval

Illustrations

Diagrams And Photos:

Includes detailed illustrations, diagrams, schematics, and potentially photographs to aid in understanding procedures

⚙️ Engine Specifications

Primary Engine

Engine Model:

Komatsu SAA6D107E-1 (typical for this series, exact model may vary slightly, check specific machine)

Performance

Gross Horsepower:

Approximately 110 HP (82 kW) at rated RPM (verify specific model)

Net Horsepower:

Approximately 105 HP (78 kW) at rated RPM (verify specific model)

Displacement:

6.67 Liters (407 cubic inches) (typical for SAA6D107E-1)

Fuel System

Fuel Injection:

Direct injection, electronically controlled common rail fuel system

Fuel Type:

Diesel

Cooling System

Cooling Method:

Water-cooled, pressurized

Lubrication System

Oil Type:

Komatsu Genuine Engine Oil or equivalent API CI-4 SAE 15W-40 (refer to manual for precise specification)

🔧 Transmission

Standard

Transmission Type:

Hydrostatic transmission (HST) with electronic control

Optional

Optional Transmission:

N/A (Typically standard for this model)

Features

Drive System:

All-wheel drive (tracks)

Speed Control:

Variable speed control via joystick or pedal

Transmission Fluid:

Komatsu Advanced Transmission Fluid (KTF) or equivalent UTF (Universal Tractor Fluid) – verify specification in manual

📐 Dimensions

Exterior

Operating Weight D38E:

Approximately 8,200 - 8,500 kg (18,000 - 18,700 lbs) (verify specific configuration)

Operating Weight D38P:

Approximately 8,600 - 8,900 kg (19,000 - 19,600 lbs) (verify specific configuration, 'P' likely indicates Power-Angle-Tilt blade option)

Ground Pressure:

Varies with track shoe width, typically around 0.45 - 0.55 kg/cm² (6.4 - 7.8 psi)

Weights

Drawbar Pull:

Up to approximately 7,000 kgf (15,400 lbf) (verify specific machine)

🛡️ Safety Features

Ratings

Rops Fops:

Equipped with ROPS (Roll-Over Protective Structure) and FOPS (Falling-Object Protective Structure) as standard or optional, compliant with relevant safety standards

Active Features

Operator Presence System:

System to prevent unintended movement when operator is not seated

Emergency Stop:

Location and function of emergency stop controls

Passive Features

Seatbelt:

Retractable seat belt for operator restraint

Warning Lights And Alarms:

Audible and visual warnings for operational status and potential hazards

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a heavy construction machine, not equipped with typical automotive infotainment systems)

Driver Assistance

Operator Aids:

Electronic controls for transmission and hydraulics enhance operability. Features like variable speed control contribute to ease of use.

Connectivity

Telematics:

Modern Komatsu machines often feature KOMTRAX™ telematics for remote monitoring of machine health, location, and operating data. This manual would cover its operational aspects if equipped.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 250-500 operating hours, depending on operating conditions and Komatsu recommendations (refer to manual for exact interval).

Fuel Filter Replacement:

As per Komatsu's recommended schedule, often tied to engine oil change intervals or indicated by system warnings.

Hydraulic Oil Filter Replacement:

Regular replacement based on operating hours or contamination monitoring, as per manual recommendations.

Track Tension Adjustment:

Regular checks and adjustments as needed based on operating environment and wear, typically inspected daily or weekly.

Fluid Specifications

Engine Oil Capacity:

Approximately 18-20 Liters (4.7-5.3 US gallons) (verify with manual)

Hydraulic Oil Capacity:

Approximately 60-70 Liters (15.8-18.5 US gallons) (verify with manual)

Coolant Type:

Permanent type engine coolant (ethylene glycol base) with appropriate antifreeze protection, typically a 50/50 mix with distilled water.

Known Issues

Common Wear Items:

Track components (links, pins, bushings), sprockets, idlers, rollers, and engine belts are common wear items requiring regular inspection and replacement.

Hydraulic System Maintenance:

Maintaining hydraulic fluid cleanliness and timely filter replacement is critical to prevent pump and valve wear.

Engine Performance Issues:

Issues like loss of power or rough running can stem from fuel system problems (injectors, filters), air intake restrictions, or turbocharger issues.

📚 Vehicle History

Brand Heritage

Komatsu Legacy:

Komatsu is a renowned Japanese multinational corporation that manufactures construction, mining, and industrial equipment. Known for its robust engineering and durability.

Model Evolution

D38 Series Context:

Part of Komatsu's line of reliable and efficient crawler tractors, designed for general construction and earthmoving tasks. Often characterized by its user-friendly operation and fuel efficiency.

Production

Manufacturing Origin:

Typically manufactured in Komatsu's global production facilities, with a significant presence in Japan and North America.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Komatsu equipment is generally well-regarded for reliability and performance, though specific awards for the D38E-1/D38P-1 model might not be widely publicized. Focus is on performance and durability.

Ratings

Component Durability Ratings:

High ratings for undercarriage and powertrain durability in typical working conditions, as expected from Komatsu.