DISASSEMBLY AND ASSEMBLY FUEL TANK

INSTALLATION OF FUEL TANK

ASSEMBLY
• Carry out installation in the reverse order to
removal.

1
Spill hose clamp:
3.3 ± 0.49 Nm {34 ± 5 kgcm}
Fuel return hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
2
Fuel supply hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
3
Fuel tank mounting bolt:
235 ± 285 Nm {23.5 ± 29.5 kgm}

fl Tighten the mounting bolts so that the clear-

ance between the fuel tank and both covers
will be even on both sides.

D61EX, PX-12 30-25

DISASSEMBLY AND ASSEMBLY DAMPER

REMOVAL OF DAMPER
ASSEMBLY

1. Remove power train and lubricating oil pump

assembly. For details, see Removal of power
train and lubricating oil pump assembly.
2. Remove underside cover of universal joint.
3. Remove suction pipe (1) for power train and
lubricating oil pump.
4. Remove universal joint (2).

5. Remove coupling (3).

6. Remove drain plug (4) to drain oil from damper
case.
6 Damper case: Approx. 1.3 ¬

7. Remove damper cover assembly according to

following procedure.
1) Sling damper cover assembly (5) temporar-
ily. Install guide bolt 1 and pull out damper
cover by using forcing screws 2.
fl Pull out the damper cover until the
spigot joint portion of damper assem-
bly (5) comes out of the flywheel hous-
ing (about 90 mm).
2) Remove forcing screws 2 and lift off
damper cover assembly (5) from underside
of machine body.

8. Remove damper (7).

9. Remove bearing (8) from flywheel.

30-26 D61EX, PX-12

DISASSEMBLY AND ASSEMBLY DAMPER

10. Disassemble damper cover according to the fol-

lowing procedure.
1) Remove snap ring (10) from damper cover
(9).
2) Turn over damper cover, and set on block,
then knock out shaft assembly (11) with plas-
tic hammer 3.

3) Remove oil seal (12) from damper cover.

4) Remove snap rings (14) and (15) from shaft
(13).

5) Using push tool 4, pull out bearing (16)

from shaft (13) with press.

D61EX, PX-12 30-27

DISASSEMBLY AND ASSEMBLY DAMPER

INSTALLATION OF DAMPER
ASSEMBLY

1. Assemble damper cover according to the fol-

lowing procedure.
1) Install snap ring (15) to shaft (13).
2) Using push tool 4, press fit bearing (16)
with press.

3) Install snap ring (14) to shaft (13).

fl Check that the snap ring is fitted se-
curely in the groove of the shaft.
4) Set damper cover (9) on block, and knock in
shaft assembly (11) with plastic hammer 3.

5) Install snap ring (10) to damper cover (9).

fl Check that the snap ring is fitted se-
curely in the groove.
6) Turn over damper cover, and install oil seal
(12).
8 Oil seal fitting surface:
Gasket sealant LG-5
fl Apply gasket sealant thinly to the inside
of the cover hole and fit oil seal.
fl Do not stick gasket sealant to the lip of
the oil seal.
8 Lip of oil seal: Grease (G2-LI)

2. Install bearing (8) to flywheel.

8 Apply grease (G2-LI) to the inside and
outside surfaces and balls of the bear-
ing. Do not apply it to the drilled hole of
the shaft, however.

30-28 D61EX, PX-12

DISASSEMBLY AND ASSEMBLY DAMPER

3. Install damper (7).

3 Mounting bolt:
57 – 73.5 Nm {6 – 7.5 kgm}

4. Install damper cover assembly according to the

following procedure.
1) Sling damper cover assembly (5) and install
it to flywheel housing.
fl Position the damper cover with guide
bolt 1, and push it in.
8 Fitting surface: Gasket sealant (LG-4)
8 Threads of mounting bolt marked
with ª (1 place):
Gasket sealant (LG-4)

2) Install coupling (3).

3) Tighten drain plug (4) and remove oil filler
plug (17) and level plug (18), then supply
oil to the damper case.
5 Damper case: Approx. 1.3 ¬ (E030-CD)
3 Plugs (4), (17), and (18):
58.8 – 78.5 Nm {6 – 8 kgm}

5. Install universal joint (2).

8 Mounting bolt of universal joint:
Liquid adhesive (LT-2)

6. Install power train and lubricating oil pump as-

sembly. For details, see Installation of power
train and lubricating oil pump assembly.

D61EX, PX-12 30-29

DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER AND TRANSMISSION

REMOVAL OF PTO, TORQUE

CONVERTER AND
TRANSMISSION ASSEMBLY

1. Drain hydraulic oil.

6 Hydraulic tank: 48 ¬
2. Drain oil from HSS.
6 HSS case: 69 ¬
(Including oil in transmission case)
3. Remove floor frame assembly. For details, see
REMOVAL OF FLOOR FRAME ASSEMBLY.
4. Remove fuel tank assembly. For details, see RE-
MOVAL OF FUEL TANK ASSEMBLY.
5. Remove work equipment and HSS control valve
assembly. For details, see REMOVAL OF WORK
EQUIPMENT AND HSS CONTROL VALVE AS-
SEMBLY.
6. Disconnect grease hose (1) from dashboard
bracket.
7. Remove dashboard bracket (2).
8. Disconnect following pipes, cables, and filters.
1) HSS and work equipment pipes (3 pieces)
fl The discharge hose (To work equipment
and main control valve) was removed
when the main control valve assembly
was removed.
• (3): Pump discharge hose
(To HSS motor)
• (4): LS pressure input hose
(From main control valve)
• (5): Suction pipe (From hydraulic tank)

2) Power train and lubricating oil pump pipes

(3 pieces)
• (6): Pump discharge hose
(To HSS lubrication system)
• (7): Pump discharge hose
(To power train filter)
• (8): Suction pipe (From hydraulic tank)

3) PPC pump pipes (4 pieces)

fl The discharge hose (To PPC valve) was
removed when the main control valve
assembly was removed.
• (9): Pump discharge hose
(To hydraulic oil cooler)
• (10): Hydraulic oil cooler return hose
(From hydraulic oil cooler)
• (11): Tank return hose (To hydraulic tank)
• (12): Oil pressure pickup hose
(To centralized oil pressure pickup)

30-30 D61EX, PX-12

DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER AND TRANSMISSION

4) Pipes on left side of transmission (4 pieces)

• (13): Power train oil cooler hose
(To power train oil cooler)
• (14): Power train oil cooler return hose
(From power train oil cooler)
• (15): Oil pressure pickup hose
(To centralized oil pressure pickup)

5) Pipes and cables on upper side and rear

side of transmission (4 pieces)
• (16): HSS lubrication hose (From pipe
on upper side of transmission)
• (17): Brake hose
• (18): HSS lubrication hose
(From scavenging pump)
• (19): Oil pressure pickup hose
(To centralized oil pressure pickup)
• (20): Transmission F/N/R cable 1
fl Before disconnecting this cable, meas-
ure its installed length.
• (21): transmission gear shift cable 2
fl Before disconnecting this cable, meas-
ure its installed length.

6) Pipes of block at right top of transmission

(3 pieces)
• (22): Hydraulic oil return hose (From
HSS and work equipment pumps)
• (23): Hydraulic oil return hose
(From PPC valve)
• (24): Hydraulic oil return hose
(To hydraulic tank)

7) Pipes on upper side of HSS (2 pieces)

• (25): Hydraulic oil return hose
(To block at right top of transmission)
• (26): Oil pressure pickup hose
(To centralized oil pressure pickup)

D61EX, PX-12 30-31

DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER AND TRANSMISSION

8) Pipes and 2 filters on hydraulic tank side

• (27): Hydraulic tank return hose
(From block hose (24) on right top
of transmission)
• (28): Oil level gauge pipe
• (29): Power train oil filter hose
(To pipe on top of transmission)
• (30): Power train oil filter hose
(From power train and lubricating
oil pump hose (7))
• (31): Hydraulic oil filter
• (32): Power train oil filter
• (33): Pump suction pipe
(To HSS and work equipment pump)

9. Remove power train and lubricating oil pump

assembly (34). 3

10. Lift off HSS and work equipment pump assem-

bly (35). 4
4 HSS and work equipment pump assembly:
80 kg

11. Remove universal joint assembly (36). 5

30-32 D61EX, PX-12

DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER AND TRANSMISSION

12. Lift off HSS motor assembly (37).

4 HSS motor assembly: 50 kg

13. Using hanging bolt 1, lift off HSS top cover

(38). 6
4 HSS top cover: 150 kg

14. Sling transmission assembly temporarily and

remove mounting bolts between transmission
and HSS.
15. Move PTO, torque converter, and transmission
assembly (39) slowly toward the front side of
the machine body to remove it.
4 PTO, torque converter, and transmission
assembly: 830 kg
fl Move the assembly toward the front side of
the machine body until the bevel pinion
comes off the HSS.
fl Take care not to damage the wiring and
piping.

D61EX, PX-12 30-33

DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER AND TRANSMISSION

INSTALLATION OF PTO,
TORQUE CONVERTER AND
TRANSMISSION ASSEMBLY
• Carry out installation in the reverse order to
removal.

12
fl Adjust the forward/reverse cable and gear
shift cable. For details, see TESTING AND
ADJUSTING, Adjusting forward/reverse le-
ver, gear shift lever, and parking brake le-
ver linkage.

34
fl When installing the pump, check that the O-
ring is omitted or caught in the pump.

5
8 Mounting bolt of universal joint:
Liquid adhesive (LT-2)

6
8 Fitting surface of HSS top cover:
Gasket sealant (LG-4)
fl The fitting surfaces of the cases and covers
must be free from bruise, rust, oil, grease,
and water.
fl Apply gasket sealant all over the fitting sur-
faces of the cases and covers.
Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
fl The following mounting bolts of 5 lengths are
used. Check their locations with the figure.
Bolt 1: 45 mm
Bolt 2: 60 mm
Bolt 3: 75 mm
Bolt 4: 90 mm
Bolt 5: 100 mm

• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank: 48 ¬ (EO10-CD)

• Refilling with oil (Transmission, HSS)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 HSS case: 69 ¬
(Including oil in transmission case) (EO30-CD)

30-34 D61EX, PX-12