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 d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)udfjjjskekmdm
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 d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)fusjefjjskekmem
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 engine manual for more details on the engine. It provides safety notices and precautions for working on the machine.
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)fujjsefksekmem
This shop manual provides maintenance and repair instructions for the D575A-2 machine model. It contains sections on general information, structure and function, testing and adjusting, disassembly and assembly, maintenance standards, and safety precautions. The document describes how to remove and install components like the power train oil cooler assembly, hydraulic cooler assembly, and fuel injection pump assembly. Safety is emphasized, with warnings to take precautions for one's safety and the safety of others when working on the equipment.
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)fjsjekkmdmme
This shop manual provides information for servicing and repairing the D575A-2 machine model. The manual contains safety precautions and general procedures for removal and installation of components. Key points include:
- The D575A-2 uses the SA12V170-1 engine which is detailed in the 12V170-1 Series Engine Shop Manual.
- Safety precautions must always be followed when servicing equipment to prevent injury.
- Procedures are provided for removal and installation of components like the power train oil cooler, hydraulic cooler, fuel injection pump, water pump, turbocharger, and cylinder head.
- Components should be installed in reverse order of removal and fluids refilled
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)jfjskekdhnejd
This shop manual provides information for servicing and repairing the D575A-2 machine model. The manual contains safety precautions and instructions for removing and installing various engine components. Key points include:
- The D575A-2 uses the SA12V170-1 engine which is detailed in the 12V170-1 Series Engine Shop Manual.
- Safety precautions must always be followed when servicing equipment to prevent injury.
- Instructions are provided for removing and installing components like the fuel injection pump assembly, water pump assembly, turbocharger assembly, and cylinder head assembly.
- Components need to be properly installed and fluids refilled after removal to ensure safe machine operation.
Komatsu D37EX-21 Bulldozer Service Repair Manual SN 5501 and up.PDFfjkksekdmdm
This document provides instructions for removing and installing the fuel injection pump assembly and cylinder head assembly on Komatsu excavators. Key steps include:
1. Disconnecting fuel lines, wiring harnesses, and other components to access the fuel injection pump and cylinder head.
2. Using positioning pins and tools to ensure the fuel injection pump is correctly timed when installed.
3. Removing the cylinder head bolts in a specified sequence and using a torque wrench to correctly tighten the bolts on installation.
The document provides detailed guidance on completing these processes while taking appropriate safety precautions.
Komatsu D31EX-21 Bulldozer Service Repair Manual SN 50501 and up.PDFfjkksekdmdm
This document provides instructions for removing and installing the fuel injection pump assembly and cylinder head assembly on Komatsu excavators. Key steps include:
1. Disconnecting fuel lines, wiring harnesses, and other components to access the fuel injection pump and cylinder head.
2. Using positioning pins and tools to ensure the fuel injection pump is correctly timed when installed.
3. Removing the cylinder head bolts in a specified sequence and using a torque wrench to correctly tighten the bolts on installation.
The document provides detailed guidance on completing these processes while taking appropriate safety precautions.
John Deere 8360R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring and other components to separate the transmission from the engine and mid-frame. Precise installation of a splitting stand and lifting fixture are described to safely support the tractor during disassembly.
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)udfjjjskekmdm
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 d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)fusjefjjskekmem
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 engine manual for more details on the engine. It provides safety notices and precautions for working on the machine.
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)fujjsefksekmem
This shop manual provides maintenance and repair instructions for the D575A-2 machine model. It contains sections on general information, structure and function, testing and adjusting, disassembly and assembly, maintenance standards, and safety precautions. The document describes how to remove and install components like the power train oil cooler assembly, hydraulic cooler assembly, and fuel injection pump assembly. Safety is emphasized, with warnings to take precautions for one's safety and the safety of others when working on the equipment.
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)fjsjekkmdmme
This shop manual provides information for servicing and repairing the D575A-2 machine model. The manual contains safety precautions and general procedures for removal and installation of components. Key points include:
- The D575A-2 uses the SA12V170-1 engine which is detailed in the 12V170-1 Series Engine Shop Manual.
- Safety precautions must always be followed when servicing equipment to prevent injury.
- Procedures are provided for removal and installation of components like the power train oil cooler, hydraulic cooler, fuel injection pump, water pump, turbocharger, and cylinder head.
- Components should be installed in reverse order of removal and fluids refilled
Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)jfjskekdhnejd
This shop manual provides information for servicing and repairing the D575A-2 machine model. The manual contains safety precautions and instructions for removing and installing various engine components. Key points include:
- The D575A-2 uses the SA12V170-1 engine which is detailed in the 12V170-1 Series Engine Shop Manual.
- Safety precautions must always be followed when servicing equipment to prevent injury.
- Instructions are provided for removing and installing components like the fuel injection pump assembly, water pump assembly, turbocharger assembly, and cylinder head assembly.
- Components need to be properly installed and fluids refilled after removal to ensure safe machine operation.
Komatsu D37EX-21 Bulldozer Service Repair Manual SN 5501 and up.PDFfjkksekdmdm
This document provides instructions for removing and installing the fuel injection pump assembly and cylinder head assembly on Komatsu excavators. Key steps include:
1. Disconnecting fuel lines, wiring harnesses, and other components to access the fuel injection pump and cylinder head.
2. Using positioning pins and tools to ensure the fuel injection pump is correctly timed when installed.
3. Removing the cylinder head bolts in a specified sequence and using a torque wrench to correctly tighten the bolts on installation.
The document provides detailed guidance on completing these processes while taking appropriate safety precautions.
Komatsu D31EX-21 Bulldozer Service Repair Manual SN 50501 and up.PDFfjkksekdmdm
This document provides instructions for removing and installing the fuel injection pump assembly and cylinder head assembly on Komatsu excavators. Key steps include:
1. Disconnecting fuel lines, wiring harnesses, and other components to access the fuel injection pump and cylinder head.
2. Using positioning pins and tools to ensure the fuel injection pump is correctly timed when installed.
3. Removing the cylinder head bolts in a specified sequence and using a torque wrench to correctly tighten the bolts on installation.
The document provides detailed guidance on completing these processes while taking appropriate safety precautions.
John Deere 8360R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring and other components to separate the transmission from the engine and mid-frame. Precise installation of a splitting stand and lifting fixture are described to safely support the tractor during disassembly.
Komatsu 6D102E-1 Diesel Engine Service Repair Manual.pdffjkksekdmdm
This shop manual provides safety precautions and maintenance techniques for Komatsu diesel engines. Proper service and repair is extremely important for safe machine operation. The manual describes servicing and repair techniques recommended by Komatsu for the current 100E-6 series and describes safety symbols used throughout. Workers should always follow the safety precautions given and take necessary actions to deal with any dangerous situations that may arise.
John Deere 8335R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring harnesses and other components to separate the transmission from the engine and mid-frame. Precision tools like a transmission lifting fixture are used to safely raise and support the transmission during the removal process. Detailed diagrams accompany each step to illustrate proper component identification and disconnection points.
John Deere 8310R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It details disconnecting various components like lines, hoses, wiring and brackets to separate the transmission from the engine and mid-frame. Splitting stands and a transmission lifting fixture are used to safely support the tractor during disassembly. Specific tools, adapters and cap screws are identified for correctly positioning the stands and lifting the transmission.
John Deere 8235R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring harnesses and other components to separate the transmission from the engine and mid-frame. Precision tools like a transmission lifting fixture are used to safely raise and support the transmission during the removal process. Detailed photos illustrate each step to ensure safe and proper removal of the transmission.
John Deere 8260R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides specifications and instructions for removing the transmission from several tractor models. It includes:
- Specifications for torque values for various transmission components.
- Steps to drain fluids, disconnect lines and electrical connections, and remove components to access the transmission for removal, such as the batteries, hood, exhaust, and auxiliary drive components.
- Instructions for using a splitting stand to separate the engine and transmission.
- Cautions and notes regarding proper support of the drive shaft and use of the splitting stand.
The document provides detailed removal instructions and specifications to correctly separate the engine and transmission on these tractor models.
John Deere 8285R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring and other components to separate the transmission from the engine and mid-frame. Precise installation of a splitting stand and lifting fixture are described to safely support the tractor during disassembly.
John Deere 6200 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required spacer washer thickness, and selecting the appropriate washers.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash.
3. Tolerances and specifications are provided for dimensions, torque values for fasteners, and available thicknesses for various washers and snap rings used in the assembly.
John Deere 6500 Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and repairing the creeper transmission for tm4523 tractors. It details installing components like connecting rings, snap rings, gears, shift collars, and needle bearings in the proper order. Tolerances and specifications are provided for components. The final section covers general repair procedures for the range transmission, emphasizing cleanliness and care when handling precision parts.
John Deere 6506 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required thickness of spacer washers, and selecting the proper washers to achieve the correct adjustment.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash and axial play.
3. Snap rings and thrust washers of varying standard thicknesses are available to set the proper spacing and play between components.
John Deere 6600 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on differentials for 6100 to 6600 tractors, including measuring specific dimensions, calculating spacer washer thickness, and examples.
2. It also details the assembly process for transmissions, including installing various gears, shafts, washers, and snap rings while checking tolerances. Proper torque specifications are provided.
3. Special tools needed for tasks like tilting the cab, supporting the tractor, and removing PTO drive shafts are listed. Measurements, part numbers, and other details are referenced.
John Deere 6500L Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and repairing the creeper transmission for tm4523 tractors. It details installing components like connecting rings, snap rings, gears, shift collars, and needle bearings in the proper order. Tolerances and specifications are provided for components like connecting ring play and snap ring thickness. The instructions also cover installing the shift linkage, repairing the shift cover, and final assembly of the creeper transmission.
John Deere 6300 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required spacer washer thickness, and selecting the appropriate washers.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash.
3. Special tools required for tasks like tilting the cab, supporting the tractor, and removing PTO components are also listed.
John Deere 6400 Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and disassembling components of the creeper transmission and range transmission for Deere tractors. It includes steps for installing bearings, gears, shafts, and other parts. Specifications are provided for measurements and torque values.
John Deere 6200L Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and repairing the creeper transmission for tm4523 tractors. It details installing components like connecting rings, snap rings, gears, shift collars, and needle bearings in the proper order. Tolerances and specifications are provided for components like connecting ring play and snap ring thickness. The instructions also cover installing the shift linkage, repairing the shift cover, and final assembly of the creeper transmission.
John Deere 6400L Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and disassembling components of the creeper transmission and range transmission used in Deere tractors. It details installing snap rings, gears, bearings, and other parts in the correct order and orientation. Tolerances and specifications are provided for measuring component wear and clearances.
John Deere 6200 Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and disassembling components of the creeper transmission and range transmission for Deere tractors. It includes steps for installing bearings, gears, shafts, and other parts. Specifications are provided for measuring component clearances and torques.
John Deere 6100 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required spacer washer thickness, and selecting the appropriate washers.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash.
3. Special tools required for tasks like tilting the cab, supporting the tractor, and removing PTO components are also listed.
John Deere 6110D (Tier 0 - Tier 3Stage IIIA) Tractors Service Repair Technica...fjkksekdmdm
The document provides instructions to split a tractor into left and right halves. Key steps include blocking the front wheels, draining fluids, removing the cab or operator station, fuel tank, and MFWD drive shaft. Steering lines and oil lines are disconnected and labeled. Support stands are placed under the tractor. Lifting eyes are installed and cap screws are removed to separate the left and right halves.
John Deere 6130D (Tier 0 - Tier 3Stage IIIA) Tractors Service Repair Technica...fjkksekdmdm
The document provides instructions to split a tractor into left and right halves. Key steps include blocking the front wheels, draining fluids, removing the cab or operator station, fuel tank, and MFWD drive shaft. Steering lines and hydraulic lines are disconnected from the mid frame. Lifting brackets are installed and cap screws are removed to separate the left and right halves.
John Deere 6125D (Tier 0 - Tier 3Stage IIIA) Tractors Service Repair Technica...fjkksekdmdm
The document provides instructions for removing and installing a final drive assembly on a tractor. It involves draining the oil, removing mounting hardware, using lifting equipment to remove the assembly, cleaning mating surfaces, applying sealant, and reinstalling the assembly. The process is reversed to install the final drive assembly, ensuring proper torque specifications are followed.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Komatsu 6D102E-1 Diesel Engine Service Repair Manual.pdffjkksekdmdm
This shop manual provides safety precautions and maintenance techniques for Komatsu diesel engines. Proper service and repair is extremely important for safe machine operation. The manual describes servicing and repair techniques recommended by Komatsu for the current 100E-6 series and describes safety symbols used throughout. Workers should always follow the safety precautions given and take necessary actions to deal with any dangerous situations that may arise.
John Deere 8335R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring harnesses and other components to separate the transmission from the engine and mid-frame. Precision tools like a transmission lifting fixture are used to safely raise and support the transmission during the removal process. Detailed diagrams accompany each step to illustrate proper component identification and disconnection points.
John Deere 8310R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It details disconnecting various components like lines, hoses, wiring and brackets to separate the transmission from the engine and mid-frame. Splitting stands and a transmission lifting fixture are used to safely support the tractor during disassembly. Specific tools, adapters and cap screws are identified for correctly positioning the stands and lifting the transmission.
John Deere 8235R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring harnesses and other components to separate the transmission from the engine and mid-frame. Precision tools like a transmission lifting fixture are used to safely raise and support the transmission during the removal process. Detailed photos illustrate each step to ensure safe and proper removal of the transmission.
John Deere 8260R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides specifications and instructions for removing the transmission from several tractor models. It includes:
- Specifications for torque values for various transmission components.
- Steps to drain fluids, disconnect lines and electrical connections, and remove components to access the transmission for removal, such as the batteries, hood, exhaust, and auxiliary drive components.
- Instructions for using a splitting stand to separate the engine and transmission.
- Cautions and notes regarding proper support of the drive shaft and use of the splitting stand.
The document provides detailed removal instructions and specifications to correctly separate the engine and transmission on these tractor models.
John Deere 8285R Tractors Service Repair Technical Manual (TM110319).pdffjkksekdmdm
This document provides instructions for removing a transmission from several tractor models. It outlines over 80 steps to disconnect lines, brackets, wiring and other components to separate the transmission from the engine and mid-frame. Precise installation of a splitting stand and lifting fixture are described to safely support the tractor during disassembly.
John Deere 6200 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required spacer washer thickness, and selecting the appropriate washers.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash.
3. Tolerances and specifications are provided for dimensions, torque values for fasteners, and available thicknesses for various washers and snap rings used in the assembly.
John Deere 6500 Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and repairing the creeper transmission for tm4523 tractors. It details installing components like connecting rings, snap rings, gears, shift collars, and needle bearings in the proper order. Tolerances and specifications are provided for components. The final section covers general repair procedures for the range transmission, emphasizing cleanliness and care when handling precision parts.
John Deere 6506 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required thickness of spacer washers, and selecting the proper washers to achieve the correct adjustment.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash and axial play.
3. Snap rings and thrust washers of varying standard thicknesses are available to set the proper spacing and play between components.
John Deere 6600 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on differentials for 6100 to 6600 tractors, including measuring specific dimensions, calculating spacer washer thickness, and examples.
2. It also details the assembly process for transmissions, including installing various gears, shafts, washers, and snap rings while checking tolerances. Proper torque specifications are provided.
3. Special tools needed for tasks like tilting the cab, supporting the tractor, and removing PTO drive shafts are listed. Measurements, part numbers, and other details are referenced.
John Deere 6500L Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and repairing the creeper transmission for tm4523 tractors. It details installing components like connecting rings, snap rings, gears, shift collars, and needle bearings in the proper order. Tolerances and specifications are provided for components like connecting ring play and snap ring thickness. The instructions also cover installing the shift linkage, repairing the shift cover, and final assembly of the creeper transmission.
John Deere 6300 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required spacer washer thickness, and selecting the appropriate washers.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash.
3. Special tools required for tasks like tilting the cab, supporting the tractor, and removing PTO components are also listed.
John Deere 6400 Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and disassembling components of the creeper transmission and range transmission for Deere tractors. It includes steps for installing bearings, gears, shafts, and other parts. Specifications are provided for measurements and torque values.
John Deere 6200L Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and repairing the creeper transmission for tm4523 tractors. It details installing components like connecting rings, snap rings, gears, shift collars, and needle bearings in the proper order. Tolerances and specifications are provided for components like connecting ring play and snap ring thickness. The instructions also cover installing the shift linkage, repairing the shift cover, and final assembly of the creeper transmission.
John Deere 6400L Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and disassembling components of the creeper transmission and range transmission used in Deere tractors. It details installing snap rings, gears, bearings, and other parts in the correct order and orientation. Tolerances and specifications are provided for measuring component wear and clearances.
John Deere 6200 Tractors Service Repair Technical Manual (TM4523).pdffjkksekdmdm
The document provides instructions for assembling and disassembling components of the creeper transmission and range transmission for Deere tractors. It includes steps for installing bearings, gears, shafts, and other parts. Specifications are provided for measuring component clearances and torques.
John Deere 6100 Tractors Service Repair Technical Manual (TM4493).pdffjkksekdmdm
1. The document provides instructions for adjusting the cone point on tractors from models 6100 to 6600. It involves measuring specific dimensions, calculating the required spacer washer thickness, and selecting the appropriate washers.
2. The instructions also provide details on assembling the transmission, including pressing in bearings, installing gears and synchronizers, and checking gear backlash.
3. Special tools required for tasks like tilting the cab, supporting the tractor, and removing PTO components are also listed.
John Deere 6110D (Tier 0 - Tier 3Stage IIIA) Tractors Service Repair Technica...fjkksekdmdm
The document provides instructions to split a tractor into left and right halves. Key steps include blocking the front wheels, draining fluids, removing the cab or operator station, fuel tank, and MFWD drive shaft. Steering lines and oil lines are disconnected and labeled. Support stands are placed under the tractor. Lifting eyes are installed and cap screws are removed to separate the left and right halves.
John Deere 6130D (Tier 0 - Tier 3Stage IIIA) Tractors Service Repair Technica...fjkksekdmdm
The document provides instructions to split a tractor into left and right halves. Key steps include blocking the front wheels, draining fluids, removing the cab or operator station, fuel tank, and MFWD drive shaft. Steering lines and hydraulic lines are disconnected from the mid frame. Lifting brackets are installed and cap screws are removed to separate the left and right halves.
John Deere 6125D (Tier 0 - Tier 3Stage IIIA) Tractors Service Repair Technica...fjkksekdmdm
The document provides instructions for removing and installing a final drive assembly on a tractor. It involves draining the oil, removing mounting hardware, using lifting equipment to remove the assembly, cleaning mating surfaces, applying sealant, and reinstalling the assembly. The process is reversed to install the final drive assembly, ensuring proper torque specifications are followed.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
Custom Solutions: We understand that every project is unique, which is why we offer custom crane solutions tailored to your specific requirements. Whether you need modifications, attachments, or specialized equipment, we can design and implement solutions that meet your needs.
At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
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2. 00-2 D65EX, PX-12
CONTENTS
01 GENERAL ......................................................................... 01-1
10 STRUCTURE AND FUNCTION ....................................... 10-1
20 TESTING AND ADJUSTING........................................... 20-1
30 DISASSEMBLY AND ASSEMBLY .................................. 30-1
40 MAINTENANCE STANDARD.......................................... 40-1
90 OTHERS............................................................................ 90-1
No. of page
2
3. 00-3
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine.
2. 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.
3. 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, hand
shield, cap and other clothes suited for weld-
ing work.
4. 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.
5. 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. 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.
8. 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.
9. When disassembling or assembling, support
the machine with blocks, jacks or stands
before starting work.
10. 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.
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 ¤ 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.
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
SAFETY SAFETY NOTICE
4. 00-4
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.
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.
SAFETY SAFETY NOTICE
5. D65EX, PX-12 30-13
?
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
REMOVAL
½ Stop the machine on level ground and lower the
blade to the ground.
NDisconnect the (-) terminal of the battery.
1. Side cover and fan cover
1) Open side cover (left) (1) and remove the
front cover and underside cover.
2) Remove the fan cover.
2. Air compressor
Remove the air compressor and fix it with rope to
the side of the machine, referring to the Remov-
al and Installation of Air Compressor section.
★ Do not disconnect the air compressor piping.
3. Harnesses and piping
1) Remove harness connectors (2) (CN-E41
and CN-E42) and (3) (CN-E52).
2) Remove fuel hoses (4) and (5).
3) Remove fuel tubes (7) and (8).
4) Remove high-pressure pipe clamps (9), (10)
and (11).
5) Remove covers (12) and (13).
6) Remove high-pressure pipes (14) and (15).
7) Remove lubrication tube (16).
4. Fuel supply pump drive gear
1) Align the damper’s stamp line for 1.6TOP
with pointer (17).
2) Remove cover (18).
q 1
q 2
q 3
q 4
6. 30-14 D65EX, PX-12
?
3) Remove the gear mounting nut and remove
fuel supply pump drive gear (19) using tool
A1.
★ Be careful so as not to allow the nuts,
washers and woodruff key on the shaft to
drop into the case.
5. Fuel supply pump
Remove bracket (20) to remove fuel supply
pump assembly (21).
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
Fuel hoses (4) and (5):
14.7 - 19.6 Nm {1.5 -2.0 kgm}
Fuel tubes (7) and (8) on filter side and
the fuel supply pump side:
24.5 - 34.3 Nm {2.5 -3.5 kgm}
★ Mounting cover (12) with its slit facing the cylin-
der block.
★ Mounting cover (13) with its slit facing down.
Lubrication tube (16)
On the fuel supply pump side:
7.9 - 12.7 Nm {0.8 - 1.3 kgm}
On the cylinder block side:
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
q 5
q 1
q 2
q 3
q 4
?
7. D65EX, PX-12 30-15
?
★ Mount fuel supply pump drive gear (19) so that
stamp line C on the surface falls on stamp line C
on the surface of camshaft gear (22).
Fuel supply pump gear:
127 - 147 Nm {13 - 15 kgm}
• Steps for mounting the fuel supply pump and the
high-pressure pipe between the fuel supply
pump and the common rail:
NDo not reuse a high-pressure pipe by bend-
ing it.
NBe sure to use genuine parts for high-pres-
sure pipe clamps and to strictly comply with
the tightening torque specifications.
1. Temporarily mount fuel supply pump (21), brack-
ets (20) and (22) and high-pressure pipes (14)
and (15), tightening them by hand.
2. Tighten high-pressure pipes (14) and (15) with
the following torque.
Sleeve nut on the common rail side:
39.2 - 58.8 Nm {4 - 6 kgm}
Sleeve nut on the fuel supply pump
side: 39.2 - 49 Nm {4 - 5 kgm}
3. Tighten the fuel supply pump mounting bolts.
Thread of mounting bolt:
Thread tightener (LG-6)
4. Tighten the mounting bolts of brackets (20) and
(22).
Between bracket (20) and the fuel sup-
ply pump:
19.6 - 29.4 Nm {2.0 - 3.0 kgm}
5. Temporarily mount high-pressure pipe clamp (9)
and brackets (23) and (24), tightening them by
hand.
6. Tighten high-pressure pipe clamp (9) with the
following torque:
High-pressure clamp:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
7. Tighten the mounting bolts for brackets (24) and
(23), in this order.
8. Tighten high-pressure pipe clamp (10) with the
following torque.
High-pressure pipe clamp:
8.8 - 14.7 Nm {0.9 - 1.5 kgm}
9. Temporarily mount high-pressure pipe clamp
(11) and bracket (25), tightening them by hand.
10. Tighten high-pressure pipe clamp (11) with the
following torque.
High-pressure pipe clamp:
8.8 - 14.7 Nm {0.9 - 1.5 kgm}
11. Tighten the mounting bolts of bracket (25).
• Bleeding Air
★ Perform air bleeding, referring to the Air
Bleeding for Fuel Circuitry section in the
testing and adjusting manual.
q 5
8. 30-16 D65EX, PX-12
?
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY
REMOVAL
½ Stop the machine on level ground and lower the
blade to the ground.
NDisconnect the (-) terminal of the battery.
1. Open both engine side covers.
2. Air cleaner
1) Remove rain cap (1).
2) Remove cover (2).
3) Remove air intake hose (3).
4) Remove air cleaner band (4).
5) Remove air cleaner (5).
★ Remove the air cleaner from the left side
of the machine body by turning it to the
right by 90 degrees.
6) Remove bracket (6).
3. Remove the heat insulation panel and turbo-
charger lubrication tube (7).
(Nozzles No. 3 and 4)
4. Remove air intake connector (8).
(Nozzles No. 3 and 4)
5. Remove fuel filter bracket (9). (Nozzle No. 1)
6. Fuel piping
1) Remove cover (10).
q 1
q 2
q 3
?
9. D65EX, PX-12 30-17
?
2) Remove high-pressure pipe junction cover
(14) on the injector side and cover (15) on
the common rail side. (The figure shows a
typical operation for removing cylinder
No.1.)
3) Remove high-pressure pipe clamp (16) for
the double-housing frame.
4) Remove high-pressure pipe clamps (17) and
(18) corresponding to the cylinders to be re-
moved.
5) Completely loosen sleeve nut (19) on the in-
jector side and sleeve nut (20) on the com-
mon rail side of the high-pressure pipe. (The
figure shows a typical operation for removing
cylinder No.1.)
7. Head cover
Remove the head cover mounting bolts and
place head cover (21) close to the air intake con-
nector. (The figure shows a typical operation for
removing cylinder No.1.)
8. Nozzle holder
1) Remove harness (23) from the injector.
2) Remove bolt (24) for mounting the nozzle
holder, then remove injector (25) along with
the holder.
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
Mounting clamp:
9.8 - 11.8 Nm {1.0 - 1.2 kgm}
Lubrication tube for turbocharger (on
the cylinder block side):
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
Air intake connector clamp:
6.8 ±
±
±
± 0.49 {69 ±
±
±
± 5 kgcm}
★ The clamp must not project from the top of
the hose.
★ Fit the slit of cover (14) in position a in the fig-
ure below.
★ Turn the slit of cover (15) toward the cylinder
block.
Head cover mounting bolt:
8.33 - 10.8 Nm {0.9 - 1.1 kgm}
Harness mounting nut:
2.0 - 2.4 Nm {0.2 - 0.24 kgm}
q 4
q 5
q 6
q 7
q 1
q 2
q 3
q 4
q 5
q 6
10. 30-18 D65EX, PX-12
?
• Steps for tightening the nozzle holder:
1. Insert gasket (b) and O-ring (c) into injector (a).
2. Insert holder (d) into injector (a) to mount it ten-
tatively on the rocker housing.
★ Fit the key of the injector into the key slot of
the rocker housing and securely insert the in-
jector until its sealing face makes contact
with that of the cylinder head.
3. Apply engine oil on the spherical portion of
spherical washer (e).
4. Tighten bolt (f) of the holder.
Holder mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
• Steps for mounting the high-pressure pipe be-
tween the common rail and the injector:
NDo not reuse a high-pressure pipe by bend-
ing it.
NBe sure to use genuine parts for high-pres-
sure pipe clamps and to strictly comply with
the tightening torque specifications.
1. Tighten sleeve nuts (19) and (20) of the high-
pressure pipe with the following torque:
Sleeve nut: 39.2 - 49 Nm {4 - 5 kgm}
2. Temporarily mount high-pressure pipe clamps
(17) and (18), tightening them by hand.
3. Tighten the mounting bolts of high-pressure pipe
clamps (17) and (18) with the following torque:
Clamp mounting bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
4. Temporarily mount high-pressure pipe clamp
(16) and double-housing frame (27).
5. Tighten the mounting bolts of high-pressure pipe
clamp (16) with the following torque:
Clamp mounting bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
6. Tighten the mounting bolts of the double-hous-
ing frame.
• Bleeding Air
★ Perform air bleeding, referring to the Air
Bleeding for Fuel Circuitry section in the
testing and adjusting manual.
q 7
?
11. D65EX, PX-12 30-19
?
REMOVAL AND INSTALLATION OF NOZZLE TIP
★ [EPA regulations]
For countries subject to EPA regulations, the en-
tire nozzle assembly of the common rail engine
shall be replaced if any of its components needs
to be replaced. For other countries, the following
procedure may be applied for replacing the noz-
zle tip.
REMOVAL
1. Fix tool A3 in vice .
★ Do not pinch the injector directly in the vice.
2. Set injector assembly (3) on tool A3.
3. Loosen retaining nut (4) with 19 mm deep socket
.
12. 30-20 D65EX, PX-12
?
4. Remove retaining nut (4) from injector assembly
(3).
5. Lift nozzle assembly (5) perpendicularly upward
to remove it.
★ Do not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
★ Be careful not to get the assembly dirty.
?
13. D65EX, PX-12 30-21
?
INSTALLATION
1. Fix tool A3 in vice .
★ Do not pinch the injector directly in the vice.
2. Set injector assembly (1) on tool A3.
3. Completely clean the lower body and screw sec-
tions of retaining nut (2) with parts cleaner, and
apply air blow.
4. Mount new nozzle assembly (3) so that the as-
sembly fits the knock pin of tip guide (4).
★ Be careful not to drop the tip.
5. Mount nozzle assembly (3) and manually tighten
retaining nut (2).
14. 30-22 D65EX, PX-12
?
6. Set 19-mm deep socket (2) in the torque wrench,
then tighten the retaining nut by following the
steps below.
★ Apply rust prevention oil on the nozzlebody.
1) Tighten with torque of 88.3 Nm {9.0 kgm}.
2) Attach identification mark (6) to retaining nut
(2) and lower body (5).
3) Tighten at an angle of 45° (angle tightening).
?
15. D65EX, PX-12 30-23
?
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL
½ Stop the machine on level ground and lower the
blade to the ground.
NDisconnect the (-) terminal of the battery.
1. Drain coolant.
2. Hood assembly and cover
1) Open the engine side cover and loosen the
clamp of hose (1).
2) Remove the mounting bolts, then lift hood
assembly (2) to remove it.
★ Lift the assembly while making sure that
no sections are interfering with each oth-
er.
3) Remove covers (3) and (3a) on both sides.
3. Air cleaner assembly
1) Loosen the clamp on the turbocharger side
of air intake hose (4).
2) Remove dust indicator hose (5).
3) Remove clamp (6) and air cleaner assembly
(7).
4) Remove air cleaner bracket (8).
q 1
q 2
q 3
16. 30-24 D65EX, PX-12
?
4. Muffler assembly
1) Remove drain tube.
2) Remove heat insulation panels (10), (11),
and (12).
3) Remove the turbocharger connecting bolts.
4) Remove the mounting bolts and nuts and lift
off muffler assembly (13).
5. Remove turbocharger lubrication tube (14).
6. Remove air intake connector (15).
7. Turbocharger and exhaust manifold assembly
1) Remove drain tube (16).
2) Sling turbocharger assembly (17) temporari-
ly, then remove the exhaust manifold mount-
ing bolts and turbocharger assembly.
Turbocharger and exhaust manifold
assembly: 45 kg
6 4
6 5
6 6
6 7
17. D65EX, PX-12 30-25
8. Wiring
1) Disconnect connector (18) (E54).
2) Disconnect heater relay terminals (19) and
(20).
3) Disconnect injector connectors (21) (E31 - E36).
4) Remove the 8 clamps and disconnect wiring
harness (22) from the engine.
9. Corrosion resistor
1) Remove the 3 clamps.
2) Remove corrosion resistor (23) and bracket
(24) together and place them by the engine.
10. Fuel filter
1) Remove the 2 clamps and remove fuel tubes
(25) and (26).
2) Remove fuel filter (27).
11. Oil filter
1) Remove the clamp and tubes (28) and (29).
2) Remove oil filter (30).
6 8
6 9
18. 30-26 D65EX, PX-12
12. Air intake manifold assembly
1) Remove aftercooler tubes (31) and (32).
2) Disconnect boost pressure sensor hose (33)
from the joint bolt.
3) Sling air intake manifold assembly (34) tem-
porarily, then remove the 24 mounting bolts
and the air intake manifold assembly.
★ Remove the gasket so that the intake air
heater will be on the cylinder head side.
13. High-pressure pipe
1) Remove the front cover of the rail and clamp
(40).
2) Remove covers (42) and (43) and high-pres-
sure pipe (44), depending on the cylinder
head to be removed.
6 10
6 11
19. D65EX, PX-12 30-27
14. Spill tube and water tube
Remove spill tube (45) and water tube (46).
Head cover
Remove head cover (47).
15. Nozzle holder
1) Remove harness (48) from the injector.
2) Remove mounting bolt (49) of the nozzle
holder, and remove injector (50) along with
the holder.
16. Rocker arm and rocker shaft assembly
1) Loosen locknut (51), and loosen adjustment
screw (52) two to three rounds.
2) Remove the mounting bolt, and remove
rocker arm and rocker shaft assembly (53).
★ To remove crosshead (56), loosen lock-
nut (54) and adjustment screw (55) two
to three rounds if the crosshead needs to
be replaced. (The cylinder head assem-
bly can be removed with the crosshead
mounted.)
17. Rocker housing
Remove six mounting bolts (57) to remove rock-
er housing (58).
18. Cylinder head assembly
Remove six mounting bolts (59) along with the
auxiliary bolts to remove cylinder head assembly
(60).
6 12
6 13
6 14
6 15
6 16
6 17
6 18
6 19
20. 30-28 D65EX, PX-12
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
Clamp: 8.3 - 9.3 Nm {0.85 - 0.95 kgm}
Joint bolt: 9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Mounting clamp:
9.8 - 11.8 Nm {1.0 - 1.2 kgm}
Turbocharger lubrication tube (on cylin-
der block side):
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
Intake air connector clamp:
6.8 ±
±
±
± 0.49 Nm {69 ±
±
±
± 5 kgcm}
★ The clamp must not project from the top of
the hose.
Mounting bolt of turbocharger lubrica-
tion tube on cylinder block side:
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
★ First tighten exhaust manifold mounting bolts in
the order shown below, and then tighten the oth-
er bolts, starting with the ones in the center and
proceeding to the outer ones.
Exhaust manifold:
58.8 - 73.5 Nm {6 - 7.5 kgm}
Fuel tube mounting bolt:
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
★ To mount the oil filter, follow the steps below.
1) Temporarily tighten filter bracket mounting
bolt (a).
2) Temporarily tighten oil tube mounting bolts
(b) and (c).
3) Tighten bolts (c), (b) and (a), in this order.
★ Tighten the air intake manifold mounting bolts
evenly outward from the center one to the outer
ones.
6 1
6 2
6 3
6 4
6 5
6 6
6 7
6 8
6 9
6 10
21. D65EX, PX-12 30-29
★ For the procedure for installing high-pressure
pipes, see the Removal and Installation of Noz-
zle Holder Assembly section.
Spill tube (45) (at both ends):
24.5 - 34.2 Nm {2.5 - 3.5 kgm}
Water tube (46):
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Head cover:
8.8 - 10.8 Nm {0.9 - 1.1 kgm}
Harness mounting nut:
8.8 - 10.8 Nm {0.9 - 1.1 kgm}
★ For the procedure for mounting the injector and
the nozzle holder, see the Removal and instal-
lation of Nozzle Holder Assembly section.
Rocker shaft mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
★ For the procedure for adjusting the valve clear-
ance, see the Adjusting Valve Clearance sec-
tion in the checking and adjusting manual.
★ To mount the crosshead, follow the steps below.
1) Mount the crosshead on the valve stem with
locknut (54) and adjustment screw (55) loos-
ened.
★ Loosen the adjustment screw (55) until it
is off the valve stem.
2) Lightly hold the face of crosshead (56) con-
tacting the rocker arm to keep it contacting
valve stem (a) on the push rod side.
3) Tighten adjustment screw (55) until it con-
tacts the valve stem.
4) Tighten locknut (54) while retaining adjust-
ment screw (55).
Locknut: 58.8 - 73.5 Nm {6 - 7.5 kgm}
6 11
6 12
6 13
6 14
6 15
6 16
6 17
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23. 30-30 D65EX, PX-12
Rocker housing mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
★ Tighten cylinder head bolts (59) in the order
shown in the figure below.
Thread section and seat surface of
bolts: Engine oil (EO-CD)
1st round: 88.3 - 108 Nm {9 - 11 kgm}
2nd round: 157 - 167 Nm {16 - 17 kgm}
3rd round: Tighten by 90° ± 30° with tool A2.
To tighten without tool A2, apply
markings on the bolts and the cylin-
der head with paint for angle refer-
ence, and tighten to the angle
specified above by using a protractor.
6 18
6 19
24. D65EX, PX-12 30-31
REMOVAL OF FUEL TANK ASSEMBLY
NDisconnect the cable from the negative (-) ter-
minal of the battery.
1. Remove seal installed to operator’s compart-
ment frame.
2. Remove cover, then disconnect fuel return hos-
es (1) and (2).
★ If the fuel tank is full, fuel will flow out when
the hoses are disconnected, so drain the fuel
to a point where the fuel will not flow out.
3. Open battery cover and remove wiring connec-
tor (3) (CN4).
4. Disconnect wiring, then remove rear lamp (4).
5. Remove cover at rear of machine.
6. Close fuel supply valve, then disconnect hose
(5).
7. Remove bracket (6). 6 1
25. 30-32 D65EX, PX-12
8. Remove cover at fender side, then remove left
and right fuel tank mounting bolts (7).
9. Set lifting tool to rear lamp mounting bracket,
then lift fuel tank assembly (8), and move to rear
to remove.
Fuel tank assembly: Approx. 400 kg
(when fuel tank is full)
INSTALLATION OF FUEL
TANK ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
Bracket mounting bolt: 110 ±
±
±
± 12.3 Nm
{11.25 ±
±
±
± 1.25 kgm}
★ Make the clearance between the fuel tank
and left and right covers uniform, and tighten
the mounting bolts.
6 2
6 1
6 2