SEBMW010702

HD785-7

SJA01316-02

© 2016
All Rights Reserved 00-1
Printed in Japan 10-16 (01) (2)
 LIST OF REVISED PAGES

Notice of revision
2nd revision 2016/10
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace

() Page to be deleted Discard

List of revised pages

Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
q 00-1 (2) 10-7 10-47 10-87
00-2 10-7-1 10-48 10-88
Q 00-2-1 (2) 10-8 10-49 10-89
Q 00-2-2 (2) 10-9 10-50 10-90
Q 00-2-3 (2) 10-10 10-51 10-91
Q 00-2-4 (2) 10-11 10-52 10-92
00-3 10-12 10-53 10-93
00-4 10-13 10-54 10-94
00-5 10-14 10-55 10-95
00-6 10-15 10-55-1 10-96
00-7 10-16 10-56 10-97
00-8 10-17 10-57 10-98
00-9 10-18 10-58 10-99
00-10 10-19 10-59 10-100
00-11 10-20 10-60 10-101
00-12 10-21 10-61 10-102
00-13 10-22 10-62 10-103
00-14 10-23 10-63 10-104
00-15 10-24 10-64 10-105
00-16 10-25 10-65 10-106
00-17 10-26 10-66 10-107
00-18 10-27 10-67 10-108
00-19 10-28 10-68 10-109
00-20 10-29 10-69 10-110
00-21 10-30 10-70 10-111
00-22 10-31 10-71 10-112
10-32 10-72 10-113
01-1 10-33 10-73 10-114
01-2 10-34 10-74 10-115
01-4 10-35 10-75 10-116
01-5 10-36 10-76 10-117
01-6 10-37 10-77 10-118
01-7 10-38 10-78 10-119
01-8 10-39 10-79 10-120
10-40 10-80 10-121
10-1 10-41 10-81 10-122
10-2 10-42 10-82 10-123
10-3 10-43 10-83 10-124
10-4 10-44 10-84 10-125
10-5 10-45 10-85 10-126
10-6 10-46 10-86 10-127

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LIST OF REVISED PAGES

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10-128 q 20-20 (2) 20-68 20-117
10-129 q 20-21 (2) 20-69 20-118
10-130 20-22 20-70 20-119
10-131 20-24 20-71 20-120
10-132 20-25 20-72 20-121
10-133 20-26 20-72-1 20-122
10-134 20-27 20-72-2 20-123
10-135 20-28 20-72-3 20-125
10-136 20-29 20-72-4 20-126
10-137 20-30 20-72-5 20-127
10-138 20-31 20-73 20-128
10-140 20-32 20-74 20-129
10-141 20-33 20-75 20-130
10-142 20-34 20-76 20-131
10-143 20-35 20-77 20-132
10-144 20-36 20-78 20-133
10-144-1 20-37 20-79 20-135
10-144-2 20-38 20-80 20-136
10-145 20-39 20-81 20-137
10-146 20-40 20-82 20-138
10-147 20-41 20-83 20-139
10-148 20-42 20-84 20-140
10-149 20-43 20-85
10-150 20-43-1 20-86 20-151
10-152 20-44 20-87 20-152
10-153 20-44-1 20-88 20-153
10-154 20-44-2 20-89 20-154
10-155 20-44-3 20-90 20-155
10-156 20-44-4 20-91 20-156
10-157 20-44-5 20-93 20-157
10-158 20-44-6 20-94 20-158
10-159 20-44-7 20-95 20-159
10-160 20-45 20-96 20-160
10-161 20-47 20-97 20-161
20-48 20-98 20-162
20-1 20-49 20-99 20-163
20-2 20-50 20-100 20-164
q 20-3 (2) 20-51 20-101 20-165
20-4 20-52 20-102 20-166
20-5 20-53 20-103 20-167
20-6 20-54 20-104 20-168
20-7 20-55 20-105 20-169
20-8 20-56 20-106 20-170
20-10 20-57 20-107 20-171
20-11 20-58 20-108 20-172
20-12 20-60 20-109 20-173
20-13 20-61 20-110 20-174
20-14 20-62 20-111 20-175
20-16 20-63 20-113 20-176
20-17 20-64 20-114 20-177
20-18 20-66 20-115 20-178
20-19 20-67 20-116 20-179

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20-180 30-34 30-86 30-138
20-181 30-35 30-87 30-139
20-182 30-36 30-88 30-140
20-183 30-37 30-89 30-141
20-184 30-38 30-90 30-142
20-185 30-39 30-91 Q 30-142-1 (2)
30-40 30-92 Q 30-142-2 (2)
20-201 30-41 30-93 Q 30-142-3 (2)
20-202 30-42 30-94 Q 30-142-4 (2)
20-204 30-43 30-95 30-143
20-205 30-44 30-96 30-144
20-206 30-45 30-97 30-145
20-207 30-46 30-98 30-146
20-208 30-47 30-99 30-147
20-209 30-48 30-100 30-148
20-210 30-49 30-101 30-148-1
20-211 30-50 30-102 30-149
20-212 30-51 30-103 30-150
30-52 30-104 30-151
q 30-1 (2) 30-53 30-105 30-152
30-2 30-54 30-106 30-153
30-3 30-55 30-107 30-154
30-4 30-56 30-108 30-155
30-5 30-57 30-109 30-156
30-6 30-58 30-110 30-157
30-7 30-59 30-111 30-158
30-8 30-60 30-112 30-159
30-9 30-61 30-113 30-160
30-10 30-62 30-114 30-161
30-11 30-63 30-115 30-162
30-12 30-64 30-116 30-163
30-13 30-65 30-117 30-164
30-14 30-66 30-118 30-165
30-15 30-67 30-119 30-166
30-16 30-68 30-120 30-167
30-17 30-69 30-121 30-168
30-18 30-70 30-122 30-169
30-19 30-71 30-123 30-170
30-20 30-72 30-124 30-171
30-21 30-73 30-125 30-172
30-22 30-74 30-126 30-173
30-23 30-75 30-127 30-174
30-24 30-76 30-128 30-175
30-25 30-77 30-129 30-176
30-26 30-78 30-130 30-177
30-27 30-79 30-131 30-178
30-28 30-80 q 30-132 (2) 30-179
30-29 30-81 30-133 30-180
30-30 30-82 30-134 30-181
30-31 30-83 30-135 30-182
30-32 30-84 30-136 30-183
30-33 30-85 30-137 30-184

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30-185 30-237
30-186 30-238
30-187 30-239
30-188 30-240
30-189 30-241
30-190 30-242
30-191 30-243
30-192 30-244
30-193 30-245
30-194
30-195 40-1
30-196 40-2
30-197 40-3
30-198 40-5
30-199 40-6
30-200 40-7
30-201 40-8
30-202 40-9
30-203 40-11
30-204 40-13
30-205 40-14
30-206 40-15
30-207 40-16
30-208 40-17
30-209 40-18
30-210 40-19
30-211 40-20
30-212 40-21
30-213 40-22
30-214 40-23
30-215 40-24
30-216 40-25
30-217 40-26
30-218 40-28
30-219 40-29
30-220 40-31
30-221 40-33
30-222 40-34
30-223 40-35
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TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE 1

Engine S6D140E-2
Classi-
item Condition Unit Standard value Permissible value
fication
High idling speed rpm
Perfor-

2,350 ± 50 2,350 ± 50
mance

Engine
Low idling speed rpm 650 +50
0 -
Quick acceleration Bosch
Max. 4.0 6.0
(Low idling→High idling) scale
Exhaust gas color
Bosch
Intake and exhaust system

At high idling Max. 1.0 2.0

scale
See "Measuring intake air
Min. 78.7 {590} 66.7 {500}
Intake pressure (Boost pressure (boost pressure)" kPa
pressure) High idling and work equipment {mmHg} Min. 32.7 {245} Min. 26.7 {200}
relief (Reference value) (Reference value)
See "Measuring exhaust gas
Exhaust temperature °C Max. 700 700
temperature"

Valve clearance (When Intake valve mm 0.43 -

engine is hot or cold) Exhaust valve mm 0.80 -
Oil temperature: 40 - 60 °C MPa Max. 3.8 {39} 2.7 {27}
Compression pressure
{kg/cm2}
Engine body

(SAE30 oil) (Engine speed) (160 - 200) (160 - 200)

(rpm)
(Water temperature inside
Blow-by pressure operating range) kPa
Max. 0.98 {100} 1.96 (200)
(SAE30 oil) {mmH20}
At rated output
(Water temperature inside
operating range)
(Oil temperature: 80 °C above)
MPa
At high idling (SAE 30) 0.3 - 0.5 {3.0 - 5.0} 0.2 {2.0}
Lubrication system

{kg/cm2}
Oil pressure (SAE30 oil) MPa
At high idling (SAE 10W) 0.25 - 0.44 {2.5 - 4.5} 0.18 {1.8}
{kg/cm2}
MPa
At low idling (SAE 30) 0.12 {1.2} 0.07 {0.7}
{kg/cm2}
MPa
At low idling (SAE 10W) 0.10 {1.0} 0.07 {0.7}
{kgcm2}
Oil temperature All speed (Oil in oil pan) °C 80 - 110 120
Cooling system Fuel system

Before top dead center

Fuel injection timing degree 16 ± 0.5 16 ± 0.5
(B. T. D. C.)

Alternator belt tension 13 - 16 -

Deflects when pushed with a
mm
force of 58.8 N {6 kg}
Fan belt tension 17 - 19 -

a The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.

20-3
(2)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 1

k When removing or installing measuring

equipment, be careful not to touch any hot
parts.

1. Install tool H to intake pressure measurement coupler

(1).
k When taking measurements, be careful not to touch
any hot parts or rotating parts.

Note:
Run the engine at a mid-range speed or above, then
use the self-seal portion of the gauge to remove oil
from inside the hose.
q Insert the gauge about half-way and repeat the
movement to open the self-seal and remove the
oil.
a If there is any oil inside the hose, the gauge will
not move, so always be sure to remove the oil.

2. Run the engine at high idle and measure the boost pres-
sure as follows.
1) Before starting measurements, set the work equip-
ment to the following posture.
A: k When setting the work equipment in position,
be careful not to let the blade hit the tire.
B: For the drawbar shift, take the center position as
the standard position.
C: Shift the blade fully to the right.
D: Rotate the circle to give a propulsion angle of
50°.
E: Raise the blade fully on both the left and right
sides.
2) Pull right blade lift lever (1) back, and hold it at the
end of its stroke.
a Raise the right end of the blade, and relieve the
circuit.
3) In the condition in Step 2), operate blade left shift
lever (2) and circle left rotation lever (3) at the same
time to the front to move the work equipment.
a Use the blade left shift lever and the circle left
rotation lever to set the oil discharge amount to
the maximum.

20-20
(2)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) STANDARD VALUE TABLE FOR ENGINE

4) In the condition in Step 3), measure the boost pres-

sure.
k The blade moves during the measurement, so be
careful to avoid the contact shown in the dia-
gram, and stop operation of the lever before
there is any contact.
A: kBe careful not to let the work equipment
hit the main frame.
B: kBe careful not to let the blade hit the tire.
a Standard intake air pressure (reference):
Min 26.7 kPa {Min. 200 mmHg}

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SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
STARTING MOTOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30-4
ALTERNATOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30-4
NOZZLE HOLDER
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30-6
FUEL INJECTION PUMP
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30-7
WATER PUMP
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30-8
ENGINE OIL COOLER CORE
Removal and Installation . . . . . . . . . . . . . . . . . . . 30-10
TURBOCHARGER
Removal and Installation . . . . . . . . . . . . . . . . . . . 30-11
AIR COMPRESSOR
Removal and Installation . . . . . . . . . . . . . . . . . . . 30-12
CYLINDER HEAD
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
ENGINE (INCL. TRANSMISSION)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
RADIATOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
FUEL TANK
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
TRANSMISSION
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
TRANSFER
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
TRANSMISSION CONTROL VALVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
HYDROSHIFT TRANSMISSION PUMP
Removal and Installation . . . . . . . . . . . . . . . . . . . 30-91
TANDEM AND FINAL DRIVE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
FINAL DRIVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
BEVEL GEAR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
BEVEL PINION
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
FRONT AXLE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
 30 DISASSEMBLY AND ASSEMBLY
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
STEERING VALVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
WHEEL BRAKE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-142-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-142-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-145
AIR TANK
Removal and Installation . . . . . . . . . . . . . . . . . . 30-148
ALCHOL INJECTOR
Filing and draining . . . . . . . . . . . . . . . . . . . . . .30-148-1
HYDRAULIC TANK
Removal and Installation . . . . . . . . . . . . . . . . . . 30-149
HYDRAULIC PUMP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-151
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-153
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167
HYDRAULIC CONTROL VALVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-191
MAIN CONTROL VALVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-192
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-194
CIRCLE ROTATION MOTOR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
DRAWBAR SHIFT CYLINDER, BLADE
LIFT CYLINDER, LIFTER GUIDE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
ARTICULATE CYLINDER
Removal and Installation . . . . . . . . . . . . . . . . . . 30-210
REAR MOUNT RIPPER CYLINDER
Removal and Installation . . . . . . . . . . . . . . . . . . 30-211
HYDRAULIC CYLINDER
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-214
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
BLADE
Removal and installation . . . . . . . . . . . . . . . . . . 30-226
CIRCLE AND DRAWBAR
Removal and Installation . . . . . . . . . . . . . . . . . . 30-227
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
REAR MOUNT RIPPER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
METHOD FOR LIFTING UP ROPS CAB . . . . . . . . 30-235
INSTALLATION OF ROPS . . . . . . . . . . . . . . . . . . . 30-237
ROPS CAB
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243
30-1
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DISASSEMBLY AND ASSEMBLY FRONT AXLE

ASSEMBLY OF FRONT AXLE ASSEMBLY 1

1. Hub shaft assembly

1) Install housing (27) to hub shaft (28).

2) Adjust rotating torque

q Reduce shims (30) and tighten bolts (25) with
washers (26) so that it starts to rotate at 294 to
343 N {30 to 35 kg}, as measured by a spring bal-
ance [1] hooked to hub bolt (29).
Turn the shaft at least 3 times left and right.
a Adjust the preload after the bearing temperature
becomes normal.
q Loosen bolt (25) and insert shims (30) so that it
can start to rotate at 147 to 196 N {15 to 20 kg}.
a Shim (30): Thickness of 0.1 or 0.2 mm
q Measure the rotating force again after rotating
housing (27) 3 times and after the bearing roller
fits well. Confirm that the starting torque becomes
147 to 196 N {15 to 20 kg}.
q Then bend lock washer (31) securely.

3) Install cover (24) with bolts (23).

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REMOVAL OF WHEEL BRAKE ASSEMBLY 1

1. Remove tandem case assembly. For details, see steps

1. to 4. of "Disassembly of final drive assembly".

2. Remove bolt (1), and remove cover (2).

3. Fix shaft (3) and cage (4) with guide bolts [1] (10 mm ×
1.5 mm - 95 mm) (2 pieces).

4. Remove bolt (5), and remove cover (6).

5. Set lock washer (7) up, remove bolt (8), and remove
holder (9) and shim (10).

6. Tighten forcing screw (20 mm x 2.5 mm) into cage (11),

and remove it together with bearing (12).

7. Remove shim (13).

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8. Set collar [2] (φ 95), tighten holder (9) lightly with bolt
(8).

9. Remove bolt (14), and remove wheel brake assembly.

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FRONT AXLE STANDARD VALUE TABLE FOR ENGINE

INSTALLATION OF WHEEL BRAKE ASSEMBLY 1

a See, "Removal of wheel brake assembly" for guide bolts

[1] and collar [2].

1. Install O-ring (16) to support (15).

2 O-ring: Grease (G2-LI)

2. Install wheel brake assembly to tandem case with bolt

(14).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 490 to 608 Nm {50 to 62 kgm}

3. Remove bolt (8), and remove holder (9) and collar [2] (φ
95).

4. Install O-ring (17) to cage (11).

2 O-ring: Grease (G2-LI)

5. Install cage (11) loosely with bolt (5).

6. Press fit bearing (12).

7. After tightening holder (9) with bolt (8), remove it once.

8. Measure clearance (A), and insert shim (10) of clear-

ance (A) - 0.2 mm.

9. Install holder (9) and lock washer (7) with bolt (8).
3 Mounting bolt: 245 to 309 Nm {25 to 31.5
kgm}

10. Remove guide bolt [1] (10 mm × 1.5 mm - 95 mm).

11. Measure the starting torque of shaft (3).

12. Loosen bolt (5), and install shim (13).

13. Measure the starting torque again.

14. Adjust thickness of shim (13) so that starting torque

becomes the value measured at step 11. + 19.6 to 24.5
Nm {2.0 to 2.5 kgm}.

15. Remove bolt (5) once, and install cover (6).

2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 490 to 608 Nm {50 to 62 kgm}

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DISASSEMBLY AND ASSEMBLY FRONT AXLE

16. Install cover (2) with bolt (1).

3 Mounting bolt: 44.1 to 53.9 Nm {4.5 to 5.5 kgm}

17. Install tandem case assembly. For details, see steps 24

to 27. of "Assembly of final drive assembly".

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