Komatsu d63 e 12 dozer bulldozer service repair manual (sn 2001 and up)

BULLDOZER
SEN04151-00
D63E-12
SERIAL NUMBERS 2001 and up

D63E-12 00-100 1
SEN04160-00
BULLDOZER 1SHOP MANUAL
D63E-12
Machine model Serial number
D63E-12 2001 and up
00 Index and foreword
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4

SEN04160-00
00-100 2 D63E-12
100 Index
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs .....................................................................SEN04151-00
00 Index and foreword ....................................................................................................................SEN04152-00
100 Index ..................................................................................................................................SEN04160-00
200 Foreword and general information.....................................................................................SEN04161-00
01 Specification...............................................................................................................................SEN04153-00
100 Index ..................................................................................................................................SEN04629-00
10 Structure, function and maintenance standard...........................................................................SEN04154-00
100 Engine and cooling system................................................................................................SEN04630-00
210 Power train, Part 1 .............................................................................................................SEN04631-00
220 Power train, Part 2 .............................................................................................................SEN04632-00
300 Undercarriage and frame...................................................................................................SEN04633-00
410 Hydraulic system, Part 1....................................................................................................SEN04634-00
420 Hydraulic system, Part 2....................................................................................................SEN04635-00
500 Work equipment.................................................................................................................SEN04636-00
600 Cab and its attachments ....................................................................................................SEN04637-00
700 Electrical system................................................................................................................SEN04638-00
20 Standard value table...................................................................................................................SEN04155-00
100 Standard service value table..............................................................................................SEN04589-00
30 Testing and adjusting .................................................................................................................SEN04156-00
110 Testing and adjusting, Part 1..............................................................................................SEN04590-00
120 Testing and adjusting, Part 2..............................................................................................SEN04591-00
40 Troubleshooting..........................................................................................................................SEN04157-00
100 General information on troubleshooting.............................................................................SEN04592-00
200 Troubleshooting of electrical system (E-mode)..................................................................SEN04593-00
300 Troubleshooting of hydraulic and mechanical system (H-mode) .......................................SEN04594-00
400 Troubleshooting of engine (S-mode)..................................................................................SEN04595-00
500 Troubleshooting of machine monitor system (M-mode).....................................................SEN04596-00
50 Disassembly and assembly........................................................................................................SEN04158-00
100 General information on disassembly and assembly ..........................................................SEN04671-00
200 Engine and cooling system................................................................................................SEN04672-00

SEN04160-00
D63E-12 00-100 3
100 Index
310 Power train, Part 1..............................................................................................................SEN04673-00
320 Power train, Part 2..............................................................................................................SEN04674-00
400 Undercarriage and frame ...................................................................................................SEN04675-00
500 Hydraulic system................................................................................................................SEN04676-00
600 Work equipment .................................................................................................................SEN04677-00
700 Cab and its attachments.....................................................................................................SEN04678-00
90 Diagrams and drawings..............................................................................................................SEN04159-00
100 Hydraulic diagrams and drawings ......................................................................................SEN04639-00
200 Electrical diagrams and drawings.......................................................................................SEN04640-00

SEN04160-00
00-100 4 D63E-12
100 Index
Table of contents 1
100 Index ..........................................................................................................................................SEN04160-00
Composition of shop manual......................................................................................................................... 2
Table of contents........................................................................................................................................... 4
200 Foreword and general information.............................................................................................SEN04161-00
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data.................................................................................................SEN04629-00
Specification drawing .................................................................................................................................... 2
Specifications ................................................................................................................................................ 3
Weight table .................................................................................................................................................. 6
Table of fuel, coolant and lubricants.............................................................................................................. 8
10 Structure, function and maintenance standard
100 Engine and cooling system........................................................................................................SEN04630-00
Radiator, power train, oil cooler..................................................................................................................... 2
Engine control ............................................................................................................................................... 4
210 Power train, Part 1 .....................................................................................................................SEN04631-00
Power train system........................................................................................................................................ 2
Power train skeleton...................................................................................................................................... 3
Power train unit ............................................................................................................................................. 4
Power train hydraulic piping diagram............................................................................................................ 5
Transmission, steering and brake control ..................................................................................................... 6
Damper, universal joint.................................................................................................................................. 8
Torque converter and PTO............................................................................................................................ 11
Transmission................................................................................................................................................. 16
Transmission control valve............................................................................................................................ 26
Main relief valve ............................................................................................................................................ 32
Lubrication relief valve .................................................................................................................................. 35
Power train oil filter........................................................................................................................................ 36
Final drive...................................................................................................................................................... 38
220 Power train, Part 2 .....................................................................................................................SEN04632-00
Bevel gear shaft, steering clutch and brake.................................................................................................. 2
Brake valve ................................................................................................................................................... 12
Reducing valve.............................................................................................................................................. 17
Scavenging pump strainer ............................................................................................................................ 18
Power train pump strainer............................................................................................................................. 19
300 Undercarriage and frame...........................................................................................................SEN04633-00
Main frame .................................................................................................................................................... 2
Suspension ................................................................................................................................................... 4
Track frame ................................................................................................................................................... 7
Recoil spring ................................................................................................................................................. 8
Idler ............................................................................................................................................................... 10
Track roller .................................................................................................................................................... 12

SEN04160-00
D63E-12 00-100 5
100 Index
Carrier roller................................................................................................................................................... 13
Track shoe..................................................................................................................................................... 14
410 Hydraulic system, Part 1 ........................................................................................................... SEN04634-00
Work equipment hydraulic piping diagram .................................................................................................... 2
Work equipment control................................................................................................................................. 6
Hydraulic tank and filter................................................................................................................................. 8
Hydraulic pump.............................................................................................................................................. 10
Power train lubrication pump......................................................................................................................... 11
Control valve.................................................................................................................................................. 12
CLSS ............................................................................................................................................................. 19
Functions and operation by valve.................................................................................................................. 21
420 Hydraulic system, Part 2 ........................................................................................................... SEN04635-00
PPC valve...................................................................................................................................................... 3
Suction valve ................................................................................................................................................. 8
500 Work equipment ........................................................................................................................ SEN04636-00
Work equipment ............................................................................................................................................ 2
Cutting edge, end bit ..................................................................................................................................... 4
Ripper............................................................................................................................................................ 5
Work equipment cylinder............................................................................................................................... 8
600 Cab and its attachments............................................................................................................ SEN04637-00
Cab mount..................................................................................................................................................... 2
Cab................................................................................................................................................................ 3
ROPS guard .................................................................................................................................................. 4
700 Electrical system ....................................................................................................................... SEN04638-00
Machine monitor system................................................................................................................................ 2
Monitor panel................................................................................................................................................. 3
Engine control................................................................................................................................................ 6
Sensors ......................................................................................................................................................... 7
20 Standard value table
100 Standard service value table ..................................................................................................... SEN04589-00
Standard value table for engine..................................................................................................................... 2
Standard value table for chassis.................................................................................................................... 3
Standard value table for electrical system..................................................................................................... 8
30 Testing and adjusting
110 Testing and adjusting, Part 1..................................................................................................... SEN04590-00
Tools for testing, adjusting, and troubleshooting ........................................................................................... 2
Testing engine speed..................................................................................................................................... 4
Testing blow-by pressure............................................................................................................................... 5
Testing exhaust color..................................................................................................................................... 6
Testing air boost pressure ............................................................................................................................. 7
Testing and adjusting valve clearance........................................................................................................... 8
Testing compression pressure....................................................................................................................... 10
Testing and adjusting fuel injection timing ..................................................................................................... 11
Testing exhaust temperature ......................................................................................................................... 13
Testing engine oil pressure............................................................................................................................ 15
Testing and adjusting engine stop solenoid................................................................................................... 16
Testing and adjusting fan belt tension ........................................................................................................... 18
Testing and adjusting air conditioner compressor belt tension...................................................................... 18
Replacing alternator belt................................................................................................................................ 19
120 Testing and adjusting, Part 2..................................................................................................... SEN04591-00
Testing speed at torque converter stall.......................................................................................................... 2
Adjusting fuel control linkage......................................................................................................................... 3
Adjusting linkages of steering, forward-reverse lever, gear shift lever, and parking brake lever ................... 5
Adjusting brake pedal linkage........................................................................................................................ 8

SEN04160-00
00-100 6 D63E-12
100 Index
Adjusting work equipment lock lever............................................................................................................. 10
Adjusting straight tiltdozer and U-dozer ........................................................................................................ 11
Testing power train hydraulic pressure.......................................................................................................... 13
Testing and adjusting work equipment oil pressure ...................................................................................... 16
Testing leakage inside cylinder ..................................................................................................................... 17
Bleeding air from hydraulic cylinder .............................................................................................................. 17
Procedure for simple test of steering brake performance ............................................................................. 18
40 Troubleshooting
100 General information on troubleshooting.....................................................................................SEN04592-00
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting......................................................................................................... 3
Testing before troubleshooting...................................................................................................................... 4
How to follow the troubleshooting flow diagrams.......................................................................................... 5
Connection table for connector pin numbers ................................................................................................ 7
T- branch box and T- branch adapter table................................................................................................... 43
200 Troubleshooting of electrical system (E-mode)..........................................................................SEN04593-00
Installing positions of fuses ........................................................................................................................... 2
Table of failure modes and causes (Electrical system) ................................................................................. 3
Electrical circuit diagram for each system..................................................................................................... 4
E-1 Starting motor is not cranked when starting switch is turned to ON ....................................................... 6
E-2 Lamps do not light up ............................................................................................................................. 8
E-3 Automatic preheating is not carried out when glow switch is turned to Auto.......................................... 10
E-4 Wiper does not work............................................................................................................................... 12
E-5 No washer fluid is sprayed out ............................................................................................................... 14
E-6 Air conditioner has no effect................................................................................................................... 16
E-7 Engine does not start (Engine stop solenoid malfunctions).................................................................... 24
300 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN04594-00
Table of failure modes and causes (hydraulic, mechanical system) ............................................................. 2
H-1 Brake does not work............................................................................................................................... 4
H-2 Machine does not turn (can travel in a straight line)............................................................................... 5
H-3 Machine overruns when turning ............................................................................................................. 6
H-4 Machine can turn in only one direction (when steering lever is operated) ............................................. 6
H-5 Excessive time lag.................................................................................................................................. 7
H-6 Machine can travel in only one direction (forward or reverse)................................................................ 7
H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd).............................. 8
H-8 Machine does not move in any speed range.......................................................................................... 10
H-9 Power train oil temperature rises too high.............................................................................................. 12
H-10 Drawbar pull is weak, travel speed is slow........................................................................................... 14
H-11 Abnormal noise is generated from around hydraulic pump.................................................................. 16
H-12 All work equipment speed is slow or lacks power ................................................................................ 16
H-13 No work equipment moves................................................................................................................... 17
H-14 Hydraulic drift of blade lift is excessive................................................................................................. 17
H-15 Hydraulic drift of blade tilt is excessive................................................................................................. 18
400 Troubleshooting of engine (S-mode)..........................................................................................SEN04595-00
Method of using troubleshooting charts ........................................................................................................ 2
S-1 Starting performance is poor (Starting always takes time)...................................................................... 6
S-2 Engine does not start.............................................................................................................................. 8
S-3 Engine does not pick up smoothly (Follow-up is poor)........................................................................... 11
S-4 Engine stops during operations.............................................................................................................. 12
S-5 Engine does not rotate smoothly (Hunting) ............................................................................................ 13
S-6 Engine lacks output (or lacks power)...................................................................................................... 14
S-7 Exhaust smoke is black (Incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down.................................................... 19

SEN04160-00
D63E-12 00-100 7
100 Index
S-12 Oil pressure monitor lights up (Drop in oil pressure)............................................................................. 20
S-13 Oil level rises (Coolant, fuel in oil)......................................................................................................... 21
S-14 Coolant temperature becomes too high (Overheating)......................................................................... 22
S-15 Abnormal noise is made ....................................................................................................................... 23
S-16 Vibration is excessive ........................................................................................................................... 24
500 Troubleshooting of machine monitor system (M-mode) ............................................................ SEN04596-00
Table of failure modes and causes (Machine monitor system)...................................................................... 2
Forestry specification, general construction specification ............................................................................. 4
M-1. No display is given on monitor panel when starting switch is turned to ON .......................................... 6
M-2. When starting switch is turned to ON, all monitor panel lamps light up and do not go out.................... 7
M-3. Preheating is abnormal ......................................................................................................................... 8
M-4. CAUTION items light up or flash ........................................................................................................... 10
M-5. Buzzer is abnormal................................................................................................................................ 14
M-6. Warning lamp is abnormal..................................................................................................................... 15
M-7. Gauge is abnormal................................................................................................................................ 16
M-8. Service meter does not move after engine is started ............................................................................ 20
M-9. Monitor panel lighting does not light up (head lamps are normal)......................................................... 21
50 Disassembly and assembly
100 General information on disassembly and assembly.................................................................. SEN04671-00
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools............................................................................................................................... 12
200 Engine and cooling system ....................................................................................................... SEN04672-00
Removal and installation of radiator and radiator guard assembly................................................................ 2
Removal and installation of engine assembly ............................................................................................... 7
Removal and installation of coolant heater assembly ................................................................................... 11
Removal and installation of hydraulic oil cooler assembly ............................................................................ 13
Removal and installation of damper assembly.............................................................................................. 14
Removal and installation of fuel tank assembly............................................................................................. 16
Removal and installation of engine hood assembly ...................................................................................... 19
Removal and installation of fuel injection pump assembly ............................................................................ 20
Removal and installation of fuel injection nozzle assembly........................................................................... 26
Removal and installation of cylinder head assembly..................................................................................... 30
Removal and installation of engine front oil seal ........................................................................................... 40
Removal and installation of engine rear oil seal............................................................................................ 43
310 Power train, Part 1..................................................................................................................... SEN04673-00
Removal and installation of PTO, torque converter and transmission assembly........................................... 2
Separation and connection of PTO, torque converter and transmission assembly....................................... 6
Disassembly and assembly of PTO assembly............................................................................................... 8
Disassembly and assembly of torque converter assembly............................................................................ 14
Disassembly and assembly of TORQFLOW transmission assembly............................................................ 19
Removal and installation of torque converter main relief valve assembly..................................................... 38
Disassembly and assembly of torque converter main relief valve assembly................................................. 39
Removal and installation of transmission control valve assembly................................................................. 41
Disassembly and assembly of transmission control valve assembly ............................................................ 42
320 Power train, Part 2..................................................................................................................... SEN04674-00
Removal and installation of brake valve assembly........................................................................................ 2
Disassembly and assembly of brake valve assembly ................................................................................... 3
Removal and installation of steering clutch and brake assembly.................................................................. 6
Disassembly and assembly of steering clutch and brake assembly.............................................................. 7
Removal and installation of bevel gear and bevel gear shaft ........................................................................ 14
Removal and installation of final drive assembly........................................................................................... 21
Disassembly and assembly of final drive assembly ...................................................................................... 23
400 Undercarriage and frame .......................................................................................................... SEN04675-00
Removal and installation of track frame assembly ........................................................................................ 2

SEN04160-00
00-100 8 D63E-12
100 Index
Removal and installation of idler assembly................................................................................................... 4
Disassembly and assembly of idler assembly............................................................................................... 5
Removal and installation of recoil spring assembly ...................................................................................... 10
Disassembly and assembly of recoil spring assembly.................................................................................. 11
Removal and installation of track roller assembly......................................................................................... 14
Disassembly and assembly of track roller assembly..................................................................................... 15
Removal and installation of carrier roller assembly....................................................................................... 19
Disassembly and assembly of carrier roller assembly .................................................................................. 20
Check before expanding track shoe assembly ............................................................................................. 23
Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly ................... 23
Overall disassembly and overall assembly of track shoe assembly ............................................................. 26
Link press-fitting jig dimensions table ........................................................................................................... 42
Field disassembly and assembly of one link................................................................................................. 43
Removal and installation of pivot shaft assembly.......................................................................................... 50
Removal and installation of equalizer bar assembly..................................................................................... 52
Removal and installation of equalizer bar side bushing................................................................................ 54
Removal and installation of segment teeth ................................................................................................... 55
500 Hydraulic system........................................................................................................................SEN04676-00
Removal and installation of work equipment valve assembly....................................................................... 2
Disassembly and assembly of work equipment control valve assembly....................................................... 5
Removal and installation of scavenging pump.............................................................................................. 6
Removal and installation of power train and lubricating oil pump assembly................................................. 7
Removal and installation of work equipment pump assembly ...................................................................... 9
Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 11
600 Work equipment.........................................................................................................................SEN04677-00
Removal and installation of blade assembly................................................................................................. 2
Removal and installation of ripper assembly................................................................................................. 5
700 Cab and its attachments ............................................................................................................SEN04678-00
Removal and installation of ROPS guard assembly ..................................................................................... 2
Removal and installation of operator cab assembly...................................................................................... 3
Removal and installation of operator’s cab glass (Stuck glass) .................................................................... 6
Removal and installation of floor frame assembly......................................................................................... 14
Removal and installation of heater unit assembly......................................................................................... 20
Removal and installation of monitor panel assembly.................................................................................... 24
Removal and installation of dashboard assembly......................................................................................... 25
90 Diagrams and drawings
100 Hydraulic diagrams and drawings..............................................................................................SEN04639-00
Power train hydraulic circuit diagram............................................................................................................ 3
Steering, work equipment hydraulic circuit diagram...................................................................................... 5
200 Electrical diagrams and drawings ..............................................................................................SEN04640-00
Electrical circuit diagram............................................................................................................................... 3
Electrical circuit diagram (Inside cab) ........................................................................................................... 5
Connector list and stereogram...................................................................................................................... 7

SEN04672-00
50-200 2 D63E-12
200 Engine and cooling system
Removal and installation of radiator and radiator guard assembly
Removal and installation of
radiator and radiator guard
assembly 1
Removal
k Stop the machine on a level place and
apply the parking brake.
k Lower the work equipment to the ground,
apply the work equipment lock lever, and
stop the engine.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the radiator coolant temperature is high,
wait until it decreases and then drain the
coolant so that you will not be scalded.
1. Loosen the radiator cap and drain the coolant.
6 Coolant: 44 l
2. Remove the engine hood assembly. For
details, see "Removal and installation of
engine hood assembly".
3. Remove the 4 mounting bolts and open radia-
tor grille (1) toward the right.
4. Disconnect hydraulic oil cooler oil hoses (2)
and (3).
a Plug the disconnected hoses to stop the
oil from flowing out.
5. Remove radiator lower covers (4) and (5).
6. Remove grommets (6) and pull hydraulic oil
cooler oil hoses (2) and (3) into under the radi-
ator.
7. Disconnect power train oil cooler inlet hose (7)
from the left side of the radiator bottom.
8. Disconnect power train oil cooler outlet hose
(8) from the right side of the radiator bottom.
a After disconnecting the hoses, close the
radiator grille.

SEN04672-00
D63E-12 50-200 3
9. Disconnect reservoir tank hose (9).
10. Remove radiator upper cover (10).
11. Disconnect aeration hose (11).
12. Remove clamp (12) and disconnect radiator
upper hose (12a). [*1]
13. Remove clamp (13).
14. Remove fan guard (14).
15. Remove clamp (15) from the right side of the
engine and disconnect radiator lower hose
(15a). [*2]

SEN04672-00
50-200 4 D63E-12
16. Disconnect light and horn wiring harness con-
nector CN-8 (16).
17. Remove clamp (17).
18. Sling the radiator and radiator guard assembly.
19. Remove 2 each of radiator guard rear mount-
ing bolts (19) on the right and left sides.
20. Remove 4 radiator guard front mounting bolts
(20) from the radiator bottom.
21. While slinging radiator and radiator guard
assembly (21), gradually move it toward the
front of the machine to remove.
a When removing the assembly, take care
that fan and shroud will not interfere with
each other since the clearance between
them is narrow.
4 Radiator and radiator guard assembly:
360 kg
22. Disassemble the radiator and radiator guard
assembly according to the following proce-
dure.
1) Set radiator and radiator guard assembly
(21) vertically.
2) Remove upper shroud plates (22) and
(23).
3) Remove lower shroud plates (24) and
(25).

SEN04672-00
D63E-12 50-200 5
4) Sling the radiator assembly.
5) Remove 4 mounting bolts (26) and discon-
nect radiator upper mounting bracket (27)
from the radiator guard.
6) Remove clamp (28) and disconnect radia-
tor lower hose (28a). [*3]
7) Remove 2 radiator lower mounting bolts
(29) on the right and left sides.
8) Remove shroud (30).
9) Lift off radiator assembly (31).
4 Radiator assembly: 138 kg

SEN04672-00
50-200 6 D63E-12
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Radiator upper hose clamp (12):
8.8 ± 0.5 Nm {0.9 ± 0.051 kgm}
[*2]
3 Radiator lower hose clamp (15):
8.8 ± 0.5 Nm {0.9 ± 0.051 kgm}
[*3]
3 Radiator lower hose clamp (28):
8.8 ± 0.5 Nm {0.9 ± 0.051 kgm}
q Refilling with coolant
Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Total quantity of coolant: Approx. 44 l
(For details, see "Table of fuel, coolant and
lubricants")
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see "Table of fuel,
coolant and lubricants"):
Add only necessary quantity.
q Refilling with oil (Power train case)
again.
5 Power train oil (For details, see "Table of
fuel, coolant and lubricants"):

SEN04672-00
D63E-12 50-200 7
Removal and installation of engine assembly
engine assembly 1
Removal
stop the engine.
6 Coolant: 44 l
2. Close the fuel valve at the bottom of the fuel
tank.
4. Remove left engine side cover (1) and power
train side cover (2).
5. Remove right engine side covers (3) and (4)
and power train side cover (5).
6. Remove the radiator and radiator guard
assembly. For details, see "Removal and
installation of radiator and radiator guard
assembly".
7. Remove transmission undercover (6) from the
bottom of the machine.
8. Remove pin (7) from the left side of the engine
and disconnect decelerator control cable (8).
[*1]
9. Remove pin (9) and disconnect fuel control
cable (10). [*2]

SEN04672-00
50-200 8 D63E-12
10. Disconnect heater unit hoses (11) and (12).
11. Disconnect ground wiring harness (13) from
the machine.
12. Remove hose clamps (14) and (15) and dis-
connect fuel spill hose (16).
a Plug the disconnected hose to stop the
fuel from flowing out.
13. Remove hose clamp (17).
14. Remove 4 mounting bolts (18) and coolant
heater heat insulation plate (19).
15. Remove hose clamps (20) and (21) and dis-
connect coolant heater fuel inlet hose (22).
16. Remove hose clamp (23) and disconnect fuel
filter inlet hose (24).
17. Remove hose clamps (25), (26) and (27) and
disconnect fuel return hose (28).

SEN04672-00
D63E-12 50-200 9
18. Disconnect wiring harness connectors CN-H2
(29) and CN-20 (30) from the right side of the
engine.
a Pull out wiring harness connectors CN-H2
(29) and CN-20 (30) from the holder.
19. Disconnect starting motor wiring harness ter-
minal B (31).
20. Remove wiring harness clamp (32) and dis-
connect wiring harness connectors CN-30
(33), CN-31 (34), CN-32 (35) and CN-33 (36).
21. Remove connector mounting bracket (37).
a Bracket (37) must be removed so that the
engine sling wires will not interfere with it.
22. Remove drive shaft (38) from the underside of
the machine. [*3]
23. Remove right and left front engine mounting
bolts (39).

SEN04672-00
50-200 10 D63E-12
24. Remove right and left rear engine mounting
bolts (40).
25. While slinging engine assembly (41), gradually
move it toward the front of the machine to
remove.
4 Engine assembly: 1,050 kg
Installation
removal.
[*1]
Adjust the decelerator control cable. For details,
see Testing and adjusting, "Adjusting fuel control
linkage".
[*2]
Adjust the decelerator control cable. For details,
see Testing and adjusting, "Adjusting fuel control
linkage".
[*3]
2 Drive shaft (38) mounting bolt:
Adhesive (LT-2)
3 Drive shaft (38) mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
lubricants")
again.
q Refilling with oil (Power train case)
again.
5 Power train oil (For details, see "Table of
fuel, coolant and lubricants"):

SEN04672-00
D63E-12 50-200 11
Removal and installation of coolant heater assembly
coolant heater assembly 1
Removal
a The coolant heater assembly is a kit for CIS
field installation.
stop the engine.
6 Coolant: 44 l
tank.
3. Open and fix left engine wing side cover (1).
a Check that the cover is locked securely.
4. Remove left engine side covers (2).
5. Remove fuel hose clamp (3).
6. Remove 4 mounting bolts (4) and heat insula-
tion plate (5).
7. Disconnect connectors (6) and (7).
a Press claws (a) to disconnect each con-
nector.
8. Disconnect fuel inlet hose (8).

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SEN04672-00
50-200 12 D63E-12
Removal and installation of coolant heater assembly
9. Remove radiator undercover (9).
10. Disconnect coolant inlet hose (10) and outlet
hose (11).
11. Disconnect exhaust pipe (12).
12. Remove the 3 mounting bolts from the reverse
side of bracket bolt holes (b).
13. Remove coolant heater assembly (13).
Installation
removal.
lubricants")

SEN04672-00
D63E-12 50-200 13
Removal and installation of hydraulic oil cooler assembly
hydraulic oil cooler assembly 1
Removal
stop the engine.
1. Remove the 4 mounting bolts and open radia-
tor grille (1) toward the right.
2. Disconnect hydraulic oil cooler oil hoses (2)
and (3).
3. Remove the 4 mounting bolts and hydraulic oil
cooler assembly (4).
Installation
removal.
again.

SEN04672-00
50-200 14 D63E-12
Removal and installation of damper assembly
damper assembly 1
Removal
stop the engine.
6 Coolant: 44 l
tank.
4. Remove the radiator and radiator guard
assembly. For details, see "Removal and
installation of radiator and radiator guard
assembly".
5. Remove the engine assembly. For details, see
"Removal and installation of engine assembly".
6. Set the engine assembly to a block.
7. Remove coupling (1).
8. Remove plug (2) to drain the oil. [*1]
6 Damper case: 1.3 l
9. Using sling [1], lift up damper cover (3).
10. Remove the mounting bolt and install guide
bolts [2].
11. Install forcing screws [3].
12. Remove all of the remaining mounting bolts.
[*2]
13. Using forcing screws [3], remove damper
cover (3). [*3]
4 Damper cover assembly (3): 25 kg
14. Remove 8 mounting bolts (4) and damper
assembly (5). [*4]

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