Seb Du 1340106

SEBMU1340106
Shop
Manual
D!i8h ,IA,IB
D58h,l~
BULLDOZER
D58E-1 - 80888
D58E-1 A - 80888
SERIAL NUMBERS
D58E-16 - 81285 and up
D58P-1 - 80588
D58P-1 B - 81261
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
June 1998 Copyright 1998 Komatsu America International Company

oo- 1
8
CONTENTS
No. of page
01 GENERAL .............................................................................................................................01-l
10 ENGINE
11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . .. .. . .. .. . .. . . . . . .. . . . . . . . . 1 l-l
12 TESTING AND ADJUSTING . .. . . . . .. . . . . . . . . . . .. . .. . . . . .. . . . . . . . .. . . . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . .. . . 12-l
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . .. . .. . .. . .. . . . . . . . . . . . . .. . .. . . . . . . . .. . . . . . . . . . . .. . . . .. . . .. . .. . .. . . .. . . . . . . 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION . .. . . .. . . . . .. . . . . . . . .. . . . . . . . . . .. . .. . . . . . .. .. . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . .. . . . 21-1
22 TESTING AND ADJUSTING . .. . . .. .. . . . . . . . .. .. . . . . . . .. . . . .. . . . . . . . . . .. . . . .. . .. . . . . .. . . . . . . . . .. .. . .. . .. . . . . . . . . . .. . .. . . . . . . 22-l
23 DISASSEMBLY AND ASSEMBLY . . .. .._................................................................................. 23-l
24 MAINTENANCE STANDARD . . . . . . .. . . . . .. . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . .. . .. .. . . . . . . . .. . . . . . . . . . . . . . .. . . . .. .. . .. . .. . .. . . . . 24-l
30 UNDERCARRIAGE
31 STRUCTURE AND FUNCTION . . . . .. . . . . . .. .. . .. . . . . . . . . . . .. .. . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . .. . . . . . . . .. . .. . . .. .. . .. . . . .. . . . 31-1
33 DISASSEMBLY AND ASSEMBLY . . . . . . . . .. . . .. . . . . . . . . . . . . .. . .. . . . .. .. . . . . . .. . . .. . . . .. . . . . . . . . . . .. .._...__.............. 33-1
34 MAINTENANCE STANDARD .. . . .. .. . . . . .. . . . .. . . . . . . . . . . . . . .. .. .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . .. . . . .. .. . .. .. . . .. . .. . 34-l
60 HYDRAULIC SYSTEM
61 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. . . . . . . . .. . .. . . . . . . . .. . .. . . .. . . . . .. .. . . .. . .. . . . . . . . . . . .. . . . . . . . . 61-1
62 TESTING AND ADJUSTING . . .. . . . . .. . . . . . . . . . . .. . .. . . . .. . . . . . . . . .. . .. . . . . . . . .. .. . . . . . . .. . . .. . . . . . . . .. . . . . . . . . . . .. . . . .. . . . . 62-l
63 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . .. . . . . . .. . . . .. . . . . . . . . 63-l
64 MAINTENANCE STANDARD .. . . . . .. . . . . . . .. . .. . .. .. . . . . . .. . . . . . .. . . .. .. . . . . . . .. . .. . . . .. . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . .. . . 64-l
70 WORK EQUIPMENT
71 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .._...................................._................. 71-1
73 DISASSEMBLY AND ASSEMBLY . . . . . .. . . . . .. . . . . . . . . . . . . .. . .. .. .. . . .. . . . . . . .. . .. . . . .. .. .. . .. . . . . . .. . . .. . . . . . . . . . . . . . . . . 73-l
74 MAINTENANCE STANDARD . .. . . . . . . . . . . . . . . .. . .. . .. . .. . . .. .. . . . . . . . . . . . . . .. . .. . . . . . . .. . .. . . .. . . . .. . . . . .. . . . . . . . . . . . . . .. . . 74-l
80 ELECTRICAL SYSTEM
81 STRUCTURE AND FUNCTION . . . . .. . .. . .. .. . . . .. . . . . . . . . . . . .. . . .. . . . . . .. . . . . . .. . . . .. . .. . .. . . . . .. . . . ..___.................. 81-1
82 TESTING AND ADJUSTING . . . . . .. .. . . . . . .. . . . .. . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . .. . . . . .. .. . .. . . . .. . . . . .. . . ..__.__._._..._.
82-1
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The affected pages are indicated by the use of the
following marks. It is requested that necessary actions Action required
Mark Indication
must be taken to these pages according to the list
0 Page to be newly added Add
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( 1 Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

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D58E. P-l 00-2-3

8
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
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 A 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.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for weid- ing signs on them.
ing work.
9. When disassembling or assembling, support
When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
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.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve 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 opportunity.
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 the following chapters; these
chapters are further divided into the each main group of components.
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 “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one
Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples show how to read the
page number. A Safety necessary when performing
the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3
TT
or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
+ work.
~~~~?~age number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT T Places that require special at-
Tightenins I
Unit number (I. Engine) tention for the tightening
w torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for & Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. - : Drain must be drained, and quan-
Example: tity to be drained.
1o-4 12-203
10-4-I -
k Added pages -c~f~~~~~~
1O-4-2
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made: L.-.. u u u
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter l- Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN 11000 kg} vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN 12000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 II000 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN I2000 kg} load at a lifting angle
40 176.5 18.0 of 150”.
a A A
50 274.6 28.0
60 392.2 40.0
* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I I I I I I
2) Sling wire ropes from the middle portion 30 60 90 120 150
of the hook. Lifting angle (degree) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
* The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu cods Container Main applications, features
l Used to prevent rubber gaskets, rubber

LT-1A Tube
cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
20 9 F‘olyethylenc
LT-1 B 790-129-9050 tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
l Features: Resistance to heat and chemi-

F‘olyethylent cals
LT-2 0994040030 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and Hardening I Can
hardening agent:
agent) 500 g
Adhesives
P‘olyethylenc Used as sealant for machined holes.
LT-4 790-129-9040 250 g l
container
Holtz l Used as heat-resisting sealant for repair-

790-1269120 75 g Tube
MH 705 ing engine.
l Quick hardening type adhesive

Three bond P‘olyethylenc l Cure time: within 5 sec. to 3 min.
790-129-9140 1 50 g * Used mainly for adhesion of metals, rub-
1735 container
bers, plastics and woods.
v Quick hardening type adhesive

l Quick cure type (max. strength after 30 min-
Aron-alpha P‘olyethylenc
790-129-9130 2 g utes)
201 container
l Used mainly for adhesion of rubbers, plas-
tics and metals.
I
D Features: Resistance to heat, chemicals

Loctite P‘olyethylens
r9A-129-9110 50 cc m Used at joint portions subject to high tem-
648-50 container peratures.
1 Used as adhesive or sealant for gaskets

LG-1 Tube
and packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant
LG-3 790-129-9070 Can to prevent seizure.
1 kg
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'tv Container Main applications, features
l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.
I LG-4 790-129-9020 200 g Tube l
l
Also possible to use as sealant for flanges
with large clearance.
Used assealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe
LG-5 (790-129-9080 ( 1 kg j ‘;$$_ll;” 1. ;;;;s’:‘~;;;raulic piping. plugs, elbows,

Used as sealant for tapered
l Features: Silicon based, resistance to heat,

Gasket cold
sealant 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
LG-7 09920-00 150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond l Used as heat-resisting sealant for repairing

(790-129-90901 100 g ( Tube / engine.
1211
l Used as lubricant for sliding portion (to pre-

Molybde- LM-G 1 ogg40-ooo51 1 ” 9 / Can 1 vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 1 09940-00040 / 200 g I Tube 1 thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
l General purpose type
Various
l Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYGZ-4OOCA-A Various Various
SYG2-160CA
SYGA-16OCNCA
Mf$g?/ SYG2-400M 1 tEp$ /elows type1

l Used for places with heavy load
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

* In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm I mm I Nm I kgm
6 10 13.2k1.4 1.35f0.15
8 13 31+3 3.2f0.3
10 17 66+7 6.7 k0.7
12 19 113flO 11.5~1
14 22 177f19 18k2
16 24 279k30 28.5f3
18 27 382+39 39f4
20 30 549+59 56f6
22 32 745k83 76f8.5
24 36 927*103 94.5f 10.5
27 41 132Ok140 135+15
30 46 172Ok190 175f20
33 50 2210+240 225rt25
36 55 2750+290 280f30
39 60 329Ok340 335f35
Thread diameter Width

of bolt across flats
mm I mm I Nm I km
6 IO 7.85k1.95 0.8f0.2
8 13 18.6k4.9 1.9f0.5
10 14 40.2f5.9 4.1f0.6
12 27 82.35f7.85 8.4f0.8
,Sealingsurface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

* In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table below.
SAW0483
Thread diameter Width across flat Tighteni I toraue
mm mm Nm kgm
14 19 24.5f4.9 2.5kO.5
18 24 49k19.6 5+2
22 27 78.5f 19.6 8+2
24 32 137.3f29.4 14f3
30 36 176.5*29.4 18f3
33 41 196.1k49 20f5
36 46 245.2?49 25+5
42 55 294.2+49 30f5
00-l 0
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Ir In the case of split flange bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 65.7f 6.8 6.7kO.7
12 17 112f9.8 11.5+1
16 22 279f29 28.5f3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

* Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Nominal No.
mm mm Nm kgm
02 14 34.3+_4.9 3.5kO.5
03,04 20 Variesdepending on 93.1f9.8 9.5&l
05.06 24 type of connector. 142.1+ 19.6 14.5f2
10, 12 33 421.4f58.8 43+6
14 42 877.1+ 132.3 89.5f 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

* Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Nominal No.
mm mm Nm kgm
08 8 14 7.35+ 1.47 0.75f0.15
10 10 17 11.27f 1.47 1.15+0.15
12 12 19 17.64k1.96 1.8kO.2
14 14 22 22.54f1.96 2.3f 0.2
16 16 24 29.4f 4.9 3+0.5
18 18 27 39.2f 4.9 4f0.5
20 20 30 49f 4.9 5kO.5
24 24 32 68.6f9.8 7fl
30 30 32 107.8f14.7 llf 1.5
33 33 - 127.4f19.6 13f2
36 36 36 151.9k24.5 15.5f2.5
42 42 - 210.7f29.4 21.5+3
52 52 - 323.4f44.1 33f 4.5
00-l 1
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 IO IL2 1.02 I!z
0.20
8 24 + 4 2.45 + 0.41
10 43 zk6 4.38 + 0.61
12 77 + 12 7.85 zk 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 8f2 0.81 + 0.20
8 IO z!I
2 1.02 f 0.20
10 12f2 1.22 Ik0.20
12 24 zk4 2.45 f 0.41
14 36 k 5 3.67 f 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
1 / 16 3kl 0.31 f 0.10
l/8 8+2 0.81 I!I
0.20
l/4 12f2 1.22 f 0.20
318 15f2 1.53 + 0.41
112 24 f 4 2.45 f 0.41
314 36 zk5 3.67 f 0.51
1 60 + 9 6.12 f 0.92
00-12
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D. CurreyMrating
Nu,t~~t;sof Dia. T;str$mds Cros;z;tion Applicable circuit
(mm)
0.85 11 0.32 0.88 2.4
2 I 26 I 0.32 I 2.09 I 3.1
5 65 0.32 5.23 4.6 37 I Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 I 85 I 0.80 I 42.73 I 11.4 135 Starting
60 I 127 I 0.80 I 63.84 13.6 178 I Starting

100 I 217 I 0.80 109.1 I 17.6 230 I Starting
CLASSIFICATION BY COLOR AND CODE
T
Circuits
p%r- CZlassi-
\
ication
Ipri_ Code
1
mav
I
t Color
Code
2
t Color
Code
3
Color
I
w Code
4 Iiary
t Color
Code
5
t Color
Code
6
t Color
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point Q gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by IO (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 ;/ 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.276 0.315 0.354

IO 0.394 0.433 0.472 0.512 0.551 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.850 1.890 1.929
. . ..50
.. . . . . . . .1.969
. . . . .. .. . .,.. .2.008
.. . . . .. . .. .2.047
. . .. .. . . . .. . . . 2.087
. . . .. . . . . . .2.126
.......... ‘%i%[ 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-14
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
- - - - -
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
\
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-15
Literto U.S. Gallon

It = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Literto U.K. Gallon

le = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-l6
kgm to ft. lb
1 kgm = 7.233ft.lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-17
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 8
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade
Conversion ; a simple way to convert a Fahrenheit temperature reading intoa Centigradetempera-
ture reading or vice versa is to enter the accompanying tablein the center or boldfacecolumn of figures.
These figuresreferto the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8"F
“C “F “C “F “C “F “C “F
-40.4 -46 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -36 -22.0 -10.6 13 55.4 8.9 46 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 64 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -6 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 166 212.0
-20.0 4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 146 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 166 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-19
01 AL
GENER
Specification drawing. ................................ Ol- 2

Specifications .............................................. Ol- 4
Weight table ................................................ 01-12
Table of fuel, coolant and lubricants ........ 01-14
D58E, PI 01-l
0
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
D58E-1, 1A
AE081030
(Overall width)
D58E-1 B
2450 (8’)
4390 (14’5”)
2410 (7’11”) 4875 (16’) (Overall length)
c- -i
(Overall width)
AE081031
3275 (10’9”) - ’
01-2 D58E. PI
0
D58E-1 B
l Power angle and power tilt dozer (Joystick control specification)
Unit: mm
SW002465
D58E. P-l 01-2-l

8
D58P-1
I- I AE081032
(Overall width)
3510 (11’6”)
AE081033
(Overall width)
01-2-2 D58E, P-l

8
D58P-16
l Power angle and power tilt dozer (Joystick control specification)
Unit: mm
D58E, P-l 01-3

8
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D58E-1 D58P-1

I
80588 - 81423
( 12,530
14,630
Blade capacity (m3) 2.9 3.2
Min. turning radius (m) I 2.9 3.5
Gradeability (de@ 30 30
Stability (de@ 35 35
Forward 1st (km/h) 0 - 3.2 0 - 2.9
3 Forward 2nd (km/h) 0 - 5.9 0 - 5.3

ol
5 Forward 3rd (km/h) 0 - 9.8 0 - 8.6
p$ Reverse 1st (km/h) 0 - 3.9 0 - 3.5
m Reverse 2nd (km/h) 0 - 7.1 0 - 6.4
Reverse 3rd (km/h) o- 11.9 0 - 10.2
32 0.024 (0.24)
i; Bare tractor (MPa (kg/cm?) 0.048 (0.49)
>m
0) With dozer UvlPa (kg/cm*)) 0.058 (0.59) 0.027 (0.28)
Y&
ii5
5,, Bare tractor (mm) 3,795 4,120
>s 4,170
I- With dozer (mm) 4,765
:_c Bare tractor (mm) 2,340 2,920

5%
5 3 With dozer (mm) 3,745 3,510
i,c To tip of exhaust pipe (mm) 2,900 2,970

6.P
52 To top of operator’s seat (mm) 2,145 2,190
frack gauge (mm) 1,880 2,060

_ength of track on ground (mm) 2,365 3,065
Nidth of track shoe (standard) (mm) 460 860
Vlin. ground clearance
(mm) 315 410
(to bottom of undercover)
-
01-4 D58E. P-l

0
D58E-1 D58P-1
82458 and up 81424and up
10,770 12,530
12,820 14,630
2.9 3.2
2.9 3.5
30 30
35 35
0 - 3.2 0 - 2.9
0 - 5.9 0 - 5.3
0 - 9.8 0 - 8.6
0 - 3.9 0 - 3.5
0 - 7.1 0 - 6.4
0 - 11.9 0 - 10.2
0.048 (0.49) 0.024 (0.24)
0.058 (0.59) 0.027 (0.28)
3,795 4,120
4,765 4,170
2,340 2,920
3,745 3,510
2,900 2,970
2,145 2,190
1,880 2,060
2,365 3,065
460 860
315 410
D58E, PI 01-5
0
I
I
Serial No. 80888 - 82457 80588 - 81423

I
Name Komatsu 6D125-1
Type 4-cycle, water-cooled, in-line,

vertical type, direct injection
No. of cylinders - bore x stroke (mm) 6 - 125 x 150
Piston displacement (cc) 11,040 11,040
Rated horsepower (KW (HP)/rpm) 98.5 (132)/l ,900 98.5 (132)/1,900
Max. torque (Nm (kgm)/rpm) 630.5 (64.3)/1,300 630.5 (64.3)/1,300
High idling speed (rpm) 1,925 + 50 1,925 rt 50

+50
Low idling speed (rpm) 650-O 650 +50
-0
Min. fuel consumption ratio (g/KW.h(g/HP*h)) 210 (155) 210 (155)
Starting motor 24V, 7.5 KW 24V, 7.5 KW
Alternator 24V. 13A 24V, 13A
Battery 12V, 150Ah x 2 12V, 150Ah x 2
Radiator core type Q type
Damper Wet type, spring friction type
Torque converter 3-element, l-stage, l-phase
Planetary gear type, hydraulically actuated,

6 TORQFLOW transmission lubrication gear pump, force feed,
tj forward 3 speed, reverse 3 speed
t
.f Bevel gear shaft Spiral bevel gear, splash type lubrication
E
G Wet type, multiple disc clutch, spring boosted,
3 Steering clutch manually operated, interconnected with brake,
B with hydraulic booster
Wet type, band type, pedal operated, interconnected

Steering brake
with clutch, with hydraulic booster
Final drive super gear, P-stage reduction, splash type lubrication
Suspension Semi-rigid balancing beam
Carrier roller (each side) 2
Track roller (each side) 6 8
Assembly type, Assembly type,

single grouser, special swamp shoe,
Track shoe 41 on each side, 49 on each side,
pitch: 175 mm pitch: 175 mm
width: 460 mm width: 860 mm
01-6 D58E, PI
0
Komatsu 6D125-2
4-cycle, water-cooled, in-line,

vertical type, direct injection
6-125x 150
11,040 11,040
99.2 (133)/1,900 99.2 (133)/l ,900
635.4 (64.8)/1,300 635.4 (64.8)/l ,300
2,100 f 50 2,100 k 50
+50 +50
85O_o 85O_o
210 (155) 210 (155)
24V, 7.5 KW 24V, 7.5 KW
24V, 35A 24V, 35A
12V, 150Ah x 2 12V, 150Ah x 2
D type D type
Wet type, spring friction type
3-element, l-stage, l-phase
Planetary gear type, hydraulically

actuated, lubrication gear pump,
force feed, forward 3 speed, reverse 3 speed
Spiral bevel gear, splash type lubrication
Wet type, multiple disc clutch, spring boosted,

manually operated, interconnected with brake,
with hydraulic booster
Wet type, band type, pedal operated, interconnected

with clutch, with hydraulic booster
Super gear, 2%tage reduction, splash type lubrication
Semi-rigid balancing beam
6 8
I
Assembly type, Assembly type,
single grouser, special swamp shoe,
41 on each side, 49 on each side,
pitch: 175 mm pitch: 175 mm
width: 460 mm width: 860 mm
D58E, PI 01-7
0
0 Work equipment hydraulic system
0:
W Hydraulic
Hydraulic cylinders pump
Blade angle Blade pitch Blade tilt
cylinder cylinder cylinder
I I I I I
D58E-1 D58P-1
82458 and up 81424 and up

I
13.7 (140)
Gear type
(KALO80)
181
Single spool type P-spool type
Double-acting piston type
90 90
55 55
1,050 1,050
1,720 1,815
670 765
160
70
- 140
- 1,043
903
- -
- -
-
-
-
-
-
-
-
-
Internally installed control valve
D58E, PI 01-9
0
Serial No. 80888 -62457 80588 - 81423

-
Type Hydraulic type angledozer Swamp type tiltdozer
Left side : Brace type

Blade support method Brace type Right side : Hydraulic
cylinder type
F
E” Max. lifting height (from ground) (mm) 930 1,115
.-a g
g Max. lowering depth (from ground) (mm) 590 440
?
E Max. tilt (mm) 400 600
+f 0
-
2 5
a
Angle of blade (deg) k 25
Range of blade cutting angle (deg) - -
{ Blade width (mm) 3,745 3,510

.-
E Blade height (mm) 926 1,025
.& Blade cutting angle (deg) 55 55
01-10 D58E, PI
0
D58E-1 D58P-1
82458 and up 81424 and up
Hydraulic type angledozer Swamp type tiltdozer
Left side : Brace type

Brace type Right side : Hydraulic
cylinder type
930 1,115
590 440
400 600
f 25 -
I
- -
3,745 3,510
926 1,025
55 55
D58E, PI 01-11
0
GENERAL WEIGHT TABLE
WEIGHT TABLE
dh This. weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model D58E-1, IA D58E-1 B D58P-1, IB
Serial numbers 80888 and up 81285 and up 80588 and up
Engine and damper assembly 1,050 1,050 1,050

l Engine assembly 950 950 950
l Damper assembly 45 45 45
Radiator guard assembly 300

l Radiator guard 280 110 280
l Radiator assembly 140 (166) 140 (166) 140 (166)
l Lift cylinder assembly (each) 85 85 85
Fuel tank assembly 110 (115) 110 (115) 110 (115)
TORQFLOW Transmission and torque converter

assembly 676 680 680
l Torque converter and PTO assembly 160 160 160
l Transmission assembly 490 490 490
l Control valve assembly 16 20 20
Bevel pinion assembly 22 22 22
Bevel pinion shaft and steering clutch assembly 210 210 210
l Bevel pinion shaft 25 25 25
l Bevel gear 90 90 90
Final drive case (each) 75 80 80
Sprocket hub and 2nd gear assembly (each) 75 75 80
1st gear and 2nd pinion assembly (each) 50 50 50
Sprocket and teeth assembly (each) 130 130 130
Sprocket shaft (each) 60 70 70
Steering case and main frame 1,150 1,350 1,150
Track assembly (each) 950 950 1,600
* The values with ( ) are for REGULATION OF EC INCLUSION.
01-12 D58E, PI
0
GENERAL WEIGHT TABLE
Unit: kg
Machine model D58E-1, IA D58E-1 B D58P-1, IB
Serial numbers 80888 and up 81285 and up 80588 and up
Track frame assembly (each) 1,200 1,350 1,400
l Track frame (each) 420 500 550
l Recoil spring assembly (each) 85 145 85
l Idler assembly (each) 180 180 180
l Track roller assembly (single, each) 45 45 45
l Track roller assembly (double, each) 50 50 50
l Carrier roller assembly (each) 40 40 40
Engine under guard 100 I 100 I 40
Transmission under guard 80 I 80 I 60
Equalizer bar 85 I 180 I 110
Operator’s seat 45 45 45
Battery (each) 45 45 45
Hydraulic tank assembly 150 220 170
l Control valve assembly 65
Straight-tiltdozer assembly 1,650 - 1,450
l Straight blade 750 - 750
. Straight frame ..H. 160, R.H. 170 - 180
l Lift cylinder assembly (each) 85 - 85
l Tilt cylinder assembly 75 - 75
Power angle power tiltdozer - 2,400 -

l Power angle power tilt blade - 850
l U-frame - 800
. Lift cylinder assembly (each) - 55
l Angle cylinder assembly - 65
l Tilt cylinder assembly - 75 -
D58E, PI 01-13
0
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF AMBIENT TEMPERATURE CAPACITY (!J,

RESERVOIR -22 -4 14 32 50 68 86 104°F
FLUID -30 -20 -10 0 10 20 30 40°C Specified Refill
Engine oil pan 30 26
63 58
35&E-l,l-A:l: 13
158E-IB: 14 14
358P-1: 14.5 14.5
Engine
Transmission case (incl.
oil 34 34
torque converter case)
DamDer case I 1.3 1.3
Carrier roller (one each) I 0.25 0.25
Track roller (one each) 0.20 0.20
0.20 0.20
Hydraulic system 92 65
Diesel -
Fuel tank 250
fuel
Cooling system Coolant Add antifreeze 57 -

I I
% ASTM D975 No. 1

NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O”C, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table SAEl5W-40 even though an atmospheric
if fuel sulphur content is above 0.5 %. temperature goes up to 10°C more or less
in the day time.
(3) Use API classification CD as engine oil and
Change interval of oil if API classification CC, reduce the engine
Fuel sulphur content
in engine oil pan oil change interval to half.
0.5 to 1.0 % l/2 of regular interval
Above 1.0 % l/4 of regular interval
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-14 D58E, PI
0
ENGINE
11 STRUCTURE AND FUNCTION
Radiator and oil cooler .................. 11-2

Engine mount ........................ 1 l-4
Engine control ........................ 11-5
Fuel tank ........................... 11-6
D58E.P-1 1 l-l
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER

The radiator core is of the D in-line type. Air is forced Radiator is mounted on main frame using the rubbers
out when the fan rotates. to absorb shock.
The transmission oil cooler (8) is mounted in the radiator

lower tank (9) to cool the transmission oil.
Section A-A
1. Upper tank F13017002

2. Water inlet hose
3. Aeration hose
4. Fan guard
5. Water outlet hose
6. Drain valve
7. Tube
8. Transmission oil cooler
9. Lower tank
10. Radiator core
11-2 D58E.P-1
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
REVERSIBLE FAN (OPTION)
The picture below indicates the fan blades position

for forcing the air out. When changing the direction of
wind frorh forcing out to suction, press down on the
blades and turn 127 degrees.
Direction of rotation Direction of wind (Pushed)
F144CO13
1. Blade
2. Shaft
3. Hub
4. Plate
5. Lock plate
6. Snap ring
D58E.P-1 11-3
STRUCTURE AND FUNCTION ENGINE MOUNT
ENGINE MOUNT
The alignment between engine assembly (engine with
damper), and transmission assembly can be made by
adjusting the shim thickness as shown below.
-.
93.5
Detail A Detail B
View Z
I=13017003
1. Bolt
Dimension are in (mm). 2. Rubber
3. Stopper
4. Shim (Standard thickness: 1.2 mm)
11-4 D58E.P-1
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
A fuel control lever is installed on the dashboard. Decelerator pedal
Decelerator pedal is equipped on D58-1. When the dece- When arriving at the top of a slope, or when dumping
lerator pedal is depressed, the absorber prevents the fuel dirt from a cliff, the travel speed will increase suddenly
control lever from moving. when unloaded. Slow down the engine speed by de-
pressing the decelerator pedal.
High idling
Low idling
Stopper for full position
1. Fuel control lever

2. Decelerator pedal
3. Absorber
4. Fuel injection pump
F13017004
D58E.P-1 1 l-5
STRUCTURE AND FUNCTION FUEL TANK
FUEL TANK
A fuel tank is on the rear part of the machine body.
Fuel flows into the fuel tank through the strainer.
The fuel gauge can be found by removing the filler cap.
The fuel from the fuel tank flows into the injection
pump through the fuel filters.
There are the fuel supply valve and the water drain valve
on the back side of the fuel tank.
1. Strainer
2. Dip stick
3. Fuel tank
4. Drain valve
5. Fuel supply valve
6. Fuel injection pump
7. Fuel filter
F13017005
11-6 D58E.P-1
ENGINE
12 TESTING AND ADJUSTING
Standards for testing and adjusting.. ....... .12- 2

Tools for testing and adjusting .................. 12- 3
Adjustment of valve clearance.. ................. 12- 4
Measurement of compression
pressure ................................................... 12- 5
Testing and adjusting fuel
injection timing ....................................... 12- 6
Testing and adjusting fan
belt tension.. ............................................ 12-10
Measuring blow-by.. .................................... 12-12
Measuring exhaust gas color ..................... 12-13
Measuring engine oil pressure ................. .12-14
Measuring engine speed ............................. 12-14
Troubleshooting of engine system
(S mode) ................................................. 12-15
D58E, P-l 12-1

0
TESTING AND ADJUSTING STANDARDS FOR TESTING AND ADJUSTING
STANDARDS FOR TESTING AND ADJUSTING

Applicable Machine Serial No.
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
Applicable model D58E, P-l
Engine 6D125-1
Standard value for Service limit value

Item Measurement conditions Unit
new machine
I
Engine speed
At sudden acceleration Bosch Max. 3.0

Exhaust gas color
At high idling index 1.0
Max.
Valve clearance Intake valve 0.33 -

mm
(normal temperature) Exhaust valve 0.71 -
I I I
I Oil temperature: I
Min. 3.3 Min. 2.4
Compression pressure Engine oil: SAE30
(Min. 34) (Min. 24)
Engine speed:
(Water temperature:
Operating range)
Blow-by pressure mmHz0 Max. 100 Max. 200
Engine oil: SAEBO
At rated output
(Water temperature:
Operating range)
At high idling 0.3 - 0.5 0.21
(SAE30) (3.0 - 5.0) (2.1)
At low idling MPa Min.O.15 0.07
Oil pressure (SAE30) (Kdcm2) (I.51 ( 0.7)
At high idling 0.25 - 0.44 0.18
(SAEIOW) (2.5 - 4.5) (1.8)
At low idling Min 0.1 0.07
(SAEIOW) (Min 1.0) (0.71
Whole speed range 120

Oil temperature “C 80- 110
(inside oil pan) I I I
I I
0
Fuel injection timing Before top dead center (decree) 22 * 1 I 22 * 1
Deflection Between
when pressed fan pulley
Belt tension with finger and mm 7.5 5- 16
force of alternator
approx. 58.8 N pulley
(6 kg)
12-2 D58E, P-l

0

D58E-1 82458 and up
D58E-IA 82458 and up
D58E-IB 82458 and up
D58P-1 81424 and up
D58P-IB 81424 and up
Applicable model D58E, P-l
Engine
I 6D125-2
Item lleasurement conditions Service limit value
High idling 2,100 * 50

Engine speed
Low idling 850 + 50
Rated speed 1,900
At sudden acceleration 5.0

Exhaust gas color
At high idling 2.0
Intake valve 0.33 -

Valve clearance
(normal temperature) Exhaust valve 0.71 -
Oil temperature:
40 - 60°C Min. 3.5
MPa Min. 2.5
Compression pressure Engine oil: SAE30
Kg/cm*) (Min. 36) (Min. 26)
Engine speed:
200 - 250 rpm
(Water temperature:
Operating range)
Blow-by pressure nmHz0 Max. 50 Max. 100
Engine oil: SAE30
At rated output
(Water temperature:
Operating range)
At high idling
At low idling
(SAE30)
MPa
I 0.3 - 0.5
(3.0 - 5.0)
Min.O.12
0.21
(2.1)
0.07
Oil pressure (SAE30) (Kg/cm2) (1.2) (0.7)
At high idling 0.25 - 0.44 0.18
(SAEIOW) (2.5 - 4.5) (1.8)
At low idling Min 0.1 0.07
(SAEIOW) (Min 1.0) (0.7)
Whole speed range 120

Oil temperature “C 80 - 110
(inside oil pan)
0
Fuel injection timing Before top dead center (degree) 15 ? 0.75 15 + 0.75
Deflection Between
when pressed fan pulley
Belt tension with finger and 8- 12
force of alternator
;I[F 58.8 N pulley
D58E, P-l 12-2- 1

0
TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
No. Check item Tool Part number Remarks
Digital display
1 Engine speed Multi-tachometer 799-2038000
I 60 - 19,999 rpm
1.1 - 1.3
.di Specific gravity tester 795-500-looo
-5 to -50°c
4 Water, oil and intake air temperature

795-500-1300
I 0 - 200°c
5 1 Exhaust gas temperature 1o-l,OOO°C

6 1 Lubricant pressure I 0 - 20 kglcms
7 1 Fuel pressure I 0 - 50 kglcms
8 Intake and exhaust pressure Pressure measuring kit 799-203-2002 0 - 1,000 mmHg
9 Blow-by pressure 0-5OOmmHsO
10 intake resistance -l,OOO-OmmHsO
11 Compression pressure Compression gauge 795-502-l 205 1 0 - 70 kg/cm”
12 Blow-by pressure Blow-by checker 799-201-1503 1 0 - 500 mmH,O
13 Valve clearance Feeler gauge
Discoloration 0 - 70% standard color

14 Exhaust color Handy smoke checker
I I
15 Water and fuel in oil Engine oil checker
Fuel injection pressure

Commercially
16 Nozzle tester 0 - 300 kg/cm’
available
Nozzle spray condition
17
I
Quality of coolant
I Water tester and
corrosion test kit
799-202-7001 PH. nitrous acid ion density
799-202-9001 0 - 2 kglcms
799-202-2001 11- 40 mls
799-61 O-l 000 Engine with DC24V starting motor
Commercially
21 Electric circuit Circuit tester Current, voltage and resistance
available
A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, and apply parking brake.
When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap while
the water is hot. Boiling water may spurt out.
Be careful not to get caught in rotating parts.
D58E, P-l 12-3

0
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE .CLEARANCE

Special tool
Part number Part name 0’t-Y
A 795-l 25-1360 Feeler gauge 1
* Adjust the valve clearance (the clearance between the

rocker lever and the crosshead). to the following
values in the manner described below.
mm
1 Intake valve 1Exhaust valve

When the engine is cold 1 0.33 1 0.71
1. When adjusting the valve clearance on No. 3 through

No. 6 cylinders, remove air cleaner (1).
2. Remove the cylinder head cover.
3. Rotate the crankshaft in the regular direction. With
No. 1 cylinder in COMPRESSION TOP DEAD
CENTER position, align pointer (3) with the stamped
line marked “1.6” TOP on crankshaft damper (2)
while observing the movement of the intake valves
on No. 1 and No. 6 cylinders.
* When No. 1 cylinder is in TOP position, the intake
valve on No. 6 cylinder will open.
Adjust the clearance on valves marked l in the Valve
Arrangement Drawing while the No. 1 cylinder is in
TOP position, then rotate the crankshaft in the
regular direction by one revolution and adjust the Valve Arrangement Drawing
clearance on valves marked 0 while the No. 6 cylinder
is in TOP position.
To make the adjustment, insert Tool A between the
rocker lever and the crosshead, adjust the clearance
with the adjustment screw just until the tool can be
slided lightly, then tighten the lock nut.
m Lock nut: 65.7 F 6.9 Nm (6.7 ? 0.7 kgm)
The valve clearance may also be adjusted in the

BKP00211
following way: first adjust the valve clearance on
the No. 1 cylinder in TOP position, then proceed
to the adjustment on the next cylinder by rotating
the crankshaft every 120 degrees in the firing
order.
l Firing order: l-5-3-6-2-4
After tightening the lock nut, recheck the valve
clearance.
12-4 D58E. P-l
0
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE

Special tools
A Take
manifold
care not to burn yourself
or muffler and not to
on the exhaust
get caught in
revolving parts of the machine while measuring the
compression pressure.
* Measure the compression pressure when the engine is
warmed up.
(Oil temperature: 40 to 6O’C)
1. Adjust the valve clearance properly. For details, see

ADJUSTMENT OF VALVE CLEARANCE.
2. Remove spill pipe (i)and disconnect fuel injection

tube (2).
3. Remove nozzle holder assembly (3) from a cylinder

to make the measurement.
* Remove the nozzle holder assembly by prying it
with a bar and using the mounting bolt of the spill
pipe.
4. Install Tool A’ (Adapter) to the nozzle holder mount-

ing section, and tighten it to the specified torque.
m Tightening torque: 21.6 k 2.9 Nm

(2.2 f 0.3 kgm)
5. Connect Tool A to the adapter.
6. Place the fuel control iever in NO INJECTION

position, crank the engine with the starting motor,
and read out the pressure after the gauge pointer has
stabilized.
.A Note
control
that the engine will start
lever is not placed in NO INJECTION
if the fuel
position.
* To minimize the compression leakage, apply a
small amount of oil to the adapter mounting
section.
D58E, P-l 12-5

0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-1B 81285 - 82457
D58P-1 80588 - 81423
D58P-1B 81261 - 81423
* When installing a fuel injection pump on the

engine, the fuel injection timing can be checked
and adiusted in the following ways.
. “Match mark alignment method”. This can
be used when the injection pump installed
on the original engine has not yet been re-
paired.
. “Delivery valve method”. This can be used
when a repaired or replaced injection pump
is installed on the engine.
* Before testing and adjusting the injection
timing, bring the No. 1 cylinder into TOP
position. For details, see ADJUSTMENT OF
VALVE CLEARANCE.
1. Testing and adjusting by the match mark align-

ment method
1) Set the No. 1 cylinder in TOP position, ro-
tate the crankshaft 30 to 40 degrees in the
reverse direction, and slowly rotate the
crankshaft in the regular direction to align
the injection timing line stamped on crank-
shaft damper (I) with pointer (2).
2) Make sure that stamped line a on the injec-

tion pump is aligned with stamped line b on
the coupling.
* If the stamped lines are out of align-
ment, loosen nut (31, align the stamped
lines by sliding the coupling, and tighten
the nut.
m Nut: 60.8 f 1.9 Nm
16.2 f 0.2 kgm)
2. Testing and adjusting by the delivery valve

method
1) Disconnect fuel injection tube (4) of the No.
1 cylinder.
2) Remove delivery valve holder (5).
12-6 D58E, P-l

0
3) Remove spring (6) and delivery valve (7)

from the delivery valve holder (51, and reas-
semble the delivery valve holder.
4) Place the fuel control lever in HIGH IDLING

position, slowly rotate the crankshaft in the
regular direction while operating the prim-
ing pump, and determine the position where
the outflow of fuel is stopped from the de-
livery valve holder.
5) In the position where the outflow of fuel

stops, confirm that the injection timing line
stamped on the crankshaft damper is aligned
with the pointer.
t If the injection timing line passed through
the pointer, it means that the injection
timing is late.
* If the injection timing line did not reach
the pointer, it means that the injection
timing is advanced.
3. If the check shows that the injection timing is

out of adjustment, adjust the fuel injection tim-
ing in the following manner:
I) Set the No. 1 cylinder in TOP position and

rotate the crankshaft 30 to 40 degrees in the
reverse direction.
2) Slowly rotate the crankshaft in the regular
direction and align the injection timing line
on the damper with the pointer.
3) Loosen nut (3) on the injection pump mount-
ing flange slot, rotate the flange on the pump
side little by little while operating the prim-
ing pump, and stop the rotation when the
outflow of fuel from the delivery valve holder
stops.
4) Tighten the nut on the injection pump
mounting flange slot.
* Check the injection timing again to con-

firm that the timing is properly adjusted.
D58E, P-l 12-7

0

D58E-1 82458 and up
D58P-1 81424 and up
Special tool
Part number Part Name O’ty
P 795-471-1200 Gauge assembly 1
1) Disconnect spill tube (I) and delivery tube (2) of

the No. 1 piston, then remove No. 1 nozzle
holder assembly (3).
2) Align No. 1 cylinder with the compression top
dead center line (1:6).
When doing this, check that the fuel injection
timing line on the fuel injection pump is near
the line on the fuel injection pump body.
3) Set dial gauge P to the nozzle holder hole where
the nozzle holder assembly has been removed.
(See the diagram.)
4) Set the scale on dial gauge P to “0” when the
piston is at the top dead center.
* Rotate the crankshaft in the normal direc-
tion and in the reverse direction in turn to
align the top dead center.
* Record the value indicated by the short in-
dicator on dial gauge P.
5) Rotate the crankshaft approx. 45” in the reverse
direction from the No. 1 cylinder TOP position.
6) Rotate the crankshaft again slowly in the normal
direction and set to specified dimension c.
* Specified dimension c: 3.8 + 0.2 mm
(injection timing: 16 k 0.5” before top dead
center)
* Always rotate the crankshaft in the normal
BLPOO439
direction to align the position.
7) Check that fuel injection timing line a on the fuel
injection pump is aligned with line b on the
coupling.
BLPOOO17
12-8 D58E, P-l

0
8) If the lines are not aligned, loosen bolt (4) in

the oblong hole, move the coupling to align the
lines, then tighten the bolt.
D58E, P-l 12-9

0
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Testing fan felt tension

Check that the fan belt deflects by the specified
amount when pushed with a force of approx.
58.8 N (6 kg) at a point midway between the fan
pulley and the alternator pulley.
2. Adjusting fan belt tension

If the deflection of the fan belt is not within the
specified range, adjust as follows:
I) Loosen mounting bolt, nut (I) and adjust-
ment plate (2).
2) Using a bar or pipe, raise alternator and

adjust tension of belt (3).
* Tension of belt: 7.5 mm
3) Tighten mounting bolt and nut (I), then
tighten mounting bolt of adjustment plate
(2) to secure alternator assembly.
12-10 D58E, P-l

0
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

D58E-1 82458 and up
D58P-1 81424 and up
1. Testing belt tension

Measure the deflection of the belt when it is
pushed with a finger force (approx. 58.8 N (6
kg)) at a point midway between the fan pulley
and the alternator pulley.
Ir Deflection of V-belt: approx. 6 - 10 mm
2. Adjusting belt
1) Loosen alternator mount bolt, mounting bolt
(2) of the adjustment screw, and mounting
bolt (3) of the adjustment plate.
2) Loosen locknut (4), then turn adjustment nut
(5) to adjust the tension of the belt.
3) After adjusting the belt tension to the stand-
ard value with adjustment nut (51, tighten
locknut (41, then tighten mounting bolt (2)
of the adjustment screw, mounting bolt (3)
of the adjustment plate, and nut (I) of the
alternator mount bolt. I 11 BED00110
D58E, P-l 12-11

0
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
Special tool
I Part number I Part Name I Q’ty
E4 799-201-I 450 Adapter 1
* Raise the coolant temperature to the operating REDO01

range before measuring.
1. Install tools E4 and El to the tip of engine
breather hose (I), then connect tools E3 and E2.
2. Run the engine at rated output, and measure
the blow-by pressure.
A When measuring, be careful not

any hot parts or rotating parts.
to touch
* The blow-by should be measured with the

engine running at rated output.
. When measuring in the field, a similar value
can be obtained at stall speed.
. In this case, the blow-by value will be about
80% of the value at rated output.
* Blow-by varies greatly according to the
condition of the engine. Therefore, if the
blow-by value is considered abnormal, check
for problems connected with defective blow-
by, such as excessive oil consumption, de-
fective exhaust gas color, and prema-
turely dirty or deteriorated oil.
BED00117
12-12 D58E, P-l

0
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR
Special tool
l When measuring in the field where there is no

air or electric power supply, use Gl; when re-
cording formal data, use G2.
* Raise the coolant temperature to the operating

g Be careful not to touch any hot parts when re-

moving or installing the measuring tools.
Measuring with Gl.

1) Install filter paper to tool Gl.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine sud-
denly, and operate the handle of tool Gl at
the same time to collect the exhaust gas on
the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
Measuring with G2
1) Insert probe 0 into the outlet port of exhaust
pipe (I), and tighten the clip to secure it to
the exhaust pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to the
tool.
* Keep the pressure of the air supply be-
low 15 kg/cm*.
3) Connect the power cord to the AC socket.
Ir When connecting the cord, check that
the power switch of the tool is OFF. BED00119
4) Loosen the cap nut of the suction pump,

and fit the filter paper.
I
* Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of the tool ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of tool G2 at the same
time to collect the exhaust gas color on the
filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
BED00120
D58E, P-l 12-13

0
MEASURING ENGINE OIL PRESSURE,
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE OIL PRESSURE
Special tool
Part number Part Name O’ty
c 1 799-401-2320 1Hydraulic gauge I 1
* Raise the coolant temperature to the operating

1. Remove main gallery plug (I) (PT1/8), then in-

stall oil pressure gauge C (1 MPa (IO kg/cm*)).
2. Start the engine, and measure the oil pressure
at low idling and high idling.
MEASURING ENGINE SPEED

Special tool
Part number Part Name Q’ty
A 799-203-8001 Multi-tachometer 1
&e careful not to touch any hot parts when re-

moving or installing the measuring tools.
* Measure the engine speed under the following
conditions.
1) Coolant temperature: Within operating range
2) Power train oil temperature: 70 - 90°C
3) Hydraulic temperature: 45 - 55°C
1. Remove cap (I) from the speed pick-up and

install the adapter of tachometer A.
2. Connect the adapter and tachometer A with the
cable.
AL When measuring the engine speed, be care-

ful not to touch the rotating parts or hot
parts.
3. Start the engine and measure the engine speed
at high idling and low idling.
* When measuring items other than above (at
torque converter stall), see the measurement
procedure for each item.
12-14 D58E, P-l

0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts . . . . . . . .. .. . . . . . .. . . . . .. .. . . . .. . .. . . . . . . .. . . . . . . . . . . .. . . . . . . .. .. . . . . . . . . . . . .. . .. . . . . . .. . . . . . . .. 12-16

s- 1 Starting performance is poor (starting always takes time) .................................................... 12-20
s- 2 Engine does not start ................................................................................................................. 12-21
0 Engine does not turn ............................................................................................................ 12-21
@ Engine turns but no exhaust smoke comes out (fuel is not being injected). ............... 12-22
@ Exhaust smoke comes out but engine does not start (fuel is being injected) .............. 12-23
s- 3 Engine does not pick up smoothly (follow-up is poor) .......................................................... 12-24
s- 4 Engine stops during operations ................................................................................................ 12-25
s- 5 Engine does not rotate smoothly (hunting) ............................................................................. 12-26
S- 6 Engine lacks output (no power). ................................................................................................ 12-27
s- 7 Exhaust smoke is black (incomplete combustion) .................................................................. 12-28
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ..................................................... 12-29
s- 9 Oil becomes contaminated quickly ........................................................................................... 12-30
S-IO Fuel consumption is excessive .................................................................................................. 12-31
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down.. .......................... 12-32
s-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................... 12-33
s-13 Oil level rises (water, fuel in oil) ............................................................................................... 12-34
S-l 4 Water temperature becomes too high (overheating) .............................................................. 12-35
s-15 Abnormal noise is made ............................................................................................................ 12-36
S-16 Vibration is excessive ................................................................................................................. 12-37
D58E, P-l 12-15

0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used’ to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @I in the chart on the right corre-
spond to the items where answers can be ob-
tained from the user. The items in @I are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
12-16 D58E, P-l

0
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items1 in
turn, taking note of the 0 or Q marks in the chart for
the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable 0 or 0 marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
%I. For (Confirm recent repair history) in the

[Questions] Section, ask the user, and mark
the Cause column with a to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
-X2. Use the n in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
D58E, P-l 12-17

0
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have a causal relationship with this problem: [Exhaust gas gradually became black], [Power
gradually became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with 5
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
s-7 Exhaust gas is black

(incomplete combustion)
Gel neral causes why exhaust gas is black.
Insufficient intake of air.
Improper condition of fuel injection.
Excessive injection of fuel.
12-18 D58E, P-l

0
Clarify the relationship between the three
section and the 5 Cause items in the vertical
6
Three symptoms
Step 2
Add up the total of Oand Omarked where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and cyl. head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculations in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
D58E, P-l 12-19

0
TROUBLESHOOTING S-l
S-l Starting performance is poor (starting always takes time)

* Check that the monitor panel does not display any abnormality in
the oovernor control svstem.
General causes why exhaust smoke comes out but engine takes
time to start
. Defective electrical system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel
(At ambient temperature of 10°C or below, use JIS No. 3 or JIS
Special No. 3)
* Battery charging rate
I I I
Ambient
‘V-L , 1.28 , 1.2
0°C . _I” 1 *_I . *
-10°C , ,.a” , I.40 , I.‘cJ , I.‘
. The specific gravity should exceed the value for the

rate of 70% in the above table.
. In cold areas the specific gravity must exceed the value for
the charging rate of 75% in the above table.
-
Y
s Mud is stuck to fuel tank cap v
2 When engine is cranked with starting motor,
v 11 Little fuel comes out even when injection pump sleeve @
nut is loosened
2) Little fuel comes out even when fuel filter air bleed
olua is loosened
”
Leakage from fuel piping

There is hunting from engine (rotation is irregular)
When fuel cap is inspected directly, it is found to be clogged 0
-X- For 60125E-2 engine. 86 8SIL w’ij

Remedy $ g 5 5 E z $ g $ ,z P c? 5 _
0) 0 P &! S 0 0) .x a S ,” b I
ccUU”U~~cccc<~U0
Legend
0 : Possible causes (judging from Questions and check items)
0,: Most probable causes (judging from Questions and check items)
a: Possible causes due to length of use (used for a long period)
0: Items to confirm the cause.
12-20 D58E, P-l
0
TROUBLESHOOTING s-2
S-2 Engine does not start

@ Engine does not turn
General causes why engine does not turn

. Internal parts of engine seized
Ir If internal parts of the engine are
seized, carry out troubleshooting for
“Engine stops during operations”.
. Failure in power train
. Defective electrical system
When starting switch is

turned to START, pinion
moves out, but
When starting switch is turned to START, pinion does not

move out 0
When starting switch is turned to ON, there is no clicking
sound 0 @
t
Battery terminal is loose @ 2
8 B
When banery is checked, battery electrolyte is found to be low
r?
Specific gravity of electrolyte, voltage of battery is low

For the following conditions I) 5). turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal Band terminal C of starting switch

are connected, engine starts
2) When terminal Band terminal C of starting motor

are connected, engine starts
p
‘G 3) When terminal B and terminal C of safety relay are
8 connected, engine starts
_c
4) There is no continuity between banery relay
z
terminal-b and terminal E
0
z When ring gear is inspected directly, tooth surface is found
< to be chipped
1Starts if universal joint is disconnected
Remedy
Legend
@: Most probable causes (judging from Questions and check items)
A: Possible causes due to length of use (used for a long period)
D58E. P-l 12-21

0
TROUBLESHOOTING s-2
@ Engine turns but no exhaust smoke

comes out
(fuel is not being injected)
General causes why engine turns but no

exhaust smoke comes out
. Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particularly
in winter)
* Fuel selection standard
AMBIENT TEI WPERATURE

KIND OF
FLUID -22 .;“o _;“o 32 50 68 86 104’F
-30 0
* In winter, if Class 3 oil is not available, you

may use mixture of Class 2 diesel fuel and
kerosene at the rate of 1 : 1.
Confirm recent repair history

Degree of use of machine Operated for long period nn n
Exhaust smoke suddenly stops coming out (when starting
again) @C30
Replacement of filters has not been carried out according to

Operation Manual 06%
I I / I I I-1 ,
lner are lnspecte
I 1When fuel cao is insoected directlv. it isfoundto be cloooed i 1 1 1 1 1 I 1ai 1

x E z Z-G Tt
Legend Remedy $ z E 5 i ;: g g %
~=ccuoaooZ
0 : Possible causes (judging from Questions and check items) _
@I: Most probable causes (judging from Questions and check items)
D58E, P-l
TROUBLESHOOTING s-2
@ Exhaust smoke comes out but engine

does not start
(Fuel is being injected)
General causes why exhaust smoke comes

out but engine does not start
. Lack of rotating force due to defective
electrical system
. Insufficient intake of air
. Improper selection of fuel and oil
When engine is cranked, abnormal noise is heard from

0
around head
Enaine oil must be added more freouentlv I 63

Non-specified fuel is being used I Dl I I I I I I lOI I 1
@9@@
Operation Manual
Rust and water are found when fuel tank is drained QQ

Dust indicator is red 0
Starting motor cranks engine slowly 0
Mud is stuck to fuel tank cao n
When fuel lever is placed at FULL position, it does not
When exhaust manifold is touched immediately

temperature of some cylinders
after
is low I I I I I I I I I IO,/
I
When fuel filter is drained, no fuel comes out I Ia
Remove head cover and check directly 0
When control rack is pushed, it is found to be heavy, or does
not return 0
When
low
compression pressure is measured, it is found to be
I I I.1I I I I I I I I
When fuel filter, strainer are inspected directly, they are . I I I I I I I-
found to be clogged I I I I I I 1.
When feed pump strainer is inspected directly, it is found to
be clogged 0
When air cleaner element is inspected directly, it is found to

be clogged 0
Either specific gravity of electrolyte or voltage of battery is

low, or both are low I I I I I I I I.1 I I I
When feed pump is operated, operation is too light or too
heavy 0
When injection nozzle is tested as individual part, spray

condition is found to be poor 0
When fuel cao is insoected directlv. it is foundto be cloaoed I l l I I Id
Legend
@ Most probable causes (judging from Questions and check items)
D58E, P-l 12-23

0
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly

(follow-up is poor) I Causes /
General causes why engine does not pick

up smoothly
. Improper intake of air
. insufficient supply of fuel
. Improper condition of fuel injection

z Operation Manual
Clanging sound is heard from around cylinder head 0

Mud is stuck to fuel tank Q
E
aJ There is leakage from fuel piping @
C
Y High idling speed under no load is normal, but speed
suddenly drops when load is applied @@ 0
8
I I II II lol
I I II 1
6 II
There is hunting from engine (rotation is irregular)
I
lolm
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Blow-by gas is excessive
When valve clearance is checked directly, it is found to be

outside standard value I I I I I I I.1 I I
When fuel cap is inspected directly, it is found to be clogged 0
heavy 0
Remedy
Legend o~oooccaccav
@I: Most probable causes (judging from Questions and check items)
12-24 D58E, P-l

0
TROUBLESHOOTING s-4
S-4 Engine stops during operations

General causes why engine stops during
operations
. Internal parts of engine seized
. Overheating
* If there is overheating and the engine
stops, carry out troubleshooting for over-
heating.
. Failure in power train
* If the engine stops because of a failure
in the power train, carry out the trouble-
shooting in the CHASSIS volume.
Condition when engine Engine overheated and stopped 1@,)O 1 1 IO 1

‘E
stopped Engine stopped _,Y..,,
L
2 There was hunting and engine QOO 1
stopped
Fuel level lamp is lighted up G3
/ placement of filters has not been carried out according to
I/

heavy I
Mud is stuck to fuel tank cap
Turns when pump auxiliary equipment is removed

! I 1
When fuel filter, strainer are inspected directly, they are
Legend
a: Possible causes due to length of use (used for a long period)
D58E, P-l 12-25

0
TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism
Degree of use of machine Operated for long period na

Occurs at a certain speed range @ @ @ 0
In Occurs at low idling 0 Q 0000
C Condition of hunting
.o Occurs even when speed is raised 0 0 0 0
occurson slopes
a Replacement of filters has not been carried out according to
063
Operation Manual

0
found to be clogged
I I I I I I / I I I I I
Legend
0: Possible causes (judging from Questions and check items)
12-26 D58E, P-l

0
TROUBLESHOOTING S-6
Causes
S-6 Engine lacks output (no power)

General causes why engine lacks output
(if non-specified fuel is used, output
drops)
. Insufficient output due to overheating
+ If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
Enoine oickuo is ooor and combustion is irreaular
When air cleaner element is inspected directly, it is found to l

be clogged
When compression pressure is measured, it is found to be 0

0
IOW

0
found to be clogged
When feed pump strainer is inspected directly, it is found to

0
be clogged

heavy
When fuel cap is inspected directly, it is found to be clogged
Legend
D58E, P-l 12-27

0
TROUBLESHOOTING s-7
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

. Excessive injection of fuel
Confirm recent repair history I I I I I I I I I

Degree of use of machine IOperatedforlongperiod lAlAlAl 1 1 1 1~1
Suddenly
Power was lost
Gradually
Non-specified fuel is being used
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular 63 I lolol Ic

E temperature of some cylinders is low
@ C
starting engine,
2 Match marks on fuel injection pump are out of alignment 8
8 Seal on injection pump has come off Q
6 Clanging sound is heard from around cylinder head @3
Exhaust noise is abnormal j 101 I I I@I I

Muffler is crushed I I I I I I I Ifal
When air cleaner is inspected directly, it is found to be clogged l

When compression pressure is measured, it is found to be
0 0
IOW
Speed does not change when operation of certain cylinders

is stopped I I I@I I I I I I
When check is made using dial gauge method, injection
timing is found to be incorrect I I I I@I I I I I
I I I I I I I I I
Injection pump test shows that injection amount is incorrect I I.1 I I I

When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal

not return
12-28 D58E, P-l

0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

* Do not run the engine at idling for more
than 20 minutes continuously. (Both low
and high idling)
General causes why oil consumption is ex-

cessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of iubrication system
,_ --
Area around engine is dirty with oil Q@,QQ@
There is oil in engine cooling water @
When exhaust pipe is removed, inside is found to be dirty

with oil
0
Oil level in clutch or damper chamber rises
-
Clamps for intake system are loose 81
When compression pressure is measured, it is found to be . .

IOW
When breather element is inspected, it is found to be

0
clogged with dirty oil
There is external leakage of oil from engine 0.0.

Pressure-tightness test of oil cooler shows there is leakage 0
Inspect rear seal directly l
When intake manifold is removed, dust is found
When intake manifold is removed, inside is found to be dirty

with oil
Legend
l : Items to confirm the cause.
D58E, P-l 12-29

0
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contami-
nated quickly
. Intake of exhaust gas due to internal
wear
l Clogging of lubrication passage
. Incomplete combustion
. Improper oil used
l Operation under excessive load
Color of exhaust gas
When safety valve is inspected directly, spring is found to be

l- o
catching or broken
8 g m z
Remedy f$ 5 $ ii : -
aoaaoa
Legend
12-30 D58E, P-l

TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is ex-
cessive
. Leakage of fuel
. Excessive injection of fuel
Condition of fuel
consumption
/
Exhaust smoke color
Black I@lOl lOI I I IO
White I I I I I 101 I
Seal on injection pump has come off Q
There is irregular combustion @

00
Match mark on injection pump is misaligned @
There is external leakage of fuel from engine 0
Engine oil level rises and smells of diesel fuel 0 @,Q

Engine low idling speed is high 0 C3
Legend
0: Possible causes (judging from Questions and check items)
D58E, P-l 12-31

0
TROUBLESHOOTING S-l 1
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
I Causes I
Hard water is being used as cooling water (tap water is not
Engine oil level has risen, oil is cloudy white

Y
ki Hydraulic, powertrain oil is cloudy white

6 When hydraulic, power train oil is drained. water is found in
I m Pressure-tightness test of oil cooler shows there is leakage l I I.1 I

i.g Pressure-tightness test of cylinder head shows there is leakage l
6 5 Remove cylinder head and inspect directly I I I.1 I I
g% Remove oil pan and inspect directly I IOIO
Legend
12-32 D58E, P-l

TROUBLESHOOTING s-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights
up
. Leakage, clogging, wear of lubricating
system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
* Standards for engine oil selection
Type of Ambient temperature

oil
ingine oi
Lights up at low idling 0 0

Condition when oil pressure Lights up at low, high idling @@@@OOO
lamp lights up Lights up on slopes 63
Legend
D58E, P-l 12-33

0
S-13 Oil level rises (water, fuel in oil)

Ir If there is oil in the cooling water, carry
out troubleshooting for “Oil is in cool-
ing water”.
General causes why oil level rises

l Water in oil (becomes cloudy white)
. Fuel in oil (diluted, and smells of diesel
fuel)
. Entry of oiil from other comoonent
I I
1
g
.g
EITh
Confirm
Degree
recent repair
of use of machine
ere is oil in radiator
history
coolina water
Operated for long period
I I I
I InI
,-,-,-,
I6Aolol
I I I
lnlnln
I II
Exhaust smoke is white Q IO 0
I/ I When engine
muffler
is first started, drops of water come from
I IIIIIIIII
Leave radiator cap open. When engine is run at idling, an
$, abnormal number of bubbles appear, or water spurts back
5 When water pump breather hole is cleaned, water comes out
0 Oil level aoes down in clutch or damoer chamber
6 Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
l
I I Pressure-tightness test of oil cooler shows there is leakage
I
I I Pressure-tightness
leakage
test of cylinder head shows there is
I Itl
I
I I I I I I I I I
When compression pressure is measured, it is found to be low 0
Remove water pump and inspect directly 0

Remove rear seal and inspect directly 0
I I g
a
When auxiliary
seal is found
equipment
to be damaged
such as pump, etc is removed,
I I I I in;- WII II II II II I
Remove head cover and inspect directly I I.1 I I I
When injection pump is removed, seal is found to be damaged 0
Defective contact at thermostat seat 0
emote oil pan and check directly 00
I I
Legend

&J: Possible causes due to length of use (used for a long period)
12-34 D58E. P-l

S-14 Water temperature becomes too high (overheating)

General causes why water temperature be-
comes too high
. Lack of cooling air (deformation, dam-
age of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
. Power train oil temperature rises
* Carry out troubleshooting for chassis.
_. _._...__....=
Always tends to overheat @3@0
tj
Rises quickly
2
cf Water temperature gauge Does not go down from red
range
I I I I I I
I I I I I I I I I I I I PI
Power train oil temperature enters red range before engine
water temperature
Temperature difference between top and bottom radiator . .

tanks is excessive Cc
63
Temperature difference between top and bottom radiator
0 2
tanks is slight
6
When function test is carried out on thermostat, it does not &
open even at cracking temperature 0
p
.-z
‘E 5
o When water temperature is measured, it is found to be
0 -2
normal
2 :
z When oil cooler is inspected directly, it is found to be clogged 0 E
0 2
2 When measurement is made with radiator cap tester, set
0 2
,I?
I-- b
pressure is found to be low
! lo 5
When compression pressure is measured, it is found to be

low
Remove oil pan and inspect directly

D58E, P-l 12-35

0
S-15 Abnormal noise is made
* Judge if the noise is an internal noise or

an external noise.
General causes why abnormal noise is made

. Abnormality due to defective parts
. Abnormal combustion
. Air sucked in from intake svstem
/ Blue under light load @
I
Color of exhaust gas
Rlark I I Inl Inl Inl I
1 Metal oarticles are found in oil filter
Blow-by gas is excessive @

Engine oickuo is poor and combustion is abnormal I I Id I I I I I I I
@O
Seal on injection pump has come off 0
Abnormal noise is loud when accelerating engine 00000 0
Clanging sound is heard from around cylinder head O@

I Vibrating noise is heard from around muffler I I I I I I I I I IQ’1
When
IOW
compression pressure is measured, it is found to be
1.1 I I I I IIIII
Remove gear cover and inspect directly 0 0
Speed does not change when operation of certain cylinders

0
is stopped

0
not return
Injection pump test shows that injection amount is incorrect 0

Fan is deformed, belt is loose 0
When valve clearance is checked, it is found to be outside

standard value
I I I I I I l@l I I I
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Legend
12-36 D58E, P-l

0
TROUBLESHOOTING S-16
S-16 Vibration is excessive
* If there is abnormal noise together with I Causes I
the vibration, carry out troubleshooting

for “Abnormal noise is made”.
General causes why vibration is excessive

. Defective parts (abnormal wear, break-
age)
. Improper alignment
l Abnormal combustion
creasea I I I I 101 I
‘olololol I I I I
e found when oil is drained I I I I I I I
Remove oil pan and inspect directly I.1 I I 1 1 1 1 I

Remove side cover and inspect directly I I.1 I I I I I I
I Inspect directly for wear, play of support pilot
! ! !.! ! ! ! ! ! I
Inspect directly for loose engine mounting
cushion
bolts, broken
I I I I.1 I I I I I
Injection pump test shows that injection amount is incorrect 0

m
d 8 8 z 8 BHg;;
Remedy % $ 5 z % k t a 2
~lzczLGdSSP2
Legend
D58E, P-l 12-37

0
ENGINE
13 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR CYLINDER HEAD

Dismounting ............................................. 13-2 Dismounting ........................................... 13- 8
Mounting .................................................. 13-2 Mounting ................................................ 13-11
Removal .................................................... 13-3 Removal ............................................... 13-14-1
Installation ................................................ 13-3 Installation .......................................... 13-14-4
ALTERNATOR THERMOSTAT
Dismounting ......................................... 13-3-1 Removal ............................................... 13-14-6
Mounting ............................................... 13-3-1 Installation .......................................... 13-14-6
Removal ................................................. 13-3-2
Installation ............................................. 13-3-2 ENGINE FRONT SEAL
Removal ............................................... 13-14-7
ENGINE OIL COOLER Installation .......................................... 13-14-7
Dismounting ............................................. 13-4
Mounting .................................................. 13-4 ENGINE REAR SEAL
Removal ............................................... 13-14-8
FUEL INJECTION PUMP Installation .......................................... 13-14-9
Dismounting ............................................. 13-6
Mounting .................................................. 13-6 RADIATOR
Removal .................................................... 13-7 Dismounting ........................................... 13-15
Installation ............................................. 13-7-1 Mounting ................................................ 13-17
WATER PUMP RADIATOR GUARD

Dismounting ......................................... 13-7-2 Dismounting ........................................... 13-19
Mounting ............................................... 13-7-2 Mounting ................................................ 13-21
Removal ................................................. 13-7-3 Removal ............................................... 13-22-1
Installation ............................................. 13-7-3 Installation .......................................... 13-22-2
NOZZLE HOLDER ENGINE

Dismounting.. ....................................... 13-7-4 Dismounting ........................................... 13-23
Mounting ............................................... 13-7-4 Mounting ................................................ 13-25
Removal ................................................. 13-7-5 Removal .................................................. 13-27
Installation ............................................. 13-7-5 Installation .............................................. 13-28
D58E, P-l 13-1

0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
DISMOUNTING STARTING MOTOR ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Disconnect the negative (-) terminal of the bat-

tery.
2. Remove the engine side covers on the RH side.
3. Remove bracket (1).
4. Discon-nect wiring (2), (31, (41, (51, and (6).
5. Dismount starting motor assembly (7).

Ir Use extension bar, 35 mm long, to remove
one of the outside mounting bolts for the
starting motor.
MOUNTING STARTING MOTOR

ASSEMBLY
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Fit a gasket and install starting motor assembly

(7).
2. Connect wiring (6), (5), (41, (31, and (2).
3. Install bracket (1).
4. Install the upper and lower engine side covers

on the RH side.
5. Connect the negative (-) terminal of the battery.
13-2 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up
A Disconnect
nal of the
the cable from the negative
battery.
(-1 termi-
1. Remove engine right side cover.
2. Disconnect 4 starting motor wires (I) and con-

nector (2).
3. Remove 3 mounting bolts, then remove start-

ing motor assembly (3).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up
l Carry out installation in the reverse order to re-

moval.
D58E, P-l 13-3

0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
DISMOUNTING ALTERNATOR ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-1B 81261 - 81423
1. Disconnect the negative (-1 terminal of the bat-

tery.
2. Remove the upper and lower engine side cov-

ers on the RH side.
3. Disconnect wiring (I) and (2).
4. Loosen mounting bolt (3) and adjustment bolt

(41, and remove V-belt (5) from the pulley.
5. Dismount alternator assembly (6).
MOUNTING ALTERNATOR
ASSEMBLY
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Temporarily install alternator assembly (6).
2. Install V-belt (5) to the pulley, stretch the V-belt

with a bar, and tighten adjustment bolt (4).
* For the belt tension, see TESTING AND AD-
JUSTING.
3. Tighten mounting bolts (3).
4. Connect wiring (2) and (I).

on the RH side.
6. Connect the negative k) terminal of the battery.
13-3-1 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
A-Disconnect the cable

minal of the battery.
from the negative (-1 ter-
2. Disconnect alternator wiring (I) and (2).
3. Loosen nut (4) of mount bolt (3) and adjust-

ment plate mounting bolt (5).
4. Loosen locknut (6), turn adjustment nut (71,

then remove 2 belts (8) from alternator assem-
i-
bly (9). m
5. Remove mount bolt (31, nut (41, and bolt (5),

then remove alternator assembly (9).
0’
CEO00954
INSTALLATION OF
ALTERNATOR ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up
. Carry out installation in the reverse order to re-

moval.
1111
* Adjust the tension of the fan belt.
For details, see TESTING AND ADJUSTING,
Adjusting fan belt tension.
D58E, P-l 13-3-2

0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
DISMOUNTING ENGINE OIL COOLER ASSEMBLY

D58E-1 80888 - 82457
D58E-1A 80888 - 82457
D58E-1 B 81285 - 82457
D58P-1 80588 - 81423
D58P-1B 81261 - 81423
1. Open drain valve (I) and drain the coolant.

* If the coolant contains anti-freeze, dispose
of it correctly.

ers on the RH side.
3. Remove clamps (2) and (3) and disconnect wires

(4) and (5).
4. Dismount engine oil cooler assembly (6).
MOUNTING ENGINE OIL

COOLER ASSEMBLY
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Fit gasket and mount engine oil cooler assem-

bly (6).
& Gasket: Liquid gasket (LG-I)
2. Connect wires (5) and (41, and install clamps (3)

and (2).

on the RH side.
4. Tighten drain valve (I) and add the coolant to

the specified level through the water filler.
+ Start the engine to let the coolant circulate
throughout the system, then recheck the
coolant level.
13-4 D58E. P-l

0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
DISMOUNTING ENGINE OIL COOLER ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
A-minal
Disconnect the cable
of the battery.
from the negative (-1 ter-
-1
1. Drain coolant.
1955
3. Remove muffler drain tube (I).
4. Disconnect starting motor wiring connector (2)

from cooler.
5. Remove mounting bolts, then remove engine

oil cooler assembly (3).
6. Remove nut (51, then remove core (7) from cover

(6).
CEP00151
MOUNTING ENGINE OIL

COOLER ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up
. Carry out installation in the reverse order to

removal.
m Cooler core mounting nut :

43.1 f 15.7 Nm (4.4 f 1.6 kgm)
. Refilling with water

Add water through water filler to the specified
level.
Run the engine to circulate the water through
the system. Then check the water level again.
D58E, P-l 13-5

0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
DISMOUNTING FUEL INJECTION PUMP ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Remove the engine side cover on the LH side.

2. Shut the fuel supply valve under the fuel tank.
3. Disconnect fuel supply hose (I).
4. Disconnect fuel hoses (2) and (3).
5. Disconnect fuel return hose (4).
6. Remove lubricating oil tubes (5) and (6).
7. Disconnect fuel control rod (7).
8. Disconnect six fuel injection tubes (8).
9. Remove two coupling mounting bolts (9).
10. Remove four fuel injection pump mounting bolts
(IO).
t With the pump leaning outside, remove one
of the inside rear mounting bolts.
11. Dismount fuel injection pump assembly (I I).
MOUNTING FUEL INJECTION

PUMP ASSEMBLY
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Install fuel injection pump assembly (11) and

tighten four mounting bolts (IO).
* Screw in one of the inside rear mounting
bolts beforehand.
2. Tighten two mounting bolts (9) for the coupling.
* Adjust the injection timing. For details, see
TESTING AND ADJUSTING.
3. Connect fuel injection tubes (8).
w Sleeve nut:
22.6 k 1.9 Nm (2.3 f 0.2 kgm)
4. Connect fuel control rod (7).

5. Fit a gasket and install lubricating oil tubes (6)
and (5).
6. Fit a gasket and install fuel return hose (4).
7. Fit gaskets and connect fuel hoses (3) and (2).
8. Fit a gasket and connect fuel supply hose (I).
9. Open the fuel supply valve under the fuel tank,
and bleed the air from the fuel system.
10. Install the engine side cover on the LH side.
13-6 D58E, P-l
0
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
1. Remove top and bottom engine left side cov-

ers.
2. Align fuel injection timing line on fuel injection

pump. CED00956
ADisconnect the cable from the negative (-)
1
terminal of the battery.
3. Close fuel supply valve.
4. Disconnect fuel control rod (I).
5. Remove fuel hoses (21, (3), (41, and (5). m
6. Remove lubrication tubes (6) and (7). m
7. Disconnect 6 delivery tubes (8). 113
7’ CED00957
8. Remove coupling bolt (9) and nut (IO).
9. Remove mounting bolt (11). a
10. Remove fuel injection pump assembly (12J.a
IO 9 t1 CED00958
D58E, P-l 13-7

0
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up

removal.
m Joint bolt :
17.2 f 2.5 Nm (1.75 k 0.25 kgm)
m Lubrication tube joint bolt

: 27.0 f 2.5 Nm (2.75 f 0.25 kgm)
(injection pump end)
: 29.4 f 4.9 Nm (3.0 + 0.5 kgm)
(cylinder block end)
m Delivery tube sleeve nut:

23.5 f 0.98 Nm (2.4 f 0.1 kgm)
m Pump mounting bolt :

22.1 + 2.5 Nm (2.25 f 0.25 kgm)
m
* Adjust the injection timing.
Adjusting fuel injection timing.
* Bleed the air from the fuel circuit.
13-7-1 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY WATER PUMP
DISMOUNTING WATER PUMP ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Open drain valve (I) and drain the coolant.

of it correctly.

ers on the RH side.
3. Disconnect pump inlet tube (2) and remove out-

let tube (3).
4. Remove three mounting bolts (4) on the timing

gear case side, and dismount water pump as-
sembly (5).
MOUNTING WATER PUMP

ASSEMBLY
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-1 B 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Fit an O-ring and install water pump assembly

(5).
2. Fit a gasket, install pump outlet tube (3), and

connect inlet tube (2).

on the RH side.
4. Shut drain valve (I) and add coolant to the speci-

fied level through the water filler.
* Start the engine to let the coolant circulate
coolant leve.
D58E, P-l 13-7-2

0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP ASSEMBLY

D58E-1 82458 and up
D58E-1A 82458 and up
D58P-1 81424 and up
1. Drain coolant.
II (II fl CED00959
3. Remove thermostat assembly.
For details, see REMOVAL OF THERMOSTAT
ASSEMBLY.
4. Remove pump inlet tube (I) and outlet tube (2).
5. Remove mounting bolts, then remove water

pump assembly (3). m
Ir There are 3 mounting bolts installed from
the radiator side.
INSTALLATION OF WATER
PUMP ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up

removal.
w Water pump mounting bolt :

66.2 + 7.4 Nm (6.75 k 0.75 kgm)

* Add water through water filler to the speci-
fied level.
Run the engine to circulate the water
through the system. Then check the water
level again.
13-7-3 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
DISMOUNTING NOZZLE HOLDER ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Remove the side covers and engine hood.
2. Remove air cleaner assembly (I) and remove

No. 3, 4, 5, and 6 nozzles.
3. Remove spill tubes (2).
4. Disconnect high pressure injection pipes (3) and

remove mounting bolts (4).
5. Install bolt @I (8 mm, P = 1.0 mm), and pry out

nozzle holder assembly (5) with bar 0.
* Remove the nozzle holder after cleaning the
upper part.
MOUNTING NOZZLE HOLDER

ASSEMBLY
D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Fit an O-ring and install nozzle holder assembly

(5).
2. Connect high pressure injection pipes (3).
3. Fit a gasket and install spill tube (2).
4. Install No. 3, 4, 5, and 6 nozzle holders, then

install air cleaner assembly (I).
5. Install the engine hood and the side covers.
D58E, P-l
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY

D58E-1 82458 and up
D58E-1B a2458 and up
D58P-1 81424 and up
D58P-18 81424 and up
1. Remove top left and right engine side covers.
2. Remove air cleaner cap, then lift off engine hood

0).
I CED00960
3. Remo\ie spiH tube (2).
4. Disconnect delivery‘ tube (4) of nozzle holder

tobe removed. m
5. Remove mounting bolts, then remove nozzle

holder assembly (3). m
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
D58E-1 82458 and up
D58E-1A 82458 and up
D58P-1 81424 and up
D58P-1B 81424 and up

removal.
w Delivery tube sleeve nut :

23.5 k 0.98 Nm (2.4 + 0.1 kgm)
& Coat the thread of the nozzle holder

mounting bolts with EO-30CD.
* Tighten the-nozzle holder mounting bolts
uniformly in turn.
m Nozzle holder mounting bolt :
21.6 + 2.9 Nm (2.2 + 0.3 kgm)
13-7-5 D58E, P-l
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
DISMOUNTING CYLINDER HEAD ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-1B 81261 - 81423
1. Draining the coolant

Remove inspection cover (I), open drain valve
(21, and drain the coolant.
of it correctly.
2. Engine side covers

Remove the engine side covers on the RH and
LH sides.
3. Engine hood
1) Remove exhaust pipe (3) and cap (4).
2) Sling engine hood (5) and remove it.
4. Oil filter assembly

Disconnect hose (61, remove oil filter assembly
(71, and put it beside the machine body.
5. Fuel filter assembly

Remove fuel filter assembly (8) and put it be-
side the machine body.
6. Heater switch
I) Disconnect wiring (9) and remove heater
switch (IO).
2) Disconnect dust indicator hose (11).
13-8 D58E, P-l

0
7. Fuel injection tubes

Disconnect six fuel injection tubes (12) from bc9th
the pump and the nozzles.
8. Intake manifold assembly

1) Remove clamp (13) for the level gauge.
2) Sling intake manifold assembly (14) antd remc we it.
9. Exhaust manifold assembly

Remove the wiring clamp, sling exhaust manifold
assembly (15). and remove it.
10. Water manifold assembly

1) Disconnect engine outlet hose (16) and aeration
hose (17).
2) Disconnect bypass tube (18).
3) Remove water manifold assembly (19).
11. Spill pipe

Remove spill pipe (20).
12. Nozzle holder assembly

Remove bolts (21), then remove nozzle holder as-
sembly (22).
* To remove the nozzle holder assembly, pry it out
with a bar with the aid of the mounting bolt for
the spill pipe.
13. Cylinder head cover

Remove cylinder head cover (23).
D58E.P-1
15. Crossheads
Remove crosshead (26).
16. Push rods

Remove push rods (27).
17. Rocker lever housing assembly

Remove rocker lever housing assembly (28).
18. Cylinder head assembly

Remove cylinder head bolts (29) and cylinder head
assembly (30).
13-10 D58E.P-1
0
MOUNTING CYLINDER HEAD ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Cylinder head assembly

1) Check that the cylinder head mounting sur-
face and the inside of cylinders are free from
dust and foreign matter, then install cylin-
der head gasket (31).
* Before installing the gasket, check that
all the grommets are properly fitted to
the gasket.
2) Install cylinder head assembly (30) and

tighten cylinder head bolts (29).
6 Before tightening the bolts, apply
some anti-friction lubricant (LM-P) to
the bolts threads and the bottom of
bolt heads.
* First screw in the mounting bolts by two

to three turns by hand, then tighten-bolts
@ through @ in the following manner:
Flrst step: Tighten the bolts to a

torque of 10 f 1 kgm.
Second step: Tighten to a torque of 14
+ 0.5 kgm.
Third step: Mark the bolt and the
cylinder head with a felt
pen, then turn the bolt
90” f 15”.
1 Tighten the bolt marked 0 to a torque

of 6.7 k 0.7 kgm.
Mark the bolt and the cylinder head with a felt pen.
13OFlOlO
2.
d I)
Rocker lever housing assembly

9 1
Fit a gasket and install rocker lever housing

go*+ 15’
13OF1009
as-
sembly (28).
3. Push rods
Install push rods (27).
D58E, P-l
4. Crossheads
Install crossheads (26).
* Adjust the crossheads in the following man-
ner:
i) Hold down the top of the crosshead
lightly with your finger, tighten the ad-
justment screw until it comes into con-
tact with the valve stem, then further
tighten the screw to an angle of 20”.
ii) While holding the adjusting screw,
tighten the lock nut.
w Lock nut: 3.8 f 0.35 kgm
5. Rocker lever assembly

With the ball section of the rocker lever fitten in
the push rod socket, install rocker lever assem-
bly (25).
6. Adjusting the valve clearance

Using a feeler gauge and adjustment screw (241,
adjust the clearance between the rocker lever
and the crosshead to the following values:
Unit: mm
* For details, see ADJUSTMENT OF VALVE

CLEARANCE under TESTING AND ADJUST-
ING.
7. Cylinder head cover

Fit an O-ring and install cylinder head cover
(23).
8. Nozzle holder assembly

Fit O-rings, install nozzle holder assembly (22),
and tighten bolts (21).
m Mounting bolt: 2.2 + 0.3 kgm
13-12 D58E, P-l
0
9. Spill pipe
Fit a gasket and install spill pipe (20).
10. Water manifold assembly

1) Fit a gasket and install water manifold assembly
(19).
2) Connect bypass tube (18).
3) Connect aeration hose (17) and engine outlet
hose (16).
11. Exhaust manifold assembly

Fit a gasket, install exhaust manifold assembly (15),
and install wiring clamp.
12. Intake manifold assembly

1) Fit a gasket, sling intake manifold assembly (14),
and install it.
2) Install level gauge clamp (13).
13. Fuel injection tubes

Connect fuel injection tubes (12).
14. Heater switch

1) Connect dust indicator hose (11).
2) Install heater switch (10) and connect wiring (9).
D58E.P-1
15. Fuel filter assembly

Install fuel filter assembly (8).
16. Oil filter assembly

Install oil filter assembly (7) and connect hose (6).
13-14 D58E.P-1
0
REMOVAL OF CYLINDER HEAD

ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up
ADisconnect the cable from the negative (-1 ter-

I
I CED00960
1. Drain coolant.
2. Remove left and right engine side covers.

(I).
4. Disconnect corrosion resistor (2) and fuel filter

(3) from manifold, then leave on chassis.
5. Disconnect tube (4) and hose (51, and remove

oil filter (6).
6. Disconnect 3 heater relay wires (7) and dust

indicator hose (8).
7. Remove clamp of delivery tube, and lift off air

cleaner and intake manifold assembly (9).
8. Lift off muffler and exhaust manifold assembly

(IO). m
964
D58E, P-l
9. Remove delivery tube (II).
10. Remove aeration tube (12) and spill tube
-’ CED00966
11. Remove head cover (14).
\ \ l-
CFnOO967
12. Remove nozzle holder assembly (15).
66
13-14-2 D58E, P-l

0
13. Remove rocker arm assembly (16).

* Loosen the locknut and turn the adjustment
screw 2 - 3 turns. 11
14. Remove bracket (171, rocker arm housing (18),

push rod (191, and crosshead (20).
* Remove bracket (17) for the No. 1 cylinder
head assembly only. (1
15. Remove cylinder head assembly (21). m
21
D58E, P-l 13-14-3

0
INSTALLATION OF CYLINDER HEAD ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
Special tool
Part Number Part Name O’ty
A 790-331-1110 Wrench 1
CEP00464
. Carry out installation in the reverse order to re-

moval.
* Screw in the exhaust manifold mounting

bolts 2 - 3 turns by hand, tighten mounting
bolts @ - 0, then tighten the remaining
mounting bolts.
w Exhaust manifold mounting bolt :
66.2 f7.4 Nm (6.75 f 0.75 kgm)
w Delivery tube clamp mounting nut :

11.8 + 2.9 Nm (1.2 f 0.3 kgm)
w Delivery tube sleeve nut :

23.5 li: 0.98 Nm (2.4 + 0.1 kgm)
m Head cover mounting bolt :

9.8 k 0.98 Nm (1 + 0.1 kgm)
* Tighten the nozzle holder mounting bolts in m Rocker arm housing mounting
turn uniformly. bolt: 66.2 & 7.4 Nm
& Nozzle holder mounting bolt thread : (6.75 f 0.75 kgm)
EO-30 Sr Adjust the crosshead as follows.
m Nozzle holder mounting bolt : i) Loosen the locknut and turn back
21.6 f 2.9 Nm (2.2 k 0.3 kgm) the adjustment screw.
ii) Press down lightly with a finger
on the top of the crosshead and
screw in the adjustment screw.
Check that the ball of the adjustment screw
iii) When the adjustment screw con-
is fitted properly into the socket of the push
tacts the valve stem, tighten it a
rod.
further 20”.
Adjust the valve clearance.
iv) Tighten the locknut to hold the
adjustment screw in position.
Adjusting valve clearance.
- Locknut :
w Rocker arm assembly mounting bolt :
66.2 i 7.4 Nm (6.75 f 0.75 kgm)
66.2 f 7.4 Nm (6.75 k 0.75 kgm)
m Locknut :
66.2 + 7.4 Nm (6.75 i 0.75 kgm)
13-14-4 D58E. P-l
0
*
If any rust of more than 5 mm square is
found on the shaft or thread of any head
bolt, replace with a new bolt.
* Check that there is no dirt or dust on the
cylinder head mounting surface or inside
the cylinder.
* Check that the grommet does not come out
when installing the gasket.
* Coat the bolt thread, seat surface, and cyl-
inder head hole seat surface completely with
molybdenum disulphide (LM-P).
6 Mounting bolt :
Anti-friction compound (LM-P)
?Ir Screw in the cylinder head mounting bolts
2 - 3 turns by hand, then tighten as shown
in the diagram.
w Cylinder head mounting bolt:
1. Tighten bolts @ - @ in the diagram in

order as follows.
1st step : Tighten to 98 f 9.8 Nm
(IO f 1 kgm)
2nd step : Tighten again to 137.3 k 4.9 Nm
(14 k 0.5 kgm)
CEP00354
3rd step :
1. When using tool A.
- Using an angle tightening
wrench, tighten the bolt 90+7. CYinder head
2. When not using tool A. start mark
1) Using the angle of the bolt

I
Socket ’
head as the base, make start start
marks on the cylinder head and
socket.
2) Make an end mark at a point End
mark
90*3r from the start mark. Position of
3) Tighten so that the start mark cylinder head
start mark Societ start
on the socket is aligned with /
Socket mark
the end mark on the cylinder
DLD02831
head at the 90c3r position.
2. Tighten bolt 0 in the diagram by the
torque method.
m Cylinder head mounting bolt 0:
66.2+ 7.4 Nm (6.75 * 0.75 kgm) Make mark with punch
* After tightening, make one punch mark on

the bolt head to indicate the number of times
it has been tightened.
. If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.

Add water to the specified level, and run the DLD02832
engine to circulate the water through the sys-
tem. Then check the water level again.
D58E, P-l 13-14-5
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up
A Disconnect the cable from the negative (-1 ter-

1. Drain coolant.
3. Disconnect engine water temperature sensor

connector (I).
4. Disconnect outlet tube (2).
5. Remove 1 bolt (3) from exhaust manifold.
6. Remove mounting bolts, then remove thermo-

stat housing (4) together with thermostat (6).
I 1I CEP00160
INSTALLATION OF
THERMOSTAT ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up

removal.

* Add water through water filler to the speci-
fied level.
Run the engine to circulate the water through
the system. Then check the water level again.
13-l 4-6 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT SEAL

D58E-1 82458 and up
D58P-1 81424 and up
1. Remove radiator and oil cooler assembly.

For details, see REMOVAL OF RADIATOR, OIL
COOLER ASSEMBLY.
2. Remove fan belt (I).

For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.
3. Remove damper (2).
4. Remove pulley (3).
5. Remove front seal (5).
INSTALLATION OF ENGINE
FRONT SEAL
I CED00974
D58E-1 82458 and up

D58P-1 81424 and up

removal.
* Adjust the belt tension.

Testing and adjusting fan belt tension. CED00975
w Damper mounting bolt :

110.3 + 12.3 Nm (11.25 f 1.25 kgm)
w Pulley mounting bolt :

277.0 + 31.9 Nm (28.25 + 3.25 kgm)
6 Lip of oil seal

(fill 50 - 80% of space at lip):
Lithium grease (G2-LI) CEP00256 a CDP00257
* Distance a for knocking in seal: II_‘: mm
D58E, P-l
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR SEAL

D58E-1 82458 and up
D58P-1 81424 and up
Special tool
Part Number Part Name O’ty

;;l;;;)ler 1
Al 795-931-1100 Y CEP00258
1. Remove torque converter assembly.

For details, see REMOVAL OF TORQUE CON-
VERTER ASSEMBLY.
2. Using eyebolt, sling flywheel (I), then remove

mounting bolts, and lift off. m
AThe flywheel pilot is shallow and it may come

off suddenly, so fit 1 guide bolt.
3. Rear seal m
Remove rear seal (2) as follows.
. Removing standard seal
Hook tip of tool Al to metal ring of seal (2),
r
and use impact force of a slide hammer to
pull out. Tool Al
* Before pulling out, knock the oil seal in
slightly. This separates the seal from the SI ide hammer
housing and makes it easier to pull out
the seal.
* Do not use a drill. The metal powder
will get inside the engine.
. Removing seal with sleeve
1) Hook tip of tool Al to metal ring of seal
(21, and use impact force of a slide ham-
mer to pull out.
Ir Before pulling out, knock the oil seal I DL002833
in slightly. This separates the seal

from the housing and makes it easier
to pull out the seal. Standerd seal Seal with sleeve
2) Using a chisel and hammer, cut sleeve
(31 and remove. Flvwheei housina Flywheel housing
* Be extremely careful not to damage
the crankshaft when cutting the
sleeve.
* Remove all the metal particles that
are produced.
Crankshaft Crankshaft
3
DLD02835
13-14-8 D58E, P-l
0
INSTALLATION OF ENGINE REAR SEAL

D58E-1 82458 and up
D58P-1 81424 and up
Special tool
Part Number Part Name GtY

795-931-1210 Seal jig 1
A2 0 1050-3 1645 Bolt 3
01050-31625 Bolt 3
795-931-1220 Seal jig 1

A3 01050-31645 Bolt 3
01050-31625 Bolt 3

removal.
* Tighten the flywheel mounting bolts in the

order shown in Fig. A.
&Mounting bolt : Lubricating oil (E030)
-Mounting bolt :
izziqzz
2nd step 289.3e19.6 (29.5?2)
Standerd seal Seal with sleeve

Using dial gauge (I), measure radial and face
runout of flywheel.
* Face runout: 0.2 mm
Ir Radial runout: 0.15 mm
* With the Teflon seal (lay down lip seal), Internal plastic tube
and assembly auide
check the condition of the wear of the shaft,
then select either a standard seal or a seal
with a sleeve, and assemble the seal. DLD02837 OLD02838
The condition of wear is judged by the
smoothness (no deformation can be felt
when touched with the flat of a finger, depth
of wear less than IO pm). If there are no
scratches, assemble a standard seal; in all
other cases, assemble a seal with a sleeve.
engine end at PTO and
Procedure for assembling standard seal
Before assembling the seal, check that there Internal Plastic
.tube and
are no scratches, burrs, flashes, or rust on assembly guide
the housing, lip sliding surface, or at the
corner of the end face of the crankshaft.
When assembling the seal, do not coat the Large inside Small inside
diameter end diameter and
shaft and seal lip with oil or grease. Wipe
off all oil from the shaft. DLD02839
Do not remove the internal plastic tube from
the standard seal until the seal is assem-
bled.
D58E. P-l 13-14-9
0
1) Put large inside diameter end of internal

plastic tube (3) in contact with end of crank-
shaft (4).
Ir Be particularly careful to assemble fac-
ing in the correct direction.
2) Hold metal ring of seal (2) with both hands

and push in with sudden force.
3) After pushing seal in, remove internal plas-

tic tube (3).
* When removing, be particularly careful
not to damage the seal lip.
4) Tighten bolts of tool A2 uniformly until end

face of tool A2 contacts end face of crank-
shaft (4) and press fit seal (2).
* When press fitting the seal, be extremely CEP00516
careful not to damage the lip at the PTO

end when setting the jig.
* After press fitting the seal, remove all
the remains of the red sealant on the
outside circumference.
. Assembly procedure for seal with sleeve

Before-assembling the seal, check that there
are no scratches, burrs, flashes, or rust on
the housing, lip sliding surface, or at the
corner of the end face of the crankshaft.
When assembling the seal, do not coat the
shaft and the area between the sleeve and
seal lip with oil or grease. Wipe off all oil
from the crankshaft.
Always handle the seal and sleeve as a set.
Never disassemble it.
Lip at engine end Lip at PTO end
q
Sleeve
OLD02840
I
13-14-10 D58E, P-l
0
1) Set sleeve/seal (2) to tool A3.

2
& Surfaceof tube inside sleeve :
A3
Gasket sealant (LG-7)
* Tool A3 includes 2 types of tightening
bolt (x6).
Slee
DLD02841
2) Put sleeve of seal in contact with end face

of crankshaft, then tighten bolts of tool A3
uniformly until end face of tool A2 contacts
end face of crankshaft (4) to press fit sleeve/
seal (2).
CEP01148
3) Remove tool A3 and install tool A2.
4) Tighten bolts of tool A2 uniformly until end

face of tool A2 contacts end face of crank-
shaft (4) to press fit sleeve/seal (2).
* After press fitting the seal, remove all the
remains of the red sealant on the outside
circumference.
CED01149
D58E, P-l 13-14-11

0
DISASSEMBLY AND ASSEMBLY RADIATOR
DISMOUNTING RADIATOR ASSEMBLY
3. Engine hood
Remove exhaust pipe (3) and cap (4). sling engine
hood (5), and remove it.
4. Underguard
Use transmission jack @ to remove underguard (6).
Engine underguard: D58E-1. 100 kg

D58P-1. 40 kg
5. Radiator upper piping

1) Disconnect radiator inlet hose (7).
2) Disconnect aeration hose (8).
6. Wiring and cover

1) Disconnect head lamp wiring (9) from the con-
nector.
2) Remove upper cover (10).
D58E.P-1
7. Plate and cover

1) Open the radiator grille and remove plates (11)
on the RH and LH sides.
2) Remove cover (12).
8. Radiator outlet tube

Disconnect radiator outlet tube (13).
9. Oil cooler inlet/outlet tubes

Disconnect oil cooler inlet/outlet tubes (14) and (15).
10. Radiator assembly

1) Remove RH and LH mounting bolts (16) at the
lower part of the radiator.
2) Remove RH and LH mounting bolts (17) at the

upper part of the radiator.
3) Sling radiator assembly (18) and remove it.

* Lift the radiator with care to avoid hitting the
head lamps.
Radiator assembly: 132 kg
D58E.P-1
MOUNTING RADIATOR ASSEMBLY

1. Radiator assembly
1) Sling radiator assembly (18) and place it in the
mounting position.
130131077
2) Tighten RH and LH mounting bolts (17) at the

upper part of the radiator.
3) Tighten RH and LH mounting bolts (16) at the

lower part of the radiator.
2. Oil cooler inlet/outlet tubes

Fit O-rings and connect oil cooler inlet/outlet tubes
(15) and (14).

Fit a gasket and connect radiator outlet tube (13).
& Gasket: LG-1
D58E.P1
4. Cover and plate

1) Install cover (12).
2) Install plates (11) on the RH and LH sides and
close the radiator grille.
5. Cover and wiring

1) Install upper cover (IO).
2) Connect head lamp wiring (9).

1) Connect aeration hose (8).
2) Connect radiator inlet hose (7).
7. Underguard
Use transmission jack @ to install underguard (6).
8. Engine hood
1) Sling engine hood (5) and install it.
2) Install cap (4) and exhaust pipe (3).
9. Side covers
Install the engine side covers on the RH and LH sides.
10. Add coolant.

Shut drain valve (2). install inspection cover (I), and
add the coolant to the specified level through the
water filler.
* Start the engine, let the coolant circulate through
the system, then recheck the coolant level.
13-18 D58E.P-1
a
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD
DISMOUNTING RADIATOR GUARD ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Drain the coolant

Remove inspection cover (I), open drain valve
(21, and drain the coolant.
+ If the coolant contains anti-freeze, dispose
of it correctly.

Remove the engine side covers on the RH and
LH sides.
3. Engine hood
Remove exhaust pipe (3) and cap (4), sling en-
gine hood (51, and remove it.
4. Underguard
Use garage jack 0 to remove underguard (6).
5. Piston rods
1) Remove cap mounting bolt (8) from piston
rod (7) in the lift cylinder.
2) Shift the work equipment control lever into
FLOAT, retract the piston rod with a crane,
fasten it with wires, and secure it to the pin
for securing the cylinder.
D58E, P-l
6. Hydraulic cylinder hoses

I) Return the work equipment control lever in
NEUTRAL.
Ir If the hose is disconnected while the
control lever is in FLOAT, hydraulic oil
will flow out of the tank.
2) Disconnect lift cylinder hoses (9) and (IO)
on the RH and LH sides.
7. Wiring
Disconnect head lamp and horn wiring (11) from
the connectors.

Disconnect radiator inlet hose (12) and aeration
hose (13).
9. Fan guard
Remove fan guard (14).
10. Oil cooler inlet/outlet hoses

Disconnect torque converter oil cooler inlet/out-
let hoses (15) and (16) at the quick disconnect
couplers.

Disconnect radiator outlet tube (17).
12. Radiator guard assembly

Sling radiator guard assembly (18) and remove
it.
&I kg Radiator guard assembly: 495 kg
13-20 D58E. P-l

0
MOUNTING RADIATOR GUARD ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-IB 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423

Sling radiator guard assembly (18) and install
it.

Fit a gasket and connect radiator outlet tube
(17).
& Gasket: LG-1
3. Oil cooler inlet/outlet hoses

Connect torque converter oil cooler inlet/outlet
hoses (16) and (15) with quick disconnect cou-
plers.
4. Fan guard
Install fan guard (14).

Connect aeration hose (13) and radiator inlet
hose (12).
6. Wiring
Connect head lamp and horn wiring (II) to the
connectors.
D58E, P-l 13-21

0
7. Hydraulic cylinder hoses

Fit O-rings and connect RH and LH lift cylinder
hoses (IO) and (9).
8. Piston rod
1) Put the work equipment control lever into
FLOAT and take out piston rod (7).
2) Place the cap in position and tighten mount-
ing bolt (8).
9. Underguard
Use garage jack @ to install underguard (6).
10. Engine hood

Sling engine hood (5) and install it. Then install
cap (4) and exhaust pipe (3).

Install the RH and LH engine side covers.
12. Add coolant

Shut drain valve (2), install inspection cover (I),
and add coolant to the specified level through
the water filler.
Ir Start the engine, let the coolant circulate
coolant level.
13-22 D58E. P-l

REMOVAL OF RADIATOR GUARD ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
ALower the work equipment to the ground and

stop the engine.
1. Raise lift cylinder and remove piston rod cap

(I) CED00600
* Before removing, make match marks on the

rod and the cap.
* Check the number and thickness of the
shims, and keep in a safe place.
2. Start engine and retract piston rod fully, then

secure lift cylinder assembly (2) to radiator
guard.
* Tie the rod with wire to prevent it from
coming out.
CEO00976
3. Using transmission jack (I), remove underguard

(3).
ADrain the coolant.
A. Disconnect the cable from the negative (-1

terminal of the battery.
4. Remove left, right, top, and bottom engine

sidecovers.
CED00977

(4).
D58E, P-l 13-22-1

0
A Operate the control

lease the remaining
levers several times to re-
pressure in the hydraulic
piping.
6. Disconnect left and right lift cylinder hoses (5)

and (6).
7. Disconnect wiring connector (7).
8. Remove fan guards (8) and (9).
9. Disconnect hoses (II) and (12). q Sl CED00979
10. Disconnect radiator hose (13) and oil cooler

hoses (14) and (15).
11. Sling radiator guard assembly, remove mount-

ing bolts, then remove radiator guard assembly
(16).
w Radiator guard assembly : 550 kg
CED00981
INSTALLATION OF RADIATOR
GUARD ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
Carry out installation in the reverse order to CED00982

removal.
Refilling with water

Add water to the specified level, and run the
engine to circulate the water through the sys-
tem. Then check the water level again.
Refilling with oil (power train case)

Add oil to the specified level, and run the en-
gine to circulate the oil through the system.
Then check the oil level again.
a3
13-22-2 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY ENGINE
DISMOUNTING ENGINE ASSEMBLY

D58E-1 80888 - 82457
D58E-IA 80888 - 82457
D58E-1 B 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423

Remove the radiator guard assembly. For de-
tails, see DISMOUNTING THE RADIATOR
GUARD ASSEMBLY.
2. Floor plate
Remove the floor plate.
3. Underguard (Rear)
Remove underguard (I) by using garage jack
0.
4. Torque converter oil temperature gauge cable

Disconnect cable (2) of the torque converter oil
temperature gauge from the sensor.
5. Dust indicator hose

Disconnect dust indicator hose (3).
6. Wiring
Disconnect heater switch wiring (4).
7. Wiring and ground cable for starting motor

I) Disconnect starting motor wiring (51, (61, (7),
(8), and (9).
2) Disconnect ground cable (IO).
D58E, P-l 13-23

0
8. Fuel supply hose

Shut the fuel supply valve under the fuel tank
and disconnect fuel supply hose (I I).
9. Fuel return hose

Disconnect fuel return hose (12).
IO. Fuel control rod

Disconnect fuel control rod (13).
11. Universal joint assembly

Remove universal joint assembly (14).
12. Engine assembly

Remove engine front mounting bolt (15) and
rear mounting bolts (16) and (17).
Sling the engine assembly a little and re-
move mounting brackets (18) on the RH and
LH sides.
Sling engine assembly (19) and remove it.
&I kg Engine assembly: 1,013 kg
D58E, P-l
MOUNTING ENGINE ASSEMBLY

D58E-1 80888 - 82457
D58E-1A 80888 - 82457
D58E-1B 81285 - 82457
D58P-1 80588 - 81423
D58P-IB 81261 - 81423
1. Engine assembly
1) Sling engine assembly (19) and place it in
position.
2) Install mounting brackets (18) on the RH and

LH sides.
3) Install the cushions to the brackets, lower

the engine assembly, and tighten rear
mounting bolts (17) and (16) and front
mounting bolt (15).

Install universal joint assembly (14).
3. Fuel control rod

Connect fuel control rod (13).
D58E, P-l 13-25

4. Fuel return hose

Fit a gasket and connect fuel return hose (12).
5. Fuel supply hose

Fit a gasket, connect fuel supply hose (II), open
the fuel supply valve under the fuel tank, and
bleed the air from the system.
6. Ground cable and wiring for starting motor

1) Connect ground cable (IO).
2) Connect starting motor wiring (91, (8), (7),
(61, and (5).
7. Wiring
Connect heater switch wiring (4).

Connect dust indicator hose (3).

Connect cable (2) of the torque converter oil
temperature gauge to the sensor, and clamp
the cable to the steering pump outlet tube.
IO. Underguard (rear)

Use garage jack @ to install underguard (I).
11. Floor plate

Install the floor plate.

Install the radiator guard assembly. For details,
see MOUNTING THE RADIATOR GUARD AS-
SEMBLY.
13-26 D58E, P-l

0
REMOVAL OF ENGINE ASSEMBLY

D58E-1 82458 and up
D58P-1 81424 and up
Remove radiator guard assembly.

For details, see REMOVAL OF RADIATOR
GUARD ASSEMBLY.
Remove floor plate.

CED00984
Using garage jack 0, remove underguard (1).
Disconnect torque converter oil temperature sen- ‘I 3 4

sor wiring (2).
Disconnect dust indicator hose (3).
Disconnect 3 heater switch wires (4).
.,,
CED00986
7. Disconnect spill hose (51, and remove clamp at

engine end.
8. Disconnect 4 starting motor wires (61, connec-

tors (7) and (8), and ground wiring (9).
CED00987 CED00988
9. Close fuel supply valve, and disconnect feed

pump inlet hose (IO). m 12 II
10. Disconnect fuel return hose (II). m
11. Disconnect fuel control rod (12).
IU
CED00989 CED00990
D58E, P-l 13-27

0
12. Disconnect universal joint assembly (13).
13. Support flywheel housing from below, and re-

move rear mount (14), then install only hook
(15).
14. Sling engine assembly, and remove front mount

(16).
15. Lift off engine assembly (17).
A kg Engine assembly: 1200 kg
INSTALLATION OF ENGINE
ASSEMBLY
D58E-1 82458 and up
D58P-1 81424 and up

removal.
w Joint bolt :
17.2 AI 2.5 Nm (1.75 + 0.25 kgm)
13-28 D58E, P-l

0
POWER TRAIN
General ............................................................... .21-2

Power train hydraulic system ........................... 21-4
Damper and universal joint .............................. 21-6
Torque converter ............................................... 21-8
Torque converter relief valve.. ........................ 21-1 1
TORQFLOW transmission ............................ 21-1 l-2
TORQFLOW transmission control linkage.. .. .21-22
Joystick control specification .......... 21-22-1
TORQFLOW hydraulic system ....................... 21-23
TORQFLOW hydraulic control ....................... 21-24
Transmission control valve.. ........................... 21-26
Transmission lubricating system ................... 21-30
Transmission lubricating valve ...................... 21-31
Transmission pump ........................................ 21-32
Transmission oil filter ..................................... 21-33
Steering clutch and brake piping ................... 21-34
Steering hydraulic piping diagram
Joystick control specification ............. 21-35
Steering clutch and brake hydraulic system ..... .21-36
Steering clutch and bevel gear.. ..................... 21-38
Steering control valve ..................................... 21-40
Steering-Brake interlocking valve
Joystick control specification ............. 21-45
Steering brake and booster ............................ 21-46
Steering relief valve ........................................ 21-52
Steering pump ................................................. 21-54
Steering strainer.. ............................................ 21-55
Steering oil filter .............................................. 21-56
Steering lever-control linkage ........................ 21-57
Brake pedal linkage ......................................... 21-58
Final drive ........................................................ 21-59
D58E, P-l 21-1

@
STRUCTURE AND FUNCTION GENERAL
GENERAL
D58E, P-l
F13017007
1. Diesel engine (6D125-1) 5. Torque converter 9. Steering brake 13. Sprocket

2. Damper 6. Hydraulic pump 10. Steering clutch 14. Steering filter
3. Transmission pump 7. Steering pump 11. Steering case
4. Universal joint 8. Transmission 12. Final drive
Driving power generated by the engine (1) is transmitted The bevel gear shaft unit is provided for delivering driv-
from the flywheel to the damper (2). The damper con- ing power from the transmission to the right and left
sists of spring loaded friction plates immersed in oil and bevel gear shafts. This unit consists of the bevel gear (P)
absorbs torsional oscillations naturally accompanying which engages with the pinion on the rear end of the
the engine rotation to prevent excessive stress from transmission output shaft.
occuring in the universal joint (4). The wet type multi-plate steering clutches (10) are pro-
Through the universal joint, driving power reaches the vided at the end of right and left bevel gear shafts. Each
torque converter (5) and then the transmission (8). The clutch cuts driving power when turning the machine to
torque converter equipped with an oil cooler is of the either the right or left. The brake (9) immersed in oil
water cooled 3-element, l-stage, single phase type and has a mechanically contracting band which tightens
automatically changes the speed of rotation of its output around the brake drum when the brake is applied.
shaft with the variation of traveling load of the machine. Driving power is transmitted from the steering clutch to
The transmission is constructed by the combination of the final drive and then to the sprocket through the
the planetary gears and the multi-plate clutch and sprocket hub. The final drive gear case contains lubri-
changes the traveling speed of the machine by hydrau- cating oil and the oil, with rotation of the gears, lubri-
lically engaging or disengaging the selected clutches. cates, the bearings and gears.
The planetary gears are the forward, reverse, 1st. 2nd The sprocket (13) drives the track, and the machine is
and 3rd gears; these gears perform 3-speed forward and moved.
3-speed reverse gearshifting. Switching of the clutches is
performed by the control valve which is easily manipu-
lated by the adoption of the finger control system.
21-2 D58E, P-l

D58E-1 B
/ / I \ \>,3
4 5 8 9,10,11
F13017060
1. Diesel engine (6D125-1) 5. Torque converter 9. Steering brake 13. Sprocket

2. Damper 6. Hydraulic pump 10. Steering clutch 14. Steering filter
3. Transmission pump 7. Steering pump 11. Steering case
4. Universal joint 8. Transmission 12. Final drive
Driving power generated by the engine (1) is transmitted The bevel gear shaft unit is provided for delivering driv-
from the flywheel to the damper (2). The damper con- ing power from the transmission to the right and left
sists of spring loaded friction plates immersed in oil and bevel gear shafts. This unit consists of the bevel gear (P)
absorbs torsional oscillations naturally accompanying which engages with the pinion on the rear end of the
the engine rotation to prevent excessive stress from transmission output shaft.
occuring in the universal joint (4). The wet type multi-plate steering clutches (10) are pro-
Through the universal joint, driving power reaches the vided at the end of right and left bevel gear shafts.
Each
torque converter (5) and then the transmission (8). The clutch cuts driving power when turning the machine to
torque converter equipped with an oil cooler is of the either the right or left. The brake (9) immersed in oil
water cooled 3-element, l-stage, single phase type and has a mechanically contracting band which tightens
automatically changes the speed of rotation of its output around the brake drum when the brake is applied.
shaft with the variation of traveling load of the machine. Driving power is transmitted from the steering clutch to
The transmission is constructed by the combination of the final drive and then to the sprocket through the
the planetary gears and the multi-plate clutch and sprocket hub. The final drive gear case contains lubri-
changes the traveling speed of the machine by hydrau- cating oil and the oil, with rotation of the gears, lubri-
lically engaging or disengaging the selected clutches. cates, the bearings and gears.
The planetary gears are the forward, reverse, lst, 2nd The sprocket (13) drives the track, and the machine is
and 3rd gears; these gears perform 3-speed forward and moved.
3-speed reverse gearshifting. Switching of the clutches is
performed by the control valve which is easily manipu-
lated by the adoption of the finger control system.
D58E,P-1 21-2-1
0
Gearshift -to-power tmnsmitting path
Forward 1 2nd 1 l-4
Forward 3rd l-3
Reverse I 1st I 2-5
Reverse 2nd 2-4
Reverse 2rd ( 2-3
E133FO07
1. Diesel engine 8. Transmission

2. Damper 9. Steering brake
3. Transmission pump 10. Steering clutch
4. Universal joint 12. Final drive
5. Torque converter 13. Sprocket
6. Hydraulic pump 15. Shoe
7. Steering pump
D58E.P-1 21-3
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC SYSTEM
POWER TRAIN HYDRAULIC SYSTEM

Engine running, Transmission in Neutral
Steering clutches in ENGAGED.
F R. 3rd 2nd 1 St
l3OFO36
(The speed valve is placed in [NEUTRAL] and the forward-reverse valve in [FORWARD] .I
21-4 D58E.P-1
STRUCTURE AND FUNCTION TORQFLOW HYDRAULIC CONTROL
* 1: Applicable serial No.
1
jetting pressure
20kglcm’ D58E-1 Serial No. 81638 and up
4 * 1: 22 kg/cm’ D58E-1A Serial No. 81638 and up
r- D58E-16
D58P-1
Serial
Serial
No.
No.
81285
81059
and
and
up
ub
I
:-I
i
!YY-----------------
/ ----1
tc: 5
A@+
-------
mJ
-----7
r________---_;_,
I r-7
I I w II I
N -1 I
.A
: ‘T
I L--____-----_t_-
L_,,______________J
No. 3 clutch
Setting pressure
7 to 9 kg/cm2
No. 2 clutch
Cracking pressure (Reverse)
FAR040 i
77.1 Qlmin
(at 1900 rpml
1 13OFO37
1. Transmission case 8. Torque converter relief valve A. Plug for transmission modulating
2. Transmission pump 9. Torque converter relief pressure (PT l/8)

3. Oil filter IO. Torque converter regulator valve (Block) B. Plug for torque converter relief
4. Modulating relief valve spool 11. Oil cooler (Radiator lower tank) pressure (PT l/8)
5. Quick return valve spool 12. Transmission lubrication relief valve C. Plug for torque converter regulator
6. Speed valve spool 13. Transmission lubrication pressure (PT l/8)
7. Directional valve spool 14. Torque converter case D. Adapter for torque converter oil
temperature
D58E,P-1 21-5
0
STRUCTURE AND FUNCTION DAMPER AND UNIVERSAL JOINT
DAMPER AND UNIVERSAL JOINT
II i _..-J-
133FO21
1. Damper case 8. Cone spring

2. Oil seal 9. Friction plate
3. Coupling 10. Hub
4. Universal joint 11. Stopper pin
5. Yoke 12. Torsion spring
6. Cover 13. Drive plate
7. Flight weight
21-6 D58E.P-1
STRUCTURE AND FUNCTION DAMPER AND UNIVERSAL JOINT
STRUCTURE
l Drive plate (13) is installed to the engine flywheel . Even if friction washer is worn, cone spring (8) acts ;
and hub (10) is fitted on coupling (3). There is a tor- to maintain a constant torque.
sion spring (12) installed between the drive plate and . The vibration of the engine is absorbed by the torsion
hub. spring and friction washer. If any strong twisting
. Cone spring (8) pushes friction plate (9) and friction force is brought (the transmitted torque becomes
washer against the flanged part of the hub. In this large), stopper pin (11) functions to transmit the
way it is structured to generate friction torque. movement of the flywheel directly to the hub.
PRINCIPLE OF OPERATION
The torsion spring of the damper acts as a cushion 2. When torsion spring and cone spring are used in
to prevent the vibration of the engine from being combination
transmitted directly to the torque converter. How- Let us now put a wall to the side of the weight, and
ever, the vibration cannot be removed immediately use a spring to push a friction plate against the side of
just by installing a spring, because one spring cannot the weight.
cushion the vibration completely. Friction will be generated between the weight and
For this reason, a cone spring is used in addition the friction plate.
to the torsion spring to improve the reduction in When this happens, the friction generated between
vibration. the weight and the friction plate will act to stop the
free movement (vibration) of the weight compara-
When only torsion spring is used tively quickly.
If a weight is hung on a spring, as in the diagram
below, and is then pulled down and released, it will
bounce up and down freely.
This bouncing (vibration) will not stop quickly, but 3
y Friction
will gradually become less over a period of time.
nt
Time
Cone spring
142FO17
l In this way, the torsion spring acts to reduce the

transmission of vibration. If a cone spring is
11
L-1 Time added, the load of the spring will generate friction
torque and this will further improve the vibration
142FO16
absorbing effect.
D58E.P-1 21-7
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
Hydraulic pump Steering pump
135FO14
The “TORQFLOW” system is a unit consisting of the and stator (13). The turbine is spline-connected to the
torque converter and the 3-speed forward, 3-speed re- transmission input shaft. The housing (9) and its cover
verse planetary gear transmission. are connected to the transmission through the rear
The transmission includes the five hydraulically con- flange of the housing.
trolled clutches which are able to be operated selectively Hydraulic oil filling the converter is supplied by the
from the operator’s seat by manually shifting the gear TORQFLOW oil pump and its pressure is regulated by
shift lever to the desired speed position. the torque converter inlet relief valve so as not to exceed
The 3-element, l-stage, single phase torque converter the maximum set pressure. The inlet relief valve is fitted
mounted on the input side of the transmission is connect- to the front of the transmission hydraulic control valve
ed to the engine-through the damper and the universal mounted on the top of the torque converter housing.
joint. The rotation of the torque converter output shaft The pressure of flowing out of the torque converter is
is transmitted to the transmission through either the regulated by the orifice located in the converter outlet
No. 1 or No. 2 sun gear arranged on the common shaft. oil passage.
The three elements of the torque converter are the pump Oil modulated by and relieved from the transmission
turbine (2) and stator (13) which acts as the guide vanes. control valve is directed into the oil passage provided in
The pump is connected to the input shaft through the the torque converter housing and returns to the oil pump
drive case (3). through the relief valve. The pump driven by the engine
Mechanical energy given by the rotation of the input feeds oil to the turbine spline-connected to the transmis-
shaft is converted by the pump (4) into kinetic energy of sion input shaft. From the turbine the oil returns to the
hydraulic oil. Hydraulic oil flow is directed to the tur- pump through the stator the shaft of which is bolted to
bine which converts kinetic energy of oil into mechanical the torque converter housing.
energy necessary for rotating the converter output shaft A part of the oil drains from the torque converter
(transmission input shaft). Therefore, the input shaft and through the drain hole provided in the stator shaft. The
the output shaft are engaged with each other through oil is regulated in pressure by the orifice provided in the
the fluid coupling inside the torque converter. converter outlet port and directed into the transmission
The main components of the torque converter are the lubricating oil circuit after it is cooled by the oil cooler.
rear housing (9), housing cover, pump (4). turbine (2)
21-8 D58E.P-1
D58F1 Serial No. 80888-81637

D58E-1 A Serial No. 80888-81637
D58P-1 Serial No. 80588-81058
1 2 3
26
Section A-A
II -
Suction B-B
135FO15
Section X-X
1. Front housing 11. Retainer 21. PTO drive gear

2. Turbine 12. Stator shaft 22. Retainer
3. Drive case 13. Stator 23. Shaft
4. Pump 14. Stator boss 24. Bearing cover
5. Plug 15. Drain plug 25. Hydraulic pump drive gear
6. Relief valve spring 16. Turbine boss 26. Boss
7. Relief valve ball 17. Coupling 27. Bearing cover
8. Relief valve body 18. Drive gear 28. Steering pump drive gear
9. Rear housing 19. Retainer 29. Transmission pump drive gear
10. Bearing cage 20. Oil seal cage
D58E,P-1 21-9
a
D58E-1 Serial No. 81638 and up

D58E-1 A Serial No. 81638 and up
D58E-1 B Serial No. 81285 and up
D58P-1 Serial No. 81059 and up
26
27
28
-29
Section B-B
U14101002
Section X-X '15
1. Front housing 11. Retainer 21. PTO drive gear

2. Turbine 12. Stator shaft 22. Retainer
3. Drive case 13. Stator 23. Shaft
4. Pump 14. Stator boss 24. Bearing cover
5. Plug 15. Drain plug 25. Hydraulic pump drive gear
6. Relief valve spring 16. Turbine boss 26. Boss
7. Relief valve ball 17. Coupling 27. Bearing cover
8. Relief valve body 18. Drive gear 28. Steering pump drive gear
9. Rear housing 19. Retainer 29. Transmission pump drive gear
10. Bearing cage 20. Oil seal cage
21-10 D58E,P-1
0
STRUCTURE AND FUNCTION TORQUE CONVERTER RELIEF VALVE
TORQUE CONVERTER RELIEF VALVE
Relief valve
The relief valve provided in the inlet port prevents oil
pressure within torque converter from excessively rising
oil supplied from the control valve under pressure flows
through the oil passage in the torque converter housing
to the torque converter after filling port A. When the
pressure of oil flowing into the torque converter rises to
7 kg/cm’ or more, the relief valve opens to drain oil to
the transmission case through the port B.
The orifice provided in the torque converter outlet port
always keeps oil pressure in the converter to 3 kg/cm’
or more.
‘l
1
1C AL 1=
Detail of orifice
seepsto rransmission
controlvalve contr0lvalve casethrough port 5.
View Y
D58E,P-1 21-11
0
STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
D58E-1 Serial No. 80888-81637
D58E-1 A Serial No. 80888-81637
D58P-1 Serial No. 80588-81058
Model D58-1 is equipped with planetary type transmis- locked by actuating the control valve.
sion and is a combination of planet gear system and disc No. 1 clutch is for Forward, No. 2 for Reverse, No. 3
clutch, and is get Forward and Reverse three speeds. for 3rd speed, No. 4 for 2nd speed, and No. 5 for 1st
For the forward or reverse and each speed, two of 5 disc speed.
clutches of the planetary gear system are hydraulically
\
25
I
24
I
23 ’
22 x
\
20
135FO16
D58E,P-1 21-11-2
0

Model D58-1 is equipped with planetary type trans- locked by actuating the control valve.
mission and is a combination of planet gear system No. 1 clutch is for Forward, No. 2 for Reverse, No. 3
and disc clutch, and is get Forward and Reverse three for 3rd speed, No. 4 for 2nd speed, and No.5 for 1 st
speeds. For the forward or reverse and each speed, speed.
two of 5 disc clutches of the planetary gear system
are hydraulically
1St
2i 26/ i5 i4 13 i2 21 2b 135F016A
21-12 D58E,P-1
0
Transmission reduction ratio
Stage 1 Work clutch No. of clutch plate No. of clutch disc
Forward Neutral No. 5 No. 1 clutch 3 4

1 St No. 1,5
No. 2 clutch 3 4
2nd No. 1,4
3rd No. 1,3 No. 3 clutch 2 3
Neutral No. 5 No. 4 clutch 2 3

Reverse
1 St No. 2,5 No. 5 clutch 1 3 I 4
2nd No. 2,4
3rd No. 2,3
1. No. 1 clutch housing A. Sun gear for No. 1 clutch (34 teeth)
2. Transmission case B. Planet gear for No. 1 clutch (19 teeth)
3. Sleeve C. Ring gear for No. 1 clutch (71 teeth)
4. No. 1 clutch housing D. Sun gear for No. 2 clutch (20 teeth)
5. No. 1 clutch piston E. Planet gear for No. 2 clutch (21 teeth)
6. Pinion shaft F. Planet gear for No. 2 clutch (19 teeth)
7. No. 2, 3 clutch housing G. Ring gear for No. 2 clutch (71 teeth)
8. No. 2 clutch piston H. Sun gear for No. 3 clutch (35 teeth)
9. No. 3 clutch piston I. Planet gear for No. 3 clutch (19 teeth)
10. Sleeve J. Ring gear for No. 3 clutch (73 teeth)
11. No. 4 clutch housing (A) K. Sun gear for No. 4 clutch (35 teeth)
12. No. 4 clutch piston L. Planet gear for No. 4 clutch (19 teeth)
13. No. 4 clutch housing (B) M. Ring gear for No. 4 clutch (73 teeth)
14. No. 5 clutch drum N. Gear for No. 5 (115 teeth)
15. No. 5 clutch housing 0. Bevel pinion (D58E-1, IA: 14 teeth)
16. Rear case (D58E-1B: 14 teeth)
17. Bearing cage (D58P-1: 13 teeth)
18. Seal cage
19. Output shaft
20. Bearing cage
21. No. 5 clutch spring
22. No. 5 clutch piston
23. No. 4 carrier
24. No. 3 carrier
25. No. 1, 2 carrier
26. Oil strainer
27. Clutch spring
28. Input shaft
D58E,P-1 21-13
0
PRINCIPLE OF PLANETARY GEAR MECHANISM
The planetary gear mechanism shown in the figure

includes three planet gears (D) engaged with the sun gear
(A) and the ring gear (B). The three planet gears (D) are
also supported by the carrier (C). When the sun gear (A)
is rotated, the ring gear (B) is held stationary; the planet
gear (D) and the carrier (C) start revolving around the
sun gear (A), while each planet gear rotates on its shaft.
When the carrier (C) is held stationary, the planet gears
(D) rotate on their shaft, allowing the ring gear (B) to
rotate in a reverse direction compared with the rotation
of the sun gear (A).
A. Sun gear
B. Ring gear
C. Carrier
D. Planet gear
E. Clutch dies
(1) When ring gear (B) is fixed:

The torque of sun gear (A) is transmitted to planet
gears (D).
As ring gear (B) meshing with planet gears (D) is
locked, planet gears (D) cannot rotate at the same
position. The planet gears, therefore, rotates
around sun gear (A) along ring gear (B). The torque
of sun gear (A) is transmitted to carrier (C) to drive
it in the same direction as sun gear (A) rotates.
(2) When carrier (C) is fixed:

The torque of sun gear (A) is transmitted to planet
gears (D).
As carrier (C) is locked, the planet gears meshing
with the sun gear rotates at its position.
Ring gear (B) meshing with the planet gears is driven
in the opposite direction to that of the rotation of
sun gear (A); thus the torque of sun gear (A) is
delivered to ring gear (D). No. 1, 3 and 4 clutches
in model D58-1 are based on the combination of
sun gear + planet gears + ring gear (or carrier). In
the case of No. 1 clutch, the sun gear acts as a
torque source and transmits torque to the carrier for
No. 2 clutch.
In the case of No. 3 and 4 clutches, the carrier acts
as a torque source and transmits torque to No. 3
and No. 4 sun gears.
2 I F034A
21-14 D58E.P-1
STRUCTURE AND FUNCTION TORdFLOW TRANSMISSION
(3) Double planet gear mechanism

The combination in which another planet gears (E)
is incorporated between
planet gears (D) and ring
gear (B) is also used. Sun gear (A) rotates while the
ring gear is locked.
As ring gear (B) is locked, planet gears (E) cannot
revolve at the same position, but rotates around sun
gear (A) along ring gear (B).
In this case, the torque of sun gear (A) is trans-
mitted to carrier(C) to drive it in the opposite
direction to the rotation of sun gear (A).
This combination of sun gear + planet gear --t planet
gear + carrier is used in model D58-1 for the No. 2
clutch, by which the machine is reversed.
21F035A
(4) Rotating clutch (No. 5 clutch for 1st speed)

No. 5 clutch is model D58-1 is rotating type clutch
9 10 11
different from clutches No. 1, No. 2, No. 3 and No.
4.
In this type, gear for No. 5 clutch is fixed to output
shaft, No. 5 clutch piston (22) presses discs and
plates to clutch drum (14). The frictional force
enables the power transmission from clutch drum
(14) to gear for No. 5 clutch. This rotating type
clutch is generally used as a 1st speed clutch having
P
a large transmitting torque. #
F13017016
D58E.P-1
ACTING OF PISTON
For locking ring gear (C), the discs (44) and plates (45)
are corporated. The clutch consists of a clutch piston
(2), clutch plates (44), clutch discs (45), pins (33) and
piston return springs (30).
The disc’s internal teeth engage with the ring gear’s ex-
ternal teeth.
The plates, whose notch on the outside diameter en-
gage with pins (33) on housing (3), are locked against
the rotating direction. Piston (2) also is locked against
the rotating direction.
c\
F I440036
l Clutch Engaged (Oil pressure is acting)

Oil from the control valve flows under pressure
through the port in housing (3) to the piston (2).
The piston presses clutch plates (44) and clutch discs
(45) together, and the frictional force developed
stops clutch discs (44) revolution, thus ring gear (C)
meshing with the disc’s internal teeth is locked.
C\
F144CO37
l Clutch Disengaged (Oil pressure is not acting)

When the supply of pressure oil from the control
valve is shut off, piston (2) returns to the initial posi-
tion by the force of piston return spring (30), thus
relieving the frictional force between plates (44) and
discs (45), bringing the ring gear (C) in free.
F144CO36
21-16 D58E.P-1
FUNCTION OF THE BALL CHECK VALVE

IN NO.5 CLUTCH
l A rotation clutch is employed for No. 5 clutch in
model D58-1.
When the gear shift lever is put into “1st speed”, oil
from the control valve enters the left side of No. 5
clutch piston (lo), and pushes piston (10) to the
right. The rotation of No. 5 piston housing (9) is
transferred to the gear for No. 5 clutch (11).
If the gear shift lever is now put into 2nd or 3rd
speed, the force of spring (29) tries to push piston
(IO) back to the left. However, the rotation applies
centrifugal force to the oil on the left side of piston
(IO), so piston (10) cannot move back to the left
immediately.
As a result, the clutch remains partially engaged, and
it is impossible to change gear.
To prevent this from happening, ball check valve (46)
is installed to allow the piston to return to the left
immediately.
1. Clutch engaged
The pressure oil from the control valve is supplied
through the port of housing (9) to the left of piston
(10). Then, ball check valve (46) closes the valve seat
(49) port, and piston (IO) presses clutch discs (47) to
clutch plates (48), engaging the disc’s internal teeth
and gear’s (11) external teeth, the plate’s external
teeth and the carrier’s (28) internal teeth, thus effect-
ing clutch engagement.
21 FO416
2. Check disengaged
When the flow of oil from the control valve is shut
off, the force pushing ball check valve (46) on to
valve seat (49) is lost. Ball check valve (46) then
moves to the outside under the centrifugal force
caused by the rotation. (See the figure on the right)
As a result, the oil on the left side of piston (IO) and
in the ball check valve (46) of housing (9) passes
through the gap in valve seat (49). From here it
drains to the transmission case. Because of this, the
centrifugal force of the oil loses its effect and the
force of return spring (29) can push piston (10) back
to the left immediately.
21 FO42B
D58E.P-1 21-17
POWER TRAIN
1st speed-Forward
F13017017
No. 1 and No. 5 clutches are engaged, No. 1 ring gear is

hold and No. 5 gear is connected directly to output
shaft.
The No. 1 clutch is engaged to hold the No. 1 ring gear is delivered into two Passages: one Passage transmits
stationaly and the No. 5 clutch is engaged to connect rotation of the No. 3 carrier to the No. 3 ring gear, the
to the output shaft. Rotation of the input shaft is No. 4 carrier and the No. 5 shaft; while the other passage
transmitted from the No. 1 sun gear to the No. 1 planeta- transmits the rotation to the No. 3 planetary gears and
ry gears and the resulting rotation of the No. 1 carrier the No. 3 sun gear which is fixed to the No. 5 shaft.
is transmitted to the No. 3 carrier. Here, driving power Then finally to output shaft.
21-18 D58E.P-1
2nd speed- Forward
F13017018
No.1 and No.4 clutches are engyed and No.1 and No.4
ring gears are hold.
The No. 1 and No. 4 clutches are engaged to hold the passage transmits the rotation of the No. 3 planetary
No. 1 and No. 4 ring gears stationary. Rotation of the gears to the No. 3 carrier and the No. 3 sun gear; while
input shaft is transmitted to the No. 1 sun gear and the the other passage transmits the rotation to the No. 3 ring
No. 1 planetary gears and the resulting rotation of the gear, the No. 4 carrier, No. 4 planetary gears and the
No. 1 planetary gears is transmitted to the No. 3 carrier. No. 2 sun gears, in that order. The No. 3 and No. 4 sun
Here, driving power is delivered into two passages: one gears combined together drive the output shaft.
D58E.P-1 21-19
3rd speed-Forward
F13017019
No.1 and No. 3 clutches are engaged, and No. 1 and

No. 3 ring gears are holded.
The No. 1 and No. 3 clutches are engaged to hold the No. 3 ring gear is hold stationary, rotation of the No. 3
No. 1 and No. 3 ring gears stationary. Rotation of the carrier is transmitted to the No. 3 planetary gears, the
input shaft is transmitted to the No. 1 sun gear and the No. 3 sun gear and finally to the output shaft.
No. 1 planetary gears to rotate the No. 1 carrier. As the
21-20 D58E.P-1
1st speed-Reverse
3rd 2nd 1st
3v 5 h
F13017020
No. 2 and No. 5 clutches are engaged, No. 2 ring gear is

hold and No. 5 gear is connected directly to output
shaft.
1st speed - Reverse 2nd speed - Reverse

The No. 2 and No. 5 clutches are engaged to hold the The No. 2 and No. 4 clutches are engaged. The flow of
No. 2 ring gear stationary and the No. 5 clutch is en- power through the directional clutch group is the same
gaged to connect to the output shaft. Rotation of the as that of the first speed-reverse transmission. The flow
input shaft is transmitted to the No. 2 sun gear, the of power through the speed clutch group is the same as
No. 2 idler gears and the No. 2 planetary gears, and the that of the second speed-forward transmission.
resulting rotation of the No. 2 carrier is transmitted
to the No. 3 carrier. Because of insertion of the idler 3rd speed - Reverse
gears, the rotation of the No. 3 carrier is opposite to The No. 2 and No. 3 clutches are engaged. The flow of
the forward rotation. Rotation of the No. 3 carrier is power through the directional clutch group is the same
transmitted to the output shaft in the same manner as as that of the first speed-reverse transmission. The flow
described for the first speed-forward transmission. of power through the speed clutch group is the same as
that of the third speed-forward transmission.
D58E.P-1 21-21
STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION CONTROL LINKAGE
TORQFLOW TRANSMISSION CONTROL LINKAGE

When moving the gear shift lever (1) from “NEUTRAL” 0 When moving the gear shift lever (1) from “F” posi-
position to 1st or 2nd or 3rd position, each part moves tion to “R” position, each part moves in the direc-
in the direction shown by an arrow resulting in tion shown by an arrow Q , resulting in pulling
I)#
pulling the speed valve spool (3). the Forward-Reverse valve spool (4).
F13017021
This Fig. shows the relation between the gear shift lever 1. Gear shift lever
and transmission control valve. 2. Safety lever for gear shift lever
3. Speed lever
4. Forward-Reverse lever
Safety switch (electric) F. Forward position

To engine
The electric safety switch is installed in the starting R. Reverse position
circuit of the electric circuit.
The starting circuit is only connected (switch ON) when
Safety switch
the gear shift lever is placed in “NEUTRAL”. The start-
ing switch can then be used to start the engine. To alternator
R. terminal
If the gear shift lever is in any position other than oN OFF To battery relay
“NEUTRAL”, the gear shift lever pushes the safety R. terminal
switch and the starting circuit is cut (switch OFF). In From battery
this situation, the engine will not start when the starting
switch is turned. F I44CO45
21-22 D58E.P-1
STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION CONTROL LINKAGE
l Joystick control specification
D58E-IB Serial No. 82467 and up

D58P-IB Serial No. 81447 and up
Travel
to Travel
FDRWIRD&_+E”ERSE
Turn to
right
1. Steering/directional/gear shift lever

2. Safety lock lever for traveling
3. Speed range display
D58E, P-l 21-22-1

@
STRUCTURE AND FUNCTION TORQFLOW HYDRAULIC SYSTEM
TORQFLOW HYDRAULIC SYSTEM

The principal components comprising the
TORQFLOW hydraulic circuit are the strainer,
transmission pump (I), oil filter (21, transmis-
sion control valve, torque converter relief valve,
torque converter (3), torque converter regulator
vale (41, oil cooler (5), transmission lubricating
relief valve, and torque converter scavenging
pump.
Transmission pump
;: Oil filter
3. Torque converter
4. Torque converter regulator valve
5. Oil cooler
6. Transmission case
F13017022
Oil in the transmission case is sucked up to trans- The regulator valve is set at 3 to 4 kg/cm*, and
mission pump (1) through strainer, and supplied maintains the torque converter inside pressure.
to transmission control valve through oil filter The oil of 3 to 4 kg/cm2 supplied by the regula-
(2). tor valve (4) is directed through oil cooler (5),
The transmission control valve is divided into where it is cooled, to transmission lubricating
the modulating relief valve group and the torque relief valve.
converter relief valve group. The oil relieved to The lubricating relief valve is set at 3.0 kg/cm*,
a pressure of 20 kg/cm* from the modulating and supplies oil to all sliding parts of the trans-
relief valve is supplied to torque converter relief mission and PTO. Oil used for lubricating torque
valve. converter (3) or oil oozing out of each contract-
The torque converter relief valve is set at 7 to 9 ing face of the converter is turned to transmis-
kg/cm* and controls oil pressure to be fed to the sion case (6).
torque converter. The oil delivered through this
valve is then directed to the lubrication circuit.
The oil is then directed out of the torque con-
verter to torque converter regulator valve (4).
D58E, P-l 21-23

0
STRUCTURE AND FUNCTION TORQFLOW HYDRAULIC SYSTEM
REGULATION OF EC INCLUSION
The principal components comprising the

TORQFLOW hydraulic circuit are the strainer,
transmission pump (I), oil filter (2), transmis-
sion control valve, torque converter relief valve,
torque converter (3), torque converter regulator
vale (41, oil cooler (51, transmission lubricating
relief valve, and torque converter scavenging
Transmission pump
Oil filter
3. Torque converter
4. Torque converter regulator valve
5. Oil cooler
SED00964
Oil in the transmission case is sucked up to trans- The regulator valve is set at 3 to 4 kg/cm*, and
mission pump (I) through strainer, and supplied maintains the torque converter inside pressure.
to transmission control valve through oil filter The oil of 3 to 4 kg/cm* supplied by the regula-
(2). tor valve (4) is directed through oil cooler (51,
The transmission control valve is divided into where it is cooled, to transmission lubricating
the modulating relief valve group and the torque relief valve.
converter relief valve group. The oil relieved to The lubricating relief valve is set at 3.0 kg/cm*,
a pressure of 20 kg/cm2 from the modulating and supplies oil to all sliding parts of the trans-
relief valve is supplied to torque converter relief mission and PTO. Oil used for lubricating torque
valve. converter (3) or oil oozing out of each contract-
The torque converter relief valve is set at 7 to 9 ing face of the converter is turned to transmis-
kg/cm2 and controls oil pressure to be fed to the sion case (6).
torque converter. The oil delivered through this
valve is then directed to the lubrication circuit.
The oil is then directed out of the torque con-
verter to torque converter regulator valve (4).
21-23-1 D58E, P-l

TORQFLOW HYDRAULIC CONTROL

Engine Running, Transmission in Neutral
F R 3rd 2nd 1 St
:036
(The speed valve is placed in [NEUTRAL] and the forward-reverse valve in [FORWARD].)
21-24 D58E, P-l

0
Setting pressure * 1: Amlicable serial No

D58E-1A Serial No. 81638 and up
No. 3 clutch
(2nd speed)
m No. 2 clutch
u (3rd speed)
setting pressure
7 fo 9 kg/cm’
No. 2 clutch
Cracking pressure
3 (Reverse)
U c”EA%”
$!!___
12
13 -;
2
FAR 040
77.1 Plmin
(3t 1900 rpm)
I
p” h 11
M SJetfing
pressure
3 kg/cm’
1 13OFO37
1. Transmission case 8. Torque converter relief valve A. Plug for transmission modulating
2. Transmission pump 9. Torque converter relief pressure (PT l/8)
3. Oil filter 10. Torque converter regulator valve (Block) B. Plug for torque converter relief
4. Modulating relief valve spool 11. Oil cooler (Radiator lower tank) pressure (PT l/8)
5. Quick return valve spool 12. Transmission lubrication relief valve C. Plug for torque converter regulator
6. Speed valve spool 13. Transmission lubrication pressure (PT 118)
7. Directional valve spool 14. Torque converter case D. Adapter for torque converter oil
temperature
The fundamental components of the transmission The hydraulic control system is used for selecting one of
hydraulic control system are the oil strainer, transmis- the three forward and reverse speeds. The speed valve
sion pump (2). and control valve group, and oil cooler feeds oil to the specified clutches so that the desired
(11). traveling direction and speed of the machine can be
The pipes are connecting the lubrication relief valve (12) attained. Oil pressure for this purpose is regulated by
to oil cooler (11). and connecting the oil strainer in the the modulating relief valve (4).
transmission bottom to the oil pump suction port. The When the engine is started and the transmission control
control valve group consists of the speed valve group and lever is placed in the “NEUTRAL” position, oil from the
the direction valve group. oil pump is directed to the modulating relief valve (4).
This valve keeps 20 kg/cm2 (* 1: 22 kg/cm*) of oil
pressure.
D58E, P-l 21-25

0

D58P-1B Serial No. 81447 and up
R 3rd 2nd 1st
21-25-1 D58E. P-l

@
. Joystick control specification
--~-----
,_____
2.16MPa
I ZZk./c.‘l
__-_-_
f-
----____-----__------
1-I
______1----
‘-;,;;
1
/
5
&-,I _I ,
I i-7
II u
I I
_J 1 ,I
j [- ~~~~~~~~______~~~L~
i!-_ _________________1
/
_-___-_-_-
2nd clutch
II
I
Directional
F cl
2
FAR040 y+fj
77Q/mi n
(At ISOOrpml
1. Transmission case 10. Torque converter regulator valve (Block)

2. Transmission pump (FAR0401 11. Oil cooler (Radiator lower tank)
3. Oil filter 12. Transmission lubricating valve
4. Modulating valve 13. Transmission lubrication
5. Quick return valve 14. Torque converter case
6. Speed valve A. Plug for transmission relief pressure
7. Directional valve B. Plug for torque converter relief pressure
8. Torque converter relief valve C. Plug for torque converter regulator pressure
9. Torque converter D. Adapter for torque converter oil thermometer
D58E, P-l 21-25-2

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSM ISSION CONTROL VALVE
F13017023
Modulating’
relief valve To torque converter
_~i 1, XFrd-reversevalve
--
From pump Quick return valve
F13017024
21-26 D58E, P-l

D58E-1 Serial No. 80888-81637

1. Valve body
D58E-IA Serial No. 80888-81637
2. Rod
D58P-1 Serial No. 80588-81058
3. Quick return valve sleeve
4. Quick return valve
5. Stopper
6. Speed valve spool
7. Stopper
8. Directional valve spool
9. Valve body
10. Collar
11. Cover
12. Stopper
13. Piston
14. Piston spring
15. Piston
16. Modulating relief valve spool
17. Modulating valve sleeve
18. Modulating valve spring
19. Spring seat
22. Stopper
23. Spring seat
Section A-A
I=13017025
Section
B-B
D58E,P-1 21-27
0
D58E-1 Serial No. 81638 and up 1. Valve body

D58E-IA Serial No. 81638 and up 2. Rod
D58E-1 B Serial No. 81285 and up 3. Quick return valve sleeve
D58P-1 Serial No. 81059 and up 4. Quick return valve
5. Plug
6. Speed valve spool
7. Stopper
8. Directional valve spool
9. Valve body
10. Collar
11. Cover
12. Stopper
13. Piston
14. Piston spring
15. Piston
16. Modulating relief valve spool
19. Spring seat
I r 21. Modulating valve spring
22. Stopper
23. Spring seat
Seaion A-A
Section B-B
21-27-1 D58E,P-1
0

6 7 8 9 IO -1I
SW002470
D58E, P-l 21-27-2

8
1. Valve body Outline

2. Rod l The main relief pressure of the transmission
3. Quick return valve sleeve control valve is set to 2.16MPa (22kg/cm?.
4. Quick return valve . For the details of the structure and function,
5. Plug see Shop Manual “BULLDOZER”.
6. Speed valve
7. Stopper
8. Directional valve
9. Valve body
10. Collar
11. Cover
12. Stopper
13. Piston
14. Piston spring
15. Piston
16. Modulating relief valve
19. Spring seat
22. Stopper
23. Spring seat
21-27-3 D58E, P-l

@
D58E-1 Serial No. 80888-81637

D58P-1 Serial No. 80588-81058
MODULATING RELIEF VALVE
2o A
Operation
t
The modulating relief valve acts as both the modulating D
valve and the reliev valve. The function of this valve is
to prevent abrupt rising of oil pressure applied to a t
clutch when the gear shift lever is shifted. The modulat-
ing engagement of the clutches prevents the machine
from starting with a shock, increases the durability of
the power transmission system, and improves operator
comfort.
The time taken to fill up the closed spaces in the clutch

with oil called “filling time”. When the spaces fill up
with oil (point 9). the oil pressure starts rising. The 6 0.5 i
modulating valve then automatically commences operat- Time (sec.1 -
F13017045
ing so to raise the oil pressure at a suitable rate to the set
value, causing the clutch to engage smoothly (point D).
D58E- 1A Serial No. 81638 and up
22 A
I I
0 0.5 1
Time (sec.1 -
Function F13017045A
1. While machine is traveling on “FORWARD-1st
speed” (Point A in Fig. F13017045)
The modulating relief valve acts as the relief valve.
The oil from the transmission pump flows to speed
valve through orifice (ds) in quick return valve (4).
The oil through orifice (g) flows to the right side of
modulating sleeve (17) through the center hole of
quick return valve (4) and pushes sleeve (17) to the
left.
The other oil from the transmission pump flows to
the piston (12) through orifice (f) in modulating
relief valve, and pushes modulating valve (16) to the
left. As modulating sleeve (17) is pushed from the
right side and modulating valve (16) is pushed from
the right side, modulating springs (201, (21) are
compressed, resulting in balancing state. In this case,
To torque converter
the oil is relieved to torque converter.
F13017046
21-28 D58E,P-1
0
A. Immediately after shifting the gear shift lever As the valve (4) has different cross-sections between its
(Point B) head (diameter: dl) and the sliding part (diameter: d2),
the valve is moved to the right by oil pressure. As a
result, cavity E is not connected to the drain port, and
oil flows into cavity E through: the throttle J of the
valve (4), thus causing back pressure in cavity E lower
than oil pressure in cavity f-i. The back pressure pushes
the sleeve valve (17) to the left and the relief port of the
valve is also moved to the left, so that increased relief
pressure sustains higher oil pressure than before to drive
it is the clutch.
Increased oil pressure in the clutch increases back pres-
sure in cavity E and, as a result, oil pressure in the clutch
is increased further. This cycle continues until the sleeve
valve comes into contact with the stopper provided on
the left end of the sleeve and the oil pressure rises gra-
To torque converter From pump dually up to 20 kg/cm* (* 1: 22 kg/cm*). Oil relieved
Fl3QlJO47
from the valve is connected to the drain port when
Oil supplied from the oil pump flows into the selected the sleeve valve stays on the right side, but the drain
clutch cylinder to fill the clutch cylinder. The oil under port is closed and a new port leading to the torque
pressure moves the quick return valve (4) to the left, and converter inlet is opened with the movement of the
cavity E is connected to the drain circuit. At the same spool to the left.
time, the valve (16) and the sleeve (17) are returned to
their original positions by the springs (21) and (20). C. When the gear shift is completed
B. During rising of pressure

(Point D)
To torque converter From pump

F1301 JO49
As long as 20 kg/cm* (* 1: 22 kg/cm*) of oil pressure

is maintained in the clutch, oil is relieved from the
To toraue converter modulating valve to the torque converter relief valve.
F1301 JO48 (The port (diameter: d3) in the head of the quick return
Nearly zero oil pressure is applied to the clutch until the valve (4) is provided to compensate for oil leakage from
clutch cylinder is filled with oil supplied from the oil the clutch cylinder and the valve.)
pump, and then the oil pressure starts rising gradually.
With rising of oil pressure in cavity H of the valve (16),
the small piston and the spring are compressed by oil * 1:Applicable serial No.
pressure and react on the valve (16) so that the valve

moves in the direction shown by an arrow, against
resistance of the spring (21), until the drain port is
opened to relieve oil pressure and prevent it from rising
excessively.
D58E,P-1 21-29
0
STRUCTURE AND FUNCTION TRANSMISSION LUBRICATING SYSTEM
TRANSMISSION LUBRICATING SYSTEM
A gear type oil pump feeds oil to be used for controlling smoothly, a bypass valve in the filter will open to allow
the transmission, operating the torque converter, and the oil to bypass the oil filter.
lubricating the transmission and the torque converter. Valves in the control valve unit act to deliver oil to the
This pump is driven by the gear engaged to the torque transmission clutches and then to the torque converter.
converter input shaft. Oil left from the torque converter is cooled by the oil
Oil in the transmission case is sucked up by the pump cooler and sent to the transmission lubricating oil relief
through a pipe that goes to the bottom of the case. For- valve, which prevents the transmission lubricating oil
eign particles in oil are.removed by the strainer before pressure from exceeding 3 kg/cm’ of the set pressure.
oil is sucked into the oil pump. Further, the oil dis- This set pressure is determined to prevent excessive rise
charged from the pump is cleaned by the oil filter before in pressure of the oil circuit preceding the relief valve,
it flows into the transmission control valve. If the oil which would cause damage to the cooler and ineffectual
filter element is clogged wit,h dirt or if oil with excessive operation or overheating of the torque converter, if a
viscosity has difficulty passing through the filter element foreign particle in the oil circuit blocks smooth oil flow.
From ) torque converter
F13017050
Lubricating oil circuit in transmission
All transmission clutches and bearings are lubricated by gears and bearings. Exceptions to this are only the No. 1
forced-circulation of oil. clutch sun gear and its bearings and the No. 2 clutch sun
After passing through the transmission lubricating valve, gear to which a part of the torque converter oil is deli-
oil under pressure is forced to flow into the oil passage vered for the purpose of lubrication.
leading to each clutch housing and lubricates all clutches,
21-30 D58E.P-1
STRUCTURE AND FUNCTION TRANSMISSION LUBRICATING VALVE
TRANSMISSION LUBRICATING VALVE
135FO21
1. Valve body GENERAL

2. Lubricating valve 0 Transmission lubricating valve is located on front
3. Valve spring L.H and it’s cracking pressure is set at 3 kg/cm2.
4. Stopper cover Oil from torque converter passes through oil cooler in
radiator lower tank and lubricating valve to lubricate
transmission gears.
D58E.P-1 21-31
STRUCTURE AND FUNCTION ‘TRANSMISSION PUMP
TRANSMISSION PUMP
FAR040
135FO22
1. Drive gear GENERAL

2. Bracket Delivery: 77.1 Q/min at 1,900 rpm
3. Gear case
4. Housing
5. Driven gear
21-32 D5BE.P-1
STRUCTURE AND FUNCTION TRANSMISSION OIL FILTER
TRANSMISSION OIL FILTER
View Z
lY
View Y
133 F022
GENERAL
1. Filter cover
l Cracking pressure 3.0 kg/cm2
2. Spring
Oil flow 210 Illmin
3. Filter case
Filtering accuracy 10 j.l
4. Cage
5. Sleeve
6. Spring
7. Spring seat
8. Element
D58E.P-1 21-33
STRUCTURE AND FUNCTION STEERING CLUTCH AND BRAKE PIPING
STEERING CLUTCH AND BRAKE PIPING
The hydraulic steering system consists mainly of strainer

(l), steering pump (2), steering filter (3). steering con-
trol valve (4), brake booster (5) and relief valve (6).
5
View Z u13401001
1. Steering strainer A: R.H steering clutch pressure

2. Steering pump B: L.H steering clutch pressure
3. Steering filter C: R.H brake booster pressure
4. Steering control valve D: L.H brake booster pressure
5. Brake booster
6. Relief valve
The oil inside the steering case passes through magnet When the steering lever is pulled halfway, the oil flowing
strainer (1) and is sucked up by steering pump (2). to steering control valve (4) flows to the steering clutch.
From here it passes through steering filter (3) and flows When the steering lever is pulled fully, the oil flows to
to steering control valve (4), brake booster (5) and relief the steering clutch and brake booster (5). This dis-
valve (6). engages the steering clutch and at the same time actuates
The oil relieved by relief valve (6) (set pressure 20 the brake.
kg/cm2 ) flows to the steering case.
21-34 D58E.P-1
STRUCTURE AND FUNCTION STEERING HYDRAULIC PIPING DIAGRAM
STEERING HYDRAULIC PIPING DIAGRAM

D58P-IB Serial No. 81447 and UD
5 6 7
1. Steering pump
2. Brake booster
3. Steering-Brake interlock valve
4. Steering main relief valve
5. Steering oil strainer
6. Steering oil filter
7. Transmission
8. Servo valve
9. Torque converter
Z SW002471
D58E, P-l 21-35

@
STRUCTURE AND FUNCTION STEERING CLUTCH AND BRAKE HYDRAULIC SYSTEM
STEERING CLUTCH AND BRAKE HYDRAULIC SYSTEM

Engine running, both steering levers are not pulled, and
both brake pedals are not depressed.
To right steering control valve
To riahr brake bonnw
t
,..
::..
....
,.,.
:.
:>:.:
.:.
;;
R
u
;j;;;
..,.:
3
..
j,.:::::
i.........
;14. 13
F13YZOl5A
21-36 D58E, P-l

0
L--b
Disengaged
!G--
F-m
Disengaged
9
FAR028
11
54.4 Plmin.
(at 1,900 rpm)
131
1. Steering strainer (magnet type) 8. Right steering clutch piston A. Plug for relief valve pressure
2. Steering pump 9. Right steering clutch lever B. Plug for left steering clutch pressure
3. Steering filter 10. Right steering clutch C. Plug for right steering clutch pressure
4. Relief valve 11. Right steering clutch D. Plug for left brake booster pressure
5. Steering control valve release yoke E. Plug for right brake booster pressure
6. Brake valve 12. Bevel gear
7. Brake booster 13. Steering case
D58E. P-l 21-37


To R.H
To R.H. brake
SW002472
D58E. P-l
Inline servo valve
r;----- , -1 I3
j _-____
1‘
5
Tl r-7. - -_-_-_
i --I
i *
--L
Set pressure:
A@+
FAL028
54.4Q/min
(At 1900r~m)
1. Steering oil strainer 8. Piston A. Plug for main relief pressure (PT1/8)
2. Steering pump (FAL028) 9. Lever B. Plug for left-hand piston pressure tPT1/8)
3. Steering oil filter 10. Release yoke C. Plug for right-hand piston pressure (PT1/8)
4. Main relief valve 11. Steering clutch D. Plug for left-hand brake pressure (PT1/8)
5. Steering valve 12. Steering case E. Plug for right-hand brake pressure (PT1/8)
6. Brake valve 13. Servo valve
7. Brake booster
D58E, P-l 21-37-2

@I
STRUCTURE AND FUNCTION STEERING CLUTCH AND GEVEL GEAR
STEERING CLUTCH AND BEVEL GEAR
‘J7U-P F
t-
u---..v
/
12
I 11
I I
14
I
10
13 Fl3YZOl7
1. Brake drum 8. Bevel gear shaft

2. Clutch drum 9. Adjusting nut
3. Disc 10. Bearing cage
4. Plate 11. Spring
5. Release yoke 12. Retainer
6. Bearing cage 13. Nut
7. Bevel gear 14. Pressure plate
21-38 D58E, P-l
@
STRUCTURE AND FUNCTION STEERING CLUTCH AND BEVEL GEAR
BEVEL GEAR SHAFT
(1) BEVEL GEAR SHAFT

The bevel pinion and gear used of a spiral bevel gear Adjusting nuts (9) are provided from moving bear-
type. ing cages (10) right and left when it is necessary to
readjust the bevel gear for proper tooth contact and
Driving power from the engine is divided into two backlash.
directions, right and left, through the bevel gear Clutch drum (2) for steering clutch are forced onto
meshed with the bevel pinion, on the rear end of the tapered splines at the end of bevel gear shaft.
transmission output shaft. The bevel gear is fitted A splash-lubrication is employed with the bevel gear
to the bevel gear shaft with 8 reamer bolts and the in an oil bath.
bevel gear shaft is supported by the steering case
through two roller bearings and the bearing cages
(6).
STEERING CLUTCH
(2) STEERING CLUTCHES STRUCTURE

Steering clutches are mounted on both ends of the In the steering clutch, the spring (11) maintains
bevel gear shaft to control the direction the machine the plates (4) and discs (3), normally in contact
travels. These clutches interrupt the flow of drive with each other, between the clutch drum (2)
from the bevel gear to the final drive, to allow and the pressure plate (14), so that rotation of
changing of the direction of travel. discs (3) can be frictionally transmitted to plates
(4).
These are wet, multi-disc, spring loaded type When a steering lever is pulled, the steering
clutches. Each steering clutch consists of the fol- control valve acts to push the yoke (5) through
lowing parts. the link lever in the direction of the steering
Clutch drum (2): This drum which is forced into clutch. The movement of the yoke (5) acts on
the bevel gear shaft spline is bolted to the bevel the pressure plate (14) through the bearing and
gear shaft (8). bearing cage (6) to release friction contact
Brake drum (1): This drum is bolted to the final between discs (3) and plates (4).
drive pinion flange. When the steering pedal is released, the pressure
Plates (4): These plates are in mesh with the plate (14) is returned to its original position by
brake drum (1). the spring, and frictional contact between discs
Disc (3): These discs are in mesh with the clutch (3) and plates (4) is recovered.
drum (2). Pulling both the right and left steering levers
Pressure plate (14): A pressure plate (14) is simultaneously disengages both the right and
slided on bevel gear shaft (8). left steering clutches. Pulling only the left steer-
This plate pushing the discs and plates against ing lever will disengage only the left steering
clutch drum (2) by springs (11) when no operat- clutch, leaving the right steering clutch engaged,
ing the steering pedals. thus permitting the machine to turn to the left.
Spring (11).
D58E.P-1 21-39
STRUCTURE AND FUNCTION STEERING CONTROL VALVE
STEERING CONTROL VALVE

The steering control valve consists of two steering valves and right which control the flow of oil to the brake
(12) which control the flow of oil to the left and right boosters.
steering clutches, and two brake valves (20) on the left
,.,J... I.“.._ ---- --
Pressure \
Setion B-B
Left brad booster Left stdering clutch

pressure pressure
1. Steering valve body

7. Lever
8. Adjustment bolt
9. Shaft
IO. Spring
11. Stopper
12. Steering valve
13. Spring
14. Piston
15. Plug
16. Guide
17. Shaft
18. Spring
19. Spring
20. Brake valve
21. Spring
22. Piston
23. Plug
24. Steering clutch lever
25. Left steering clutch piston
26. Pipe
27. Seat
Section A-A
Fl3YZOl8
21-40 D58E.P-1
2. Tube From steering pump

3. Brake valve body
I
4. Bolt
5. Plate
6. Lever
5 4
Section B-B
From steering pump

\ TO right brake
To right
- brake booster
To left
brake booster
Section C-C
F I44CO54
D5BE.P-1 21-41
Function
1. When steering lever is not pulled:
(Steering clutch engaged; brake not applied)
The oil from the steering pump flows to relief valve
(24), port (A) of the steering control valve, and the
brake booster. However, the circuit for the steering
control valve and the brake booster is closed, so the
hydraulic pressure rises. When the pressure exceeds
the set pressure of the relief valve (24), the oil flow to
the oil cooler and the hydraulic pressure is main-
tained at 20 kg/cm’.
To brake booster
Fl3YZOl9
2. When steering lever is pulled slightly:
(Steering clutch partially engaged; brake not applied)
When the steering lever is pulled, lever (7) is pushed
in the direction of the arrow and compresses spring
From
(10). Spring (10) then pushes steering valve (12) in
the direction of the arrow. As a result, the flow of
oil from port (B) to port (G) is shut off. At the same
time, the flow of oil from port (A) to port (B) is con-
nected, and it flows to the steering clutch. When the
steering clutch is filled with oil, the oil pressure rises.
TO brake booster
144F04lA
The oil flowing through orifice (a) to port (C) pushes

piston (14) and the reaction pushes the steering valve
(12) in the direction of the arrow and compresses
spring (IO). The steering valve (12) shuts off the flow
of oil from port (A) to port (B), and the hydraulic
pressure comes into balance with the force of spring
(10).
If the steering lever is pulled further, spring (10) is
compressed accordingly, so the force of the spring
(10) and the hydraulic pressure in balance with the
spring both rise. This partially engages the steering
clutch.
To brake booster
I44F042A
21-42 D58E.P-1
3. When steering lever is pulled to detent:

From
(Steering clutch disengaged; brake not applied) steering
When the steering lever is pulled to the detent posi-
tion, shaft (9) moves in the direction of the arrow
and comes into contact with stopper (11). Shaft (9)
pushes stopper (11 ), which then pushes steering valve
(12), so even if the hydraulic pressure at port (B)
rises, steering valve (12) cannot move to the left.
Spring (10) is fully compressed and the hydraulic
pressure reaches 18.9 kg/cm2 (Completion of modu-
lation).
The hydraulic pressure continues to rise to 20
To brake booster
kg/cm’, the set pressure of the main relief valve, and
the steering clutch is disengaged. I44F043A
4. When steering lever is pulled further: From

steering
(Steering clutch disengaged; brake circuit oil pressure 9 10 11 pump 12
starts to rise) \'\ I /
Shaft (9) is in contact with stopper (1 I), so port (A)
and port (B) open the same amount that shaft (9) has
moved.
To brake booster
I44F044A
Because of adjustment bolt (8), shaft (17) also moves From steering valve
to the right and pushes brake valve (20).

As a result, the flow of oil from port (E) to port (H)
is shut off. At the same time, the flow of oil to port
(D) and port (E) is connected, and it flows to the
brake booster.
To brake booster
I44F045A
From steering valve

The oil flowing through orifice (b) to port (F) pushes
piston (22) and the reaction pushes the brake valve
(20) to the left and compresses spring (18). The
brake valve (20) shuts off the flow of oil from port
(D) to port (E), and the hydraulic pressure comes
into balance with the force of spring (18).
If the steering lever is pulled further, spring (18) is
compressed accordingly, so the force of the spring,
and the hydraulic pressure, which is in balance with
the spring both rise. This starts to actuate the brake. To brake booster
l44F046A
D58E.P-1 21-43
5. When steering lever is pulled fully:

(Steering clutch disengaged; brake applied)
Shaft (9) moves to the right until stopper (G) and (H)
are in contact. .From here, the shaft (9) cannot move
any further. The steering valve (12), like shaft (9)
can also not move any further. Because of adjust-
ment bolt (B), shaft (17) also moves to the right and
pushes brake valve (20).
To brake booster
I44F044A- I
However, even when shaft (9) reaches the end of

stroke, shaft (17) does not reach the end of stroke.
Therefore the oil flowing from orifice (b) to port
(F) pushes piston (22) and the reaction pushes brake
valve (20) to the left and compresses spring (18).
Brake valve (20) shuts off the flow of oil from port
(D) to port (E). The hydraulic pressure and the force
of spring (18) are brought into balance. When this
happens, the force of spring (18) is at its maximum.
The hydraulic pressure, which is in balance with the
force of the spring (18) is also at its maximum (16.7
kg/cm’ ) and the brake is therefore fully applied.
I44F04S.A
6. When steering lever is released: .j

(Steering clutch engaged; brake not applied)
I’
Shaft (9), shaft (17), brake valve (20) and steering
valve (12) are all returned to their original positions
by the force of each spring. When this happens, steer-
ing valve (12) shuts off the flow of oil from port (A)
to port (B). At the same time, it connects the flow of
oil at port (B) and port (G). Therefore, the oil in the
ram steering clutch
steering clutch is drained from port (G) to the steer-
ing case.
case From brake booster
In addition, brake valve (20) shuts off the flow of oil 17
from port (D) to port (E). At the same time, it con-

I44F049A
nects the flow of oil from port (E) to port (H), and
the oil in the brake booster is drained from port (H)
to the steering case.
21-44 D58E.P-1
STRUCTURE AND FUNCTION STEERING-BRAKE INTERLOCKING VALVE
STEERING-BRAKE INTERLOCKING VALVE


Right br ‘ake Right steering

booster pressure clutch oressure
From steering
B-B
Left brake booster Left steering
A-A SW002474
1. Valve body 9. Plug 17. Modulating spring

2. Lever 10. Seat 18. Return spring
3. Shaft 11. Slow return valve 19. Shaft
4. Modulating spring 12. Plug 20. Guide
5. Spring guide 13. Piston 21. Lever
6. Steering valve 14. Return spring 22. Piston
7. Return spring 15. Brake valve 23. Lever
8. Piston 16. Brake valve body
D58E, P-l 21-45

c3
STRUCTURE AND FUNCTION STEERING-BRAKE INTEkLOCKlNG VALVE
Outline
. When the steering/directional/gear shift lever is
moved to the right or left, the steering clutches
are disengaged.
If the steering/directional/gear shift lever is
moved further, the brake is turned ON.
This mechanism is called the steering clutch-
brake interlock mechanism. With this mecha-
nism, the operator can turn the machine gently
or sharply by controlling the lever properly, while
the conventional machine is steered with the
control linkage.
As the hydraulic brake is employed, the conven-
tional steering valve is eliminated, but a new
steering valve and brake valve are combined
and operated with lever (23). This combined unit
is called the steering-brake interlocking valve.
21-45-1 D58E, P-l

0
Operation
1. Steering and brake valves “Neutral”

The oil from the steering pump enters ports A
and D of main relief valve (25) and interlocking
valve. Since the steering clutch and brake booster
circuits are closed, only the oil pressure in the
circuit rises and the oil flows in the drain circuit,
opening main relief valve (25).
Accordingly, the oil is always relieving and the
From steering
clutch is turned “ON” and the brake is “RE-
LEASED” while the steering/directional/gear shift
lever is not operated.
At this time, the oil pressure in the circuit is
2.35MPa {24kg/cm2).
2. Steering valve “Oil pressure starts rising”

When the steering/directional/gear shift lever is
moved, lever (22) pushes shaft (3) to the right
and compresses spring (4). Compressed spring
(4) pushes steering valve (6) to the right with its
reactive force. Then, the circuit of ports B and G
are closed and those of ports A and B are To steering
opened, then the oil flows in the yoke piston.

TO brake booster 2475
When the circuit from the pump to the yoke SWDO
piston is filled with the oil, the oil pressure starts

rising again.
The oil flowing from orifice a into port C pushes
piston (8). The reactive force of piston (8) pushes
back steering valve (6) to the right and com-
presses spring (4) to close the circuit of ports A
+0
Ll
and B.
At this time, the oil pressure in the circuit from
port B to the yoke piston is balanced with the
fitting load of spring (4), and the oil pressure is
kept constant.
moved further, the fitting load of spring (4) is
rising gradually. Accordingly, the oil pressure erino clutch SWDo24,S
after port B is also rises and the clutch is “HALF

ENGAGED”.
g clutch SW002477
D58E, P-l 21-45-2

@I
3. Steering valve “Oil pressure rose fully”

moved further from the state in 2 above, shaft
(3) moves to the right until it reaches spring
guide (5).
Under this condition, shaft (3) pushes steering
valve (6) through spring guide (5). Even if the
oil pressure after port B rises, it cannot pushe
steering valve (6) back to the left.
At this time, the fitting load of spring (4) be-
comes maximum and the oil pressure in the
circuit becomes 2.11MPa {21.5kg/cm2} and the
SWDO2479
steering valve completes modulation. Then, the
oil pressure rises further to the set level of the
main relief valve, and the clutch is “DISEN-
GAGED”.
4. Brake valve “Oil pressure starts rising” From ournp

moved further from the state in 3 above, the
circuit of ports A and B are opened by the mov-
ing distance of shaft (31, since the latter is in
contact with spring guide (5).
Shaft (19) is also moved to the right by the
roller to push brake valve (15) to close the cir-
cuit of ports E and H and open the circuit of
ports D and E. Accordingly, the oil flows in the 9 Clutch SWDO2479
brake booster.
On the other hand, the oil flowing from orifice b
into port F pushes piston (13). The reactive force
of piston (13) pushes back brake valve (15) to From steering
the left to shorten spring (17) to close the circuit I I valve
of ports D and E.
port E to the booster is balanced with the fitting
load of spring (171, and the oil pressure is kept
constant.
If the steering/directional/gear shift lever is II/I r
moved further, the fitting load of spring (17) is
increased gradually. Accordingly, the oil pres- TO brake booster SWDO2490
sure after port E is also increased and the brake
start working.
/ , From steering
is i3
To brake booster SWD02481
21-45-3 D58E, P-l

8
5. Steering valve “Oil pressure rose fully”

-
moved fully to the end, shaft (3) moves to the
right until it reaches stoppers (26) and (271, and
steering valve (6) does not move any more.
Ii 3
From DU~D
Shaft (19) is also moved to the right by the

roller to push brake valve (15).
Even if shaft (3) reaches the stroke end, shaft
(19) does not reach the stroke end. Accordingly,
the oil flowing from orifice b of brake valve (15)
into port F pushes piston (13). The reactive force
of piston (13) pushes back brake valve (15) to SW002482
the left and compresses spring (17) to close the
circuit of ports D and E.
port E to the booster is balanced with the ex-
panding force of spring (17) which is under the From steering
maximum fitting load, and the oil pressure is

kept constant and the braking operation is com-
pleted.
At this time, the oil pressure in the circuit after
port .E is 1.45MPa {14.8kg/cm21.
6. Steering and brake valves “Neutral”

released, shafts (3) and (191, brake valve (15) To brake boaster SW002483
and steering valve (6) are returned to the left by
the respective springs.
Then, steering valve (6) closes the circuit of ports
A and B and opens the circuit of ports B and G,
then the oil in the yoke piston is drained through
port G to the steering case.
Brake valve (15) closes the circuit of ports D and
E and opens the circuit of ports E and H, then
the oil in the brake booster is drained through
port H to the steering case. eerine
H
se
steering clutch
19 steering From brake\

case booster 15 SWDO2484
D58E, P-l 21-45-4

03
Operation of brake oil pressure booster

(Joystick control specification)
. A brake booster is used for operation of the

steering brake to reduce the operating effort of
the steering/directional/gear shift lever and brake
pedal.
1. Brake “Opening”
There are two oil circuits from the steering pump;
one enters port A by operating of the interlock From steering
valve (22), and the other enters port B directly

without passing through the interlock valve (22).
Since the steering/directional/gear shift lever is
not operated, interlocking valve (22) does not
work and the circuit to port A is closed.
Accordingly, all the oil flows in port B, then flows
through orifice a to pot-t C.
However, the brake pedal is not operated, the
circuit of ports C and D is closed, only the oil
pressure in the circuit rises and the oil opens
main relief valve (23) and flows in the lubricat-
ing circuit.
2.35MPa (24kg/cm*I.
2. Steering/directional/gear shift lever “Moved”,

Brake “Operated”
moved fully, the interlocking valve works and
the oil from the pump flows in port A.
If the pressure of the oil in port A rises, it moves
piston (2) to the left, then the end of piston (2)
pushes lever (15) to operate the brake.
1.45MPa {I 4.8kg/cm2}.
* For the operation of the interlocking, see
page 21-45-2.
From From
brake valve steerins turns
SWD02486
2 1-45-5 D58E, P-l

63
3. Brake pedal “Pressed”, Brake “Operated”

When the pedal is pressed, lever (6) pushes spool bD Ba
(3) to the left to open the circuit of ports C and

D.
Accordingly, the oil from the pump flows through
port B and orifice a to port C, then through
orifice b to port D.
If the pressure of the oil in’port D rises, it moves
piston (2) to the left to open the path of ports D
and A, then the oil is drained through port A to
the steering case.
SWDQ2497
The pedal is pressed for the opening ratio of the
path to push spool (3) to throttle port A.
When the above operation is carried out in a
short time by follow-up mechanism and spool
(3) moves to the left further, the short circuit TO From
2 brake valve steering hump
between ports B and D opens. Then, more oil
flows in port D and piston (2) moves faster.
During the period, the piston end pushes lever
(15) to shrink the brake band smoothly to oper-
ate the brake.
By the above two-stage operation, the oil pushes
piston (2) lightly first and pushes strongly after
the short circuit of between ports B and D opens.
Accordingly, the brake is not applied sharply.
If the pedal is pressed to the stroke end, ports D
and A are kept closed and the main relief valve
opens, then the oil flows in the lubricating cir-
cuit.
15 2 3
2.35MPa {24kg/cm2). \ \ A D B /
D58E, P-l 21-45-6

@
STRUCTURE AND FUNCTION STEERING BRAKE AND BOOSTER
STEERING BRAKE AND BOOSTER
U14101013A
1. Brake booster body 8. Anchor 15. Lever

2. Piston 9. Lever 16. Adjusting bolt
3. Spool 10. End 17. Pin
4. Sleeve 11. Brake lining 18. Rod
5. Spring 12. Brake band 19. Pin
6. Lever 13. Plate 20. Adjusting nut
7. Brake cover 14. Lever 21. Pin
21-46 D58E, P-l

a
The contracting band type brake is mounted on the ment of steering clutches. The right pedal is provided
brake drum and immersed in the steering clutch case oil. with a locking device to keep the pedal in the depressed
This brake is actuated as a steering when a steering lever position.
is pulled, and as a parking brake when the both brake One end of the brake band (12) is suspended from the
pedals are depressed. When a steering lever is pulled, anchor (8) through the end (10) and pin (21). While
first a steering clutch is disengaged and then the operat- the other end is suspended from anchor (8) through
ing force of pedal depressing is decreased by equipment rod (18), adjusting nut (20) and pin (21).
of brake booster. A steering brake interlocked with Two springs are provided for making uniform the
the brake pedal is actuated. When both brake pedals tension of brake band (12) around the drum. The
are depressed, both the right and left brakes actuates adjusting nut (20) is used for adjusting the clearance
simultaneously to stop the machine without disengage- between brake lining (11) and the brake drum.
Section B-B
Seaion A-A
18 19 20
View Z
section D-D
Section C-C
133F036A
D58E.P-1 21-47
0
Functions
When one steering lever on the turning side of machine
is pulled, the steering clutch on the same side is dis-
engaged. Then, the track on the side where the flow of
drive (power has been cut off by the steering clutch) is
free from driving power. However, it is dragged some-
what by the track on the opposite side, thereby causing
the machine to make a gradual turn. When the same
steering lever is further pulled, the steering control valve
is moved to flow into brake booster, and brake booster
Linked to brake
acts. As a result, the brake band contracts the brake
drum and the track is held still, thereby causing the
machine to make a sharp turn.
When brake pedal is depressed, the brake booster acts
and brake band contacts the brake drum.
1. Brake operation when the machine is traveling for-

ward
When pulling a steering lever fully, brake booster
piston moves at left, and lever (3) turns in the lever
(15) moves upward.
As the brake drum turns counterclockwise while the
machine is traveling forward, the brake band is pull-
ed counterclockwise. Therefore, rod (19) is pulled
to the left, and pin (18) pushes anchor (14). As a
result, lever (15) turns clockwise as a forum of B
point, end (16) moves in the direction shown by the
arrow Q and the brake band contracts the brake
drum.
F144CO55B
2. Brake operation when the machine is traveling reverse

While the machine is traveling reverse, the brake drum
is turning clockwise. Therefore, the brake band (12)
is pulled clockwise. Accordingly, end (16) is pushes
to the right, and pin (21) pushes anchor (14). As a
result, lever (15) turns clockwise as a forum of A
point, pin (20) moves in the direction as shown by
the arrow R and the brake band contracts the brake
drum.
F144CO56B
21-48 D58E.P-1
0
Operation of hydraulic brake booster
1. When brake pedal is not depressed, and steering lever

is not pulled (brake not applied)
If brake valve (20) operates, one oil line from the
steering pump flows to port (A), another oil line
flows directly to port (B) without passing through
steering valve.
The steering lever is not being pulled, so valve (20)
does not move. The oil does not flow to port (A),
but only flows to port (B). It then passes through
orifice (a) and flows to port (C). However, the brake
pedal is not being depressed, so the flow of oil at port From steering pump -
(C) and port (D) is shut off. As a result, the
hydraulic pressure rises, and when it exceeds the set
pressure of the relief valve (24), it flows to the oil
cooler, and the hydraulic pressure is maintained at 20
kg/cm’.
2. When steering lever is pulled fully (brake applied) F I 3YZO22
Brake valve (20) operates and oil flows to port (A).

When the hydraulic pressure in the circuit rises, the
oil at port (A) pushes piston (5) to the left lever (3),
(4) move and applies the brake.
The hydraulic pressure at this point is 16.7 kg/cm’.
* For details of the operation of the steering valve,

see P2 I-40.
I44F056A
D58E.P-1 21-49
3. When brake pedal is depressed (brake applied)

When the brake pedal is depressed slightly, lever (9)
pushes spool (6) to the left, and the flow of oil at
port (C) and port (D) is connected. Because of this,
the oil from the pump passes from port (B) and flows
through orifice (a) to port (C).
I44F057A
When the hydraulic pressure at port (D) rises, it

pushes piston (5) to the left and connects the flow of
oil at port (D) and port (A). The oil then drains from
port (A) to the steering case. The brake pedal travels
the same distance that piston (5) moves by slight
depressing force. This movement of the piston (5)
and pedal, and the oil flow is repeated over a short
period (follow-up movement).
From neerim I I
pump _
To brake valve
5
\ t I I I
I44F058A
21-50 D58E.P-1
STRUCTURE AND FUNCTION STEERING tiRAKE AND BOOSTER
Spool (6) moves further to the left and connects the

flow of oil at port (B) and port (D). The volume of
oil flowing to port (D) increases and piston (5) moves
faster. Piston (5) continues to push lever (3), then
brake band contracts smoothly and the brake is
applied.
In this way, the hydraulic pressure rises in two stages.
At first, the oil pushes piston (5) lightly, and when
the flow of oil at port (D) and port (B) is connected,
it pushes strongly. This prevents the brake from
being applied suddenly.
I44F059A
4. When brake pedal is depressed fully (brake applied)

When the brake pedal reaches the end of its travel,
the flow of oil at port (D) and port (A) remains shut
off, and the hydraulic pressure rises further. When
the pressure reaches 20 kg/cm’, the main relief valve
functions and the oil flows into the lubrication cir-
cuit.
l44F060A
D58E.P-1
STRUCTURE AND FUNCTION STEERING RELIEF VALVE
STEERING RELIEF VALVE

Relief valve (6) adjusts the pressure in the steering cir-
cuit to 20 kg/cm2.
Drain port
From
steering
pump
/ A-_)
From steering pump
Section A-A
From steering - F_C
1. Plug
2. Plug
3. Plug
4. Spring (small)
5. Spring (large)
6. Relief valve
7. Relief valve body
F I3YZO23 8. Piston
Section B-B 9. Piston
10. Spring
11. Plug
21-52 D58E.P-1
STRUCTURE AND FUNCTION STEERING RELIEF VALVE
-) To Steering case
_ To Steering case
Section C-C Section D-D
F144CO55
Operation
The oil from the steering pump flows to port (A), then
passes through orifice (a) of relief valve (6) and flows
to piston valve (8). When the hydraulic pressure rises, To steering case
the oil pushes piston valve (8) and the reaction moves
relief valve (6) to the right. As a result, port (A) and
port (8) are connected, and oil flows to the steering
case.
8 From pump 6 B
D58E.P-1 21-53
STRUCTURE AND FUNCTION STEERING PUMP
STEERING PUMP
FAR028
135FO31
1. Drive gear Type: Gear pump

2. Bracket Delivery: 54.4 Rlmin. (at 1,900 rpm)
3. Gear case Setting pressure: 20 kg/cm2
4. Housing
5. Driven gear
21-54 D58E.P-1
STRUCTURE AND FUNCTION STEERING STRAINER
STEERING STRAINER
1. Strainer cover
2. Spring
3. Case
4. Magnet element
A. From steering case
B. To steering pump
-A
130FO47
D58E, P-l 21-55

0
STRUCTURE AND FUNCTION STEERING OIL FILTER
STEERING OIL FILTER
F I 3YZOZ6
The oil delivered from the steering pump enters 1. Cover

from the inlet port and is filtered by element (7). It 2. Spring
’ then flows from the outlet port to the inlet port of 3. Retainer
the control valve. If element (7) is heavily clogged, 4. Valve
and the difference in pressure before and after valve 5. Spring
(4) reaches 3 kg/cm2, valve (4) opens. 6. Seat
7. Element
8. Filter case
9. Outlet oil pressure tap
A. From pump
B. To valve
21-56 D58E, P-l

0
STRUCTURE AND FUNCTION STEERING OIL FILTER
LI
0 0
-
0 -
0 L _-- J 0 -
‘\
B A SED00965
The oil delivered from the steering pump enters 1. Cover

from the inlet port and is filtered by element (7). It 2. Spring
then flows from the outlet port to the inlet port of 3. Retainer
the control valve. If element (7) is heavily clogged, 4. Valve
and the difference in pressure before and after valve 5. Spring
(4) reaches 3 kg/cm2, valve (4) opens. 6. Seat
7. Element
8. Filter case
9. Outlet oil pressure tap
A. From pump
B. To valve
D58E, P-l 21-56-1

0
STRUCTURE AND FUNCTION STEERING LEVER-CONTROL LINKAGE
STEERING LEVER-CONTROL LINKAGE

(STEERING CLUTCH AND BRAKE LINKAGE MECHANISM)
F13017027
0 When pulling the steering lever to detent position, 1. Steering lever

each part moves in the direction of the arrow. 2. Brake system
As a result, the right steering control valve is run 3. Steering control valve
away and the clutch is disengaged and brake is not 4. Rod
applied.
l When pulling the steering lever fully, each part
moves same as above. As a result, the clutch is dis-
engaged and brake is applied (see page 21-42 to page
21-44).
D58E.P-1 21-57
0
STRUCTURE AND FUNCTION BRAKE PEDAL LINKAGE
BRAKE PEDAL LINKAGE
Parking brake lever
F13017028
0 When depressing the left brake pedal, each part moves 1. Brake pedal
in the direction of the arrow. The left brake booster 2. Brake system
moves and left brake is applied. 3. Rod
0 If the parking brake lever is pulled, operate the
following procedure;
- Depress the right brake pedal fully.
- Pull the parking brake lever to lock the pedal to this
position.
21-58 D58E.P-1
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
l D58E-1
F I 3Y2027
Number of teeth: 1. Flange 8. Key

No. 1 drive pinion: 13 2. 1 st pinion 9. Floating seal
No. 1 driven gear: 38 3. 1st driven gear 10. Retainer
No. 2 drive pinion: 11 4. 2nd pinion 11. Key
No. 2 driven gear: 42 5. 2nd driven gear 12. Bearing
Sprocket 27 6. Sprocket hub 13. Sprocket
7. Sprocket shaft 14. Plane bearing
The final drive is of the spur gear, 2-stage reduction Inserted between the final drive case and the sprocket is
type. Driving power from the steering clutch is trans- the floating seal (9) which prevents mud and dirt from
mitted to the 1st pinion (2) through the brake drum and entering the case. The final drive case forms an oil sump,
the flange (1). Driving power is then transmitted to the and bearings and gears are lubricated with oil when the
sprocket (13) to rotate it through the 1st driven gear oil is splashed by rotation of the gears.
(3), 2nd pinion (4), 2nd driven gear (5) and sprocket Rotation of the 13 teeth of 1st pinion gear is trans-
hub (6). in that order. mitted to the 42 teeth of 2nd driven gear with a reduc-
The sprocket is fitted to the sprocket hub with six keys tion ratio of 11.16 through the 38 teeth of 1st driven
(8) and the sprocket hub is supported on the sprocket gear and the 11 teeth of 2nd pinion gear.
shaft (7) through the bearing (12) and plane bearing
(14). The sprocket shaft is press-fitted into the steering
case and the opposite end of the shaft is supported on
the track frame through retainer (10).
D58E.P-1 21-59
. D58P-1
12
23
11
10
3
22
21
20
7
19
ii 6
133FO40
1. Final drive flange 9. Floating seal 17. Seal guard

2. 1st pinion (13 teeth) 10. Retainer 18. Sprocket boss
3. 1st gear (38 teeth) 11. Key 19. Bearing cage
4. 2nd pinion (11 teeth) 12. Bearing 20. Retainer
5. 2nd gear (42 teeth) 13. Sprocket teeth 21. Sprocket support
6. Sprocket hub 14. Plane bearing 22. Cover
7. Sprocket shaft 15. Final drive case 23. Floating seal
8. Key 16. Bearing cage
21-60 D58E.P-1
Model D58-1 employes the double reduction type using

spur gears, and splash lubrication by the gear rotation.
Power from the bevel gear shaft and steering clutch Final drive case functions as a lubricating oil tank
is transmitted through the brake drum to final drive for each gears. The rotating sliding parts of the
flange (1), rotating 1 st pinion (2) on the flange. sprocket are equipped with floating seals (9) and
The 1st pinion engages with 1st gear (3), rotating in order to prevent entry of dust or mud, and oil
the 2nd pinion (4). Power is further transmitted leakage.
from the 2nd pinion to 2nd gear (5) engaging with
the 2nd pinion, with speed reduction effected.
Due to the construction in which the 2nd gear is
bolted on sprocket hub (6), into which sprocket
boss is pressed in final drive hub, the rotation of
gear is transmitted to the sprocket.
-6
~-
F13017046
F13017029
D58E.P-1 21-61
POWER TRAIN
Standards for testing and adjusting.. ....... 22- 2

Standard values of chassis
Joystick control specification ............. 22-3-3
Testing and adjusting tool list .................. 22- 4
Oil pressure measurement locations ........ 22- 5
Oil pressure adjustment locations ............ 22- 6
Adjusting clearance between
brake band and drum .......................... 22- 7
Adjusting steering lever travel .................. 22- 8
Adjusting brake pedal travel ..................... 22- 9
Adjustment of brake pedal
Joystick control specification .............. 22-9-l
Adjustment of steering/directional/
gear shift lever
Joystick control specification ............. 22-9-2
Measuring torque converter stall.. ............ 22-10
Troubleshooting .......................................... 22-l 1
D58E, P-l 22-l

8

D58E-1
D58E-1, IA, IB
Item Conditions Unit
Standard Permissible
value value
High idling 2,100 It 50

* Engine coolant temperature: within
operating range
Low idling 825 + 25
* Power train oil temperature: 60 - 80°C

Torque converter
. Hydraulic oil temperature: 45 - 55°C
rpm
1,630 f 50
stalling
Torque converter operating range
stalling + hydraulic * Place the machine on flat surface 1,360
valve relief * Transmissin shift lever: F3
Low idling --f
Fuel control lever High idling
* Center of lever knob
Low idling + Stop
Decelerator pedal . Center of pedal
Between each
Transmission
. Center of lever knob gear speed
shift lever
F-R
- Center of lever knob Fu,l stroke

Steering lever
* Engine low idling 198+;'
* Engine stopped
Brake pedal * Center of brake pedal
* Depress with a force of 147N (15 kg) (When 105 * 10
(each side)
a clearance from lining to drum is 0.3 mm)
Low idling + 78.4 + 9.8

High idling (8? I)
Fuel control lever - Center of lever knob
Max. 78.4
Low idling + Stop
(Max. 8)
* Engine stopped 58.8 * 19.6
Decelerator pedal
* Center of decelerator pedal (6 i: 2)
Between each 39.2_Ps.s
Transmission gear speed (4-Z 1
* Engine stopped
shift lever 39.2_$.s
F*R
(4-Z)
* Engine low idling
Steering lever 78.4 + 29.4
* Center of steering lever
(each) (8 ? 3)
(of the ooint of 200 mm travelina)
* Engine low idling
Brake pedal * Center of individual speed
(of the point of 200 mm traveling)
TORQFLOW Engine high idling

transmission
setting oil pressure
1Engine low idling -
2.o+y
- Power train oil
Steering setting MPa (20140)
temperature:
oil pressure :g/cm? 2.0~~00::
60 - 80°C
(20::)
I 1.6 + 0.17
(16.7 Itr 1.7)
Brake oil pressure
I 1.6 i 0.17
(16.7 + 1.7) I
NOTE: Engine speed standard values given in this table are applicable to engines mounted on machine.
* The values with ( ) are for the following machines.
D58E-1 82458 and up
D58E, P-l
D58E-1, IA, IB
value value
Fl 3.2
* On flat surface F2 5.9

- Engine at high idling
9 Engine coolant temp.: F3 9.8
Within operating range km/h
Travel speed
- Traveling distance before RI 3.9
measurement: 10 - 30 m
- Measure the time while
7.1
traveling a distance of 20 m R2
R3 11.9
* Place the fuel control lever in “high

idling” position.
* Toraue converter oil temperature:
Time lag when
60 -’ 80°C +0.5
shifting the
* Measure the time starting to move the
sec. 0.5 o
gear shift lever
track when moving the gear shift lever
from “Neutral” position to the desired
speed position.
Engine
temp.
coolant
Test conditions
l Specified oil and coolant levels
- Repeat 30 to 40 m excavating and
I Max. 100
I
Engine oil
temp. filling operations until heat balance is
reached.
Steering case - Wind speed within 5 m/s.
oil temp. * Stop test in overcast or rainy weather.
* Carry out test with thermostat fully
Final drive oil
temp.
open.
I Max. 120
I
D58E, P-l 22-3

0
D58P-1
Item Conditions
unit 11
-1 operating range ~
825 ?z 25
* Power train oil temperature: 60 - 80°C rpm

Torque converter
- Hydraulic oil temperature: 45 - 55OC 1,630 2 50
stalling
Torque converter operating range
* Place the machine on flat surface
stalling + hydraulic
valve relief * Transmissin shift lever: F3
I 1,360 I
Low idling +
Fuel control lever
I * Center of lever knob
High idling I
Low idling + Stop ,
Decelerator pedal . Center of pedal
I Between each
Transmission gear speed 42f 15
* Center of lever knob mm
shift lever
FttR 70* 15
* Center of lever knob

Steering lever Full stroke
* Engine low idling
* Engine stopped
Brake pedal l Center of brake pedal
* Depress with a force of 147N(15 kg) (When j
leach side)
a clearance from lining to drum is 0.3 mm)
Low idling + 78.4 + 9.8
High idling I (8+ 1)
Fuel control lever * Center of lever knob
Max. 78.4
Low idling --f Stop ,
(Max. 8)
* Engine stopped 58.8 f 19.6
Decelerator pedal
- Center of decelerator pedal (6 f 2)
Between each 39.2~y9.s
gear speed (4-Z)
Transmission * Engine stopped
shift lever 39.2_&
FttR
(4-Z 1
l Engine low idling
Steering lever 78.4 * 29.4
* Center of steering lever
(each) (8 ? 3)
I (of the point of 200 mm travelina)
* Engine low idling
147 f 19.4
Brake pedal . Center of individual soeed
(15 i 2)
(of the point of 200 mm traveling)
2.5 9:
TORQFLOW Engine high idlin! 3
(25 ‘:,
transmission I
setting oil pressure 1 Engine low idling -
I 2.0+?
* Power train oil Engine high idlin! 3
Steering setting MPa (20+40)
temperature:
oil pressure
60 - 80°C
(kg/cm2) 2.0::::
Engine low idling (20::)
I
Brake oil pressure

3 I 1.6 ? 0.17
(16.7 * 1.7) I
I
1.6 * 0.17
(16.7 * 1.7)
NOTE: Engine speed standard values given in this table are applicable to engines mounted on machine.
t The values with ( ) are for the following machines.

D58P-1 81424 and up
D58P-1B 81424 and up
22-3-l D58E, P-l
0
D58P-1
value value
Fl 2.9
* On flat surface F2 5.3

* Engine at high idling
* Engine coolant temp.: F3 8.6
Within operating range km/h
Travel speed
* Traveling distance before RI 3.5
measurement: IO - 30 m
* Measure the time while
R2 6.4
traveling a distance of 20 m
R3 10.2
* Place the fuel control lever in “high

idling” position.
* Torque converter oil temperature:
Time lag when
60 - 80°C +0.5
shifting the sec. 0.5 o
* Measure the time starting to move the
gear shift lever
track when moving the gear shift lever
from “Neutral” position to the desired
speed position.
Engine coolant
Test conditions Max. 100
temp.
. Specified oil and coolant levels
. Repeat 30 to 40 m excavating and
Engine oil temp. Max. 120
filling operations until heat balance is
reached. “C
Steering case - Wind speed within 5 m/s.
3il temp. * Stop test in overcast or rainy weather. Max. 120
* Carry out test with thermostat fully
Final drive oil open.
Max. 120
temp.
D58E. P-l 22-3-2

0
TESTING AND ADJUSTING STANDARD VALUES OF CHASSIS
STANDARD VALUES OF CHASSIS

. Joystick control specification
Divi Standard value Permissible value

Item
sior
Fuel control lever -~~
Decelerator pedal
Between two gear

(deiree) 15 f 2
speeds
N + Forward 52 f 8
N + Reverse 55 f 8
Steering/directional/gear
- Center of lever knob N + Left swing 97* 15
shift lever
N + Right swing 92+ 14
N --f Left pivot turn 56
Brake pedal
Hold + Raise 75* 11
Hold + Lower 68 * 10
Hold + Float 133 f 20

Blade control lever * Center of lever knob
Hold -+ Left tilt 58 + 9
Hold + Right tilt 59 f 9

0
Hold + Right/Left angle (deoree) 15.5 rt 2
Fuel control lever
Decelerator pedal
* Engine stop
Steering/directional/gear * Center of lever knob
shift lever
Brake pedal
Hold tf Float
Blade control lever * Center of lever
knob
._.- - ,
4.41 * 0.88
Hold + Right/Left angle I/g:)
lO.45 * 0.091
+x Only the items to be changed when the joystick control specification (wrist control type single-lever specification) is applied
are given in this table.
For items not given in this table, see the standard value table for D58E, P-IB standard machine.
22-3-3 D58E, P-l

@
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST
No. Check item Tool Part No. Remarks
1 Oil temperature Thermistor kit 799-101-6000 0 - 1,OOO’C
Pressure gauge:
2 Hydraulic pressure Hydraulic tester D 799-101-5000
25, 60, 400, 600 kg/cm2
3 Engine speed Multi-tachometer 799-203-8000 Digital display L: 60 - 2,000 rpm
H: 60 - 19,999 rpm
4 Operating force Commercially -

Push-pull scale
available
5 Travel Scale - -
22-4 D58E. P-l

@
TESTING AND ADJUSTING OIL PRESSURE MEASUREMENT LOCATIONS
OIL PRESSURE MEASUREMEN T

LOCATIONS
1. Measurement plug (1) (PT1/8) for torque converter
inlet oil pressure.
* The plug is located under the torque converter
outlet tube.
13OFlOOl
2. Measurement plug (2) (PT1/8) for torque converter

outlet oil pressure.
3. Measurement plug (3) (PT1/8) for TORQFLOW

transmission clutch oil pressure.
* Remove cover (4) before measuring.
4. Measurement plugs (5) and (6) (PT1/8) for steering

clutch oil pressure.
t Plug (5) is for the LH clutch and plug (6) for the
RH clutch.
5. Measurement plugs (7) and (8) (PT1/8) for steering

brake oil pressure.
* Plug (7) is for the LH brake and plug (8) for the
RH brake.
D58E.P-1
TESTING AND ADJUSTING OIL PRESSURE ADJUSTMENT LOCATIONS
OIL PRESSURE ADJUSTMENT

LOCATIONS
1. TORQFLOW transmission relief valve
If the measurement shows that the oil pressure is
lower than the standard value, disassemble the
modulating relief valve, measure the free lengths and
mounting loads of springs (1). (21, and (3). and
replace them, if defective.
2. Steering clutch and brake circuit relief valve

Adjust the oil pressure by adding or reducing shim
(4) in relief valve.
* Oil pressure variation for one shim:
0.2 mm: 0.22 kg/cm*/sheet
0.5 mm: 0.55 kg/cm*/sheet
* Standard thickness of shim at time of assembly:
3mm
13OF1003
22-6 D58E.P-1
TESTING AND ADJUSTING CLEARANCE BETWEEN BRAKE BAND AND DRUM
ADJUSTING CLEARANCE BETWEEN BRAKE BAND

AND DRUM
U14101017A
1. Loose adjustment bolt (1) until clearance a is reduced 4. Lock adjustment bolt (1) with nut (5).
to zero.
5. Turn adjustment nut (2) in counterclockwise for l-3/6
2. Tighten adjustment nut (2) to torque of 9 kgm. rotation.
* Turn adjustment nut in counterclockwise for l-3/6
3. Adjust adjustment bolt (1) so that clearance a be- so that clearance between brake band and drum is
tween adjustment bolt (1) and lever (4) is zero. approx. 0.3 mm.
At same time, booster piston (3) shall be contacted
with lever (4).
D58E.P-1 22-7
a
TESTING AND ADJUSTING STEERING LEVER TRAVEL
ADJUSTING STEERING LEVER TRAVEL
Steering lever travel 198 - 208
Approx. 1,180
1. Before adjusting lever travel, adjust the clearance be- 4. Tighten turnbuckle (3) so that the standard lever
tween the brake band and drum for 0.3 mm. travel is 198 - 208 mm.
See page 22-7 for adjustment.
5. Adjust nut (4) so that the clearance A is 1 mm.
2. Adjust stopper bolt (1) so that the distance from the
center of steering lever knob to the dashboard is 115 6. Pull the steering lever until the steering linkage begins
mm. to compress the spring of steering control valve. At
+ Push the steering lever to forward to measuring. that time, adjust nut (4) so that the steering lever
linkage begin to push yoke (5).
3. Connect rod (2), the length which is extended fully.
22-8 D58E.P-1
TESTING AND ADJUSTING BRAKE PEDAL TRAVEL
ADJUSTING BRAKE PEDAL TRAVEL
First play (Approx. 5mm)
Pedal travel
I- ._ .- -
1. Before adjusting pedal travel, adjust the 3. Connect rod (2), the length of which is ex-
clearance between the brake band and drum tended fully. Turn rod (2) until the first play
for 0.3 mm. is 5 mm, with depressing the pedal by hand
See page 22-7 for adjustment. slightly.
* There are two kinds of play. Don’t tighten
2. Adjust stopper bolt (I) so that the height of it until the second play is reduced to
brake pedal from the floor plate is 190 mm. zero.
4. Confirm the pedal travel when stopping the

engine.
Pedal travel is 95 - 115 mm with depressing
force of 147.1 N (15 kg).
D58E, P-l 22-9

0
TESTING AND ADJUSTING ADJUSTMENT OF BRAKE PEDAL
ADJUSTMENT OF BRAKE
PEDAL,

* Tighten the lock nut of the rod and cable se-

curely and bend the cotter pin securely.
1. Adjustment of brake lining clearance

TWO00927 TWD00928
1) Remove caps (I) on both sides.
2) Tighten adjustment nuts (2) on both sides to
88.3Nm (9kgm) to fit the lining and brake
drum to each other, then return the adjust-
ment nut by 316 turns.
* If the adjustment nut is returned by 1
and l/2 turns, the clearance between the
lining and drum becomes about 0.3mm.
2. Adjustment of brake pedal

I) Adjust stopper bolt (3) so that distance be-
tween the floor plate top and the center of
the pedal will become “A”.
Ir Dimension “A”: 190mm
TWO00929
2) Install rod (4) a little longer. Tightening rod
(41, press the pedal lightly with the hand
occasionally. Tighten rod until the first play
becomes 5 - IOmm. Screw rod until play becomes 5-10mm
* There are first and second plays as

Depressing
shown in the attached drawing. Take care
force
extremely not to reduce the second play
by adjusting the linkage.
3) With the engine stopped, press the pedal
with the force of 15kg and check that the
pedal stroke-is 79 + IOmm.
Stroke
TWnOOQQO
22-9-l D58E, P-l
8
TESTING AND ADJUSTING ADJUSTMENT OF STEERING/DIRECTIONAL/GEAR SHIFT LEVER
ADJUSTMENT OF STEERING/
DIRECTIONAL/GEAR SHIFT
LEVER

Ir Tighten the lock nut of each rod and cable se-

curely and bend the cotter pin securely.
t Gear shift lever (1) and directional lever (2) are
installed to the transmission, and each gear
speed and direction are positioned by the TWD
detents in the transmission.
1. Adjustment of steering linkage

1) Turn turnbuckle (5) so that the distance be-
tween center of the top of the steering lever
and the notch of cover (4) will become “A”
when lever (3) is in the horizontal position
and the steering lever is in the “N” position.
View from forward
-f Dimension “A”: 63.5mm
2) Connect rods (6) and (7).
3) Turn rods (6) and (7) so that clearance “a” of
oblong hole (8) will be Omm and the angle
of the lever of the steering brake interlock
valve will become “B”. TWD00932
* Angle “B”: 16” 44’
2. Adiustment of directional linkage 6 .7

1) -Install cable (9) when directional lever (2) of
the transmission is locked at the “N” posi-
tion.
2) Turn turnbuckle (10) so that directional le-
ver will return to the “N” position when the
safety lock lever is moved from the “Free”
position to the “Lock” position while the di-
rectional lever is at the “F” or “R” position.
3. Adjustment of gear shift linkage

1) Connect rod (11).
t Standard length of rod (11): 93.5mm
2) Install knob (13) so that its indication “2”
will be on the front side when lever (12) is
just lateral.
3) Install cable (14).
4) Adjust turnbuckle (16) so that indication “2”
on indicator panel (15) will be at the center
Forward
of the speed indicator window when the gear
+
shift lever is at the “2nd” position, then re-
turn and set it by a half turn.
TWD00934
D58E, P-l 22-9-2

8
TESTING AND ADJUSTING MEASURING TORQUE CONVERTER STALL SPEED
MEASURING TORQUE CONVERTER STALL

Special tool
Part Number Part Name Q’ty
A 799-203-8001 Multi-tachometer 1
j, Measure the stall speed under the following

conditions.
. Coolant temperature: Within operating range
. Power train oil temperature: 70 - 90°C
Hydraulic oil temperature: Min. 50°C
a’ Make sure that there is no one near the ma-

chine before starting measurements.
1. Remove cap (I) of the engine speed pick-up

port and install tachometer A.
2. Depress the brake pedal firmly and move the
gear shift lever to F3.
ADepress the brake pedal fully and be abso-

lutely sure that the machine does not move.
3. Depress the decelerator pedal, set the fuel con-

trol lever to FULL, run the engine at full throt-
tle, and stall the torque converter.
4. When the torque converter oil temperature
gauge enters the red range, immediately return
the gear shift lever to neutral and lower the oil
temperature.
5. Repeat Steps 2 - 4 three times.
6. Repeat Steps 2 - 4 to stall the torque converter
again.
7. Measure the engine speed immediately the
torque converter oil temperature gauge enters
the red range.
Ir After completion of the measurement, return
the gear shift lever swiftly to neutral, and run
the engine at high idling to lower the oil tem-
perature.
a Precautions when relieving the torque converter
1) Depress the decelerator pedal gradually be-

fore pulling the fuel control lever to the FULL
position.
2) Release the decelerator pedal to run the en-
gine at full throttle. However, for safety rea-
sons, always keep your right foot on the
decelerator pedal until the completion of the
measurement operation.
I
I
BDD00113
22-10 D58E, P-l
0
TESTING AND ADJUSTING TROUBLESHOOTING
TROUBLESHOOTING
* FOR HOW TO USE TROUBLESHOOTING, SEE “62 TROUBLESHOOTING”
Diagnostic tables
1. High oil temperature in torque converter . , . 22-12
2. The machine will not start . . . . . . . . . . . . 22-13
3. Weak traction power or slow machine
travel speed . . . . . . . . . . . . . . . . . . . . . . 22- 14
4. The machine moves when the engine
is started . . . . . . . . . . . . . . . . . . . . . . . . 22-I 6
5. Excessive time lag when starting off or
changing Qear speeds . . . . . . . . . . . . . . . . 22-I 7
6. The machine receivers severe shocks when
starting off or when changing gear speeds . . 22-I 8
7. Control lever slips out . . . . . . . . . . . . . . . 22-18
8. Control lever is heavy to shift . . . . . . . . . . 22-18
9. The oil level in the transmission case and
steering case goes up or goes down . . . . . . . 22-l 8
10. Steering clutch fails to disengage . . . . . . . . 22-19
11. Steering clutch slips . . . . . . . . . . . . . . . . 22-29
12. Steering brake does not work . . . . . . . . . . 22-21
PREPARATION FOR TROUBLESHOOTING
SAFETY
A . .
Place the machine on level ground and apply the brakes without
During joint work, keep close contact with cooperators and keep off other people.
fail.
. Be careful not to touch hot or rotating parts.

. Keep the negative terminal of the battery disconnected when disconnecting wiring.
Be sure to release remaining oil, water or air pressure, before removing a plug or cap.
Connect testing equipment securely.
CAUTION
Pay attention to the following during troubleshooting, especially when removal and disassembly are necessary.
. Proceed with the disassembly by confirming the fitting conditions of the relative parts; their positions fore-and-
aft, left-and-right and upper-and-lower, and their proper removal sequence.
. Put match marks across mating joints where required, before disassembling parts, and identify each part by
scribe marks.
The part should be clearly marked to prevent confusion at the time of assembly.
. When a part, after removal of mounting nuts and bolts, still does not move, never force the part; carefully check
for the cause.
. Before assembly or installation, throughly clean parts and remove scratches and nicks.
. Throughly remove dust, grease and oil from surfaces to be coated with liquid gasket.
D58E.P-1 22-11
DIAGNOSTIC TABLES
1. HIGH OIL TEMPERATURE IN TORQUE CONVERTER
Ask the operator the following question.

l Does the oil temperature rise when the torque
converter stalls, and fall when it does not stall?
+ If so, normal (Caused by improper selection of
gear speed)
Inspection before troubleshooting

l Are the oil levels in the transmission and in the
steering clutch case normal?
Checking for abnormalities

l Is the oil temperature of the torque converter
higher than the standerd temperature in the Table
of Standards for testing and adjustment?
* If the oil temperature gauge on the machine
indicates that the temperature exceeds the
operating range, despite the fact that the actual
temperature is normal, --t the oil temperature
gauge is defective.
temperature is low.
2 High and low idling speeds are low. I I I I I lol

3 ( Oil p ressure at the torque converter outlet is low. I I I I I lol
4 Oil pressure at the torque converter inlet is low. 0
5 Modulating pressure in the transmission is low. 000
6 Excessive internal leakage in the torque converter. 0

I
L If none of the symptoms are applicable,
this is the cause.
The following symbols are used in “Remedy” column

to indicate the action to be taken when a cause of
failure is located.
X: Replace A: Repair
A: Adjust C: Clean
22-12 D58E.P-1
2. THE MACHINE WILL NOT START
Ask the operator the following questions.

l Did the machine suddenly fail to start?
+ Internal seizure or breakdown
l Did the machine produce any abnormal noise at
that time?
+ Breakdown of the machine parts

l Are the oil levels in the transmission and steering
clutch case proper?
l Is the valve spool travel proper?
l Is the steering brake locked?
Transmission
abcdef
I I I I I I
No. CA AA
4 1The pump produces abnormal noise when the oil

’ 1 temperature is low.
2 ITh e machine fails to start at any gear speed.
3 ITh e machine starts off in a certain gear speed.

I I I I I I
In the case of No. 3, the machine fails to start only in
4
1 st gear speed.
5 The machine fails to start when the oil temoerature rises. 0
6 The pressure is low at any gear speed. 000 00

The modulatina ~
7
:omes normal at a
0
,d.
l--l
The pressure is not stable and the
6
needle of the gauge fluctuates greatly.
When the pressure tap plug is removed, no oil flows

9
out even though the engine is cranked. 0
* If none of the symptoms are applicable, the cause is a slipping steering clutch.
* If none of the causes listed in the above table are applicable to the low modulating pressure in the transmission,
the valve or the transmission body may be cracked.

D58E.P1 22-13
3. WEAK TRACTION POWER OR SLOW MACHINE TRAVEL SPEED

l Have you been operating this machine for a long
time?
l How did you notice that the machine lost perform-
ance?
l Present performance is less than before.
+ There is a large possibility that the machine
has defects.
. Compared with other models (especially larger
machines), the machine has less performance.
+ There is a greater possibility that the
machine is normal.

l Are oil levels in the transmission and steering clutch
case normal?
l Is there any oil leakage on the piping or valve
joints?
. Is the steering brake locked?
l Is the tension of the track shoes maintained
properly?

. See if the traction power and the machine travel
speed are actually insufficient by referring to the
Table of Standards for testing and adjustment.
-
NO
-
1
The pump produces abnormal noise while the oil
temoerature is low. lolol I I I I I I I
-
2
Both the traction power and the machine travel speed
become normal at a soecific aear weed. I I I I lolddd I
3 The oil temperature in the torque converter is high. 000 0
-
4 The stall speed of the torque converter is low.
-
-
5 High and low idling speed are low
IIIIIIIII I
6 The pressure is low at any gear speeds 0 0 0 0
-
The modulating
7 pressure in the
The pressure returns to normal at a
specific gear speed
0 00
- transmission is
low.
The pressure is not stable and the
8 00
-
9 The oil pressure at the torque converter inlet is low. 000 0
-
10 The oil pressure at the torque converter outlet is low. 000 0
-
11 Excessive internal leakage in the torque converter.
-
Fragments of steel or aluminum are found on the drain
12
plug and strainer on the torque converter case.
-
* When the troubleshooting reveals that the engine is defective, check the engine according to the engines shop
manual.
22-14 D58E.P-1
* If the cause of the trouble is related to the steering

brake and steering clutch system, inspect and adjust
it by referring to the Troubleshooting Table for the
steering brake and steering clutch system.

failure is located.
A: Adjust C: Clean
D58E.P-1 22-15
4. THE MACHINE MOVES WHEN THE ENGINE IS STARTED
1. If the engine will start when the shift lever is placed into any gear speed position + Defective neutral safety switch.
2. If the machine will move when the engine is started with the control lever in NEUTRAL position + Transmission
clutch is seized.
3. In the preceeding case, if warming up for 10 to 15 min. will return it to the normal condition + Dragging owing to a
high-viscosity oil. (Confirm that the proper grade of oil is used.)
22-16 D58E.P-1
5. EXCESSIVE TIME LAG WHEN STARTING OFF OR CHANGING GEAR SPEEDS

l Are the proper oil levels maintained in the trans-
mission and the steering clutch case?
l Is there any external oil leakage from the piping or
the valve joint.

l See it the time lag is actually larger by referring
to the Table of Standards for testing and adjust-
ment.
n n
cxx * cxxxx
I
. 1 The pump produces abnormal noise when the oil - - I
’ I temperature is low.
2 1The time lag is excessive at any gear speed. lddol 0 ldd I I I

The machine will start traveling normally only at a
3
specific gear speed. I I I I I I l+iol
In the case of No. 3, the time lag is excessive especially
4 00
in 1 st gear speed.
The transmission modulating pressure is low at any gear

5 000 0 0
speed.
In the case of No. 5, the pressure is unstable and the

6
HoI I I I I I I I
The torque converter oil temperature exceeds the
7 000
operating range.
* If none of the symptoms is applicable, a slipping steering clutch is the cause of the trouble.

failure is located.
A: Adjust C: Clean
D58E.P-1 22-17
6. THE MACHINE RECEIVES SEVERE SHOCKS WHEN STARTING OFF OR WHEN CHANGING
GEAR SPEEDS

l to determine the intensity of shocks, consider the shocks to be large, in the following
Since it is difficult cases.
l When it is obvious that the shocks experienced are greater than the previous ones.
l When the machine experiences large shocks than other machines of the same model.
Causes Remedy
l Clogged orifice in modulating valve or its malfunctioning + c -A *X
l Clogged orifice in quick-return valve or its malfunctioning + c -A *X
7. SHIFT LEVER SLIPS OUT
Remedy
Cause: Defective speed valve detent for control valve + X
8. SHIFT LEVER IS HEAVY TO SHIFT

l See if shifting the lever actually requires greater force. See the Table of Judgement Standards.
Problems and causes

l Disconnect the control lever from the control valve spool and try to move the shift lever.
Cause Remedy
If it is heavy + Interference at turning sections of the control lever linkage + A. X
If it is light + Bent spool, or binding detent -+AbX
9. THE OIL LEVEL IN THE TRANSMISSION AND STEERING CLUTCH CASE GOES UP OR GOES
DOWN
Problem: When the oil level in the transmission goes down, while that in the steering clutch case goes up
Remedy
+ Defective oil seal or defective O-ring on the transmission output shaft. + X

22-18 D58E.P-1
lO.STEERING CLUTCH FAILS TO DISENGAGE

. Did the clutch fail to disengage all of a sudden?
+ Seizure or damage of internal parts.
l Did you hear any abnormal noise at that time?
+ Damaged parts.
Check before troubleshooting

l Check that proper oil levels are maintained in the
transmission and the steering clutch case.
. Check that the valve spool has a normal travel.
. Check that the steering control linkage is properly
adjusted.
. Check that the brake works.
Checking for abnormality

l Relief oil pressure in the clutch circuit.
The pump produces abnormal noise when the oil

2 00
temperature is low.
The clutch fails to disengage when the oil temperature

3
rises. 0 00
4
I
The clutch occasionally fails to operate, or fails to return
from the disengaged position.
I I I loI I I I I
5 The clutch fails to operate at the normal oil pressure. 0
Only the LH (or RHI clutch fails to operate (at the
6 00
normal oil pressure)
Poor turning performance on level ground or on a

7
downhill slope. I I I I I I I I 101
The clutch fails to disengage when the oil temperature
8
rises, even though item No. 6 is normal. I I I I I
9
I
The oil pressure becomes normal by overhauling the
relief valve or by adding shims. I I I
Note: See Item No. 7 and cause “i”. Since the machine keeps moving on a downhill by inertia even if the clutch is
disengaged, the machine will not turn unless the brake works.

failure is located.
A: Adjust C: Clean
D58E.P-1 22-19
11. STEERING CLUTCH SLIPS

. Did the clutch slips all of a sudden?
+ Damaged parts.
Checking before troubleshooting

l Check that proper oil levels are maintained in the
transmission and the steering clutch case.
l Check that the valve spool has a normal travel.
l Check that the steering control linkage is properly
adjusted.
Problems and Causes

Problem Cause Remedy
1. Only the LH (or RH) clutch slips. > Defective parts in the clutch
l Deteriorated spring + X
l Worn or distorted disc and plate + X
2. Disengaged clutch fails to return to engaged position + Improper operation of steering valve spool + A *X

failure is located.
A: Adjust C: Clean
22-20 D58E.P-1
12. STEERING BRAKE DOES NOT WORK

l Did the brake become ineffective all of a sudden?
+ Damaged parts.
Check before troubleshooting

Check that proper oil levels are maintained in the
transmission and steering clutch case.
Check that the brake control linkage is properly
adjusted.
Check that the brake lining clearance is properly
adjusted.
fering with other parts.

l Relief oil pressure
. Operating effort of brake pedal and lever.
The oil pressure becomesnormal after overhauling the

8
relief valve or after adding the shim. 0

failure is located.
A: Adjust C: Clean
D58E.P-1 22-2 1
POWER TRAIN
DAMPER STEERING BRAKE BOOSTER

Dismounting ...................... 23- 2 Dismounting ................. . . . 23- 83
Mounting ........................ 23- 4 Mounting ................... . . 23- 85
TORQFLOW TRANSMISSION AND TORQUE STEERING CONTROL VALVE

CONVERTER Dismounting ................. . . . 23- 87
Dismounting ...................... 23- 6 Mounting ................... . . . 23- 87
Mounting ........................ 23- 9
STEERING
Disjointing ....................... 23-12
.................. . * . 23- 88
Disassembly
Jointing ......................... 23-12
................... . . . 23- 88
Assembly
TORQUE CONVERTER
STEERING MAIN RELIEF VALVE
Disassembly ....................... 23-13
.................. . . . 23- 90
Disassembly
Assembly ........................ 23-20
. . . 23- 90
Assembly ...................
TORQUE CONVERTER RELIEF VALVE
TRANSMISSION PUMP
Dismounting ...................... 23-30
................. . . . 23- 92
Dismounting
Mounting ........................ 23-30
Mounting ................... . . . 23- 94
STEERING PUMP
Disassembly. ...................... 23-31
................. . . . 23- 96
Dismounting
Assembly ........................ 23-43
................... . . . 23- 96
Mounting
TRANSMISSION CONTROL VALVE
FINAL DRIVE FIRST PINION
Dismounting ...................... 23-56
................. . . . 23- 98
Dismounting
Mounting. ........................ 23-56
................... . . . 23-100
Mounting
Disassembly. ...................... 23-58
Assembly ........................ 23-58 FINAL DRIVE
Disassembly .................. . . . 23-102
BEVEL PINION
Assembly ................... . . . 23-107
Dismounting ...................... 23-62
Mounting ........................ 23-62
Disassembly. ...................... 23-63
Assembly ........................ 23-64
BEVEL GEAR SHAFT AND STEERING CLUTCH

Dismounting ...................... 23-66
Mounting ........................ 23-69
Disassembly. ...................... 23-73
Assembly ........................ 23-78
D5BE.P-1 23-l
0
DISASSEMBLY AND ASSEMBLY DAMPER
DISMOUNTING DAMPER ASSEMBLY

Special tool
Part number Part name O’ty
A 790-201-3100 Guide bolt kit 1
Raising body
1) Place blocks @ behind the rear of body and
move machine backward over block.
2) Raising the front of body with blade, place block
@ under shoes and lower body on it slowly.
* When raising body, surely apply brake.
* If it is impossible to run engine, raise body with
a jack or a crane.
Under cover’(Rear)
Supporting under cover (rear) with jack 0, remove
bolts mounting cover, remove cover (1 j.
Under cover (rear): D58E- 1. 78 kg

D58P- 1. 57 kg
3. Universal joint
Remove universal joint (2).
4. Flange
Remove flange (3) by pulling out.
23-2 D58E.P-1
0
5. Damper cover
1) Remove bolts.
2) Install guide bolt A and remove cover (4) with
two forcing bolts (12 mm, P = 1.75).
Damper cover: 15 kg
* Place a oil container to receive oil of approx.

1.3 Q when removing cover.
D58E.P-1 23-3
a
MOUNTING DAMPER ASSEMBLY

Special tool
Part number Part name
A 790-201-3100 Guide bolt kit 1
1. Damper assembly
Secure damper assembly (6) with bolts and lock them
with lock plates (5).
2. Damper cover
1) Fitting O-ring to damper cover (4), set it in the
mounting position by using guide bolt A.
2) Tighten mounting bolts.
3. Flange
Install flange (3).
* Confirm that needle of needle bearing is fall off.
23-4 D58E.P-1
0
4. Supplying oil
Removing oil filler plug (7) and level plug (8). supply
approx. 1.3 P of engine oil (EOBO-CD) and tighten
plugs (7) and (8).
5. Universal joint
Secure universal joint (2) with bolts.
6. Underguard (rear)
Set underguard (1) in the mounting position by
raising it with jack @ and secure it with bolts.
7. Lowering body
1) Start engine and raise the front of body by using
blade.
Lower the front of body on the ground after
taking block 0 out.
* Be sure to apply brake when doing so.
2) Lower body on the ground by forwarding machine
from block 0.
* If it is impossible to run engine, lower body by
a jack or a crane.
D58E.P-1 23-5
a
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION AND TORQUE CONVERTER
DISMOUNTING TORQFLOW TRANSMISSION AND TORQUE

CONVERTER ASSEMBLY
1. Drain the oil
1) Remove drain plug (1) on the hydraulic tank and
drain the oil.
& Oil: Approx.65Q
2) Remove drain plug (2) on the transmission case

and drain the transmission oil.
& Oil: Approx. 34 !Z
3) Remove drain plug (3) on the steering clutch case,

and drain the oil from the case.
A Oil: Approx. 58 R
2. Underguard
Use garage jack @ to remove underguard (4).
3. Dashboard assembly
Remove the dashboard assembly. For details, see
DISMOUNTING DASHBOARD ASSEMBLY.
23-6 D58E.P-1
0
6. Wiring
Disconnect wiring (7).
7. Lift cylinder piping

Remove tube (8) connecting to the lift cylinder head.
8. Steering piping
1) Remove steering valve inlet tube (9).
2) Remove steering strainer inlet tube (10).
9. Steering pump inlet tube

Remove steering pump inlet tube (11).
D58E.P-1 23-7
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION-TORQUE CONVERTER
12. Torque converter oil temperature gauge wire

Disconnect wire (16) of the torque converter oil
temperature gauge.
13. Torque converter outlet tube

Disconnect torque converter outlet tube (17).
14. Transmission lubricating tube

Disconnect transmission lubricating tube (18).

Remove universal joint assembly (19).
16. TORQFLOW transmission and torque converter

assembly
1) Using eye bolts (20 mm, P = 2.5 - one bolt,
16 mm, P = 2.0 - one bolt), temporarily sling the
transmission and torque converter assembly and
remove the mounting bolts (20) on the RH and
LH sides.
2) Remove mounting bolt (21). Remove TORQ-

FLOW transmission and torque converter assembly
(22).
TORQFLOW transmission and torque
converter assembly: 755 kg
23-8 D58E.P-1
a
MOUNTING TORQFLOW TRANSMISSION AND TORQUE

CONVERTER ASSEMBLY
1. TORQFLOW transmission and torque converter
assembly
1) Fit O-rings using two eye bolts (20 mm, P = 2.5
and 16 mm, P = 2.0), install TORQFLOW trans-
mission and torque converter assembly (22).
2) Tighten mounting bolt (21).
3) Tighten mounting bolts (20) on the RH and LH

sides.

Install universal joint assembly (19).
Transmission lubricating tube

Fit an O-ring and connect transmission lubricating
tube (18).
Torque converter outlet tube

Fit an O-ring and connect torque converter outlet
tube (17).
Torque converter oil temperature gauge wire

Connect wire (16) of the torque converter oil tem-
perature gauge, and clamp the wire together with
steering outlet tube.
D58E.P-1 23-9
0
6. Hydraulic pump piping

Fit O-rings and connect pump outlet tube (15) and
inlet tube (14).
7. Eye bolts and breather

I) Install eye bolts (13) on the RH and LH sides.
2) Install breather (12).
8. Steering pump inlet tube

Fit an O-ring and install steering pump inlet tube
(II).
9. Steering piping
I) Fit an O-ring and install steering strainer inlet tube
(IO).
* Clamp the tube together with the wiring.
2) Fit an O-ring and install steering valve inlet tube
(9).

Fit an O-ring and install tube (8) to the lift cylinder
head.
11. Wiring
Connect wiring (7).
23-10 D58E.P-1
a
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION AND’TORQUE CONVERTER
12. Battery
Install battery (61, and secure it with holder (5).
13. Operator’s seat and frame assembly

Install the operator’s seat and frame assembly. For
details, see MOUNTING THE OPERATOR’S SEAT
AND FRAME ASSEMBLY.

Install the dashboard assembly. For details, see
MOUNTING THE DASHBOARD ASSEMBLY.
15. Underguard
Use garage jack 0 to install underguard (4).
16. Add oil

1) Tighten drain plug (3) on the steering clutch case.
Add oil to the specified level through the oil filler.
2) Tighten drain plug (2) on the transmission case.

3) Tighten drain plug (I) on the hydraulic tank.

* Start the engine, let the oil circulate throughout
the system, then recheck the oil level.
D5BE.P-1 23-11
0
DISJOINTING TORQFLOW TRANSMISSION AND TORQUE

CONVERTER ASSEMBLY
1. Torque converter assembly
Removing torque converter housing mounting bolts
and bolts securing suction tube to transmission
housing remove torque converter (1) by slinging.
elks Torque converter: 187 kg
2. Sleeve
Pull out sleeve (2).
JOINTING TORQFLOW TRANSMISSION AND TORQUE

CONVERTER ASSEMBLY
1. Sleeve
Putting O-ring to sleeve (21, install it on housing.
2. Torque converter assembly

Install O-ring in housing of torque converter (1).
Match sleeve and attach with bolts.
Attach O-ring to end surface of suction tube, and
connect torque converter assembly to transmission
housing.
23-12 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY

Special tools
Part number Part name Qw
1;
790-501-5000 Unit repair stand
Preparatory work
. Set torque converter and PTO assembly on unit repair
stand A.
1. Hydraulic pump assembly

Remove hydraulic pump (1).
2. Steering pump assembly

Remove tube by removing bolts mounting outlet
tube clamp bracket (3) on steering pump (21, and
remove pump assembly.
3. Transmission filter
1) Disconnect inlet and outlet tubes of transmission
filter (4) from pump and torque converter case.
2) Remove filter (4) and tube by removing bolts
mounting bracket of filter.
4. Steering strainer and bracket

Remove steering strainer and bracket (5) together as
one-piece.
D58E.P-1 23-13
DISASSEMBLY AND ASSEMBLY TORQUECONVERTER
5. Transmission pump assembly

Remove transmission pump assembly (6).
6. Relief valve
Remove relief valve (7).
7. Yoke
1) Straighten lock plate (8), remove bolts and remove
retainer (9).
2) Remove yoke (IO).
8. PTO housing assembly

1) Remove mounting bolts while slinging housing by
a wire or the like, with hanging bolts attached.
2) Pull out housing assembly (11) with two forcing
bolts (12 mm, P = 1.75).
PTO housing assembly: 61 kg
23-14 D58E.P-1
0
9. Gear
Removing bolts, pull out gear (12) with
bolts (10 mm, P = 1.5 ‘mm).
10. Case
1) Turn over stand and remove bolts mounting case
(13) and pump (23).
2) Turn over the stand and remove snap ring (14),
spacer (15) and plate (16).
3) Remove case with puller
* When bolts mounting case and pump are
removed, case and turbine can be removed
together. In that case, separate case from
turbine after they are removed.
11. Turbine assembly

Remove turbine assembly (17).
D58E.P-1 23-15
0
12. Stator
1) Remove snap ring (18).
2) Remove stator (19).
13. Nut
Remove nut (21) with wrench (B).
23-16 D58E.P-1
a
14. Pump assembly

Inclining stand, remove bolts (22) and pump as-
sembly (23).
DISASSEMBLY OF TORQUE CONVERTER

PUMP ASSEMBLY
15. Shaft
Hammer out shaft (24).
16. Cover
Remove cover (25) by removing bolts.
17. Cage assembly

Remove cage (26).
D58E.P-1 23-17
0
D1lSASSEMBLY OF PTO HOUSING

AS!iiEMBLY
18. Cover
Remove cover (33).
19. Hydraulic pump drive shaft assembly

Remove bolts and hammer out shaft assembly (34)
by lightly tapping it from the opposite side.
20. Transmission and steering pump drive shaft assembly

Remove bolts on cover and hammer out shaft as-
sembly (38) by lightly tapping it firm the opposite
side.
21. Plate
Remove plate (40).
23-18 D58E.P-1
a
22. Snap ring

Remove snap ring (41).
23. Gear and shaft

1) Take out bearing (44) from gear (42) by hammer-
ing shaft (43) and bearing (44).
2) Remove gear and shaft.
24. Cover
Remove cover (47).
25. Bearing
Remove bearing (48).
D58E.P-1 23-19
0
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (112)

ASSEMBLY OF TRANSMISSION AND
STEERING PUMP DRIVE SHAFT ASSEMBLY
1. Bearing
Press-fit bearing (40) to shaft (39).
2. Bearing
Press-fit bearing (41) to shaft.
3. Cover
Press-fit shaft assembly (39) to cover (42).
ASSEMBLY OF HYDRAULIC PUMP DRIVE

SHAFT ASSEMBLY
4. Bearing
Press-fit bearing (36) to shaft (35).
23-20 D58E.P-1
a
5. Bearing
Press-fit bearing (37).
6. Cover
Press-fit shaft assembly (35) to cover (38)
ASSEMBLY OF PTO HOUSING ASSEMBLY
7. Bearing
Drive in bearing (48).
8. Gear and shaft

1) Locate shaft (43) in the mounting position while
inserting shaft into gear (42).
2) Press-fit bearing (44) in gear by hammering shaft.
D58E.P-1 23-21
0
9. Snap ring
Install snap ring (41).
10. Plate
Install plate (40).
11. Snap ring

12. Hydraulic pump drive shaft assembly

Install drive shaft assembly (34) and fasten it with
bolts.
23-22 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY ‘TORQUE CONVERTER
13. Snap ring

14. Transmission and Steering pump drive shaft assembly

Install drive shaft assembly (38) and fasten it with
bolts.
15. Cover
Secure cover (47) with bolts.
16. Cover
Install cover (33).
D58E.P-1 23-23
0
TORQUE CONVERTER
ASSEMBLY OF TURBINE ASSEMBLY
17. Bearing
Press-fit bearing (28) on turbine (27)
18. Spacer, plate, and snap ring

Install plate (161, spacer (15) and snap ring.
19. Case
Install case (13) and fit snap ring (29).
D58E.P-1
23-24
0
ASSEMBLY OF PUMP ASSEMBLY
20. Seal ring

Fit seal ring (30) to shaft (24).
21. Bearing
Press-fit bearing (31) in cage (26).
22. Cage assembly

Install cage assembly (26) to housing.
23. Cover
Secure cover (25) with bolts.
24. Pump assembly

Install pump assembly (23) on shaft (24) by lightly
tapping pump assembly and lightly screw nut (21)
in shaft.
D58E.P-1 23-25
0
ASSEMBLY OF TORQUE CONVERTER (Z/2)

Special tools
Part number Part name Q’tv
A 790-501-5000 Unit repair stand 1
AI 790-901-2110 Bracket 1
AZ 790-901-2120 Plate 1
B 791-342-1310 Wrench 1
Preparatory work
l Set housing (32) on unit repair stand.
2. Nut
Tighten nut with wrench B.
Qy Bearing retaining nut: 18 kgm
3. Stator
1) Fit snap ring (20).
23-26 D58E.P-1
0
2) Install stator (19).
3) Fit snap ring (18).
4. Turbine case assembly

Install turbine case assembly and secure case (13) and
pump (23) with bolts.
* Align cut-out of case with rib of pump.
13OF1036
5. Gear
Secure gear (12) with bolts with thread tightener
(LT-2) applied.
D58E.P-1 23-27
0
6. PfO housing assembly

1) Fit O-ring to housing, its torque converter side.
2) Install housing assembly (11) by slinging and

tighten bolts.
7. Yoke
1) Install yoke (10).
2) Install retainer (9) and lock plate (8) with bolts
and bend lock plate.
8. Relief valve
Install relief valve (7) with O-ring fitted to its mount-
ing surface.

Install pump assembly (6) with bolts, with O-ring
fitted to its mounting surface.
23-28 D58E.P-1
0
10. Steering strainer and bracket

Install steering strainer and bracket (5).
11. Transmission filter

1) Fit O-ring to inlet and outlet tubes flange end faces
of transmission filter (4) and install filter on
bracket.
2) Connect inlet and outlet tubes to pump and torque
converter case.
12. Steering pump assembly

Fitting O-ring to mating surface of steering pump as-
sembly (21, install assembly on PTO case and install
outlet tube clamp bracket (3) on case.
13. Hydraulic pump assembly

Fitting O-ring to mating surface of hydraulic pump
(l), install hydraulic pump in PTO case.
D58E.P-1 23-29
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER RELIEF VALVE
DISMOUNTING TORQUE CONVERTER RELIEF VALVE

ASSEMBLY
1. Remove floor plates (1) and (2).
2. Disconnect cable (3) of the torque converter oil

temperature gauge.
3. Disconnect torque converter outlet tube (4).
4. Remove torque converter relief valve assembly (5).
MOUNTING TORQUE CONVERTER

RELIEF VALVE ASSEMBLY
1. Fit an O-ring and install torque converter relief valve

assembly (5).
2. Fit an O-ring and connect torque converter outlet

tube (4).
3. Connect cable (3) of the torque converter oil tem-

perature gauge.
4. Install floor plates (2) and (1).
23-30 D58E.P-1
a
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DISASSEMBLY OF TORQFLOW TR ANSMISSION ASSEMBLY

Special tools
Part number Part name IQ%
A 790-501-5000 Unit repair stand 1
AI 790-901-3110 Bracket 1
Preparatory work
l Set transmission on unit repair stand A.
TQRQFLOW transmission assembly: 610 kg
1. Cover
1) Remove cover (3) by removing bolts.
2. Control valve assembly

1) Remove snap ring (5) to valve side and pull out
sleeve (6) from valve.
2) Removing mounting bolts (4), remove valve

assembly (7).
D58E.P-1 23-31
0
Remove transmission mounting bolts (8) and remove
case (9) by lifting it with two sling bolts (10 mm,
P=1.5mm).
Transmission case: 120 kg
4. Input shaft assembly

2) Remove shaft assembly (11) by lifting it.
5. Tie bolt
Remove tie bolts (14).
6. Cage
23-32 D58E.P-1
a
2) Slinging cage (16) with two sling bolts (12 mm,

P = 1.75 mm), remove it by prising portion around
dowel pin.
7. Disc, plate and spring

Remove springs (17), discs (18) and plates (19).
8. No.1 ring gear

Remove ring gear (20).
9. No.1 housing
Remove housing (21) together with piston (22).
D58E.P-1 23-33
0
10. Disc, plate, spring and guide

Remove springs (231,guides (241, discs (25) and plates
(26).
11. No.2 ring gear

12. No.2 housing and carrier assembly

Remove housing assembly (28) with two sling bolts
(12 mm, P = 1.75 mm).
13. Piston
Remove piston (29).
23-34 D58E.P-1
a
14. Disc, plate, spring and guide

Remove springs (30), guides (31), discs (32) and
plates (33).
15. Ring gear

2) Remove ring gear (35).
16. No. 3 housing

Remove housing (36) with two sling bolts (12 mm,
P = 1.75 mm).

Remove springs (371, discs (38) and plates (39).
D58E.P-1 23-35
0
18. Ring gear

19. Plate
Remove plate (41) with two sling bolts (12 mm,
P = 1.75 mm).
20. Bearing cover

Removing bolt, remove cover (42).
21. First speed clutch assembly

2) While keeping first speed clutch lifted with its
cover slightly inclines, remove cage (44) with forc-
ing bolts (12 mm, P = 1.75 mm).
3) Remove first speed clutch (45) by lifting it.
First speed clutch: 90 kg
23-36 D58E.P-1
0
DISASSEMBLY OF FIRST SPEED CLUTCH

ASSEMBLY
22. Sun gear and inner race

2) Attaching gear puller @ to sun gear, remove

inner race (50) and sun gear (51).
23. Carrier assembly

1) Remove three carrier mounting bolts.
2) Remove carrier assembly (52) with puller 0.
D58E.P-1 23-37
0
24. Drum assembly

1) Turn over clutch assembly and remove bolts (53).
2) Disconnect drum (54) from housing with forcing

bolts (12 mm, P = 1.75 mm) and remove housing
assembly (55) while leaving drum.
25. Seal ring

Remove seal rings (56)
26. Gear
2) Attaching bolts to gear (58), remove it with gear
puller 0.
36P1343A
23-38 D58E.P-1
0
27. Spring
Removing snap ring (591, remove spring (60).
28. Piston
Remove piston (61).
* As piston has two balls (621, be careful not to lose
them.
29. Shaft
Removing bolts, remove shaft (63).
30. Disc and plate

Remove discs (64) and plates (65) from drum (54).
3OP1346
f30P1369
D58E.P-1 23-39
0
DISASSEMBLY OF NO. 2 HOUSING AND

FORWARD-REVERSE CARRIER ASSEMBLY
31. Piston
Remove piston (71).
73
73OP1350
32. Carrier for forward-reverse gear

Remove carrier assembly (72) from housing (28),
by lightly tapping it.
33. Carrier for third speed

2) Remove carrier assembly (74) by tapping it.
I
34. Bearing
Removing snap ring (75), remove bearing (76).
23-40 D58E.P-1
a
DISASSEMBLY OF INPUT SHAFT

ASSEMBLY
35. Seal ring

Remove seal ring (81).
36. Cage assembly

1) Removing snap ring (82). removing spacer (83)
and plate (84).
2) Supporting cage (85) with a press, push out shaft

(86).
37. Gear
Removing snap ring (87). remove gear (88) and collar
189).
89
13OP1359 T30Pf358
D58E.P-1 23-41
0
DISASSEMBLY OF CARRIER
38. Planetary gear

Remove shaft (92) by lightly tapping it and remove
thrust washer (93) and gear (94).
* Be careful not to lose retaining ball which prevents
shaft from turning.
* Follow the same procedure for disassembling other
carriers.
13OP1360
23-42 D58E.P-1
a
ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY

Special tool
Part number Part name Q’ty
A 799-301-I 300 Air checker 1
ASSEMBLY OF CARRIER
1. Planetary gear
1) Install needle bearing in gear.
2) Install thrust washer (93) and gear (94) in carrier.
3) Press shaft (92) into gear and thrust washer.
* Install balls in shaft without fail.
ASSEMBLY OF INPUT SHAFT ASSEMBLY
2. Bearing
Press-fit bearing (90) to cage (85) and install snap
ring.
3. Shaft assembly
1) Install spacer (89) and gear (88) on shaft. 88
83
33OP3359
2) Install snap ring (87).
13OP1358
D58E.P-1 23-43
0
4. Cage assembly
1) Putting inner race of bearing to shaft (86), install
it together with cage assembly (85).
2) Install plate (84). spacer (83) and snap ring (82)

in this order.
5. Seal ring
Install seal ring (81).
130Pf355
ASSEMBLY NO. 2 HOUSING AND

FORWARD-REVERSE CARRIER ASSEMBLY
6. Third speed carrier assembly

1) Install spacer (77) and seal ring (78) in carrier
(74).
13OP1363
23-44 D58E.P-1
0
7. Bearing
Press-fit bearing (76) and install snap rings (75).
8. Carrier for forward-reverse gear

Place housing (28) on carrier (74) and install it by
tapping.
* Fit dimension of spline is that the A portion is
slightly below the surface. Confirm it from the
third carrier side.
. 13OP1366
13OF1039
D58E.P-1 23-45
a
10. Piston
1) Install seal ring in housing.
2) Install seal ring on piston (71) and install it on
housing.
13OP1350
ASSEMBLY OF FIRST SPEED CLUTCH

ASSEMBLY
11. Shaft
1) Secure shaft (63) on housing (65) with bolts.
* Apply thread tightener (LT-2) to bolts.
2) Install seal ring (67).
12. Piston
1) Grease two balls (62) and install them.
13OP1369
23-46 D58E.P-1
al
2) Install seal ring (68).

3) Push plate (65) into position.
* Be careful not to allow seal ring to interlock.
13. Spring
Install spring (60) and install snap ring (59).
14. Gear
1) Place gear (58) on spring.
2) Press-fit bearing (69).
.13OP1372
3) Install snap ring (57).
D58E.P-1 23-47
0
15. Seal ring

16. Disc and plate

Install discs (64) and plates (65).
17. Drum
1) Align outer teeth of all discs.
2) Align bolts holes of housing (66) and drum (54).
and loosely fasten them with two bolts from under
side.
3) Turn over clutch assembly and tighten bolts.
18. Carrier assembly

’ Install carrier assembly (52) with dowels aligned and
tighten bolts.
23-48 D58E.P-1
0
19. Sun gear and inner race

1) Install sun gear (51).
2) Press-fit inner race (50) and install snap ring (49).
20. Seal ring

ASSEMBLY OF TORQFLOW TRANSMISSION

ASSEMBLY
Preparatory work
l Set transmission housing on unit repair stand 0.
21. Bearing cage

Put O-ring to cage (44) and lightly fasten it with
three bolts.
D58E.P-1 23-49
0
22. First speed clutch assembly

1) Slinging first speed clutch assembly (45), install
it on housing.
2) Inclining stand, press-fit bearing from the under
side.
3) Install snap ring.
23. Cover
1) Press-fit oil seal to cover (42).
2) Secure it on cage with bolts.
24. Plate
Putting O-ring to plate (41), install it with dowels
aligned.
25. Ring gear

Install ring gear (40) with its larger cut-out downward.
23-50
0
DISASSEMBLY AND ASSEMBLY TOR’QFLOW TRANSMISSION
26. Disc, plate, guide and spring

Install discs (38), plates (39), guides (31) and springs
(37) in this order.
27. No. 3 housing

1) Install piston in housing (36).
2) Install housing on guides (31) aligning them with
guide holes.
* Be careful not to drop lower piston.
28. Ring gear

1) Engage inner teeth of ring gear (35) with planetary
gear with its snap ring groove downward.
2) Pressing housing, install snap ring (34) inside.

Install discs (32), plates (33) and springs (39).
D58E.P-1 23-51
a
30. No. 2 housing and carrier assembly

Install housing assembly (28) by slinging it.
* Be careful not to drop lower piston.
t30Pf386
31. Ring gear

Install ring gear (27) with its larger cut-out downward.
32. Disc, plate, guide and spring

Install discs (25), plates (26), guides (24) and springs
(23) in this order.
33. No. 1 housing

Install piston in housing (21) and install them.
23-52 D58E.P-1
a

Install discs (18), plates (19) and springs (17).
36. Cage
Install cage (16).
13OPT392
37. Tie bolt

14
Apply thread tightener (LT-2) to tie bolts (14) and
tighten it. .~-\i
r
w Tie bolt: 17 * 1 kgm
_ ‘r30Pf393
D58E.P-1 23-53
0
38. Bearing
I) Press-fit bearing (13) between cage (16) and carrier
(74).
* Slinging carrier assembly, press-fit bearing as
far as snap ring can be installed.
2) Install snap ring.
39. Input shaft assembly

Install shaft assembly (11) and install snap ring (10).
40. Air test

Confirm that each piston operates smoothly with air
checker A.
Travel 1 Air pressure

No.1 clutch 1 5mm 1 3-5 kg/cm’
No.2 clutch 1 5mm 1 3-5 kg/cm’
No.3 clutch 1 5mm 1 3-5 kg/cm2
No.4 clutch 5mm 3-5 kg/cm*
No.5 clutch 4mm 3-5 kg/cm2
41. Case
1) Apply gasket sealant (LG-1) to gasket and attach
gasket to case.
2) Slining case (9). secure it with bolts (8).
23-54 D58E.P-1
0
3) Match speed valve spool (96) with lever (97) of

control valve assembly (7) and its directional valve
spool (98) with lever (99) and secure them with
bolts (4).
m Valve mounting bolt: 6.5 + 1 kgm
4) Push sleeve (6) into valve and install snap ring (5).
43. Cover
Install cover (3).
D58E.P-1 23-55
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
DISMOUNTING TRANSMISSION CONTROL VALVE
MOUNTING TRANSMISSION
CONTROL VALVE ASSEMBLY
1. Fit an O-ring, align speed valve spool (6) of control

valve assembly (5) with lever (7). align directional
valve spool (8) with lever (9). and install the control
valve assembly by inserting it into the valve inlet and
outlet sleeves.
2. Press sleeve (4) into the valve and install snap ring (3).
3. Fit an O-ring and install quick-return valve (2).
m Valve mounting bolt: 6.5 * 1.0 kgm
4. Fit a gasket on mounting surface and install valve

cover (1).
& Gasket: Liquid gasket LG-1
5. Install the plate and floor plates.
13OF1040
23-56 D58E.P-1
0
DISASSEMBLY OF TRANSMISSION CONTROL VALVE

ASSEMBLY (l/2)
DISASSEMBLY OF SPEED VALVE AND MODULATING VALVE ASSEMBLY
1. Remove speed valve spool (1).

2. Remove mounting bolts (2). Then remove directional
valve spool (3) and cover (4) at the same time.
3. Remove cover (5) and shims (6).
4. Remove spacer (7), large spring (8), and small spring
(9).
5. Remove washer (IO).
6. Remove modulating valve assembly (11).
7. Remove seat (12), spring (13). and valve spool (14).
8. Remove large piston (15). spring (16). and small
piston (17).
ASSEMBLY OF TRANSMISSION CONTROL VALVE

ASSEMBLY (l/2)
ASSEMBLY OF SPEED VALVE AND MODULATING VALVE ASSEMBLY
1. Insert small piston (17) into valve spool (14) with the
round end facing inward, and insert spring (16) and
large piston (15) with the round end facing outward.
2. Insert valve (14) to valve (11). Install spring (13) and
seat (12).
3. Install modulating valve assembly (11) to the valve
body.
4. Install washer (10) to the inside of the valve body
from the side opposite to the modulating valve.
5. Install small spring (9). large spring (8). and spacer
(7).
6. Install shims (6) and cover (5).
7. Fit O-rings, install cover (4) and directional valve
spool (3) at the same time, and tighten mounting bolts
(2).
8. Install speed valve spool (1).
23-58 D58E.P-1
0
13OF1041
D58E.P1 23-59
0
DISASSEMBLY OF TRANSMISSION CONTROL VALVE

ASSEMBLY (2/2)
DISASSEMBLY OF QUICK-RETURN VALVE
1. Remove snap ring (1). Then remove sleeve (2) and

spool (3) at the same time.
2. Remove snap ring (4) and stopper (5).

D58E-1 B
Remove plug (5) and O-ring (4).
3. Remove snap ring (6) and cover (7). then remove rod
(8).
ASSEMBLY OF TRANSMISSION CONTROL VALVE

ASSEMBLY (2/2)
ASSEMBLY OF QUICK-RETURN VALVE
Insert rod (8) into the valve body, and install cover
(7) and snap ring (6).
Insert stopper (5) and install snap ring (4).

D58E-1 B
Fit O-ring (4) and install plug (5).
Insert spool (3) and sleeve (2), then install snap ring
(1).
23-60 D58E,P-1
0
13OF1042
* 1 : Applicable serial NO.
D58E,P-1 23-61
0
DISASSEMBLY AND ASSEMBLY BEVEL PINION
DISMOUNTING BEVEL PINION ASSEMBLY

1. Transmission assembly
Refer to DISMOUNTING TRANSMISSION section.
2. Bevel pinion assembly

Removing bolts and pull out bevel pinion assembly
(1) with forcing bolt @ (12 mm, P = 1.75 mm).
Then sling out bevel pinion (1) with a crane.
Bevel pinion: 26 kg
* Record amount and thickness of shims (2)

between bevel gear shaft and bearing cage mating
surface, and keep them.
* The standard shim thickness: 2 mm
MOUNTING BEVEL PINION

ASSEMBLY
1. Bevel pinion assembly
Apply moly lubricant (LM-P) to bearing cage surface,
insert shims (2) kept after disassemble between bear-
ing cage and bevel gear shaft case and install bevel
pinion (I).
* If necessary, bevel pinion should be replaced
together with bevel gear as a matched set.
2. Transmission assembly
Refer to MOUNTING TRANSMISSION section.
23-62 D58E.P-1
0
DISASSEMBLY OF BEVEL PINION ASSEMBLY

Special tool
A 790-102-1710 Wrench 1
1. Nut
1) Straighten lock plate (l), remove bolts and remove
plate (2) which prevents lock pin from coming
out.
2) Pull out lock pin (3).
3) Remove nut (4) with special tool A.
2. Bevel pinion
Push out bevel pinion by setting it to press.
D58E.P-1 23-63
a
ASSEMBLY OF BEVEL PINION ASSEMBLY

Special tool
A 790-l 02-I 710 Wrench 1
1. Bearing inner race

Press-fif inner race (7) in bevel pinion (6).
2. Bearing outer race

Press-fit outer race (9) in bearing cage (8).
3. Bearing outer race

Press-fit outer race (10) in bearing cage (8).
4. Bearing cage assembly

Set bevel pinion assembly (11) to a press, assemble
cage assembly (12). and press-fit inner race (13).
23-64 D58E.P-1
Cc
5. Nut
1) Fix bevel pinion, tighten nut (4) with special tool
A and set pinion in such position as lock pin can
be inserted within the specified torque while
measuring torque.
* Bevel pinion rotating torque: 0.41 - 0.50 kgm

(Rotating torque at cage mounting bolts hole:
5.4 - 6.5 kg)
2) Insert lock pin (3) in pin hole

* After pin is inserted, unscrew nut until clear-
ance in pin hole disappears.
3) Install lock plate (2), tighten it with bolt and lock

it with lock plate (1).
B Mounting bolt for plate: 0.9 - 1.5 kgm
D58E.P-1 23-65
0
DISASSEMBLY AND ASSEMBLY BEVEL GEAR SHAFT AND STEERING CLUTCH
DISMOUNTING BEVEL GEAR SHAFT AND STEERING

CLUTCH ASSEMBLY
Dismount the operator’s seat and frame assembly.
For details, see DISMOUNTING THE OPERATOR’S
SEAT FRAME ASSEMBLY.
2. Drain the oil

Remove plug (1) and drain the oil from the steering
clutch case.
* Oil drain: Approx. 58 R
3. Hydraulic tank cover

Remove hydraulic tank cover (2).
4. Rear cover
Open rear cover (3).
5. Fuel tank assembly

1) Shut valve (4), and disconnect fuel supply tube
(5).
2) Disconnect fuel return tube (6).
23-66 D58E.P-1
a
3) Disconnect the lamp wiring, sling fuel tank as-

sembly (7), and remove it.
6. Battery
1) Disconnect the wiring from the batteries, and
remove two batteries (8).
2) Remove battery frame (9).
7. Steering linkage
1) Remove steering rods (10) and (11).
2) Remove brake rods (12) and (13).
8. Frame
Remove frame (14).
9. Piping
1) Remove wiring clamp (15).
2) Remove steering clutch case outlet tube (16).
3) Remove steering control valve inlet tube (17).
D58E.P-1 23-67
a
10. Clutch cover

1) Remove inspection cover (18), fully loosen brake
adjustment nut (191, then tighten the nut two to
three turns.
* Be sure to screw in the nut. If the nut is left
loose, the brake rod will fall down.
2) Using three eye bolts (two bolts: 12 mm, P = 1.75

mm; one bolt: 10 mm, P = 1.5 mm), sling clutch
cover (20) and remove it.
11. Clutch mounting bolts

Remove clutch mounting bolts (21).
* Remove the mounting bolts by placing a jack at
the grouser of the track shoe and rotating the
brake drum.
12. Spring
Remove front and rear springs (22).
13. Filler
Remove filler (24).
14. Adjustment nut

Remove RH and LH locks (25), and use tool @ to
loosen adjustment nut (26).
15. Caps
Remove RH and LH caps (27).
16. Bevel gear shaft and steering clutch assembly

Sling bevel gear shaft and steering clutch assembly
(28) and remove it.
Bevel gear shaft and steering clutch assembly:

228 kg
23-68 D58E.P-1
MOUNTING BEVEL GEAR SHAFT AND STEERING CLUTCH

ASSEMBLY
1. Bevel gear shaft and steering dutch assembly
Lift bevel gear shaft and steering clutch assembly (28)
horizontally, and install the assembly into the
steering clutch case.
* Fit the ball section on the yoke end securely.
2. Caps
Install caps (27) in alignment with the groove on the
cage, and temporarily tighten the mounting bolts.
3. Adjustment
1) Adjust the bevel gear preload by using tool @
while tightening adjustment nut (26).
* Preload: 8.25 + 0.75 kg at the tooth crest of
bevel gear.
2) Adjust the backlash of the bevel gear with fuse or
dial gauge, and check that the tooth contact is
normal.
* Backlash: 0.29 t 0.04 mm
3) Tighten the mounting bolts for cap (27) evenly,
and secure the bolts with lock (25).
QZ Mounting bolt: 56 * 6 kgm
4) Check the clutch yoke travel.

* Travel: 16.9 + I mm
4. Filler
Install filler (24).
5. Spring
Install spring (22).
6. Clutch mounting bolts

Align the spigot joint, and tighten mounting bolts
(21).
* Tighten the mounting bolts by placing a jack at
the grouser of the track shoe while rotating the
brake drum.
D58E.P-1
7. Clutch cover
1) Fit a gasket to the mounting surface. Using three
eye bolts (two bolts: 12 mm, P = 1.75 mm;
one bolt: 10 mm, P = 1.5 mm), sling clutch cover
(20) and install it.
a Gasket: Liquid gasket (LG-1)
* When installing the cover, take care not to let

the steering valve piston fall down. Be sure to
let the brake band engage with the rod pin at
the front of the band. Place the brake band in
position by pressing it from the rear side of the
steering clutch case.
2) Tighten brake adjustment nut (19) and confirm
that the brake is properly connected.
8. Piping
1) Fit O-rings and install steering control valve inlet
tube (17).
2) Fit O-rings and install steering case outlet tube
(16).
3) Connect wiring clamp (15).
9. Frame
Install frame (14).
10. Steering linkage

1) Install brake rods (13) and (12).
2) Install steering rods (11) and (IO).
23-70 D58E.P-1
0
11. Adjustment
1) Tighten brake adjustment nut (19) to a torque of
9 kgm, then turn the nut in the opposite direction
by I-316 turns.
t Brake pedal travel at this stage:
95to115mm
* Steering lever stroke: 198 to 208 mm
2) Fit a gasket and install inspection cover (18).
& Gasket: Liquid gasket (LG-1)
12. Batteries
1) Install battery frame (9).
2) Install two batteries (8) and connect the wiring.

1) Sling fuel tank assembly (7) and install it.
2) Connect fuel return tube (6).

3) Connect fuel supply tube (5) and open valve (4).
D58E.P-1 23-71
a
14. Rear cover

Close rear cover (3).
15. Hydraulic tank cover.

Install hydraulic tank cover (2).

Mount the operator’s seat and frame assembly. For
FRAME ASSEMBLY.
17. Add oil

Tighten drain plug (1). Add engine oil to the specified
level through the oil filler.
* Start the engine, let the oil circulate throughout
the system, then recheck the oil level.
23-72 D58E.P-1
0
DISASSEMBLY OF BEVEL GEAR SHAFT AND STEERING

CLUTCH ASSEMBLY
Special tools
Part number Part name I O’tv

A 791-442-l 500 Socket (width across 1
flats of nut: 70 mm)
B 791-442-I 000 Remover A 1
B1 790-101-1101 Pump 1
B2 791-101-I 801 Puller (50 ton) 1
cI 791-442-l 300 1 Wrench I ’

D 791-430-5000 Compressor 1
D, 790-101-2101 Puller (30 ton) 1
1. Right and left brake bands

Remove brake bands (1).
2. Right and left brake drums

Pull out brake drums (2) straight.
3. Right and left bevel gear shaft nuts

1) Place bevel gear shaft and steering clutch assembly
on a bench in such manner as to prevent them from
rolling. Remove bolt, then remove lock plate (3).
2) Remove bevel gear shaft nut (4) with special tool
A.
* Width across flats of nut: 70 mm
4. Right and left steering clutch 81 yoke assembly

Pull out steering clutch & yoke assembly (5) with
special tool B.
A To prevent bevel gear shaft nut from being

pulled out, tighten nut two or three pitches
with hand loosely.
D58E.P-1 23-73
10. Nut
1) Remove nut (14) with special tool C.
13OP1431
,, j, ,,, ‘, f30PT432
DISASSEMBLY OF YOKE ASSEMBLY
11. Snap ring-

Remove snap ring (17).
12. Bearing
Remove bearing (18).
- 13OP1433
D58E.P-1 23-75
0
DISASSEMBLY OF STEERING CLUTCH

ASSEMBLY 19
13. Lock
Remove lock (19) by compressing spring with special
tool D.
f
1
?3OP1435
14. Spring seat and spring

Remove spring seat (20) and spring (21) inside
I
tool D.
13OP1437
15. Pressure plate

Turn drum round and remove rod (22), then remove
pressure plate (23).
130P1438A
23-76 D58E.P-1
0
16. Disc and plate

1) Measure the assembled thickness H of discs and
plates before removing them to determine the
necessity of their replacement.
IAssembled thickness H of discs
D58-1 I 52 mm
13OF1046
2) Remove discs (24) and plates (25).

* Place discs and plates on level place to prevent
strain.
f30P1439
D58E.P-1 23-77
a
DISASSEMBLY AND ASSEMBLY BEVEL GEAR SHAFT AND STEi$~$Ik
_- _.__
_^.__.._.-.--- ---“-
ASSEMBLY OF BEVEL GEAF3,S~~~~~~~~~STEERING

CLUTCH ASSEMBLY
I.,,.52,
,--_..- -e,”
_-_:
Special tools
ASSEMBLY OF STEERING CLUTCH

ASSEMBLY
1. Disc and plate

install discs (24) and plates (25) on inner drum (26)
alternately starting with disc.
* The plate to be installed first (clutch drum side) is
thicker than other plates.
* When installing, apply engine oil (E-0 ,36rICD)
between each disc and plate. -. i.d“-.
2. Pressure plate
Install pressure plate (23) while aligning gear teeth
and spring rod holes.
. ____~
_II :_
.,.
3. Temporary assembly and special tools

1) Align all teeth and temporarily install outer drum
(2).
2) Insert bolts &? into spring rod hole and fasten
discs and plates.
13OP 1443
23-78 D58E.P-1
a
3) Remove outer drum, turn it round and reinstall

it. Remove bolt @ and set special tools D.
4. Spring seat and spring

Insert rod (22) from the underside and install spring
seat (20) and spring (21).
* Install inner spring seat with its projecting part up.
5. Lock
Using special tool D, press-fit pressure plate and insert
lock (19) by pushing up rod (22) from the underside
and remove outer drum. .
D58E.P-1 23-79
a
ASSEMBLY OF YOKE ASSEMBLY
6. Bearing
Press-fit bearing (18).
7. Snap ring
Fix snap ring (17).
ASSEMBLY OF STEERING CLUTCH AND

YOKE ASSEMBLY
8. Nut
1) Install yoke assembly (15) in bearing inner race of
steering clutch assembly (16).
13OP1448
2) Tighten nut (14) with special tool C.
m Nut: 50 kgm
13OP1449
9. Lock screw
Machining lock bolt hole thread by a tap (8 mm,
P = 1.25 mm), lock it with lock screw (13) and peen
its head to prevent its turning.
13OP1430
23-80 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION-TORQUE CONVERTER
10. Bevel gear

Install bevel gear (12) on shaft, insert bolts (1 I),
then attach lock plate (9), fasten them with nut
(IO) and bend lock plate firmly.
11. Right and left bearings

Install bearing inner race (8) after heating it.
* As excessive heating may change metallic struc-
ture, surface temperature should be lower than
1 lo”c.
12. Right and left nuts

Install nuts (7).
13. Right and left bearing cages

Install bearing cages (6).
14. Right and left steering clutch & yoke assembly

Apply moly lubricant (LM-P) to taper serration and
press-fit steering clutch & yoke assembly (5) with
special tool B.
* Press-fitting force for steering clutch and yoke
ass’y: 4.5 - 9 ton
* After press-fitting, confirm that the distance H
between joggling part of bevel gear shaft and inner
drum end surface is in the range of 2.5 f 10 mm.
13OF1048
D58E.P-1 23-81
0
DISASSEMBLY AND ASSEMBLY BEVEL GEAR SHAFT AND STE’ERING CLUTCH
15. Right and left bevel gear shaft nuts

1) Apply moly lubricant (LM-P) to the threaded part
and tighten bevel gear shaft nut (4) with special
tool A.
m Bevel gear shaft nut: 54 ?r:18 kgm
2) Attach lock plate (3) and lock nut (4).
16. Right and left brake drums

Align all teeth and install brake drum (2) straight.
17. Right and left brake bands

Install brake band (1).
23-82 D58E.P-1
a
DISASSEMBLY AND ASSEMBLY STEERING BRAKE BOOSTER
DISMOUNTING STEERING BRAKE BOOSTER ASSEMBLY

Disconnect the lamp wiring, sling fuel tank assembly
(41, and remove it.
4. Batteries
Disconnect battery cables, sling two batteries (5),
remove them, and remove battery frame (6).
5. Steering rods
1) Remove steering rods (7) and (8).
2) Remove brake rods (9) and (IO).
D58E.P-1 23-83
a
6. Frame
Remove frame (11).
7. Piping
Remove tubes (I 2) and (I 3).
8. Inspection cover
Remove inspection cover (14). fully loosen brake
adjustment nut (15), and screw in the nut by two to
three turns.
* If the nut is left loose, the brake rod will fall
down in removing the booster assembly.
9. Steering brake booster assembly

Using two eye bolts (12 mm, P = 1.75 mm), sling
steering brake booster assembly (16) and remove it.
13OP1462
23-84 D58E.P-1
a
MOUNTING STEERING BRAKE BO( XTER ASSEMBLY

1. Steering brake booster assembly
Fit a gasket to the mounting surface, using two eye
bolts (12 mm, P = 1.75 mm), sling steering brake
booster assembly (16) and install it.
& Gasket: Liquid gasket (LG-1)
* To install the steering brake booster assembly,

engage the band with the rod pin in the front of
the brake band and pressing the brake band into
position.
* Tighten the brake adjustment nut and confirm
that the brake is connected. 130Pf 462
2. Adjustment
Tighten brake adjustment nut (15) to a torque of
9 kgm with torque wrench 0, and loosen the nut
by l-3/6 turns.
* Brake pedal travel at this stage: 95 - 115 mm
* Steering lever travel: 198 - 268 mm
3. Inspection cover
Fit a gasket and-install inspection cover (14).
a Gasket: Liquid gasket (LG-1 )
4. Piping
Install tubes (13) and (12).
D58E.P-1 23-85
0
DISASSEMBLY AND ASSEMBLY STEERING BRA’KE BOOSTER
5. Frame
Install frame (11).
6. Steering rods
1) Install brake rods (10) and (9).
2) Install steering rods (8) and (7).
7. Batteries
Install battery frame (6) and two batteries (51, and
connect the battery cables.

Sling fuel tank assembly (4) and install it, and
connect the lamp wiring.
9. Fuel piping
Connect fuel return tube (3) and fuel supply tube (21,
open valve (I), and close the rear cover.

Mount the operator’s seat and frame assembly. For
AND FRAME ASSEMBLY.
23-86
0
DISASSEMBLY AND ASSEMBLY STEERING CONTROL VALVE
DISMOUNTING STEERING CONTROL VALVE ASSEMBLY

1. Sling operator’s seat assembly (1) and remove it.
Operator’s seat assembly: 43 kg
2. Remove the LH side cover, and open the rear cover.
3. Disconnect RH brake rod (2) and steering rods (3)

and (4).
4. Remove valve inlet tube (5) and brake tubes (6),

(7), (8), and (9).
5. Remove tube (10) and oil pressure measurement

tubes (11). (12). (13), and (14) together with the
bracket as a unit.
6. Remove steering control valve assembly (15).
MOUNTING STEERING CONTROL

VALVE ASSEMBLY
1 Fit an O-ring to sleeve (16), and a gasket to the seat,

align bore position (17) of the sleeve, and install
steering control valve assembly (15).
A?& Gasket: Liquid gasket (LG-1)
2. Connect pressure measurement tubes (14), (13), (12),

(1 l), fit O-rings and connect tube (10).
3. Connect brake tubes (9). (8), (7), (6), fit O-ring, and
connect valve inlet tube (5).
4. Connect steering rods (4) and (3) and RH brake rod

(2).
* Bend the cotter pins securely.
5. Install the LH side cover and shut the rear cover.
6. Sling operator’s seat assembly (1) and install it.
D58E.P-1 23-87
a
DISASSEMBLY AND ASSEMBLY STEERING
DISASSEMBLY OF STEERING ASSEMBLY

1. Remove brake control valve assembly (2) from
steering valve assembly (1).
2. Remove plate (41, guide (5). and shaft assembly (6)

from brake valve assembly (21, then remove plug (7).
spring (81, valve (9) and piston (IO) from brake valve
assembly (2).
3. Remove bolt (1 I), pull out lever (12) and remove

lever (13).
4. Remove shaft assembly (14).
5. Remove plug (151, then remove spring (161, valve

(17) and piston (18).
ASSEMBLY OF STEERING ASSEMBLY
1. Install piston (18) into valve (17), insert valve in body

together with spring (16), then fit O-ring and install
Pkl (15).
w Plug: 11 f 1.5 kgm
2. Install shaft assembly (14).
3. Set lever (13) in position, connect lever (12), and

tighten bolt (1 1).
4. Install piston (IO) into valve (91, insert valve in body

together with spring (8), then fit O-ring and install
plug (7).
m Plug: 4 * 0.5 kgm
5. Install shaft assembly (6). attach guide (5), and install

plate (4).
6. Fit O-ring and assemblesleeve (191, then install brake

valve assembly (2).
23-88 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY STEERING
15
b
lS\S
‘*\;
‘7.
8
'14
I44F280
D58E.P-1 23-89
0
DISASSEMBLY AND ASSEMBLY STEERING MAIN ‘RELIEF VALVE
DISASSEMBLY OF STEERING MAIN RELIEF VALVE

ASSEMBLY
1. Remove plate (I), use forcing screw (Dia. = IO mm,
Pitch = 1.5 mm) to remove plug (2) together with
shim (3).
2. Remove spacer (41, springs (5) and (6), then remove

valves (7), (8) and spring (9) together with spool (IO).
3. Remove plug (Ill with forcing screw (Dia. = 10 mm,

Pitch = 1.5 mm), then remove spring (12) and valve
(13).
4. Remove plate (14). then remove plugs (15) and (16).
ASSEMBLY OF STEERING MAIN RELIEF VALVE ASSEMBLY

1. Fit O-ring and install plugs (15) and (16) into body
(17). then install plate (14).
2. Install valve (12) and spring (1 I), then fit O-ring and
install plug (IO).
3. Install valves (7) and (81, and spring (9) into spool
(IO), and install spool in body (17) together with
springs (5) and (6).
4. Fit O-ring and install plug (2). shims (31, and spacer
(4) in body (17).
5. Install plate (1).
23-90 D58E.P-1
0
RELIEF VALVE
DlSASSEMBLY AND ASSEMBLY STEERING MAIN
I44F28 I
D58E.P-1 23-9 1
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION PUMP
DISMOUNTING TRANSMISSION PUMP ASSEMBLY

1. Underguard - .“.‘\
Use garage jack @ to remove underguard (1).
2. Floor plates
Remove floor plates (2) and (3).
3. LH side cover
Remove the LH side cover.
4. Transmission control valve inlet tube

Remove transmission control valve inlet tube (4).
5. Steering filter outlet tube

Disconnect steering filter outlet tube (5).
23-92 D58E.P-1
0
6. Steering filter inlet tube

Remove steering filter inlet tube (6).
7. Filter assembly
Remove steering filter assembly (7).
8. Transmission pump inlet tube

Disconnect transmission pump inlet tube (8).
9. Transmission pump outlet tube

Disconnect transmission pump outlet tube (9).

Pull out transmission pump assembly (10) and
remove it.
* The inlet tube of the pump has a spigot joint.
However, since a rubber hose is attached
to the
inlet tube, pull out and then lift up the pump shaft
before disconnecting inlet tube.
D58E.P-1
23-93
0
MOUNTING TRANSMISSION PUMP ASSEMBLY

1.Transmission pump assembly
Fit O-rings to the pump inlet tube and the mounting
section of the pump, align transmission pump as-
sembly (10) with the inlet tube, and install the pump
assembly.
2. Transmission outlet tube

Fit an O-ring and connect transmission outlet tube
(9).
3. Transmission inlet tube

Connect transmission inlet tube (8).
4. Filter assembly
Install steering filter assembly (7).
5. Steering filter inlet tube

Fit an O-ring and install steering filter inlet tube
(6).
6. Steering filter outlet tube

Fit an O-ring and connect steering filter outlet tube
(5).
23-94 D58E.P-1
0
7. Transmission control valve inlet tube

Fit an O-ring and install transmission control valve
inlet tube (4).
8. LH side cover
Install the LH side cover.
9. Floor plates
Install floor plates (3) and (2).
10. Underguard
Use garage jack @ to install underguard (1).
D58E.P-1 23-95
0
DISASSEMBLY AND ASSEMBLY STEERING PUMP
DISMOUNTING STEERING PUMP ASSEMBLY

1. Remove the upper and lower sections of the engine
LH side covers.
2. Remove the floor plates.
3. Disconnect pump outlet tube (1) and raise it with a

sling.
4. Disconnect pump inlet tube (2) and loosen the

mounting bolts on the strainer side.
5. Dismount pump assembly (3).
MOUNTING STEERING PUMP ASSEMBLY

1. Fit an O-ring and install pump assembly (3).
2. Fit an O-ring, connect pump inlet tube (2). and

tighten the mounting bolts on the strainer side.
3. Fit an O-ring and connect pump outlet tube (1).
4. Install the floor plates.
5. Install the upper and lower sections of the engine

LH side covers.
23-96 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE FIRST PINION
DISMOUNTING FINAL DRIVE FIRST PINION ASSEMBLY

Special tools
Part number Part name IQ’ty
A 791-442-1600 Socket (width across 1

flats: 75 mm)
B 791-442-I 000 Remover A 1
IB1 / 790-101-1101 1 Pump I 1

82 790-101-1801 Puller (50 ton) 1

Refer to DISMOUNTING BEVEL GEAR SHAFT
AND STEERING CLUTCH section.
2. Nut
I) Straighten lock plate (I ).
2) Remove nut (2) with socket A. Remove bolts and

remove lock plate.
* Loosen flange giving locking means in bolts
hole.
* Nut width across flats: 75 mm
3) Remove rubber packing (3).
3. Flange
Remove flange (4) with special tools B.
23-98
0
4. Cage
Remove bolt and remove cage (5) with forcing bolts
(12 mm, P = 1.25 mm).
5. Final drive first pinion

Pull out first pinion (6).
D58E.P-1 23-99
0
MOUNTING FINAL DRIVE FIRST PINION ASSEMBLY

Special tools
A 791-442-I 600 Socket (width across 1

flats: 75 mm)
B 791-435-4000 Installer 1
Br 790-101-l 101 Pump 1
Bz 790-101-1801 Puller (50 ton) 1
1. Final drive first pinion

Install first pinion (6) meshing it with final drive
first driven gear.
* Press-fit bearing inner race to first pinion both
side.
2. Cage
Install cage (5) in such direction as its oil hole is
located above steering case while tightening bolts
evenly.
* Press-fit bearing outer race and oil seal in cage,
apply grease (G2-LI) to seal lip and out it O-ring.
3. Flange
Apply moly lubricant (LM-PI to press-fitting part of
shaft and press-fit flange (4) to shaft with care not to
damage oil seal lip, by using special tools A.
* Flange press-fitting force: 10 ton
23-100 D58E.P-1
0
4. Nut
1) Apply liquid gasket (LG-1) to rubber packing (31,
install it.
2) Install lock plate with bolts, and utilizing bolt

holes in flange, prevent flange from being rotated,
and then install nut (2) with special tool B.
w Nut: 55* 15 kgm
3) Lock the lock plate (1).

Refer to MOUNTING BEVEL GEAR SHAFT AND
STEEING CLUTCH section.
130Pf480
D5BE.P-1 23-101
0
DISASSEMBLY AND ASSEMBLY ‘FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE ASSEMBLY

Special tools
‘~
C 791-542-5001 Remover A 1
C1 790-101-1101 Pump 1
1 Cz 1 790-101-1600 / Cylinder (70 ton) 1 1
D I 790-102-I 651 1 Wrench I 1

E I 791-530-5000 1 Remover A I1
IE,I 790 -101 -1300 1Cylinder (100 ton) I1
1. Track frame assembly
Refer to DISMOUNTING TRACK FRAME AS-
SEMBLY section.
2. Drain
Remove drain plug (I) and drain oil from final drive
case.
- : Amount of final drive case oil (each side):

D58E-1. 13Q
D58P-1. 14.5 Q
* When draining, loosening level plug (2) would faci-

litate drainage.
3. Cap
Remove bolts and remove cap (3).
4. Nut
Straighten lock plate (4), remove nut (5) with special
tool A and remove plate (6).
* Nut width across flats: 75 mm
23- 102 D5BE.P-1
a
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6. Bearing retainer
Remove bolts and remove retainer (8).
7. Collar
Remove collar (9).
8. Collar
Pull out key (10) and remove collar (11).
D58E.P-1 23- 103

a
9. Bearing cage
Remove bolts and pull out cage (12) with forcing
bolts (12 mm, P = 1.75 mm).
10. Collar
Remove collar (13).
11. Sprocket nut

Straighten lock plate (14) and remove nut (15) with
special tool B.
12. Sprocket
Pull out press-fitting part of sprocket (16) with
Special tool C and remove sprocket by slinging it.
& kg Sprocket: 145 kg
* After removal of sprocket, keep floating seals of

sprocket side and final drive cover side as a pair.
23-104 D58E.P-1
13. Final drive cover

1) Remove bolts and separate cover (17) from case
with forcing bolt (14 mm, P = 2 mm).
* When separating cover from case, use a guide
bar to prevent cover from falling.
2) Install two sling bolts (14 mm, P = 2 mm) into

forcing bolt hole, and remove cover with sling tool
0.
fi kg Final drive cover: 83 kg
14. Final drive hub and final second driven gear assembly
Winding wire around final drive hub and slinging
assembly with crane, remove final drive hub and
second driven gear assembly (18).
Final drive hub and second driven gear
& kg
assembly: 81 kg
15. Final drive first driven gear & second pinion assembly
1) Remove oil pan (19).
2) Winding wire around final drive first driven gear
and second pinion assembly (20), remove it with
crane.
Final drive first gear and second pinion
assembly: 33 kg
23-105
0

Pull out inner race (21) with puller 0.
17. Collar
Remove collar (22)
18. Sprocket shaft nut

I) Remove lock ring (23) and remove lock pin (24).
2) Remove shaft nut (25) with special tool D.
19. Sprocket shaft

Pull out shaft (26) with special tool E.
23-106 D58E.P-1
ASSEMBLY OF FINAL DRIVE ASSEMBLY

Special tools
ASSEMBLY OF FINAL DRIVE FIRST GEAR

AND SECOND PINION ASSEMBLY

Press-fit inner race (43).
2. Key
Fit key (42) into second pinion.
3. First gear and second pinion

Hold second pinion (39). apply molybdenum disul-
fide (LM-P) to press-fitting part and press-fit first
gear (38).
* Press fitting force for first gear and second
pinion: 15 - 24 ton

Install spacer (41) and press-fit inner race (40).
5. Shaft
Insert shaft (37). put holder (36) and lock washer
(341, secure them with nut (35) and lock them with
lock washer.
D Nut: 21.5k3.5 kgm
D58E.P-1 23- 107

ASSEMBLY OF FINAL DRIVE HUB AND

SECOND GEAR ASSEMBLY
6. Bearing
Press-fit bearing (33) in final drive hub and secure
with snap ring (32).
7. Gear
Put second driven gear (29) in final drive hub (30).
install reamer bolt (31) and lock plate (27). secure
them with nut (28) and lock them with lock plate.
w Nut: 50*5 kgm
23-108 D58E.P-1
a
ASSEMBLY OF FINAL DRIVE ASSEMBLY
8. Sprocket shaft
Apply molybdenum disulfide (LM-P) to the press-
fitting part of shaft (26) and press-fit shaft with
special tool E.
* Press fitting force for sprocket: 17 - 32 ton.
9. Sprocket shaft nut

I) Install shaft nut (25) with special tool D.
w Nut: 50 If: 20 kgm
2) Tap dowel pin (24) and lock with lock ring (23).
10. Collar
Install collar.

Install inner race (21) in shaft after heating it.
* Excessive heating may change metallic structure
of race.
Surface temperature should be lower than 1 1O’C.
D58E.P-1 23-109
a
12. Final drive first driven gear and second pinion assem-
bly
1) Slinging first driven gear and second pinion as-
sembly (20) with wire, push them meshing first
pinion with first driven gear.
2) Install oil pan (19).
13. Final drive hub and second gear assembly

Slinging final hub and second gear assembly (18) with
wire winding around it, push it meshing second
pinion and second gear.
14. Final drive cover

1) Apply liquid gasket (LG-1) to the mounting face,
attach gasket, secure cover (17) with bolts sliging it
with sling tool 0, and crane.
m Cover mounting bolts: 18 f 2 kgm
* Install plane bearing by cold fit.
23-110 D58E.P-1
0
2) Measure runout of plane bearing in reference to

shaft.
* Runout: 0.5 mm max.
15. Sprocket
1) Put floating seals to final drive cover and sprocket
side.
* Applying grease (G2-LI) thinly to O-ring, install
it in such manner as to prevent twisting. Apply
engine oil (EO 30-CD) to seal ring sliding sur-
face after checking it for scar or dust.
2) Slinging sprocket (16) with crane and applying

moly lubricant (LM-P) to press-fitting portion of
final drive hub and sprocket, push in them aligning
spline.
D58E.P-1 23-111
0
3) Pr,ess-fit sprocket (16) with special tool C.

* Press-fitting force for sprocket: 10 - 40 ton
* After sprocket is press-fitted, confirm the depth
of sprocket in hub measuring the distance H
from sprocket boss end face to final drive hub
end face.
Standard distance H : 28 f 0.8 mm
13OF1055
16. Sprocket nut

install lock and tighten nut with wrench B to lock it.
B to lock it.
m Sprocket nut: 150 ? 20 kgm
17. Collar
Install collar (13).
23-112 D58E.P-1
a
18. Bearing cage

Putting O-ring to cage and using guide bolts, press-fit
cage (12) straight with special tool and secure it with
bolts.
19. Collar
Install collar (1 1) and fit key (10).
20. Collar
Install collar (9).
21. Bearing retainer

Fit O-ring to the mounting face and secure retainer
(8) with bolts.
D58E.P-1 23-113
0
22. Support
1) Put floating seals to retainer side and support side
of support.
* Applying grease (G2-LI) thinly to O-ring install

it in such manner as to avoid twisting. Apply
engine oil (EO 30-CD) to seal ring sliding
surface after checking it for scar or dust.
2) Install support (7) on sprocket shaft.
23. Nut
Install plate (6) and lock plate (41, tighten nut (5)
with special tool A and lock them with lock plate.
B Nut: 60*20 kgm
D58E.P-1
24. Cap
Put O-ring to cap (3) and secure it with bolts.
* Tighten bolts while rotating support lightly.
25. Add oil

After confirming that drain plug (1) is closed, add
oil up to level plug opening through level plug (2).
I& Final drive case: D58E-1. 13 Q (E030CD)

D58P-1. 14.5 Q (E030-CD)

Refer to MOUNTING TRACK FRAME section.
D58E.P-1 23-115
a
POWER TRAIN
24 MAINTENANCE STANDARD
Damper joint ...............

and universal 24- 2
Torque .......................
converter 24- 4
TORQUEFLOW transmission ............. 24- 6
Transmission control valve .............. 24- 8
TORQUEFLOW transmission (D58E-1 B) 24-9-l
Transmission control valve B) ....
(D58E-1 24-9-3
Transmission lubricating ...........
valve 24-l 0
Transmission pump ..................... 24-l 1
Bevel gear shaft and steering system ..... 24-l 2
Steering control valve ................... 24-l 4
Relief valve ............................. 24-l 6
Steeringpump ......................... 24-l 7
Steering brake .......................... 24-l 8
Finaldrive .............................. 24-20
D58E,P-1 24-l
0
MAINTENANCE STANDARD DAMPER AND UNIVERSAL JOINT
DAMPER AND UNIVERSAL JOINT
13OFO63
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit

Repair or
1 0.D of seal contact surface in coupling replace
0 -
75
-0.03
Tightening torque for universal joint Retighten

2 6.7 + 0.7 kgm
assembly fitting bolt
These valves are measured at 130

* Axial runout: 1 .O or less when damper output shaft is rotated Adjust
3 Bevel deviation and eccentricity * Radial runout: 1.5 or less simultaneously with torque convert-
er input shaft.
24-2 D58E.P-1
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
D58E-1 Serial No. 80888-81637
D58E-1 A Serial No. 80888-81637
D58P-1 Serial No. 80588-81058
m 5.5 + 0.5kgm
/ .75
?7520kgm
135FO40
24-4 D58E,P-1
0
MAINTENANCE STANDARQ TORQUE CONVERTER
Unit: mm
-
NO. Check item Criteria Remedy
Standard size Repair limit
1 0.D of seal contact surface in coupling
85 84.8
Chrome plating
or replace
2 I.D of seal ring contact surface in stator shaft 40 40.1
-
3 I.D of seal ring contact surface in retainer 95 95.3
Width: 2.5 2.2

4 Stator shaft seal ring
Thickness: 3.8 3.3
Standard clearance Clearance limit
5 Backlash between drive gear and PTO gear
0.15 - 0.46 1 .o
Replace
Free Installed Installed Free Installed

6 Relief valve spring
length length I oad length load
44 29 9.1 kg 43 8.5 kg
-
D58E,P-1 24-5
0

,6
m 5.5kO.5 kgm
, m 6.7520.75. kgm
.._r-
l---- 7 “-L-
2 3
24-5 - 1 D58E,P-1
0
Unit: mm
No Check item Criteria Remedy
1 0.D of seal contact surface in coupling
85 84.8
Chrome plating
or replace
2 I.D of seal ring contact surface in stator shaft 45 45.1
3 I.D of seal ring contact surface in retainer 95 95.3
4 Stator shaft seal ring

I Width:
Thickness:
2.5
3.8
I
2.2
3.3
5 Backlash between drive gear and PTO gear -
0.15 - 0.46 1 .o
. Replace
6
I 1
44 29 9.1 kg 43 8.5 kg
D58E,P-1
24-5-2
0
MAINTENANCE STANDARD TORQFLOW TRANSMISSION
D58E-1 Serial No. 80888-81637
D58P-1 Serial No. 80588-81058
B 11.25?1.25 kgm
2 m 14 8 12 17 9 13 18 15 Qa 16
17 f 1 .Okgm 11.25k1.25 kgm 11.25k1.25 kgm
133F108
Unit: mm

Backlash between No. 1,3,4, sun gear and
1
planet gear
0.14 - 0.35 0.75
- Replace
Backlash between No. 2 sun gear and planet
2 0.13 - 0.32 0.75
gear
3 Backlash between No. 1, 2, 3,4 and planet 0.15 - 0.44 0.75

gear
24-6 D58E,P-1
0
Unit: mm

I
4 Thickness of clutch disc

I
5 1 Thickne ss of clutch plate

I 5
I 4.5
I
6 Thickness 2, 5
for No. 1, of clutches
assembled 4 discs and 3 plates 35 / 31.5 I
7 for No. 2 and

Thickness No. 3 clutches
of assembled 3 discs and 2 plates I 25 22.5 1
Replace
Free Installed installed Free Installed
8 No. 1 clutch spring
length length
lengeh load load
56.8 46.5 6.7 kg 54.5 5.2 kg
9 No. 2 clutch spring 58.0 46.5 9.0 kg 55.5 7.1 kg
10 No. 3, 4 clutch spring 59.0 43.0 16.0 kg 1 55.9 / 12.9 kg

I

0.D of oil seal contact surface in output Chrome plating
11
shaft or replace
70 69.9
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between No. 1, 4 cylinder and
12 Shaft Hole
0.D piston
-
325 -0.500 +0.089 0.500 1 .o
-0.700 0 0.789
-
13 Clearance between No. 2, 3 cylinder and 335 -0.500 +0.089 0.500 1 .o
0.D piston -0.700 0 0.789
-
14 Clearance between No. 1, 2, 3,4 cylinder 285 -0.110 +0.081 0.110 1 .o
and I.D piston -0.191 0 0.272
-
15 Clearance between No. 5 cylinder and 300 -0.500 +0.081 0.500 1 .o Replace
0.D piston -0.700 0 0.781
16 Clearance between No. 5 cylinder and 250 -0.100 +0.072

I .D piston -0.172 0
Standard size Tolerance Repalr limit
17 Dta. of seal ring of No. 1, 2, 3 carriers

Width: 4.0 Width: -0.01 3.5
Thickness: 5.0 -0.04
Thickness: +0.15 4.7
Width: -0.01
18 Dia. of seal ring of output shaft Width: 3.0 -0.03 2.6
Thickness: 3.5
Thickness: +O.lO 3.2
D58E,P-1 24-7
0
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

D58E-1 Serial No. 80888-81637
D58E-1 A Serial No. 80888-81637
D58P-1 Serial No. 80588-81058
Section A-A
Section B-B
F13017030
24-8 D58E,P-1
0
Unit: mm
T
C

L
Tolerance
Clearance between speed valve, directional
1 Shaft Hole
valve and body
0.08
Clearance between quick return valve and -

2
body
J
Clearance between quick return valve and 0.08
3
sleeve
-
Clearance between modulating valve and 0.08
4
sleeve
Clearance between modulating valve sleeve

5 0.08
and body
- ~ Replace
Clearance between modulating valve and
6 0.08
piston
7 Modulating valve spring (in)
8 Modulating valve spring (out) 43 33 20.3 kg 42.5 19.3 kg
9 Modulating valve spring 52 21 27.2 kg 50.5 25.8 kg
10 Modulating valve piston spring 26 20 0.5 kg 25.7 0.47 kg
D58E.P-1 24-9

D58E-IA Serial No. 81638 and up
\ y 11.25?1.25kgm
1721 kgm 11.25e1.25 kgm 1 1.25 AZ 1.25 kgm

u141010 19A
Unit: mm

1 Backlash between No. 1, 3,4, sun gear and
planet gear
0.14 - 0.35 0.75
Replace
Backlash between No. 2 sun gear and planet
2 0.13 - 0.32 0.75
gear
3 Backlash between No. 1, 2, 3,4 and planet 0.15 - 0.44 0.75

gear
24-9-l D58E,P-1
0
Unit: mm
Check item Criteria Remedy
Thlckness of clutch disc
5 4.5
5 Thickness of clutch plate 5 4.5
Thickness of assembled 4 discs and 3 plates

6 for No. 1, 2, 5 clutches 35 31.5
Thickness of assembled 3 discs and 2 plates

7 for No. 2 and No. 3 clutches 25 22.5
Replace
8 No. 1 clutch spring
lengeh length load length load
56.8 46.5 6.7 kg 54.5 5.2 kg
9 No. 2 clutch spring 58.0 46.5 9.0 kg 55.5 7.1 kg
10 No. 3, 4 clutch spring 59.0 43.0 16.0 kg 55.9 12.9 kg

0.D of oil seal contact surface in output Chrome plating
11
shaft or replace
70 69.9
Tolerance
Clearance between No. 1, 4 cylinder and
12 Shaft Hole
0.D piston
325 -0.500 +0.089 0.500 - 1 .o

-0.700 0 0.789
Clearance between No. 2, 3 cylinder and -0.500 +0.089 0.500 -

1: 0.D piston 335 -0.700 0 0.789 1 .o
Clearance between No. 1, 2, 3,4 cylinder -0.110 +0.081 0.110 -

14 and I.D piston 285 -0.191 0 0.272 1 .o
Clearance between No. 5 cylinder and -0.500 +0.081 0.500 -

1E 0.D piston 300 -0.700 0 1 .o Replace
0.781
-
Clearance between No. 5 cylinder and -0.100 co.072 0.100 -

1E 250 -0.172 0 0.244 1 .o
I .D piston
17 Dia. of seal ring of No. 1, 2, 3 carriers

Width: 4.0 Width: -0.01 3.5
Thickness: 5.0 -0.04
Thickness: eO.15 4.7
Width: 3.0 Width: -0.01 2.6

1E Dia. of seal ring of output shaft Thickness: 3.5 -0.03
Thickness: eO.10 3.2
D58E,P-1 24-9-2
0

i Section A-A
A
Seaion B-B
F13017030A
24-9-3 D58E,P-1
0
MAINTENANCE STANDARD .TRANSMISSION CONTROL VALVE
Unit: mm
Clearance between speed valve, dfrectional

1
valve and body
Clearance between quick return valve and 0 +0.033

25 o-0.133 0.16
body -0.1 0
Clearance between quick return valve and -

12 -0.035 +0.011 0.035 0.08.
sleeve -0.045 0 0.056
Clearance between modulating valve and -

4 20 -0.035 10.013 0.035 0.08
sleeve -0.045 0 0.058
Clearance between modulating valve sleeve -

5 30 -0.035 +0.013 0.035 0.08
and body -0.045 0 0.058
Replace
Clearance between modulating valve and -
6 12 -0.020 +0.018 0.020 0.08
piston -0.030 0 0.048
-
Standard sjze I Repair limit
7 Modulating valve sprfng (IIT)
6 Modulatfng valve sprfng (out)
9 Modulating valve spring 52 21 27.2 kg 50.5 25.8 kg
10 Modulating valve piston sprtng 26 20 0.5 kg 25.7 0.47 kg
D58E, P-l 24-9-4

0

24-9-5 D58E, P-l

@
Unit: mm
-
No Check item
-
Clearance between speed

valve, directional valve
and body
7 Modulating valve spring

(inner)
Modulating valve piston 4.9N 4.61 N

10 26 20 25.2
spring 10.5kgI (0.47kgI
D58E, P-l 24-9-6

@
MAINTENANCE STANDARD TRANSMISSION LUBRICATING VALVE
TRANSMISSION LUBRICATING VALVE
135FO43
Unit: mm
Tolerance
Clearance between lubricating valve and
1 Shaft Hole
body
-
22 -0.020 co.033 0.020 0.18
-0.041 0 0.074
Replace
Free Iwtalled Installed Free Installed

Lubricating valve spring
length length load length load
44 32 7.28 kg 41.9 S kg
24-l 0 D58E, P-l

MAINTENANCE STANDARD TRANSMISSION PUMP
TRANSMISSION PUMP
FAR040
135FO44
Unit: mm
Standard size Clearance limit

Radial clearance between gear and gear
1
caSe
-
. Replace
2 Axial clearance between gear and gear case 0.100 - 0.150 0.19
3 Clearance between gear shaft and bushing 0.060 - 0.125 0.20
Tightening torque of housing and case

4 8.5 * 0.5 kgm
mounting bolt
. Retighten
- Discharge at 50 - 55°C 82Qlmin. at 2,300 rpm
D58E,P-1 24-11
MAINTENANCE STANDARD BEVEL GEAR SHAFT AND STEERING SYSTEM
BEVEL GEAR SHAFT AND STEERING SYSTEM
J ;t_l
I ..-
10 8 4 6 5 ;1
F I3Y2033
24-12 D58E.P-1
MAINTENANCE STANDARD BEVEL GEAR SHAFT AND STEERING SYSTEM
Unit: mm

-
Thickness of plate Repair
2.6 2.3
1
Tolerance Repair limit
Correct or
Strain of plate replace
within 0.3 0.5

Thickness of plate Replace
6.8 5.3
2
Correct or
Strain of plate replace
Within 0.3 0.5

Thickness of disc Replace
4.2 3.5
3
Correct or
Strain of disc replace
within 0.3 0.5

Total assembled thickness
of drive plate and driven plate
69.6 64.1

Backlash between plate and
clutch drum 1.0
0.3 - 0.7
Backlash between disc and Replace

0.3 - 0.7 1.0
brake drum
Outside diameter of brake 380

385 2 0.1
drum
8 Brake drum radial runout Within 0.15
Clutch drum lock nut Ratighten

9 54* 18 kgm
tightening torque I
Clutch return spring Free Installed Installed Free

Load
length length load length
10
Large 108.5 74.2 127.5 kg 105.8 121.1 kg
Small 82.0 58.2 66JJ kg 79.0 56-J kg

Replace
Tolerance
Clearance between yoke Shaft Hole
11
ball and ball seat
I 30
I
I
3::
II
+0.2
0
1
0.1 - 0.4
1
2
I
12 Adjusting stroke of sleeve yoke 16.9 ? 1, clearance between stopper and adjustment bolt head Adjust
Axial run out of back surface Less than 0.07 mm (with bevel gear shaft mounted)
13 Repair limit: Replace
of bevel oear
-
Backlash between bevel t
14 Standard clearance: 0.25 - 0.33
pinion and gear
Bevel gear shaft turning torque at tip of tooth:

15 Preload of bevel gear bearing Adjust
1.5 - 1.8 kgm (with pinion engaged)
-
16 Press fit force of clutch drum 4.5 - 9 ton
Dimension between clutch Replace

17 drum and bevel gear shaft 2.5 f 1 .o
end face after press fit
*: Replace or repair. (Bevel gear and bevel pinion should be replaced as a unit.)
D58E.P-1 24-13
I44F072A
D58E.P-1
24-14
MAINTENANCE STANDARD STEERING CONTROL VALVE
Unit: mm
Tolerance
Clearance between lever Shaft Hole
1
shaft and bushing
+0.019 +0.156
18 0.067 - 0.155 0.20
+0.001 +0.086
Clearance between lever shaft +0.023 +0.170

2 22 0.063 - 0.168 0.20
and bushing +0.002 +0.086
3 Clearance between shaft and 26 -0.035 +0.013 0.035 - 0.058 0.08

valve body -0.045 0
4 Clearance between steering 10 -0.03 +0.015 0.030 - 0.055 0.08

valve and piston -0.04 0
I I I I I I
I
5 Clearance between steering 26 -0.035 +0.013 0.035 - 0.058 0.08

valve and valve body -0.045 0
Replace
valve and piston
Shaft return spring
Modulating valve spring
12 Brake valve spring ISmall) 28.5 25.5 3.0 kg 28 2.8 kg
13 Brake valve spring (Large) 90 27.0 4.48 kg 77.4 3.6 kg
14 Brake valve spring 50.5 14.0 2.36 kg 49.5 2.2 kg
15 Stroke of brake valve play 13.7 + 0.2 Adjust
D58E, P-l 24-15


li ii lb ‘3 ‘8
24-15-1 D58E, P-l

@
Unit: mm
-
NO Check item Criteria Remedy
-
Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Clearance between lever
1 shaft and bushing
+0.019 +0.117 0.010 -
18 0.20
+O.OOl +0.029 0.116
- I I I I I I
Clearance between lever +0.023 +0.130 0.007 -
2 shaft and bushing 22 +0.002 0.20
+0.030 0.128
-
Clearance between shaft -0.035 +0.013 0.035 -
3 and valve body 26 -0.045 0 0.058 0.08
-
Clearance between steer-
4 ing valve and piston 1 9 ‘1 2:;; / +;“I5 1 “““,9,,5 1 0.08 1
-
Clearance between steer- -0.035 +0.013 0.035 -
5 ing valve and valve body 26 -0.045 0 0.058 0.08
-
Clearance between guide -0.01 +0.021 0.010 -
6 and brake valve body 26 -0.03 0 0.051 0.08
- Replace
Clearance between brake -0.025 +0.018 0.025 -
7 valve and valve body 16 -0.035 0 0.053 0.08
-
Clearance between brake -0.010 +0.012 0.010 -
8 valve and piston 6 -0.018 0 0.030 0.08
-

37.0 35.5 73.5N 36.3 69.6N

I7.5kgI V.lkgI
-

1 g1.6 / 26.8 1 {4436;& / 8g.8 1 p4X~~ /
-
11 Brake valve spring (Small) 1 31.8 / 25.3 1 g$fl / 31.2 / z$i$ 1

-
Brake valve spring (Large) 29.ON 27.5N
12 59.2 27.0 58.0
{2.96kg} (2.8kgI
-
21.6N
13 Brake valve spring 50.5 15.0 22.7N 49.5
(2.31 kg} {2.2kgI
14 Stroke of brake valve play 5.7 Adjust

-
D58E, P-l 24-15-2

@
MAINTENANCE STANDARD RELIEF VALVE
RELIEF VALVE
F I3Y2034
Unit: mm
NC Check item Criteria Remedy
Clearance
limit
Clearance between body
and valve
0.08
Clearance between valve

2 0.08
and piston
I
Replace
3 Spring (Large) length length load length load
272N 258N
52 35.8 51.0 {26.3kg}
{27.7kgI
-
4 Spring (Small) 105N IOON

52.4 42 51.4 {10.2kg}
{I 0.7kg)
5.69N 5.39N
5 Piston spring 26 19 25.5
{0.58kg) {0.55kg}
- Relief valve setting

Adjust
pressure
-
24-16 D58E, P-l
8
MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
FAR028
Unit: mm
Standard size Standard clearance

Radial clearance between gear and gear
1
case
0.100-0.150 0.19
2 Axial clearance between gear and gear 0.100-0.150 0.19

case
Tightening torque of housing and case

mounting bolt
4 6 f 0.5 kgm
Retighten
- Discharge at 50 - 55” C 65Qimin. at 2,600 rpm
24-17
STEERING BRAKE
STEERING BRAKE
,B
‘7
4
U14101020A
24-18
D58E.P-1
0
MAINTENANCE STANDARD STEERING BRAKE
Unit: mm
NO. Check item I Criteria I Remedy

Thickness of assembled brake band and
1
linina I
2 Thickness of brake lining 9.0 5.5
Replace
3 Brake band supporting spring
3A
36
-
Standard clearance
Clearance between brake lining and brake
4 Adjust
drum
0.3
-
5 Clearance between housing and piston
-
50 -0.025 co.025 0.025 0.1
-0.041 0 0.066
-
-
6 Clearance between bushing and spool I 25 0
-0.210
+0.063
co.043
0.043
0.273
0.1 Replace
Repair limit
Standard size I I
7 Booster spring
89 58 10 kg 84 9.2 kg
1. Loosen adjustment bolt (A) so that dimension (a) is 0 mm.

2. Tighten adjustment nut (B) by 9 kgm.
3. Tighten adjustment bolt (A) so that the clearance between
- Adjustment of clearance between brake
adjustment bolt (A) and lever (C) is 0 mm while
lining and brake drum
pushing lever (C) to booster piston (E). And tighten nut (D)
due to lock adjustment bolt (A).
4. Loosen adjustment nut (B) about l-3/6 turns.
D58E.P-1 24-19
0
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
m 39.5 ,f 4kw-n
55 + 15kgm
50 2 20kgm
F13YZO35
Unit: mm
Less than 0.30 mm

1 F lang face runout
(at 347 mm dia. in reference to the center of bevel gear shaft)
Less than 0.40 mm

2 Flang radial runout
(in reference to the center of bevel gear shaft) Adjust or
replace
3 Flange press fit force 10 ton
Standard size Tolerance

Distance between flange and
4
No. 1 pinion shaft end face
0 -t 0.5
24-20 D58E,P-1
0
Unit: mm
5 No. 2 pinion press fit force 15-24ton Retighten
Sprocket boss to hub press 20 ton

6 Adjust or
fit force
replace
I
Distance between sprocket Standard size Tolerance
7 boss end surface and sprocket
hub end surface 33 * 0.8
Tolerance
Standard Standard
size interference
Fitting between sprocket Shaft Hole Rebuild or
8 replace
shaft and steering case
I 120
I
+0.130
+0.110 I
+0.040
0
0.130 - 0.070
Adjust or
9 Sprocket shaft press fit force Standard: 18 - 31 ton
replace
10 Bending at sprocket shaft end Standard: 0 + 1.5
Repair or
Distance between sprocket Standard clearance Tolerance
replace
11 shaft end and steering case
surface D58E1, IA. D58P-1: 632 2 1.0
D58E-1 B: 667

Backlash between No. 1
12
pinion and No. 1 gear
0.23 - 0.64 -
Replace
Backlash between No. 2 -
13 0.28 - 0.74
pinion and No. 2 gear

14 Wear of tips of sprocket teeth
775.4 L 2.0 763.4
Wear of roots of sprocket +1.0

15 699.97 688.0 Repair by
teeth 0
padding or
replace
16 Face width of sprocket ..,-..,--.
teeth (Teeth crest)
55 46
Face width of sprocket 66

17 75
teeth (Bottom land)
I /
D58E,P-1 24-21
0
Cheking procedure
1. Fitting between sprodcet shaft and steering case 2. Bending at sproket shaft end
When the sprocket shaft is removed in order to bend- Install a dial indicator to that its point rests at right
ing and damage, check the diameter of both the shaft angles on the sprocket shaft end. Turn the indicator
and steering case hole at least 4 positions in circum- one complete revolution around the shaft while
ference and 5 positions in the axial direction, in order observing the total indicator reading. If TIR (Total
to assure proper fitting between the shaft and hole. Indicator Reading) exceeds 1.5 mm, draw the shaft
If any measurement exceeds the repair limit, repair from the final drive case and repair it in a press.
the shaft by hard chrome plating.
Front -
24FO22
24-22 D58E.P-1
UNDERCARRIAGE
Track group. ..... .............. 31- 2

Recoil spring ..... .............. 31- 4
Idler ........... .............. 31- 5
Carrier roller ..... .............. 31- 6
Track roller ...... .............. 31- 7
Track .......... .............. 31- 8
Suspension ...... .............. 31-12
D58E.P-1 31-1
STRUCTURE AND FUNCTION TRACK GROUP
TRACK GROUP
D58E-1
u13401002
. Track roller: 6
. Track roller: 7 (D58E-1B for EC. TBG)
1. Idler The tracks which bear and spread the weight of the
2. Carrier roller machine on the ground convert the driving power trans-
3. Sprocket cover mitted from the sprockets into tractional force. The
4. Track roller (single flange) track group includes a pair of right and left track frames
5. Track roller (double flange) (7), front idlers (l), carrier rollers (2) and track rollers
6. Track roller guard (4) and (5) are mounted. The track looped around each
7. Track frame track frame is driven by the sprocket wheel and its
8. Diagonal brace rolling is guided by the front idler, carrier roller and
S. Single flange type track rollers. The track roller guard (6) attached on the
D. Double flange type bottom surface of each track frame prevents the track
from slipping off due to intrusion of stones.
31-2 D58E,P-1
Q
STRUCTURE AND FUNCTION TRACK GROUP
D58P-1
u13401003
l Track roller: 8
1. Idler The tracks which bear and spread the weight of the
2. Carrier roller machine on the ground convert the driving power trans-
3. Sprocket cover mitted from the sprockets into tractional force. The
4. Track roller (single flange) track group includes a pair of right and left track frames
5. Track roller (double flange) (7), front idlers (11, carrier rollers (2) and track rollers
6. Track roller guard (4) and (5) are mounted. The track looped around each
7. Track frame track frame is driven by the sprocket wheel and its
8. Diagonal brace rolling is guided by the front idler, carrier roller and
S. Single flange type track rollers. The track roller guard (6) attached on the
D. Double flange type bottom surface of each track frame prevents the track
from slipping off due to intrusion of stones.
D58E.P-1 31-3
STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
13OFO73
1. Yoke 8. Rear support

2. Rod 9. Nut
I 3. Cylinder 10. Cover
._& 4.
5.
6. Cover
Piston
Front support 13. Wearing
12.
11. Collar
Lubricator
7. Recoil spring
Section A-A
The idler cushion is mounted on the track frame be- The adjusting cylinder is provided with the lubricator
tween the front idler and the sprocket wheel. It per- (13). Feeding grease through the lubricator causes the
forms the following functions: cylinder piston to push the idler forward so that track
1) Maintaining proper track tension. tension is increased. On the other hand, track tension is
2) Absorbing shocks which the front idler is subjected to decreased by loosening the lubricator to discharge the
during traveling of the machine. grease.
One end of the rod (2) is connected to the idler yoke (1)
and the other end to the adjusting cylinder
contains grease sealed under high pressure by piston (4).
(3) which A To loosen track tension,
one turn.
loosen the lubricator
If grease does not ooze out easily, try
by
The recoil spring support (6) and the piston are always moving the machine back and forth a short dis-
pushed toward the forward part of the machine by the tance. Do not loosen the lubricator more than one
recoil spring (7), and the rod is also pushed forward by complete turn in order to prevent dangerous spurt-
force from the piston through the grease filling the ing of grease under high pressure. Although the
cylinder. protector is provided to prevent the lubricator
When the front idler, connected to the recoil spring from flying out, this precaution should be kept in
through the adjusting cylinder, is subjected to an impact mind for safety.
exceeding the initial preload of the recoil spring, the re-
coil spring will retract to absorb the shock. Also, when
mud, stones or snow get lodged between the track and
the sprocket wheel, the recoil spring will absorb the
shock caused by a sudden increase of track tension, thus
preventing damage to the track, sprocket or other rollers.
31-4 D58E.P-1
STRUCTURE AND FUNCTION IDLER
IDLER
1. Idler
2. Bushing
3. Shaft
I.-. _-.-.-.-.A 4. Cover
5. Floating seal
13OFO74 6. Guide
The front idler (1) mounted at the front-end of each Lubricating oil (engine oil) enters the oil hole provided
track frame is supported on the idler shaft (3) through in the shaft to lubrjcate the sliding surface of the bush-
the guide (6) and bushing (2). ing. Each end of the bushing is provided with a floating
The idler assembly including the yoke, which is con- seal to prevent both leakage of oil and inclusion of mud
nected to the idler shaft bearings, is slidable back and and water.
forth along the track frame by the guideplates attached To improve its wear-resistant property, the idler is made
to the underside of the bearings and the cover (4), so of siliconmanganese steel casting, the tread of the idler
that smooth rolling of the track can always be main- which the track !ink contacts, is hardened by high-
tained. frequency hardening treatment.
D58E.P-1 31-5
STRUCTURE AND FUNCTION IDLER
For PAT
1. Idler
2. Bushing
3. Shaft
4. Cover
5. Floating seal
6. Guide
I 13OF18013
The front idler (1) mounted at the front-end of each Lubricating oil (engine oil) enters the oil hole provided
track frame is supported on the idler shaft (3) through in the shaft to lubricate the sliding surface of the bush-
the guide (6) and bushing (2). ing. Each end of the bushing is provided with a floating
The idler assembly including the yoke, which is con- seal to prevent both leakage of oil and inclusion of mud
nected to the idler shaft bearings, is slidable back and and water.
forth along the track frame by the guideplates attached To improve its wear-resistant property, the idler is made
to the underside of the bearings and the cover (4), so of siliconmanganese steel casting, the tread of the idler
that smooth rolling of the track can always be main- which the track link contacts, is hardened by high-
tained. frequency hardening treatment.
D5BE.P-1
STRUCTURE AND FUNCTION CARRIER ROLLER
CARRIER ROLLER
135FO54
1. Support Carrier rollers are arranged above each track frame, this
2. Shaft act to support the upper half of the track loop in the
3. Collar proper rolling condition, preventing the track from
4. Floating seal dangling by its own weight.
5. Carrier roller The roller made of special alloy steel is hardened by heat
6. Bushing treatment of its tread and flanges. The flanges are pro-
7. Cover vided for receiving thrust load (load in the axial direc-
tion), thus preventing the track from slipping off the
carrier rollers.
The shaft is provided with an oil hole to feed lubricating
oil (engine oil) to the sliding surface of the bushing.
Each end of the bushing is provided with a floating seal
to prevent both leakage of oil and inclusion of mud and
water.
31-6 D58E.P-1
0
STRUCTURE AND FUNCTION TRACK ROLLER
TRACK ROLLER (Single Flange)
1. Track roller
2. Bushing
3. Bushing
4. Shaft
5. Floating seal
6. Collar
! n--l II 7l
ii Iii iii ti
135F053A
Track rollers are arranged under each track frame, they

distribute the machine weight evenly onto the tracks on
which the track rollers rotate.
The track roller assembly consists of the roller (I), bush-
ing (2) and (3), floating seal (51, shaft (4) and collar (6).
The roller is made of special alloy steel and is treated by
quenching and tempering. Two kinds of rollers are pro-
vided: one bearing only the outside flange and the other
with both inside and outside flange. These receive thrust
load (load in the axial direction) and are arranged alter-
nately.
The shaft is provided with an oil hole to feed lubricating
oil (engine oil) to the sliding surface of the bushing.
Each end of the bushing is provided with a floating seal
to prevent both leakage of oil and inclusion of much and
water.
D58E.P-1 31-7
STRUCTURE AND FUNCTION TRACK
TRACK
(1) Master pin type
D58E-1
1 2 3 4
II \ \ III \
“1 ,:” I 7
Y -0
133FO41
1. Regular bushing 5. Link
2. Regular pin 6. Track shoe (single)
3. Master bushing 7. Shoe bolt
4. Master pin 8. Shoe nut
31-8 D58E.P-1
D58P-1 1
\ f
133FO43
1. Regular bushing 5. Shoe bolt

2. Regular pin 6. Shoe nut
3. Master bushing 7. Link
4. Master pin 8. Track shoe
D58E.P-1 31-9
(2) Master link type

D58E-1
133FO42
1. Bushing 5. Master link (Pin side)

2. Pin 6. Track shoe (single)
3. Regular link 7. Shoe bolt
4. Master link (Shoe side) 8. Shoe nut
31-10 D58E.P-1
D58P-1
133F044
1. Bushing 5. Master link (Shoe side)

2. Pin 6. Master link (Pin side)
3. Regular link 7. Shoe nut
4. Shoe bolt 8. Track shoe
D58E.P-1 31-11
STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
Section A-A
ri
133FO45
1. Equalizer bar Semi-solid type suspension is employed in this machine.

2. Stopper pin As shown in the above figure, the equalizer bar (I) is
3. Bushing fitted to the main frame of the machine through the
center pin and is supported at each end of the bar on the
track frame. With this construction of the equalizer bar,
the weight of the front-half of the machine is delivered
to the track frames through the equalizer bar and shocks
from the track frames to the main frame are absorbed by
the equalizer bar. The stopper pin (2) on each of the
right and left track frames prevents the front of the
machine body from rising excessively during machine
travelling and working. Also, the equalizer is designed to
be able to roll on the center shaft.
To lubricate the equalizer bar, a grease fitting is provided
on the main frame. Grease is sent through the grease
tube and the oil hole in the center shaft to the center
shaft to lubricate the sliding surface between the shaft
and its bushing.
31-12 D58E.P-1
UNDERCARRIAGE
TRACK FRAME
Dismounting . . . . .. . . . . . .. . . . . .. .. . . . . . . . . .. . . . . . . . .. .. 33- 2
Mounting . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . .. . .. . . . . . . . .. . .. 33- 4
RECOIL SPRING
Dismounting . . . . .. .. . . . . .. . . . . . . .. .. . . . . . . . . .. . . . . .. .. 33- 5
Mounting . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . .. .. . . . .. . .. . . . . . 33- 8
FRONT IDLER
Dismounting . . . . .. . .. . . . . . . .. .. . . . . . . .. . . . . . .. . .. . .. .. 33-12
Mounting . . . . .. . .. . . . . . . . .. . . . . .. . .. . . . . . .. . . . . . . . .. . . . . 33-13
TRACK ROLLER
Dismounting.. ........................................ 33-14
Mounting ............................................... 33-15
Disassembly ....................................... 33-15-1
Assembly ............................................ 33-l 5-3
CARRIER ROLLER
Dismounting .......................................... 33-16
Mounting ............................................... 33-16
TRACK SHOE
Dismounting.. ........................................ 33-18
Mounting ............................................... 33-20
Adjusting ............................................... 33-22
D58E, P-l 33-1

0
DISASSEMBLY AND ASSEMBLY TRACK FRAME
DISMOUNTING TRACK FRAME ASSEMBLY

1. Remove track
Refer to DISMOUNTING TRACK SHOE ASSEM-
BLY.
2. Raising body
1) Raising the rear of body by a hydraulic jack
or a crane, place a block and slowly lower
body on it.
2) Lifting radiator guard by a crane or raising
equalizer bar by a hydraulic jack, place a
block under radiator guard and lower body
on block.
3. Sprocket cover
Remove cover (I).
4. Support mounting bolt

1) Temporarily lift track frame by winding wire
on front and rear of carrier roller.
2) Remove bolts (2) mounting support.
5. Diagonal brace cap

Remove caps by removing mounting bolts (3).
33-2 D58E, P-l
a
6. Front support
Remove support (4).
D58E.P-1 33-3
a
MOUNTING TRACK FRAME ASSEMBLY

1) Using a crane lift track frame assembly (6) with
wires around front and rear carrier rollers.
2) Locate track frame (6) in place by pushing it from
obliquely frontward.
Sprocket shaft support

Temporarily secure support with bolts (2) by aligning
track frame mounting holes.
Diagonal brace cap

1) Install cap (3) with bolts.
2) Fully tighten support mounting bolts which are
loosely tightened.
Front support
Install support (4) and remove lifting tool.
5. Sprocket cover
Remove cover (1).
6. Lowering body
1) Lifting radiator guard by a crane or raising
equalizer bar by a hydraulic jack, remove block
and lower the front of body.
2) Raising the rear of body by a crane or a hydraulic
jack, remove block and lower body slowly.
7. Install track
Refer to MOUNTING TRACK SHOE ASSEMBLY.
D58E.P-1
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISMOUNTING RECOIL SPRING ASSEMBLY

1. Securing front idler
Remove shims by loosening bolts on guide (1) and
secure front idler by tightening the bolts.
2. Front and center covers

Remove covers (2) and (3).
3. Carrier roller and roller support assembly

1) Raise track by hydraulic jack 0 placed between
recoil spring case and track.
2) Lift off carrier roller and roller support assembly

(4).
Roller and support assembly: 54 kg
D58E.P-1 33-5
0
4. Yoke and rod assembly

1) Remove bolts (5) mounting yoke.
2) Unscrew lubricator (6) one or two turns.

3) Remove yoke and rod assembly (8) by removing
mounting bolts (7) on cylinder side.
Yoke and rod assembly: 33 kg
5. Cylinder assembly
Remove cylinder assembly (9).
6. Sprocket cover
Remove cover (10).
33-6 D58E.P-1
0
7. Spring case rear cover

Remove cover (11).
8. Tightening recoil spring rear nut

1) Remove lock (13) by removing bolts (12).
2) Fully tighten nut (14) by the hand and loosen it
approx. a quarter turn.
* Mark nut before loosening. And record the
number of turns.
9. Spring cover
Remove cover (15) by loosening bolts gradually and
evenly.
* Bolts are heavy in removing since cover is pressed
by recoil spring until it comes out 2 to 3 mm.
10. Spring assembly

1) Remove collar (16).
2) Push out spring from rear cover and lift off spring
assembly (17) by a crane.
Recoil spring: 85 kg
D58E.P-1
MOUNTING RECOIL SPRING ASSEMBLY
1. Recoil spring assembly

1) Place recoil spring (17) on track frame by lifting
it by a crane.
2) Push into case and further push it while guiding
it from the rear of case.
3) Install collar (16).
2. Spring cover
Install cover (15) by tightening bolts gradually and
evenly.
t Bolts are heavy in tightening for the last 2 to
3 mm since cover contracts spring.
3. Cylinder assembly
1) Install cylinder (9).
2) Install piston assembled in the following order on
cylinder.
* Assembly of piston assembly
Install wear ring (19). cylinder packing (20) and
snap ring (21) on piston (18).
* Install wear ring with its cut-outs arranged
symmetrically and cylinder packing with its
pressure receiving side (concave side) faced to
snap ring (21).
* Supply grease to cylinder.
13OF1070
33-8 D58E.P-1
0
4. Yoke and rod assembly

1) Fit O-ring to cylinder mounting surface of yoke
and rod assembly (8) and install its yoke end with
mounting bolts (5).
2) Install cylinder end of yoke and rod assembly to

cylinder with mounting bolts (7).
3) Tighten lubricator (6).
5. Carrier roller and support assembly

1) Install carrier roller support assembly (4) by
lifting it by a crane.
6. Front and center covers

1) Install covers (3) and (2).
D58E.P-1
2) Lower track by retracting hydraulic jack 0.
7. Loosening idler
Insert shims by loosening guide plate (I) mounting
bolts and retighten bolts.
* At the same time, adjust clearance between track
frame and guide plate.
Standard clearance: 1 mm
8. Loosening nut
Loosen spring nut (14) by a distance the same as
tightened when removing it and lock the nut (13) by
tightening bolts (12).
9. Spring case rear cover

Install cover (II).
33-10 D58E.P-1
0
10. Sprocket cover

Install cover (IO).
11. Adjusting track tension

Adjust track tension by supplying grease from
lubricator (6).
D58E.P-1 33-11
0
DISASSEMBLY AND ASSEMBLY FRONT IDLER
DISMOUNTING FRONT IDLER ASSEMBLY

1. Separating track
Refer to DISMOUNTING TRACK SHOE ASSEM-
BLY.
2. Front cover
Remove cover (1).
3. Loosening guide plate

Loosen bolts (2) mounting guide plate.
4. Yoke mounting bolt

Remove six bolts (3) mounting yoke.
13oP1559
5. Front idler assembly

Remove front idler (4) by sliding it along track frame
and by lifting it by a crane.
& Front idler: 180 kg
33-12 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY FRONT IDLER
MOUNTING FRONT IDLER ASSEMBLY

1. Front idler assembly
Lift front idler (4) by a crane and push front idler
sliding along track frame.
2. Yoke mounting bolt

Install six bolts (3) mounting yoke.
3. Front cover
Install cover (1).
4. Adjusting guide plate tightening

Tighten guide plate (2) by adjusting shims so that
clearance between guide plate and track frame be-
comes 1 mm.
5. Installing track
Refer to MOUNTING TRACK SHOE ASSEMBLY.
D58E.P-1 33-13
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISMOUNTING TRACK ROLLER ASSEMBLY

1. Loosening track tension
Loosen track tension by loosening lubricator (1)
approx. one turn.
+ If tension is not loosened enough, move machine
forward and reverse instead of trying to loosen
lubricator more.
Roller guard
1) Raise blade and place a block under blade and
lower blade on it.
2) Remove bolts by removing nut (2) for roller guard
tension bolt.
3) Remove plate (3) by removing bolts.
4) Remove inner guard (4) and outer guard (5) by
removing bolts (8) mounting guards.
& Inner roller guard: 19 kg
& Outer roller guard: 23 kg
Roller mounting bolt

Remove bolts (6) mounting roller.
Roller assembly
1) Raising body by hydraulic jack @ placed under
final drive case or steering case, leave roller (7) on
track link.
2) Remove roller (7).
* If body is not raised enough, raise the front of
body by blade when removing front roller.
& Track roller (Single flange): 45 kg
Track roller (Double flange): 50 kg
D58E.P-1
MOUNTING TRACK ROLLER ASSEMBLY

1. Track roller
Install plate on track roller (7) and place track
roller on track link with oil feed plug faced out-
side.
2. Roller mounting bolt

I) Loosely install mounting bolts (6) when
clearance between track frame and roller
becomes approx. 10 mm by lowering body
slowly with hydraulic jack 0.
2) Lower body on the ground and fully tighten
mounting bolts (6).
3. Roller guard
1) Install inner roller guard (4).
2) Install guard tension bolt faced outside and
install collar through it.
3) Locate guard tension bolt on outer roller
guard (5) and tighten guard mounting bolts
(8) and guard tension bolt nuts (2).
4) Install plate (3).

Adjusting track tension by tightening lubricator
(I) and filling grease.
D58E, P-l 33-15

0
DISASSEMBLY OF TRACK ROLLER ASSEMBLY

1. Remove plug (I) and drain oil.
- : Track roller : Approx. 260 cc
Lf---+ m
CED00996
2. Set roller assembly (2) on block 0.

3. Push collar (3) and pull out ring (41, then re-
move collar (3).
CEO00997
4. Remove floating seal (5) from collar (3).

5. Pull out roller (6) from shaft (13).
CED00998 CED00999
6. Remove floating seals (7) and (8) from roller

(6).
7. Remove bushings (9) and (IO) from roller (6).
CEDOlOOO CEDOlOOl
33-l 5-l D58E, P-l

0
8. Remove ring (1 I), then remove collar (12) from

shaft (13).
CED01002
9. Remove
10. Remove
floating seal (14) from collar (12).
O-ring from shaft (13).
1
JO-rino
O-ring
CED01003 DLD02842
D58E, P-l 33-15-2

0
ASSEMBLY OF TRACK ROLLER ASSEMBLY

Special tools
Part Number Part Name Q’ty
A 796-670-1010 installer 1
B 791-601-1000 Oil pump 1
1. Fit O-ring to shaft (13), assemble collar (12),

then install ring (11).
CED01004
* After assembling, tighten plug (I) tempo-
rarily.
2. Using tool A, install floating seal (14) to collar

and shaft (15) assembly.
* Precautions when assembling floating seal
1) When assembling the floating seal, wash
the O-ring and O-ring contact surface to
completely remove all oil and grease, then
dry it fully. (See Fig. A.)
2) After assembling, check that the angle of
the floating seal is less than 1 mm.
3) Check that protrusion (a) of the floating seal
is within 7 - 11 mm. (See Fig. B.)
Fig. A Fio. B
Remove ai I and
greese
DLD02843 DKD02844
3. Using push tool 0, press fit bushings (IO) and

(9) to roller (6) with press.
& Bushing press-fitting portion :

Engine oil (E030-CD)
* Press-fitting force for bushing :

15.7 - 101.9 kN (1.6 - 10.4 ton)
33- 15-3 D58E. P-l

0
4. Using tool A, install floating seal (8) to roller

(6).
* Follow the same precautions as in Step 2
when installing the floating seal.
CEDOl
5. Set shaft and collar assembly (15) on block 0,

and assemble roller (6).
* Coat the floating seal sliding surface with
engine oil and be careful not to get dirt or
dust on the surface.
* When assembling the roller, coat the shaft
or bushing with engine oil.
CEDOlOOB
6. Refilling with oil

Add oil through clearance between shaft (13)
and roller (6).
Q Track roller : Approx. 260 cc (E030-CD)
* When using tool B to refill with oil, refill

after the completion of assembly.
CED01009
7. Using tool A, install floating seal (7).

* Follow the same precautions as in Step 2
CEDOIOIO
D58E, P-l
8. Using tool A, install floating seal (5) to collar

(3).
Ir Follow the same precautions as in Step 2
* Coat the floating seal sliding surface with
engine oil and be careful not to get dirt or
dust on the surface.
I CEDOlOll
9. Assemble collar (3) to roller (2), and install ring

(4).
:ED0099
10. Using tool B, apply standard pressure to roller

oil filler port, and check for leakage of oil from
seal.
+ Standard pressure: 0.1 MPa (1 kg/cm21
* Method of checking
Hold the standard pressure for 10 seconds
and check that the gauge indicator does not
go down.
\
CEDOIOIZ
11. If oil was not added in Step 6, use tool B and fill
track roller assembly with oil.
Track roller : Approx. 150 cc (E030-CD)
To vacuum tank
DLD02845
33-15-5 D58E, P-l

0
12. Tighten plug (1).
w Plug : 117.7.k 19.6 Nm (12 * 2 kgm)
w M
CED00996
D58E. P-l 33- 15-6

0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISMOUNTING CARRIER ROLLER ASSEMBLY

1. Loosening track tension
Loosen track tension a little by loosening lubri-
cator (I) and retighten it.
* Since track link is not removed from carrier
roller unless it is raised higher if track is
excessively loosened, be careful when loos-
ening track tension.
2. Raising track
Raise track by hydraulic jack 0 placed on recoil
spring case.

I) Remove three bolts (2) mounting roller sup-
port.
2) Remove other remaining bolts by directing
roller outside of carrier roller and support
assembly (3).
r+ kg Carrier roller and roller support

assembly: 40 kg
MOUNTING CARRIER ROLLER

ASSEMBLY
1. Raisiirg track
Raise track by placing hydraulic jack @ on re-
coil spring case.

I) Temporarily install one bolt on carrier roller
and roller support assembly (3).
2) Direct roller in the positive direction and
secure it with bolt (2).

Adjust track tension by supplying grease from
lubricator (I).
33-16 D58E, P-l

0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
DISMOUNTING TRACK SHOE ASSEMBLY (Master link type)

1. Blade assembly
See DISMOUNTING THE BLADE
2. Positioning the machine

Move the machine into an area wide enough to sepa-
rate the tracks.
Stop the machine with master link (1) of each track
aligned with the center line of the front idler.
3. Relieving track tension

Loosen lubricator (2) by about one turn, to release
track shoe tension.
A The adjustment cylinder is under

high pressure. Never loosen the lubricator
extremely
more
than one turn.
* If the track tension is not relieved, move the
machine backwards and forwards.
4. Shoe bolts for the master link

1) Put wooden block @ under the grouser just below
the master link (3).
2) Remove four shoe bolts (4) and master shoe (5)

from the master link.
* Height of wooden block: approx. 150 mm
33-18 D58E.P-1
0
5. Detaching the master link

1) Drive the machine over a wooden block to relieve
the tension of the master link.
2) Detach the master link with bar 0.
6. Spreading the track

1) Sling the end of the link (7) with a crane.
2) Slowly back the machine, allowing track frame (6)
to ride over the carrier rollers and come off the
sprocket.
Sr Move the crane along with the machine as it
travels.
A Exchange signals with co-workers and

work step by step.
D58E.P-1 33-19
0
MOUNTING TRACK SHOE ASSEMBLY (Master link type)

1. Winding track
1) With the track end supported on wooden block 0,
move the machine backward along the track until
the sprocket is brought just ahead of four shoes as
shown.
* Height of wooden block: approx. 150 mm
2) Sling the end of link (7) with a crane.
3) Slowly move the machine forward and guide the

track to the sprocket so that the track is installed
along the track frame (6).
2. Engaging the master link

Make sure the teeth on both ends of master link (5)
are engaged.
33-20 D58E.P-1
0
3. Assembling track shoe

install track shoe (3). then tighten mounting bolts (4)
as follows.
a Mounting bolt:
Seizure prevention compound
Tightening sequence
1) Tighten to a tightening torque of 20 * 2 kgm, and

check that contact surface is in close contact.
2) After checking, tighten a further 180 + 10’.

See ADJUSTING TENSION OF TRACK SHOE.
5. Blade assembly
See MOUNTING THE BLADE.
D58E.P-1 33-21
0
ADJUSTING TENSION OF TRACK SHOE

1. Testing tension of track shoe
1) Stop machine on level ground.
* Put the gear shift lever in FORWARD and do
not apply the brake.
2) Put a straight bar 0 on top of grouser at carrier
roller and idler, and check that clearance A between
bar and grouser is within a range of 20 to 30 mm.
* If the results of the test show that the tension
of the track shoe is not within the specified
range, or if the track shoe has been replaced or
serviced, adjust as follows.

1) Open cover.
2) To increase track tension, pump in grease (G2-LI)
through grease nipple of lubrication valve (1). to
relieve track tension, extract grease by reversely
rotating plug (1) for “one rotation”.
*y Do not loosen plug (1) over one complete

rotation. Also, be careful not to loose any
part other than plug (1).
If plug (1) or any other part should be
loosened excessively, it will be liable to fly
out under the high pressure of jammed
grease.
* If grease does not ooze smoothly, try moving
the machine back and forth for a short dis-
tance.
* Repeat the procedure for testing the track
tension and check that the tension is within
the specified range.
* When adjusting the tension, pump in grease
until distance B is 0 mm, but if the track is
still loose, it means that the pin and bushing
are worn, so turn or replace the pin and
bushing.
33-22 D58E.P-1
0
UNDERCARRIAGE
Track frame. .................... . 34- 2

Recoil spring .................... . 34- 3
Idler. ......................... . 34- 4
Track roller ..................... . 34- 6
Carrier roller .................... . 34- 8
Measuring procedure of rollers ........ . 34-10
Track ......................... . 34-12
Suspension ..................... . 34-22
D58E.P-1 34-l
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
u13401004
Unit: mm
Item Repair limit

I
Bending 713000
I
1 Deformation of track frame Repair
Distance between right and left track

2
frame center D58E-1, 1 A: 1,880
Difference between front
D58E-1 B: 1,950
and rear: 15 max.
D58P-1 : 2.060
Clearance
limit
Clearance between sprocket shaft and Replace
3
diagonal brace bushing bushing
-0.030 +0.174 0.130 -

65.0 1 .o
-0.060 +0.100 0.234
34-2 D58E,P-1
0
MAINTENANCE STANDARD RICOIL SPRING
RECOIL SPRING
Section A-A
13OFO82
Unit: mm
Standard size I Repair limit

I
I
Recoil spring
Free I.nstalled Installed Free
Load Repair
length length load length
628 510 10,000 kg 615 8,800 kg
I Tolerance I I
Clearance between bushing and cylinder Replace

bushing
-
95 -0.120 +0.270 0.181 1.0
-0.270 +0.061 0.477
Idler yoke press-fit force 30 ton Adjust
D58E, P-l 34-3

IDLER
IDLER
D58E-1. IA, IB
D58P-1
g\
14 9
\ /
\
iI
13OFO83
34-4 D58E, P-l

@
MAINTENANCE STANDARD IDLER
Unit: mm
-
-
Standard clearance Repair limit
1 Idler drum outside

diameter 720.0 705.0
-
Idler tread outside
2 680.0 665.0
diameter I I
-
3 Idler drum width 85 73 Rebuild

- or replace
4 Idler tread width 39.5 43.5

-
5 Idler wheel width 164 154

-
6 Width of shaft flange 20.0 18.5

-
Clearance between idler

7 shaft and bushing
-
Standard Tolerance Standard Repair
size interference limit Replace
Interference between Shaft Hole
8 bushing
idler and bushing
+0.105 +0.054 0.003 -
100
+0.051 0 0.105 -
-
9 Axial play of shaft

0.25 - 0.90 1.5
-
Clearance between guide Rebuild
10 2.0 5.0
plate and support or replace
-
Adjust shim
Clearance between guide 3.0 or replace
11 1.0
plate and side plate plate
-
Standard shim thickness
12 4 Adjust
of side plate mounting part
-
Lubricating plug 205.9 + 49.0 Nm (21.0 + 5 kgm)
13
tightening torque
- Retighten
Support mounting nut
14 269.7 f 39.2 Nm 127.5 + 4 kgm)
tightening torque
-
D58E, P-l 34-5

0
For PAT
D58P-1 B
r-l-i
3
13OF18051
34-5-l D58E,. P-l

8
Unit: mm
Standard clearance Repair limit

1 Idler drum outside
diameter 655 640
Idler tread outside 615 600

2
diameter
3 Idler drum width 86 73 Rebuild

or replace
4 Idler tread width 39 43.5
5 Idler wheel width 164 154
6 Width of shaft flange 20.0 18.5
Standard Tolerance Standard Clearance

Clearance between idler Shaft Hole
7 shafi t and bushing
-0.250 +0.074 0.250 -
60.0
-0.290 0 0.364 -
I
Standard Tolerance Standard Repair

size interference limit Replace
Interference between Shaft Hole
bushing
8 idler and bushing
+0.105 +0.054 0.003 -
100
+0.051 0 0.105 -

0.25 - 0.90 1.5
1o Clearance between guide Rebuild

plate and support 1.0 5.0
or replace
Adjust shim
11 Clearance between guide 0.5 3.0 or replace
plate and side plate plate
,2 Standard shim thickness Adjust

5
of side plate mounting part
.,3 plug
Lubricating torque
tightening 205.9 f 49.0 Nm (21.0 + 5 kgm}
Retighten
,4 Support mounting nut
tightening torque 269.7 + 39.2 Nm i27.5 + 4 kgm}
D58E, P-l 34-5-2

@
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Ill--
a 6
12
13
135F060A
34-6 D58E, P-l

MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

1 Track roller flange outside diameter
233.0 220
inside flange of double-flange roller outside

2 227.0 215
diameter
3 Track roller tread outside diameter 200.0 190.0
4 Track roller width 217.0 -
5 Track roller tread width (Single-flange roller) Rebuild or

47.0 52.0
replace
Track
6 roller) roller tread width (Double-flange 43.5 53.5
Track roller flange width (Single-flange -

7 22.0
roller)
6 ff~~~~roller flange width (Double-flange

17.5 12.5
91 lnsrde flange width (Double-flange roller) 17.5 I 12.5 I
10 IT rack roller shaft flange width 16.0 14.5

I I I
Tolerance
Clearance between track roller shaft and
11 Shaft Hole
bushing
-0.250 +0.074 0.250 -

60 1 .o
-0.290 0 0.364
Replace
bushing
Tolerance
Standard Standard Interference
size interference limit
Interference between track roller and
12 Shaft Hole Replace
bushing bushing
iC.105 fl.054 0.003 - _
100
+0.051 0 0.105
Track roller mounting bolt tightening

13 27.5 + 4 kgm
torque
Retighten
14 1 Lubricating plug tightening torque 21.0 f 5kgm
D58E.P-1 34-7
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
I35FO6 I
34-8 D58E.P- 1
MAINTENANCE STANDARD CARRIER ROLLER
Unit: mm

Carrier roller flange outside diameter
190 178
2 Carrier roller tread outside diameter 165 155

-
3 Carrier roller tread outside width 82 76
4 Carrier roller tread width 43 46

I
Replace
5 Clearance between bushing and shaft
-
45 -0.150 +0.025 0.150 1 .o
-0.200 0 0.225
-
io.117 io.030 0.057 -
6 Interference between bushing and roller 58 1.0
+0.087 0 0.117

0.375 - 0.550 1.5
-
8 Tightening torque of holder mounting bolt 5.3 +_1.4 kgm

Retighten
9 Tightening torque of lubricating bolt 21+5kgm

I
D58E.P-1 34-9
MAINTENANCE STANDARD MEASURING PROCEDURE OF ROLLERS
MEASURING PROCEDURE OF ROLLERS

(TRACK ROLLER, CARRIER ROLLER AND IDLER)
Wear Measuring Procedure

Measure each roller with a multi-scale, scale and calipers.
09POO8
Depth of Idler Tread

1) Measure the depth of each tread from the drum
surface, using a multi-scale as shown in the figure.
Width of Idler Tread

Put a multi-scale on the idler tread and read the tread
width. Repeat this measurement on the opposite tread.
Compute the difference between left and right tread
widths to determine the mis-alignment of the idler.
Width of Idler Drum

Using a multi-scale, measure the width of the idler drum.
34-10 D58E.P-1
MAINTENANCE STANDARD MEASURING PROCEDURE OF ROLLERS
Track Roller Outside Diameter

Using a multi-scale as the depth gauge, perform the
following measurements and computation:
1) Height of link tread

Apply the depth gauge across the links and read
depth C to the shoe surface at right angles.
2) Bring the tread of the links, with which depth C is

measured, in full contact with the roller tread.
Measure height B with the multi-scale.
3) Compute the required tread O.D.

Tread O.D.A= (B-C) x 2
OSFO3 I
Carrier Roller Outside Diameter

Using a pair of vernier calipers or other calipers, measure
the carrier roller outside diameter.
Flange Width (Track rollers and carrier rollers)

Using a multi-scale or calipers, measure the flange width.
D58E.P-1
MAINTENANCE STANDARD TRACK
TRACK
(1) Master pin type
D58E-1
8 1
t-
133F114
FI 14COSS
34-12 D58E.P-1
Unit: mm

React or
1 Link pitch
replace
175.25 178.25
Lug welding or
2 Grouser height 25.0
replace
Lug welding or
3 Link height 95.0
replace
Light loading: 53.5 React or

4 Bushing outside diameter 58.5
Heavy laading 56.5 replace
I I
Tolerance
Interference between link and master
5 Shaft Hole
bushing
/
+0.304 +0.074 0.190 -
55.0 0.100
+0.264 0 0.304
-
+0.172 +0.062 0.01 - -
6 Interference between link and regular pin 37.8
+0.072 0 0.172
+0.230 +0.062 0.138 -

7 Interference between link and master pin 37.8 0.078 Replace
+0.200 0 0.230
- I I I I 1
Tolerance
8 Clearance between bushing and regular pin Shaft Hole
38.0 +0.172 +0.902 0.230 - _

+0.072 +0.402 0.830
9 Clearance between bushing and master pin 38.0 -0.200 +0.630 0.430 - -
-0.400 +0.230 1.030
-
10 Protrusion of bushing 5.05
I
11 Protrusion of pin 4.0

-
12 Press-fit force for regular pin 18.4 - 39.7 ton
I Adjust
13 Press-fit force for master pin 15.8 - 34.2 ton
14 Tightening torque for shoe bolt First.20 * 2 kgm. 2nd tighten another 120” t 10’ Retighten
I
D58E.P-1 34-13
0
ci
D58P-1
10 7 5
:
‘1
u
1
t-
133Fl16
34-14 D58E.P-1
Unit: mm

React or
Link pitch
replace
175.25 178.25
2 Shoe height 91 .o 76.0

I Lug welding or
replace
Lug welding or
3 Link height 101.5 95.0
replace
Light loading: 53.5 Lug welding or

4 Bushing outside diameter 58.5
Heavy loading: 55.5 replace
Tolerance
5 Interference between bushing and link Shaft Hole
-
55.0 +0.304 +0.074 0.190 0.100
+0.264 0 0.304
6 Interference between regular pin and link 37.8 +O.l72 +0.062 0.01 - -
+0.072 0 0.172
-
-
7 Interference between master pin and link 37.8 +0.230 +0.062 0.138 0.078 Replace
+0.200 0 0.230
Clearance between regular pin and

8
bushing
-0.200 +0.630 0.430 - _

9 Clearance between master pin and bushing 38.0
-0.400 +0.230 1.030
10 Protrusion of bushing 5.05
11 Protrusion of pin 4.0

1 Adjust
12 Press’fit of regular pin 18.4 - 39.7 ton
13 Press-fit of master pin 15.8 - 34.2 ton

-
14 Tightening torque for shoe bolt First, 20 f 2 kgm, 2nd tighten another 120’ + 10’ Retighten
D58E.P-1 34-15
0
Master link n/f=

D58EP-1
1 !
12 11
F114C119A
34-16 D58E.P-1
Unit: mm
No
1 Link pitch
2 Grouser height
3
-
4
-
5
-
6 interference between bushing and link
8 Clearance between pin and bushing
0.830 -
9
-
10
-
11
12
D58E.P-1
MEASURING PROCEDURE OF TRACK
1. Link pitch measuring procedure
Block
Link pitch measuring position /
dlaster pin
OSFO20
Insert a piece of timber between the track and _

sprocket wheel to remove track slackness. Measure
the length L over 4 links stretched into line. Com-
pare one-fouth of L with the basic value of the track
link pitch. pin to pin.
’ OSFO21
Be sure to select any 4 links which are at least two
links away from the master pin.
The judgement as to whether the pins and bushings
are to be turned or replaced with new ones should
not be made after only one measurement. This Criteria of pins and bushings to be turned:
should be determined as a result of the measure- . Where the elongation of link pitch exceeds 3mm,
ment at several places along the track. . Where the wear of bushing O.D., exceeds 3 mm.
2. Measuring procedure of bushing outside diameter

Using a multi-scale of calipers, measure the bushing
O.D. at three different directions as shown in the
figure. Compare the minimum value obtained with
the basic size of the bushing O.D. Replace the
bushing when the wear of bushing O.D., exceeds 3
mm, or when the bushing is cracked.
If the specific interference fit cannot be obtained
between a bushing and mating link hole, when
reinstalling a turned bushing, replace the bushing
with an oversize one.
OSFO22
34-18 D58E.P-1
3. Measuring procedure of shoe grouser height

Place a straight edge across the grouser of two
adjacent links and measure the height A above the
shoe plate surface.
* Before performing this measurement, give the ten-

sion to the track by inserting a piece of timber
between the track and the sprocket teeth.
* This measurement should be performed at the

center of a grouser to minimize error which may
result from wear of the grouser and shoe plate or
from uneven wear of the grouser.
4. Measuring procedure of link height

Apply a multi-scale to a link from the underside
surface and read the height to the shoe.
Precautions for measurement:
1. Measure the height of a link at a position where
the most excessive wear of the tread is found.
2. Pay sufficient attention to prevent possible
error due to bending of a shoe or any other
abnormal conditions.
3. A link that is cracked or excessively worn on its
side surfaces should be considered as defective,
even if the height of the shoe does not reach
the service limit.
5. Measuring procedure of link mating surface

Check the link mating surface clearance with a
thickness gauge.
Precautions for measurement:
Insert a piece of timber between the track and
sprocket to remove slackness of the track, and insert
the thickness gauge from the underside in a clear-
ance selected in the part of the track stretched
straight.
Criteria:
Standard clearance (a - b), each side 1 .l mm
Service limit clearance (a . b), each side -
Standard clearance (a + b), both sides 2.2 mm
Service limit clearance (a + b), both sides -
D58E.P-1
SUSPENSION
_..-
Section A-A
I
T-
c --
rl
133F118
Unit: mm
1 Clearance between center pin and bushing Replace
70 -
-0.100 +o 22 0.260 0.5
-0.146 +0.16 0.366
34-20 D58E.P-1
HYDRAULIC SYSTE,M
Hydraulic oil piping for blade lift.. ............ 61- 2

Hydraulic oil piping for blade tilt.. ............ 61- 3
Ripper piping and control linkage ............ 61- 4
Hydraulic pump.. ......................................... 61- 5
Hydraulic control system ........................... 61- 6
Straight-tiltdozer ................................... 61- 6
Straight-tiltdozer with ripper.. ............. 61- 8
Power angle, power tiltdozer.. .......... .61-9-l
Joystick control specification ............ .61-9-3
Blade control ............................................... 61-10
Straight-tiltdozer ................................... 61-10
Power angle, power tiltdozer ........... 61-11-1
Joystick control specification ............ 61-1 l-2
Servo valve (For angle operation) ... .61-l l-3
Hydraulic piping of work equipment.. .. .61-l l-7
Hydraulic tank ............................................. 61-12
Straight-tiltdozer with ripper.. ......... .61-12-l
Power angle, power tiltdozer.. ........ .61-12-2
Joystick control specification ............ 61-12-3
Blade lift and tilt control valve
(Straight-tiltdozer) ....................................... 61-13
Main relief valve ................................... 61-14
Suction valve ........................................ 61-15
Blade control valve
(Power angle, power tiltdozer). .............. 61-15-1
Blade lift, tilt valve ............................ 61-15-1
Suction valve ..................................... 61-15-1
Blade angle valve .............................. 61-15-2
Safety valve, suction valve.. ............. 61-15-2
Main relief valve ................................ 61-15-3
Ripper control valve ................................... 61-16
Work equipment cylinder.. ......................... 61-18
Power angle, power tiltdozer ........... 61-19-1
Ripper cylinder ..................................... 61-20
D58E, P-l 61-1

@
STRUCTURE AND FUNCTION HYDRAULIC OIL PIPING FOR BLADE LIFT
HYDRAULIC OIL PIPING FOR BLADE LIFT
The hydraulic oil piping for blade lift of work Hydraulic pump (4) is mounted on the top of the
equipment connects to hydraulic pump (4), hy- torque converter.
draulic tank (I), hydraulic filter (51, control valve
(2) built in hydraulic tank and blade lift cylinder
(3).
D58P-1
1. Hydraulic tank
2. Hydraulic control valve
3. Blade lift cylinder
4. Hydraulic pump
5. Hydraulic filter
61-2 D58E, P-l

STRUCTURE AND FUNCTION HYDRAULIC OIL PIPING FOR BLADE LIFT
The hydraulic oil piping for blade lift of work Hydraulic pump (4) is mounted on the top of the
equipment connects to hydraulic pump (41, hy- torque converter.
draulic tank (I), hydraulic filter (51, control valve
(2) built in hydraulic tank and blade lift cylinder
(3).
D58E-1
SED00966
1. Hydraulic tank
4. Hydraulic pump
5. Hydraulic filter
D58E, P-l 61-2-1

0
STRUCTURE AND FUNCTION HYDRAULIC OIL PIPING FOR BLADE TILT
HYDRAULIC OIL PIPING FOR BLADE TILT

A blade tilt unit is installed on the D58E, P-l. The piping
from hydraulic tank (1) to blade tilt cylinder (3) passes
through the center of straight frame (4), so it cannot be
seen from the outside.
F13017033
1. Hydraulic tank
3. Blade tilt cylinder
4. Straight frame
D58E.P-1 61-3
STRUCTURE AND FUNCTION RIPPER PIPING AND CONTROL LINKAGE
RIPPER PIPING AND CONTROL LINKAGE

The diagram below shows the piping and control linkage “HOLD” to “RAISE”, the linkage and spool moves in
when a parallelogram ripper is installed as the rear the direction of the arrow. The pressure oil from the
attachment. valve (2) enters the head of the ripper lift cylinder (4).
When the ripper control lever (3) is moved from This retracts the piston rod and the ripper rises.
1. Hydraulic tank
2. Ripper control valve
3. Ripper control lever
4. Ripper lift cylinder
F13017034
61-4 D58E.P-1
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
13OFO99
1. Drive gear Type: Gear pump (KAL080)

2. Bracket 181 P/min at 1,900 rpm
3. Gear case
4. Bushing
5. Cover
6. Driven gear
D58E.P-1 61-5
STRUCTURE AND FUNCTION HYDRAULIC CONTROL SYSTEM
HYDRAULIC CONTROL SYSTEM

l Straight-tiltdozer
Engine running, two blade control levers in “HOLD”

position.
....
.A..
.A.. ,
.A..
:.:.:.:.:. ::::: .+:.:.,.:
ii . i . . . ... . ..
ti
ii..... .A.. . . . . ..
@ Left tilt
@ Hold @ Hold
@ Lower 0 Right tilt
@ Float
F I44CO76-1
61-6 D58E,P-1
0
Float Lower iold Raise

1-L --
Ti l-
Right tilt Left tilt
1
-
Left
Hold tilt
140 kg/cm’
r--i
r’
KALOBO
M 181 Q/min. (at 1,900 rpm)
1
I44F094A
1. Hydraulic pump 7. Blade lift control valve spool

2. Main relief valve 8. Blade lift cylinder
3. Flow control valve 9. Suction valve for head
4. Blade tilt control valve spool 10. Suction valve for bottom
5. Tilt cylinder 11. Hydraulic filter
6. Chedk valve 12. Hydraulic tank
A: Tap for main relief valve pressure
D58E.P-1 61-7

l Straight-tiltdozer with ripper
Raise Lower
Engine running, blade control levers are in “HOLD”

position.
10
F144C077A
i
BLADE LIFT BLADE TILT RIPPER
t (
$
g j::
:.
.:,:
:.:.:
0 RAISE @ LEFT TILT @ RAISE
.....
.....
@ HOLD @ HOLD @ HOLD
,.,., 8
;>:;:;:::,i:i:$;
j;;;j
,\
@ LOWER 0 RIGHT TILT f@ LOWER
:.:.:.:.:.:::::.: jjjjj ;jg
.................
t......... . ...
@ FLOAT
61-8 D58E,P-1
0
- Lower
13Raise
Cracking pressure
Right Left
tilt
-
tilt
(at 1,900 rpm)
I --I19
F 144CO78A
1. Hydraulic pump 14. Safety valve for ripper cylinder head

2. Main relief valve 15. Suction valve for ripper cylinder bottom
3. Flow control valve 16. Suction valve for ripper cylinder head
4. Tilt control valve spool 17. Safety valve for ripper cylinder bottom
5. Tilt cylinder 18. Hydraulic filter
6. Check valve 19. Hydraulic tank
7. Blade lift control valve spool A: Tap for main relief valve pressure
9. Suction valve for lift cylinder head
10. Suction valve for lift cylinder bottom
11. Check valve
12. Ripper control valve spool
13. Ripper cylinder
D58E.P-1 61-9

l Power angle, power tiltdozer
~~
,:,:, _,
,.,.,.,.,.,.,
(, ... .
.,.,......
..I/....,....... . . . . . .. . . . . . .. . .. . .. . . .. .. . ..~A....
.._. ,, . . L.H.
-
R.H.
L.H.
3 BLADE LIFT BLADE TILT BLADE ANGLE

0 RAISE @ LEFT TILT @ RIGHT ANGLE
0 HOLD @ HOLD @ HOLD
2
@ LOWER 0 RIGHT TILT @ LEFT ANGLE
ii3
@ FLOAT
1
13OF18020
61-9-1 D58E,P-1
0
I
I
Raise
u 14 0 13 ( 1
u
JLb
Set pressure
205 kg/cm’
I?- 7
I(
8
Right angle
I R.H. L.H.
I-
205 kg/cm’
Set pressure
Cracking
pressure
2.2 kg/cm:
I--
I D58: KAL080
170Qlmin
(at 1900 rpm)
13OF18021
1
I. Hydraulic tank 10. Blade tilt cylinder

2. Hydraulic pump (D58E-1 B: KAL080) 1 1. Blade lift check valve
3. Main relief valve 12. Blade lift valve
4. Check valve 13. Blade lift cylinder
5. Blade angle valve 14. RAISE suction valve
6. Blade angle cylinder 15. LOWER suction valve
7. Blade angle safety valve 16. Oil filter
8. Blade tilt check valve A. Main relief pressure outlet port
9. Blade tilt valve
* For ripper unit, please refer section “Straight-tiltdozer with ripper”.
D58E, P-l 61-9-2

0

SWD02501
D58E, P-l
Right tilt Left t1 It
iet pressure
20.1 MPa
(At 1900reml
SW002502
1. Hydraulic tank 10. Blade tilt cylinder

2. Work equipment pump (KAL080) 11. Blade lift check valve
3. Main relief valve 12. Blade lift valve
4. Check valve 13. Blade lift cylinder
5. Blade angle valve 14. Suction valve on raise side
6. Blade angle cylinder 15. Suction valve on lower side
7. Blade angle safety valve 16. Oil filter
8. Blade tilt check valve A. Plug for main relief pressure
9. Blade tilt valve
D58E, P-l 61-9-4

@
STRUCTURE AND FUNCTION BRADE CONTROL
BLADE CONTROL
When the blade control lever (4) is moved to “LEFT

TILT”, the linkage moves in the direction of the arrow,
and the spool of the blade tilt control connected with
lever (6) moves to the LEFT TILT position.
I I
i F13017035
3
/
1. Lever 0 RIGHT TILT

2. Shaft 0 HOLD
3. Lever @ LEFT TILT
4. Blade control lever
5. Blade safety lever
6. Blade tilt control valve lever
61-10 D58E, P-l

0
STRUCTURE AND FUNCTION BLADE CONTROL
When the blade control lever (4) is moved to “RAISE”,

the linkage moves in the direction of the arrow, and the
spool of the blade tilt control connected with lever (9)
moves to the RAISE position.
F13017036
3. Lever
4. Blade control lever
5. Blade safety lever
7. Lever
8. Rod
9. Blade lift control valve lever
D58E.P-1 61-11
BLADE CONTROL
Section A-A View 2 Section C-C
13OF18032
8 ;lGHJTlLT
8 ;;yA;LT
1. Work equipment control lever (for blade LIFT, TILT)

2. Lock lever g :ER
3. Work equipment control lever (for blade ANGLE) 0 RAISE
4. Work equipment control valve (for blade LIFT, TILT) @ LEFT ANGLE
5. Work equipment control valve (for blade ANGLE) @ HOLD
@j) RIGHT ANGLE
61-11-l D58E,P-1
0

Right tilt Hold
l-/---deft tilt
Riaht
Holb-
Left angle
I’
---I-
/ I
Lock
SWD02503
1. Work equipment control lever (For lifting, tilting and angling blade)
2. Safety lock lever
3. Servo valve
D58E, P-l 61-11-Z

@
l Servo valve (for angle operation)
T1 T2
A4
A-A SWDO2504
1. Input spool 6. Pilot spool Port PI: From steering pump

2. Plate 7. Piston (Output spool) Port Tl: To steering case
3. Holder 8. Body Port T2: To steering case
4. Spring 9. Plate
5. Spacer 10. Joint
61-l l-3 D58E, P-l

@
Function
. Since the angle lever is controlled by turning . To reduce the operating effort of the angle
the lever to the right and left, the operator control lever, a servo valve is used.
cannot operate the lever strongly and the op- . The servo valve is kind of booster. If its in-
erating effort is heavy. In addition, since the put spool is moved, the pilot spool is moved.
blade lifting control must be operated to- As a result, the output spool is moved by
gether with the angle control, the operating the pilot oil pressure from the steering pump,
stroke of the angle lever cannot be set long. then it moves the angle control valve through
the yoke.
Operation
1. Operation of left-hand angle
L
/\I
B b a
\ A SWDO2505
. When the blade control lever is moved to . Piston (7) stops when both notches a and b
the left angle side to move input spool (I) to are closed.
the left, pilot spool (6) and input spool are l Since piston (7) and output spool are made
moved to the left simultaneously to compress in one unit and equipped with joint (IO), the
spring (4) through the retainer, since they latter moves to the left to push the spool of
are connected to each other. (The force to the angle control valve through the yoke to
compress the spring at this time is the oper- angle the blade.
ating effort of the lever.) . When the blade control valve is moved to
. If pilot spool (6) moves to the left, notch a is the left further, piston (7) moves to the left
kept closed but notch b is opened. As a similarly for the moving distance of input
result, the oil in piston chamber B is con- spool (1).
nected through notch b to port Tl, thus the l The output of piston (7) at the time when the
pressure in chamber B lowers. left-hand angle is controlled is indicated by
. The pressure oil from the steering pump flows the following formula.
through port P in piston chamber A to press
piston (7). Then, piston (7) moves to the left F1= 4 (D? - Dz*) x & (kg)
to a point where notch b is closed.
D58E, P-l 61-11-4

@
2. Operation of right-hand angle
. When the blade control lever is moved to the l When the blade control valve is moved to the
right angle side to move input spool (I) to the right further, piston (7) moves to the right simi-
right, pilot spool (6) is moved to the right and larly for the moving distance of input spool (1).
compresses spring (4) through the retainer. (The l The output of piston (7) at the time when the
force to compress the spring at this time is the right-hand angle is controlled is indicated by the
operating effort of the lever.) following formula.
l When pilot spool (6) moves to the right, notch b
P
is kept closed but notch a is opened. As a re- F2 = 4 (D22 - D32) x m (kg)
sult, the oil in piston chamber B is connected
through notch a to piston chamber A, then the
pressure oil from the steering pump flows
through port P in piston chamber B to press
piston (7). Then, piston (7) moves to the right to
a point where notch a is closed.
. Piston (7) stops when both notches a and b are
closed.
Since piston (7) and output spool are made in
one unit and equipped with joint (IO), the joint
moves to the right to pull the spool of the angle
control valve through the yoke to angle the blade.
61-11-5 D58E, P-l

@
3. Operation while engine is stopped
-t-- 0 SW002507
. When the blade control lever is moved to the If input spool (I) is moved to the right fur-
left angle side to move input spool (I) to the ther, piston (7) moves to the right and joint
left, pilot spool (6) is moved to the left. When (IO) also moves to the right.
gap C (1.5mm) becomes “O”, pilot spool (6) Accordingly, the angle control valve con-
and piston (7) are connected to each other. nected by the yoke to joint (IO) is operated
When input spool (I) is moved to the left toward the right-hand angle.
further, piston (7) moves to the left and joint . As explained above, the servo valve can be
(IO) also moves to the left. operated even if the engine is stopped. If
Accordingly, the angle control valve con- the hydraulic source is not available, the op-
nected by the yoke to joint (IO) is operated erating effort becomes remarkably heavy
toward the left-hand angle. since the servo valve and the spool of the
. When the blade control lever is moved to control valve must be operated simultane-
the right angle side to move input spool (1) ously.
to the right, pilot spool (6) is moved to the
right. When gap D (1.5mm) becomes “O”,
pilot spool (6) and joint (IO) are connected to
each other.
D58E, P-l 61-11-6

@
STRUCTURE AND FUNCTION HYDRAULIC PIPING OF WORK EQUIPMENT
HYDRAULIC PIPING OF WORK EQUIPMENT

(Power angle, power tiltdozer)
1. Angle cylinder
2. Lift cylinder
3. Work equipment pump
4. Hydraulic tank
5. Tilt cylinder
I I-/
61-11 7
D58E, P-l
@
STRUCTURE AND FUNCTION HYDRAULIC OIL PIPING OF WORK EQUIPMENT
/ - I I
1. Angle cylinder
2. Lift cylinder
3. Work equipment pump
4. Hydraulic tank
5. Tilt cylinder
D58E, P-l 61-l l-8

@
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
7
Section A-A
Section C-C
Bection B-B
Section D-D
Section E-E
-2
133FO50
Hydraulic oil filter

. Cracking pressure 2.2 kg/cm’
1. Hydraulic tank A. To hydraulic pump

2. Work equipment control valve B. From hydraulic pump
3. Level gauge C. To blade tilt cylinder bottom
4. Filter cover D. To blade tilt cylinder head
5. Spring E. To blade lift cylinder bottom
6. Valve F. To blade lift cylinder head
7. Element
61-12 D58E, P-l

0
HYDRAULIC TANK
l Straight-tiltdozer with ripper
Sction A-A Section C-C
Section B-B
Section D-D
Section E-E
u13401005

l Cracking pressure 2.2 kg/cm2

2. Work equipment control valve B. From hydraulic pump
3. Level gauge C. To blade tilt cylinder bottom
4. Filter cover D. To blade tilt cylinder head
5. Spring E. To blade lift cylinder bottom
6. Valve F. To blade lift cylinder head
7. Element G. To ripper cylinder bottom
H. To ripper cylinder heed
D58E,P-1 61-12-l
0
HYDRAULIC TANK
Section C-C
Section E-E
Section B-B
Section D-D
Section A-A
13OF18024

. Cracking pressure: 2.2 kg/cm2
* For ripper unit, please refer section

“Straight-tiltdozer with ripper”.

2. Work equipment control valve 8. To lift cylinder bottom end (LOWER)
(for blade LIFT, TILT) C. To tilt cylinder head end (RIGHT TILT)
3. Work equipment control valve D. To tilt cylinder bottom end (LEFT TILT)
(for blade ANGLE) E. To lift cylinder head end (RAISE)
4. Main relief valve F. To right angle cylinder head end, left angle
5. Level gauge cylinder bottom end (RIGHT ANGLE)
6. Filter cover G. Hydraulic pump
7. Spring H. To right angle cylinder bottom end, left angle
8. Valve cylinder head end (LEFT ANGLE)
9. Element
61-12-2 D58E,P-1
0

D-D
1. Hydraulic tank A. To work equipment pump Outline

2. Work equipment B. To lift cylinder bottom (lower) . Hydraulic tank (I) has work equip-
control valve (For side ment control valves (2) and (3) in
lifting/tilting blade) C. To tilt cylinder head (right tilt) it, and its capacity is about 65 liters
3. Work equipment side in the range of oil level gauge (4).
control valve (For D. To tilt cylinder bottom (left tilt) The hydraulic tank and hydraulic
angling blade) side oil filter are made in one unit.
4. Main relief valve E. To lift cylinder head (raise) side The cracking pressure and the
5. Level gauge F. To right angle cylinder head side maximum passing rate of the hy-
6. Filter cover and left angle cylinder bottom draulic oil filter is set to 0.2MPa
7. Spring (right angle) side {2.2kg/cm2) and 140 Umin respec-
8. Valve G. To work equipment pump tively.
9. Element H. To right angle cylinder bottom
side and left angle cylinder head
(left angle) side
D58E, P-l 61-12-3

@
STRUCTURE AND FUNCTION BLADE CONTROL VALVE
BLADE LIFT AND TILT CONTROL VALVE

F I44C64
1 2 3 4567 8
1. Valve body 14. Seat

2. Lift spool 15. Case
3. Retainer 16. Spring
9 Collar 17. Retainer
10 ;: Retainer 18. Plate
11 6. Spring 19. Seat
12 7. Case 20. Spring
8. Detent 21. Flow control valve
13 9 Detent ball 22. Collar
14 10: Guide 23. Spring
11. Spring 24. Lift check valve
‘5 12. Plug 25. Tilt spool
16 ‘3. Plate
Hydraulic
pump / / / I I I I I \ section A-A
25 24 23 22 21 20 19 18 17 6lF006A
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 35
Section8-B Section C-C

6 I FOO7B 6 I FOO8B
26. Pressure adjusting plug 31. Seat 35. Valve body 39. Suction valve body
27. Lock nut 32. Valve body 36. Suction valve for lower 40. Suction valve for raise
28. Case 33. Spring 37. Spring 41. Spring
29. Spring 34. Main relief valve 38. Plate 42. Valve seat
30. Pilot valve
D58E.P-1
STRUCTURE AND FUNCTION MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Pressure adjusting plug

2. Lock nut
3. Case
4. Spring
5. Pilot valve
6. Seat
7. Valve body
8. Spring
9. Main relief valve
I 6 I FO07
Structure
A pilot type of valve is used for the main relief valve. and is pushed against the seat (6). Almost all of the
The pilot type valve consists of two valves: a main oil at port (A) is drained to the tank through port (C).
relief valve (9) and a pilot valve (5). The setting of The hydraulic pressure in the circuit does not rise
the hydraulic pressure is determined by the move- any further, and the set pressure is maintained.
ment of the pilot valve. The set pressure of the main relief valve is determined
The main relief valve is installed inside the hydraulic by the strength of spring (4).
tank. When the main relief valve functions, the oil Therefore, the set pressure can be adjusted by turning
is drained directly inside the tank. pressure adjustment plug (1) to change the strength
of spring (4).
In addition, with the pilot type main relief valve,
Operation there is little difference between the pressure at
Blade control valve in “HOLD” position which port (D) opens and the pressure at which port
The oil from the hydraulic pump fills ports (A) and (C) opens (set pressure). This means that little oil
(B), passes through the control valve and is drained escapes at below the set pressure, so the efficiency
to the tank. is high.
The hydraulic pressure on the left and right (port (A)
I 4 5 6 8 9
and port (B)) is equal.
Blade control valve not in “HOLD” position
The oil from the hydraulic pump passes through the
control valve and flows to the cylinders. The hydrau-
lic pressure rises and moves the cylinders. When the
cylinders reach the end of their stroke, the hydraulic
pressure rises further. When the hydraulic pressure
in the circuit becomes greater than the force of spring
(4), it moves valve (5) to the left and the oil is drain-
ed to port (E). When the oil is drained to port (E),
the oil flows through orifice (a), so the hydraulic
pressure at port (B) becomes lower than the hydraulic
pressure at port (A). Because of this difference in
pressure, the main relief valve (9) moves to the left, IOOF303A
Drain
61-14 D58E.P-1
STRUCTURE AND FUNCTION SUCTION VALVE
SUCTION VALVE
Type A TYW B
Tank
Cyl’inder
head
t Cylinder bottom
6 I FO08
From cylinder head
(Drain)
1. Valve body 5. Suction valve body
2. Suction valve for lower 6. Suction valve for raise
3. Spring 7. Spring
4. Plate 8. Valve seat
Structure Type B
The suction valve is a poppet type. l In the same way as with type A, the oil sent from
There are two types of suction valve, as shown above. the pump to the cylinder is not
sufficient, and
Type A is a forced pushing type, and type B is a negative pressure is formed at the cylinder head.
natural suction type. Because of the difference between the pressure at
With type A, the forced pushing type, when the oil the cylinder head (negative pressure) and the pres-
from the cylinder returns to the tank, it restricts sure inside the tank, suction valve (6) operates. The
the drain circuit and reduces the flow of oil to the oil inside the tank then flows to the cylinder head
tank. It sends oil directly to the cylinder bottom and prevents the formation of negative pressure.
circuit, so is highly efficient.
Operation
Tvpe A
Port (A) is connected to the bottom end of the blade
lift cylinder. Port (B) is connected to the drain cir-
cuit at the cylinder head. When the control lever is
placed in the “LOWER” position, the oil from the From
pump flows to the cylinder bottom (port (A)), and tank
-
the blade is lowered. However, the weight of the
blade increases the lowering speed of the blade, so
the oil sent from the pump to the cylinder bottom
is not sufficient, and negative pressure is formed at
the cylinder bottom.
At the same time, the oil at the cylinder head is I
drained Cylinder
at port (B). However, the drain circuit is From cylinder head
bottom
restricted, so the hydraulic pressure at port (B) rises. I OOF321 A
Because of the pressure difference between port (A)

and port (B), the valve (2) moves to the right and
the oil at port (B) flows to port (A) to prevent the
formation of negative pressure.
D58E.P-1
61-15
,,‘-
BLADE CONTROL VALVE

BLADE 1.IFT. TILT VALVE
13OF102-1
SUCTION VALVE (LIFT CIRCUIT)
13OF104-1
61-15-l D58E,P-1
0
BLADE ANGLE VALVE 35 36 37 38
42 41 40 39 13OF18025
SAFETY VALVE, SUCTION VALVE (ANGLE CIRCUIT)
43 44 45 46 47 48 49 59
13OF18026
1. Valve body 14. Case 27. Spring 40. Seat

2. Lift spool 15. Spring 28. Plate 41. Spring
3. Retainer 16. Retainer 29. Sleeve 42. Angle check valve
4. Retainer 17. Plate 30. RAISE suction valve 43. Seat
5. Spring 18. Seat 3 I. Spring 44. Spring
6. Case 19. Spring 32. Valve seat 45. Sleeve
7. Detent 20. Tilt check valve 33. Valve body 46. Rod
8. Detent spring 21. Collar 34. Angle spool 47. Poppet
9. Guide 22. Spring 35. Retainer 48. Valve body
10. Detent ball 23. Lift check valve 36. Retainer 49. Valve body
1 1. Detent 24. Tilt spool 37. Spring 50. Suction valve
12. Plate 25. Valve body 38. Case 51. Spring
13. Seat 26. LOWER suction valve 39. Plate 52. Seat
D58E,P-1 61-15-2
0
STRUCTION AND FUNCTION BLADE ‘CONTROL VALVE
,-
MAIN RELIEF VALVE
! 3 4 5 6 1 6
13OF103-1
1. Pressure adjusting plug * Pressure adjusting plug (1)

2. Spring Adjustable 29.4 kg/cm’ per one turning
3. Popet
4. Case
5. Seat
6. Spring
8. Valve body
61-15-3 D58E,P-1
0
STRUCTURE AND FUNCTION RIPPER CdNTROL VALVE
RIPPER CONTROL VALVE

for DRP 060 Ripper
Cylinder bottom Cylinder head
Closed by hydraulic tank
Suction valve To hydraulic filter
oke
Safe& valve From blade control valve
View Y View 2
F13017037
61-16 D58E.P-1
STRUCTURE AND FUNCTION RIPPER CONTROL VALVE
Section A-A
Ripper control valve
Section B-B Section C-C
Safety valve Suction valve
F13017038
1. Valve body 6. Case 11. Suction valve 16. Poppet

2. Spool 7. Plate 12. Spring 17. Valve body
3. Retainer 8. Seat 13. Plug 18. Seat
4. Retainer 9. Spring 14. Plug seat
5. Spring 10. Check valve 15. Spring
D58E.P-1 61-17
STRUCTURE AND FUNCTION WORK EQUlPMEilT CYLINDER
WORK EQUIPMENT CYLINDER

3
FT CYLINDER
D58E-1
I /_ /
ii&Ll -R- j/,
133FO51
LIFT CYLINDER
D58P- 1 8 9 10 11 12 13
133FO52
61-18 D58E,P-1
0
STRUCTURE AND FUNCTION WORK EbUlPMENT CYLINDER
TILT CYLINDER
133FO53
1. Cap
2. Bushing Unit: mm
3. Gland Lift Lift Tilt
Check item Ripper
4. Bushing (D58E-1) (D58P-1) (D58E,P-1)
5. Cylinder head Piston rod O.D. 55 55 70 75

6. Cylinder Cylinder I.D 90 90 160 160
7. Piston rod Stroke I.050 1,050 140 250
8. Slider Cylinder max. length 1 1,720 1 1,815 1 1,043 1 880
9. Retainer Cylinder min. length 670 765 903 630
10. Piston Piston nut
(width across flats) 41 41 80 75
11. Piston valve
12. Piston valve seat
13. Piston nut
14. Wear ring
15. Packing
D58E.P-1 61-19
STRUCTION AND FUNCTION WORK EQUIPMENT CYLINDER

LIFT CYLINDER
D58E-1 B
13OF18027
TILT CYLINDER
D58E-1 B
10 9 8
13OF18028
61-19-1 D58E,P-1
0
STRUCTION AND FUNCTION WORK EQUIPMENT CYLINDER
ANGLE CYLINDER
D58E-1 B
16 0
13OF18029
1. Bushing
2. Cylinder head
3. Cylinder
4. Piston rod
5.. Piston
6. Piston nut
7. Bushing
8. Wear ring
9. Piston ring
10. Bushing
Unit: mm
Check item Lift Tilt Angle
Outside diameter of piston rod 60 75 60

I I
I
Inside diameter of cylinder 120 150 120
I I
Stroke 445 192 532
Max. distance between pins 1,289 996 1,454
Min. distance between pins 844 804 922
Width across flats of piston nut 60 85 60
D58E,P-1 61-19-2
0
STRUCTURE AND FUNCTION WORK EQUIPMENT CYLINDER

RIPPER CYLINDER
F13017039
1. Dust seal 10. Nut

2. Cylinder head 11. Piston
3. Cylinder 12. Snap ring
4. Piston rod 13. Retainer
5. Snap ring 14. Piston packing
6. Retainer 15. Plate
7. U-packing 16. Bushing
8. Piston ring 17. Dust seal
9. U-packing
61-20 D58E,P-1
0
HYDRAULIC SYSTEM
Standards for testing and adjusting.. ......... 62-2

Testing and adjusting tool list .................... 62-3
Measurement locations for hydraulic
oil pressure ............................................. 62-4
Hydraulic oil pressure adjustment.. ............ 62-4
Bleeding air from hydraulic cylinders.. . ..62-4- 1
Troubleshooting ............................................ 62-5
D58E, P-l 62-l

0
D58E-1
D58E-1, IA
Item Condition Unit Standard Permissible
value value
HOLD + RAISE 67?r 15
HOLD + LOWER 67* 15

Blade control lever
LOWER+ FLOAT 72f 15
HOLD -+ LEFT TILT 45 f 5

mm
HOLD+ RIGHT TILT 46 + 5
HOLD + RAISE 68k 15

Engine low idling
Ripper control lever Center of lever grip
Oil temperature: HOLD + LOWER 66? 15
45 - 55°C
HOLD + TILT 80f 15
19.6 + 9.8
(2? 1)
N
Blade control lever LOWER + FLOAT
I (kg)
HOLD +
Engine high idling

l Oil temperature: MPa
Main relief pressure
45 - 55°C (kg/cm*)
Engine low idling
L
l Engine at high idling

l Hydraulic oil temp.: 45 - 55°C
l Blade: Ground tf Highest raised position
, l Fully L.H. tilted ts Fully R.H. tilted
i-
sec.
/
r RAISE
I
Blade lift
LOWER
I Work equipment
moving speed RIGHT TILT
Blade tilt
LEFT TILT
62-2 D58E, P-l
0
D58E-1, IA
Item Condition Unit St;;lperd Permissible
value

l Measure the cylinder drift during 15 minutes every each
5 minutes after an interval of one minute after stopping -t
the engine.
l With blade raised 300 mm high from

Blade cylinder drift -i--f
ground level
mm/l5min
l From a position where the side end of
blade is placed on block.
Tilt cylinder drift l From a position where the front of 100
machine is fully raised with R.H.
(L.H.) tilted blade.
l From a position where the ripper is

Ripper cylinder drift fully raised 100
l Engine stopped
l Specified oil and coolant level

l Perform digging 30 to 40 m and filling
Hydraulic oil
back until heat balance is reached. +
l Wind velocity: Max. 5 m/s max. “C 100
temperature
l Discontinue in case of extreme cloudy
or rain.
l Thermostat fully opened.
D58E, P-l 62-2-l

0
D58P-1
Item Condition Unit

T- D58P-1
value value
HOLD + RAISE 67+ 15
HOLD --f LOWER 67+ 15

Blade control lever
LOWER+ FLOAT 72k 15

I
HOLD -+ LEFT TILT

mm
HOLD+ RIGHT TILT 46 5 5
Engine low idling HOLD --f RAISE

Oil temperature: HOLD + LOWER
45 - 55°C
HOLD + TILT
I 39.2 rt: 19.6

RAISE (4 * 2)
HOLD -+
19.6 f 9.8
LOWER (2k 1)
N 39.2 k 19.6
Blade control lever LOWER --f FLOAT
(kg) (4 * 2)
49 + 19.6
LEFT, RIGHT (5 k 2)
HOLD --f
TILT
Engine high idling

l Oil temperature: MPa
45 - 55°C (kg/cm*)
Engine low idling
I
l Engine at high idling
l Blade: Ground cs Highest raised position
-
l Fully L.H. tilted tf Fully R.H. tilted
L
RAISE sec. 2.0 * 0.3
=E
: Blade lift
Work equipment LOWER 1.3 * 0.2
moving speed
RIGHT TILT 2.0 f 0.5
2.9 + 0.5
62-2-2 D58E, P-l

0
Item Condition l- Unit

D58P-1

5 minutes after an interval of one minute after stopping
the engine.

Blade cylinder drift
ground level
mmll5min.
l From a position where
the side end of
Tilt cylinder drift l From a position where the front of
{L.H.) tilted blade.

Ripper cylinder drift fully raised
l Engine stopped

back until heat balance is reached.
Hydraulic oil
l Wind velocity: Max. 5 m/s max. “C
temperature
or rain.
D58E, P-l 62-2-3

0
D58E-1 B
D58E-1 B
Item Condition Unit
HOLD + RAISE
HOLD --f LOWER

Blade control lever
LOWER+ FLOAT
HOLD + LEFT TILT

mm
HOLD-t RIGHT TILT
Engine low idling HOLD + RAISE

Oil temperature: HOLD + LOWER
45 - 55°C
HOLD + TILT 8Ok 15
39.2 + 19.6
RAISE (4 * 2)
HOLD -+
19.6 * 9.8
LOWER (2f 1)
39.2 + 19.6
31ade control lever LOWER --f FLOAT (4 i 2)
49 f 19.6
LEFT, RIGHT (5 + 2)
N
HOLD --f
(kg)
TILT
HOLD --f L.H ANGLE
HOLD + R.H ANGLE
Engine high idling

1 Oil temperature: MPa
45 - 55°C (kg/cm*)
Engine low idling
Engine at high idling

Hydraulic oil temp.: 45 - 55°C
-
Blade: Ground H Highest raised position
1
Fully L.H. tilted H Fully R.H. tilted
RAISE sec. 1.9 + 0.3

Blade lift
lNork equipment LOWER 1.4 f 0.3
noving speed
RIGHT TILT 3.0 + 0.5
Blade tilt
LEFT TILT 3.0 + 0.5
62-2-4 D58E, P-l

0
D58E-1 B
Condition Unit Standard Permissible
value value
Work equipment 5,ace LEFT ANGLE 3.5 * 0.5

angle sec.
moving speed
RIGHT ANGLE 3.5 * 0.5

5 minutes after an interval of one minute after stopping
the engine.

Blade cylinder drift 100
ground level
mm/l5min.
l From a position where the side end of
Tilt cylinder drift l From a position where the front of 100
(L.H.) tilted blade.
-I-
Ripper cylinder drift fully raised 100
l Engine stopped

back until heat balance is reached.
Hydraulic oil
l Wind velocity: Max. 5 m/s max. “C 100
temperature
or rain.
D58E, P-l 62-2-5

0
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST
Flowmeter kit
D58E.P-1 62-3
MEASUREMENT LOCATIONS FOR HYDRAULIC OIL PRESSURE
HYDRAULIC OIL PRESSURE ADJUSTMENT
TESTING AND ADJUSTING
MEASUREMENT LOCATIONS FOR HYDRAULIC OIL PRESSURE

1. Measurement of the relief oil pressure
1) Disconnect the raising or lowering side of blade
cylinder hose (1).
2) Install adapter @ contained in the oil pressure
gauge kit, and connect hose (1) again.
* Install the RH and LH adapters on the same
side. (If one adapter is installed on the raising
side, both adapters should be installed on the
raising side)
3) Connect oil pressure gauge A to adapter 0.
4) Start the engine. Measure the relief oil pressure
while operating the blade control lever.
13OF1004
HYDRAULIC OIL PRESSURE ADJUSTMENT

1) Drain the hydraulic oil and remove the tank cover.
2) Loosen nut (1) and adjust the valve by turning
plug (2)
* Before removing the tank cover, measure the oil
pressure, and see how much the oil pressure is
higher (or lower) than the standard pressure.
1
13OF1005
62-4 D58E.P-1
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CYLINDERS
BLEEDING AIR FROM

HYDRAULIC CYLINDERS
* After replacing or installing hydraulic cylinders
or hydraulic piping, bleed the air from the hy-
draulic cylinders as follows:
1. Start the engine and run at idling for about 5

minutes.
2. Run the engine at low idling, and raise and
lower the blade or ripper 4 - 5 times.
Ir Stop the piston rod about 100 mm from the
end of the stroke. Never operate it to the
relief position.
3. Run the engine at full throttle and repeat the
precedure in Step 2. Then run the engine at low
idling and operate the piston rod to the end of
the stroke to relieve the circuit.
D58E, P-l 62-4-l

0
TROUBLESHOOTING
Preparation for troubleshooting . . . . . . . . . . . . 62- 5

How to use diagnostic tables . . . . . . . . . . . . . . 62- 7
Preventing recurrence of the same trouble . . . . . 62- 9
Diagnostic tables
1. Insufficient raising power and raising
speedofblade . . . . . . . . . . . . . . . . . . . ‘62-10
2. Blade fails to be raised . . . . . . . . . . . . . . 62-11
3. Blade cannot lift the machine body . . . . . 62-12
4. Excessive hydraulic drift of blade . . . . . . 62-l 3
5. The blade fluctuates up and down in leveling
work (with control lever in hold position) . . 62-14
6. The blade lowers . . . . . . . . . . . . . . . . . 62-14
7. The blade is raised unevenly
(Applicable only to straight dozer) . . . . . . 62-14
8. Insufficient tilting power and tilting speed,
or inability to raise the machine body with
tilt dozer. . . . . . . . . . . . . . . . . . . . . . . 62-l 5
9. The blade fails to tilt . . . . . . . . . . . . . . . 62-I 6
10. Excessive hydraulic drift of tilted blade . . 62-17
PREPARATION FOR TROUBLESHOOTING
SAFETY
A .
.
Place the machine on level ground and apply the brakes without fail.
During joint work, keep close contact with cooperators and keep off other people.
. Be careful not to touch hot or rotating parts.
. Keep the negative terminal of the battery disconnected when disconnecting wiring.
*L . Be sure to release remaining oil, water or air pressure, before removing a plug or cap.
L? Connect testing equipment securely.
CAUTION
Pay attention to the following during troubleshooting, especially when removal and disassembly are necessary.
. Proceed with the disassembly by confirming the fitting conditions of the relative parts; their positions fore-and-
aft, left-and-right and upper-and-lower, and their proper removal sequence.
. Put match marks across mating joints where required, before disassembling parts, and identify each part by
scribe marks.
The part should be clearly marked to prevent confusion at the time of assembly.
. When a part, after removal of mounting nuts and bolts, still does not move, never force the part; carefully check
for the cause.
. Before assembly or installation, throughly clean parts and remove scratches and nicks.
. Throughly remove dust, grease and oil from surfaces to be coated with liquid gasket.
D58E.P-1 62-5
1. Never attempt to disassemble thoughtlessly. 3) Roughly locate a possible cause of the trouble
Hasty disassembly will cause + Proceed to diagnosis.
l needless disassembly of unrelated parts, and l Strictly observe the specified test condi-
l hindrance of troubleshooting. tions when inspecting matters largely
Such faults will not only result in losses from un- dependent on oil temperature (such as
necessary replacement parts and man-hour costs, spontaneous drift speed of work equip-
but also in failure to prove yourself worthy of user’s ment supported by hydraulic cylinders).
and operator’s trust.
Careful examination and systematic diagnosis 5. Diagnosis
should be made before disassembly. After finishing checks and inspections described in
steps 2 to 4, proceed to diagnosis, referring to the
2. Inquire of the user and operator the following: diagnostic tables and using the following procedure:
1) Are there trouble symptoms other than that 1) Start checking from a portion easy to check.
you have already been informed of? 2) Start checking from a portion where the
2) Were any abnormal indications noticed previous trouble is most probable.
to the trouble? l The concept of 1) and 2) above is incorpo-
3) Whether the trouble arose suddenly or gradual- rated in the compilation of the diagnostic
lY. tables.
4) What were the conditions under which the 3) Check related matters too.
trouble arose? 4) Check to see whether other trouble symptoms
5) If repair of the machine was made previous to or faulty parts are noted.
the trouble. When? and Who? See the next pages for use of the diagnostic tables.
6) Whether or not the same trouble has occurred
before. 6. Removing the fundametal cause of trouble.
Dealing with the present trouble is not always
3. Check the following before troubleshooting: enough to prevent repetition of the same trouble,
1) Oil level if the fundamental cause of trouble is left.
2) Oil leaking out from the piping and hydraulic It is necessary to find out and remove the
devices. fundamental cause of trouble.
3) Control lever travel. For details, see the paragraph “Preventing Recur-
4) Control valve spool travel. rence of the Same Trouble.”
5) Other necessary maintenance items which can
be checked visually from the outside of the
machine.
4. Examine the trouble symptoms.

1) Ask the user and operator how they judged the
machine is out of order on the basis of some
data, in comparison with something, or by
senses.
2) Examine the magnitude of trouble by yourself
in reference to critical values.
0 Be sure to confirm safety before testing the
machine.
l Never make any tests which would cause
further trouble.
(Consult with the user and operator about
examination.)
62-6 D58E.P-1
HOW TO USE DIAGNOSTIC TABLES
MARKS IN TABLE
Marks under the heading “Causes” mean the following measures are
to be taken to remove the causes of trouble:
X: Replacement A: Repair A: Adjustment

C: Cleaning
HOW TO USE DIAGNOSTIC TABLES
0 “0” in the table indicates a correlation between a diagnosis and

a cause. When the correlation between them is not clear, the
block is left blank.
l Refer to Example 1 table at right. If the result of Diagnosis 1
shows an abnormality, “a” to “d” can be regarded as the
possible causes of the trouble symptom for which the table is
prepared. Although “e” is not defined as the possible cause of
the trouble symptom only by Diagnosis 1, the difinition must
be entrusted to the next diagnosis. (Because there is a possibility
of two or more troubles overlapping.) If the result of diagnosis
1 does not show any abnormality, “a” to “d” are cleaned from
suspicion. In this case, diagnosis 2 or 5 should be made before
defining “e” as the cause of trouble symptom.
l If Diagnosis 1 shows abnormality while Diagnosis 2 shows
normality, “a”, ” b” and “c” are suspected as the cause of the
trouble symptom. Proceed to Diagnosis 3. If the result shows
abnormality, “b” and “d” are left under suspicion. To define
which is the cause, “b” or “c”, proceed to Diagnosis 4.
0 Carry out the diagnoses one after another to select the suspects,
blacking out circles in line with a diagnosis (0 + 0) each time
the result the diagnosis shows an abnormality.
Example 1
Diagnosis 1 + abnormal
As shown in example 1 table,
Diagnosis 2 + normal
cause “b” is selected.
Diagnosis 3 -f abnormal
Diagnosis 4 + normal 1
Example 2
Diagnosis 1 + normal As shown in Example 2 Table,
Diagnosis 2 + abnormal 1 cause “e” is selected.
* Diagnosis 2 is made only for the purpose of confirmation,

although the cause “e” is definitely selected by Diagnosis 1.
D58E.P-1 62-7
Example 3
Causes “a”, “c” and “e” are
selected on Example 3 Table.
Diagnosis 3 + normal I
Continued on example 3-1 table.
Diagnosis 4 + normal As shown in Example 3-1 Table, Causes

Diagnosis 5 + normal 1 cause “c” is selected.
Example 3-l table a b c d e
X C fi A X
1 0 0 0 0
2 0 0
3 I l@l lol 1
Example 4 I Causes I
Diagnosis 1 + abnormal Causes “a”, “b” and “d” are
Diagnosis 2 + normal selected on Example 4 Table.
Continued on Example 4-l table.
Diagnosis 3 + abnormal Causes “a” and “d” are left

Diagnosis 4 + abnormal under suspicion on Example 4-l
Diagnosis 5 + normal I Table.
As shown in the above mentioned examples, it is not always neces-

sary to carry out all.
If one or more checked circles 0 are in a column of a “cause” in a

table, the “cause” cannot be regarded as the cause of the trouble
symptom for which the table is prepared.
62-8 D58E.P-1
PREVENTINGRECURRENCEOFTHESAMETROUBLE
l The diagnostic tables are useful for locating damaged or otherwise faulty parts, but useless for tracing the sources
from which damage and faults resulted.
l Also, diagnostic tables indicate only the correction of damaged or faulty parts; no indication is made about the
measures to be taken to remove the source of troubles.
l To prevent recurrence of the same trouble therefore, it is necessary to detect the source of a trouble by carefully
referring to the matters described below.
HYDRAULIC SYSTEM
1. CHECKING OIL 2. REMOVING PIECES OF BROKEN PARTS

Most hydraulic system troubles are attributed to If damage to a part is found, clean the oil to remove
water, air or foreign matter in the oil. Check the oil pieces of damaged part which may circulate in the
for foreign matter and locate the place of entry. oil circuit.
1) Checking oil If necessary, disassemble and clean the valves,
0 Mixing with water cylinders and other devices in which pieces of the
Check with an diesel engine oil checker or broken part or other foreign matter are liable to
with a hot plate. accumulate, so that recurrence of trouble can be
l Mixing with foreign matter prevented.
Remove the drain plug and filter. Check
for foreign matter accumulated on the
bottom of tank and in the filter. Also,
check the degree of contamination with
the contamination checker.
l Viscosity
Check viscosity of oil with a viscosimeter
to see whether proper viscosity oil is used
or not.
2) Locating the point of entry.
When water or other foreign matter is noticed,
locate the point of entry.
Water ..... oil tank, breather, etc.
Dirt and dust . . . . . oil refilling and
changing methods
Rubber. ... Cylinder packings, etc.
Metal particles ..... worn or damaged
hydraulic pump or hydraulic
motor.
3) Cleaning or changing oil

When metal particles or other foreign matter is
excessive clean the oil with oil refresher or
change oil.
t Oil refresher is useless for removing water
mixed in oil.
t Wash or replace the strainer and replace
the filter when cleaning the oil.
D58E.P-1 62-9
DIAGNOSTIC TABLES
1. INSUFFICIENT RAISING POWER AND

RAISING SPEED OF BLADE
Checks before troubleshooting

l Check the oil level in hydraulic tank.
. Check that the travels of the control lever and
control valve spool are proper.
See if the relief oil pressure is normal when

the blade is raised to the upper limit while
running the engine at high idling.
See Troubleshooting See Troubleshooting

Chart.
Cuased by “a”
in the chart.
e engme IS runnmg at
When operating the lever, the circuit oil pressure is

7
excessive in spite of the low operating speed. 0
III/II I
For Item No. 1, if the machine is not equipped with a tilt dozer, measure the relief oil pressure with one side of the
lift cylinder piping plugged up.
Causes “i” through “k” for Item No. 1 are applicable to machines other than those equipped with tilt dozers.
If the cylinder bottom packing is also defective, “j” or “k” may be the cause.
Causes “d” and “h” indicate that there is oil leakage from the contacting surface between the control valve and
the tank.

failure is located.
A: Adjust C: Clean
62-10 D58E.P-1
2. BLADE FAILS TO BE RAISED
Ask the operator the following questions:

l Did it happen suddenly?
+ Seizure or damage of hydraulic components
l Any abnormal noise at that time? (from where?)
* Damage of hydraulic components
l Did you notice that the blade raising speed was
getting slower?
--f Worn parts or permanent set of spring in fatigue.

l Confirm that the hydraulic tank is filled with the
proper amount of hydraulic oil.
l Check that the travel of the control lever and
Little pressure rise in the lift cylinder on the raising side,
When the lift cylinder bottom piping is removed and t

control lever is shifted to RAISE with the engine idlin
the oil flows out even though the cylinder does not
operate.
6 Little delivery of the hydraulic pump under load. 00
* If the machine is not equipped with a tilt dozer, measure the relief oil pressure with one side of the lift cylinder
piping plugged up before proceeding to Item No.3.
* Causes “e” and “f” indicate that there is oil leakage from the mating surface between the control valve and the
tank.

failure is located.
A: Adiust C: Clean
D58E.P-1 62-11
3. BLADE CANNOT LIFT THE MACHINE

BODY

l Check the oil level in the hydraulic tank.
. Check that the travel of the control lever and
control valve spool are normal.
No.
The relief oil pressure is insufficient when the blade is

xx x xx x
1 raised to the upper limit when the engine is running at 1 See the Troubleshooting
high idling. Chart for INSUFFICIENT
RAISING POWER AND
2 The same as above, with the engine at low idling. RAISING SPEED OF
BLADE
The relief oil pressure is insufficient in the lift cylinder on
3
the lower side when the engine is running at high idling. 0 0 000
The operating pressure on the blade lowering side is too
4 0
high when the engine is running at high idling.
When the lift cylinder piping on the head side is removed

and the control lever is shifted into “LOWER” with the
engine running at low idling, the oil flows out even
When removing the tank cover, oil leaks outside the
* Cause “I$’ indicgtes that there is oil leakage from the mating surface between the control valve and the tank.
~“’
column to indicate the action to be taken when a
62-12 D58E.P-1
4. EXCESSIVE HYDRAULIC DRIFT OF

BLADE

. Did the hydraulic drift become excessive all of a
sudden?
+ Dust or dirt has gotten into the valve and parts
are damaged.
. Did it become excessive gradually? + Worn parts

l See if the hydraulic drift returns to the standard
value when the control lever rod is disconnected
from the control valve.
+ Bending or interference of the rod
. See if the hydraulic drift of the blade is actually

excessive by referring to the Table of Standard
for testing and adjustment.
* Cause “c” indicates that there is oil leakage from the contacting surface between the control valve and the tank.
The following symbols are used in “Remedy”

D58E.P-1
5. THE BLADE FLUCTUATES UP AND DOWN IN LEVELING

WORK (WITH CONTROL LEVER IN HOLD POSITION)
Symptoms and causes

l Measure the hydraulic drift of the blade.
If it exceeds the standard value + See 4. EXCESSIVE HYDRAULIC DRIFT OF BLADE.
If it is within the standard value + A vacuum is formed in the cylinder + Raise the machine body with the lift
cylinder, then gradually lower the machine body to eliminate the vacuum.
* If the vacuum formation takes place frequently + Defective suction valve on the lowering side.
6. THE BLADE LOWERS
1) When shifting the control lever from HOLD to RAISE, and

2) When the engine is stopped and the control lever is in RAISE position, the blade lowers gradually.
Remedy
Cause: Incomplete seating of the check valve for lift control valve + C - X
7. THE BLADE IS RAISED UNEVENLY (APPLICABLE ONLY TO STRAIGHT DOZER)

Remedy
Cause: Loose mounting of the blade or improper adjustment of shims. + C -A

column to indicate the action to ha taken when a
cause of failure is located.
x: Replace A: Repair
A: Adiust C: Clean
62-14 D58E.P-1
8. INSUFFICIENT TILTING POWER AND TILTING SPEED,

OR INABILITY TO RAISE THE MACHINE BODY WITH TILT DOZER

l Check that the oil in hydraulic oil tank
adequate.
l Check that the travel of the control lever and tl
control valve spool are normal.
See if the relief oil pressure is normal

when the blade reaches the tilting limit
while the engine is running at high idling.
X 0
What happens when the

engine is running at low
idling?
I I.
in the chart Control valve
The hydraulic drift of the tilt blade is still e
7
-
* Causes “d” and “h” indicate that there is oil leakage from the mating surface between the control valve and the
tank.
1 The followina svmbols are used in “Remedv” 1

A: Adjust C: Clean
D58E.P-1 62-15
9. THE BLADE FAILS TO TILT

l Did the tilting fail to work 211 of a sudden?
+ Seizure or damage of hydraulic components
l Any abnormal noise at that time? (From where?)
+ Damaged hydraulic components
l Where phenomena such as slow tilting speed
recognized in the past?
+ Worn parts, deformation of spring.

l Check that the oil level in the hydraulic tank is
proper.
l Check that the travels of the control lever and
When the outlet piping on the faulty side is removed and

the control lever is shifted into the faulty side with the
engine running at low idling, the oil flows out even
* Causes “c” and “f” indicate that there is oil leakage from the mating surface between the control valve and the
tank.

A: Adjust C: Clean 1
62-16 D58E.P-1
10. EXCESSIVE HYDRAULIC DRIFT OF TILTED BLADE
Ask the op’erator the following questions:

l Did the hydraulic drift become excessive all of a
sudden? + Damaged parts
l Has it increased gradually? + Worn parts

l See if the hydraulic drift returns to the standard
value when the control lever rod is disconnected
from the control valve.
+ Bending or interference of the rod

l See if the hydraulic drift is actually excessive when
the blade is tilted. See the Table of Standards for
testing and adjustment.
No. I- Problem
nemeoy 1 LI
Oil flows out when the piping on the tilt cylinder head
1 0
side is disconnected.
The hydraulic drift is excessive even with the tilt cylinder

2
head piping plugged up. II lol
3 Oil leakage outside the control valve 0

Removethe
tank cover. Oil leakage from drain tube for control
i
4
valve. 0

A: Adiust C: Clean
D58E.P-1 62-17
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Dismounting ...................... 63- 2
Mounting ........................ 63- 3
WORK EQUIPMENT CONTROL VALVE

Dismounting ...................... 63- 4
Mounting ........................ 63- 6
Disassembly. ...................... 63- 8
Assembly ........................ 63- 8
LIFT CYLINDER
Dismounting ...................... 63-12
Mounting ........................ 63-l 2
Disassembly ....................... 63-13
Assembly ........................ 63-17
* Always bleed the air as follows when you first operate hydraulic cylinders after reassembling cylinders, pumps and
piping.
1. Start engine and run at low idling.
2. Operate hydraulic cylinder 4 -. 5 times, stopping 100 mm from stroke end.
3. Next operate cylinder 3 - 4 times to stroke end.
4. After doing this, run engine at normal speed.
* After repair or long storage, follow same procedure.
D58E.P-1 63-l
a
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
DISMOUNTING HYDRAULIC PUMP ASSEMBLY

*A& Lower the work equipment to the ground, slowly
4 loosen the oil filler cap on the tank to release the
internal pressure from the hydraulic tank.
1. Remove drain plug (1) from the hydraulic tank and

drain the hydraulic oil.
& Oil: Approx. 65 Q
2. Remove floor plates (2) and (3).
3. Disconnect the rod from the decelerator pedal and

remove plate (4).
4. Remove the engine RH side cover and the machine

body RH side cover.
5. Disconnect wiring (5). (6). (7), and (8).
6. Remove eye bolt (9).
7. Remove bracket (10) and disconnect cylinder tube

(11).
8. Disconnect outlet tube (12) and inlet tube (13) from

the hydraulic pump.
9. Remove hydraulic pump assembly (14).
63-2 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
MOUNTING HYDRAULIC PUMP ASSEMBLY

1. Fit an O-ring and install hydraulic pump assembly
(14).
2. Fit O-rings and connect outlet tube (13) and inlet

tube (12) to hydraulic pump.
3. Fit an O-ring, connect cylinder tube (ll), and install

bracket (10).
4. Install eye bolt (9).
5. Connect wiring (8). (7). (61, and (5).
6. Install the machine body RH side cover and the

engine RH side cover.
7. Connect the decelerator pedal rod and install plate

(4).
8. Install floor plates (3) and (2).
9. Tighten drain plug (1) on the hydraulic tank and add

hydraulic oil to the specified level through the oil
filler.
* Start the engine, let the oil circulate in the piping,
and check the oil level again.
D58E.P-1 63-3
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE
DISMOUNTING WORK EQUIPMENT CONTROL VALVE

ASSEMBLY
1. Draining oil
Drain oil from hydraulic tank by removing drain plug
(1).
A Oil amount to be drained: 65 P
2. RH rear cover
Remove RH rear cover (2).
3. Tank cover
1) Remove bolts mounting tank cover (3) and open
cover.
2) Disconnect hose (5) by loosening clamp (4) and

remove cover.
63-4 D58E.P-1
a
4. Control rod
Disconnect control rod (6) from spool joint pin.
5. Piping
Disconnect pipes (7), (8) and (9).
6. Control valve assembly

1) Temporarily lift control valve assembly (10) by
a crane.
Control valve assembly: 27 kg
2) Remove control valve assembly by removing two

mounting bolts (11).
D58E.P-1
MOUNTING WORK EQUIPMENT CONTROL VALVE

ASSEMBLY
1. Control valve
Place control valve (10) in the mounting position by
lifting by a crane, with O-ring fitted to its mounting
surface, and secure it with two mounting bolts (11)
from inside tank.
* Install control valve after aligning pipe mounting
bolts holes.
2. Piping
Connect pipes (7), (8) and (9) to tank with O-ring
fitted to their flange end faces.
3. Control rod
Connect control rod (6) to spool.
* Surely bend cotter pin.
63-6 D58E.P-1
0
4. Tank cover
1) Apply liquid gasket (LG-1) to mounting surface
of tank cover and attach gasket.
2) Conhect filter hose (5) of tank cover (3) to valve,
tighten clamp (4) and secure cover with mounting
bolts.
5. RH rear cover
Install RH rear cover (2).
6. Supplying oil
After confirming that drain plug (1) is closed, supply
engine oil (EOIO-CD) from oil filler (12) and check
oil level with level gauge.
* Oil amount to be supplied: Approx. 60 Q
* After supplying oil, start engine to circulate oil
and refill with oil up to the level specified on level
gauge.
D58E.P-1
DISASSEMBLY OF WORK EQUIPMENT CONTROL VALVE

ASSEMBLY (I /2)
1. Remove suction valve assembly (1).
2. Remove main relief valve assembly (2).
3. Remove plug (3), then remove spring (41, guide (51.

and ball (61.
4. Remove case (7) and spool assembly 181.
5. Remove bolt (91, then remove detent (IO), collar

(I I), spring (12), and collar (13) from spool (14).
6. Remove plate (151, then remove seat (161, spring

(I 71, and valve (18).
ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE

ASSEMBLY (I /2)
1. Install valve (18), spring (17), and an O-ring, insert
seat (161, and install plate (I 5).
2. Install collar (13), spring (121, collar (I I), and detent

(10) to spool (14) and tighten bolt (9).
3. Insert spool assembly (8) into body (19) and install

case (7).
4. Insert ball (61, guide (51, and spring (4) and install
plug (31.
5. Fit an O-ring and install main relief valve assembly

(2).
6. Fit an O-ring and install suction valve assembly (I 1.
63-8 D58E.P-1
0
WORK EQUIPMENT CONTROL VALVE
13OF1062
D58E.P.1
63-9
a

ASSEMBLY (2/2)
Special tool
Part number Part name o’ty
A 799-301-l 500 Oil leak tester I
1. Remove plate (l), then remove spring (2) and valve

(3) from housing (4).
2. Push out collar (5) by applying air pressure with Tool

A, then remove valve (6), spring (7). and seat (8).
3. Disconnect housing (9) from body (IO), then remove

spring (I 1) and seat (I 2).
+ Housing (9) and valve (13) are supplied as a set
only.
4. Loosen nut (14). remove plug (15), then remove
spring (I 6) and poppet (I 7).
* Before loosening the plug, measure the amount of
its projection (See photo).

ASSEMBLY (2/2)
1. Insert poppet (17) and spring (16) into body (IO),

and install plug (15) and nut (14).
* Tighten plug (15) to the dimension measured at
the time of disassembly. Temporarily tighten lock
nut (14), install the valve assembly to the machine
then adjust the oil pressure.
2. Insert seat (12) and spring (II) into body (IO),

insert valve (13) into housing (9), and put body (IO)
and housing (9) together.
3. Insert seat (S), spring (7). and valve (6) into housing
(4), fit an O-ring, and install collar (5).
4. Insert valve (3) and spring (2) into housing (4), fit
an O-ring, and install plate (1).
63-10 D58E.P-I
0
13OF1063
D58E.P-1 63-11
0
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
DISMOUNTING LIFT CYLINDER ASSEMBLY

Temporarily sling the head side of the lift cylinder,
remove bolt (2), start the engine, and fully retract rod
(1).
* Fasten the rod with a wire to prevent it from
sliding out.
Stop the engine, release the residual pressure from the

piping by operating the work equipment control
lever two or three times, and disconnect hose (3).
Sling the cylinder horizontally with a crane, remove

cap (4) from the support, and dismount lift cylinder
assembly (5).
Lift cylinder assembly: D58E-1 83 kg

D58P-1 85 kg
MOUNTING LIFT CYLINDER

ASSEMBLY
1. Sling lift cylinder assembly (5) horizontally, place it
in position, and install cap (4).
2. Fit an O-ring and connect hose (3).
3. Sling the head side of the cylinder, start the engine,

extend the piston rod, and align it with the frame
mounting pin.
4. Install cap (1).
63-12 D58E.P-1
0
DISASSEMBLY OF LIFT CYLINDER ASSEMBLY

Special tool
I 790-502-I 000
A 1 790-502-2000 1 Cylinder stand 1
790-502-3000

Disconnect lift cylinder head side pipe (1) from
cylinder head by removing mounting bolts.
2. Piston rod and head assembly.

Take out piston rod and head assembly (2) by re-
moving mounting bolts, and place it on cylinder stand
A.
DISASSEMBLY OF CYLINDER ROD AND

HEAD ASSEMBLY
Piston nut
Remove piston nut by loosening it.
* Piston nut width across flats: 41 mm
Piston assembly
Remove piston assembly (3) and slider (4) from rod.
Head assembly
Remove head assembly from rod (5).
'L3OP!598
D58E.P-1 63-13
0
DISASSEMBLY OF PISTON ASSEMBLY
6. Retainer
Remove retainer (6) from piston.
13OP1599
7. Piston packing
Remove piston packing (7) from piston.
130Pt600
8. Retainer
Remove retainer (8) from piston.
9. Piston packing
Remove piston packing (9) from piston.
10. Wear ring

Remove wear ring (10) fyom piston.
liOP1602
63-14 D58E.P-1
0
DISASSEMBLY OF HEAD ASSEMBLY
11. Gland
Remove gland (11) by removing mounting bolts.
* When replacing dust seal (12), remove snap ring
(13).
12. Nylon heel

Remove nylon heel (14) from head.
13. U-packing
Remove U-packing (I 5) from head.
D58E.P-1 63-15
0
14. O-ring
Remove O-ring (16) from head.
15. Back-up ring

Remove back-up ring (17) from head.
* If no flaw are found on ring, removal of ring is
unnecessary.
16. Valve seat

1) Remove seat (19) by depressing valve (18).
2) Remove the other seats after turning over piston.
63-16 D58E.P-1
0
ASSEMBLY OF LIFT CYLINDER ASSEMBLY

Special tool
1. Valve and seat

Press-fit seat (19) to cylinder piston, install valve
(18). and press-fit another seat in opposite end.
ASSEMBLY OF HEAD ASSEMBLY
2. Back-up ring
Install back-up ring (17) on head by shrink fit.
* Use press-fitting tool B when replacing bushing
on head.
3. O-ring
Install O-ring (16) on head.
4. U-packing
Install U-packing (15) on head.
13OP1613
D58E.P-1
5. Nylon heel
install nylon heel (14) on head.
6. Gland
Secure gland (11) on head with mounting bolts.
* Press-fit dust seal to gland with press-fitting tool

D and install snap ring.
* Use press-fitting tool B when replacing gland
bushing.
* Be sure to install O-ring (20).
ASSEMBLY OF PISTON ASSEMBLY
7. Wear ring
Install wear ring (10) on piston.
8. Piston-packing
Install piston packing (9) on piston.
13OP1602
63-18 D58E.P-1
0
9. Retainer
Install retainer (8) on piston.
10. U-packing
Install U-packing (7) on piston.
,13OP1600
11. Retainer
Install retainer (6) on piston.
ASSEMBLY OF PISTON ROD AND HEAD

ASSEMBLY
12. Head
Set piston rod on cylinder stand A and install head
(5).
* Use press-fitting tool C when replacing bushing on
230P1599
piston rod.
13OP1598
D58E.P-1 63-19
a
DfSASSEMBLY AND ASSEMBLY LIFT CYLINDER
13. Piston
Install slider (4) and piston assembly (3) on piston
rod.
14. Piston nut

Tighten piston nut.
D Piston nut: 63k6.3 kgm (Width across flats

41 mm)
15. Piston rod and head assembly

Install piston rod and head assembly (2) on cylinder
body and loosely tighten head with cylinder head
mounting bolts.
* Fully tighten head mounting bolts after mounting
cylinder on the machine.
16. Cylinder pipe

Connect cylinder head side pipe (I) to cylinder head
with mounting bolts.
63-20 D58E.P-1
0
HYDRAULIC SYSTEM
64 MEINTENANCE STANDARD
Hydraulic control valve ................................. 64-2

Straigt-tiltdozer.. ...................................... 64-2
Power angle, power tiltdozer ................. 64-4
Ripper control valve.. ........................... 64-4-4
Servo valve
Joystick control specification .............. 64-4-5
Cylinder .......................................................... 64-5
Strait-tiltdozer .......................................... 64-5
Power angle, power tiltdozer ................. 64-8
Ripper lift cylinder ....................................... 64-10
Hydraulic pump ........................................... 64-l 1
D58E, -P-l 64-l.

@
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE
HYDRAULIC CONTROL VALVE

(1) Blade lift control valve
13OF113
2
Unit: mm

1 I I I
1 Lift valve spool return spring
I I length length load length load I
128.0 65.0 9.9 kg 115.4 7.92 kg
2 Tilt valve spool return spring 128.0 65.0 9.9 kg 115.4 7.92 kg Replace
3. Check valve spring 74.5 44.5 0.9 kg Reuse if no damage
4 Flow check valve spring 57.0 51.0 3.59 kg 55.8 2.9 kg
5 Detent spring 20.5 17.0 2.7 kg 19.8 2.2 kg
64-2 D58E, P-l

0
Main relief valve, Suction valve

6 2
13OF114
13OF115
Unit:mm
55.0 34.0 5.72 kg Reuse if no damage

. Replace
2 Pilot valve spring 37.1 30.0 27.4 kg 35.7 21.9 kg
3. Suction valve spring for blade lower 74.5 44.5 0.9 kg

Reuse if no damage
4 Suction valve spring for blade rise 20.0 13.5 0.064 kg

-
Main relief pressure adjustment plug
5 12.5 (Adjustable 29.4 kg/cm* per one turning) Adjust
standard size I I
6 Lock nut tightening torque 14rZkgm Retighten
D58E.P-1
HYDRAULIC CONTROL VALVE

(1) Blade lift, tilt valve
i 13OF‘113
i
Unit: mm
Free Installation Installation Free Installation

length length load (kg) length load (kg)
1 Lift valve spool return spring
128.0 65.0 9.9 kg 7.92 kg
2 Tilt valve spool return spring i 28.0 65.0 9.9 kg 7.92 kg Replace
3 Check valve spring 74.5 44.5 0.9 kg 0.7 kg

-
4 Flow check valve spring 57.0 51.0 3.59 kg 2.88 kg
Detent spring 20.5 17.0 2.7 kg 2.2 kg
64- 4 D58E,P-1
0
(2) Blade angle valve
13OF18053
Unit: mm
Free Installation Installation Free Installation

length length load (kg) length load (kg)
1 Spool return spring Replace
128.0 65.0 9.9 kg 115.4 7.92 kg
2 Check valve spring 62.0 42.0 0.22 kg 58.0 0.18 kg
D58E,P-1 64-4- 1
0
(3) Main relief valve
13OF114
(4) Suction valve (blade lift circuit)
13OF115
64-4-2 D58E,P-1
0
(5) Suction valve (blade angle circuit)
13OF18054
Unit: mm

-
1 Relief valve spring
2 Pilot valve spring 45.0 30.4 27.4 kg 21.9 kg Replace

-
3 Lower side valve spring 74.5 44.5 0.9 kg 0.7 kg
4 Raise side valve spring 20.0 13.5 0 084 kg 0.06 kg
5 Suction valve spring (for angle circuit) 61.9 31 .o 0.34 kg 0.28 kg

-
Main relief pressure adjusting
6 12.5 (Adjustable 29.4 kg/cm’ per one turn) Adjust
plug standard size
D58E,P-1 64-4-3
MAINTENANCE STANDARD RIPPER CONTROL VALVE
RIPPER CONTROL VALVE
F13017040
Unit: mm
Ripper suction valve spring Reuse if no damage

I I
- Safety valve set pressure 160 kg/cm* (Adjustable 53.9 kg/cm* per one turning) Adjust
64-4-4 D58E,P-1
0
MAINTENANCE STANDARD SERVO VALVE
SERVO VALVE

63.7*9.BNm
(6.5 f l.Oknml
Unit: mm
-
-
Free Installed Installed Free Installed If damaged

length length load length load or deformed,
1 Spool return spring
replace
78.5N 62.8N
88.4 x 26.0 37.0
(8.0kg) - 16.4kgI
2 Input spool and holder

-
3 Repair or
Sliding surfaces must not have any flaw.
replace
Spool must move smoothly when only it is set.
assembly
Piston and valve body

I
D58E, P-l 64-4-5

@
MAINTENANCE STANDARD CYLINDER
CYLINDER
(I) Blade lift cylinder
6.3 kgm
41 mm)
113F119A
Unit: mm

-
Tolerance
Clearance
1 Sta2:rd ,,,,,,,,,I E.:“n’p, limit
1 Clearance between piston rod and bushing
55 -0.100 +0.163 0.106 -

0.637 Replace
-0.174 +0.006 0.337
Clearance between piston rod bushing -0.2 +0.039 0.2 -

2 1.5
and pin 35 -0.4 0 0.439
Clearance between cylinder support -0.080 +0.106 0.090 -

3
bushing and boss 45 -0.142 +0.010 0.248
1 .o
D58E,P-1 64-5
0
(2) Blade tilt cylinder
133F120
Unit: mm
Clearance between piston rod and bushing
70 -0.100 +0.271 0.175 -

-0.174 0.745
+0.075 0.445
Replace
Clearance between cylinder bottom bushing -
2 50 -0.200 +0.142 0.280 0.842
and pin -0.400 +0.080 0.542
3 Clearance between piston rod and retainer

70 -0.300
-0.100 +10 BOO 0.1001.300
- -
-
4 Piston nut tightening torque 405 ? 40.5 kgm (Width across flat: 80 mm) Retighten
64-6 D58E.P-1
CYLINDER
0 Power angle, power tiltzozer
(I 1 Blade lift cylinder
m 180? 18kgm
loo+- 1Okgm (Width across flat: 60mm)
13OF18055
(2) Blade tilt cylinder
530 2 53 kgm
ross flat: 85mm)
B 25.5 ? 2.5 kgm

13OF18056
(3) Blade angle cylinder

m 180r18kgm
B 1002 IOkgm (Width across flat: 60mm)
13OF18057
64-8 D58E,P-1
0
Unit: mm

1
I I I I
-
Lift 60 -0.030 +0.163 0.036 0.567
-0.104 +0.006 0.267
-_ ! 1 I
I
Clearance between piston rod -0.030 +0.291 0.107 -
and bushing Tilt 75 -0.104 +0.077 0.395 0.695
I Angle 60 -0.104
-0.030 +0.006
f0.163 0.036
0.267- 0.567
1
I I I I I
Retighten
+0.174
Lift 60 1.0
+0.100
I I 1 ! ! I
2
I Piston rod clearance between
bushing and pin
Tilt
I
55
+0.046
0
0.5
I
f0.039
Angle 45 0.5
I 0
-
f0.174
Lift 60
+0.100
1.o
Cylinder bottle clearance +0.046

3 Tilt 55 0.5
between bushing and pin 0
+0.046
Angle 45 0.5
0
-
D58E,P-1 64-9
MAINTENANCE STANDARD RIPPER LIFT CYLINDER
RIPPER LIFT CYLINDER
w 405 & 40.5 kgm

(Width across flat: 80mm)
F13017041
Unit: mm
-
No. Check item I Criteria Remedy
Clearance between bushing and pin j’;f ~~~~,lCl~e~~e~,ace
2 Clearance between piston rod and bushing ( 75 ( 1;:;;: / ;;:;;; ( “6’&-- ( 0.765 /
64-10 D58E,P-1
0
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
. KAL080
130Flll
Unit: mm
1 Radial clearance between gear and gear case

_ _
Replace
2 Axial clearance between gear and gear case 0.10 - 0.15 0.19
- Discharge at 50 - 55OC 184 Q/min. at 2,500 rpm
D58E,P-1 64-11
0
WORK EQUIPMENT
Straight-tiltdozer .......................... 7 1-2

Power angle, power tiltdozer ................ 7 1-3
Ripper.. .................................. 71-4
D58E,P-1
71-l
0
STRUCTURE AND FUNCTION STRAIGHT-TILTDOZER
STRAIGHT-TILTDOZER
1. Blade
2. Cutting edge
3. End bit
4. Brace
Section B-B Section C-C
5. Brace Section A-A
Detail of R.H. turnnion pal
6. Straight frame
7. Trunnion
8. Yoke
8s
Section E-E Section F-F
Section D-D
Section GG
133 F056
The blade (1) with the front plate made of high tensile frame by means of trunnion (7). The straight frame is
steel is tough enough to endure severe works. The moved up and down by the action of the brade lift
cutting edge (2) is made of carbon steel, and is of split- cylinder.
ting type so that the edge can easily be reversed. The The brace supports both blade and straight frame on
end bit (3) is made of cast steel having good wear re- their right side, and the tilt cylinder supports them on
sistance with excellent strength. The straight frame (6) their left side.
made also of high tensile steel is constructed to be box- The blade is supported by straight frames (6), tilt
type, the front of which is stationed to the blade via cylinder on left side and tilt brace on right side.
joint bracket, and the rear of which is fixed to the track
71-2 D58E.P-1
STRUCTURE AND FUNCTION POWER ANGLE, POWER TILTDOZER
POWER ANGLE, POWER TILTDOZER
-..
-
Section A-A Section B-B Section C-C Section D-D
Section E-E Section F-F Section H-H Section J-J

Section G-G
13OF18034
1. Blade 5. Angie cylinder

2. Cutting edge 6. U-frame
3. End fit 7. Lift cylinder
4. Tilt cylinder 8. Loader frame
D58E,P-1 71-3
0
STRUCTURE AND FUNCTION RIPPER
RIPPER
1 2 3
Section A-A Section B-B
Section E-E Suction F-F
Section G-G
View Z
F13017042
1. Ripper bracket 6. Point

2. Ripper cylinder 7. Link (lower)
3. Link (upper)
4. Beam
5. Shank
71-4 D58E,P-1
0
WORK EQUIPMENT
WORK EQUIPMENT
Dismounting.. . . . 73-2
Mounting............................... 73-3
STRAIGHT-TILT DOZER
Installation and adjusting . 73-4
WORK EQUIPMENT
Removal _, . . 73-5-l
Installation . . 73-5-2
BLADE
Removal . 73-5-3
Installation . .. 73-5-3
BLADE LIFT CYLINDER

Removal .. . . 73-5-4
Installation . . . 73-5-4
ANGLE CYLINDER
Removal .. . . _. 73-5-5
Installation . . 73-5-5
TILT CYLINDER
Removal . 73-5-6
Installation . . _. 73-5-6
DASHBOARD
Dismounting . . . 73-6
Mounting . . . 73-8
OPERATOR’S SEAT AND FRAME

Dismounting . .. . 73-l 0
Mounting . . 73-13
D58E,P-1 73- 1
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
DISMOUNTING WORK EQUIPMENT ASSEMBLY

1. Setting block
Place blocks @ (approx. 200 mm high) under both
LH and RH sides of straight frame and lower blade to
the ground.
* Place blocks in such manner to prevent straight
frame from falling when disconnected from trun-
nion.
2. Lift cylinder rod

1) Remove bolts (2) mounting caps for LH and RH
lift cylinder piston rods (1).
2) Start engine to retract lift cylinder rod and fix

piston rod at fixture pin and secure it with wire
or the like to prevent it from coming off.
3. Trunnion cap
Removing bolts, take out both LH and RH trunnion
caps (3).
4. Work equipment assembly

Start engine and reverse machine slowly to disconnect
straight frame from trunnion and remove blade assem-
bly.
* Temporarily install trunnion caps on straight frame

to avoid misassembly.
73-2 D58E.P-1
0
MOUNTING WORK EQUIPMENT ASSEMBLY

1) Raise trunnion pivot center up to the .height of
trunnion center (approx. 370 mm above the
ground in case of a new machine).
21 Move machine forward slowly until trunnion
comes into alignment with straight frame trunnion
pivot and install blade assembly (4).
* If trunnion hardly comes into alignment with
pivot, support straight frame on jack and adjust
the height of pivot.
2. Trunnion cap
Install both LH and RH trunnion caps (3).
3. Lift cylinder rod

Start engine to extend lift cylinder rod so that it
comes in the position where it is connected to
straight frame.
Connect lift cylinder piston rod (1) to straight
frame with bolts (2) mounting cap.
D58E.P-1 73-3
0
DISASSEMBLY AND ASSEMBLY STRAIGHT-TILT DOZER
INSTALLATION AND ADJUSTMENT OF STRAIGHT-TILT

DOZER
_-
: ..i!kb
.4!z - .
::
73-4 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY STRAIGHT-TILT DOZER
1. Assemble the blade and install it to the machine.
2. Confirm the horizontalness of the blade

1) Set the distance (L, ) between the installation Pin
and shims for the tilt cylinder (1).
Distance L1 : 978 mm
2) If the blade is still not horizontal after the distance

between the mounting pins is set, rotate the brace
(opposite side of tilt cylinder) until the blade is
horizontal.
* Adjust shims (2) so that the play of the tilt cylin-

der (1) in the axial direction is less than 0.5 mm.
Standard thickness of shims: 4 mm
3. Confirm the parallelism of the straight frame

1) Set distance (Lz) between the mounting pin and
shims for L.H. and R.H. braces (3).
Distance Lz : 823 mm
* Adjust shims (4) so that the play of the brace (3) in

the axial direction is less than 0.5 mm.
Standard thickness of shims: 4 mm
2) Raise the blade about 400 mm above the ground

and adjust braces (3) so that clearance A between
straight frame (5) and track (6) is equal of left and
right.
3) To minimize the sideways movement of the blade,
tense the both braces (3) to a torque of 3.75 * 1.25
kgm.
4) Tighten brace securing bolt (7).
m Brace securing bolts: 46 2 5 kgm
D58E.P-1 73-5
a
REMOVAL OF WORK EQUIPMENT ASSEMBLY

1. Setting block
Set blocks @ under frame on both left and right,
and lower blade to ground.
A Set the blocks so that the frame

fall when it is disconnected.
does not
2. Blade lift cylinder head pin (1)

Sr Pull out the head pin, then run the engine and
retract cylinder (2). then lift the cylinder up and
secure it to the chassis.
F13017047
3. Angle cylinder hose (3)

Disconnect left and right (2 each) angle cylinder
hoses (3).
*F Stop the engine and loosen the hydraulic

tank cap slowly, then operate the control
levers several times to release the remianing
pressure in the cylinders and hydraulic tank.
Then disconnect the hose.
4. Tilt cylinder hose (4)
5. Frame mounting pin (5)

I
F13017048
* After pulling out the pin, move the chassis in
reverse slowly and disconnect it from the work
equipment assembly.
5 4
F13017049
73-5-l D58E,P-1
0
DISASSEMBLY AND ASSEMBLY ‘WORK EQUIPMENT
INSTALLATION OF WORK EQUIPMENT ASSEMBLY

Power angle, power tiltdozer
Work equipment assembly

Align position of work equipment frame
mounting pin hole with height of body
mounting position.
+ The center of the pin hole is approx. 440
mm from the ground on new machines.
Move the machine forward slowly, align -work

equipment frame pin hole and body mounting
position, then install frame mounting pin (5).
F13017050
Tilt cylinder hose (4)

+ For left tilt, connect to the bottom end, and for
right tilt, connect to the head end.
Angle cylinder hose (3)

* On the left side of the machine, connect the
hose from the head end to the tube on the
outside, and the hose from the bottom end to
the tube on the inside.
* On the right side of the machine, in the same
way, connect the hose from the head end to
the tube on the outside, and the hose from the
bottom end to the tube on the inside.
F13017051
4. Blade lift cylinder (2)
Release cylinder secured above chassis and
connect to work equipment assembly with pin (I 1.
5. Refilling with oil

Add the oil to the specified level, then run the
engine and check the oil level.
F13017052
D58E,P-1 73-5-2
0
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE ASSEMBLY

. power angle, power tiltdozer
1. Tilt cylinder assembly bottom pin (I 1

+ Pull out pin (I), then run the engine, retract the
tilt cylinder rod, and secure it to the chassis.
2. Pull out angle cylinder head pins (2) and (3).

* Fit a block 0 under the cylinder tube, pull out
pins (2) and (3), then run the engine and retract
the cylinder rod.
3. Remove rod (4).
4. Remove blade assembly (5).

* Sling blade assembly (5). and remove the bolt
of cap (61, then remove the blade assembly.
Blade assembly: 1300 kg
INSTALLATION OF BLADE
ASSEMBLY
. Power angle, power tiltdozer
1. Install blade assembly (5).

* Sling the blade assembly (5). and adjust so that
F13017054
the front-to-rear clearance at the ball portion is
0.5 mm when the bolt of cap (6) is installed.
Standard shim thickness: 3 mm
* When tightening the bolts, tighten in 2 - 3

passes so that the bolts are tightened uniformly
on the left and right.
a Bolt: Thread tightener (LT-2)
m Bolt: 59 * 3 kgm
2. Install rod (4).

F13017055
3. Install angle cylinder head pins (2) and (3).
* Run the engine, extend the cylinder rod slowly,
and align the position of the pin hole, then in-
stall pins (2) and (3).
4. Tilt cylinder assembly bottom pin (1)

* Run the engine, extend the cylinder rod slowly,
and align the position of the pin hole, then in-
stall pin (I ).
73-5-3 D58E,P-1
0
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER
REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY

1. Blade lift cylinder head pin (I)

* Lower the blade assembly to the ground, sling
lift cylinder, and pull out pin (I). Then run the
engine and retract the cylinder.
2. Blade lift cylinder hose (2)

*&
Stop the engine and loosen the hydraulic
$ ,H ---
levers several times to release the remianing
Then disconnect the hose. F13017056
3. Blade lift cylinder bottom pin (3)
4. Blade lift cylinder assembly (4)
Lift cylinder assembly: 50kg
INSTALLATION OF BLADE
LIFT CYLINDER ASSEMBLY
Power angle, power tiltdozer
Blade lift cylinder assembly (4)

Install blade lift cylinder assembly (4) with cylinder
bottom pin (3).
Blade lift cylinder hose (21
Blade lift cylinder head pin (1)

* Add the hydraulic oil to the specified level and
run the engine and check the oil level. Then
extend the cylinder slowly, align the position of
the pin hole, and install pin (I 1.
D58E,P-1 73-5-4
0
DISASSEMBLY AND ASSEMBLY ANGLE CYLINDER
REMOVAL OF ANGLE CYLINDER ASSEMBLY

1. Remove the cover (1).

* Lower the work equipment assembly to the
ground, and after removing cover (1). sling the
cylinder assembly.
2. Remove cylinder head mounting pin (2).

* After removing pin (21, run the engine, then re-
tract the cylinder rod, and secure the rod so
that it does not fall out.
F13017057
3. Disconnect cylinder hose (3). H
*y Stop the engine and loosen the hydraulic

levers several times to release the remaining
4. Angle cylinder assembly (4)

Pull out pin (5) and remove cylinder assembly (4).
Angle cylinder assembly: 63 kg
F13017058
INSTALLATION OF ANGLE
CYLINDER ASSEMBLY
1. Angle cylinder assembly (4)

Install cylinder assembly (4) with mounting pin (5).
2. Install cylinder hose (3).

* The hoses connected to the tubes on the out-
side on both the left and right sides of the chas-
sis are for the cylinder head end; the hoses con-
nected to the tubes on the inside are for the
cylinder bottom end.
3. Cylinder head mounting pin (2)

* Add the hydraulic oil to the specified level and
the pin hole, and install pin (2).
4. Install cover (1).
73-5 -5 D58E,P-1
0
DISASSEMBLY AND ASSEMBLY TILT CYLINDER
REMOVAL OF TILT CYLINDER ASSEMBLY

1. Remove tilt cylinder head pin (I 1.

* Sling the cylinder assembly, then after pulling
out pin (I 1, run the engine and retract the cylin-
der rod, then secure the rod so that it does not
extend.
2. Disconnect tilt cylinder hose (2).
Stop the engine and loosen the hydraulic

levers several times to release the remaining
pressure in the cylinders and hydraulic tank. F13017059
3. Remove tilt cylinder bottom pin (3).
4. Remove tilt cylinder assembly (4).
Tilt cylinder assembly: 73 kg
INSTALLATION OF TILT
CYLINDER ASSEMBLY
. power angle, power tiltdozer
1. Install tilt cylinder assembly (4).

Install pin (3) to bottom end of tilt cylinder assem-
bly.
2. Install tilt cylinder hose (2).

* Install to the bottom end for left tilt, and to the
head end for right tilt.
3. Install tilt cylinder head pin (I).

t Add the hydraulic oil to the specified level and
the pin hole.
D58E,P-1 73-5-6
0
DISASSEMBLY AND ASSEMBLY DASHBOARD
DISMOUNTING DASHBOAD ASSEMBLY

1. RH and LH engine side covers
Remove RH and LH engine side covers (1) and (2).
2. Engine hood
Remove air cleaner cap (3), sling engine hood (41,
and remove it.
3. Floor plates
4. RH and LH steering linkages

Disconnect RH and LH brake rods (7) and (8) and
RH and LH steering rods (9) and (IO).

Disconnect dust indicator hose (I I).
73-6 D58E.P-1
0
6. Fuel control rod

Disconnect Fuel control rod (12).
7. Wiring
Remove clamps (13) and (14) and disconnect con-
nector (15).

Disconnect cable (16) of the torque converter oil
temperature gauge from the sensor.
dashboard assembly (17) and remove it.
Dashboard assembly: 148 kg
D58E.P-1
DISASSEMBLY AND ASSEMBLY DASH BOARD
MOUNTING DASHBOAD ASSEMBLY

Dashboard assembly
dashboard assembly (17) and install it.
Dashboard assembly: 148 kg
3. Wiring
Connect connector (15) and install clamps (14) and
(13).
4. Fuel control rod

Connect fuel control rod (12).
73-8 D58E.P-1
a

Connect dust indicator hose (11).
6. RH and LH steering linkage

Connect RH and LH steering rods (IO) and (9) and
RH and LH brake rods (8) and (7).
7. Floor plates
8. Engine hood
Sling engine hood (41, and install it. Then install
air cleaner cap (3).
9. RH and LH engine side covers

Install RH and LH engine side covers (2) and (1).
D58E.P-1
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT,AND FRAME
DISMOUNTING OPERATOR’S SEAT AND FRAME-

ASSEMBLY
A Disconnect
battery.
the negative (-1 terminal of the
Floor plates
Operator’s seat assembly

Sling operator’s seat assembly (3) and remove it.
3. RH rear cover
Remove RH rear cover (4).
4. Transmission control linkage

Disconnect directional rod (5) and speed rod (6).
73-10 D58E.P-1
0
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT AND FRAME
5. Brake rods
Disconnect brake rods (7) and (8)
6. Wiring
1) Disconnect wiring clamps (9) and (10).
2) Disconnect cable (11) on the positive (+) side of
the battery from the battery relay.
7. Cover
Remove cover (12) and arm rest (13).
”
8. Horn wiring
Disconnect horn wiring connector (14) and clamp
(15). .i
130331652
D58E.P-1 73-11
0
9. Work equipment control lever

1) Remove safety lock lever (16).
2) Remove cover (17) and work equipment control
lever (18).
10. Operator’s seat frame assembly

Remove the lamp wiring, sling operator’s seat frame
assembly (191, and remove it.
Operator’s seat frame assembly: 120 kg
73-12 D58E.P-1
0
MOUNTING OPERATOR’S SEAT AND FRAME ASSEMBLY

1. Operator’s seat frame assembly
Sling operator’s seat frame assembly (19) and install
it. Then connect the lamp wiring.
&I &I Operator’s seat frame assembly: 120 kg
2. Work equipment control lever

1) Install work equipment control lever (18) and
cover (17).
2) Install safety lock lever (16).
3. Horn wiring
Connect clamp (15) and horn wiring connector (14).
13W7652
4. Cover
Install arm rest (13) and cover (12).
D58E.P-1
5. Wiring
1) Connect cable (11) on the positive (+) side of the
battery to the battery relay.
2) Connect wiring clamps (10) and (9).
6. Brake rods
Connect brake rods (8) and (7).
7. Transmission control linkage

Connect speed rod (6) and directional rod (5).
8. RH rear cover
Install RH rear cover (4).
13OP1646
73-14 D58E.P-1
0
9. Operator’s seat assembly

Sling operator’s seat assembly (3) and install it.
10. Floor plates

D58E.P-1 73-15
0
WORK EQUIPMENT
Straight-tiltdozer .......................... 74-2

Power angle, power tiltdozer .............. 74-5-l
Ripper.. .................................. 74-6
D58E,P-1 74- 1
0
MAINTENANCE STANDARD STRAIGHT-TILTDOZER
/
STRAIGHT-TILTDOZER
(1) Blade, frame, arm, brace and cylinder yoke
Section B-B
Section A-A
Sction D-D
Section E-E Section F-F Section G-G

133F122
74-2 D58E.P-1
MAINTENANCE STANDARD STRAIGHT-TILTDOZER
Unit: mm
-
NO. Check item
Spherical clearance between trunnion

1
cap and trunnion (Left side)
Spherical clearance between trunnion cap

2
and trunnion (Right side)
Clearance between frame pin and blade

3
brat ket
Spherical clearance between frame pin and

4
frame
Spherical clearance between frame bearing

5
and bushing
6 Clearance between bracket and brace
7 Clearance between frame and brace pin

-
8 Clearance between brace and brace pin
9 Spherical clearance between bracket and arm
10 Clearance between frame and arm pin
11 Clearance between arm and arm pin
Clearance between lift cylinder support

12
shaft and bushing
Clearance between cylinder piston rod

13
bushing and pin
D58E.P-1
MAINTENANCE STANDARD STRAIGHT-TILTDOZER ,
(2) Cutting edge, end bit
13OF128
Unit: mm

1 Cutting edge height
204 155
Replace
2 End bit height 222 202
3 End bit width 325 310
4 Tightening torque for mounting bolt 47 + 7 kgm Retighten
74-4 D58E.P-1
MAINTENANCE STANDARD POWER ANGLE, POWEh TILTDOZER
/
POWER ANGLE, POWER TILTDOZER

(I) Blade, frame and loader frame
m 94.5 & 10.5 kgm
4 i
Section A-A Section B-B Section C-C Section D-D
,4 7 0
9 li
Section F-F Section H-H Section J-J
Section E-E Section G-G
13OF18060
D58E,P-1
MAINTENANCE STANDARD POWER ANGLE, bOWER TILTDOZER
Unit: mm
Tolerance
Clearance between tilt cylinder
1 Shaft Hole
installation pin and bracket
-0.030 +0.300 0.130 -

55 0.376
-0.076 +0.100
Clearance between tilt cylinder -0.030 +0.046 0.030 -

2 55 0.122
installation pin and cylinder bushing -0.076 0
Clearance between angle cylinder -0.025 +0.300 0.125 -

3 45 -0.064 +0.100 0.364
installation pin and bracket
Clearance between angle cylinder -0.025 +0.039 0.025 -

4 45 -0.064 0 0.103
installation pin and cylinder bushing
Clearance between pitching rod -0.030 +0.300 0.130 -

5 50 Replace
installation pin and bracket -0.076 +0.100 0.376

6 50 -0.076 0 0.122
installation pin and rod bushing
Clearance between lift cylinder -0.030 +0.300 0.130 -

7 60 -0.076 +0.100 0.376
installation pin and frame
Clearance between lift cylinder -0.030 +0.174 0.130 -

8 installation pin and cylinder bushing
60
-0.076 +0.100 0.250
Clearance between dozer frame -0.030 +0.020 0.034 -

9 75
installation pin and loader frame I -0.076 +0.004 0.276 I
-
IO 75
-0.076 -IO.147 0.276
installation pin and frame bushing

11 90 1.350
cap and blade ball -0.750 +0.300

12 120 1.350
cap and blade ball -0.750 f0.300
Standard shim thickness of dozer Adjusting

13 3.0 shim
frame cap
D58E,P-1 74-5-2
0
MAINTENANCE STANDARD POWER ANGLE, POWER TILTDOZER
(2) Cutting edge, end bit
I’
i
I
13OF126
Unit: mm

1 Height of cutting edge
204
2 Height of outside of end bit 255 Replace
3 Height of inside of end bit 222
4 Width of end bit 325
74-5-3 D58E,P-1
0 .;_.
MAINTENANCE STANDARD RIPPER /
RIPPER (DRPO60)
I ‘\
Section A-A Bection B-B
Section E-E Section F-F
Section G-G
View Z
F13017043
74-6 D58E.P-1
MAINTENANCE STANDARD RIPPER
Unit: mm

I
Clearance between bracket pin and

1
bushing
-
56 -0.030 +0.046 0.030 0.5
-0.076 0 0.122
-
2 Clearance between lever pin and bushing 56 -0.030 +0.3 0.230 0.5
-0.076 co.2 0.376
-
3 Clearance between lever pin and bushing 70 -0.030 +0.3 0.230 0.5 Replace
-0.076 +0.2 0.376
1
-
-0.076 +0.2 0.376
-
-0.076 +0.2 0.376
-
-0.030 -
6 Clearance between lever pin and bushing 70 +0.3 0.230 0.5
-0.076 +0.2 0.376
7 Clearance between lever pin and bushing
D58E.P-1 74 -7
ELECTRICAL SYSTEM
Electrical wiring diagram ................ 81 .2

Electrical circuit diagram ................ 81 .3
D58E.P-1 81-1
a
ELECTRICAL WIRING DIAGRAM
STRUCTURE AND FUNCTION
ELECTRICAL WIRING DIAGRAM
Horn switch Rear lamp
Thermistor for
water temperature
nsmission safety switch
torque converter
Starting motor
F13017044
81-2 D58E.P-1
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
Air conditionercompressor m-1
Head lamp(Right)
Head lamp(Left1 Tb air condltloner1
'T-m Light using sweep

r----
Tzif
-1
Horn Transmission safety switch

Torque converter
/ /
011 temperature
Is--__ sensor
-7
heater
Safety switch Rx=

Heater signal
Starting motor
24V,5.5KW
Engine oody earth
?
2 steos switch
alternator
I
L....
---- i
Battery
011 pressure switch

@%-
Charging lamp
Coolant
temperature
sensor Service meter
Torque converter
oil temperature meter
Coolant
temperature gauge
SAD00513
D58E, PI 81-3
0
1REGULATION OF EC INCLUSION 1
Air conditioner compressor [17
r----
------ ----- ------
-y I 02Y
OZL
i3ow
neaa lamp To air conditioner ,
I. . I, ,,\
control
OzRcgl Light using sweep
Horn
Heater relay
k alarm switch
Electrical
heater
Safety switchgxE
Starting motor
24’. 5.5KW
Engine body earth
Alternator
24V,13A
Body earth (3OOW)
~- -- -.--
$Fge capacity
alternator
24V,35A
~o_ow,
-_-_i -
Battery
Oil pressure switch

@%7
Charging lamp
Coolant
temperature
sensor Service meter
Torque converter
oil temperature meter Power take-off
= connetor
Coolant .Intermittentflash
temperature gauge light
.Maintenancelight
SAD00514
81-4 D58E, P-l

0

Service meter
I
2 Steps switch
BOW
2RW Rear
Enslne oil
I amp
pressure
Rear I
~ --i
Heater BOW Iamp
signal
-___________i (OPT):
Air conditioning I
comgressor (OPT) 1 Back UD I
I alarm switch I
L. H.
8OW
Horn switch
40W
Electrical intake
air heater relay
Electrical n
air heater
Starti ng
motor wi
safety
relay
Starting \asa
motor
SWD02512
D58E, P-l 81-5

@
ELECTRICAL SYSTEM
Troubleshooting of electrical system

(E-mode) ...... .. ..... .. .. ....... .. ....... ......... ..... .. . 82-3
D58E, P-l 82-1

0
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
E-l. Engine does not start . . .. . .. . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . .. . .. .. . .. . . .. . .. . . . . . . .. .. . . . . . .. . . .. . . . . . . .. .. . . . .. . . .. . . . . . . .. . . .. . . . .. . 82-4
D58E, P-l 82-3

0
ELECTRICAL SYSTEM E-l
E-l. Engine does not start

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always cormect any disconnected connectors before going on to the next step.
4 YES
Is voltage between
YE starting motor
terminal Band
chassis normal?
* Turn starting NO
switch ON.
YE starting motor - 20 - 29v
make noise of 6 YES
Is voltage between
YES starting motor
* Turn starting
5 terminal R and
switch to
chassis normal?
START. Is voltage between
starting switch _ *Turn starting NO
N terminal C and switch to START.
chassis normal?
* Turn starting
When starting switch to START. NO
YE
switch is turned .20-29v
OFF, is there noise
from battery relay? t g YES
-Turn starting
switch ON +
OFF.
1
Is voltage and
specific gravity
of battery * Between harness and chassis: Min. 1MD
normal?
* Min. 24V
* Specific gravity:
Min. 1.26 . Connect (-) pole I
of tester to (+) I
terminal of NO
battery.
-2o-29v
NO
82-4 D58E, P-l

0
CaUSt? Remedy
Defective starting motor lepair or

aplace
Defective contact of
wiring harness between
leplace wiring
battery (+) terminal and
larness
starting motor terminal B
Defective contaku or
disonnection in wiring
;eplace wiring
harness between starting
larness
switch terminal C and
starting motor terminal S
(including safety switch)
lepair or
Defective alternator
eplace
Defective starting switch

eplace
(between terminals B and C)
Defective battery relay leplace
Defective contact or
disconnection in wiring
leplace wiring
. harness between starting
arness
switch terminal BR and
battery relay terminal BR
Defective starting switch ;eplace

(between B and BR)
Defective contact or
disconnection in wiring
harness between battery leplace wiring
(+) terminal and starting larness
motor, or between
starting motor and
starting switch
Low battery capacity :harge or
eplace
D58E, P-l 82-5

0
E-l. Related electrical circuit diagram
IQ-Q_
I
Starting switch
Transmission
safety snitch
A7- Battery relay

TKD00674
82-6 D58E, P-l

0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
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S DEPARTMENT: DATE:
E
R NAME:
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S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
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If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

Seb Du 1340106

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SEBMU1340106

June 1998 Copyright 1998 Komatsu America International Company

00-2 D58E. P-l

0 Page to be newly added Add

l Page to be replaced Replace

( 1 Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

0 oo- 1 II- 3 12-36 @ 13-21 @ 0 21-25-2 @

D58E, P-l 00-2-l

21-54 23-21 23- 77 @ 24-11 34- 2 0

00-2-2 D58E, P-l

61-16 64- 4-2

D58E. P-l 00-2-3

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

* The allowable load value is estimated to

Category Komatsu cods Container Main applications, features

l Used to prevent rubber gaskets, rubber

l Used in places requiring an immediately

l Features: Resistance to heat and chemi-

790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

Holtz l Used as heat-resisting sealant for repair-

l Quick hardening type adhesive

v Quick hardening type adhesive

D Features: Resistance to heat, chemicals

1 Used as adhesive or sealant for gaskets

Features: Resistance to heat

l Features: Resistance to water, oil

I LG-4 790-129-9020 200 g Tube l

l Used as sealant for various threads, pipe

LG-5 (790-129-9080 ( 1 kg j ‘;$$_ll;” 1. ;;;;s’:‘~;;;raulic piping. plugs, elbows,

l Features: Silicon based, resistance to heat,

l Features: Silicon based, quick hardening

Three bond l Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

l General purpose type

l Used for normal temperature, light load

Mf$g?/ SYG2-400M 1 tEp$ /elows type1

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tighteni I toraue

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)