SEBMO144B01 SIMO IMTA\INITOA\ IL KOMATSU D6OA,P-6 D6OSA,P-6 MACHINE MODEL SERIAL NO. D60A-6 31001 and up D60P-6 32001 and up D60PL-6 30001 and up D65A-6 32001 and up D65P-6 31001 and up setae 00-1‘The affected pages are indicated by the use of the following marks. It i requested that necessary actions be taken to these pages according to the table below. Page to be newly added Action required Add Page to be replaced Replace Page to be deleted Pages having no marks are not revised. LIST OF REVISED PAGES Mork Page Revision |mtark Page Revision |mtark Page Revision |atark Page Revision | ark Page Revitgon ° 7 2? o 18-22 1 8 18-102 eat @ 15:23 13 68 13-108 Cra 15:24 18-64 13-108 ei 13-25 13-65 13-105 . es @ 13-26 13- 68 13-106 12-6 13:27 13-67 13-107 17 13-28 13° 68 13-108 oe 13-29 13-69 13-109 eins 13-50 13 70 13-110 12-10 13-31 13-71 1-111 tent 13-32 13 72 15-112 ere © 18-33 18- 78 13-118 12-14 15-34 13-74 13-114 . 12-18 13-35 13-75 15-118 . 12-18 13-36 13- 76 13-118 1217 13-87 13-77 is-117 1218 19-38 13 78 13-118 12-19 13-38 13-79 13-119 12-20 13-40 13-80 emt @ eB @ 13-41 13: 81 21-2 13-2 13-42 13-82 aie 8 133 13-43 13- 88 ae 4 134 13-84 eos o 1a 5 13:45 13-85 ems G 13 6 13-46 13-88 a7 . 13-7 13-47 a7 2-8 13-8 13-48 8 2-9 13-9 15-49 89 2-10 13-10 13-80 90 eit . 1-11 13:51 3 aie 12 . 18-12 13:52 92 eos © e 18-13 13-53 93 a4 iat 1358 oy ers @& 13-15 13°55, = 95 21-16 . 13-18 13-56 96 2-17 18-17 18-57 7 © 28 13-18 13°58 13- 88 ea 13-19 13-59 13-99 © 12 13-20 15-60 13-100 2i- 21 e 13:21 13:61 e101 21-22 00-2 D60.65A+P‘numer Mack Page Revision Jaark page eVsION Iatark Page Fviton mark Pane WIC” IMark Pane jee fer fe m6 25-55 90 wie 27 28-26 23-91 125-146 . 28 23-37 23-92 2-147 29 23-88 23: 98 25-148, 22-10 23-39 23 4 © t149 . ait 23-40 28: 95 © 25-150 . mn 23-41 23- 98 28-181 ° © m3 23-42 23: 87 28-152 em 28-43 25: 98 18-158 © mG 23-44 23-98 13-154 20-16 23-45 23-100 23-155 omer 23-48 28-101 28-156 22-18 23-47 23-102 23-157 2-18 23-48, 23-108 23-158 22-20 23-49 23-104 28-159 © 221 23-50 23-105 © 3-160 22 23-51 28-108 25-161 . 22-28 23-52 23-107 23-162 . ° mu 23-58 23-108 13-168 . 22-25 23-54 23-108 23-164 © neo 23-55 25-110 28-165 21 23-56 2st 28-166 23-2 23-57 2-112 23-187 23-3 23-58, 28-118 23-168 24 © ws 28-114 28-169 . 25 23-60 28-115 23-170 2B 23-61 28-116 25-171 e149 1 23-62 at 3-172 ° 8 23-63 23-118 © 8178 . © 64 28-119 © B74 23-65 23-120 28-175 23-66 © Bia 28-176 23-67 28-122 © B77 . 23-68 25-128 2-178 ° 23-68, 23-104 28-179 . 28-70 28-125 28-180 . 23-71 28-128 2-181 28-72 28-127 28-182 28-73 28-128 28-183 23-74 23-128 23-184 28-75, 23-190 28-185 28-76 23-181 © 3-188 23-77 28-182 13-187 23-78 28-188 25-188 28-78 28-184 28-189 . 23-80 28-185 28-190 . 23-81 28-188 28-191 . 23-82 28-187 23-192 . 23-83, 23-138 23-193 . © BHF 28-188 18-194 . 28-85 23-140 28-195 23-86, 23-141 23-196 23-87 23-182 15-197 23-88, 28-148 eet ° i 23-89 23-144 ew 2 260,54: 0-2-1 rMark work Pago REO Jorge Pose REWHOM Tatrk Pape RENO" Tata Page Revision : we . @1 a 77 ° 0-18 2 ie ° 16 a3 a) s-17 a4 7-10 ° ate 6-5 Tet . eo a 36 emt 4 oo oe 6-7 m2 om 4 at a8 m3 emi Mee a9 m4 . a1 D . 343 68-10 . mH 6 i eo mn 7 le ee ent 7 ow ows ss-i2 148 oo mis ab fe ws 19 wr a ome fle we? 4 a-14 2 4 eu 4 fe we 62-5 a3 4 oom ab fe wes a-16 s0-4 eo own 4 fe sei 6-17 oso eum vie oi ua i? ° un a8 2 28 eos oh 24 (61-5) 26-26 oe e 24-27 a . 6I-7 i o ue @ fe see 4 eo oum o fe oo 4 ©2430 si-10 2431 ea a oor eee 4 eo? G@ fe oe wrt @ fe ss a fo saz a fe oie a Lo eons @ fe or a le ae © oie a5 eae oo fo a 1-20 ° a ea ° a8 61-22 . aI eae ob fe 31-10 ar-26 att ot ai? 2-2 . oom Gg a4 a2 a5 3 a6 a4 @a7 5 8 a6 62-9 a7 © 0 4 a8 ent . a8 eo-12 a-10 2-18 et a-14 a1 ais 18 62-16 060,654-PCONTENTS GENERAL ENGINE 12 TESTING AND ADJUSTING 13 DISASSEMBLY AND ASSEMBLY POWER TRAIN 21 STRUCTURE AND FUNCTION 22 TESTING AND ADJUSTING 23 DISASSEMBLY AND ASSEMBLY 24 MAINTENANCE STANDARD. UNDERCARRIAGE 31 STRUCTURE AND FUNCTION 33 DISASSEMBLY AND ASSEMBLY 34° MAINTENANCE STANDARD HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION 62 TESTING AND ADJUSTING 63 DISASSEMBLY AND ASSEMBLY 64 MAINTENANCE STANDARD WORK EQUIPMENT 71 STRUCTURE AND FUNCTION 73 DISASSEMBLY AND ASSEMBLY 74 MAINTENANCE STANDARD. OTHERS 90 ELECTRICAL SYSTEM 60,654: No. of page ort 12-1 13-1 21-4 22-1 23-1 24-1 31-1 33-1 34-1 61-1 62-1 63-1 64-1 1-1 73-1 74-1 90-1IMPORTANT SAFETY NOTICE IMPORTANT SAFETY NOTICE froer weve rep inva pert forth at opnaon of machin, The snc eee Seca enter omen posnss btn wana The talon scompervnn te fmbele hod sys Paral cash ty arnqrane ros cna or ay post foe ecersey, 00-4 060,654-PFOREWORD FOREWORD ‘This shop manual has been prepared as an aid in improving the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every availably opportunity. Organization This shop manual mainly contains the necessary technical information for ‘operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following Structure and function ‘This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting, Testing and adjusting ‘This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Diagnoses” to “Causes are also in cluded in this section, Disassembly and assembly This section explains the order to be followed when removing, installing, isassembling or assembling each component, as well as precautions to be taken for these operations. Maintenance stendards This section gives the judgement standards when inspecting disassembled parts D60-65A, P-6 00-5FOREWORD USING THE SHOP MANUAL. Volumes Distribution and Updating ‘Shop manuals are issued for carrying out repairs. ‘They are divided as follows: Chas Engine volume issued for each engine: is volure: _issued for every machine model Electrical volume :) Fuel system volume : }each issued as one volume to cover all models: Attachments volume: | In addition, the following volumes are issued for high level rebuilding tech- niques to cover all models. Engine volume Undercarriage volume ‘The following volumes fe issued for inspection and tests after repairs: Guidance for reusabie parts volume Bench test methods volume ‘These various volumes are designed to avoid duplicating the same information, Therefore to deal with all repairs for any model, itis necessary to have the shop rranual for that model as well as the relevant engine volume, the fuel system volume and the electrical volume, ‘This shop manual is chassis volume, Recipients of shop manuals are recorded at the Komatsu Head Office, Any additions, amendments or other changes will be sent to all recipients without fail, so someone should be appointed to be in charge of manuals. In this way, pages can be added or removed immediately and the manuals kept up to date ‘and easy to use. 60-654, 2-6Filing Method Revised Edition Mark 60-654, P-6 » 2) 3) FOREWORD File under the manual title file printed on the bottom o* the page. Method of taking out the pages for filing is as follows: First order each item number starting with the lowest, and next order according to the consecutive page number for each item. Example: 00-6 21-3 LL sunanee —} \ Consecutive page number for each item ——! Additional pages: Additional pages are indicated by a dash (—) and number after the page number. File as in the example. Example: 21 21 Pages added between 21 ~ 4 and 21 —5 Besides this, when necessary, information will be written in the filing ring hole’s margin. Look when filing. When 2 manual is revised, a revision number is placed within a circle and printed on the bottom inside corner of the pages to distinguish it from the fold manual, Therefore, higher circled numbers supersede lower ones. [A table listing revisions and revised pages to the present is printed on the ‘back of the title page, so when there is a revision, revise the title page also, and use it to keep the file in order 00-7FOREWORD Symbols So that the shop manual can be of sufficient practical use, we have marked important places for safety and quality with the following symbols. SYMBOL | ITEM REMARKS This indicates work that requires special precau: Security | tions for the security of the machine when as sembling. | Special satety precautions are. necessary when performing the work Safety = Extra. special safety precautions are necessary when performing the work because it is under | internal pressure. Special technical precautions or other precautions Caution | for preserving standards are necessary when per- forming the work. Weight of parts or systems. 7 Weight | Caution necessary when selecting hoisting wire, or ks _J when working posture is important, ete. Tighten- | Places that require special care with the tightening ing torque| torque when assembling. | Places to be coated with adhesives, etc. when = ANS | Ot | assembling . — Oil, water| Places for filling with oil, ete. Oil capacity | Drain | Places for draining oll, etc. Quantity to be drained. 00-8 D60-65A, P-6Network Diagrams Troubleshooting Chart D60-65A, P-6 FOREWORD ‘The standard procedures for disassembly and assembly are cLescribed and shown in photographs for each part of the machine, ‘The sequence or steps employed in disassembly and assemb ly are shown in net- work diagrams as depicted below. Pak The sequence of the procedural steps is given in arabic numbers on the top right of each block. For example, when it is necessary to remove part D from the assembly, the steps for removal should be A-* BD, Or, to remove part Ethe step is A>E, [F Ass'y] is an assembly for which the disassembling procedure is described separately. For assembly, the secquence is presented under each section, in the same manner as for disassembly. ‘As shown below, the symptoms relating to a particular troutsle are described in the line designated “Diagnoses”. The cause of the trouble is then correlated Under the "Causes" column and is shown marked. Problem No. 1. Reduced tractive power or ow travel sped cme Fal a i : 5 |3 Diagoses < “Torque converter oil pressure gauge shows lower than normal prasu re eer ee ofelo “anion ol ress au awa Tow Tan Paral aon ot mal 352 Soren om | 3 00-9FOREWORD DEFINITION Standard Size, “The dimension of rished pars each cfr ite, Therefore, when determin Tolerance ing the finshed dimensions of pars, a ciension that wil be standard is deter mined provionally. and then the sifference allowed from iti indicted, The former ealed the standard sit, and the ltter the tlaance. The way to tow this s by a plus or minus sin with te folerance in sale humeral tothe ight the standard ae, Example: 120-2922 (The same mesning as 119.874 ~ 119.978) Moreover, when expressing the dimensions of a hole and the shaft that goes inside forthe sake of convenience the standard size forthe hole an the shat Usually taken asthe sae, and the tolerances changed to indicate the tghtnee of the fit For example the fit of revolving shaft is indicated s follows, and ieshownin te drawing Hote 60°96 shaft 60 9939 3 88 sg : 3g 22 is 8 a a 8 eH 8 00-10 D60-65A, P-6‘Standard Size Repair Limit Standard Clearance Clearance Limit Maintenance ‘Standard 60-654, P-6 FOREWORD ‘This is the standard value at the time of design, the finished dimension of new parts, ‘This is the limit in dimension up to which the part can be used. (The size of parts changes due to wear or distortion during use). When parts exceed the repair limit, they must be repaired or replaced as specified. This is the clearance between two new parts after assembly, shown as a range between minimum clearance and maximum clearance. In general, parts are adjusted to this clearance after repair. This is the maximum clearance allowed between parts. (The clearance increases due to wear, etc, during use.) When the clearance exceeds the clearance limit, the parts must be repaired or replaced as specified ‘This is the number given to items in diagrams of individual components. The same number is given in the leftshand column for ease of identification. Unit: men NNo.| Check item criteria Remedy Standard size T T t Unit: mm NNo.} cheek Criteria Remedy Tolerance Serial | Stendard i Standard | Ciearance| Nor | see | eae | wow [eooance| im 10 T T T 00-11SHOP AWAY G DGO,GSA‘P-e OI GENERALO11 GENERAL D60,65A-P General views - 01-2 Specifications. ....... ++. 2 O14 General assembly drawing . : O16 Engine assembly drawing... . see) OM Engine specifications . s+. 0113 Engine performance curve. = 0114 Weight table. . eee O17 Positions of serial numbers .. 0... ss s22+ +++ 01-20 Table of oll and coolant quantities . .......-. 01-22 Oil and water filling and drain points. 01-23GENERAL VIEWS sso Pose GENERAL GENERAL VIEWS D60A-6 31001 and up Litt eylindor Fuel tank Sprocket “Track shor Caria roller Blade fare alee Brace D6OP-6 32001 and up, D6OPL-6 30001 and up Tite evtinder Beaxomapnn 01-2 60,6507“oo SGENERAL VIEWS GENERAL D65A-6 32001 and up Litt evinder Fu take Sprocket Track shoe Carlet roller D65P-6 31001 and up Blade Tite evindar 060,65A-P 01-3eens GENERAL SPECIFICATIONS: st sets SPECIFICATIONS Machine mode eons eos ‘eoPL-6 Desa esr Sel mums 231001 ndup | 32001 andup | 30001 andup | 92001 and up | 31001 and up ] operating woiont tks) | 15590 | 7140 16200 18720 17790 sy ti) | 20 | ata 1690 2320 2140 sToctor mm] 4000 4210 4088 4000 4310 With work =) *Mulomen mm] S195 506 sa 5198 505 }— 5 tov] 2290 2000 2500 2300 3000 | BE) witn work | eaten: Gomi] 9970 2070 4190 2070 3070 gu) Tothe top of | BE, “emaurtpive (mm) 3015 3058 3040 3015 3088 F) cromoot cimen| | Preseamer” ovm)| 2005 ass 2408 2408 2aas oon Track gage (ovm)] 1090 1050 2300 1890 2050 Length of track onaound om] 280 2140 2096 2400 3140 Shon width (STO) (nem)| 510 950 1200 510 950 Ground cesrance — (nm)] 400 510 495 400 s10 | Ground posure gfe | track 82 0.24 0.20 052 028 With wor eaipment ors 0.29 02 0.6 020 | tin, tuing radios td) at 26 29 a4 28 | Notice roar st cus of track contact sures) ertor | Gradabilty texsi| 30 2 | # 30 20 mance | Number of gear shift | Forward 5 speeds |Forward 6 speeds | Forward 5 speeds | Forward 3 speeds| Forward 3 speeds Feeverse 4 speeds |Revorse 4 speeds | Reverse 4 speeds | Reverse 3 speeds | Reverse 3 spoods 01-4 D60,65A+P(GENERAL tse eens ates SPECUFICATIONS T T Machine model vsons | vers | pecPLe esas pases Machine seri! numbers 31001 sndup | 32001 andup| 20001 and.up | 32001 and up | 21001 and up ‘Wet, multiple ds inertia brake, hand operated ‘Main clutch with hydraulic booster ~ orque converter - A etement singe sage ond Tora ‘3 phase | | Pranetry gear and multiple die | ranamiion | Htc ger constant mesh hand operate, forced | lite, ydrouliclly sewusts, | lbteadon‘Fonwera 5 spsce Heveree 4 wpaae | forced tuo | Revere 3 seed Power ton Bevel par shat Spiral bev! ger, splash lubrication Sterng teh Wet, multe, hydraulic with spring type I Wet, contracting band with ltch booster ‘Storing brake | Interconnected with steering lute Final crve ‘Sur gpa, double reduction, path lubrication 1 T Zesch side | 2each side Zeech side | each side | 2each side Goocnside |Teoensie | Tewensise —[Gancnsie | 7 eachside Uneerorige Some ren nao router! Sueno thos | Swamp shoe | Shale woume | Seomp show Track ‘hoe wath | Shoowiath | Shoswot | “Shee wann | eras | “Sfotmm” | °380mmm” | Yom sromm | Seb mm Max. cll resus 140 glem™ tyra | ender | Doutie stn, itn tee Control valve | Buln nyeratc tank D60,65A-P 01-5GENERAL ASSEMBLY DRAWING © GENERAL ASSEMBLY DRAWING D60A-6 31001 and up 01-6 GENERAL oreo! 060.6507GENERAL © shit GEINERAL ASSEMBLY DRAWING D6OP-6 32001 and up 802 $208 ————_~ po—086: oze——+| | sat | iF o1roo2 5380 $2935 —___+| wor 260,654-P 01-7GENERAL ASSEMBLY DRAWING St DGOPL-6 30001 and up Se eee GENERAL 2335— 5215 060,65A-PD65A-6 32001 and upGENERAL ASSEMBLY DRAWING D65P-6 31001 and up oxoe. S54 01-10 a GENERAL 060,654-P(GENERAL screenees ENGINE ASSEMBLY DRAWING (D60-6) Fen Mutter Air lear Altemator Ful fter Fullfow filter Accessory drive pulley Vibration damper Engin oil cooler 10. Cowosion rsietor 11. Starting motor 12, Suzerng oi! cooler 01-11 260,654.RNS GENERAL ENGINE ASSEMBLY DRAWING buster (D65-6) Fen Muttlor Alrcloanor Alternator Fuel fitter Full-flow filter ‘Accessory drive pulley Vibration damper 8. Engine oil cooler 10. Cortaston resistor 11, Starting motor 12, Torque converter oil cooler 01-12 D60,65A-P_GENERAL, ENGINE SPECIFICATIONS. ENGINE SPECIFICATIONS Model D60A6 D60P.6 | Dears | De5AS 08sP6 ‘oral jor | S200] saqor | ooor | 22001 31001 tel moe Ee ee ee wza0er8 | wnzzoero "[evamere [wnaanare Ena mea imi No, of evindersbore x stroke (mm Piston displacement (cs) Water cooled, 4cycle, overhasd valve, direct injection type, closet 6— 130.2% 1524 12170 Fig onder ta5-3-6-2-4 § | Ove inns tm 18 § | over wih tn 20 : 8 | ovat nee tne ave | Flvetes!Ronepower (HP) 140 185 140 | wo} 185, Fras new tom 1800 sm00 | sooo | sso | aso 5 | atx, ore tea) 25/1000 7eii100 | 75/1000 | 72/1060 | 78/1000 © | unt consumotion ratio (gn) 185 185 | ee ory wight to 1490 7350 Ft pune Commins PTS os poe Governor Meshal see conta Staring motor v.74 Gonwator 2,128 satiny 12V, 2008h «2 060,65A-P 01-13ENGINE PERFORMANCE CURVE 3 si so GENERAL ENGINE PERFORMANCE CURVE NH-220-Cl, B, D (D60A, P, PL-6) Rated horsepower 140 HP/1600 rom Maximum torque 76 kgrn/1000 rpm Minimum fuel consumption tio 185 g/HPh Torque | 80 ae , | wo # | | 5 | wo & | 0 —— 1 | 120 4 —— | | z oe + + ~ 6 | / | | =o | | | 60 — | — | = | | = «0f}—- 1200 Fuel consume’ 8 _| | 7 8 | & 20 T — - 10 E | 2 | m 8 L & ° soo t000”~C~a00~«AO]~«GD~~«BO RPM 01-14 D60.65A+Psunpinei ENGINE PERFORMANCE CURVE GENERAL Z2scoumnico au AAS CEA NH-220-Cl, F (D65A-6) Rated hosepower 140 HP/1850 rpm ‘Maximum torque 73 kgrn/1000rpm Maximum fuel consumption ratio 185 g/HPh | | L 1 | . — 78 | | wo & | | é ] T a 40 | | 120 - | S i ot = | Pa g | é 7 : 1 S | | | & | | | | = + zs © + } z | 5 | & 40 20 E ! z } + 7 20) T - - + te © | | | j | 170 5 | oe Cr eT eT ne eT) RPM o1roo7 D60,65A-P 01-15ENGINE PERFORMANCE CURVE ‘:=inunsaneneoaemnenmey NH-220-Cl, C (D65P-6) Rated hosepower 155 HP/1850 rpm Maximum torque 75 kgrn/1000 rpm Maximum fuel consumption ratio 185 g/HPh 40 120 Output (HP) Ey 01-16 4 Toraue \ 1 200 —«1000~=«00~=S«a0D~=S«T600.~=SC«*BOD RPM 2000 os 70 a 5 oe 0 z 3 z ™ § x0 E 2 100 § wo 2 eirooe GENERAL, 060,65A+PGENERAL WEIGHT TABLE WEIGHT TABLE Units ka 3806 Des Moss! — a |e Pt A ° orl number sioor | s2001 | 00m | sa00 | ston atop | andup | andup | andup | andup Engine, main clutch ay 1800 ~ + Engine ay 1600 - + Main clutch ay 20 = Engine, torque converter ay 1750 Engine any 1600 Torque converter ai'y 150 Radiator gard, blade it tinder a'y 50 v0 | 700 00 780 + Raatr goons 400 | 500 | 440 400 00 + Radiator oxy Soo 10 | 160 Life etinder n'y (one sds) a | os 9s = | 8 _L | Fue ank ey 98 | es 96 | ‘Univers joint o'y ® “Transition as 30 ~ TORAFLOW transition a'y 600 contro valve ay 35 vl gar shat, steering leh ay 210 © eval ger satt 6 + Bove gear 7 Staring control ve ay 2 Final dive cat onesie) 98 98 120 060,6507 01-17 iWEIGHT TABLE GENERAL unis ko 2008) pees Model —_ A . m A . Ser urn zacor | sooo | sacar | stonr Ea ee cE! Sree ub gar sry oe) =) =] «= | = | = {egw 2 lon foe se a ‘enon on) ® Sree oe 189 Sroka se ons) o [ «| ms zw t00 Storing ca a ae 1350 ‘Track ass'y (one side) 1200 1850 1750 1200 ] 1850 + Trak ame ay (ne ‘ooo | vs | v0 | vem | v7e0 + lorasey 200 | xo | ow | mo | 00 «cori roeray 6 eo 8 “ “ ak ra ie) % oo % fo oo (Dosbe os os os os 4 mao srng ay (one ie vo | wo | wo | tg | 0 ak tame ones) so | m0 | 0 | so | 100 ng cr urd mo | | as | ao) Trermision nar ur 109 8 = | wo | | | a wo | wo) wo | mo | 100 opto at we Hydraulic tank ass'y_ 130 200 | 130 i300 | 200 + convstsie ty © | @ | “0 eo 01-18 1060,65A-PGENERAL WEIGHT TABLE eet oes ace at couonne en ee Soa eee ars = pen ana 7 «s ]- - 5 Otte ay vo | smo | oo | xo | 10m © Blade goo | 950 850 900 960 treo ree er oo | me | mm | om | me tein ceh ecewetet pe = : TORGFLOW pe ary ~ ves vvaauepump wy te e0.ssae 01-19GENERAL POSITIONS OF SERIAL NUMBERS tities POSITIONS OF SERIAL NUMBERS (ENGINE) © Radiator No. fi 3 Starting motor No. ‘© Hydraulic pump No, '* PT pump No. | orPoDe Pha oiros ‘¢ Steering pump No. (D65) * Toraflow pump No. (065) ‘© Main clutch and steering ‘pump (DEO) 01-20 D60,65A-PGENERAL POSITIONS OF SERIAL NUMBERS POSITIONS OF SERIAL NUMBERS (BODY) ‘© Torque converter No, (D65) ‘¢ Machine serial No. D60,65A- olrere, Transmission No. (060) — 7 + Torafiow tansmisson No | (065) 0} 8 a : = [KL + yt No ej} — | JS oiroio 01-21‘TABLE OF OIL AND COOLANT QUANTITIES GENERAL TABLE OF OIL AND COOLANT QUANTITIES Feed oi! & coolant quantities Mose! ovone | onore | oaorte | ofsae | esr Remarks t vo mumper sroor | 32001 | sooo | szom | s2001 ‘Serial number and up and up and up and up and up Emin coon seo we “28a O87S No.2 Fuel tank 2808 Below —10°C: aha 0878 No.1 TAP Senieecesifenton ‘ubri t 2 O Engine lubricating oil 43: “Above 0°C: SAE3O Siar 8s. Bow Teaue conver aaron - we ‘rnsmision, set as worse) | - pl Sevieecsitetion a 8 Skes0 Storing case - roewse) Fina eae fone sie) = |= | » | os | » Man hh me ~ Apt Serves cleteaton + 88 vara convo! 1 10 1 Berow avi ror 0% woe saeson “Track roller fone) 250 ce ler (one dt indicated above represent the quantities required for replenishment up to a * The fuel, oil and coolant quantit specified level in a dry-up condition. + Figure in (_) indicate quantities required at fluid change. ASTM: American Society for Testing and Mater API: American Petroleum Institute Society of Automotive Engineers 01-22 D60,65A-P 4GENERAL, OIL AND WATER FILLING AND DRAIN POINTS OIL AND WATER FILLING AND DRAIN POINTS (ENGINE) D60A6 — 31001 andup D60P-6 32001 and up D6OPL-6 30001 and up D65A-6 — 32001 and up D65P-6 31001 andup ‘© Coolant drain © Coolant filling port ee ‘© Engine oil drain © Fuel drain j iro D60,65A-F 01-23OIL AND WATER FILLING AND DRAIN POINTS Zivsstnettaern pogenmeeeeen GENERAL OIL. AND WATER FILLING AND DRAIN POINTS (BODY) DGOAS — 31001 andup D60P-6 32001 and up D6OPL-6 30001 and up ‘© Hydraulic tank filling port © Hydraulic tank drain ‘© Steoring case drain copie © Final drive case filling port 01-24 260,65A:7GENERAL 88 ‘eeeeeeeeeeenteet OL AND WATER FILLING AND DRAIN POINTS D65A6 32001 and up DESP-6 31001 and up ‘¢ Torque converter case drain © Transmission case drain © Hydraulic tank filing port if SSSR 01038 © Transmission case and torque converter case filling port ° «© Steering case filling port D60,65A-P 01-25MEMO 01-26 D60,654-PSHO RMN UANIUAN: DGO,6GSA:P-e 12 ENGINE TESTING AND ADJUSTINGENGINE 12 TESTING AND ADJUSTING 80,654: Standard for testing and adjusting. Tools for testing and adjusting General instructions “Measuring engine speed. Checking glow plug and heater signal. Cranking method, Intake and exhaust system ‘Checking air cleaner element for e’ogging (Checking exhaust color. Adjustment of valve clearance Engine body ‘Measuring compression pressure Measuring blow-by. . . Lubrication system Checking oll. ... eee ‘Checking oil pressure and temperature. Fuel system Checking fuel... .... Checking fuel pressure... . “Measuring vacuum by PT pump Checking injector . . Cooling systern Checking coolant... . 62 2eeee eee Checking and adjusting fan belt tension Checking and adjusting alternator drive belt 2122 1123 24 1124 1125 126 2127 2128 12:10 + 1242 2 1214 21245, - 1246 1247 1247 2 1247 12.18 12.19 1219STANDARD FOR TESTING AND ADJUSTING TESTING AND ADJUSTING STANDARD FOR TESTING AND ADJUSTING Engine wn220-c1 o808,PL8 Machine mods Ber (eng. sone upto Eng Serle NO oa "26160805 and up) Cate] conditions. «=| Unit standard | Repsicimit | Standard | Repair tim Sa _eetm ond | Stands | ear tmit | Stnaira | Rep ii 3 | coane wigniangoms | om | 90220 | srm020 | s900540 | 1200540 | Ensine sored | Ly iting oe om 215 | sess15 | sass is 5 | fo ing ome = 5 1 : © | Speed needed for | °C “pm - [| - - = = | Seay “20°¢ tne waringnis) | rom | 110min = home | = Intake resistance | At rated output | mmH,0 380 max. 635 380 max. 635 | inate prmer | Ateewd ouput 5 * : . = 5 | cxnauetormire | at rod outs coma : : = |S % | cxrmun amp. | whotespeedrancezotci | "6 | @somex. | ssomex | somes. | 680.max 3 Suddevaccelwaon — [Roschindex| 68 max Smox | 68max a | exneust color | ® ei | 65: E Athi ting oxen index] A8max | Amex | Amex | 4.5mm : = 4 a es om | ossoan | — | ose oan = Warm eo) | Exhaust wave mm [osm | - | oso | — Compranion | ovvenp: 40-e0"e | tam | 28min | 28min | 28min | 20min a | pene (Engine speed! tom) | 230-2601 | 230-2501 | 2x0 280) | (220 260 i ‘At high idling Bowbypreure | ARN ing ge | mmiiso | odmex | 120, 60 me 120 Oil pressure | Ac high iting kgfem? 35-85 38-55 35 — - tare oh ing | tent | 38-5 ss | as—s5 g | rns | Attomiating seen’ | 20min | 20min, | 20min. | 20min E t : hol oned range ; - wo | E | ciltamosrature | Wholesome a a ed 20 20-98 120 aL i ‘As continuous ried | oitconsumetion | ourpur 3 | ons feelers) “ 1.0 max. 1.0 mex 1.0.mex, 1.0 max. SSmurpton| | | | TE] erpump wer | Atvoted ouput wien? | o5-58 | - | 60-05 | — F8| proture Sudienscaeation | tale? ae ee - ‘wholesome noe | Gootans | Engine outer water “ ro-s0 | 10 | 70-90 100 mors ‘eopentore | ral ‘atv eracking tmp. vc | ms—705 | 5-705 | 5-725 | 145-78 ess Fl open tao, *c 80 = 90 - e | Ful ope it om = tomin = | t0min 3 | faciatororoure | valve cocking premire | yajems S| Giketindson | lores aaron len 076 a ow |e Fanbatewrtion | sick men pupedwith | feratoe | Slack men puted with | ayy 2% | maa 2 ce crankshaft pulley) | 9" 12-2 D60,65A-P‘TESTING AND ADJUSTING STANDARD FOR TESTING AND ADJUSTING De5as scars |_ opti 208s +20 | 2068 = 30 565215 | 565215 some | | ttomin = ee 380 max. | 635 380 max. 636 some | esoma. | es0mex. | 680 me Game | 68mm | Geman | Smo tSmen | 48men | 48men | 8mm | semen | S5me co csstoms | | ceoery | — 28min. | 28min. 28 min. 28 min. (230-260) | (230 - 260) «220 260) | (250.- 260) come vo | oom | azo gees | as-ss | sees | a0—se zomn | 20mm | 20mm | 20mm T woos | 120 | cows | a0 1.0 max, 4.0 max. 1.0 max. | 1.0 max. - = at een ee ee ey 145-785 | 745-785 | 745-785 | 745-785 o |e 90 = = | tom “ tome ee eee 260,65A+P 12-2-1‘TESTING AND ADJUSTING ‘TOOLS FOR TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING we] ow re Tet rhe i oe pees «| eascharainne 0-0" 3 [ ena wnpemwre Tao 7 | Fo pemee 020 ten = =iaemeala a T1900 =e @ 5 eee | emer main] n ee = —— Teozorien2 [oso mmro eaten [aa Tam aaa er woe HS eee 14 | Exhaust color Handy e 799-201-9000 | piscoloration 90 — 1/70 % Bosch index! eee | eee Gieel anon a olor roozoeme | Hess. a et eee Tamron] [02s went 77 | Prewe wn pee | Vasu wom ee | oe = Tenovton : To [Gone ocean == eva | RTGS SST no | Sei lt ES | tra we reazc2oo0 | 02 tte ee cnet 7ee6101000 | erae win OBO arg nar Tar AAS wien carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety pins, ‘and block the tracks. AS wnen working in groups, use sgreed sgniis and do not allow unauthorized persons near the machine AR Wine checking the wate level inthe radiator, wait forthe water to eo0. Do not remove the radiator exp wile theater hol. Beilng water ay spurt out A Be careful not to get caught in rotating parts, 160,65A+P 12-3GENERAL INSTRUCTIONS "ists coaeaeaemeet TESTING AND ADJUSTING GENERAL INSTRUCTIONS MEASURING ENGINE SPEED 1. Remove cap for service meter {1) and install tachometer adapter rN 2. Connect cable 8 to adapter and body C. Switch on tachometer and measure engine speed. * Parts number: tachometer 799-202-500 CHECKING GLOW PLUG AND HEATER SIGNAL 1. Set heater switeh (1) in “ON", put key into starting switch (2) ‘and turn it to “HEAT” position. 2. Check to see if heater signal (3) turns red. 12-4 060,654+7‘TESTING AND ADJUSTING !cttstiteesnmneemenan so GENERAL INSTRUCTIONS CRANKING METHOD 1. Connect cranking kit 2s follows. Cable on Note: Completely tighten terminal nut sine large mount ofelacticty, tows een (TUTTE Sareea conpreemnas [PEPER RE [D, battery or head of chasis "Cranking kit to remove this short-circuit ba. bore Crankioa control engine | Ht f0 remove thie sh * Spaed by turning speed by turning |__ cay tamote smiten (Engine starts when pushing it and stops when relering, The eable can be extended {To where you can check erenk angle) | 2F001 2. Push down compression release lever (1) to'release compression, 3. Fully tum handle of eran switch. kit clockwise and push remote 4, Turn handle counterclockwise while observing engine speed, and stop handle when engine speed decreases to the desired speed. ‘% Engine may fail to start while inching because of poor charging of battery. In such case, control handle again. * Cranking kit No. 795610-1000 060,654-P 12-5INTAKE AND EXHAUST SYSTEM sitiiiemm jovi TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM CHECKING AIR CLEANER ELEMENT FOR CLOGGING 1. Checking dust indicator Check to see if dust indicator (1) works (indicated in red at the service level position). 4 Dust indicator indicates red when intake resistance in- creases due to clogging of air cleaner element and intake negative pressure reaches 635 mm by water manometer. 2. Checking element Check element itself as follows when dust indicator indicates red or exhaust color is black; 1) Remove wing nut (1); remove cover (2). a 2) Remove wing nut (3); remove outer element (4). 3) If dust indicator indicates red or exhaust color is black after ‘outer element is cleaned or replaced, remove wing nut (5); remove inner element (6) . (Check and clean or replace it. % When checking, cleaning or replacing element, clean also the inside of air cleaner. % Take care not to allow dust to enter enging 4% Bo sure to fully tighten wing nuts. 4% Reset dust indicator by pushing reset button. 12-6 D60,65A:PTESTING AND ADJUSTING #:cissameeennainenan INTAKE AND EXHAUST SYSTEM CHECKING EXHAUST COLOR (BOSCH smoke meter) Read carefully operation manual attached to smoke m 1. Fit probe A to exhaust pipe (1). 2. Connect probe to smoke meter B with tube. Intake smoke and read meter indication. D60,65A-P 12-7~ooeheeyitetieteemaaiees TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM sxssnmnens ADJUSTMENT OF VALVE CLEARANCE Adjust valve clearance between rocker arm lever and crosshead as follows; Valve Cold (20°C) Hot (60°C) Intake valve 0.41 mm 0.36. mm Exhaust valve 0.74 mm 0.69 mm % Adjustment is effected following the firing order 1-5-3.6:2-4, Checking and adjusting procedure of valve clearance 1. Remove rocker arm housing cover (1) Tzr010) 2. Rotate crankshaft in the normal direction to bring piston to the top dead center position (where intake valve and exhaust valve close). Xn 7 3. Rotate crankshaft 60° further in the normal direction to align VS mark on accessory pulley (2) with mark on gear case cover 3). To check valve clearance, insert feeter gauge of the specifi ed clearance between rocker arm lever and crosshead, and check to s2e if gauge can be lightly moved. (Refer to Step. 5) + Feoler gauge No. Cold: 795-562-1200 Hot: 796-562-1300 4, Loosen lock nut (5) on adjustment screw (4, 060,654: 12-8TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM 5. Insert feeler gauge A between rocker arm fever (6) and cross- hhead (7) and adjust adjustment screw so that gauge can be ‘moved lightly, 6. Tighten tock nut at the above position to secure adjustment screw. Ge] Lock nut: 10.4 + 0.7 kgm fadapter is used: 7.30.5 kgm * After tightening lock nut, confirm vaive clearance. 7. Make adjustment on the remaining cylinders by the same * Valve layout 0oYoo|(o0“%o00)(o0“%oo Foe ea|joo oo|joo 0° O torake veive O Exhaust valve 12003 8. Install rocker arm housing cover GSD Rocker arm housing cover mounting bolt: 1.0£0.1 kgm # Wrench adapter No. for tightening adjustment screw and lock nut: 795-130-2101 060,654:P 12-9ENGINE BODY i TESTING AND ADJUSTING ENGINE BODY MEASURING COMPRESSION PRESSURE 1. Remove fuel manifolds (1) and (2) from cylinder head. 2, Remove injector connections (3) and (4) from cylinder head. 3. Adjust valve clearance. (Refer to ADJUSTMENT OF VALVE CLEARANCE, 12:8) 4, Loosen lock nut (6) on injector lever (5) and fully loosen adjust- ment screw (7). 5. Remove push rod (8). 6. Raise rocker arm (5) and remove bolt mounting injector (6). 7. Remove injector. 8. Install adapter A for compression pressure gauge (measuring tool) on injector mounted portion. % Be careful not to damage injector and injector mounted portion and to stop dust and foreign matters from entering mounted portion. 12-10 D60,65A-PTESTING AND ADJUSTING #22: cenratemnemaaenaa ENGINE BODY 9. Connect hose B and pressure gauge C to adapter. 10. Remove cord from PT pump. 11. Tur on starting motor switch to start engine and measure com- pression pressure. * Compression pressure must satisfy the following: Engine speed: 230 to 260 rpm Oil temperatur 40 to 60°C. Compression pressure: 28 kg/em? and over 12, Remove compression pressure gauge and adapter. 13, Install injector and screw in injector connections. 4. ten injector mounting bolt. SSE) Injector mounting bolt: 1.80.1 kam iten Injector connections G3 Injector connection: 3.20.3 kgm 16. Insert push rods. 17. Adjust injector 1). Rotate cylinder to be measured 60° further from the top ead center in the normal direction to align VS mark on ‘accessory pulley with mark on gear case. 2). Serew in injector adjustment screw until plunger of injector is brought into contact with cup and screw in it 15° further ‘to.expel fuel from cup. 3) Unscrew adjustment screw and tighten it with torque ‘wrench used for injector. GB Adjusting torque for injector adjustment serew Cold (20°C): 0.55 kgm Hot (60°C): 0.69 kgm 4) Tighten adjustment screw lock nut to secure adjustment screw. GED Injector adjustment screw lock nut: 10.4 £ 0.7 kam Ifadapteris used: | 7.3 + 0.5 kgm 18, Install rocker arm housing coves. == Rocker arm housing cover mounting bolt: 1.0 0.1 kam 19, Connect fuel manifolds. * Compression pressure gauge (measuring tool) kit No. 795-502-1202 Adapter No. for Cummins engine N743 series: 795-502-1290 * Torque wrench kit No. for injector adjustment screw: 795-630-1802 * Wrench adapter No. for tightening adjustment screw lock nut: 796-130-2101 D60,65A:P 12-11ENGINE BODY © ace coeeteaieueeneeeaceane TESTING AND ADJUSTING MEASURING BLOW-BY 1. Remove ech rocker arm housing cover and stop up air vent, hole (a hole through which air passes from cylinder head to in- take side). 2. Install each rocker arm housing cover (1) and stop up outlet port of breather (2). TEPOIG 3, Remove cap from oil filler. 14, Screw in checker A into adzpter ring which is an attached part of blow-by checker, fit O-ring to ring and install it on oil filler. 5. Connect blow-by checker to manometer B or pressure gauge (0 te 1,000 mm H3 0) with tube for measuring * Check blow-by while engine is in the rated horsepower opere- ton. If engine is operated under fullstalling condition, approximate ‘measurement is obtained. * If both rated horsepower oseration and full-salling operation are impossible, operate engine at high-idling speed. In such case, blow-by measurement at high-idling speed will be ‘approx. 80% of blow-by to be obtained under rated horsepower ‘operation, 6. After measuring, remove rocker arm housing covers and open air vent hole. This work is liable to be neglected, Do without fail 7. Install rocker arm housing covers. ‘Gauz} Rocker arm housing cover mounting bol 1.02 0.1 kom 12-12 060,654-P 1LUBRICATION SYSTEM * chenameame TESTING AND ADJUSTING LUBRICATION SYSTEM CHECKING OIL Checking oi level ‘Check oll level with oil level gauge (1). * Oil level should be between H and L marked on cil level gauge. * Check oil level before starting engine, using ENGINE STOP side of gauge. * Oil level can also be shecked during low-idling operation of ‘engine, using ENGINE IDLING side of gauge. In this case, remove oil filler cap (2) to discharge intemal pressure from engine before checking. * Checking of oil level during lowidling operation of engine is liable to be subjected to influence of coil temperature or oil circulation. : tangas If such accurate oil level as measurement of oil consump tion is, therefore, required, check it before starting engine, Checking oil for water mixed in col can be judged by increase of oil, ‘clouding of cil or decrease of coolant. Remove cap (2) from oil filler and check it for waterdrops atta- ched inside, Easy judgement can te obtained while engine Is warm. ‘When engine is in operation, attach oll to oll level gauge (1) and drip it on exhaust manifold to see if water springs out. Before starting engine, loosen oil drain plug (3) and gradually loosen drain cock to see if water comes out, % This is the sures method for checking oll for water mixed 12-14 D60,65A-P‘TESTING AND ADJUSTING :2:zissninsanienenteoaeengmee eon LUBRICATION SYSTEM CHECKING OIL PRESSURE AND TEMPERATURE Checking oil pressure ‘Start engine to see if oil pressure gauge (4) works. While engine is in operation, confirm that ofl pressure gauge indicator stays in the green range. % Indicator may go beyond green range due to high viscosity of oil if engine is speeded up immediately after itis started. Checking oil temperature Remove oll level gauge and insert sensor of thermistor thermo- meter A into level gauge guide (6) to measure oll temperature oil pan. D60,654-P 12-15FUEL SYSTEM Sin sonssomammnncicteanR AN FUEL SYSTEM CHECKING FUEL Checking fuel level Remove oil filler cap (1) on fuel tank and check fuel level with level gauge. * Fill up tank with fuel after the day’s work, If vacant room is left In tank, moisture mixes in fuel, sepa rated from the air when itis cooled at night. Checking fuel for dust and water Fuel tank. 1) Gradually loosen drain cock (2) to check fuel for dust and water. 2) Remove strainer to check for dust. Clean it if necessary. Fuel filter Gradually loosen drain cock (4) to check for dust and water. PT pump magnet sreen Remove cap (5); remove screens (6) and (7) for checking. Clean them if necessary. + Install finer sereen upper side and face hold side downward, Gx Magnetic screencap: 3.20.3 kgm Checking fuel system for air leaks and bleeding air Remove cover (1) from fuel filter and check to see if fuel filter is filled up with fuel. 1f fuel filter is not filled up with fuel, air leaks are suspected be- ‘ween filter and fuel tank. To bleed air, just fill up filter with fuel, % Take care not to damage gasket on fuel filter. 12-16 sat TESTING AND ADJUSTING 060,654-7‘TESTING AND ADJUSTING CHECKING FUEL PRESSURE MEASURING VACUUM BY PT PUMP CHECKING INJECTOR 1 vo) FUEL SYSTEM 1) Remove plug for fuel pressure from PT pump shu-off valve. 2) Connect fuel pressure gauge A. 3) Start engine and warm up it for § to 10 minutes. 4) Read maximum indication of pressure gauge when fuel con- trol lever is quickly pulled from low-idle position to high: idle position. ‘Standard fuel pressure: 5.5 to 5.9 kg/em? %* Fuel pressure gauge No.: 799-201-1300 1) Connect vacuum gauge B to fuel hose between PT pump and fuel filter. 2). Start engine and warm up for § to 10 minutes. 3) Read indication of vacuum gauge when engine is operated at rated horsepower or at high-idling speed. ‘Vacuum gauge No.: 799-201-1200 Remove injector. To remove injector, follow the procedure provided for removing it when measuring compression pressure. (Refer to MEASUR- ING COMPRESSION PRESSURE.) Checking injection by injector Remove injector spring and inject fue! against white paper by ‘quickly pressing injector plunger with hands. If injection nozzle is covered with hand, may be in- Jured by high-pressure of injection. Be careful. taro D60,65A-P 12-17COOLING SYSTEM sinsovry COOLING SYSTEM CHECKING COOLANT Checking coolant level Remove radiator cap and check to see if coolant is filled up to the upper side of upper tank. If cap Is removed while engine is still hot, water blows ‘out, causing scald. Be careful. * If coolant is reduced, leaks are suspected in cooling system. Check for thom and rep # If engine oil is increased or oil mixes in coolant, leaks into congine are suspected. Check for them repair. (Checking cootant level ‘Check to see if water temperature gauge (2) indicator stays in ‘the green range while engine is in operation, If water temperature rises excessively high, check coolant level, fan belt tension, radiator core for distortion, dust or dirt If water temperature is excessively low, check thermostat. Measuring water temperature 1) Remove water temperature takingout port from water manifold 2). Install adapter and sensor of thermometer sensor on water ‘temperature taking-out port. 3) Connect sensor to thermistor to measure water tempera: ‘ure. 4 Thermistor No.: 790-500-1300 12-18 ceeaaROReRRAREeMNR) TESTING AND ADJUSTING eae 12006 260,654:‘TESTING AND ADJUSTING #20 counts COOLING SYSTEM CHECKING AND ADJUSTING FAN BELT TENSION Tension pulley, To check fan belt tension, measure yielding when belt is de- pressed with fingor (approx. 6 kg) at the middle between fan pulley. Standard yielding of fan belt: Approx. 25mm. CCrankshofe pulley Adjusting fan belt tension 1) Loosen bolt (2) mounting alternator and lock bolt (1) on ‘tension adjustment plate. 2). Insert a wooden bar between altemator and cylinder block ‘to move alternator while observing belt tension, and tighten altemator mounting bolt and lock bolt. 3) After adjusting, tihgten alternator mounting bolt and ad- Justment plate lock bolt. ie CHECKING AND ADJUSTING ALTERNATOR DRIVE BELT Checking drive belt tension ‘Check deflection of belt when pressing in the middie of accessory drive pulley and alternator pulley with the force of about 6 kg, Standard: Approx. 10 mm Adjusting drive belt tension 1) Loosen mounting bolts (2) of alternator (1) and lock bolts (3) of adjustment plate. 2), Puta wooden bar in between alternator and cylinder block. “Adjust the tension by moving alternator. Tighten alternator mounting bolts and lock bolts. 3) Tighten altemator mounting bolts and adjustment plate lock bolts. 260,65A-P 12-19MEMO 12-20 D60,65A-PDG6O,6S5A:P-e D60A-6 26241 and up D65A-6 28229 and up D60P-6 28523 and up D6S5P-6 30001 and up D60PL-6 28013 and up 13 ENGINE DISASSEMBLY AND ASSEMBLYENGINE 13 DISASSEMBLY AND ASSEMBLY STARTING MOTOR Dismounting. . . Mounting. ALTERNATOR Dismmounting. Mounting ENGINE OIL COOLER (D60AP), Dismounting. : STEERING OIL COOLER (060A?) Dismounting, . Mounting. . ENGINE OIL COOLER (D60A—P) Mounting. . ENGINE OIL COOLER (065AP) Dismounting. TORQUE CONVERTER OIL COOLER (D65AP) Dismounting, Mounting. ... « ENGINE OIL COOLER (D65AP)_ Mounting... . ENGINE OIL PUMP Dismounting. . Mounting. PT PUMP Dismounting. . Mounting. WATER PUMP Dismounting. Mounting, 060,654-P 13, 13. 13. 13, 13 13. 13 13 13 13. 13 13 13, 13 13 13. 13 13. 12 14 16 20 24 28 32 34 38 40 INJECTOR Dismounting. 02... 02-5 2 18 a4 Mounting. .. 13: 46 CYLINDER HEAD Dismounting. . 13: 48 Mounting, 13: 64 RADIATOR GUARD Dismounting. 13. 62 RADIATOR Dismounting. «2.6.0. 0ee ee ss 13 68 Mounting, 13:71 RADIATOR GUARD Mounting. See eee eee eee mI c174 FLOAT TANK Dismounting. «2.222... eeeeeeeeee 13 80 Mounting... 0.2.22. ccceeeee eee es 12 BF FUEL TANK Dismounting. ......... coves 18 82 Mounting, 13. 83 CHASSIS RELATED PARTS FROM ENGINE (D60AP) Dismounting. .....- +++ seen 18 BA ENGINE (D60AP) Dismounting. ...... 2+. +22 020 13 88 CHASSIS RELATED PARTS ON ENGINE (D60AP) Mounting, 13. 94 ENGINE (D60AP) Mounting, = 13 98 ENGINE AND DASHBOARD (D654?) Dismounting. ...... +. cove 13104 Mounting. 06.2 2e es eee cece ences 3MI2 13-1STARTING MOTOR DISMOUNTING STARTING MOTOR Ensine Ed cove 1 |vsossa.| Serine Bulldozer motor L 2 Wing 1. Engine side cover Remove R.H. engine side cover (1) 2. Wiring Disconnect wires (2), (3) and (4). 4 Disconnect battery terminal (negative) before disconnecting wiring. 3. Starting motor Remove starting motor (61 by removing bolts, fig) Starting motor: 25.5 kg 13-2 DISASSEMBLY AND ASSEMBLY 060.654:DISASSEMBLY AND ASSEMBLY MOUNTING STARTING MOTOR [butaozer moor _]\ l \ 3 Engine Litscower | 1. Starting motor Install starting motor (6. i/ = Starting 2. Wiring 1) Connect wires (4), (3) and (2). 2) After connecting the wiring, connect battery terminal (negative), 3. Engine side cover Install R.H. engine side cover (1). 60,654-P STARTING MOTORALTERNATOR: a as DISMOUNTING ALTERNATOR Engine side cover eossarel | wing Awa | |Bulldozer ne | / vebatt 1, Engine side cover Remove L.H. engine side cover (1). ing sonnect wires (2) and (3). % Disconnect R terminal wire (white/red) at connector. 3. Vebolt Loose tension adjustment bolts (4) and (5) and alternator fastening bolt (6), and remove V-belt (7) by bringing alternator down inside. 4, Alternator Remove alternator (8) by removing tension adjustment bolt (5) ‘and alternator fastening bolt (6). 13-4 DISASSEMBLY AND ASSEMBLY 060,654-7DISASSEMBLY AND ASSEMBLY ALTERNATOR MOUNTING ALTERNATOR vebatt [peo.esaP-S) | atcemetor | wiring Bulldozer L Engine cca 13008 1. Alternator Install alternator (8) with fastening bolt (6) and adjustment bolt (5). 2. V-belt Fit V-belt (7) in alternator pulley groove, adjust tension of V- belt and tighton bolts (4), (5) and (6). 4 V-belt yield when itis depressed by finger: Approx. 10 mm 3. Wiring Connect wires (3) and (2). 4. Engine side cover Install LH. engine side cover (1). D60,65A-PENGINE OIL COOLER ee DISASSEMBLY AND ASSEMBLY 1 DISMOUNTING ENGINE OIL COOLER (D60A-P) Deoars Tnepestion Dealning cover coolant it cooler 1. Inspection cover Remove inspection cover (1). 2. Draining cootant (Open drain valve (2) to drain coolant, If antifreeze is used, take care not to discharge it. Use ‘corrosion rasister as far as it is effective. %* Coolant amount: 55 litres 3. RAH. engine side cover Remove R.H. engine side cover (3). 4, Steering oil cooler mounting bolt Loosen steering oil cooler mounting bolts (4). % Unscrew bolts three turns after tension of spring washer is lost. 13-6 DOO.5A-PDISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER 5. Oil cool Remove mounting bolts (5) and (6), five bolts each, mové steer ing cooler (7) outside of body and remove oil cooler (8) by ‘moving it rearward, ‘When removing oil cooler, take care not to allow retainer to {all off from cylinder block side mounting position. 060,654-P 13-7STEERING OIL COOLER DISASSEMBLY AND ASSEMBLY DISMOUNTING STEERING OIL COOLER (D60A-P) Draining 1 Awa Tnapection corer a | nate Bulldozer 5 4 piping FL. engine Side cover / 1. Inspection cover Remove inspection cover (1). 2. Draining water Open drain valve (2) to drain coolant. When antifreeze is used, take care not to discharge it. Reuse corrosion resister at far as it is effective. * Coolant amount: 55 litres 3, Water inlet tube » Disconnect water inlet tube (3) from cooler by removing flange bolts 4. BH. engine side cover Remove R.H. engine side cover (4), 13-8 060,65A-PDISASSEMBLY AND ASSEMBLY 5. Water piping 1) Disconnect corrosion resistor to radiator hose (7) from cooler by loosening clamp. 2) Disconnect cooler to radiator hose (7) from cooler by loosening clamp (6). 3} Remove water bypass tube (9) by loosening clamp (8) and removing flange bolts 6. Cooler inlot and outlet oil tubes 1) Remove tube clamp (10). 2) Disconnect cooler inlet tube (11) and cooler outlet tube (12) from cooler by removing flange bolts. 7. Oil cooler 1) Remove oil cooler (18) by removing mounting bolts (13) and (14). [ig] Olleooler: — 30-kg 2) Remove engine oil cooler (17) from upper cover (16) by removing mounting bolts. D60,65A-P STEERING OIL COOLER n 13-9STEERING OIL COOLER Se . DISASSEMBLY AND ASSEMBLY MOUNTING STEERING OIL COOLER (D60A-P) eae [ee ‘ aoa a) side cover | Pin veel oeoare |_| |S oi cote Bulldozer ° s 8 [weer ie ote ‘2007 1. it ooter 1) Fit O-ring and gasket to mounting face and install engine oil cooler (17) on upper cover (16). 2). Install O-ring and retainer on end face of engine oil cooler ‘and install cooler assembly (18) with gasket fitted to mounting face. ‘# Coat gasket with gasket sealant (LG-1). * When installing coole”,take care not to allow retainer to fall off. 2. Cooler inlet and outlet oil tubes 1) Fit O-rings to flanges, and connect cooler outlet tube (12) and cooler inlet tube (11) 0 cooler. 2). Install tube clamp (10), 1) Attach gasket to cooler mounting face, install water bypass tube (9) and tighten clamp (8). 4% Coat gasket with gasket sealant (LG-1), 13-10 D60,65A.FDISASSEMBLY AND ASSEMBLY once 2) Connect cooler to radiator hose (7) to cooler and tighten clamp (6). 3} Connect corrosion resister to cooler hose (6) to cooler and tighten clamp. 4, BH. engine side cover Install P.H. engine side cover (4). 5. Water inlet tube 1) Attach gasket to flange and connect water inlet tube (3) to cooler. Coat gasket with gasket sealant (LG-1) 2) Close water drain valve (2). 6. Inspection cover Install inspection cover (1). 7. Supplying water ‘Supply radiator with water from water filler (18). ‘+ Use soft water for coolant. 60,654-P STEERING OIL COOLERENGINE OIL COOLER z DISASSEMBLY AND ASSEMBLY MOUNTING ENGINE OIL COOLER (D60A-P) a waa [an ae Fae bolt} | side cover peoars | —— Pinmactor] Bulldozer [—|_ Oil cooler cover \ 7 Le] isro0s 1. Oil cooler 1) Coat gaskets with gasket sealant (LG-1) and put them to ‘cooler mounting faces (cylinder block side and upper cover, side). 2). Install oil cooler (8) with O-ring and retainer fitted to eyl- inder block side and O-ring fitted to upper cover side, and secure it with mounting bolts (6) and (6). Install cooler, taking care not to allow retsiner to fall off, by sliding it reversing steps for dismounting, 2. Steering oll cooler mounting bolt Tighten steering oil cooler mounting bolts (4) 3. RH. engine side cor Install R.H. engine side cover (3) 13-12 D60,65A-PDISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER 4, Inspection cover 1) Close coolant drain valve (2). 2). Install inspection cover (1). 5. Supplying water Supply radiator with water through water filler (9) % Use soft water for coolant. ss 60,654: 13-13ENGINE OIL COOLER DISASSEMBLY AND ASSEMBLY DISMOUNTING ENGINE OIL COOLER (D65A-P) DearS Bulldozer \ 2 a 4 5 (RH enaine i f Engine ot | Ssecover" f—_Newe_ F-~]_Sover cooler 12009 1. Draining cooting water Remove inspection cover (1) and drain water from radiator Tower drain cock (2), QA 22 not drain water immediately ater engin but after water tempera:ure has fallen. stopped, 2. RLH. engine side cover Remove R.H. engine side cover (3). 13-14 D60.65A:DISASSEMBLY AND ASSEMBLY s ENGINE OIL COOLER 3. 1) Disconnect corrosion resister outlet hose (4) by loosening clamp. 2) Disconnect cooler outlet hose (5) by loosening clamp, 4. Cover Remove cooler cover (6). 5. Engine oil cooler Remove oll cooler (7) by removing bolts. ‘# Prepare a container to receive oll which comes out when oil cooler is removed D60,654+P 13-15‘TORQUE CONVERTER OIL COOLER DISASSEMBLY AND ASSEMBLY DISMOUNTING TORQUE CONVERTER OIL COOLER (D65A-P) a adiotor oatlat tube 1 Engine ‘under guard : " Piping — jeri / : ) pests «| [ston |_ __/} sic / Pil 1 sj) \ \\ How Engine ot} | : | \ oom vs I a a Preparatory work Lower blade on the ground and remove pressure from cylinder by ‘operating control lever several times 1. Engine under guard Remove under guard (1) with tanamision jack es Under guard: 185 kx cay Under ou o 2. Draining cooling water Drain water from radiator lower drain cock (2). Do not drain water immediately after stopping engine. Water should be drained when water temperature has fallen, 13-16 060,454:DISASSEMBLY AND ASSEMBLY 3. Radiator outlet tube Disconnect outlet tube (3). Remove cover (4) 5. Piping v Remove steering cooler outlet tube (5) from cooler and from engine lower part. 2) Remove steering cooler inlet tube (6) from lower part of engine. 3) Disconnect clamp (7) for steering cooler inlet and outlet ‘tube from torque converter cooler bracket. 4) Disconnect torque converter cooler outlet tube (8) from cooler and from lower part of engine. 5) Remove torque converter cooler inlet tube (9) from lower part of engi 6) Remove torque converter cooler outlet tube (8) by remov: ing clamp (10) for torque converter cooler inlet and outlet tubes. 7) Remove torque converter cooler inlet tube (9) by discon- necting tube from cooler. 8) Remove steering cooler inlet tube (6) together with outlet ‘ube by disconnecting inlet tube from cooler. 060,654: ‘TORQUE CONVERTER OIL COOLER 13-17‘TORQUE CONVERTER OIL COOLER 6. Blade hose Disconnect cylinder head side hose (11) by removing flange bolts. 7. Hose 1) Disconnect corrosion resister outlet hose (12) by loosening clamp. 2). Disconnect cooler outlet hose (13) by loosening clamp. 8. Cooler tube 1) Remove thermostat to cooler tube (14) by removing it from cooler after removing bolt and by disconnecting tube from thermostat by loosening clamps. 2) Pull out radiator outlet to cooler tube (16) by removing bolts from cooler. 9. Engine oll cooler 1) Remove bolts mounting cooler cover. 2} Remove oil cooler by removing bolts. * When removing cooler, remove bolts (17) mounting torque converter cooler on engine, and keep torque converter cooler pulled frontward, 10. Torque converte oll cooler Litt out cooler (19) by removing two bolt (18) mounting as sembly on lower bracket. wy Torque converte cooler: S5kg 13-18 DISASSEMBLY AND ASSEMBLY D60,65A+PMOUNTING TORQUE CONVERTER OIL COOLER [[25~ D60,65A-P 13-19TORQUE CONVERTER OIL COOLER DISASSEMBLY AND ASSEMBLY MOUNTING TORQUE CONVERTER OIL COOLER (D65A-P) pe ivi j war i 3 | Engin oil cooler | co5APS ‘Torque on- | undoser | —| eee! | LF Racine utter tube 1. Torque converter oil cooler Hoist and install oil cooler (19) on lower bracket with two bolts (18). 2. Engine oil cooler 1) Attach gasket to oil cooler mounting face. 2) Install oil cooler (16) with bolts. * After installing assembly, secure torque converter cooler with bolts (17) on engine. 3) Install cooler cover mounting bolts. 13-20 260,654.DISASSEMBLY AND ASSEMBLY 3. Cooler tube 1) Fit O-ring to tute and insert radiator outlet to cooler tube (15) and secure it with bolts with gasket fitted to cooler side mounting face. 2) Insert thermostat to cooler tube (14) into thermostat and fasten it with clamp and secure it on cooler with bolts with gasket fitted to mounting face. 4. Hose 1) Connect cooler outlet hose (13) and fasten it with clamp. 2) Connect corrosion resister outlet hose (12) and fasten it with clamp, 5. Blade hose Connect hose (11) to cylinder head with flange bolts 060,654: TORQUE CONVERTER OIL COOLER 13-21‘TORQUE CONVERTER OIL COOLER DISASSEMBLY AND ASSEMBLY 6. Piping 1) Connect inlet tube (6) of steering cooler inlet and outlet ‘tubes, with O-ring fitted to its flange, to cooler. 2) Connect torque converter inlet tube (9), with O-ring fitted to its flange, to cooler. 3) Temporarily secure torque converter cooler outlet tube (8) Cn inlet tube with clamp (10). 4) Attach O-ring to flange and connect torque converter Cooler inlet tube (9) to lower part of engine, 5) Attach O-ring to flange and connect torque converter outlet tube (8) to cooler and to lower part of engine and tighten clamp (10). 6) Loosely tighten clamp (7) for steering cooler inlet and ‘outlet tube on torque converter cooler bracket. 7) Attach O-ring to flange and connect steering cooler inlet ‘tube (6) to lower part of engine. 8) Attach O-ring to flange connect steering cooler outlet tube (5) to cooler and to lower part of engine, and tighten clamp 7. 7. LH. engine side cover Install cover (4). 8. Radiator outlet tube ‘Apply gasket sealant (LG-1) to flange, install gasket and connect outlet tube (3). 13-22 260.654?DISASSEMBLY AND ASSEMBLY / TORQUE CONVERTER OIL COOLER 9. Supplying water ‘After confirming that radiator lower drain cock (2) is closed, supply radiator with water until water overflows from water filler port. When coolant is changed, replas © Refill oll the same amount as corrosion resistor also. lled when removing. 410. Engine under guard Install under guard (1) with transmission jack . 060,65A-P 13-23ENGINE OIL COOLER ss DISASSEMBLY AND ASSEMBLY MOUNTING ENGINE OIL COOLER (D65A-P) 1 2 4 Engine oil — = FH. engine coaler cc a Se over DesAP.6 Bulldoz L_| 5 Supping 1. Engine off cooter Fit gasket to mounting face and install oil cooler (7) with bolts. 2. Cover Fit gasket to mounting face and install cooler cover (6) outlet hose (5) and tighten it with clamp. jon resister outlet hose (4) and fasten it with 2) Connect corr clamp. 13-24 260,654:7DISASSEMBLY AND ASSEMBLY st ENGINE OIL COOLER 4. RH. engine side cover Install cover (3) 5. Supplying water ‘After confirming that radiator lower drain cock (2) is closed, supply radiator with water until water overflows from water filler port, and install inspection cover (1) %* When cooling water is changed, replace also corrosion resister. + Refill oil the same amount spilled when dismounting 060,654+P 13-25ENGINE OIL PUMP so DISASSEMBLY AND ASSEMBLY DISMOUNTING ENGINE OIL PUMP Draining} | scat’ I 1 ipoo.s5a-s ‘ii pump Bulldozer pees) 1! pump iaro1e 1. Draining engine oil 1) Remove inspection cover (1). 2) Remove drain plug (2) and open drain vaive (3) to drain engine oil. Remove L.H. engine side cover (4). 13-26 D60,65A-P,DISASSEMBLY AND ASSEMBLY. 3. Oil filler and gauge Remove oil filler and gauge (6) by removing two mounting bolts (8) and filler clamp bolt 4, Fuel feed hos Disconnect fuel feed hose (7) from PT pump by removing sleeve ut 5. Bypass filter hose Disconnect bypass filter hose (8) from oil pump by removing rut 6, Full-flow filter 1) Disconnect full-flow filter outlet (9) and inlet (10) hoses from oil pump by removing sleeve nut, and remove clamps (11) and (12. 2) Remove full-flow filter (14) by removing four mounting bolts (13). 7. Oil pump piping 1) Pull out and remove scavenging tube (15) and scavenging to oil pan tube (16) by removing flange bolts. ‘% Tubes’ ends are of spigot type at pump side and of flange type at another side. ‘# Since tubes are made of copper, handle them with care not to bend them unnecessarily. 2). Disconnect main suction tube (17) from oil pan by re: ‘moving flange bolts. 8 Oil pump Remove oil pump (19) by removing five mounting bolts. # Width across flats of five mounting bolt is 6/8 inch (15.9 mm. Sie} Ol! pump: 18ks 060.654 ENGINE OIL PUMPENGINE OIL PUMP DISASSEMBLY AND ASSEMBLY MOUNTING ENGINE OIL. PUMP § Si pune |_| Oise [ae [Si | | Funston | | ftacey 1 | LH. engine af) side cover peoeearel [orn P| Bm, : Buldozer La | ‘ Suopiving sronach sores 1. Oi pump ‘Attach gasket to mounting face (pump side) and install oil ‘pump assembly (19) there, aligning gear position + Coat gasket with gasket sealant (LG-1). ll pump piping 1) Connect main suction tube (17) with gasket fitted to its ‘lange with gasket sealant (LG-1). 2) Connect scavenging pump to oil pan tube (16) and scaveng- ing tube (15) to oil pump, with O-rings fitted to their flanges, and tighten flange bolts. # Coat Oxrings to be fitted to spigot type ends of tubes with grease (G2-L1) to protect O-rings from damaging. 13-28 060,654-PDISASSEMBLY AND ASSEMBLY eS 3. Full-low filter 1) Install full-flow filter (14) on bracket. 2) Connect full-flow filter outlet (9) and inlet (10) hoses to oll pump and install clamps (11) and (12). ‘To tighten sleeve nuts, use two wrenches, one for hold- Jing hose and another tightening sleeve nut. 4. Bypass filter hose Connect bypass filter hose (8) to oll pump. 5. Fuel feed hose Connect fue! hose (7) to PT pump. ‘Attach gasket to mounting face and install oil filler and gauge (6) there. As mounting bolt (6) also fastens clamp for scavenging tube, install it without fall ‘Coat gasket with gasket sealant (LG-1).. jne side cover Install L.H. engine side cover (4). D60,654-P ENGINE OIL PUMP 13-29ENGINE OIL PUMP so DISASSEMBLY AND ASSEMBLY 8. Supplying oit 1) Close drain valve (3), install drain plug (2) and supply oil ‘through oil filler (20) # Oiltobeused: Class CD SAE 30 (43 litres) % Supply oil while checking il level with level gauge (21) and recheok oil level after starting engine. 2), Install inspection cover (1). 13-30 D60,654-PDISMOUNTING PT PUMP [25 D60,65A-P 13-31PT PUMP. DISASSEMBLY AND ASSEMBLY DISMOUNTING PT PUMP ; cael Ta Po i fiter : —feh , | loans Nims \ 5 oe 1. LH. engine side cover Remove LH. engine side cover (1). 2. oll filles Remove connecting bracket (2) for engine oil supply and inspection tube, and remove tube assembly (3) by removing ‘mounting bolts. 3. Pin Pull out pin (4) connecting fuel control rod to control lever. 13-32 60,6507DISASSEMBLY AND ASSEMBLY % PT PUMP 4. Wiring Disconnect shut-off valve wire (6). 5. Piping 1) Disconnect PT pump to fuel supply manifold tube (6) from pump. 2). Disconnect PT pump to drain manifold tube (7) from mani- fold, 3) Disconnect PT pump to fuel filter hose (8) from PT pump. 6. PT pump Remove PT pump (9) by removing four mounting bolts. D60,65A-P 13-33PT PUMP MOUNTING PT PUMP Pong 3 if} wees penssars PT pump 4 Buidorr - Pin 5 4 cotter |_f 5 sgine 1. PT pump Install coupling (10) on drive shaft and spine-it PT pump (9). Oil filler cap is fastened together with PT pump with sme mounting bolt. 2. Piping 1) Connect PT pump-to-ue! filler hose (8). 2) Connect PT pump-to-drain manifold tube (7). 3) Connect PT pump-to-fuel supply manifold tube (6). 13-34 DISASSEMBLY AND ASSEMBLY 60,6547PT PUMP DISASSEMBLY AND ASSEMBLY 3. Wiring Connect shut-off valve wire (5) 4. Pin Install pin (4) connecting fuel control rod to control lever. 5. Oil filler Install oil filer tube assembly (9) and connect tube assembly to bracket (2) # Oil pump tube clamp is also fastened with tube mounting bolt. 6. LH. engine side cover Install L1H. engine side cover (1). 060,65A+P 13-35,WATER PUMP DISASSEMBLY AND ASSEMBLY DISMOUNTING WATER PUMP. 4 ; Inspection |__| Draining | ; | aaa | oe : ' : if : — i «vet He} ree} a / /KOMACLONE| || Vo 5 ) 1 ' \ LH. engine ‘Bisson | \ cover Sear [—° \\ { ; € From A From 8 Frome Ss From —| i rome —| Ss 13-36 060,654.DISASSEMBLY AND ASSEMBLY 1. Inspection cover Remove inspection cover (1). 2. Draining water (Open drain plug (2) to drain coolant. An, When loosening radiator cap, loosen i siowiy after coolant temperature falls. When antifreeze is used, take care not to discharge Reuse corrosion resister as far as itis effective. %* Coolant amount: 56 litres 3. Exhaust pipe Ramove exhaust ipe (4) by loosening band (3), 4, KOMACLONE air cleaner Remove KOMACLONE air cleaner (6) by loosening band (5) and tube clamp. 5. Hood Remove hood (7) by removing hook and mounting bolts. 6. LH. engine side cover Remove R.H. engine side cover (8). 7. LH. engine side cover Remove L.H. engine side cover. 060,654-P WATER PUMP 13-37WATER PUMP DISASSEMBLY AND ASSEMBLY 8 Fan guard se 1) Disconnect radiator inlet hose (10) from upper tank (11) by loosening hose clamp, 2) Remove fan guard (12). iT % Fan guard is divided into two halves, Remove upper half of fan guard. 9. Fan Remove mounting bolts anc keep fan (13) moved to radiator side. 10, Fan belt 1) Loosen bolts (18) mounting tension pulley bracket. 2) Remove fan belt (18) by loosening locknut (16) to unscrew adjustment bolt (17) to loosen fan belt. 11. Tension pulley Remove tension pulley (with bracket) (20) by removing mount- ing bolts (19). AY When plle is removed bolts fall oft ‘Take care not harm your fingers. 12, Alternator and water pump belt 1) Move alternator (25) to engine side and remove V-belt (26) by loosening adjustment plate mounting bolts (22), slide bolts (23) and alternator mounting bolts (24), Take care not to harm you by accidental falling of alternator down to engine side. 2) Remove adjustment plate (21) by removing mour (22) and slide bolts (23). bolts 13. Fan pulley and bracket Remove fan pulley and bracket (27) by removing mounting bolts. ‘When bracket is removed, bolts fal off +S Take care not to harm your fingers. (ote) Fan pulley and bracket: 25 kg 13-38 D60,65A+PDISASSEMBLY AND ASSEMBLY WATER PUMP 14, Fan bracket support Remove bracket (28) and fan bracket support (29) by removing mounting bolts. 15, Greasing tube Remove water pump greasing tube (30) by loosening sleave nut. 16. Fan bracket Remove fan bracket (31) by removing mounting bolts. 17. Water pump Remove water pump (32) by pulling D60,654P 13-39WATER PUMP MOUNTING oy WATER PUMP 1 2 DISASSEMBLY AND ASSEMBLY 3 ‘Grose be | ‘ | Fan basket | [sspport =] ame §//Leumpbett | an pulley J ane Grane Tension pulley ps0.650.P-5| Bulldozer 13-40 ‘Water pump | — Fan bracket From A, froma —{ ince" [CH engine ide 8 w Il rom —————|_ Hood Frome Lv From D From & ~ is Exhaust ibe 6 Inspection W soppiving water laro1e 060.6507DISASSEMBLY AND ASSEMBLY % Water pump Install water pump (32) with gasket attached to its mounting face (water pump side). 2. Fan bracket Install fan bracket (31). Install bracket confirming the fan bracket support mount- ing position (to avoid difficulty in installing fan bracket support in the later step). 3. Groasing tube Connect greasing tube (30) to water pump. 4. Fan bracket support Install fan bracket support (29), bracket (28) and greasing tube (30). % Bracket and greasing tube are fastened together with fan bracket support. 4 If greasing tube is not installed in the desired position, ‘correct it with sleeve nut with which water pump is con nected. 5. Fan pulley and bracket Install fan pulley and bracket (27). 6. Alternator and water pump belt 1) Install adjustment plate (21). + Hore'in this step, tighten mounting bolts (22) and slide bolts (23) loosely, not fully 2) Install and fit V-belt (26) in groove of accessory pulloy, water pump pulley and alternator. 3) Adjusting belt tension i) Tighten adjustment plate mounting bolts (22), slide bolts (23) and alternator mounting bolt (24) as loose as 10 allow alternator (25) to move. ii) Adjust tension by bringing alternator down outside by inserting a bar between alternator (25) and cylinder block. ‘Adjust tension so that belt fields approx. 10 mm at the middle between alternator pulley and acces sory pulley. iii) Fully tighten adjustment mounting bolts (22), slide bolts (23) and alternator mounting bolt (24). 60,6540 WATER PUMP 13-41WATER PUMP DISASSEMBLY AND ASSEMBLY Tension pulley Install tension pulley (20). Tighten mounting bolts loosely, not fully. 8. Fan bolt 1) Install fan belt (18) and fit it in groove of crankshaft pulley, fan pulley and tention pulley. 2) Adjusting fan belt tension i) Adjust tension by tightening adjustment bolt (17). ‘# Adjust tension so that belt yields approx. 10 mm at the middle between fan pulley and tension pulley. ii) Lock adjustment bolt (17) with locknut (16) and tighten tension pulley mounting bolts (15) 9. Fan Install fan (13) with six mounting bolts. 10, Fan guard 41) Install fan gurad (12). 2) Connect radiator inlet hose (10) to upper tank (11) and tighten clamp. 11. RLH. engine side cover Install R.H. engine side cover (8). 12. LH. engine side cover Install L.H. engine side cover. 13-42 060,654:DISASSEMBLY AND ASSEMBLY WATER PUMP 13, Hood Install hood (7), tighten mounting bolts and hook it. 14, KOMACLONE air cleaner Install and secure KOMACLONE air cleaner (6) with band (5), ‘and connect KOMACLONE tube. 15, Exhaust pipe Install and secure exhaust pipe (4) with band (3). 16. Inspection cover Close coolant drain valve (2) and install inspection cover (1). 17. Supplying water Supply radiator with water through water filler (33). + Use soft water for coolant. D60,65A-P 13-43INJECTOR DISASSEMBLY AND ASSEMBLY DISMOUNTING INJECTOR Pc Rocker hous-|__[ Aajurtment jsman mam Lom | | Bulldozer 2 l | = _ 1. Rocker housing cover Remove rocker housing cover (1). 2. Connection Remove supply connection (6) and drain connection (7) by re moving each sleeve nut for fuel supply manifold (4) and drain manifold (5). 3. Adjustment screw Remove injector adjustment screw (3) by loosening locknut (2). 4, Push rod Pull out push rod (8) by bringing rocker arm (8) down. 5. Injector Remove injector (10) by removing mounting bolt. 13-44 060,654-PMOUNTING INJECTOR [=> D60,65A-P 13-45INJECTOR “ i MOUNTING INJECTOR DISASSEMBLY AND ASSEMBLY : : s ‘ 1 [roses | [seem | [Sie | fists col wossars| [cw F tee _ NOS concn Sposa ol reir Spec took rogue a 7066107000 | Cankna Ki 7 1. Injector Install injector (10) on cylinder head and tighten mounting bolt =] Mounting bolt: 1.8 0. 2.0 kgm ‘mark on injector body with that on plunger. 2. Push rod Install push rod (8). After installing push rod, confirm that it is fitted in socket of injector cam lever. 3. Adjustment screw Install injector adjustment screw (3) on rocker arm by raising rocker arm. ‘Confirm that adjustment screw end is fitted in socket of push rod. 4, Connection 1) Install supply connection (6) and drain connection (7) on injector by screwing them into threaded part of injector. S32) Connection: 2.8 ~ 3.5 kgm 2) Connect fuel supply manifold (4) and drain manifold (5) to conne * To connect manifold, use two spanners, one for hold: ing manifold and another for tightening sleeve nut. FE Slowe nut: 15~ 1.8 kgm 13-46 Upper side \ of body Upper side of plunger 260,654DISASSEMBLY AND ASSEMBLY INJECTOR 5. Adjusting injector 1) Set cranking kit (A) to rotate crankshaft positively. Turn it 90° from the top dead center to align VS mark on accessory pulley with mark on gear cover. * Connection of cranking kit (connection of wires) clelm, els] | c/o ~ zg £ (= shortecircuit | 6 Wellhel|exaversseatecs ale TL O18] 8] Secuaie m | AR When connecting, remove batery negative terminal 2). Screw in injector adjustment screw until plunger reaches ‘cup, and serew in it 15° further to expel fuel from cup. 3) Once untighten screw. Tighten it to the specified torque with torque wrench and fock it with tock nut (2). ‘Z Adjustment screw: Cold (20°C) 0.55 kg.m Hot (60°C) 0.69 kg.m SD Locknut: 16 t0 22.0 kgm 6. Rocker housing cover Install rocker housing cover (1). # Replace damaged gasket. Install gasket, taking care to avoid its runout. GED Bolt! 0.910 1.1 kgm D60,65A+P 13-47CYLINDER HEAD DISASSEMBLY AND ASSEMBLY DISMOUNTING CYLINDER HEAD 1 1 Taspection| Draining -— Engine de cover 4 | xno ie] / j Hood Komaccone| 0 Agee 8 A menifols® _ ____[ Glow plas [peo.ssars| | Bulldozer Ss Dust Indicator 2 eration hose a eye 6 { wae | i) uw manifold \ outer te ‘ \ eae \ 0 } —— Connection i L____ ae 13-48 D60,65A-PDISASSEMBLY AND ASSEMBLY CYLINDER HEAD | 2 per id Fela om eo 7, Crosshese D60,65A-P 13-49CYLINDER HEAD 1. Inspection cover Remove inspection cover (1). 2. Draining coolant (Open drain valve (2) to drain coolant, When antifreeze is used, take care not to discharge it. Reuse corrosion resister as ‘ar as itis effective. % Coolant amount: 56 litres 3. Engine side cover Remove LH. (3) and R.H. (4) engine side covers. 4. Exhaust pipe Remove exhaust pipe (6) by loosening band (6). 5, KOMACLONE air cleaner Remove KOMACLONE air cleaner (8) by loosening band (7) ‘and KOMACLONE tube clamp. 6. Hood Remove hood (9) by removing hook and mounting bolts 13-50 DISASSEMBLY AND ASSEMBLY D60,65A-PDISASSEMBLY AND ASSEMBLY CYLINDER HEAD Disconnect fuel tube (10) from nozzle by removing sleeve nut. 8. Glow plug wiring Disconnect glow plug wire (11) from terminal by removing nut. 9. Dust indicator hose Disconnect dust indicator hose (12) from intake tube by remov- ing sieeve nut. 10, Air cleaner and intake manifold assembly Lift out air cleaner and intake manifold assembly (13) with crane by removing mounting bolt. 111, Muffler and exhaust manifold assembly Hoist assembly by crane. Raise up lockplates and remove six clamps (14) and remove muffler and exhaust manifold assembly (15). 12, Aeration hose Disconnect aeration hose (16) from water manifold by loosen ing clamp. 13, Steering cooler hose clamp Loosen clamp (17) for steering cooler bypass hose. 14, Thermostat outlet tube \isconnect thermostat outlet tube (18) from housing by re- ‘moving flange bolts, 16. Water temperature gauge cable isconnect water temperature gauge cable (19) from water manifold by removing clamp and sleeve nut. 16. Water manifold Remove water manifold (20) by removing mounting bolts. 060,65A-P 13-51CYLINDER HEAD DISASSEMBLY AND ASSEMBLY 17. Connection 1) Disconnect fuel supply manifold (21) and drain manifold (22) from supply connections (23) and drain connections (24) respectively, by removing sleeve nut. 2) Remove supply connections (23) and drain connections (24) Remove connections only for cylinder head to be re- moved. 18, Rocker housing cover Remove rocker housing cover (26) by removing mounting bolts. 19, Rocker arm housign 1) Remove gasket (Copper washer) by removing lubrication oil ‘tube cap (26) 2) Remove rocker arm housing assembly (27) by removing ‘mounting bolts. Loosen locknuts and loosen adjustment screws. 20. Push rod Remove push rods (28) (for intake, exhaust and injector). 21. Crosshead Remove crosshead (28). 22. Cylinder head Remove cylinder head (31) together with injector by removing cylinder head bolts (30), 13-52 060,654-7MOUNTING CYLINDER HEAD [25~ 060,65A-P 13-53CYLINDER HEAD DISASSEMBLY AND ASSEMBLY MOUNTING CYLINDER HEAD 2 a Crosthesd | ‘Adjusting Croshead 5 8 J Rocker arm «4 J housing | eee : | r (Patho Connection 13-54 D60,65A-PDISASSEMBLY AND ASSEMBLY 0 (Water tape is sche n Thermostat Suter tbe 2 — 7; ir hose 8 ‘Aeration hose sisal os 5 inlay 060,65A-P ieing Glow plug 8 __[ trspection CYLINDER HEAD Special tools required ‘Special tools required A 795-610-1000 | Cranking kit 1 — 4 Suppiving water taro2e 13-55CYLINDER HEAD Cylinder head Put gasket on mounting face and install cylinder head (31). 4 Face TOP mark to head. %* Apply oil (Class CD EO30) to threaded part of head bolt. GED Head bolt: 63.6 to 66.4 kg.m 2. Crosshead Install crossheads (28). 3. Adjusting crosshead 1) Loosen locknut (33). 2) Holding the center of crosshead with fingers, screw in adjustment sorew (34) until it contacts valve stem and fur- ‘ther scrow in it 20° 4 If crossheads and guide are not new, sorew it 30°, 3) Lock adjustment screw with locknut. ZI Locknut: 3.8 t04.1 kgm 4, Push rod Install push rods (28) (for intake, exhaust and injector) When installing push rods, confirm that they are fitted in sockets of cam follower levers. + As there are three kinds of push rods, take care not to con- fuse them, 5. Rocker arm housing 1) Install gasket (cork) on lubrication oil tube and gasket on ‘mounting face. 2). Install rocker arm housing (27) while inserting sphere of each adjustment serew end into sockets of push rods, and tighten mounting bolts. = Mountingbolt: 13 to. 17.0 kgm 3) Install gasket (copper washer) on lubrication oil pipe and install cap (26) Sam Cap: 9.0 kam 13-56 DISASSEMBLY AND ASSEMBLY 60,6547DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 6. Adjusting injector and valve clearance Adjustment is effected according to the firing order, and injec: ‘tor and valve clearance are adjusted at the same cranking posi- tion. 1) Adjusting injector i) Set eranking kit (A) to rotate crankshaft positively and rotate it 90° further from the top dead center to align VS mark on accessory pulley with that on gear cover. * Connection of cranking kit ‘Geanking Kit [SRemove shortcireuie ‘ber Between My ter: minal of starting mo- tor end M,_tarminal fof magnetic snitch | without fal ‘Starting motor = ° A wren connacting, remove bettery termina ii) Screw in injector adjustment screw (35) until plunger contacts cup, and screw it in further 15° to expel fuel from cup. iii) Once loosen screw. Tighten it to the specified torque with torque wrench and lock it with locknut (36). Goa) Adjustment screw: Cold (20°C); 0.55 kg.m Hot (60°C); 0.69 kgm FE Locknut: 16 to 22 kg.m 2) Adjusting valve clearance i) Insert feeler gauge between rocker arm end and corss- head and adjust clearance with adjustment screw (37). ‘Valve clearance [ cote (20°C) Hot (60°C) Tnakevave | 041 0.36 Exhaurtvalwe | 0.74 068 Ui) Look adjustment serew with nut (98). SEI Locknut: 16 t0 22 kgm % The final adjustment will be effected when engine is warmed up aftor itis started. D60,65A-PCYLINDER HEAD 7. Rocker housing cover, Fit gasket to mounting face and install rocker housing cover (25). SD) Mounting bolt: 0.9 to 1.1 kgm # As cover is made of aluminum, take care not to tighten bolt excessively. Confirm that no runout of gasket is prosent after itis installed, 8. Connection 1) Install supply connection (23) and drain connection (24) (on fuel inlet of injector and fuel outlet of injector respect! vely, * Replace gasket (copper made) with new one. ‘SD Connection: 2.8 to 3.5 kgm 2). Install fuel supply manifold (21) and drain manifold (22) fon supply connection and drain connection respectively and tighten sleeve nut. * Use two spanners, one for holding manifold end another for tightening sleeve nut. Gz] Sleeve nut: 1.6 to 1.8 kgm 9. Water manifold Fit plate and gasket tomounting face and insert water manifold (20) into cooler bypass hose. HE) Mounting bolt: 35 t0 4.0 kam 10. Water temperature gauce cable Connect water tempersture gauge cable (19) to water manifold by tightening sleeve nut and fasten cable with clamp. 11, Thermostat outlet tube ‘Attach gasket to flange and connect thermostat outlet tube (18) te housing, 4% Cost gasket with gasket sealant (LG-1). 12, Steering cooler hose clamp ‘Tighten clamp (17) for steering cooler bypass hose, 13, Aeration hose Connection aeration hose (16) to water manifold and secure it with clamp. 13-58 DISASSEMBLY AND ASSEMBLY 60,654-PDISASSEMBLY AND ASSEMBLY CYLINDER HEAD 1“. 16. 16. v7. 18. 9. 20. 21. D60,65A-P ‘Muffler and exhaust manifold assembly ‘Attach gasket to mounting face and hoist muffler and exhaust manifold assembly (15) in place. Secure it there with clamps ‘and lock them with lockplates (41) % To install gasket (40), set lockplates (41) and clamp (14) on. bolts and install gasket with other remaining bolt (42). ‘4 Confirm that mounting portion of manifold is not on dowel pin (43) and tighten mounting bolts evenly at right and left. S55) Mountingbolt: 0.30 t03.5 kg.m Ar cleaner and intake manifold assembly Loosely tighten lower mounting bolt and attach gasket to mounting face. lastall sir cleaner and intake manifold assembly (13) by hoisting it by crane. % To install gasket, insert two bolts (upper ones) into mani- fold and put gasket to threaded part of bolts. == Mounting bott 3.0 t0 35 kam Dust indicator hose Connect dust indicator hose (12) to intake tube with sleeve nut. Glow plug wiring Connect glow plug wire (11) to terminal Air intake heater fuel tube Connect fuel tube (10) to nozzle with sleeve nut. Hood Install hood (8), tighten mounting bolts and hook hood. KOMACLONE air clesner Install KOMACLONE (8) and fasten it with band (7), Connect KOMACLONE tube. Exhaust pipe Install exhaust pipe (6) and secure it with band (6).CYLINDER HEAD x DISASSEMBLY AND ASSEMBLY 22. Engine side cover Install L.H. (3) and R.H. (4) engine side covers. 23. Inspection cover Close water drain valve (2) and instal inspection cover (1). 24. Supplying water ‘Supply radiator with water from water filler (44). # Use soft water for coolant. 13-60 060,65A-PDISMOUNTING RADIATOR GUARD [7 260,654+P 13-61RADIATOR GUARD DISASSEMBLY AND ASSEMBLY DISMOUNTING RADIATOR GUARD Resistor |_{ ripping | — a 4 5 ge] —_____ sore I) 2 " poossare| ‘aeration | Racior | Bulldozer ‘hose guard 7 / in —} Precieaner | ee Wiring al Fan guard exhaust pioe 1. Draining coolant Remove inspection cover (1) and drain water from radiator ‘through radiator lower drain cock (2). Do not drain water immediately after stopping engine, bbut when water temperature has fallen 13-62 260,654:7DISASSEMBLY AND ASSEMBLY Tilt hose (Tittdozers only) connect tilt hoses (3) by removing flange bolts. Radiator mask (Tiltdozers only) 1) Remove bumper (4). 2) Remove radiator mask (6). 4, Tilt tube (Titdozers only) Remove tilt tubes (7) by removing clamp (6) and flange bolts. 5. LH. and RH, blade lift cylinders 1) Take out piston rod connecting pin (9) by removing lock pin (8). 060,654: RADIATOR GUARD 13-63RADIATOR GUARD DISASSEMBLY AND ASSEMBLY 2) Retract piston rod and fix cylinder (10) on hook. 6. Engine side cover Remove L.H. and R.H. engine side covers (11). 7. Procieaner Remove precleaner (12) by loosening hose clamp and removing bolt. 8, Exhaust pipe Remove exhaust pipe (13) by loosening nut. 9, Hood Remove hood (14) by removing catchers and bolts 13-64 60,654:DISASSEMBLY AND ASSEMBLY 10, Radiator outlet tube Disconnect radiator outlet tube (18). 11. LH. and RH, blade hoses Disconnect L.H. and R.H. blade hoses (16) by removing flange bolt, 12. Aeration hose Disconnect aeration hose (17) by loosening clamp. 13, Radiator inlet hose Disconnect radiator inlet hose (18) by loosening clamp. 14, Cooler outlet hose Disconnect cooler outlet hose (19) by loosening clamp, 3 Remove clip and disconnect lamp cable (20) at connector, 060.6546 15 RADIATOR GUARD 13-65RADIATOR GUARD 16. Fan guard Remove fan guard (21) by removing bolts. Hoisting gurad (22) with crane, remove guard mounting bolts and lift out guard frontward. Radiator guard: 750 kg 13-66 DISASSEMBLY AND ASSEMBLY D80.85A-PDISMOUNTING RADIATOR [25~ 260,65A-P 13-67RADIATOR: DISASSEMBLY AND ASSEMBLY DISMOUNTING RADIATOR [comactone Overtiow ube —{_seppor 13r0se TERT 1. Inspection cover Remove inspection cover (1). 2. Draining coolant Open drain valve (2) to drain coolant. AR, When toosening radiator cap, loosen it stowly when water temporature hes fallen, 13-68 060,654-PDISASSEMBLY AND ASSEMBLY 3, Exhaust pipe Remove exhaust pipe (4) by loosening band (2). 4, KOMACLONE sir cleaner Remove KOMACLONE air cleaner (6) by loosening band (5) ‘and KOMACLONE tube clamp. 5. Hood Remove hood (7) by removing mounting hook bolt. 6. Cover Remove cover (8) by removing mounting bolts 7. Radiator outlet tube Disconnect tube (9) from lower tank by removing flange mount: ing bolts. 8 Shroud mounting bolt Remove three bolts (10) mounting shroud. 9. Overflow tube Disconnect overflow tube (11) from pressure valve (12). 10, Radiator inlet hose Disconnect radiator inlet hoses (13), (14) and (15) from upper ‘tank (16) by loosening respective hose clamps. 60,654-P RADIATOR ical 13-69RADIATOR 11, Support Remove supports (17) (both LH. and RH.) 4 When removing mounting bolts, take care not to allow sup- ports to fallin under cover. 12, Radiator 1) Remove mounting bolts (18) (both LLH. and R.H.). 2) Lift off radiator (19) slowly with crane, = Radiator assembly: 130 kg. 13-70 DISASSEMBLY AND ASSEMBLY D60,65ADISASSEMBLY AND ASSEMBLY * RADIATOR MOUNTING RADIATOR Support Radiator inspection | [cutie tive [| cover ———_ Radiator i 8 Overflow f tube pe0.esars| [a caistor Bulldozer 2 \ ‘Shroug Bole 0 Iomactone 8 a Jnecienee Cover Hood 0 Exhaust ibe 2 - Supplying at sar027 1. Radiator 1) Lift down radiator (19) in place slowly, avoiding inter ference with neighbouring parts. 2) Coat mounting bolts (18) with thread tightener (LT-2) and tighten them. 60,6540RADIATOR. DISASSEMBLY AND ASSEMBLY 2. Support Install supports (17) (both L.H. and R.H.) on lower tank with plate of shroud held in between. 3. Radiator outlet tube Attach gasket to flange with gasket sealant (LG-1) and install radiator outlet tube (9) on lower tank, 4. Inspection cover Close coolant drain valve (2) and install inspection cover (1). 5. Radiator inlet hose Connect radiator inlet hoses (13), (14) and (15) to upper tank and tighten respective hose clamps. + Apply soapsuds to hose mounting surfaces and hoses can be connected smoothly. 6. Overflow tube Connect overfiow tube (11) to pressure valve (12) and clamp it with wire 13-72 D60,65A-PDISASSEMBLY AND ASSEMBLY ee 7. Shroud mounting bolt Tighten three bolts (10) mounting shroud. 8, Cover Install cover (8). 9, Hood Install hood (7), tighten mounting bolts and hook it 10. KOMACLONE air cleaner Install KOMACLONE air cleaner (6), secure it with band (5) and connect KOMACLONE tube. 11, Exhaust pipe Install exhaust pipe (4) and fasten it with band (3). 12. Supplying water Supply radiator with water through water filler (20). ‘+ Use soft water for coolant. 260,454: RADIATOR 13-73RADIATOR GUARD DISASSEMBLY AND ASSEMBLY MOUNTING RADIATOR GUARD Fan guard 0 Wiring Exhaust pie| at Ceolee ater hose Hood " Radio | Hath rclener / | psossars| [roaixor fF Avaton [Bulldozer ard howe h i 1 || [scene \ Win | : A ae ee \ a Radiotor fore puller tube 1. Radiator guard Place guard (2) in place with crane and secure it there with mounting bolts. =) Guard mounting bolt: 50 to 62 kgm 2. Fan guard Install fan guard (21) with bo ts. Pa D60,65A7 13-74DISASSEMBLY AND ASSEMBLY 3. Wiring Connect lamp cable (20) at connector and clamp it. 4, Cooler outlet hose Connect cooler outlet hose (19) and fasten it with clamp. 5. Radiator inlet hose Connect radiator inlet hose (18) and fasten it with clamp. 6. Aeration hose Connect aeration hose (17) and fasten it with clamp. 7. LH. and RH. blade hoses Connect L.H. and R.H. blade hoses (16) with flange bolts. 8. Radiator outlet tube Apply gasket sealant (LG-1) to mounting surface and attach ‘gasket to it, and connect outlet tube (15) D60,654-P RADIATOR GUARD 13-75RADIATOR GUARD DISASSEMBLY AND ASSEMBLY 9, Hood Install hood (14) with mounting bolts and lock it with catchers. 10. Exhaust pipe Install exhaust pipe (13) and fasten it with nut. 11, Precleaner Install precleaner (12) and tighten hose clamp. ii Install L.H. and R.H. engine side covers (11). 19, LH. and R.H. blade lift cylinders 1) Remove eylinder (10) from hooks and extend piston rod. 13-76 060,654-PDISASSEMBLY AND ASSEMBLY piston rod connecting pin (8) and lock it with lock ing (Tiltdozers only} Connect tilt tubes (7) with flange bolts and fasten them with 18, Radiator mask (Tiltdazers only) 1) Install radiator mask (5). 2). Install bumper (4). 16. Tilt hose (Tiltdozers only) Connect tilt hoses (3) with flange bolts. D60,65A-P RADIATOR GUARD 13-77RADIATOR GUARD DISASSEMBLY AND ASSEMBLY 17. Supplying water e + ‘After confirming that radiator lower drain cock (2) is closed, supply radietor with water until water overflows from water filler port and install inspection cover (1). 13-78 D60,65A-PDISMOUNTING FLOAT TANK [[#5~ D60,65A-P 13-79FLOAT TANK DISASSEMBLY AND ASSEMBLY DISMOUNTING FLOAT TANK | 1 2 3 060.654P-6 Floor plate Piping Float valve Bulldozer , 1. Floor plate Remove floor plate (1). 2. Piping 1) Close fuel tank tower f2ed cock. 2). Disconnect float tank inlet hose (2). 3. Floatvalve Remove valve (4) by removing mounting bolts (3) 13-80 D60,654-PDISASSEMBLY AND ASSEMBLY FLOAT TANK MOUNTING FLOAT TANK 1 a a r ; [260.6546 |__ ose vive Piping Floor plate ‘Butdozer 13090 1. Float valve Install O-ring on valve (4), position valve in mounting position and secure it there with mounting bolts (3) 2. Piping 1) Connect float tank inlet hose (2). 2) Open tank lower feed cock. 3. Floor plate Install floor plate (1). 060,654-P 13-81FUEL TANK cane DISMOUNTING FUEL TANK | 60.6506 Bulldozer www [-[ rom [nome 1. Rear cover Open rear cover (1). 2. Piping Close fuel feed cock (2) and disconnect feed hose (3) at nipple, Pull not drain hose (4) from clamp. 3. Fuel tank 1) Remove six bolts (6) mounting fuel tank. 2) Install eye bolts (10 mm, P = 1.5] on upper screw holes on fuel tank (6) and hoist tank with crane. 13-82 DISASSEMBLY AND ASSEMBLY wae ween = SOMES ae D60,65A+PDISASSEMBLY AND ASSEMBLY MOUNTING FUEL TANK | 1 2 4 jpooesars| [eusitink || Prine esr cover Bulldozer L 1. Fuel tank 1) Install eye bolts (10 mm, P = 1.8) on upper screw holes on fuel tank (6) and hoist it into the mounting position, 2) Apply thread tightener (LT-2) to mounting bolts (5) and Install them. Piping 1). Pass fuel drain hose (4) through clamp. 2) Connect feed hose (3). 3) Open feed cock (2). 3. Rear cover Close rear cover (1). D60,65A-P FUEL TANK crrsgcercrcsceemmenener: =OMATSO