Download KOMATSU D65EX-12 Operation & Maintenance Manual –

Replacing the pressure plate on a Komatsu D65EX-12 dozer involves several detailed steps that require careful attention to safety and proper procedure. click here for more details on the download manual…..

Below is a comprehensive guide to help you understand the components involved and the steps needed to complete the replacement.

### Components Involved

1. **Pressure Plate**: This component holds the clutch disc against the flywheel, transmitting power from the engine to the transmission.
2. **Clutch Disc**: Sits between the pressure plate and flywheel, allowing for smooth engagement and disengagement of the engine power.
3. **Flywheel**: Attached to the engine, the flywheel provides a surface for the clutch disc to engage.
4. **Release Bearing**: Assists in disengaging the clutch when the operator presses the clutch pedal.
5. **Clutch Fork**: Transfers the motion from the clutch pedal to the release bearing.
6. **Bolts and Fasteners**: Secure the pressure plate to the flywheel and the clutch assembly.
7. **Alignment Tool**: A tool used to keep the clutch disc centered during installation.

### Tools Required

– Socket set (metric)
– Torque wrench
– Screwdrivers
– Clutch alignment tool
– Pry bar
– Jack and jack stands
– Safety equipment (gloves, goggles, etc.)
– Service manual for specific torque specifications

### steps for Pressure Plate Replacement

#### 1. Preparation and Safety
– **Safety First**: Ensure the dozer is parked on a flat surface, and engage the parking brake. Use wheel chocks to prevent movement.
– **Disconnect Battery**: Remove the negative terminal of the battery to prevent any electrical accidents.

#### 2. Accessing the Clutch Assembly
– **Remove the Transmission access Cover**: Depending on the model, you may need to remove a cover to access the clutch assembly. This may involve removing nuts/bolts using a socket set.
– **Disconnect any Obstructions**: Remove any components that block access to the clutch, such as hydraulic lines or other engine components.

#### 3. Removing the Old Pressure Plate
– **Mark the Position**: Before removing, mark the position of the pressure plate and flywheel for easier alignment during reinstallation.
– **Unbolt the Pressure Plate**: Using the socket set, remove the bolts securing the pressure plate to the flywheel. Keep track of these bolts as they will be reused.
– **Remove the Clutch Disc**: Once the pressure plate is unbolted, carefully slide it off along with the clutch disc. Take note of how the disc is oriented for reinstalling.
– **Inspect the Flywheel**: Check the flywheel for any signs of wear or damage. If necessary, it may need resurfacing or replacement.

#### 4. Installing the New Pressure Plate
– **Position the Clutch Disc**: Use the alignment tool to center the new clutch disc on the flywheel. This is critical for proper engagement.
– **Install the New Pressure Plate**: Align the pressure plate with the marks made earlier. Carefully slide it over the clutch disc.
– **Secure the Pressure Plate**: download KOMATSU D65EX 12 Operation workshop manual Hand-tighten the bolts initially, then use a torque wrench to secure them to the specifications provided in the service manual. Ensure the pressure plate is evenly tightened to avoid warping.

#### 5. Reassembling the Components
– **Reinstall the Transmission access Cover**: Secure it back in place.
– **Reconnect Any Removed Components**: Reattach any hydraulic lines or other components that were removed to access the clutch assembly.
– **Reconnect the Battery**: Reconnect the negative terminal and ensure all electrical connections are secure.

#### 6. Testing
– **Start the Dozer**: After reassembly, start the engine and let it idle.
– **Test the Clutch**: Press the clutch pedal to ensure it engages and disengages smoothly. Listen for any abnormal noises.

#### 7. Final Checks
– **Inspect for Leaks**: Check around the transmission and clutch area for any signs of fluid leaks.
– **Perform a Road Test**: If possible, take the dozer for a short drive to ensure everything functions correctly.

### Conclusion
Replacing the pressure plate on a Komatsu D65EX-12 dozer is a meticulous process that requires attention to detail and adherence to safety procedures. Always refer to the manufacturer’s service manual for specific torque specifications and other details. If you’re unsure about any step, consulting a professional mechanic is recommended.
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