This shop manual provides maintenance and repair instructions for the D575A-2 machine model. The manual contains information on machine structure and function, testing and adjusting procedures, disassembly and assembly instructions, and maintenance standards. It summarizes that the D575A-2 mounts the SA12V170-1 engine and refers technicians to the 12V170-1 Series Engine Shop Manual for engine details. The document provides safety precautions and instructions for removing and installing components like the power train oil cooler assembly, hydraulic cooler assembly, and fuel injection pump assemblies.
Komatsu d475 a 2 dozer bulldozer service repair manual (sn 10201 and up)udfjjjskekmdm
This document provides instructions for removing and installing various components of a Komatsu D475A-2 machine. It describes how to remove and install the torque converter cooler assembly, fuel injection pump assembly, water pump assembly, turbocharger assembly, aftercooler core assembly, nozzle holder assembly, cylinder head assembly, fuel tank assembly, and radiator assembly. The instructions include lists of parts to disconnect or remove for each component and the order of removal and installation steps. Weights and tightening specifications are provided for some components.
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The document provides precautions and guidelines for disassembling and assembling an excavator. It discusses cleaning the machine before disassembly, inspecting components, preparing tools and workspace, and proper procedures for disassembly and assembly. Specific precautions are given for removing and installing hydraulic components and bleeding air from the system. The document also provides terminology for maintenance standards and cautions for using nylon slings.
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The document provides maintenance information for hydraulic excavators, including:
1) Precautions and guidelines for disassembling and assembling excavator components safely and properly, such as cleaning parts, using matching marks, and bleeding air from hydraulic systems.
2) Specifications for tightening torques for bolts and nuts, as well as guidelines for piping joints and periodic replacement of parts.
3) Procedures for painting excavator components.
4) Instructions for bleeding air from the hydraulic oil tank.
Komatsu pw160 7 k hydraulic excavator service repair manual (sn k40001 and up)ufjjdjkkskemmd
This document provides instructions for removing and installing various engine components on a Komatsu PW160-7K wheel loader, including the governor motor assembly, starting motor assembly, fuel injection pump assembly, engine front seal, and engine rear seal. The summary highlights the key steps:
1. Disconnect negative battery terminal before removing components.
2. For governor motor removal, disconnect rod and electrical connectors and remove three securing bolts. Installation is the reverse.
3. For starting motor removal, disconnect two wires and remove two mounting bolts. Installation is the reverse.
4. For fuel injection pump removal, disconnect linkages, remove access cap and retaining nut, and pull pump gear loose
Hitachi zaxis zx 85 usblc 3 excavator service repair manualjfjskekdhnejd
This document provides guidelines for disassembling and assembling excavator components. It outlines important precautions such as cleaning parts, using matching marks, inspecting components, and bleeding air from hydraulic systems. Proper procedures are described for tasks like removing and installing floating seals. The document also includes torque specifications for various excavator bolts and nuts.
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This document provides instructions for disassembling and assembling hydraulic components, including:
1. Hydraulic gear pump disassembly instructions involving removing mounting bolts, draining oil, marking parts for reassembly, and removing individual parts like shafts, seals, and bearing blocks.
2. Hydraulic gear pump assembly instructions covering installing new seals, pressing in the shaft seal, installing bearing blocks and gears, and torquing mounting bolts.
3. Main control valve assembly instructions involving stacking sections with o-rings installed, inserting tie rods, and torquing nuts to attach sections.
Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000fusefjskekkmem
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Komatsu d475 a 2 dozer bulldozer service repair manual (sn 10201 and up)udfjjjskekmdm
This document provides instructions for removing and installing various components of a Komatsu D475A-2 machine. It describes how to remove and install the torque converter cooler assembly, fuel injection pump assembly, water pump assembly, turbocharger assembly, aftercooler core assembly, nozzle holder assembly, cylinder head assembly, fuel tank assembly, and radiator assembly. The instructions include lists of parts to disconnect or remove for each component and the order of removal and installation steps. Weights and tightening specifications are provided for some components.
Hitachi ex8000 excavator service repair manualfhhsjdkmem
The document provides precautions and guidelines for disassembling and assembling an excavator. It discusses cleaning the machine before disassembly, inspecting components, preparing tools and workspace, and proper procedures for disassembly and assembly. Specific precautions are given for removing and installing hydraulic components and bleeding air from the system. The document also provides terminology for maintenance standards and cautions for using nylon slings.
Hitachi zaxis 670 lch 3 excavator service repair manualfjskekazswdmme
The document provides maintenance information for hydraulic excavators, including:
1) Precautions and guidelines for disassembling and assembling excavator components safely and properly, such as cleaning parts, using matching marks, and bleeding air from hydraulic systems.
2) Specifications for tightening torques for bolts and nuts, as well as guidelines for piping joints and periodic replacement of parts.
3) Procedures for painting excavator components.
4) Instructions for bleeding air from the hydraulic oil tank.
Komatsu pw160 7 k hydraulic excavator service repair manual (sn k40001 and up)ufjjdjkkskemmd
This document provides instructions for removing and installing various engine components on a Komatsu PW160-7K wheel loader, including the governor motor assembly, starting motor assembly, fuel injection pump assembly, engine front seal, and engine rear seal. The summary highlights the key steps:
1. Disconnect negative battery terminal before removing components.
2. For governor motor removal, disconnect rod and electrical connectors and remove three securing bolts. Installation is the reverse.
3. For starting motor removal, disconnect two wires and remove two mounting bolts. Installation is the reverse.
4. For fuel injection pump removal, disconnect linkages, remove access cap and retaining nut, and pull pump gear loose
Hitachi zaxis zx 85 usblc 3 excavator service repair manualjfjskekdhnejd
This document provides guidelines for disassembling and assembling excavator components. It outlines important precautions such as cleaning parts, using matching marks, inspecting components, and bleeding air from hydraulic systems. Proper procedures are described for tasks like removing and installing floating seals. The document also includes torque specifications for various excavator bolts and nuts.
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This document provides instructions for disassembling and assembling hydraulic components, including:
1. Hydraulic gear pump disassembly instructions involving removing mounting bolts, draining oil, marking parts for reassembly, and removing individual parts like shafts, seals, and bearing blocks.
2. Hydraulic gear pump assembly instructions covering installing new seals, pressing in the shaft seal, installing bearing blocks and gears, and torquing mounting bolts.
3. Main control valve assembly instructions involving stacking sections with o-rings installed, inserting tie rods, and torquing nuts to attach sections.
Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000fusefjskekkmem
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
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This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Komatsu d65 px 12 dozer bulldozer service repair manual sn 65275 and upfujjsefksekmem
1) This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator.
2) The D65EX/PX-12 uses the SA6D125E-3 engine. The engine shop manual should be consulted for engine service.
3) Proper safety precautions must be followed when servicing equipment, including wearing protective equipment, blocking the machine, and lowering attachments to the ground.
Komatsu d65 ex 12 dozer bulldozer service repair manual sn 65209 and upudfjjjskekmdm
1) This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator.
2) The D65EX/PX-12 uses the SA6D125E-3 engine, with engine service details covered in a separate manual.
3) Proper safety precautions must be followed when servicing equipment, including the use of protective equipment and blocking of moving parts.
Komatsu d65 px 12 dozer bulldozer service repair manual sn 65275 and upudfjjjskekmdm
This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator. It contains general safety precautions and procedures for testing, disassembly, assembly, and maintenance. The document summarizes how to remove and install the fuel supply pump assembly and nozzle holder assembly, including disconnecting wiring and piping, loosening mounting hardware, and reversing steps for installation. Proper torque specifications are listed for reinstalling components.
Komatsu d65 px 12 dozer bulldozer service repair manual sn 65275 and upjfjskekdhnejd
1) This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator.
2) The D65EX/PX-12 uses the SA6D125E-3 engine. The engine shop manual should be consulted for engine service.
3) Proper safety precautions must be followed when servicing equipment, including wearing protective equipment, blocking the machine, and lowering attachments to the ground.
Komatsu d65 ex 12 dozer bulldozer service repair manual sn 65209 and upjfjskekdhnejd
This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator. It contains general safety precautions and procedures for testing, disassembly, assembly, and maintenance. The document summarizes how to remove and install the fuel supply pump assembly and nozzle holder assembly, including disconnecting wiring and piping, loosening mounting hardware, and reversing steps for installation. Proper torque specifications are listed for reinstalling components.
Komatsu d65 px 12 dozer bulldozer service repair manual sn 65275 and upfusjefjjskekmem
1) This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator.
2) The D65EX/PX-12 uses the SA6D125E-3 engine. The engine shop manual should be consulted for engine service.
3) Proper safety precautions must be followed when servicing equipment, including wearing protective equipment, blocking the machine, and lowering attachments to the ground.
Komatsu d65 ex 12 dozer bulldozer service repair manual sn 65209 and upfujjsefksekmem
This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator. It contains general safety precautions and procedures for testing, disassembly, assembly, and maintenance. The document summarizes how to remove and install the fuel supply pump assembly and nozzle holder assembly, including disconnecting wiring and piping, loosening mounting hardware, and reversing steps for installation. Proper torque specifications are listed for reinstalling components.
Komatsu d65 ex 12 dozer bulldozer service repair manual sn 65209 and upfusjefjjskekmem
1) This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator.
2) The D65EX/PX-12 uses the SA6D125E-3 engine, with engine service details covered in a separate manual.
3) Proper safety precautions must be followed when servicing equipment, including the use of protective equipment and blocking of moving parts.
Komatsu d65 ex 12 dozer bulldozer service repair manual sn 65209 and upfjsjekkmdmme
This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator. It contains sections on general information, structure and function, testing and adjusting, disassembly and assembly, maintenance standards, and other topics. Safety precautions are emphasized, including wearing protective equipment and blocking the excavator before performing any work. The document provides step-by-step instructions for removing and installing components like the fuel supply pump assembly and nozzle holder assembly. Tightening torques are specified for all fasteners.
Komatsu d65 px 12 dozer bulldozer service repair manual sn 65275 and upfjsjekkmdmme
This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator. It contains sections on general information, structure and function, testing and adjusting, disassembly and assembly, maintenance standards, and other topics. Safety precautions are emphasized, including wearing protective equipment and blocking the excavator before performing any work. The document provides step-by-step instructions for removing and installing components like the fuel supply pump assembly and nozzle holder assembly. Tightening torques are specified for all fasteners.
Komatsu D65PX-12 Dozer Bulldozer Service Repair Manual SN 65275 and up.pdffjkksekdmdm
1) This shop manual provides maintenance and repair instructions for Komatsu D65EX and D65PX-12 bulldozers.
2) The bulldozers are equipped with a SA6D125E-3 engine. The engine shop manual should be consulted for engine service details.
3) Proper safety precautions must be followed when servicing equipment, including wearing protective equipment, blocking the machine, and lowering attachments to the ground before starting work. Failure to follow precautions could result in injury.
Komatsu D65EX-12 Dozer Bulldozer Service Repair Manual SN 65209 and up.pdffjkksekdmdm
This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator. It contains sections on general information, structure and function, testing and adjusting, disassembly and assembly, maintenance standards, and other topics. Safety precautions are emphasized, including wearing protective equipment and blocking the excavator before performing any work. The document provides step-by-step instructions for removing and installing components like the fuel supply pump assembly and nozzle holder assembly. Tightening torques are specified for all fasteners.
Komatsu wa270 pt 3 wheel loader service repair manual sn wa270h30051 and upujjjjfkksekmmdm
This document provides instructions for servicing a wheel loader, including:
1) Removing and installing the engine hood, which requires disconnecting wiring, hoses, and other components.
2) Removing and installing the engine, which requires draining fluids, removing wiring, hoses, and other attachments to the engine before lifting it out.
3) Additional sections provide instructions for removing and installing other components like the radiator, fuel tank, and counterweight. Precise steps are outlined for safely supporting and disconnecting each part.
Komatsu wa270 pt 3 wheel loader service repair manual sn wa270h30051 and upfjkskekxsdcmdmme
The document provides instructions for removing and installing an engine hood assembly and removing an engine on a wheel loader. Key steps include:
1. Disconnecting electrical and hydraulic connections and draining fluids before removal.
2. Removing mounting bolts, nuts and hoses to lift off the engine hood assembly.
3. Draining the coolant and removing hoses, fan guard, transmission connections, steering pump hoses and electrical wiring when removing the engine.
4. Carrying out reinstallation in reverse order and reconnecting all electrical, hydraulic and cooling system components. Precautions like using lifting equipment and releasing pressure are emphasized.
Komatsu WA270PT-3 Wheel Loader Service Repair Manual SN WA270H30051 and up.pdff8usuejkddm3e
This document provides instructions for servicing a wheel loader, including:
1) Removing and installing the engine hood, which requires disconnecting wiring, hoses, and other components.
2) Removing and installing the engine, which has many steps including draining fluids, removing wiring, hoses, and mounting components.
3) Procedures for removing and installing other major components like the radiator, fuel tank, and counterweight. Detailed safety precautions and instructions are provided.
Komatsu WA270-3 Wheel Loader Service Repair Manual SN WA270H20051 and up.pdff8usuejkddm3e
The document provides instructions for removing and installing an engine hood assembly and removing an engine on a wheel loader. Key steps include:
1. Disconnecting electrical and hydraulic connections and draining fluids before removal.
2. Removing mounting bolts, nuts and hoses to lift off the engine hood assembly.
3. Draining the coolant and removing hoses, fan guard, transmission connections, steering pump hoses and electrical wiring when removing the engine.
4. Carrying out reinstallation in reverse order and reconnecting all electrical, hydraulic and cooling system components. Precautions like using lifting equipment and releasing pressure are emphasized.
Komatsu wa270 pt 3 wheel loader service repair manual sn wa270h30051 and upufjjsejfkskemme
The document provides instructions for removing and installing an engine hood assembly and removing an engine on a wheel loader. Key steps include:
1. Disconnecting electrical and hydraulic connections and draining fluids before removal.
2. Removing mounting bolts, nuts and hoses to lift off the engine hood assembly.
3. Draining the coolant and removing hoses, fan guard, transmission connections, steering pump hoses and electrical wiring when removing the engine.
4. Carrying out reinstallation in reverse order and reconnecting all electrical, hydraulic and coolant connections. Precautions like using lifting equipment and releasing pressures are emphasized.
Mc cormick fxl techno tier 2 (2003 2008) - rp52 - f85 fgexl tractor service r...udfjjjskekmdm
This document provides component part numbers and descriptions for engine repairs and replacements. It includes kits for replacing engine parts between specific serial numbers, as well as individual replacement parts like pistons, rods, bearings, gaskets, plugs, and other engine components. Repair codes indicate whether components should be replaced or overhauled.
Mc cormick fxl techno tier 2 (2003 2008) - rp52 - f80 fge tractor service rep...udfjjjskekmdm
This document contains parts lists and technical specifications for components of Perkins diesel engines. It includes items like cylinders, crankshafts, pistons, rods, valves, heads, pumps, and other engine parts. Repair and replacement procedures are indicated for some components, with time estimates provided. Serial numbers and engine models are referenced for applicability.
Mc cormick fxl techno tier 2 (2003 2008) - rp52 - f75 fgexl tractor service r...udfjjjskekmdm
This document provides component part information for the repair and replacement of engine parts. It includes lists of components with identification numbers, replacement part numbers, and other technical specifications. Components listed include pistons, rods, crankshafts, pumps, gears, valves, plugs, gaskets and other engine parts. Replacement part kits and overhaul kits are also specified for various engine components.
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This document contains parts lists and repair instructions for engine components. It lists individual parts, part numbers, quantities needed and repair/replacement instructions. It provides details on repairs, overhauls and replacements for the engine, including the cylinder head, crankshaft, pistons, valves, camshaft and other internal components.
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1) This shop manual provides instructions for servicing a Komatsu D65EX/PX-12 excavator.
2) The D65EX/PX-12 uses the SA6D125E-3 engine. The engine shop manual should be consulted for engine service.
3) Proper safety precautions must be followed when servicing equipment, including wearing protective equipment, blocking the machine, and lowering attachments to the ground.
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2) The D65EX/PX-12 uses the SA6D125E-3 engine, with engine service details covered in a separate manual.
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2) The D65EX/PX-12 uses the SA6D125E-3 engine. The engine shop manual should be consulted for engine service.
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2) The D65EX/PX-12 uses the SA6D125E-3 engine. The engine shop manual should be consulted for engine service.
3) Proper safety precautions must be followed when servicing equipment, including wearing protective equipment, blocking the machine, and lowering attachments to the ground.
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The document provides instructions for removing and installing an engine hood assembly and removing an engine on a wheel loader. Key steps include:
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The document provides instructions for removing and installing an engine hood assembly and removing an engine on a wheel loader. Key steps include:
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3. Draining the coolant and removing hoses, fan guard, transmission connections, steering pump hoses and electrical wiring when removing the engine.
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Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)
1. SEBM000105
KOMA’SU
D57SA=z
MACHINE MODEL SERIAL NUMBER
D575A-2 10001 and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
D575A-2 mounts the SA12V170-1 engine.
For details of the engine, see the 12V170-1 Series Engine Shop Manual.
0 1995 K-lb!
All Rights Reserved
09-95(02)00401
00-l
0
2. CONTENTS
No. of page
01 GENERAL ......................................................... 01-1
10 STRUCTURE AND FUNCTION ........................... IO-I
20 TESTING AND ADJUSTING .............................. 20-1
30 DISASSEMBLY AND ASSEMBLY ...................... 30-1
40 MAINTENANCE STANDARD ............................ 40-1
s
H
3. SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A. IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1.
2.
3.
4.
5.
Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine.
When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
. Always wear safety glasses when hitting
parts with a hammer.
. Always wear safety glasses when grind-
ing parts with a grinder, etc.
If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work, al-
ways wear welding gloves, apron, glasses,
cap and other clothes suited for welding
work.
When carrying out any operation with two
or more workers, always agree on the oper-
ating procedure before starting. Always in-
form your fellow workers before starting any
step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls
in the operator’s compartment.
Keep all tools in good condition and learn
the correct way to use them.
6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smok-
ing. Never smoke while working.
PREPARATIONS FOR WORK
7.
8.
9.
10.
Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warn-
ing signs on them.
When disassembling or assembling, support
the machine with blocks, jacks or stands
before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the ma-
chine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
00-3
4. SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug
or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing compo-
nents of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
12. The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before
carrying out any work on the oil or water
circuits.
13. Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist
or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hit-
ting any other part. Do not work with any
part still raised by the hoist or crane.
15. When removing covers which are under in-
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
19. Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is be-
ing operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
21. When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards,
or parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
22. When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assem-
bled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track sepa-
rates suddenly, so never let anyone stand at
either end of the track.
5. REMOVAL OF POWER TRAIN OIL COOLER ASSEMBLY
1.
2.
3.
4.
5.
6.
Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY.
Remove radiator top cover.
For details, see REMOVAL OF ENGINE ASSEMBLY.
Open underguard.
For details, see REMOVAL OF FAN MOTOR
ASSEMBLY.
Disconnect cooler inlet hose (1).
l For R.H. cooler
* 50 - 60 liters of oil will flow out, so prepare
a container to catch it.
Disconnect cooler outlet hose (2).
l For L.H. cooler
Ir 50 - 60 liters of oil will flow out, so prepare
a container to catch it.
Disconnect hose (3).
* Disconnect only from the cooler that is to be
removed.
7. Remove cushion (4).
* Remove only from the cooler that is to be
removed.
30-16
8
6. 8. Remove hose (5).
9. Remove pin (6).
It Remove only from the cooler that is to be
removed.
10. Remove bracket (7).
* Remove only from the cooler that is to be
removed.
* On the left side, remove the clamp of wiring
harness (8), and move it the side.
11. Lift off power train cooler assembly (9).
Power train cooler assembly: 150 kg
Ii c’9M02310
7. INSTALLATION OF POWER TRAIN OIL COOLER ASSEMBLY
. Carry out installation in the reverseorderto removal.
_
. Refilling with oil
+ Add oil to replace the oil that leaked out when
the cooler was removed.
Add oil to the specified level, and run the engine
to circulate the oil through the system. Then
check the oil level again.
0
C’
8. REMOVAL OF HYDRAULIC COOLER ASSEMBLY
1. Remove fan motor assembly.
For details, see REMOVAL OF FAN MOTOR
SUPPORT ASSEMBLY.
2. Remove hose (1).
3. Remove block (2).
4. Remove cooler assemblies (3) and (4).
Hydraulic cooler assembly (each): 45 kg
INSTALLATION OF HYDRAULC
COOLER ASSEMBLY
. Carry out installation in the reverse orderto removal.
. Refilling with oil
+ Add oil to replace the oil that leaked out when
the cooler was removed.
Add oil to the specified level, and run the engine
to circulate the oil through the system. Then
check the oil level again.
r
-19M02311
jiL’
====% 9M02312
9. REMOVAL OF FUEL INJECTION PUMP ASSEMBLY (Left and right)
1.
2.
3.
4.
.
Link
1) Cut seal and remove center bolt (6). m
2) Loosen locknut (7), then remove stud (8).
3) Remove cover (9).
I F19M02902
4) Remove link (10).
Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY.
Remove air cleaner and muffler assembly.
For details, see REMOVAL OF CYLINDER HEAD
ASSEMBLY.
Close fuel supply valve.
Injection pump for left bank
1) Remove injection pipe (1). m
2) Disconnect lubrication hose (2) and air hose (3).
F19M02903
10. 3) Disconnect fuel hose (4).
4) Remove injection pump assembly (5). m
* Remove the mounting bolts, move it towards
the rear, then lift it out.
pump assembly (with governor):
47 kg
. Injection pump for right bank
1) Remove injection pipe (1). m
2) Disconnect hose (6), (7) and tube (8).
3) Disconnect lubrication tube (9).
F19M02314
11. 4) Disconnect fuel hose (10).
5) Remove injection pump assembly (11). m
* Remove the mounting bolts, move it towards
the rear, then lift it out.
elkg Injection pump assembly
(without governor): 30 kg
F19M02317
12. INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
(Left and right)
. Carry out installation in thereverseorderto removal.
m
w Sleeve nut: 2.25 F 0.25 kgm
* Align the spline of the coupling and install, then
align the line of the body, and tighten the
mounting bolts.
* Adjust the fuel injection timing, and adjust the
injection amount for the left and right banks.
For details, see TESTING AND ADJUSTING.
l Install ling as follows.
1) Insert pins at tips of link (10) into both rack
2)
3)
4)
Pull link (10) towards injection pump, pass
stud (8) through nut inside link, then tighten
approx. 4 turns.
Pass stud (8) through stud hole in housing
(11) and turn until it contacts the end. (approx.
7 turns = 14 mm)
After it contacts the end, turn stud (8) back
approx. 2 turns.
* The stud moves 4 mm and the center of
5)
6)
the link fulcrum moves 2 mm forwards.
Tighten locknut (7) temporarily.
Fit O-ring on top of link, then fit gasket and
install cover (9).
7) Fit washer, then tighten center bolt (6).
joints.
w Center bolt : 5.5 * 2 kgm
* Adjust the difference in exhaust temper-
ature between the left and right. For
details, see TESTING AND ADJUSTING.
I F19M02904
F19M02905
9 6
I’ ‘I
F19M02906
13. REMOVAL OF WATER PUMP ASSEMBLY
1. Drain cooling water.
2. Remove engine side cover (right).
3. Open main frame right side cover.
4. Remove exhaust pipe cover (1).
5. Remove tube (2).
P19M02012
6. Remove tube (3).
+ Remove bolts (4), and pull out.
7.
8.
9.
Disconnect hose (5).
Remove tube (6).
Remove water pump assembly (7).
* Raise the water pump assembly from above, then
remove the mounting bolts and lower it.
Water pump assembly: 35 kg
INSTALLATION OF WATER PUMP
ASSEMBLY
. Carry out installation in the reverse orderto removal.
F19M0231!
. Refilling with water
Add water to the specified level, and run the engine
to circulate the water through the system. Then
check the water level again.
30&23
14. REMOVAL OF TURBOCHARGER ASSEMBLY (Left)
1. Drain cooling water.
+ Drain about l/3 of the cooling water.
2. Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY.
3. Remove intake connectors (1) and (2).
4. Remove air intake connector (3).
5. Remove cover (4).
6. Remove tubes (5) and (6).
7. Disconnect tubes (7) and (8).
8. Remove turbocharger assembly (left) (9). m
Turbocharger assembly: 35 kg
INSTALLATION OF TURBOCHARGER
ASSEMBLY (Left)
. Carry out installation in the reverse orderto removal.
m
w Mounting bolt: 8.5 k 0.5 kgm
. Refilling with water
Add water to the specified level, and run the engine
to circulate the water through the system. Then
check the water level again.
0
P19M02015
15. REMOVAL OF TURBOCHARGER ASSEMBLY (Right)
1. Drain cooling water.
+ Drain about l/3 of the cooling water.
2. Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY.
3. Remove intake connector (1).
4. Remove air intake connector (2).
5. Remove cover (3).
6. Remove tubes (4) and (5).
7. Disconnect tubes (6) and (7).
8. Remove turbocharger assembly (right) (8). m
6 kg Turbocharger assembly: 35 kg
INSTALLATION OF TURBOCHARGER
ASSEMBLY (Right)
. Carry out installation in the reverse order to removal.
w Mounting bolt: 8.5 I!Z0.5 kgm
. Refilling with water
Add water to the specified level, and run the engine
to circulate the water through the system. Then
check the water level again.
16. REMOVAL OF AFTER-COOLER CORE ASSEMBLY
1. Remove air cleaner assembly and muffler assembly
For details, see REMOVAL OF CYLINDER ASSEM.
BLY.
2. Remove connector (l), tube (2), and connectors (3).
* Remove 2 connectors (3) (top and bottom).
3. Remove tube (4).
4. Remove connector (5), tube (6). and connector (7).
* Remove 2 connectors (7) (top and bottom).
5. Remove tube (8).
6. Remove cover assemblies (9) and (10).
7. Remove cores (11) and (12) from cover assemblies
(9) and (10).
INSTALLATION OF AFTER-COOLER
CORE ASSEMBLY
. Carry out installation in the reverse order to removal.
. Refilling with water
Add water to the specified level, and run the engine
to circulate the water through the system. Then
check the water level again.
F19M02321
17. REMOVAL OF NOZZLE HOLDER ASSEMBLY
1. Remove fuel injection pipe (1) on side to be removed.
m
2. Remove spill hose (2).
3. Remove joint (3).
4. Remove head cover (4). 1#21
5. Remove nozzle holder assembly (5). m
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
. Carry out installation in the reverse order to removal.
D Sleeve nut: 2.25 AI 0.25 kgm
Ir Tighten the head cover mounting bolts in the
order shown in the diagram below.
198F1302
m Mounting bolt: 3.25 f 0.25 kgm
m Nozzle holder mounting bolt:
2.75 + 0.25 kgm
30-27
I@
18. REMOVAL OF CYLINDER HEAD ASSEMBLY
1. Drain cooling water.
2. Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY
3. Remove engine side cover.
4. Remove air cleaner and muffler assembly.
1) Disconnect tube (1) and hose (2).
2) Disconnect rods (3) and (4).
3) Remove pipe (5).
4) Remove plate (6).
5) Remove air cleaner and muffler assembly (7).
+ Raise the air cleaner lightly, pull out from the
intake connector, then remove.
elkg Air cleaner, muffler assembly: 610 kg
0
P19M02032
30628
19. 5. Remove left and right exhaust manifold covers (8).
I (Left)
F19M02324
6. Remove exhaust manifold (9). m
(Left)
9
F19M02325
(Right)
Fl SM02326
30629
20. 7. Remove fuel injection tube (10). m
8. Remove spill hose (11).
9. Remove joint (12). then remove head cover (13).
m
10. Remove nozzle holder (14). m’
11. Remove rocker arm assembly (15). m (nsJ
* Loosen locknut (,16), then loosen adjustment
screw (17) 2 - 3 turns.
12. Disconnect tube (18)
_1 .r
F19M02327
21. 13. Remove rocker arm housing (19). m
+ Pull out pin (20), then put a rod in contact with
portion @, and hit with a hammer in the direction
shown by the arrow to move pipe (21) aside.
14. Remove push rod (22). I#81
15. Remove crosshead (23). m
16. Remove cylinder head assembly (24). m
* Remove the head bolt, then remove the cylinder
head assembly using lifting tool @.
Cylinder head assembly: 40 kg
22. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
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click on the link above,
please download the PDF
document first and then
click on it.
23. INSTALLATION CYLINDER HEAD ASSEMBLY
. Carry out installation in the reverse order to removal.
Fig 1 (Lef? side)
m
+ Install the exhaust manifold, and tighten in the ) I
following order and to the following torque.
i) Install in the order A - B - C shown in Figs.
1 and 2.
ii) Tighten in the order shown in Figs. 3 and 4.
Fig. 3 (left side)
F19M02329
F6,66, ,6 Fig 2 (Right side)
Fig. 4 (right side)
B A C
F19M02330
w Mounting bolts: 1st step 5 z!z1 kgm
2nd step 8.5 + 0.5 kgm
m Sleeve nut: 2.25 I!Z0.25 kgm
* Tighten the head cover mounting bolts in the
order shown in Fig. 5.
w Mounting bolt: 3.25 t 0.25 kgm
w Nozzle holder mounting bolt: 2.75 + 0.25 kgm
Fig 5
5
/
1
0
2
cl-3 4
198F1302
24. + Check that the ball of the adjustment screw is
fitted securely in the socket of the push rod.
QZ Rocker arm mounting bolt: 10 + 0.5 kgm
* Adjust the valve clearance.
For details, see TESTING AND ADJUSTING,
Adjusting valve clearance.
w Rocker arm, screw, locknut: 6.9 ?z 1.O kgm
w Rocker arm housing mounting bolt:
10 + 0.5 kgm
+ Check that the push rod is fitted securely in the
cam follower.
+ Adjust the crosshead as follows.
4
ii)
iii)
iv)
Loosen the locknut, and turn back the
adjustment screw.
Press down lightly on the top surface of the
crosshead, and screw in the adjusment
screw.
After the adjustment screw contacts the valve
stem, tighten it a further 20°.
Tighten the locknut to hold the screw in
position.
w Locknut: 5.6 f 0.4 kgm
* Tighten the cylinder head bolts in the order shown
in Fig. 6.
& Bolt thread, seat surface:
Anti-friction compound (LM-P)
D Cylinder head bolt:
Unit: kgm
Fig 6
I 198F1305
. Refilling with water
Add water to the specified level, and run the engine
to circulate the water through the system. Then
check the water level again.
25. REMOVAL OF RADIATOR ASSEMBLY
1. Drain cooling water.
2. Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY.
3. Remove radiator top cover.
For details, see REMOVAL OF ENGINE ASSEMBLY.
4. Open underground.
For details, see REMOVAL OF FAN MOTOR
ASSEMBLY.
5. Disconnect radiator outlet tube (1).
6. Disconnect wiring (2).
* Remove the connector and clamp, and disconnect
from the radiator.
7. Disconnect hoses (3). (4). and (5).
8. Remove left and right cushions (6).
9. Remove left and right pins (7).
10. Remove left and right brackets (8)