Komatsu d65 px 15 (sn 67001 and up) dozer bulldozer service repair manual

Komatsu d65 px 15 (sn 67001 and up) dozer bulldozer service repair manual.pdf,This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.

1. SEBM029508
Machine model Serial number
• This shop manual may contain attachments a
nd optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are
subject to change without notice.
• D65-15 mount the SA6D125E-3 engine.
For details of the engine, see the 125-3 Series Engine Shop Manual.
D65EX-15 67001 and up
D65PX-15 67001 and up
D65WX-15 67001 and up
00-1
(8)
© 2008
All Rights Reserved
Printed in Japan 0
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2. 00-2 D65EX,PX-15
(2)
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20 TESTING AND ADJUSTING ............................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY .................................................. 30-1
90 OTHERS ........................................................................................... 90-1

3. D65EX, PX-15 00-3
FOREWORD SAFETY NOTICE
(8)
SAFETY NOTICE
Important safety notice
Proper service and repair are 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
k is used to mark safety precautions in this manual. The cau-
tions accompanying these symbols should always be followed carefully. If any dangerous situation
arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situa-
tion.
1. General precautions
kMistakes in operation are extremely dan-
gerous. Read the Operation and Mainte-
nance Manual carefully before operating
the machine.
1) Before carrying out any greasing or repairs,
read all the safety plates stuck to the
machine. For the locations of the safety
plates and detailed explanation of precau-
tions, see the Operation and Maintenance
Manual.
2) 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, water, or oil on the
floor. Smoke only in the areas provided for
smoking. Never smoke while working.
3) 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.
4) When carrying out any operation with 2 or
more workers, always agree on the operat-
ing procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning signs in the oper-
ator's compartment.
5) Only qualified workers must carry out work
and operation which require license or quali-
fication.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones of them. Before starting work, thor-
oughly check the tools, machine, forklift,
service car, etc.
7) If welding repairs are needed, always have
a trained and experienced welder carry out
the work. When carrying out welding work,
always wear welding gloves, apron, shield-
ing goggles, cap and other clothes suited for
welding work.
8) Before starting work, warm up your body
thoroughly to start work under good condi-
tion.
2. Preparations for work
1) Before adding oil or making any repairs,
park the machine on hard and level ground,
and apply the parking brake and block the
wheels or tracks to prevent the machine
from moving.
2) Before starting work, lower the work equip-
ment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equip-
ment from falling. In addition, be sure to lock
all the control levers and hang warning
signs on them.
3) When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. 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.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by
unlicensed workers
6 Safety check before starting work
7
Wearing protective goggles
(for cleaning or grinding work)
8
Wearing shielding goggles and protectors
(for welding work)
9 Good physical condition and preparation
10
Precautions against work which you are
not used to or you are used to too much
(Rev. 2007/03)

4. 00-4 D65EX, PX-15
FOREWORD SAFETY NOTICE
(8)
3. Precautions during work
1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from spurt-
ing out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and cool-
ant to cool before carrying out any work on
the oil or water circuits.
3) Before starting work, stop the engine. When
working on or around a rotating part, in par-
ticular, stop the engine. When checking the
machine without stopping the engine (meas-
uring oil pressure, revolving speed, temper-
ature, etc.), take extreme care not to get
rolled or caught in rotating parts or moving
parts.
4) Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (–) terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) 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 and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused 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
operated.
11) 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. In addition, check that connecting
parts are correctly installed.
12) When assembling or installing parts, always
tighten them to the specified 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.
13) When aligning 2 holes, never insert your fin-
gers or hand. Be careful not to get your fin-
gers caught in a hole.
14) When measuring hydraulic pressure, check
that the measuring tools are correctly
assembled.
15) Take care when removing or installing the
tracks of track-type machines. When remov-
ing the track, the track separates suddenly,
so never let anyone stand at either end of
the track.
16) If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.

5. D65EX, PX-15 30-13
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP
ASSEMBLY
SPECIAL TOOL
REMOVAL
kDisconnect the cable from the negative (–) termi-
nal of the battery.
1.Release the residual pressure from the fuel sys-
tem. For details, see TESTING AND ADJUST-
ING, Releasing residual pressure from fuel
system.
2.Close the fuel supply valve of the fuel tank.
3.Remove the engine undercover.
4.Open engine left cover (1).
5.Remove covers (2) and (3).
6.Remove the clamp and move hose (4).
7.Disconnect fuel supply pump wiring connectors
PCV1 (5), PCV2 (6), and G (7).
8.Remove fuel hoses (8) and (9).
9.Remove the 2 clamps and fuel tubes (10) and
(11).
10.Remove covers (12) and (13).
11.Remove high-pressure pipe clamps (14), (15),
(16), and (17).
aClamp (15) is on the back side of the oil feed
pipe.
12.
Remove high-pressure pipes (18) and (19).
13.Remove lubrication tube (20).
Symbol Part No. Part name
Q’ty
Sketch

A1
795-471-1800 Remover t1
1 795-471-1810 • Plate 1
2 795-471-1820 • Bolt 1
3 795-471-1830 • Bracket 1
4 01435-01035 • Bolt 3
5 01435-01025 • Bolt 1
Neces-
sity
New/
remodel
1*
2*
3*
4*
5*
6*
(5)

6. 30-14 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
14.Removal of fuel supply pump.
1) Remove cover (22).
2) Remove gear mounting nut (23) and washer
(24).
aTake great care not to drop the nut and
washer in the case.
3) Rotate the crankshaft forward to bring supply
pump key position "e" up.
aUse the damper mounting bolt to rotate
the crankshaft.
4) Install plate A1-1 with its shouldered side to-
ward the gear and tighten bolt A1-4 with your
fingers.
aInstall the plate with tap hole "f" up.
5) Install bracket A1-3.
• Rotate the crankshaft to match tap hole
"f" of plate A1-1 and secure bracket A1-
3 with bolt A1-5.
6) Install bolt A1-2.
• Tighten the bolt with your fingers until it
touches the pump shaft.
(4)

7. D65EX, PX-15 30-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
7) Remove bracket (26) and 4 mounting bolts
(32) of fuel supply pump (27).
• Tighten 1 mounting bolt on the upper
side temporarily as a guide bolt.
8)Tighten bolt A1-2 and remove the gear and
fuel supply pump (27).
3 Tightning torque of bolt:
Approx. 196 – 294 Nm
{20 – 30 kgm}
aTake care not to drop the woodruff key of
the supply pump shaft.
aDo not remove bracket A1-3 until you will
install the supply pump assembly again.
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
3 Fuel hoses (8) and (9):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Eyebolts of fuel tubes (10) and (11)
(Both on filter side and fuel supply
pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
aInstall cover (12) with its slit on the cylinder
block side. Install cover (13) with its face
down.
kDo not correct the high-pressure pipe by
bending before installing it.
kBe sure to use the genuine high-pressure
pipe clamp and observe the tightening
torque.
kInstall the high-pressure pipe and wiring har-
ness at least 10 mm apart from each other.
aWhen installing each high-pressure pipe,
check the taper seal of its joint (Part "a": Part
of 2 mm from the end) for visible lengthwise
slit "b" and spot "c" and check part "d" (End
of taper seal: Part of 2 mm from the end) for
stepped-type wear caused by fatigue which
your nail can feel. If there is any of those de-
fects, it can cause fuel leakage. In this case,
replace the high-pressure pipe.
1
2
3
4 5 8
(4)

8. 30-16 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
aInstall the fuel supply pump and the parts be-
tween it and common rail according to the
following procedure.
1) Installation of fuel supply pump assembly.
i) Remove bolt A1-2 from plate A1-1.
ii) Insert supply pump (27) with key (33) up
and matched to the key way of the gear,
and then secure it temporarily.
iii) Tighten supply pump drive gear mount-
ing nut (23) and washer (24) temporarily.
iv) Remove bracket A1-3 and plate A1-1.
v) Tighten supply pump drive gear mount-
ing nut (23).
3 Mounting nut:
127 – 147 Nm {13 – 15 kgm}
vi) Install gear cover (22).
3 Mounting nut:
14.7 – 17.6 Nm {1.5 – 1.8 kgm}
2) Installation of high-pressure pipe.
i) Tighten brackets (26) and (28) and high-
pressure pipes (18) and (19) with your
fingers.
ii) Tighten high-pressure pipes (18) and
(19) permanently.
3 Sleeve nut on common rail side:
39.2 – 58.8 Nm {4 – 6 kgm}
3 Sleeve nut on supply pump side:
39.2 – 49 Nm {4 – 5 kgm}
iii) Tighten supply pump (27) permanently.
2 4 supply pump mounting bolts:
Adhesive (LT-2)
iv) Tighten bracket (26) and (28) perma-
nently.
v) Install high-pressure pipe clamp (14) and
brackets (29) and (30) with your fingers.
vi) Tighten high-pressure clamp (16) per-
manently.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
vii) Tighten bracket (29), and then tighten
bracket (30) permanently.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
(4)

9. D65EX, PX-15 30-16-1
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
viii) Install clamps (16) and (17) and bracket
(31) with your fingers.
iv) Tighten clamps (16) and (17) perma-
nently.
x) Tighten bracket (31) permanently.
xi) Install clamp (15).
3 Lubrication tube (20)
Joint bolt on supply pump side:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Joint bolt on engine side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
• Checking for fuel leakage
Check for fuel leakage. For details, see
TESTING AND ADJUSTING, Checking
fuel system for leakage.
• Bleeding air
Bleed air from the fuel circuit. For de-
tails, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.
6
(4)

10. D65EX, PX-15 30-17
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL
1.Remove right and left covers (1).
2.Open cover (2).
3.Loosen the clamp and disconnect air conditioner
duct hose (3).
4.Lift off engine hood assembly (4).
4 Engine hood assembly:160 kg
INSTALLATION
Carry out installation in the reverse order to re-
moval.
(2)

11. 30-18 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR
ASSEMBLY
REMOVAL
kDisconnect the cable from the negative (–) termi-
nal of the battery.
1.Open the right and left engine side covers.
2.Remove cap assembly (1) and cover (2).
3.Remove air cleaner assembly (3) and bracket
(4).
aRotate the air cleaner assembly in the cir-
cumferential direction and remove it, letting
the tube at the end through the hole of the
hood.
4.Remove eyebolt (5) and fuel filter and bracket
assembly (6) (when removing and installing the
No. 1 cylinder injector).
5.Remove oil filter and bracket assembly (7).
6.Remove air intake connector (8).
7.Remove common rail cover (9).
8.Remove 6 injector-side covers (10) and common
rail-side cover (11) from the high-pressure pipe
junction.
9.Remove high-pressure pipe clamp (12) and
gate-type frame (25).
10.Remove high-pressure pipe clamps (13), (14),
and (15) and plates (23) and (24) according to
the fuel injectors to be removed and installed.
11.Remove common rail-side sleeve nut (17) and
fuel injector-side sleeve nut (18) of high-pres-
sure pipe (16).
12.Remove head cover (19).
1
2
3
4
5
6
7
8
9
(2)

12. D65EX, PX-15 30-19
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
13.Remove wiring harness (20) from the fuel injec-
tor.
14.Remove holder mounting bolts (21), and then re-
move the holder and fuel injector assembly (22)
together.
aDo not grip the solenoid valve at the top of
theinjectorwithpliers,etc.
INSTALLATION
Carry out installation in the reverse order to re-
moval.
3 Air cleaner band:
9.8–11.76Nm{1.0–1.2kgm}
3 Eyebolt:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3 Hose clamp between air intake connec-
tor and turbocharger:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
kDo not bend the high-pressure pipes before
using them.
kBe sure to use the genuine high-pressure
pipe clamps and tighten them to the speci-
fied torque.
kInstall the high-pressure pipes and wiring
harness at least 10 mm apart.
aWhen installing each high-pressure pipe,
check the taper seal of its joint (Part “a”: Part
of 2 mm from the end) for visible lengthwise
slit “b” and spot “c” and check part “d”(End
of taper seal: Part of 2 mm from the end) for
stepped-type wear (fatigue) which your nail
can feel. If there is any of those defects, it
can cause fuel leakage. In this case, replace
the high-pressure pipe.
aInstall high-pressure pipes (16) between the
common rail and fuel injector according to
the following procedure.
1) Tighten sleeve nuts (17) and (18) of 6 high-
pressure pipes (16).
3 High-pressure pipe sleeve nut:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
2) Tighten high-pressure pipe clamps (13),
(14), and (15) and plates (23) and (24) tem-
porarily with the fingers.
3) Tighten high-pressure clamps (13), (14), and
(15) permanently.
3 Clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
4) Tighten plates (23) and (24) permanently.
5) Install the common rail cover, high-pressure
pipe clamp (12), and gate-type frame (25)
temporarily.
6) Tighten common rail cover and high-pres-
sure pipe clamp (12) permanently first, then
tighten gate-type frame (25) permanently.
3 Clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
10
11
1
2
3
4 6 7 8
(2)

13. 30-20 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
aTurn the slit of the cover on the common rail
side to face the cylinder block.
aTurn the slit of cover (10) on the fuel injector
side to face “a” position in the figure.
3 Head cover mounting bolt:
9.8±1Nm{1.0±0.1kgm}
3 Wiring harness mounting nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
aInstall the fuel injector assembly in the fol-
lowing manner.
1) Fit gasket (b) and O-ring (c) to fuel injector
(a).
2) Put holder (d) in injector (a) and install to the
rocker housing temporarily.
aAlign the injector key with the rocker
housing keyway, and push in until the in-
jector seal face comes into contact with
the seal face on the cylinder head side.
3) Coat the face of spherical washer (e)with
engine oil.
4) Tighten bolt (f) for the holder.
3 Injector holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5
9
10
11
(2)

14. D65EX, PX-15 30-21
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
Check for fuel leak
Check for fuel leak, referring to the section of
“CHECKING FOR LEAKAGE IN FUEL CIR-
CUIT” in INSPECTION AND MAINTENANCE.
Air bleeding
Bleed air from the fuel circuit, referring to the
section of “BLEEDING AIR FROM FUEL CIR-
CUIT” in INSPECTION AND MAINTENANCE.
(2)

15. 30-22 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP
a[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.
SPECIAL TOOL
REMOVAL
1.Fix toolA3in vice [1].
aDo not pinch the injector directly in the vice.
2.Set injector assembly (3) on toolA3.
3.Loosen retaining nut (4) with 19 mm deep socket
[3].
4.Remove retaining nut (4) from injector assembly
(3).
5.Lift nozzle assembly (5) perpendicularly upward
to remove it.
aDo not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
aBe careful not to get the assembly dirty.
Symbol Part No. Part name
A3 795T-471-1550 Wrench t1 Q
(2)

16. D65EX, PX-15 30-23
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
INSTALLATION
1.Fit toolA3in vice [1].
aDo not pinch the injector directly in the vice.
2.Set injector assembly (1) on toolA3.
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).
aBe careful not to drop the tip.
5.Mount nozzle assembly (3) and manually tighten
retaining nut (2).
6.Set 19 mm deep socket [2] in the torque wrench,
then tighten the retaining nut by following the
steps below.
aApply rust prevention oil on the nozzle body.
1) Tighten with torque of88.3 Nm {9.0 kgm}.
2) Attach identification mark (6) to retaining nut
(2) and lower body (5).
3) Tighten at an angle of 45º (angle tightening).
(2)

17. 30-24 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOL
REMOVAL
kDisconnect the cable from the negative (–) termi-
nal of the battery.
1.Remove the undercover.
2.Remove air conditioner compressor belt (1) and
alternator belt (2). For details, see TESTING
AND ADJUSTING, Testing adjusting air condi-
tioner compressor belt tension and TESTING
AND ADJUSTING, Testing and adjusting alter-
nator belt tension.
3.Remove 6 mounting bolts (3) and crank pulley
(4).
aOne of the mounting bolts has a smaller di-
ameter than the others.
4.Remove engine front seal (5).
INSTALLATION
Carry out installation in the reverse order to re-
moval.
1.Using guide bolt [1], set the crank pulley.
2.Tighten the mounting bolts.
3 Mounting bolt:
(M14):157 – 196 Nm {16 – 20 kgm}
(M16):245 – 308.7 Nm {25 – 31 kgm}
aTighten the bolts of toolA2evenly until the
end of toolA2touches the end of crankshaft
(6) to press fit engine front seal (5).
aFill the space between the seal lips with lith-
iumgreaseupto50–80%.
aFitting dimension “a”:16 mm
Symbol Part No. Part name
A2
795T-521-1140 Push tool t1 Q
01010-31640 Bolt t3
1
2
1
2
1
0
+
(2)

18. D65EX, PX-15 30-25
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL
1.Remove the floor frame assembly. For details,
see REMOVAL AND INSTALLATION OF
FLOOR FRAME ASSEMBLY.
2.Remove the power train and lubricating oil pump
assembly. For details, see REMOVAL AND IN-
STALLATION OF POWER TRAIN AND LUBRI-
CATING OIL PUMP ASSEMBLY.
3.Remove universal joint (1).
4 Universal joint:25 kg
4.Drain oil from the damper case.
6 Damper case:1.7llll
5.Using guide bolt [1], remove damper cover (2).
4 Damper cover:35 kg
6.Remove damper assembly (3).
INSTALLATION
Carry out installation in the reverse order to re-
moval.
2 Mounting bolt:
Liquefied adhesive (LT-2)
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
2 Cover mounting face:
Gasket sealant (LG-6)
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil. Then, stop the
engine and check the oil level again.
5Damper case:1.7llll(TO30)
3 Drain plug:58.8–78.5Nm{6–8kgm}
1
2
3
1
2
3
(2)

19. 30-26 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOL
REMOVAL
1.Remove the damper assembly. For details, see
REMOVAL AND INSTALLATION OF DAMPER
ASSEMBLY.
2.Using guide bolt [1], remove flywheel assembly
(1).
4 Flywheel assembly:60 kg
3.Remove engine rear seal (2).
INSTALLATION
Carry out installation in the reverse order to re-
moval.
aApply sufficient amount of clean lubricating
oil (EO30-CD) to the threads, seats, and
washers of the bolts.
a
Tighten the 6 flywheel mounting bolts in the or-
derof1–6asshowninthefollowingfigure
.
aTighten each mounting bolt twice.
4 Mounting bolt:
1st tightening torque:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd tightening torque:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
Procedure for installing engine rear seal (2)
aBefore installing the Teflon seal (lay-down lip
seal) 6151-21-4160 check the shaft for wear.
Then, install “standard sealA”or“sleeved
sealB” according to the check result.
aIf the shaft is still glossy (If the wear depth felt
with a finger cushion is 10 µm or less) and it
does not have a flaw, install “standard seal
A”. In other cases, install “sleeved sealB”.
aPart (3) is the internal plastic cylinder which
is also used as a installation guide.
Symbol Part No. Part name
A
4
795-931-1210 Push tool t1
01050-31625 Bolt t3
01050-31645 Bolt t3
5
795-931-1220 Push tool t1
01050-31645 Bolt t3
1
2
1
2
(2)

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21. D65EX, PX-15 30-27
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
Procedure for installing standard seal A
aBefore installing the seal, check the rims of
the crankshaft end, sliding surfaces of the lip,
and housing for flaw, burr, sharp fin, rust, etc.
aWhen installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
aNever remove internal plastic cylinder (3) of
the spare seal before installing the seal.
1) Put large inside diameter side “b” of internal
plastic cylinder (3) to the end of crankshaft
(4).
aTake care not to mistake the direction of
the plastic internal cylinder.
2) Evenly push in the metallic ring of seal (2)
with both hands, getting over the large diam-
eter side of the internal plastic cylinder.
3) After pushing in seal (2), remove internal
plastic cylinder (3).
aWhen removing, take care not to dam-
age the seal lip.
4) Tighten the bolt of toolA4evenly until the
end of toolA4touches the end of crankshaft
(4) to press fit seal (2).
aWhen press fitting the seal, take care not
to damage the lip on the damper side
with the tool, etc.
aAfter press fitting the seal, remove the
red sealant layer on its periphery.
(2)

22. 30-28 D65EX, PX-15
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
Procedure for installing sleeved seal B
aBefore installing the seal, check the rims of
the crankshaft end, sliding faces of the lip,
and housing for flaw, burr, sharp fin, rust, etc.
aWhen installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
aHandle the seal and sleeve as an assembly.
Never separate them from each other.
1) Set sleeved seal (2) to toolA5.
aTake care not to mistake the direction of
the seal.
2 Internal cylinder (C) of sleeve:
Gasket sealant (LG-7)
2) Put the sleeve of the seal to the end of the
crankshaft and tighten the bolt of toolA5
evenly until the end of toolA5touches the
end of crankshaft (4) to press fit sleeved seal
(2).
3) Remove toolA5and install toolA4.
4) Tighten the bolt of toolA4evenly until the
end of toolA4touches the end of crankshaft
(4) to press fit sleeved seal (2).
aAfter press fitting the seal, remove the
red sealant layer on its periphery.
(2)

23. D65EX, PX-15 30-29
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD
ASSEMBLY
SPECIAL TOOL
REMOVAL
kDisconnect the cable from the negative (–) termi-
nal of the battery.
1.Drain cooling water.
2.Close the fuel feed valve.
3.Remove the engine hood assembly. For details,
see REMOVAL AND INSTALLATION OF EN-
GINE HOOD ASSEMBLY.
4.Remove the right and left side covers.
5.Remove air cleaner assembly (1) and bracket
(2).
6.Remove tube (3) and oil filter and bracket as-
sembly (4).
7.Remove tube (5) and fuel filter and bracket as-
sembly (6).
8.Remove corrosion resistor (7) and bracket to-
gether and fix them on the chassis side.
9.Remove air intake connector (8).
10.Disconnect wiring connectorsE21(9) andE22
(10) and remove bracket.
11.Disconnect 6 wiring connectors of the injector
and move the wiring harness.
12.Remove tube (11).
13.Remove high-pressure pipe clamps (12), (13),
and (14), 2 pieces each.
14.Remove bracket (15).
15.Remove filler tube (16).
Symbol Part No. Part name
A6 790-331-1110 Wrench q1
1
2
3
4
5
6
(2)