service repair workshop manual

1. 00-1
1
SEBM027202
MACHINE MODEL SERIAL NUMBER
D65EX-12 65209 and up
D65PX-12 65275 and up
• This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require. Materials and
specifications are subject to change without notice.
• D65EX/PX-12 mount the SA6D125E-3 engine.
For details of the engine, see the SA6D125E Series Engine Shop Manual.
© 2002 1
All Rights Reserved
Printed in Japan 03-02 (03)
-
-
(EU SPEC.)
2

2. 00-2 D65EX, PX-12
CONTENTS
01 GENERAL ......................................................................... 01-1
10 STRUCTURE AND FUNCTION ....................................... 10-1
20 TESTING AND ADJUSTING........................................... 20-1
30 DISASSEMBLY AND ASSEMBLY .................................. 30-1
40 MAINTENANCE STANDARD.......................................... 40-1
90 OTHERS............................................................................ 90-1
No. of page
2

3. 00-3
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grind-
ing parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work, al-
ways wear welding gloves, apron, hand
shield, cap and other clothes suited for weld-
ing work.
4. When carrying out any operation with two
or more workers, always agree on the oper-
ating procedure before starting. Always in-
form your fellow workers before starting any
step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls
in the operator's compartment.
5. Keep all tools in good condition and learn
the correct way to use them.
6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smok-
ing. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
8. Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warn-
ing signs on them.
9. When disassembling or assembling, support
the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or
other places used to get on and off the ma-
chine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
SAFETY SAFETY NOTICE

4. 00-4
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug
or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing compo-
nents of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
12. The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before
carrying out any work on the oil or water
circuits.
13. Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (–) terminal first.
14. When raising heavy components, use a hoist
or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hit-
ting any other part. Do not work with any
part still raised by the hoist or crane.
15. When removing covers which are under in-
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
19. Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.
• When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is be-
ing operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
21. When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards,
or parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
22. When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assem-
bled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track sepa-
rates suddenly, so never let anyone stand at
either end of the track.
SAFETY SAFETY NOTICE

5. D65EX, PX-12 30-13
?
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
REMOVAL
½ Stop the machine on level ground and lower the
blade to the ground.
NDisconnect the (-) terminal of the battery.
1. Side cover and fan cover
1) Open side cover (left) (1) and remove the
front cover and underside cover.
2) Remove the fan cover.
2. Air compressor
Remove the air compressor and fix it with rope to
the side of the machine, referring to the Remov-
al and Installation of Air Compressor section.
5 Do not disconnect the air compressor piping.
3. Harnesses and piping
1) Remove harness connectors (2) (CN-E41
and CN-E42) and (3) (CN-E52).
2) Remove fuel hoses (4) and (5).
3) Remove fuel tubes (7) and (8).
4) Remove high-pressure pipe clamps (9), (10)
and (11).
5) Remove covers (12) and (13).
6) Remove high-pressure pipes (14) and (15).
7) Remove lubrication tube (16).
4. Fuel supply pump drive gear
1) Align the damper’s stamp line for 1.6TOP
with pointer (17).
2) Remove cover (18).
q 1
q 2
q 3
q 4

6. 30-14 D65EX, PX-12
?
3) Remove the gear mounting nut and remove
fuel supply pump drive gear (19) using tool
A1.
5 Be careful so as not to allow the nuts,
washers and woodruff key on the shaft to
drop into the case.
5. Fuel supply pump
Remove bracket (20) to remove fuel supply
pump assembly (21).
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
Fuel hoses (4) and (5):
14.7 - 19.6 Nm {1.5 -2.0 kgm}
Fuel tubes (7) and (8) on filter side and
the fuel supply pump side:
24.5 - 34.3 Nm {2.5 -3.5 kgm}
5 Mounting cover (12) with its slit facing the cylin-
der block.
5 Mounting cover (13) with its slit facing down.
Lubrication tube (16)
On the fuel supply pump side:
7.9 - 12.7 Nm {0.8 - 1.3 kgm}
On the cylinder block side:
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
q 5
q 1
q 2
q 3
q 4
?

7. D65EX, PX-12 30-15
?
5 Mount fuel supply pump drive gear (19) so that
stamp line C on the surface falls on stamp line C
on the surface of camshaft gear (22).
Fuel supply pump gear:
127 - 147 Nm {13 - 15 kgm}
• Steps for mounting the fuel supply pump and the
high-pressure pipe between the fuel supply
pump and the common rail:
NDo not reuse a high-pressure pipe by bend-
ing it.
NBe sure to use genuine parts for high-pres-
sure pipe clamps and to strictly comply with
the tightening torque specifications.
1. Temporarily mount fuel supply pump (21), brack-
ets (20) and (22) and high-pressure pipes (14)
and (15), tightening them by hand.
2. Tighten high-pressure pipes (14) and (15) with
the following torque.
Sleeve nut on the common rail side:
39.2 - 58.8 Nm {4 - 6 kgm}
Sleeve nut on the fuel supply pump
side: 39.2 - 49 Nm {4 - 5 kgm}
3. Tighten the fuel supply pump mounting bolts.
Thread of mounting bolt:
Thread tightener (LG-6)
4. Tighten the mounting bolts of brackets (20) and
(22).
Between bracket (20) and the fuel sup-
ply pump:
19.6 - 29.4 Nm {2.0 - 3.0 kgm}
5. Temporarily mount high-pressure pipe clamp (9)
and brackets (23) and (24), tightening them by
hand.
6. Tighten high-pressure pipe clamp (9) with the
following torque:
High-pressure clamp:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
7. Tighten the mounting bolts for brackets (24) and
(23), in this order.
8. Tighten high-pressure pipe clamp (10) with the
following torque.
High-pressure pipe clamp:
8.8 - 14.7 Nm {0.9 - 1.5 kgm}
9. Temporarily mount high-pressure pipe clamp
(11) and bracket (25), tightening them by hand.
10. Tighten high-pressure pipe clamp (11) with the
following torque.
High-pressure pipe clamp:
8.8 - 14.7 Nm {0.9 - 1.5 kgm}
11. Tighten the mounting bolts of bracket (25).
• Bleeding Air
5 Perform air bleeding, referring to the Air
Bleeding for Fuel Circuitry section in the
testing and adjusting manual.
q 5

8. 30-16 D65EX, PX-12
?
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY
REMOVAL
½ Stop the machine on level ground and lower the
blade to the ground.
NDisconnect the (-) terminal of the battery.
1. Open both engine side covers.
2. Air cleaner
1) Remove rain cap (1).
2) Remove cover (2).
3) Remove air intake hose (3).
4) Remove air cleaner band (4).
5) Remove air cleaner (5).
5 Remove the air cleaner from the left side
of the machine body by turning it to the
right by 90 degrees.
6) Remove bracket (6).
3. Remove the heat insulation panel and turbo-
charger lubrication tube (7).
(Nozzles No. 3 and 4)
4. Remove air intake connector (8).
(Nozzles No. 3 and 4)
5. Remove fuel filter bracket (9). (Nozzle No. 1)
6. Fuel piping
1) Remove cover (10).
q 1
q 2
q 3
?

9. D65EX, PX-12 30-17
?
2) Remove high-pressure pipe junction cover
(14) on the injector side and cover (15) on
the common rail side. (The figure shows a
typical operation for removing cylinder
No.1.)
3) Remove high-pressure pipe clamp (16) for
the double-housing frame.
4) Remove high-pressure pipe clamps (17) and
(18) corresponding to the cylinders to be re-
moved.
5) Completely loosen sleeve nut (19) on the in-
jector side and sleeve nut (20) on the com-
mon rail side of the high-pressure pipe. (The
figure shows a typical operation for removing
cylinder No.1.)
7. Head cover
Remove the head cover mounting bolts and
place head cover (21) close to the air intake con-
nector. (The figure shows a typical operation for
removing cylinder No.1.)
8. Nozzle holder
1) Remove harness (23) from the injector.
2) Remove bolt (24) for mounting the nozzle
holder, then remove injector (25) along with
the holder.
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
Mounting clamp:
9.8 - 11.8 Nm {1.0 - 1.2 kgm}
Lubrication tube for turbocharger (on
the cylinder block side):
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
Air intake connector clamp:
6.8 ±±±± 0.49 {69 ±±±± 5 kgcm}
5 The clamp must not project from the top of
the hose.
5 Fit the slit of cover (14) in position a in the fig-
ure below.
5 Turn the slit of cover (15) toward the cylinder
block.
Head cover mounting bolt:
8.33 - 10.8 Nm {0.9 - 1.1 kgm}
Harness mounting nut:
2.0 - 2.4 Nm {0.2 - 0.24 kgm}
q 4
q 5
q 6
q 7
q 1
q 2
q 3
q 4
q 5
q 6

10. 30-18 D65EX, PX-12
?
• Steps for tightening the nozzle holder:
1. Insert gasket (b) and O-ring (c) into injector (a).
2. Insert holder (d) into injector (a) to mount it ten-
tatively on the rocker housing.
5 Fit the key of the injector into the key slot of
the rocker housing and securely insert the in-
jector until its sealing face makes contact
with that of the cylinder head.
3. Apply engine oil on the spherical portion of
spherical washer (e).
4. Tighten bolt (f) of the holder.
Holder mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
• Steps for mounting the high-pressure pipe be-
tween the common rail and the injector:
NDo not reuse a high-pressure pipe by bend-
ing it.
NBe sure to use genuine parts for high-pres-
sure pipe clamps and to strictly comply with
the tightening torque specifications.
1. Tighten sleeve nuts (19) and (20) of the high-
pressure pipe with the following torque:
Sleeve nut: 39.2 - 49 Nm {4 - 5 kgm}
2. Temporarily mount high-pressure pipe clamps
(17) and (18), tightening them by hand.
3. Tighten the mounting bolts of high-pressure pipe
clamps (17) and (18) with the following torque:
Clamp mounting bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
4. Temporarily mount high-pressure pipe clamp
(16) and double-housing frame (27).
5. Tighten the mounting bolts of high-pressure pipe
clamp (16) with the following torque:
Clamp mounting bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
6. Tighten the mounting bolts of the double-hous-
ing frame.
• Bleeding Air
5 Perform air bleeding, referring to the Air
Bleeding for Fuel Circuitry section in the
testing and adjusting manual.
q 7
?

11. D65EX, PX-12 30-19
?
REMOVAL AND INSTALLATION OF NOZZLE TIP
5 [EPA regulations]
For countries subject to EPA regulations, the en-
tire nozzle assembly of the common rail engine
shall be replaced if any of its components needs
to be replaced. For other countries, the following
procedure may be applied for replacing the noz-
zle tip.
REMOVAL
1. Fix tool A3 in vice .
5 Do not pinch the injector directly in the vice.
2. Set injector assembly (3) on tool A3.
3. Loosen retaining nut (4) with 19 mm deep socket
.

12. 30-20 D65EX, PX-12
?
4. Remove retaining nut (4) from injector assembly
(3).
5. Lift nozzle assembly (5) perpendicularly upward
to remove it.
5 Do not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
5 Be careful not to get the assembly dirty.
?

13. D65EX, PX-12 30-21
?
INSTALLATION
1. Fix tool A3 in vice .
5 Do not pinch the injector directly in the vice.
2. Set injector assembly (1) on tool A3.
3. Completely clean the lower body and screw sec-
tions of retaining nut (2) with parts cleaner, and
apply air blow.
4. Mount new nozzle assembly (3) so that the as-
sembly fits the knock pin of tip guide (4).
5 Be careful not to drop the tip.
5. Mount nozzle assembly (3) and manually tighten
retaining nut (2).

14. 30-22 D65EX, PX-12
?
6. Set 19-mm deep socket (2) in the torque wrench,
then tighten the retaining nut by following the
steps below.
5 Apply rust prevention oil on the nozzlebody.
1) Tighten with torque of 88.3 Nm {9.0 kgm}.
2) Attach identification mark (6) to retaining nut
(2) and lower body (5).
3) Tighten at an angle of 45° (angle tightening).
?

15. D65EX, PX-12 30-23
?
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL
½ Stop the machine on level ground and lower the
blade to the ground.
NDisconnect the (-) terminal of the battery.
1. Drain coolant.
2. Hood assembly and cover
1) Open the engine side cover and loosen the
clamp of hose (1).
2) Remove the mounting bolts, then lift hood
assembly (2) to remove it.
5 Lift the assembly while making sure that
no sections are interfering with each oth-
er.
3) Remove covers (3) and (3a) on both sides.
3. Air cleaner assembly
1) Loosen the clamp on the turbocharger side
of air intake hose (4).
2) Remove dust indicator hose (5).
3) Remove clamp (6) and air cleaner assembly
(7).
4) Remove air cleaner bracket (8).
q 1
q 2
q 3

16. 30-24 D65EX, PX-12
?
4. Muffler assembly
1) Remove drain tube.
2) Remove heat insulation panels (10), (11),
and (12).
3) Remove the turbocharger connecting bolts.
4) Remove the mounting bolts and nuts and lift
off muffler assembly (13).
5. Remove turbocharger lubrication tube (14).
6. Remove air intake connector (15).
7. Turbocharger and exhaust manifold assembly
1) Remove drain tube (16).
2) Sling turbocharger assembly (17) temporari-
ly, then remove the exhaust manifold mount-
ing bolts and turbocharger assembly.
Turbocharger and exhaust manifold
assembly: 45 kg
6 4
6 5
6 6
6 7

17. D65EX, PX-12 30-25
8. Wiring
1) Disconnect connector (18) (E54).
2) Disconnect heater relay terminals (19) and
(20).
3) Disconnect injector connectors (21) (E31 - E36).
4) Remove the 8 clamps and disconnect wiring
harness (22) from the engine.
9. Corrosion resistor
1) Remove the 3 clamps.
2) Remove corrosion resistor (23) and bracket
(24) together and place them by the engine.
10. Fuel filter
1) Remove the 2 clamps and remove fuel tubes
(25) and (26).
2) Remove fuel filter (27).
11. Oil filter
1) Remove the clamp and tubes (28) and (29).
2) Remove oil filter (30).
6 8
6 9

18. 30-26 D65EX, PX-12
12. Air intake manifold assembly
1) Remove aftercooler tubes (31) and (32).
2) Disconnect boost pressure sensor hose (33)
from the joint bolt.
3) Sling air intake manifold assembly (34) tem-
porarily, then remove the 24 mounting bolts
and the air intake manifold assembly.
5 Remove the gasket so that the intake air
heater will be on the cylinder head side.
13. High-pressure pipe
1) Remove the front cover of the rail and clamp
(40).
2) Remove covers (42) and (43) and high-pres-
sure pipe (44), depending on the cylinder
head to be removed.
6 10
6 11

19. D65EX, PX-12 30-27
14. Spill tube and water tube
Remove spill tube (45) and water tube (46).
Head cover
Remove head cover (47).
15. Nozzle holder
1) Remove harness (48) from the injector.
2) Remove mounting bolt (49) of the nozzle
holder, and remove injector (50) along with
the holder.
16. Rocker arm and rocker shaft assembly
1) Loosen locknut (51), and loosen adjustment
screw (52) two to three rounds.
2) Remove the mounting bolt, and remove
rocker arm and rocker shaft assembly (53).
5 To remove crosshead (56), loosen lock-
nut (54) and adjustment screw (55) two
to three rounds if the crosshead needs to
be replaced. (The cylinder head assem-
bly can be removed with the crosshead
mounted.)
17. Rocker housing
Remove six mounting bolts (57) to remove rock-
er housing (58).
18. Cylinder head assembly
Remove six mounting bolts (59) along with the
auxiliary bolts to remove cylinder head assembly
(60).
6 12
6 13
6 14
6 15
6 16
6 17
6 18
6 19

20. 30-28 D65EX, PX-12
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
Clamp: 8.3 - 9.3 Nm {0.85 - 0.95 kgm}
Joint bolt: 9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Mounting clamp:
9.8 - 11.8 Nm {1.0 - 1.2 kgm}
Turbocharger lubrication tube (on cylin-
der block side):
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
Intake air connector clamp:
6.8 ±±±± 0.49 Nm {69 ±±±± 5 kgcm}
5 The clamp must not project from the top of
the hose.
Mounting bolt of turbocharger lubrica-
tion tube on cylinder block side:
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
5 First tighten exhaust manifold mounting bolts in
the order shown below, and then tighten the oth-
er bolts, starting with the ones in the center and
proceeding to the outer ones.
Exhaust manifold:
58.8 - 73.5 Nm {6 - 7.5 kgm}
Fuel tube mounting bolt:
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
5 To mount the oil filter, follow the steps below.
1) Temporarily tighten filter bracket mounting
bolt (a).
2) Temporarily tighten oil tube mounting bolts
(b) and (c).
3) Tighten bolts (c), (b) and (a), in this order.
5 Tighten the air intake manifold mounting bolts
evenly outward from the center one to the outer
ones.
6 1
6 2
6 3
6 4
6 5
6 6
6 7
6 8
6 9
6 10

21. D65EX, PX-12 30-29
5 For the procedure for installing high-pressure
pipes, see the Removal and Installation of Noz-
zle Holder Assembly section.
Spill tube (45) (at both ends):
24.5 - 34.2 Nm {2.5 - 3.5 kgm}
Water tube (46):
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Head cover:
8.8 - 10.8 Nm {0.9 - 1.1 kgm}
Harness mounting nut:
8.8 - 10.8 Nm {0.9 - 1.1 kgm}
5 For the procedure for mounting the injector and
the nozzle holder, see the Removal and instal-
lation of Nozzle Holder Assembly section.
Rocker shaft mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
5 For the procedure for adjusting the valve clear-
ance, see the Adjusting Valve Clearance sec-
tion in the checking and adjusting manual.
5 To mount the crosshead, follow the steps below.
1) Mount the crosshead on the valve stem with
locknut (54) and adjustment screw (55) loos-
ened.
5 Loosen the adjustment screw (55) until it
is off the valve stem.
2) Lightly hold the face of crosshead (56) con-
tacting the rocker arm to keep it contacting
valve stem (a) on the push rod side.
3) Tighten adjustment screw (55) until it con-
tacts the valve stem.
4) Tighten locknut (54) while retaining adjust-
ment screw (55).
Locknut: 58.8 - 73.5 Nm {6 - 7.5 kgm}
6 11
6 12
6 13
6 14
6 15
6 16
6 17

22. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

23. 30-30 D65EX, PX-12
Rocker housing mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
5 Tighten cylinder head bolts (59) in the order
shown in the figure below.
Thread section and seat surface of
bolts: Engine oil (EO-CD)
1st round: 88.3 - 108 Nm {9 - 11 kgm}
2nd round: 157 - 167 Nm {16 - 17 kgm}
3rd round: Tighten by 90° ± 30° with tool A2.
To tighten without tool A2, apply
markings on the bolts and the cylin-
der head with paint for angle refer-
ence, and tighten to the angle
specified above by using a protractor.
6 18
6 19

24. D65EX, PX-12 30-31
REMOVAL OF FUEL TANK ASSEMBLY
NDisconnect the cable from the negative (-) ter-
minal of the battery.
1. Remove seal installed to operator’s compart-
ment frame.
2. Remove cover, then disconnect fuel return hos-
es (1) and (2).
5 If the fuel tank is full, fuel will flow out when
the hoses are disconnected, so drain the fuel
to a point where the fuel will not flow out.
3. Open battery cover and remove wiring connec-
tor (3) (CN4).
4. Disconnect wiring, then remove rear lamp (4).
5. Remove cover at rear of machine.
6. Close fuel supply valve, then disconnect hose
(5).
7. Remove bracket (6). 6 1

25. 30-32 D65EX, PX-12
8. Remove cover at fender side, then remove left
and right fuel tank mounting bolts (7).
9. Set lifting tool to rear lamp mounting bracket,
then lift fuel tank assembly (8), and move to rear
to remove.
Fuel tank assembly: Approx. 400 kg
(when fuel tank is full)
INSTALLATION OF FUEL
TANK ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
Bracket mounting bolt: 110 ±±±± 12.3 Nm
{11.25 ±±±± 1.25 kgm}
5 Make the clearance between the fuel tank
and left and right covers uniform, and tighten
the mounting bolts.
6 2
6 1
6 2