B100 6901844 enUS SM

B100
Service
Manual
(S/N 570011001 & Above)
(S/N 570111001 & Above)
Dealer Copy -- Not for Resale
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
6901844 (6-12) Printed in U.S.A. © Bobcat Company 2011
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Ma intenance Manual, Operator’s Handbook and
WARNING
WARNING
signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-16639 B-16527

Never service the B obcat Loader Always use an approved lift arm Cleaning and m aintenance are
Backhoe without instructions. support device when servicing the required daily.
loader backhoe with the lift arms NEVER modify equipment or add
raised. Replace the lift arm support attachments not a pproved by
device if damaged or missing. Bobcat.
Disconnecting or loosening any
hydraulic tubeline, hose, fitting
component, or p art failure can
cause lift arms or backhoe boom
to drop.

WRONG WRONG WRONG
B-16570 B-16517 B-16696

Have good ventilation when Vent exhaust to o utside when Never work on loader backhoe
welding or grinding painted engine must be run for service. with lift arms raised unless
parts. Exhaust system must be tightly supported by an approved lift
Wear dust mask when grinding sealed. Ex haust Fumes can kill arm support device.
painted parts. Toxic dust and gas without warning. Always lower the b ackhoe
can be produced. bucket to the ground before
doing any maintenance.
WRONG WRONG WRONG
B-16571 B-16572 B-6589

B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust machine exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If ac id
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It ca n penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep engine cover closed except attention.
running, while s moking or when for service. Close and latch
near open flame. engine cover before operating
the loader backhoe.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW15-0805
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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 70-01 HYDROSTATIC TESTING.......................................30-01

AIR CLEANER SERVICE ....................................... 10-01
ALTERNATOR ........................................................ 60-01 INSTRUMENT PANEL.............................................60-01
ALTERNATOR BELT............................................... 10-01
ARM CYLINDER ..................................................... 20-01 LOADER BACKHOE SPECIFICATIONS........... SPEC-01
ARM ........................................................................ 50-01 LOADER BACKHOE TORQUE ......................... SPEC-01
AXLE AND DIFFERENTIAL.................................... 40-01 LOADER CONTROL VALVE ...................................20-01
AXLE HUB (FRONT) .............................................. 50-01 LIFT ARMS ..............................................................50-01
AXLE TOE-IN.......................................................... 10-01 LIFT ARM SUPPORT DEVICE................................10-01
LIFT CYLINDER ......................................................20-01
BACKHOE BOOM LOCK........................................ 10-01 LIFTING AND BLOCKING THE
BACKHOE CONTROL VALVE................................ 20-01 LOADER BACKHOE ...............................................10-01
BATTERY................................................................ 60-01 LUBRICATING THE LOADER BACKHOE ..............10-01
BOB-TACH.............................................................. 50-01
BOB-TACH HAND LEVER...................................... 10-01 MAIN RELIEF VALVE ..............................................20-01
BOOM ..................................................................... 50-01 MUFFLER................................................................70-01
BOOM CYLINDER .................................................. 20-01
BRAKE CALIPER ................................................... 40-01 OIL COOLER...........................................................30-01
BUCKET ................................................................. 50-01 OPERATOR CAB ....................................................50-01
BUCKET CYLINDER .............................................. 20-01 OPERATOR SEAT...................................................50-01
CAB LIGHTS........................................................... 60-01 PARKING BRAKE....................................................40-01

CONVERSIONS ................................................SPEC-01 PORT RELIEF VALVE
(BACKHOE CONTROL VALVE) ..............................20-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 PORT RELIEF VALVE
ENGINE .................................................................. 70-01 (LOADER CONTROL VALVE).................................20-01
ENGINE COMPONENENTS AND TESTING ......... 70-01
ENGINE COOLING SYSTEM ................................. 10-01 RADIATOR ..............................................................70-01
ENGINE COVER ......................................... 10-01, 50-01 REAR AXLE .................................................10-01, 40-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 REAR AXLE AND DIFFERENTIAL .........................40-01
ENGINE SIDE COVERS......................................... 50-01 RECONDITIONING THE ENGINE ..........................70-01
ENGINE SPECIFICATIONS...............................SPEC-01 RUBBER DRIVE COUPLER ...................................70-01
ENGINE SPEED CONTROL .................................. 70-01
SERVICE SCHEDULE ............................................10-01
FENDER ................................................................. 50-01 SPINDLE .................................................................50-01
FLOOR PANELS..................................................... 50-01 STABILIZER ............................................................50-01
FLYWHEEL ............................................................. 70-01 STABILIZER CYLINDER .........................................20-01
FLYWHEEL HOUSING ........................................... 70-01 STEERING CYLINDER ...........................................20-01
FRONT AXLE ......................................................... 50-01 STARTER ................................................................60-01
FUEL LEVEL SENDER........................................... 60-01 STEERING PUMP ...................................................20-01
FUEL SYSTEM ....................................................... 10-01 SWING CYLINDER .................................................20-01
FUEL TANK............................................................. 50-01 SWING FRAME .....................................................50-170
GEAR PUMP .......................................................... 20-01 TILT CYLINDER ......................................................20-01

GRILL...................................................................... 50-01 TIRE MAINTENANCE .............................................10-01
GRILL FRAME ........................................................ 50-01 TORQUE SPECIFICATIONS
FOR BOLTS....................................................... SPEC-01
HYDRAULIC FLUID RESERVOIR.......................... 20-01 TOWING THE LOADER BACKHOE .......................10-01
HYDRAULIC FILTER HOUSING ............................ 20-01 TRANSPORTING THE LOADER BACKHOE..........10-01
HYDRAULIC/HYDROSTATIC FLUID TRAVEL PEDAL ......................................................20-01
SPECIFICATIONS .............................................SPEC-01 TROUBLESHOOTING .................................40-01, 70-01
HYDRAULIC/HYDROSTATIC SYSTEM ................. 10-01 TURBOCHARGER ..................................................70-01
HYDRAULIC SYSTEM INFORMATION.................. 20-01
HYDROSTATIC DRIVE MOTOR............................. 30-01 X-CHANGE™ ..........................................................50-01
HYDROSTATIC PUMP ........................................... 30-01
HYDROSTATIC SYSTEM INFORMATION ............. 30-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . X
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
SYSTEM &
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SERVICE
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
B100 Bobcat Loader Backhoe

I Service Manual
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that ROPS mounting 9. Bob-Tach wedges and
hardware is tightened and is linkages must function
Bobcat approved. correctly and be in good
condition.
2. The seat belt must be 10. Safety treads must be in good

correctly installed, functional condition.
and in good condition.
3. Check lift arm support device, 11. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models.

4. Machine signs must be 12. Check hydraulic fluid level,
legible and in the correct engine oil level and fuel
location. supply.
5. Foot pedal must return to 13. Inspect for fuel, oil or

neutral. hydraulic fluid leaks.
6. Check for correct function of 14. Lubricate the loader backhoe.

the work lights
7. The parking brake must 15. Check the condition of the

function correctly. battery and cables.
8. Enclosure door latches must 16. Inspect the air cleaner for
open and close freely. damage or leaks. Check the
condition of the element.

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17. Check the electrical charging 20. Operate the loader and check
system. all functions.
18. Check tires for wear and 21. Check for any field
pressure. modification not completed.
19. Inspect for loosen or broken 22. Recommend to t he owner

parts or connections. that all necessary corrections
be made before the machine
is returned to service.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.

III Service Manual
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IV Service Manual
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the

W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Loader Backhoe Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Loader Backhoe.
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284
• The Loader Backhoe Safety Video is available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI LB-0206 SM

V Service Manual
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.

Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI LB-0206 SM

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SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of hi gh temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a s ource of ar cs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to av oid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the eng ine and exhaust
system, but the muffler and the ex haust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks

or hot c omponents can contact flammable material,

explosive dust or gases.
• The operator cab, engine compartment, and engine

cooling system must be inspected every day and • Know where fire extinguishers and first aid kits are
cleaned if nec essary to pr event fire hazard and located and how to use them. Fire extinguishers are
overheating. available from your Bobcat dealer [Figure 1].
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do no t
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fi re extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI LB-0206 SM

VII Service Manual
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VIII Service Manual
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader backhoe Figure 3

when requesting service information or when ordering
parts. Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Backhoe Serial Number
Figure 2
P-32753
The engine serial number is located on the valve cover at

the right side of the engine [Figure 3].
DELIVERY REPORT

Figure 4
P-32734
The loader backhoe serial number plate is located under

the fender in front of the left rear tire [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
1. The four digit Model/Engine Combination Module B-16315

number identifies the model number and engine
combination.
The Delivery Report must be filled out by the dealer and
2. The five digit Production Sequence Number identifies signed by the owner or operator when the Bobcat loader
the order which the loader is produced. backhoe is delivered. An explanation of the form must be
given to the owner. Make sure it is filled out completely
[Figure 4].

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BOBCAT LOADER IDENTIFICATION
OPERATOR MANUAL
ARM REAR LIGHTS GRAB HANDLE
CYLINDER
LIFT ARM/BUCKET
BUCKET CONTROL
CYLINDER
OPERATOR HANDBOOK
TRAVEL
PEDAL LIFT
CYLINDER
LIFT ARM
TILT
DIPPER CYLINDER
ARM
X-CHANGE
BUCKET
LIFT ARM
BACKHOE BOOM SUPPORT
LATCH PARKING

BOOM DEVICE
BRAKE
STABILIZER
*CANOPY/CAB
(ROPS/FOPS) OPERATOR SEAT
FRONT LIGHTS WITH SEAT BELT
BACKHOE
CONTROL
ENGINE COVER
FRONT AUXILIARY
QUICK COUPLERS
ENGINE
SPEED
CONTROL
TIRES
B-16504
BUCKET† B-16503
† BUCKET - Several different buckets and other attachments are available for the Bobcat loader backhoe.
* ROPS, FOPS - Roll Over Protective Structure, Falling Object Protective Structure, per SAE j1040 and ISO 3471 and
Falling Object Protective Structure per SAE J1043 and ISO 3449, Level 1.

X Service Manual
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SAFETY &
SAFETY & MAINTENANCE
MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . 10-160-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
BACKHOE BOOM LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Disengaging The Boom Lock. . . . . . . . . . . . . . . . . . . . . . 10-140-1 DRIVE
Engaging Boom Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2 SYSTEM
BOB-TACH HAND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

ELECTRICAL
ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1 SYSTEM &
ANALYSIS
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 ENGINE
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2 SERVICE
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2 SPECIFICATIONS
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Cleaning The Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing The Lift Arm Support Device. . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER BACKHOE . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER BACKHOE . . . . . . . . . . . . . . 10-170-1

Continued On Next Page

10-01 Service Manual
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SAFETY & MAINTENANCE (CONT’D)
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TOWING THE LOADER BACKHOE . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE LOADER BACKHOE . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

18 of 642
LIFTING AND BLOCKING THE LOADER BACKHOE Figure 10-10-2
Procedure
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
P-33337
operators and failure to follow ins tructions can
cause injury or death.
W-2003-0199
Lift the rear of the loader backhoe and install jackstands
[Figure 10-10-2].
Figure 10-10-1
Figure 10-10-3

B-7023
P-33336
Read the removal and installation, disassembly and

assembly, etc., completely to become familiar with the Lift the front of the loader backhoe and put jackstands
procedure before beginning [Figure 10-10-1]. under the axle [Figure 10-10-3].
Always park the loader backhoe on a level surface. Note: Make sure the jackstands do not touch the
tires.
Stop the engine, and engage the parking brake.
WARNING
Put jackstands under the front and rear axle before
running the engine for service. Failure to us e
jackstands can allow the machine to fall or move and
W-2461-0303

10-10-1 Service Manual
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LIFT ARM SUPPORT DEVICE Figure 10-20-2
Maintenance and service work can be do ne with the lift

arms lowered. If the lift arms are raised, use the following
procedures to install and remove the approved lift arm
support device:
Installing The Lift Arm Support Device
WARNING 1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
P-33316
support device. Failure to us e an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. Install the lift arm support device (Item 1) [Figure 10-20-
W-2059-0598
2] over the lift cylinder rod.
Figure 10-20-3
WARNING

Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Figure 10-20-1
P-32752
1
Start the engine and lower the lift ams slowly until the
support device is held securely [Figure 10-20-3].
Stop the engine.
P-32750
Remove the approved lift arm support device (Item 1)

[Figure 10-20-1] from the storage position.
With the operator in the seat, fasten seat belt and engage
the parking brake. Start the engine and raise the lift arms.
After the lift arms are raised fully, stop the engine.

21 of 642
LIFT ARM SUPPORT DEVICE (CONT'D)
Removing The Lift Arm Support Device
Figure 10-20-4
P-33316
With the operator in the seat, seat belt fastened and the
parking brake engaged, start the engine and raise the lift
arms. After the lift arms are raised fully, stop the engine.

Remove the approved lift arm support device (Item 1)
[Figure 10-20-4].
Start the engine and lower the lift arms fully.
Figure 10-20-5
P-32750
Put the lift arm support (Item 1) [Figure 10-20-5] in the

storage position.

22 of 642
ENGINE COVER Figure 10-30-3
Figure 10-30-1
1
P-33778
P-32767
Place the end of the support rod (Item 1) [Figure 10-30-
3] into the hole located on the hood to hold the engine
Open the latch (Item 1) [Figure 10-30-1] on each side of cover open.
the engine cover.
Raise the engine cover.

Figure 10-30-2
P-33507
Remove the engine cover support rod (Item 1) [Figure

10-30-2] from the storage position.

23 of 642

24 of 642
TRANSPORTING THE LOADER BACKHOE Figure 10-40-3
Procedure
WARNING P-32627
Adequately designed ramps of sufficient strength are

needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
Figure 10-40-1 P-32628
Figure 10-40-4

P-32626
1
P-32621
Be sure the transport and towing vehicles are of P-32622

adequate size and capacity. (See Performance on Page
SPEC-10-2.)
Use the following procedure to fasten the loader backhoe
The rear of the trailer must be blocked or supported (Item to the transport vehicle to pr event the loader backhoe
1) [Figure 10-40-1] when loading or unloading the loader from moving during sudden stops or when going up or
backhoe to prevent the front end of the trailer from raising down slopes.
up.
• Lower the loader bucket.
Figure 10-40-2 • Lower the backhoe bucket.
• Stop the engine.
• Engage the parking brake.
• Install chains at the rear of the mac hine [Figure 10-
40-2] front of the machine [Figure 10-40-3] and the
backhoe [Figure 10-40-4].
P-32625 • Fasten each end of the chain to the transport vehicle
For height restrictions when transporting the loader

backhoe on a trailer, the backhoe boom lock must not be
engaged. The backhoe boom must be lowered onto the
trailer bed and chained.
P-32624

25 of 642

26 of 642
TOWING THE LOADER BACKHOE
Procedure
Place blocks in front and behind rear wheels.
Remove the front floor panel. (See FLOOR PANELS on

Page 50-30-1.)
Figure 10-50-1

P-42731
Loosen the tow valve (Item 1) [Figure 10-50-1].
Figure 10-50-2
P-42732
Rotate the tow valve (Item 1) [Figure 10-50-2]

counterclockwise approximately three turns.
To prevent damage to the l oader backhoe hydrostatic

system, the loader backhoe must be towed only a short
distance at s low speed. (Example: Moving the l oader
backhoe onto a transport vehicle.
The towing chain (or cable) must be rated at 1-1/2 times

the weight of the loader. (See Performance on P age
SPEC-10-2.)

27 of 642

28 of 642
AXLE TOE-IN Figure 10-60-3
Adjustment
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to us e an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-32810
Figure 10-60-1
Measure the distance between the centerlines on the

front of the tires and compare it to the measurement
taken from the centerlines on the backside of the tires
[Figure 10-60-3]. The measurement must be equal.
Figure 10-60-4

1
P-33319
Turn the steering wheel until the front wheels are 2 3

positioned as shown [Figure 10-60-1].
2
Figure 10-60-2
P-33323
If measurement is not the same, adjust both tie rod ends

(Item 1) [Figure 10-60-4] by loosening both jam nuts
(Item 2) [Figure 10-60-4], loosen or tighten the track rod
(Item 3) [Figure 10-60-4] of both tie rods until the
measurement is the same.
P-33322
Measure the exposed part of the c ylinder rod on each

side of the steering cylinder housing making sure they
are the same length [Figure 10-60-2].

29 of 642

30 of 642
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader backhoe.
Instructions are necessary before operating or servicing machine. Read

and understand the Operation & Maintenance Manual and signs (decals) on
WARNING machine. Follow wa rnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-1285
SERVICE SCHEDULE HOURS
■
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the engine oil level and add as needed.
Engine Air Filter and Air Check display panel. Service only when required. Check for
System leakes and damaged components.
Engine Cooling System Clean debris from oil cooler radiator & grill.
Lift Arms, Cyl., Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins, Wedges
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Belt Reactors Check the condition of seat belt. Clean or replace seat belt
retractors as needed.

Stabilizers Check the pins and operating parts.
Safety Signs and Safety Check for damaged signs (decals) and safety treads. Replace
Treads any signs or safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition
of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Parking Brake Check operation, adjust as required.
Hydraulic Fluid, Hoses and Check fluid level & add as needed. check for damage & leaks.
Tubelines Repair or replace as needed.
Rear Differential Check oil level. Add oil as needed.
Wheel Nuts Check for loose wheel nuts and tighten to 140 ft.-lb.
(190 N•m) torque.
Hydraulic Filter Check filter.
Battery Check cables, connnections and electrolyte level. Add distilled
water as needed.
Engine Cooling System Check engine cooling system. *
Alternator Belt Check tension and adjust as needed.
Fuel Injectors Check fuel injector nozzles.
Fuel Filter Replace the filter element.
Steering King Pins Lubricate with multi-purpose lithium based grease.
Hyd./Hydro. Filter Replace the filter element
Engine Oil and Filter Replace oil & filter. Use CD or better grade oil and Bobcat filter.
Hyd. Res. Breather Cap Replace the reservoir breather cap.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves. #
Wheel Bearings Repack the wheel bearings.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace gydraulic/hydrostatic filter element when the transmission warning light comes ON.
† First oil and filter change must occur at 50 hours: 250 hours thereafter.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Service Manual for procedure.)
■ Or every 12 months.
▼ Or every five years

31 of 642

32 of 642
AIR CLEANER SERVICE Figure 10-80-2
Replacing Filter Element
Figure 10-80-1
P-32771
1
Remove the filter element and cover from the housing
P-32764 [Figure 10-80-2].
NOTE: Make sure all sealing surfaces are free of dirt

See SERVICE SCHEDULE on Page 10-70-1 for the and debris.
correct service interval.

Install a new element onto the housing cover.
Open the engine cover. (See ENGINE COVER on Page
10-30-1.) Install filter element/cover [Figure 10-80-2].
Loosen the filter cover nut (Item 1) [Figure 10-80-1]. Tighten the filter cover nut (Item 1) [Figure 10-80-1].

33 of 642

34 of 642
ENGINE COOLING SYSTEM Figure 10-90-3
Coolant Replacement
WARNING
1
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
Figure 10-90-1
P-32733
1
Open the engine block drain valve (Item 1) [Figure 10-
90-3] and drain the coolant into a container.
After all the coolant is removed, close both drain valves.
Recycle or dispose of coolant in an environmentally safe

manner.
Mix the coolant in a separate container. (See Capacities

on Page SPEC-10-4.)
P-32764
NOTE: The loader backhoe is factory filled with
ethylene glycol. DO NOT mix propylene glycol
See SERVICE SCHEDULE on Page 10-70-1 for the with ethylene glycol.
correct service intervals.
Add premixed coolant; 50% water and 50% et hylene
Stop the engine, open the engine cover. glycol to the recover tank if the coolant level is low.
When the engine is cool, loosen and remove the radiator One gallon and one pint of e thylene glycol mixed with
cap (Item 1) [Figure 10-90-1]. one gallon of water is the correct mixture of coolant to
provide a -34°F (-37°C) freeze protection.
Figure 10-90-2
Use a refractometer to check the condition of ethylene
glycol in your cooling system.
Fill the radiator with the premixed coolant until it is full.

1 Run the engine at idle speed for about 5-10 minutes to
remove the air from the cooling system (leave the
radiator cap off during this operation).
Stop the engine. Check the coolant level and add as

needed to bring it up to the radiator filler neck. Install the
radiator cap and tighten.
P-32806
Open the radiator drain valve (Item 1) [Figure 10-90-2] at

bottom of radiator. Drain the coolant into a container.

35 of 642

36 of 642
FUEL SYSTEM
Fuel Specifications
WARNING
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obe y warnings can cause an
The following is one suggested blending guideline which explosion or fire.
should prevent fuel gelling during cold temperatures: W-2063-0887
Figure 10-100-2
Temp. F° (C°) No. 2 No. 1
WRONG
+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
Contact your fuel supplier for local recommendations.
Filling The Fuel Tank
Figure 10-100-1

B-16575
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
1 SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].
P-32748
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285

37 of 642
FUEL SYSTEM (CONT'D)
Fuel Filter
WARNING
Figure 10-100-3
W-2103-1285
Figure 10-100-4
1
1
P-32774
See SERVICE SCHEDULE on Page 10-70-1 for the

service interval for removing water from, or replacing the
fuel filter.

Open the engine cover.
P-32774
Remove the filter element (Item 1) [Figure 10-100-3].

After replacing the filter element or when the fuel tank
Clean the area around the filter housing. Put clean oil on has run out of fuel, the air must be removed from the fuel
the seal of the new filter element. Install the fuel filter, and system before starting the engine.
hand tighten.
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
Remove the air from the fuel system. See “Removing Air housing.
From The Fuel System” on page 2.
Turn the engine over with the starter until fuel flows from
Removing Air From The Fuel System the vent with no air bubbles.
Close the vent (Item 1) [Figure 10-100-4].
WARNING
Diesel fuel or hydraulic fluid unde r pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496

38 of 642
ENGINE LUBRICATION SYSTEM Oil Chart
RECOMMENDED SAE VISCOSITY NUMBER
Checking Engine Oil
C ° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
Figure 10-110-1
P-32732
F ° TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CD, CF4, CG4)
* Can be used ONLY when available with appropriate diesel rating
Check the engine oil level every day before starting the
engine for the work shift.

Open the engine cover and remove the dipstick (Item 1)
[Figure 10-110-1].
Keep the oil level between the marks on the dipstick.
Engine oil is also used to provide engine cooling. Check

oil level every day for correct engine lubrication and
cooling.
Use a good quality motor oil that meets API Service

Classification of CD or better. See “Oil Chart” on page 1.

39 of 642
ENGINE LUBRICATION SYSTEM (CONT'D) Figure 10-110-3
Replacing Oil And Filter

service interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature. Stop

the engine.
1
Figure 10-110-2
P-32731
1 Remove the oil filter (Item 1) [Figure 10-110-3].
Clean the filter housing surface.
Use genuine Bobcat filter only.

Put oil on the new filter gasket. Install the filter and hand
P-32777 tighten.
Figure 10-110-4
Remove the drain plug (Item 1) [Figure 10-110-2].
Drain the oil into a container and dispose of used oil in an

1
environmentally safe manner.
Reinstall the drain plug.

2
WARNING
P-32732
W-2103-1285
Remove the fi ll cap (Item 1) [Figure 10-110-4]. Put 4.3

qts. (4 L) of oil in the engine.
Start the engine and let it run for several minutes.
Stop the engine and check for leaks at the oil filter.

40 of 642
ENGINE LUBRICATION SYSTEM (CONT'D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-5
P-32743
Remove the dipstick (Item 2) [Figure 10-110-4 on Page

10-110-2] and check the oil level. Add oil as needed if it is
not at the top mark on the dipstick (Item 1) [Figure 10-

110-5].
Install the dipstick and close the engine cover.

41 of 642

42 of 642
HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-3
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system.

(See HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.)
Put the loader backhoe on a level surface.
Remove the boom lock. (See Disengaging The Boom

Lock on Page 10-140-1.)
Retract the arm and bucket cylinders, put the bucket on

the ground.
Lower the lift arms and tilt the Bob-Tach fully back. P-32781
Stop the engine.

Check the condition of the fill strainer [Figure 10-120-3].
Figure 10-120-1 The screen must be installed in the fill neck when adding
oil.
Add the fl uid as needed to bring the level on the s ight

gauge to 2/3 to 3/4 full.

Install the fill cap (Item 1) [Figure 10-120-2].
Cleaning The Cooler
Figure 10-120-4
P-32749
1
Check the fluid level in the sight gauge [Figure 10-120-

1].
Figure 10-120-2
P-32797
The hydraulic oil cooler (Item 1) [Figure 10-120-4] is

located under the operator seat floor panel.
Use low air pressure or water pressure to clean the oil

cooler.
P-32782
Remove the fill cap (Item 1) [Figure 10-120-2].

43 of 642
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-7
Replacing Hydraulic/Hydrostatic Filter
See SERVICE SCHEDULE on Page 10-70-1 for the 1

Figure 10-120-5
2 1
1
P-33455
1
1 Remove the plastic spacer (Item 1) [Figure 10-120-7].
Figure 10-120-8
P-32802

1
Remove the four mounting bolts (Item 1) [Figure 10-120-
5] and cover (Item 2) [Figure 10-120-5].
Figure 10-120-6
1 P-33454
Remove the hydraulic filter element (Item 1) [Figure 10-

120-8] and dispose of in an enviromentally safe manner.
Install the new hydraulic filter, spacer and cap.
P-32803 Start the e ngine and operate the l oader hydraulic

controls.
Loosen and remove the hydraulic filter cap (Item 1) Stop the engine and check for leaks at the filter.
[Figure 10-120-6].
Install the floor panel (Item 2) [Figure 10-120-5] and four
mounting bolts (Item 1) [Figure 10-120-5].
Check the fluid level in the reservoir and add as needed.

44 of 642
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-9
Replacing Hydraulic Fluid
WARNING
Failure to use care around combustibles can cause 1
W-2103-1285
P-32809
WARNING Remove the fill cap.

Remove the dr ain plug (Item 1) [Figure 10-120-9] and
drain the fluid into a container.
Use a piece of cardboard or wood to find le aks. Do
Recycle or dispose of us ed fluid in an en vironmentally

safe manner.
W-2072-0496

45 of 642

46 of 642
REAR AXLE Draining Oil
Checking Oil Level Figure 10-130-2
Figure 10-130-1
P-32779
P-32778
With the machine on a level surface, remove the plug
(Item 1) [Figure 10-130-1]. The oil level should be at the With the machine on a le vel surface remove the plug
bottom edge of the plug hole.

(Item 1) [Figure 10-130-2] and drain into a c ontainer.
Recycle or dispose of the used lubricant in an
Add 9W-gear oil through the hole if the oil level is below environmentally safe manner.
the hole.
Install and tighten the plug.

47 of 642

48 of 642
BACKHOE BOOM LOCK Figure 10-140-2
Disengaging The Boom Lock
WARNING
AVOID CRUSHING HAZARD
• Do not lean over controls.
• Engage and disengage the boom loc k with the
engine off.
1
• Do not ope rate the loader controls from outside
the operators area.
W-2425-0302
P-32658
Figure 10-140-1
Raise the boom lock (Item 1) [Figure 10-140-2] and
reinstall the retainer (Item 2) [Figure 10-140-2].

P-32654
Slightly raise the backhoe boom to r elease pressure on

the boom lock.
Stop the engine, engage the parking brake and exit the
machine.
Remove the boom lock retaining pin (Item 1) [Figure 10-

140-1].

49 of 642
BACKHOE BOOM LOCK (CONT'D) Figure 10-140-5
Engaging Boom Lock
WARNING
AVOID CRUSHING HAZARD
• Do not lean over controls.
• Engage and disengage the boom loc k with the
engine off.
• Do not ope rate the loader controls from outside
the operators area. 1
W-2425-0302
P-32655
Figure 10-140-3
Remove the pin (Item 1) [Figure 10-140-4] and lower the
1 lock (Item 1) [Figure 10-140-5] onto the po st (Item 2)
[Figure 10-140-5].
Figure 10-140-6

2
P-32656
Raise the boom completely and align the hole (Item 1)

[Figure 10-140-3] in the lock with the post (Item 2)
[Figure 10-140-3]. P-32654
Stop the engine and exit the loader backhoe.

Install the pin (Item 1) [Figure 10-140-6].
Figure 10-140-4
P-32658

50 of 642
BOB-TACH HAND LEVER Figure 10-150-3
Inspection And Maintenance
Figure 10-150-1 Bob-Tach

Wedge
Wedge Must Contact

Lower Edge Of Hole
In The Attachment
B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]

P-32760 must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
Move the Bob-tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-150-1]. The levers and wedges must move freely. [Figure 10-150-2] and [Figure 10-150-3], the

attachment will be loose and can come off the Bob-Tach.
The wedges must extend through the holes in th e
attachment mounting frame (Item 1) [Figure 10-150-1]. Figure 10-150-4
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-2
TS-1062A
Inspect the mounting frame on th e attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
1
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.)
P-32757

51 of 642

52 of 642
ALTERNATOR BELT Figure 10-160-2
Adjusting The Alternator Belt
Figure 10-160-1
P-32795
1
Move the alternator until the belt has 5/16 inch (8,0 mm)
P-32730 movement at the middle of the belt span with 15 lbs. (66
N) of force [Figure 10-160-2].
Stop the engine. Tighten the adjustment and mounting bolts.
Loosen alternator mounting and adjustment bolts (Item 1)

[Figure 10-160-1].

53 of 642

54 of 642
LUBRICATING THE LOADER BACKHOE Figure 10-170-3
Lubricate the lo ader as specified in Contents, Page 10-

01 for the best performance of the loader.
Record the operating hours each time you lubricate the

loader backhoe.
3
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader backhoe.
Figure 10-170-1
P-32785
3. Lift Arm Pivot Pin (Both sides) [Figure 10-170-3]
Figure 10-170-4

1
P-32784
1. Rod End Lift Cylinder (Both sides) [Figure 10-170-1] 4
Figure 10-170-2
P-32787
4. Base End Tilt Cylinder (Both sides) [Figure 10-170-4]
P-32786
2. Base End Lift Cylinder (Both sides) [Figure 10-170-2]

55 of 642
LUBRICATING THE LOADER BACKHOE (CONT'D) Figure 10-170-7
Figure 10-170-5
10
7 10
P-32790
6
P-32788
10. Tie Rod Ends (Both sides) [Figure 10-170-7]
5. Rod End Tilt Cylinder (Both sides) [Figure 10-170-5] Figure 10-170-8
6. Bob-Tach Pivot Pin (Both sides) [Figure 10-170-5]

13
7. Bob-Tach Wedge (Both sides) [Figure 10-170-5]

Figure 10-170-6 12
11
9
P19384
8
11. Bucket Cylinder Rod End [Figure 10-170-8]
12. Dipper Arm Bucket Pivot [Figure 10-170-8]

P-32789
13. Bucket Link Pivot [Figure 10-170-8]
8. Front Axle (Both sides) [Figure 10-170-6]
9. Front Axle Pivot Pin [Figure 10-170-6] located in the

center of the front axle.

56 of 642
Figure 10-170-9
16
14
P-32727
P-32723
16. Arm Cylinder Base End [Figure 10-170-11]
14. Bucket Cylinder Base End [Figure 10-170-9] Figure 10-170-12
Figure 10-170-10

15
17
P-32725
P-32724
17. Boom Pivot Pin [Figure 10-170-12]
15. Arm Cylinder Rod End [Figure 10-170-10]

57 of 642
Figure 10-170-13
20
18
20
20
P-32793
P-32720
20. Swing Cylinder (Both sides) [Figure 10-170-15]
18. Arm Cylinder Base End [Figure 10-170-13] Figure 10-170-16
Figure 10-170-14

19
21
P-32718
P-32719
21. Boom Swing Pin [Figure 10-170-16]
19. Arm Cylinder Rod End [Figure 10-170-14]

58 of 642
Figure 10-170-17
24
22
P-32791
P-32721
24. Stabilizer Rod End [Figure 10-170-19]
22. Boom Pivot Pin [Figure 10-170-17] Figure 10-170-20
Figure 10-170-18

23
25
P-32728
P-32792
25. Stabilizer Pivot Pin [Figure 10-170-20]
23. Stabilizer Base End [Figure 10-170-18]

59 of 642
LUBRICATING THE LOADER BACKHOE (CONT'D)
Figure 10-170-21
26
P-33490
26. Parking Brake Cable [Figure 10-170-21].

60 of 642
TIRE MAINTENANCE Tire Pressure
Wheel Nuts
Figure 10-180-1
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
Front tire pressure - 36 PSI (250 kPa)

Rear tire pressure - 58 PSI (400 kPa)
Always replace the tires with the same size tires.
P-32762

service interval to check the wheel nuts. The correct
torque is 140 ft.-lb. (190 N•m) torque [Figure 10-180-1].

Mounting
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
Check the tires regularly for wear, damage and pressure.
Tires are to be repaired only by an authorized person

using the proper procedures and safety equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a

rubber lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

cause serious injury or death.
During inflation of th e tire, check the ti re pressure

frequently to avoid over inflation.

61 of 642

62 of 642
HYDRAULIC SYSTEM
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-9
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6 SYSTEM
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Arm Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Boom Swing Valve Section . . . . . . . . . . . . . . . . . . . . . . . 20-60-24
Boom Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-21 DRIVE
Tilt Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11 SYSTEM
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Inlet/Outlet Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Left Stabilizer Valve Section. . . . . . . . . . . . . . . . . . . . . . . 20-60-17
Outlet Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-27
Right Stabilizer Valve Section . . . . . . . . . . . . . . . . . . . . . 20-60-14

ELECTRICAL
SYSTEM &
ANALYSIS
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ENGINE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 SERVICE
BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1 SPECIFICATIONS

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-9
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-6
GEAR PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-5
HYDRAULIC FILTER HOUSING. . . . . . . . . . . . . . . . . . . . . . . 20-71-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-2

63 of 642
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . 20-70-1

Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-70-3
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-7
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Auxiliary Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-14
Inlet/Outlet Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5

Lift Arm Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Tilt Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-2
Testing The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-40-1
PORT RELIEF VALVE (BACKHOE CONTROL VALVE) . . . . . 20-41-1

Testing And Adjusting (Arm Control) . . . . . . . . . . . . . . . . . 20-41-1
Testing And Adjusting (Boom Control) . . . . . . . . . . . . . . . . 20-41-3
Testing And Adjusting (Boom Swing Control) . . . . . . . . . . 20-41-5
PORT RELIEF VALVE (LOADER CONTROL VALVE) . . . . . . 20-42-1

Testing And Adjusting (Bucket Tilt) . . . . . . . . . . . . . . . . . . 20-42-1
Testing And Adjusting (Front Auxiliary) . . . . . . . . . . . . . . . 20-42-3
STABILIZER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-10
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-7

64 of 642
HYDRAULIC SYSTEM (CONT’D)
STEERING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-9
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-6
STEERING PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-14
SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-8
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . 20-22-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Parts Identification (Left Side) . . . . . . . . . . . . . . . . . . . . . . 20-22-3

Parts Identification (Right Side) . . . . . . . . . . . . . . . . . . . . . 20-22-4
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-8
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Parts Identification (Left Side) . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Parts Identification (Right Side) . . . . . . . . . . . . . . . . . . . . . 20-30-4
TRAVEL PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

65 of 642

66 of 642
HYDRAULIC/HYDROSTATIC SCHEMATIC
B100 (S/N 570011001 AND ABOVE))
(S/N 570111001 AND ABOVE)
(PRINTED OCTOBER 2002)
V-0190le
LEGEND
1 HYDRAULIC RESERVOIR 18 ORIFICE (Arm Rod) 0.17 inch (4,3 mm)
Capacity . . . . . . . 54 Qts. (51 L)
19 RELIEF/REPLENISHING VALVE - HIGH
PRESSURE . . . . . . . 3625 PSI (24993 kPa)
2 SCREEN (Suction)
W/By-Pass . . . . . . . 4 PSI (30 kPa) 20 RELIEF VALVE - Charge Pressure
319 PSI (2199 kPa)
3 HYDRAULIC FILTER ELEMENT
N/A Micron 21 CHARGE PUMP
4 FILTER BY-PASS . . . . . . . 36 PSI (250 kPa) 6.7 GPM (25,4 L/min) at 3000 RPM
22 SHUTTLE VALVE - Control Pressure

5 DIFFERENTIAL PRESSURE SWITCH
N/A PSI (N/A kPa)

Normally Closed 23 RELIEF VALVE - Control Pressure
6 CHARGE BUILD-UP 24 SHUTTLE RELIEF VALVE
7 BREATHER/FILL CAP 25 DRIVE MOTOR SHUTTLE VALVE
8 OIL COOLER 26 NEUTRAL PRESSURE SWITCH
9 27 TOW VALVE
RELIEF VALVE (S/N 570011001 & Above)
. . . . . . . 2320 PSI (15996 kPa)
28 PRIORITY VALVE - Steering
RELIEF VALVE (S/N 570111001 & Above)
. . . . . . . 2465 PSI (16996 kPa)
10 PORT RELIEF VALVE 29 RELIEF VALVE
TILT CYLINDER (Rod & Base) 4060 PSI (27993 kPa)
30 RELIEF VALVE (2)
11 PORT RELIEF VALVE VARIABLE CAPACITY DISPLACEMENT BI-
AUXILIARY (Male & Female) 3625 PSI (24994 kPa) 31
DIRECTIONAL HYDROSTATIC PUMP
12 PORT RELIEF VALVE 32 SERVO PISTON - Swash Plate
BACKHOE SWING CYLINDER (Rod & Base)
2320 PSI (15996 kPa) 33 ORIFICE - 0.04 inch (1,0 mm)
13 ORIFICE (Swing Base & Rod) 0.10 inch (2,5 mm) 34 GEAR PUMP (S/N 570011001 & Above)
9.98 GPM (37,8 L/min) at 3000 RPM
14 PORT RELIEF VALVE
GEAR PUMP (S/N 570111001 & Above)
BACKHOE BOOM CYLINDER (Rod & Base) 11.76 GPM (44,6 L/min) at 3000 RPM
4060 PSI (27993 kPa)
35 ORIFICE (Lift Base) - 0.15 inch (3,7 mm)
15 ORIFICE (Boom Rod) 0.12 inch (3,0 mm)
16 LOAD CHECK VALVE (2)
17 PORT RELIEF VALVE NOTE: Unless otherwise specified

BACKHOE ARM CYLINDER (Rod & Base)
4060 PSI (27993 kPa)
springs have NO significant
pressure value.
Printed in U.S.A. V-0190le (10-3-02)
67 of 642
LOADER HYDRAULIC CONTROL VALVE BACKHOE HYDRAULIC CONTROL VALVE
HYDRAULIC/HYDROSTATIC SCHEMATIC
B100 (S/N 570011001 AND ABOVE) 13
(S/N 570111001 AND ABOVE) 10 10 12
TILT
(PRINTED OCTOBER 2002) SWING CYLINDERS
V-0190 9
LIFT
AUX
10 10
Printable Version Click Here 12
SWING 13
14
15
BOOM CYLINDER
P
RIGHT STABILIZER
14 16
BOOM
T LOCK VALVE
CYLINDER
35
R.H.
STABILIZER LOCK VALVE
HYDRAULIC FILTER GROUP
LEFT STABILIZER
3 4
8
FEMALE
CYLINDER
MALE
LIFT TILT FRONT AUXLIARY
CYLINDERS
IN CYLINDERS QUICK COUPLERS L.H.
STABILIZER
16
6 FOOT PEDAL BUCKET CYLINDER
5 25 BUCKET
OUT
ARM CYLINDER
1 P 17
7
T 2
FRONT STEERING
CYLINDER 24
2
1 26 23
HYDRAULIC OIL RESERVOIR 17
ARM 18
33
22
R/CF
DRIVE MOTOR
EF A
19
T 20 27
30 A WORKING CIRCUIT
GEAR PUMP
PILOT CIRCUIT
32 DRAIN CIRCUIT
P 31 B COMPONENTS
L 28 M
B
LOAD SENSING
STEERING UNIT 29
21 HYDROSTATIC PUMP GROUP 34
68 of 642 V-0190 (10-3-02)
HYDRAULIC SYSTEM INFORMATION

69 of 642
HYDRAULIC SYSTEM INFORMATION (CONT’D)

70 of 642
HYDRAULIC SYSTEM INFORMATION (CONT'D)

71 of 642

72 of 642
HYDRAULIC SYSTEM INFORMATION (CONT'D)
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The transmission warning light comes ON when hydraulics are operating. 1, 2
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Lift arms go up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The lift arms come down with the lever in neutral position. 7, 8, 9
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The hydraulic pump has damage.

3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.)
6. Using the loader for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

73 of 642
HYDRAULIC SYSTEM INFORMATION (CONT'D) Figure 20-10-2
Description
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-33422
Figure 20-10-1
The loader backhoe is equipped with two control valves.

1 The loader control valve (Item 1) [Figure 20-10-1] is
2 located under the operator seat and controls the loader
lift arm cylinders, bucket cylinders, front auxiliary
couplers and the optional rear auxiliary couplers.

The second control valve (backhoe control valve) (Item
1) [Figure 20-10-2] is located in the bac khoe control
panel. It controls the boom cylinder, arm cylinder, bucket
cylinder, swing cylinders and stabilizer cylinders.
There is one main relief valve (Item 2) [Figure 20-10-1]

that is located on the l oader control valve. It al so works
P-33329 as the main relief valve for the backhoe control valve.

74 of 642
ARM CYLINDER Figure 20-20-3
Checking
Set the bucket flat on the work surface.
Stop the engine. Engage the parking brake.
Figure 20-20-1
P-33742
With the parking brake engaged, start the engine and

2 fully retract the arm cylinder (Item 1) [Figure 20-20-3].
Stop the engine and engage the parking brake.
P-33739 With the engine off, move the backhoe control levers to

relieve hydraulic pressure.
Support the arm assembly with a ch ain hoist (Item 1)

[Figure 20-20-1].
Remove the pivot pin retainer bolt (Item 2) [Figure 20-

20-1] and nut.
Installation: Tighten the bolt to 18-19 ft.-lb. (24-26 N•m)

torque.
Figure 20-20-2
P-33740
Remove the pivot pin (Item 1) [Figure 20-20-2] and lower

the cylinder (Item 2) [Figure 20-20-2].

75 of 642
ARM CYLINDER (CONT’D)
Checking (Cont’d)
Figure 20-20-4
P-33744
Remove the h ose (Item 1) [Figure 20-20-4] from the

base of the cylinder.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Install a plug (Item 2) [Figure 20-20-4] on the hose and

tighten.
With the p arking brake engage, start the engine and

retract the arm cylinder.
If there is any leakage from the base end fitting (Item 3)

[Figure 20-20-4] on the arm cylinder, remove the
cylinder for repair or replacement.

76 of 642
ARM CYLINDER (CONT’D) Figure 20-20-6
Removal And Installation
Figure 20-20-5 1
2
P-33740
Remove the rod end pivot pin (Item 1) [Figure 20-20-6]

P-33739 and lower the cylinder.
Figure 20-20-7
Set the bucket flat on the ground. Install a hoist (Item 1)
[Figure 20-20-5] on the arm.

With the engine off, move the backhoe control levers to
Remove the bolt (Item 2) [Figure 20-20-5] and nut. 1

torque.
WARNING P-33743

sufficient force to enter a person’s body by Remove the two hoses (Item 1) [Figure 20-20-7].
immediately.
W-2145-0290
IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hos es,
damage the system.
I-2056-0793

77 of 642
Removal And Installation (Cont’d)
Figure 20-20-8
P-33745

20-8] and nut.

torque.
Figure 20-20-9
P-33746
Support the cylinder and remove the pivot pin (Item 1)

[Figure 20-20-9].
Remove the cylinder.

78 of 642
Parts Identification
1. Housing
2. Grease fitting
3. Bushing
4. Back-up ring
5. Seal
6. Piston
7. O-Ring
8. Head
9. Wiper
10. Rod
3 5

2
9
3 4
5
8
7
2
7
6
5
10
B-16969

79 of 642
Disassembly
1
Use the following tool to disassemble the cylinder:
MEL1075
Figure 20-20-10
P-36891
Remove the rod assembly (Item 1) [Figure 20-20-12]

from the housing.
Figure 20-20-13
P-36963

Put the base end of the cylinder in a vise [Figure 20-20-
10].
Figure 20-20-11
P-36892
Put the rod end of the cylinder in a vise [Figure 20-20-

13].
P-36890
Use a gland nut wrench (MEL 1075) and remove the

head gland (Item 1) [Figure 20-20-11].

80 of 642
Disassembly (Cont’d)
Figure 20-20-14 1
P-38035
Remove the ex pander band (Item 1) [Figure 20-20-16]

P-36893 from the piston.
Apply moderate heat to the piston/rod to break the loctite

Support the cylinder rod on a wood block [Figure 20-20- bond. Do not overheat.
14].

Figure 20-20-17
Figure 20-20-15
1
P-38033
P-36894
Use a gla nd nut wrench (MEL1075) and remove the

Remove the two wear rings (Item 1) [Figure 20-20-15] piston assembly (Item 1) [Figure 20-20-17] from the rod.
and seal (Item 2) [Figure 20-20-15] from the piston.

81 of 642
Figure 20-20-18 1
P-36897
Remove the two wea r rings (Item 1) [Figure 20-20-20]

P-36896 from the head.
Figure 20-20-21
Remove the O-ring (Item 1) [Figure 20-20-18].
Figure 20-20-19

1 2
1
P-36898
P-36900 Remove the wiper (Item 1) [Figure 20-20-21] and seal

(Item 2) [Figure 20-20-21] from the head.
Remove the head gland (Item 1) [Figure 20-20-19] from

the rod.

82 of 642
ARM CYLINDER (CONT’D) Assembly
Disassembly (Cont’d) Wash the cylinder parts in solvent and dry with
compressed air.
Figure 20-20-22
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
1
1 Lubricate all O-rings and seals with hydraulic oil during
2 installation.
Install the two O -rings (Item 1) [Figure 20-20-22] and

backup ring (Item 2) [Figure 20-20-22] on the head
gland.
Figure 20-20-23
P-36899 1
2
Remove the two O-rings (Item 1) [Figure 20-20-22] and

back-up ring (Item 2) [Figure 20-20-22] from the head.

P-36898
Install the wipe r (Item 1) [Figure 20-20-23] and seal

(Item 2) [Figure 20-20-23] in the head gland.
Figure 20-20-24
P-36897
Install the two w ear rings (Item 1) [Figure 20-20-24] in

the head.

83 of 642
Assembly (Cont’d) 1
Figure 20-20-25
P-36901
Install the expander band (Item 1) [Figure 20-20-27] onto

P-36900 the piston.
Figure 20-20-28
Install the head gland (Item 1) [Figure 20-20-25] onto the
cylinder rod. 2

Figure 20-20-26
1
P-36895
Install the two wear rings (Item 1) [Figure 20-20-28] and

P-36896 seal (Item 2) [Figure 20-20-28] onto the piston.
Install the O-ring (Item 1) [Figure 20-20-26] in the piston.

84 of 642
Assembly (Cont’d)
Figure 20-20-29 1
P-36890
Use a gla nd nut wrench (MEL1075) to tighten the head

P-36894 gland (Item 1) [Figure 20-20-31].
Clean and dry the cylinder rod threads and apply loctite
271 or equivelant. Install the piston (Item 1) [Figure 20-
20-29] onto the rod and tighten.

Figure 20-20-30
P-36891
Install the rod assembly (Item 1) [Figure 20-20-30] into

the housing.

85 of 642

86 of 642
BOOM CYLINDER Figure 20-21-2
Checking
Install the approved backhoe boom lock. (See Engaging

Boom Lock on Page 10-140-2.)
Operate the control levers to relieve hydraulic pressure. 2
WARNING 1
P-36212
penetrating the skin. This can cause serious injury Install a p lug (Item 1) [Figure 20-21-2] in the hose and
and possible death if proper medical treatment by a tighten.
immediately. With the parking brake engaged, start the engine and
W-2145-0290
retract the boom cylinder.

Figure 20-21-1 If there is any leakage from the base end fitting (Item 2)
[Figure 20-21-2] remove the cylinder for repair or
replacement.
P-36211

base end of the cylinder.

87 of 642
BOOM CYLINDER (CONT’D) Figure 20-21-4
Extend the ba ckhoe arm out, l ower the bo om to th e

ground.
Stop the engine, engage parking brake.
Operate control levers to relieve hydrualic pressure.
WARNING
P-36834
penetrating the skin. This can cause serious injury Start the engine. Fully retract the boom cylinder [Figure
and possible death if proper medical treatment by a 20-21-4].
immediately. Stop the engine. Operate control levers to relieve
W-2145-0290
hydraulic pressure.

Figure 20-21-3 Figure 20-21-5
P-36830 P-36833
Support the boom cylinder. Remove the pivot pin retainer Remove the pivot pin retainer bolt (Item 1) [Figure 20-
bolt (Item 1) [Figure 20-21-3]. Remove the pivot pin 21-5]. Remove the pivot pin (Item 2) [Figure 20-21-5].
(Item 2) [Figure 20-21-3].

torque.

88 of 642
BOOM CYLINDER (CONT’D)
Figure 20-21-6
P-36835
Slide the cylinder from the boom and remove the hoses
(Item 1) [Figure 20-21-6].

NOTE: Mark the hoses for correct assembly.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-21-7
P-36837
Remove the cylinder [Figure 20-21-7].

89 of 642
BOOM CYLINDER (CONT’D)
1. Housing
2. Grease fitting
3. Bushing
4. Piston
5. O-ring
6. Seal
7. Wiper
8. Seal
9. Back-up Ring
10. Head
11. Rod

2
3 3 6
5
8
5
10
9 2
4
3
11
8
B-16971

90 of 642
Disassembly
1
MEL1075
Figure 20-21-8
P-36891

from the housing.
Figure 20-21-11
P-36889

8].
Figure 20-21-9
P-36892

11].
P-36890


91 of 642
Figure 20-21-12 1
P-38035


12].

Figure 20-21-15
Figure 20-21-13
1
P-38033
P-36894


92 of 642
Figure 20-21-16 1
P-36897

Figure 20-21-19
Remove the O -ring (Item 1) [Figure 20-21-16] from the
piston.

Figure 20-21-17 2
1
P-36898
Remove the wip er (Item 1) [Figure 20-21-19] and seal

P-36900 (Item 2) [Figure 20-21-19] from the head.

the rod.

93 of 642
BOOM CYLINDER (CONT’D) Assembly
compressed air.
Figure 20-21-20
1
2 installation.

gland.
Figure 20-21-21
P-36899 1
2


P-36898

Figure 20-21-22
P-36897

the head.

94 of 642
Figure 20-21-23
P-36901

P-36900 the piston.
Figure 20-21-26
cylinder rod. 2

Figure 20-21-24
1
P-36895


95 of 642
Assembly (Cont’d)
Figure 20-21-27 1
P-36890


Figure 20-21-28
P-36891

the housing.

96 of 642
SWING CYLINDER Figure 20-22-2
Removal And Installation 1 1
Extend the backhoe arm out, lower boom to the ground.
Operate control levers to relieve hydraulic pressure. 1

2
Remove rear floor panel. (See Rear Panel Removal And

Installation on Page 50-30-2.)
Remove battery. (See Removal And Installation on Page

60-20-1.)
P-36845
WARNING Remove the five cylinder support bolts (Item 1) [Figure

20-22-2]. Remove the two grease fittings (Item 2)
[Figure 20-22-2].
sufficient force to enter a person’s body by Installation: Tighten the bolts to 55-60 ft.-lb. (75-85 N•m)
penetrating the skin. This can cause serious injury torque.

physician familiar with this injury is not received Figure 20-22-3
immediately.
W-2145-0290
Figure 20-22-1
1 1
1
P-36846
Remove the two hoses (Item 1) [Figure 20-22-3].

P-36844

22-1] on the arm. Remove the pivot pin (Item 2) [Figure
20-22-1].
IMPORTANT
Installation: Tighten the retainer bolt to 32-35 ft.-lb. (43-
47 N•m) torque. When making repairs on hydraulic system, clean the
clean. Always use caps and plugs on hoses,
damage the system.
I-2056-0793

97 of 642
SWING CYLINDER (CONT’D)
Figure 20-22-4
P-36873
Remove the cylinder (Item 1) [Figure 20-22-4].
Bushing Removal And Installation

Figure 20-22-5
P-36874
Inspect bushings and replace as necessary.
Remove the bushings (Item 1) [Figure 20-22-5].
NOTE: The direction of the bushings as it is removed

for correct assembly.
Installation: Install the bushings until they are flush with

the support

98 of 642
Parts Identification (Left Side)
1. Wiper
2. Seal
3. O-Ring
4. Piston
5. Housing
6. Grease Fitting
7. Head
8. Back-up Ring
9. Bushing
10. Rod
5

3 2
3 3
2
8
1
7
10
B-16975

99 of 642
Parts Identification (Right Side)
1. Wiper
2. Seal
3. O-Ring
4. Piston
5. Housing
6. Grease Fitting
7. Head
8. Back-up Ring
9. Bushing
10. Rod

2
4
3
3
8
3
7
2
2
1
10
B-16976

100 of 642
SWING CYLINDER (CONT’D) Figure 20-22-8
Disassembly
1
MEL1075
Figure 20-22-6
P-36891
Remove the rod assembly (Item 1) [Figure 20-22-8] from

the housing.
Figure 20-22-9
P-36946

Put the cylinder in a vise [Figure 20-22-6].
Figure 20-22-7
1 P-36892
Put the rod end of the cylinder in a vise [Figure 20-22-9].
P-36947


101 of 642
Figure 20-22-10 1
P-38035


10].

Figure 20-22-13
Figure 20-22-11
1
P-38033
P-36894
Remove the piston assembly (Item 1) [Figure 20-22-13]

Remove the two wear rings (Item 1) [Figure 20-22-11] from the rod.

102 of 642
Figure 20-22-14 1
P-36897

Figure 20-22-17
piston.

Figure 20-22-15 2
1
P-36898
Remove the wip er (Item 1) [Figure 20-22-17] and seal

P-36900 (Item 2) [Figure 20-22-17] from the head.

the rod.

103 of 642
SWING CYLINDER (CONT’D) Install the wipe r (Item 1) [Figure 20-22-19] and seal
Figure 20-22-20
Figure 20-22-18
1 1
1
2
P-36897
P-36899

Remove the two O-rings (Item 1) [Figure 20-22-18] and the head.

Figure 20-22-21
Assembly
Wash the cylinder parts in solvent and dry with 1

compressed air.

Lubricate all O-rings and s eals with hydraulic oil during

installation.

gland.
P-36900
Figure 20-22-19

cylinder rod.
1
2
P-36898

104 of 642
Figure 20-22-22
1
P-36895

Figure 20-22-25
Figure 20-22-23

1
1
P-36894
P-36901 Clean and dry the cylinder rod threads and apply loctite
the piston.

105 of 642
Assembly (Cont’d)
Figure 20-22-26
P-36891

the housing.

Figure 20-22-27
P-36947

gland (Item 1) [Figure 20-22-27].

106 of 642
BUCKET CYLINDER Figure 20-23-3
Checking
Set the bucket flat on the work surface.
Figure 20-23-1 1
P-33732
Remove the pivot pin (Item 1) [Figure 20-23-3].

2
Figure 20-23-4
P-33739

Support the arm with a chain hoist (Item 1) [Figure 20-
23-1].
1
Figure 20-23-2
P-33732
1
With the parking brake engaged, start the engine and

fully retract the bucket cylinder (Item 1) [Figure 20-23-4].
P-33731
Remove the pivot pin retainer bolt(Item 1) [Figure 20-23-

2].

torque.

107 of 642
BUCKET CYLINDER (CONT’D)
Checking (Cont’d)
Figure 20-23-5
P-33736

base end of the cylinder.

WARNING
immediately.
W-2145-0290

tighten.
With the p arking brake engage, start the engine and

retract the arm cylinder.
If there is any leakage from the base end fitting (Item 3)

[Figure 20-23-5] on the bucket cylinder, remove the

108 of 642
BUCKET CYLINDER (CONT’D) Figure 20-23-7
Figure 20-23-6
1
1
P-33735
Remove the two hoses (Item 1) [Figure 20-23-7] from

P-33739 the bucket cylinder.
Install caps and plugs.

Set the bucket flat on the wor k surface. Install a hoist
(Item 1) [Figure 20-23-6] on the arm. NOTE: Mark the hoses for correct assembly.

Relieve hydraulic pressure. Figure 20-23-8
WARNING
1
penetrating the skin. This can cause serious injury 1
immediately.
W-2145-0290
2
P-33731
IMPORTANT Remove the retainer bolt (Item 1) [Figure 20-23-8] from

the rod end pivot pin of the bucket cylinder.
work area before disassemble and keep all parts Installation: Tighten bolt to 1 8-19 ft.-lb. (24-26 N•m)
clean. Always use caps and plugs on hos es, torque.
damage the system. Remove the piviot pin (Item 2) [Figure 20-23-8].
I-2056-0793

109 of 642
Figure 20-23-9
P-33737

23-9].

Installation: Tighten bolt to 18-19 ft.-lb. (24-26 N•m)
torque.
Figure 20-23-10
P-33738
Support the cylinder, and remove the pivot pin (Item 1)

[Figure 20-23-10] from the bucket cylinder.
Remove the bucket cylinder.

110 of 642
1. Bushing
2. Grease fitting
3. Cover
4. Bolt
5. Seal
6. Back-up Ring
7. Head
8. Piston
9. O-ring
10. Wiper
11. Rod
12. Washer
4
12

2 5
1
7
6 10
1 7 5
9
9 1
9
5 2
11
B-16970

111 of 642
Disassembly
1
MEL1075
Figure 20-23-11
P-36891

from the housing.
Figure 20-23-14
P-36889

Remove cover before disassembly. Put the base end of
the cylinder in a vise [Figure 20-23-11].
Figure 20-23-12
P-36892

14].
P-36890


112 of 642
Figure 20-23-15 1
P-38035


15].

Figure 20-23-18
Figure 20-23-16
1
P-38033
P-36894


113 of 642
Figure 20-23-19 1
P-36897

Figure 20-23-22
Figure 20-23-20

1 2
1
P-36898


the rod.

114 of 642
BUCKET CYLINDER (CONT’D) Assembly
compressed air.
Figure 20-23-23
1
2 installation.

gland.
Figure 20-23-24
P-36899 1
2


P-36898

Figure 20-23-25
P-36897

the head.

115 of 642
Figure 20-23-26
P-36901

P-36900 the piston.
Figure 20-23-29
cylinder rod. 2

Figure 20-23-27
1
P-36895


116 of 642
Assembly (Cont’d)
Figure 20-23-30 1
P-36890


Figure 20-23-31
P-36891

the housing.

117 of 642

118 of 642
STABILIZER CYLINDER Figure 20-24-3
Checking
The procedure for checking the stabilizer cylinders is the 1

same. The right stabilizer is shown.
Figure 20-24-1
P-33757
Figure 20-24-4
P-33755

Lower the stabilizer to the work surface [Figure 20-24-1].
Figure 20-24-2
1
P-33758
Remove the cover bolt on t he back side of t he cover

[Figure 20-24-4]. Remove the cover (Item 1) [Figure 20-
24-4]

P-33756 torque.
Remove the pivot pin retaining bolt (Item 1) [Figure 20-

24-2].

torque.

119 of 642
STABILIZER CYLINDER (CONT’D) Figure 20-24-6
Checking (Cont’d)
Figure 20-24-5
P-33761
Remove the hose (Item 1) [Figure 20-24-6] from the

P-33760 base end of the cylinder.
Figure 20-24-7
Engage the parking brake and start the engine. Fully
retract the stabilizer cylinder (Item 1) [Figure 20-24-5].

Stop the engine. Move the hydraulic control levers to
release the hydraulic pressure.
WARNING 2

P-33762
immediately.
W-2145-0290
Install a plug (Item 1) [Figure 20-24-7] on the hose fitting
and tighten.
Engage the parking brake and start the eng ine. Retract
the stabilizer cylinder.
If there is any leakage from the fitting (Item 2) [Figure 20-

24-7], remove the cylinder for repair or replacement.

120 of 642
The procedure is the same for both stabilizer cylinders.

The right stabilizer is shown. 1
Figure 20-24-8
P-33756
Remove the retainer bolt (Item 1) [Figure 20-24-9].

torque.
P-33755
Figure 20-24-10

Lower the stabilizer to the work surface [Figure 20-24-8].
1
Relieve hydraulic pressure.
IMPORTANT
P-33757
damage the system.
I-2003-0888

121 of 642
Figure 20-24-11
1
1 P-33764

P-33758 24-13].

Remove the cover bolt on th e back side of t he cover torque.
[Figure 20-24-11].

Figure 20-24-14
Remove the cover (Item 1) [Figure 20-24-11].

torque.
Figure 20-24-12
1 P-33765
P-33761
Remove the two h oses (Item 1) [Figure 20-24-12] from

the stabilizer cylinder.
NOTE: Mark hoses for correct assembly.

122 of 642
STABILIZER CYLINDER (CONT’D)
Figure 20-24-15
P-33766
Remove the stabilizer cylinder [Figure 20-24-15].

123 of 642
STABILIZER CYLINDER (CONT’D)
1. Bushing
2. Bolt
3. Lock body
4. O-ring
5. Grease fitting
6. Housing
7. Seal
8. Piston 2
9. Head
10. Wiper
11. Rod
12. Back-up ring 6
3
4
4

10
1 7
7
9
5
4 1
12
4
5
4
8 11
7
B-16973

124 of 642
Disassembly
MEL1075
1
Figure 20-24-16
P-36968

from the housing.
Figure 20-24-19
P-36969

16]. Remove the load lock body (Item 1) [Figure 20-24-
16].
Figure 20-24-17
P-36842
1
19].
P-36967


125 of 642
Figure 20-24-20 1
P-38035


20].

Figure 20-24-23
Figure 20-24-21
1
P-38033
P-36894


126 of 642
Figure 20-24-24 1
P-36897

Figure 20-24-27
Figure 20-24-25

1 2
1
P-36898
P-36900 Remove the wip er (Item 1) [Figure 20-24-27] and seal


the rod.

127 of 642
STABILIZER CYLINDER (CONT’D) Assembly
compressed air.
Figure 20-24-28
1
2 installation.

gland.
Figure 20-24-29
P-36899 1
2


P-36898

Figure 20-24-30
P-36897

the head.

128 of 642
Figure 20-24-31
P-36901

P-36900 the piston.
Figure 20-24-34
cylinder rod. 2

Figure 20-24-32
1
P-36895


129 of 642
Assembly (Cont’d)
Figure 20-24-35 1
P-36890

Figure 20-24-38

Figure 20-24-36 1
P-36969
Install load lock body (Item 1) [Figure 20-24-38].
P-36891

the housing.

130 of 642
TILT CYLINDER Figure 20-30-2
Checking
Remove attachment from the Bob-Tach.
Lower the l ift arms to the g round, fully retract the tilt
cylinders.
Stop the engine, engage the parking brake. 2
Operate the control lever to relieve hydraulic pressure.

1
WARNING P-36974
Hydraulic fluid escaping under pressure can have Install a p lug (Item 1) [Figure 20-30-2] in the hose and
sufficient force to enter a person’s body by tighten.
and possible death if proper medical treatment by a With the parking brake engaged, start the engine and
physician familiar with this injury is not received retract the cylinder.
immediately.
W-2145-0290

Figure 20-30-1 If there is any leakage from the base end fitting (Item 2)
[Figure 20-30-2], remove the cylinder for repair or
replacement.
P-36973
Check only one cylinder at a t ime. Disconnect the hose

(Item 1) [Figure 20-30-1] from the b ase end of the tilt
cylinder.

131 of 642
TILT CYLINDER (CONT’D) Figure 20-30-4
Lower the lift arms to the ground.

1
Operate control levers to relieve hydraulic pressure.
WARNING 2

P-36975
and possible death if proper medical treatment by a Remove the pivot pin retainer bolt (Item 1) [Figure 20-
physician familiar with this injury is not received 30-4]. Remove the pivot pin (Item 2) [Figure 20-30-4].
immediately. Lower the cylinder.
W-2145-0290

Figure 20-30-3 torque.

Figure 20-30-5
1
2
P-36973
P-36976
NOTE: Mark the hoses for correct assembly. Remove the pivot pin retainer bolt (Item 1) [Figure 20-
30-5]. Remove the pivot pin (Item 2) [Figure 20-30-5].
Installation: Tighten the bolts to 32-35 ft.-lb. (43-47 N•m)

IMPORTANT torque.
Remove the cylinder.

damage the system.
I-2056-0793

132 of 642
TILT CYLINDER (CONT’D)
Parts Identification (Left Side)
1. Bushing
2. Grease fitting
3. Housing
4. Seal
5. Piston
6. O-ring
7. Back-up Ring
8. Head
9. Wiper 3
10. Rod
2
1

4
1 4
8
6
7
6
1
6
5 2
4
10
B-16977

133 of 642
TILT CYLINDER (CONT’D)
Parts Identification (Right Side)
1. Bushing
2. Grease fitting
3. Housing
4. Seal
5. Piston
6. O-ring
7. Back-up Ring
8. Head
9. Wiper 3
10. Rod
2
1

4
1 4
8
6
7
6
1
6
5 2
4
10
B-16977

134 of 642
Disassembly
1
MEL1075
Figure 20-30-6
P-36891

the housing.
Figure 20-30-9
P-36889

6].
Figure 20-30-7
P-36892
Put the rod end of the cylinder in a vise [Figure 20-30-9].
P-36890


135 of 642
Figure 20-30-10 1
P-38035


10].

Figure 20-30-13
Figure 20-30-11
1
P-38033
P-36894


136 of 642
Figure 20-30-14 1
P-36897

Figure 20-30-17
Figure 20-30-15

1 2
1
P-36898


the rod.

137 of 642
TILT CYLINDER (CONT’D) Assembly
compressed air.
Figure 20-30-18
1
2 installation.

gland.
Figure 20-30-19
P-36899 1
2


P-36898

Figure 20-30-20
P-36897

the head.

138 of 642
Figure 20-30-21
P-36901

P-36900 the piston.
Figure 20-30-24
cylinder rod. 2

Figure 20-30-22
1
P-36895


139 of 642
Assembly (Cont’d)
Figure 20-30-25 1
P-36890

Clean and the dry cylinder rod threads and apply loctite

Figure 20-30-26
P-36891

the housing.

140 of 642
LIFT CYLINDER Figure 20-31-2
Checking
Lower the lift arms. Stop the engine.
Engage the parking brake and exit the machine.
WARNING 1

P-33545
enters skin or eyes, get immediate medical attention Install a p lug (Item 1) [Figure 20-31-2] in the hose and
from a physician familiar with this injury. tighten.
W-2072-0496
Engage the parking brake. Start the engine and retract

Figure 20-31-1 the lift cylinder.

If there is any leakage from the fitt ing, remove the
P-33544
Check only one cylinder at a t ime. Disconnect the hose

(Item 1) [Figure 20-31-1] which goes to the base end of
the lift cylinder.

141 of 642
LIFT CYLINDER (CONT’D) Figure 20-31-5
Figure 20-31-3
P-33550
Remove the retainer bolt and nut (Item 1) [Figure 20-31-

P-33544 5] from the rod end pivot pin.
Installation: Tighten the retainer bolt and nut to 32-35 ft.-

Mark the hoses for correct installation. lb. (43-47 N•m) torque.

Install the caps and plugs.
WARNING
Figure 20-31-4
1
W-2103-1285
2
Figure 20-31-6
P-33548

31-4].

27 N•m) torque.
P-33553
Remove the pivot pin (Item 2) [Figure 20-31-4] and lower

the cylinder. Remove the rod end of the cylinder from the pivot pin
[Figure 20-31-6].

142 of 642
LIFT CYLINDER (CONT’D)
1. Bushing
2. Grease fitting
3. Housing
4. Seal
5. Piston
6. O-ring
7. Back-up ring
8. Head
9. Wiper
10. Rod
2 4
1

9
1
4
8
6
7
6
1
6 10
5 2
4
B-16972

143 of 642
Disassembly
1
MEL1075
Figure 20-31-7
P-36891

the housing.
Figure 20-31-10
P-36889

7].
Figure 20-31-8
P-36892

10].
P-36890


144 of 642
Figure 20-31-11 1
P-38035


11].

Figure 20-31-14
Figure 20-31-12
1
P-38033
P-36894


145 of 642
Figure 20-31-15 1
P-36897

Figure 20-31-18
Figure 20-31-16

1 2
1
P-36898


the rod.

146 of 642
LIFT CYLINDER (CONT’D) Assembly
compressed air.
Figure 20-31-19
1
2 installation.

gland.
Figure 20-31-20
P-36899 1
2


P-36898

Figure 20-31-21
P-36897

the head.

147 of 642
Figure 20-31-22
P-36901

P-36900 the piston.
Figure 20-31-25
cylinder rod. 2

Figure 20-31-23
1
P-36895


148 of 642
Assembly (Cont’d)
Figure 20-31-26 1
P-36890


Figure 20-31-27
P-36891

the housing.

149 of 642

150 of 642
STEERING CYLINDER Figure 20-32-2
Checking
Remove the grill. (See GRILL on Page 50-40-1.)

1
Remove the grill guard. (See GRILL FRAME on Page 50-
50-1.)
Figure 20-32-1
2 1
P-33566

tighten.
Start the engine and turn the steering wheel in the same
direction it was originally turned.

P-33565 If there is any leakage from the open port, remove the
The steering cylinder can be checked by fully turning the

steering wheel in either direction.
Start the engine and turn the steering wheel fully in either
direction. Stop the engine.
If the steering wheel was turned to th e left remove the

hose (Item 1) [Figure 20-32-1] from the steering cylinder.
If the steering wheel was turned to the right remove the
hose (Item 2) [Figure 20-32-1] from the steering cylinder.

151 of 642
STEERING CYLINDER (CONT’D) Figure 20-32-3
Remove the grill. (See GRILL on Page 50-40-1.) 1

1
Remove the grill guard. (See GRILL FRAME on Page 50-
50-1.)
Raise the lift arms and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)
WARNING P-33565
Hydraulic fluid escaping under pressure can have Remove the ho ses (Item 1) [Figure 20-32-3] from the
sufficient force to enter a person’s body by steering cylinder. Install caps and plugs.
and possible death if proper medical treatment by a Figure 20-32-4
immediately.
W-2145-0290

1
IMPORTANT 2
damage the system.
I-2056-0793
P-33570
Mark the hoses for correct installation.

Remove the nut (Item 1) [Figure 20-32-4] and washer
Relieve hydraulic pressure by turning the steering wheel (Item 2) [Figure 20-32-4] from the tie rod (both sides).
with the engine off.
Installation: Tighten the nut to 140-155 ft.-lb. (190-210
N•m) torque.

152 of 642
Figure 20-32-5
P-33573
Move the steering cylinder forward [Figure 20-32-7].

P-33571
Figure 20-32-8
Loosen the tie rod [Figure 20-32-5] (both sides).
Figure 20-32-6

1 1
P-33574
1 1
Remove the ti e rods (Item 1) [Figure 20-32-8].(Both
P-33572 sides.)
Remove the fo ur nuts (Item 1) [Figure 20-32-6] and

washers.

torque.

153 of 642
STEERING CYLINDER (CONT’D)
Figure 20-32-9
P-33575
Remove the steering cylinder [Figure 20-32-9].
Installation: Check the toe in on the loader backhoe

whenever the steering cylinder has been removed.

154 of 642
1. Wiper
2. Seal
3. Head
4. O-ring
5. Back-up ring
6. Housing
7. Grease fitting 1
8. Rod end
9. Rod and Piston 13
10. Nut
11. Snap ring 4
12. Bearing
13. Wear Ring 4 2
6 3

5
8
4
1 7
10
4
13
2 9
12 11
11 12
B-16974

155 of 642
Disassembly
Use the following tools to disassemble the cylinder: 1

2
MEL1074 - O-ring Seal Hook
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Special Offset Pins
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder.
Figure 20-32-10
P-33598
Mark or measure the location of t he bearing holders for

correct installation. Toe in adjustments will be affected by
the location of the bearing holders.
Loosen the jam nut (Item 1) [Figure 20-32-11] from the

rod end bearing holder and remove the bearing holder

(Item 2) [Figure 20-32-11] (both sides).
Figure 20-32-12
P-33597 1
Put the cylinder housing in a vise [Figure 20-32-10].
Be careful not to damage the cylinder housing.
P-33599
Remove the snap ring (Item 1) [Figure 20-32-12] from

the bearing holders.

156 of 642
Figure 20-32-13 1
P-33603
Remove the head (Item 1) [Figure 20-32-15] from the

P-33600 cylinder rod (both sides).
Figure 20-32-16
Remove the bearing (Item 1) [Figure 20-32-13].
Figure 20-32-14

1
P-33605
1

(Item 2) [Figure 20-32-16] from the heads.
Using the adjustable gland nut wrench (Item 1) [Figure

20-32-14] loosen the head (both sides).

157 of 642
Figure 20-32-17
1
P-33607
Remove the rod and piston assembly (Item 1) [Figure

P-33606 20-32-19] from the housing.
Figure 20-32-20
Remove the two wear rings (Item 1) [Figure 20-32-17]
from the heads.
1

Figure 20-32-18
P-33609
2 Remove the wear rings (Item 1) [Figure 20-32-20].

P-33604
Remove the O -rings (Item 1) [Figure 20-32-18] and

backup ring (Item 2) [Figure 20-32-18] from the heads.

158 of 642
STEERING CYLINDER (CONT’D) Assembly
Disassembly (Cont’d) Use the following tools to assemble the cylinder:
Figure 20-32-21 MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
MEL1075 - Adjustable Gland Nut Wrench
1 MEL1075-2 - Special Offset Pins
Piston Ring Compressor
Wash the cylinder parts in c lean solvent and dry with

compressed air.

Always install new O-rings, seals and nut during

assembly.
P-33615 Lubricate all O-rings and seals with hydraulic fluid during
assembly.
Remove the backup rings (Item 1) [Figure 20-32-21]. Figure 20-32-23
Figure 20-32-22

1 1
P-23442
P-33611
Install the seal (Item 1) [Figure 20-32-23] on the seal
expander.
Remove the seal (Item 1) [Figure 20-32-22].

159 of 642
Assembly (Cont’d)
1
Figure 20-32-24
1
3
2
1
2
3
2
P-33604
Install the O-rings (Item 1) [Figure 20-32-26] and backup

P-23649 ring (Item 2) [Figure 20-32-26] on the heads.
Figure 20-32-27
Figure 20-32-25

2 2 3
3
P-33606
B-16001
Install the wea r rings (Item 1) [Figure 20-32-27] in the

Install the seal (Item 1) [Figure 20-32-24] and [Figure heads.
20-32-25] on the piston.
Install the backup rings (Item 2) [Figure 20-32-24] and

[Figure 20-32-25] and wear rings (Item 3) [Figure 20-32-
24] and [Figure 20-32-25].

160 of 642
Assembly (Cont’d)
Figure 20-32-28
P-33605
Install the wiper (Item 1) [Figure 20-32-30] in the heads.

P7427
Figure 20-32-31
Install the rod seal on the rod seal tool [Figure 20-32-28].
NOTE: During installation, the spring side of the seal

must be toward the inside of the cylinder.
Rotate the handles to co llapse the r od seal [Figure 20-

32-28].
Figure 20-32-29
P-33614
Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-32-31].
P-23758
Install the rod seal in the head [Figure 20-32-29].

161 of 642
Figure 20-32-32
P-33602
Using the adjustable gland nut wrench (Item 1) [Figure

P-33607 20-32-34] tighten the h ead until it is flush with the
cylinder housing.
Clamp the cylinder housing in a vise. Figure 20-32-35
Use care not to damage the housing.

Install the rod and piston assembly (Item 1) [Figure 20-
32-32] into the housing. 1
Figure 20-32-33
P-33600
Install the bea ring (Item 1) [Figure 20-32-35] in the

bearing holder.
P-33603
Install the head (Item 1) [Figure 20-32-33] (both sides).

162 of 642
Assembly (Cont’d)
Figure 20-32-36
P-33599
Install the snap ring (Item 1) [Figure 20-32-36].
Figure 20-32-37

2 1
P-33598
Install the bearing holder (Item 1) [Figure 20-32-37] in its

original location. Tighten the jam nut (Item 2) [Figure 20-
32-37].(Both sides.)
NOTE: Toe in adjustment will be affected by the

location of the bearing holder.

163 of 642

164 of 642
MAIN RELIEF VALVE With the parking brake engaged, start the engine and run
at low RPM until the hydraulic fluid is at operating
Testing The Main Relief Valve temperature 140-160°F (60-71°C)
P-33329 P-32635
The main relief valve is located on the lo ader control With the hydraulic fluid at operating temperature, run the
valve under the operator seat. engine at fu ll RPM. Press the o perate button (Item 1)

[Figure 20-40-3]. Push the loader lift arm control lever
All testing is done with the hydraulic oil at ope rating forward until the loader lift arms are completely lowered.
temperature and engine at full RPM.
The main relief valve pressure should be 2320-2900 PSI
Block the front and rear of the Loader Backhoe. (See (17500 kPa).
LIFTING AND BLOCKING THE LOADER BACKHOE on
Page 10-10-1.) If adjustment is needed, (See Adjustment on Page 20-
40-2.)
Remove the o perator seat. (See OPERATOR SEAT on
Page 50-20-1.)

loader lift arm valve section.
Figure 20-40-2
P-33324
Install a tee fitting and gauge as shown to the loader lift

arm valve section [Figure 20-40-2].

165 of 642
MAIN RELIEF VALVE (CONT’D)
Adjustment
Figure 20-40-4
P-33326
Loosen and remove the cap (Item 1) [Figure 20-40-4].
Figure 20-40-5

1
P-33327
Turn the adjustment screw (Item 1) [Figure 20-40-5]

clockwise to increase the pressure or counterclockwise
to decrease the pressure.
NOTE: One 1/4 t urn in clockwise rotation will

increase the pressure approximately 300 PSI
(2069 kPa).
Install and tighten the cap (Item 1) [Figure 20-40-4].
Retest the main relief valve after adjustment.

166 of 642
PORT RELIEF VALVE (BACKHOE CONTROL VALVE) The correct reading should be:
Testing And Adjusting (Arm Control) Rod End 4000 PSI (27500 kPa)
Base End 4000 PSI (27500 kPa)
Figure 20-41-1
If the port relief pressure setting needs to be adjusted,

release the hand pump pressure valve.
Remove the cap (Item 1) [Figure 20-41-2].
1 Figure 20-41-3
1
P-33422
Remove the cover from the backhoe control panel.
A portable hydraulic hand pump will be used to test the

work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat P-33426
hydraulic fluid or use SAE 10W-30 motor oil.
Remove the hose (Item 1) [Figure 20-41-1] from the arm Remove the first locking plug (Item 1) [Figure 20-41-3].
control section.
Figure 20-41-2
P-33424
Install the hand pump hose and a pr essure gauge

minimum of 5000 PSI) into the valve section work port in
which the port relief valve is located [Figure 20-41-2].
Pressurize this section with the hand pump until the port
relief valve opens and make a note of the pressure
reading.

167 of 642
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)
(CONT’D)
Testing And Adjusting (Arm Control) (Cont’d)
Figure 20-41-4
P-33427
Turn the adjusting screw (Item 1) [Figure 20-41-4]

clockwise to increase the pressure and counterclockwise

to reduce the pressure.
NOTE: 1/4 turn is approximately 300 PSI (2069 kPa)

when the correct pressure setting is obtained,
tighten the locknut while holding the
adjustment screw from turning.
Adjust the port relief valve until the correct setting is

obtained.
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

168 of 642
(CONT’D)
Rod End 4000 PSI (27500 kPa)
Testing And Adjusting (Boom Control) Base End 4000 PSI (27500 kPa)
Figure 20-41-5
Figure 20-41-7
1
P-33422

work port relief valves. The hand pump must have clean P-33429
hydraulic fluid that is compatible with the Bobcat
Remove the first locking plug (Item 1) [Figure 20-41-7].
boom section.
Figure 20-41-6
P-33428

(minimum of 5000 PSI) into the valve section work port in
reading.

169 of 642
(CONT’D)
Testing And Adjusting (Boom Control) (Cont’d)
Figure 20-41-8
P-33430




obtained.
WARNING
W-2019-1285

170 of 642
(CONT’D)
Rod End 2320-2900 PSI (17500 kPa)
Testing And Adjusting (Boom Swing Control) Base End 2320-2900 PSI (17500 kPa)
Figure 20-41-9
Figure 20-41-11
1
P-33422

P-33432
hydraulic fluid that is compatible with the Bobcat Remove the cap (Item 1) [Figure 20-41-11].

boom swing section.
Figure 20-41-10
P-33431

reading.

171 of 642
(CONT’D)
Testing And Adjusting (Boom Swing Control)

(Cont’d)
Figure 20-41-12
P-33433



obtained.
WARNING
W-2019-1285

172 of 642
PORT RELIEF VALVE (LOADER CONTROL VALVE) The correct reading should be:
Testing And Adjusting (Bucket Tilt) Rod End 4000 PSI (27500 kPa)
Base End 4000 PSI (27500 kPa)
Figure 20-42-1

1 Figure 20-42-3
P-33330

Page 50-20-1.)

Remove the battery. (See BATTERY on Page 60-20-1.)
P-33340
hydraulic fluid that is compatible with the Bobcat Remove the first locking plug (Item 1) [Figure 20-42-3].

loader bucket tilt section.
Figure 20-42-2
P-33331

minimum of 5000 PSI) into the valve section work port in
reading.

173 of 642
PORT RELIEF VALVE (LOADER CONTROL VALVE)
(CONT’D)
Testing And Adjusting (Bucket Tilt) (Cont’d)
Figure 20-42-4
P-33341




obtained.
WARNING
W-2019-1285

174 of 642
PORT RELIEF VALVE (LOADER CONTROL VALVE) The correct reading should be:
(CONT’D)
Rod End 4000 PSI (27500 kPa)
Testing And Adjusting (Front Auxiliary) Base End 4000 PSI (27500 kPa)
Figure 20-42-5

1
Figure 20-42-7
P-33330

Page 50-20-1.)

Remove the battery. (See Removal And Installation on
Page 60-20-1.) P-33334

work port relief valves. The hand pump must have clean Remove the cap (Item 1) [Figure 20-42-7].
hydraulic fluid that is compatible with the Bobcat

front auxiliary valve section.
Figure 20-42-6
P-33333

reading.

175 of 642
(CONT’D)
Testing And Adjusting (Front Auxiliary) (Cont’d)
Figure 20-42-8
P-33335




obtained.
WARNING
W-2019-1285

176 of 642
LOADER CONTROL VALVE Figure 20-50-2
IMPORTANT
1
damage the system.
I-2003-0888
P-35373
Rotate the battery disconnect lever counterclockwise to Remove the dust cover (Item 1) [Figure 20-50-2].
disconnect the battery from the system.
Figure 20-50-3
With engine stopped, loader in lowered position, operate
the control levers to relieve hydraulic pressure.

Remove the operator seat. (See Removal And
Installation on Page 50-20-1.) 1
Figure 20-50-1 2
P-35372
Remove the bolt (Item 1) [Figure 20-50-3].

1
Loosen jam nut (Item 2) [Figure 20-50-3].
Remove the lever.

P-35370
Remove the auxiliary control lever (Item 1) [Figure 20-

50-1].

177 of 642
LOADER CONTROL VALVE (CONT’D)
Figure 20-50-4
P-33329
Remove the hoses [Figure 20-50-4] from the control

valve.

Figure 20-50-5
P-35371
Remove the 3 mounting bolts (Item 1) [Figure 20-50-5].
Installation: Tighten the bolts to 18 to 19 ft.-lb. (24 to 26

N•m) torque.
Remove the control valve.

178 of 642
3 2 1
4

7
P-38572
ITEM B100 LOADER BACKHOE

1 Inlet/Outlet Valve Section
2 Lift Arm Valve Section
3 Tilt Valve Section
4 Auxiliary Valve Section
5 Outlet Section
6 Port Relief
7 Main Relief

179 of 642
LOADER CONTROL VALVE (CONT’D) Figure 20-50-8
Disassembly And Assembly
IMPORTANT 1

damage the system. 1
I-2056-0793
2
P-38574
Figure 20-50-6
Remove the 3 locknuts (Item 1) and turnbuckles (Item 2)

[Figure 20-50-8].
Figure 20-50-9

2
P-38572
Mark all of the se ctions of the control valve for proper 1

installation [Figure 20-50-6].
P-38575
Remove all hydraulic fittings.
Figure 20-50-7 Remove the 5 bolts (Item 1) and mount bracket (Item 2)
[Figure 20-50-9].
1 2
P-38573
Remove the 3 bolts (Item 1) and control plate (Item 2)

[Figure 20-50-7].

180 of 642
LOADER CONTROL VALVE (CONT’D) Inlet/Outlet Valve Section
Disassembly And Assembly (Cont’d) Figure 20-50-12
Figure 20-50-10
1 P-38578
2
P-38576
Remove the inlet/outlet valve section (Item 1) [Figure 20-
50-12].
Remove the 4 bolts (Item 1) and plate (Item 2) [Figure
20-50-10]. Figure 20-50-13

Figure 20-50-11
1
1
P-38579
P-38577
Remove the 3 O -rings (Item 1) [Figure 20-50-13] from
the valve section.
Remove the thru-bolt nuts and washers (Item 1) [Figure
20-50-11].

181 of 642
Inlet/Outlet Valve Section (Cont’d)
Figure 20-50-14
4
3
1 2
1
P-38584
Remove the main relief valve assembly (Item 1), spring

P-38580 retainer (Item 2), spring (Item 3) and po ppet (Item 4)
[Figure 20-50-16].
Remove the plug (Item 1) [Figure 20-50-14] from the Figure 20-50-17
valve section.

Figure 20-50-15
3 2
1
P-38586
P-38582 Remove the O-ring (Item 1), cap (Item 2) and washer
(Item 3) [Figure 20-50-17].
Remove the O -ring (Item 1) [Figure 20-50-15] from the Measure and record the distance from the end of th e
plug. adjusting screw to the shoulder of the fitting [Figure 20-
50-17].

182 of 642
Figure 20-50-18
P-38589

P-38587 the valve section.
Figure 20-50-21
Remove the adjusting screw (Item 1) [Figure 20-50-18].
Lift Arm Valve Section

Figure 20-50-19
1
P-38590
1 Remove the retainer (Item 1) [Figure 20-50-21] from the

valve section.
P-38588
Remove the lift arm valve section (Item 1) [Figure 20-50-

19].

183 of 642
Lift Arm Valve Section (Cont’d)
Figure 20-50-22
1
1 P-38593
Remove the spool assembly (Item 1) [Figure 20-50-24].

P-38591
Figure 20-50-25
retainer.

Figure 20-50-23
2
1 P-38594
1 Remove the snap ring (Item 1) and cap (Item 2) [Figure

20-50-25].
P-38592
Remove the 4 bolts (Item 1) [Figure 20-50-23].

184 of 642
Lift Arm Valve Section (Cont’d)
Figure 20-50-26
1
2
3
6
4
5
1
P-38598
Remove the l arge spring retainer (Item 1), spring (Item

P-38596 2), small spring retainer (Item 3), washer (Item 4), and
bolt (Item 5) from the cover (Item 6) [Figure 20-50-28].
Use a flat blade screw driver to loosen the spring Figure 20-50-29
assembly (Item 1) [Figure 20-50-26].

Figure 20-50-27
4
3 1
2 P-38599
1
P-38597 Loosen the plug (Item 1) [Figure 20-50-29].
Remove the cover (Item 1), seal (Item 2) and O-ring

(Item 3) from the spool (Item 4) [Figure 20-50-27].

185 of 642
LOADER CONTROL VALVE (CONT’D) Tilt Valve Section
Lift Arm Valve Section (Cont’d) Figure 20-50-32
Figure 20-50-30
3
2 1
P-38602
P-38600
Remove the tilt valve section (Item 1) [Figure 20-50-32].
Remove the plug (Item 1), spring (Item 2) and poppet Figure 20-50-33
(Item 3) [Figure 20-50-30].

Figure 20-50-31
P-38603
P-38601 Remove the 3 O -rings (Item 1) [Figure 20-50-33] from

the bucket valve section.

plug.

186 of 642
Tilt Valve Section (Cont’d)
Figure 20-50-34
1 2 3
P-38607
Remove the 2 O-rings (Item 1), seal (Item 2) and cap

P-38604 (Item 3) [Figure 20-50-36].
Figure 20-50-37
Loosen the 2 port relief valves (Item 1) [Figure 20-50-
34].

Figure 20-50-35
2 1
1 1 P-38608
Remove the seal (Item 1) and O-ring (Item 2) from the

P-38605 actuating end of the spool (Item 3) [Figure 20-50-37].
Remove the 2 port relief valves (Item 1) [Figure 20-50-

35].

187 of 642
Figure 20-50-38
1
1
P-38611
1
Remove the spool assembly (Item 1) [Figure 20-50-40].
P-38609
Figure 20-50-41
Loosen the 2 bolts (Item 1) [Figure 20-50-38].
Figure 20-50-39

1
P-38612
1
2
Use a flat blade screw driver to loosen the bolt (Item 1)
P-38610 [Figure 20-50-41].
Remove the bolts (Item 1) and cover (Item 2) [Figure 20-

50-39].

188 of 642
Figure 20-50-42
3
2 1
6
P-38550
4 5
3
2 Remove the plug (Item 1), spring (Item 2) and poppet
1 P-38613 (Item 3) [Figure 20-50-44].
Figure 20-50-45
Remove the bolt (Item 1), spring retainer (Item 2), spring
(Item 3), spring retainer (Item 4), seal (Item 5) and O-ring

1
Figure 20-50-43
P-38601
1 Remove the O -ring (Item 1) [Figure 20-50-45] from the

plug.
P-38614
Loosen the plug (Item 1) [Figure 20-50-43].

189 of 642
Auxiliary Valve Section
Figure 20-50-46
2 1
P-38555
1
Lower the boot (Item 1) and loosen the pin (Item 2)

P-38551 [Figure 20-50-48].
Figure 20-50-49
Remove the auxiliary valve section (Item 1) [Figure 20-
50-46].

Figure 20-50-47
1 2 3
P-38556
1
Remove the pin (Item 1), boot (Item 2) and actuator (Item
P-38552 3) [Figure 20-50-49].

the auxiliary valve section.

190 of 642
Auxiliary Valve Section (Cont’d)
Figure 20-50-50
3 3
5
2
1
1
4
4
2
P-38559

Figure 20-50-53
Installation: Install the end of the actuator (Item 1) into
the hole (Item 2) in the spool. Align the hole (Item 3) in
the actuator with the pin holes (Item 4) and install the pin

(Item 5) [Figure 20-50-50].
Figure 20-50-51 1
1
1
P-38558
2
Remove the 4 bolts (Item 1) [Figure 20-50-53] from the
cover.
P-38557
Remove the 4 bolts (Item 1) and cover (Item 2) [Figure

20-50-51].

191 of 642
Figure 20-50-54
1 1
P-38563
2
P-38560 [Figure 20-50-56].
Figure 20-50-57
Remove the cover (Item 1) and spool assembly (Item 2)
[Figure 20-50-54].

Figure 20-50-55
3
2
2 1
P-38564
1
Remove the spacer (Item 1), bolt (Item 2) and cover
P-38561 (Item 3) [Figure 20-50-57].
Remove the snap ring (Item 1) and cap (Item 2) [Figure

20-50-55].

192 of 642
Auxiliary Valve Section (Cont’d) 1
Figure 20-50-58
1
P-38567

P-38565 60].
Figure 20-50-61
[Figure 20-50-58].

Figure 20-50-59
1
2
3
4
5 1
6 P-38568
7
Remove the port relief valves (Item 1) [Figure 20-50-61].
P-38566

193 of 642
Figure 20-50-62
2 3
1 3
2
1
P-38550
Remove the plug (Item 1), spring (Item 2) and poppet

P-38607 (Item 3) [Figure 20-50-64].
Figure 20-50-65
Remove the 2 O-rings (Item 1), cap (Item 2) and seal
(Item 3) [Figure 20-50-62] from each port relief valve.

Figure 20-50-63 1
P-38601
1
P-38570 plug.

194 of 642
BACKHOE CONTROL VALVE Figure 20-60-2
IMPORTANT 1

2
damage the system.
I-2003-0888
P-35376
Install the approved backhoe boom lock. (See Engaging
Boom Lock on Page 10-140-2.)
Disconnect the h arness connector (Item 1) and remove
Stop the engine, engage the parking brake. the cover (Item 2) [Figure 20-60-2].
Rotate the battery disconnect lever counterclockwise to Figure 20-60-3


Operate the control levers to relieve hydraulic pressure.
Figure 20-60-1
1
1
1
P-35377
1
Loosen the jam nuts (Item 1) [Figure 20-60-3] on the
control valve levers. Remove the levers.
P-35374
NOTE: Mark the control valve levers for installation.
Remove the 6 cover bolts (Item 1) [Figure 20-60-1].

195 of 642
BACKHOE CONTROL VALVE (CONT’D)
Figure 20-60-4
P-35390
Remove the hoses [Figure 20-60-4].

Figure 20-60-5
P-35378
Remove the four control valve mounting bolts (Item 1)

[Figure 20-60-5].
Installation: Tighten bolts to 18 to 19 ft.-lb. (24 to 26

N•m) torque.
Remove the control valve.

196 of 642
2 10
8 7 6 5 4 3
10

P-38946
ITEM B100 LOADER BACKHOE

1 Inlet/Outlet Valve Section
2 Lift Arm Valve Section
3 Bracket Valve Section
4 Right Stabilizer Valve Section
5 Left Stabilizer Valve Section
6 Boom Valve Section
7 Boom Swing Valve Section
8 Outlet Valve Section
9 Port Relief
10 Plug

197 of 642
BACKHOE CONTROL VALVE (CONT’D) Figure 20-60-7
IMPORTANT 1
3

tubelines and ports to keep dirt out. Dirt can quickly 1
I-2056-0793
2
P-38946
Figure 20-60-6
Remove the 6 bolts (Item 1) and remove the control plate

(Item 2). Mark all of the c ontrol valve sections (Item 3)
[Figure 20-60-7] for correct assembly.
Figure 20-60-8
2

1
1 1
1
P-38945
Remove the dust covers (Item 1) and remove all the

hydraulic fittings (Item 2) [Figure 20-60-6]. 2 1 1
2
NOTE: Mark location of fittings for correct assembly. P-38947
Remove the 6 lo ck nuts (Item 1) and tu rn buckle

hardware (Item 2) [Figure 20-60-8].

198 of 642
Disassembly And Assembly (Cont’d)
Figure 20-60-9
1 1
1 1 P-38950
1 1
2 2
Remove the thru-bolt nuts and washers (Item 1) [Figure
P-38948 20-60-11]
Installation: Tighten nuts to 32 to 3 5 ft.-lb. (43 to 4 7

Remove the 10 bolts (Item 1) and 2 mounting brackets N•m) torque.
(Item 2) [Figure 20-60-9].

Figure 20-60-10
1 1 1
1
1 1
2 2
P-38949
Remove the 8 bolts (Item 1) and 2 plates (Item 2) [Figure

20-60-10].
Assembly: Apply LOCTITE 242 or equivalent to threads

of bolts.

199 of 642
Inlet/Outlet Valve Section
Figure 20-60-12
P-38953
1
Remove the washer (Item 1) [Figure 20-60-14] from the

P-38951 plug. Inspect and replace as necessary.
Figure 20-60-15
Remove the inlet/outlet valve section (Item 1) [Figure 20-
60-12]

Figure 20-60-13
P-38954
1
Remove the plug (Item 1) [Figure 20-60-15] from the
P-38952 valve section.
Remove the 3 O-rings (Item 1) and plug (Item 2) [Figure

20-60-13] from the valve section.

200 of 642
Figure 20-60-16
P-38957
1

P-38955 plug. Replace as needed.

plug. Replace as needed.

Figure 20-60-17
P-38956
Remove the plug (Item 1) [Figure 20-60-17] from the

valve section.

201 of 642
Arm Valve Section
Figure 20-60-19
3
2
P-38960
1 Remove the seal (Item 1) and O-ring (Item 2) from the

Figure 20-60-22
Remove the arm valve section (Item 1) [Figure 20-60-
19].

Figure 20-60-20
1
P-38961
1
P-38959

the arm valve section.

202 of 642
Arm Valve Section (Cont’d)
Figure 20-60-23
7
6 5
4
3 2
1
2
P-38964
P-38962 (Item 3), spring retainer (Item 4), seal (Item 5) and O-ring
Remove the spool assembly (Item 1) and check the spool Figure 20-60-26
for scratches, or wear. Replace as needed. Remove the
cover (Item 2) [Figure 20-60-23].

Figure 20-60-24
1 P-38965

P-38963
Loosen the bolt (Item 1) [Figure 20-60-24].
Assembly: Tighten the bolt to 6 ft.-lb. (8,0 N•m) torque.

203 of 642
Arm Valve Section (Cont’d)

1
Figure 20-60-27
3
2 1
P-38968

P-38966 29].
Figure 20-60-30
Remove the plug (Item 1) spring (Item 2) and poppet
(Item 3) [Figure 20-60-27]. Check the spring and poppet
for damage or wear.

Figure 20-60-28
P-38969

30].
P-38967


204 of 642
BACKHOE CONTROL VALVE (CONT’D) Tilt Valve Section
Arm Valve Section (Cont’d) Figure 20-60-32
Figure 20-60-31
1
1
2 3 P-38971
P-38970
Remove the bucket valve section (Item 1) [Figure 20-60-
32].
Remove the 2 O-rings (Item 1). washer (Item 2) and cap
(Item 3) [Figure 20-60-31] Replace O-rings and washer Figure 20-60-33
as needed.

1
P-38972

the bucket valve section.

205 of 642
Figure 20-60-34
1 2
P-38975
3
2 Remove the spool assembly (Item 1) and check the spool

P-38973 for scratches or wear. Replace as needed. Remove the
Remove the seal (Item 1) and O-ring (Item 2) from the Figure 20-60-37
actuating end of the spool (Item 3) [Figure 20-60-34].

Figure 20-60-35
1
1
P-38963
1
P-38974 Loosen the bolt (Item 1) [Figure 20-60-37].


206 of 642
Figure 20-60-38
7 2 1
6 5
4
3 2
1
P-38977

P-38964 (Item 3) [Figure 20-60-40]. Check the spring and poppet
for damage or wear.
Remove the bolt (Item 1), spring retainer (Item 2) spring Figure 20-60-41
(Item 3), spring retainer (Item 4), seal (Item 5 and O-ring

Figure 20-60-39
P-38978
1

207 of 642
Right Stabilizer Valve Section
Figure 20-60-42
P-38981
1
Lower the boot (Item 1) and loosen the pin (Item 2)
P-38979 [Figure 20-60-44].
Figure 20-60-45
Remove the right stabilizer valve section (Item 1) [Figure
20-60-42]

Figure 20-60-43
1 2 3
P-38982
1
P-38980 3) [Figure 20-60-45].

the stabilizer valve section.

208 of 642
Right Stabilizer Valve Section (Cont’d)
Figure 20-60-46
2
3
5
1 3
4 1
2
4
P-38984

P-38571 actuating end of spool (Item 3) [Figure 20-60-48].
Figure 20-60-49
the hole (Item 2) in the spool. Align the hole (Item 3) in

(Item 5) [Figure 20-60-46].
Figure 20-60-47
1
1
P-38974
2
P-38983
Remove the 4 bolts (Item 1) and remove the cover (Item

2) [Figure 20-60-47].

209 of 642
Right Stabilizer Valve Section (Cont’d)

7
Figure 20-60-50
6
5
4
3
2
1 1
2
P-38987
Remove the bolt (Item 1), spring retainer (Item 2) spring

P-38985 (Item 3) spring retainer (Item 4), seal (Item 5) and O-ring
Remove the spool assembly (Item 1) and check the spool Figure 20-60-53
for scratches or wear. Replace as needed. Remove the

Figure 20-60-51
P-38614
1 Loosen the plug (Item 1) [Figure 20-60-53].

P-38986

210 of 642
BACKHOE CONTROL VALVE (CONT’D) Left Stabilizer Valve Section
Right Stabilizer Valve Section (Cont’d) Figure 20-60-56
Figure 20-60-54
3
2
1
P-38988
P-38550
Remove the left stabilizer valve section (Item 1) [Figure
20-60-56]
(Item 3) [Figure 20-60-54]. Check the spring and poppet Figure 20-60-57
for damage or wear.

Figure 20-60-55
P-38980
P-38601 Remove the 3 O -rings (Item 1) [Figure 20-60-57] from

the stabilizer valve section.


211 of 642
Left Stabilizer Valve Section (Cont’d)
Figure 20-60-58 3
5
1
4
4 2
P-38571
1

P-38981 the hole (Item 2) in the spool. Align the hole (Item 3) in
(Item 5) [Figure 20-60-60].
Lower the boot (Item 1) and l oosen the pin (Item 2)
[Figure 20-60-58]. Figure 20-60-61

Figure 20-60-59
P-38983
1 2 3
P-38982
2) [Figure 20-60-61].
3) [Figure 20-60-59].

212 of 642
Figure 20-60-62
1
2
2
3
P-38985
1
Remove the spool assembly (Item 1) and check the spool

P-38984 for scratches or wear. Replace as needed. Remove the
Remove the seal (Item 1) and O-ring (Item 2) from the Figure 20-60-65

Figure 20-60-63
1
1 P-38986
P-38974 Loosen the bolt (Item 1) [Figure 20-60-65].


213 of 642
Figure 20-60-66
7
3
6 2
1
5
4
3
2
1
P-38550

P-38987 (Item 3) [Figure 20-60-68]. Check the spring and poppet
for damage or wear.
Remove the bolt (Item 1), spring retainer (Item 2), spring Figure 20-60-69

Figure 20-60-67 1
P-38601
1
P-38614 plug. replace as needed.

214 of 642
Boom Valve Section
Figure 20-60-70
3 2
P-38960

P-38989 actuating end of the spool (Item 3) [Figure 20-60-72]
Figure 20-60-73
Remove the boom valve section (Item 1) [Figure 20-60-
70].

Figure 20-60-71
1
P-38961
1
P-38959

the boom valve section.

215 of 642
Boom Valve Section (Cont’d)
Figure 20-60-74
7
6 5
4 3 2
1
2
P-38964
P-38962 (Item 3), spring retainer (Item 4), seal (Item 5) and O-ring
Remove the spool assembly (Item 1). Check the spool for Figure 20-60-77
scratches or wear. Replace a needed. Remove the cover
(Item 2) [Figure 20-60-74].

Figure 20-60-75
P-38965
1

P-38963

216 of 642

1
Figure 20-60-78
3
2 1
P-38968
Loosen the 2 port relief valves (Item 1) [Figure 20-60-80]

P-38966
Figure 20-60-81

for damage or wear.

Figure 20-60-79
1
1
P-38969

81]
P-38967


217 of 642
Figure 20-60-82
P-38939
1
2 3
P-38970 the boom swing section.
Figure 20-60-85
Remove the 2 O-rings (Item 1), washer (Item 2) and cap
(Item 3) [Figure 20-60-82]. Replace O-rings and washer
as needed.

Boom Swing Valve Section 2
Figure 20-60-83
3
1
P-38936

1
P-38938
Remove the boom swing valve section (Item 1) [Figure

20-60-83].

218 of 642
Boom Swing Valve Section (Cont’d)
Figure 20-60-86
P-38963
1
P-38935
Remove the 2 bolts (item 1) [Figure 20-60-86]. Figure 20-60-89
Figure 20-60-87

7
6 5
4
3 2
1
1
P-38964
P-38940
Remove the bolt (Item 1), spring retainer (Item 2) spring
Remove the spool assembly (Item 1). Check the spool for (Item 6) from the spool (Item 7) [Figure 20-60-89].
scratches or wear. Replace as needed. Remove the

219 of 642
Boom Swing Valve Section (Cont’d)
Figure 20-60-90
1
P-38967
1
Remove the O-ring (Item 10 [Figure 20-60-92] from the
Figure 20-60-93
Figure 20-60-91

1
3
P-38942
2
1
P-38966 Loosen the 2 port relief valves (Item 1) [Figure 20-60-93]

for damage or wear.

220 of 642
BACKHOE CONTROL VALVE (CONT’D) Outlet Valve Section
Boom Swing Valve Section (Cont’d) Figure 20-60-96
Figure 20-60-94
1
P-38937
P-38943
Inspect outlet valve section (Item 1) and thru-bolts (Item
2) [Figure 20-60-96] for wear and damage. Replace as
Remove the 2 port relief valves (Item 1) [Figure 20-60- needed.
94].

Figure 20-60-95
2 3
1
P-38944
Remove the tw o O-rings (Item 1), washer (Item 2) and

cap (Item 3) [Figure 20-60-95] Replace O-rings and
washer as needed.

221 of 642

222 of 642
HYDRAULIC FLUID RESERVOIR Figure 20-70-2

2
3
Remove the right engine side cover. (See ENGINE SIDE
COVERS on Page 50-60-1.)
Rotate the battery disconnect lever counterclockwise to

Remove the front floor panels. (See FLOOR PANELS on

Page 50-30-1.)
1
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid
on Page 10-120-3.)
P-36815
Figure 20-70-1
Disconnect the h arness connector (Item 1) [Figure 20-

70-2].
Remove the hose (Item 2) [Figure 20-70-2] and two

tubelines (Item 3) [Figure 20-70-2].

Figure 20-70-3
1
P-36814 1
Remove the hose (Item 1) [Figure 20-70-1].
IMPORTANT
P-36818
Remove the front hose (Item 1) [Figure 20-70-3].

damage the system.
I-2056-0793

223 of 642
HYDRAULIC FLUID RESERVOIR (CONT’D)
Figure 20-70-4
P-36816A
Figure 20-70-5

1
P-36817
Support the reservoir. Remove the mounting bolts (Item

1) [Figure 20-70-4] & [Figure 20-70-5].
Installation: Tighten bolts to 32- 35 ft.-lb. (43-47 N•m)

torque.
Remove the reservoir.

224 of 642
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-70-8
Filter Removal And Installation 1
Remove the filter housing. (See HYDRAULIC FILTER

HOUSING on Page 20-71-1.)
Figure 20-70-6
P-36859
1
Remove the filter (Item 1) [Figure 20-70-8] from the inlet

tube.
NOTE: The strainer is threaded on to the tube.

P-36857
Figure 20-70-9

Remove the twelve reservoir cover bolts (Item 1) an d
hose (Item 2) [Figure 20-70-6].
Installation: Tighten bolts to 4-5 ft.-lb. (5-6 N•m) torque.
Figure 20-70-7
1
1
P-36860
Wash the filter in solvent and dry with compressed air.

Inspect filter for any damage. Inspect bypass (Item 1)
[Figure 20-70-9] for correct operation. Replace filter as
necessary.
P-36858
Reverse the removal procedure to install reservoir filter.
Remove the reservoir cover (Item 2) [Figure 20-70-7].

225 of 642

226 of 642
HYDRAULIC FILTER HOUSING Figure 20-71-2

1
disconnect the battery from the system. 1
Remove the right front floor panel. (See Right Front

Panel Removal And Installation on Page 50-30-1.)
Figure 20-71-1
1 P-36848
Remove the two mounting bolts (Item 1) [Figure 20-71-

2].
2 Installation: Tighten bolts to 32- 35 ft.-lb. (43-47 N•m)

torque.

Figure 20-71-3
P-36815
1
Remove the two tubelines (Item 1). Disconnect the
harness connector (Item 2) [Figure 20-71-1].
NOTE: Mark tubelines for correct assembly.
IMPORTANT
P-36849
parts clean. Always use caps and plugs on hoses, Remove the filter housing (Item 1) [Figure 20-71-3] from
tubelines and ports to keep dirt out. Dirt can quickly hydraulic reservoir.
damage the system.
I-2003-0888

227 of 642
Disassembly
Remove the fi lter housing (See “Removal And

Installation” on page 1.)
Figure 20-71-4
1
P-36852
Remove the spacer (Item 1) [Figure 20-71-6].
Figure 20-71-7
P-36850
2

Remove the O-ring (Item 1) [Figure 20-71-4] from the
base.
Figure 20-71-5
1 P-36853
Remove the bypass housing (Item 1) from the base (Item

2) [Figure 20-71-7].
P-36851

228 of 642
Figure 20-71-8
2 P-36856
Inspect the bypass valves and springs [Figure 20-71-

P-36854 10].
Assembly
Remove the filter (Item 1) from the bypass housing (Item
2) [Figure 20-71-8]. Wash filter housing parts in solvent and dry with

compressed air.
Figure 20-71-9
Inspect filter housing parts for damage. Replace any
damaged parts or replace assembly as necessary.
Figure 20-71-11
P-36855 2
Inspect the one way check valve (Item 1) in t he bypass

housing (Item 2) [Figure 20-71-9] for closing and free
P-36854
movement.
Install the filter (Item 1) into bypass housing (Item 2)

[Figure 20-71-11].

229 of 642
Assembly (Cont’d)
Figure 20-71-12
2
1
1
P-36851
Install the cover (Item 1) [Figure 20-71-14].

P-36853
Figure 20-71-15
Install the bypass housing (Item 1) into base (Item 2)

[Figure 20-71-12].

Figure 20-71-13
1
P-36850
Install the base O-ring (Item 1) [Figure 20-71-15].
P-36852 Install the filter housing into reservoir cover.
Install the spacer (Item 1) [Figure 20-71-13].

230 of 642
GEAR PUMP Figure 20-80-2

Page 50-30-1.)
IMPORTANT
When making repairs on hydraulic system, clean the 1
P-38126
damage the system.
I-2056-0793
Remove the lower hose (Item 1) [Figure 20-80-2].
Figure 20-80-3
WARNING

immediately.
W-2145-0290
1
Figure 20-80-1
P-38127
Remove the mounting bolts (Item 1) [Figure 20-80-3]
1 Remove the pump.
P-38125

231 of 642
GEAR PUMP (CONT’D)
1. BOLT
2. WASHER
3. COVER
4. O-RING SEAL
5. SEAL RING
6. BACKUP RING
7. HOUSING
8. GEAR HOLDER
9. DRIVE GEAR
10. IDLER GEAR
11. BOTTOM HOUSING

1
2
3
4
5 6 7
8
10
8 6
5
4
11
TS-01022

232 of 642
GEAR PUMP (CONT’D) Figure 20-80-5
Disassembly And Assembly 1

1
IMPORTANT
damage the system.
I-2003-0888
P-38109
Figure 20-80-4
Remove the four bolts (Item 1) [Figure 20-80-5] and

remove the cover.
Assembly: Tighten the bolts to 3 7- ft.-lb. (50 N•m)

torque.

Figure 20-80-6
1
1
P-38108 2
Mark the pump housing for correct assembly and remove

the fittings (Item 1) [Figure 20-80-4].
3
4
P-38111
Remove the gear holder (Item 1) from the housing (Item

2) [Figure 20-80-6].
Assembly: The position of the small opening (Item 3) on

the gear holders will point towards the port (Item 4)
[Figure 20-80-6] on the housing.

233 of 642
Figure 20-80-7 1
1
2
P-38116
Remove the both O-rings (Item 1) [Figure 20-80-9] from

P-38112 the housing.
Figure 20-80-10
Remove the backup ring (Item 1) and seal ring (Item 2)
[Figure 20-80-7] from the gear holder.

Assembly: The seal ring (Item 2) [Figure 20-80-7] is 1
installed onto the gear holder first, followed by the
backup ring.
Figure 20-80-8
P-38118
Remove both pump gears and holder (Item 1) [Figure

20-80-10] from the body.
P-38114
Remove the upper housing (Item 1) [Figure 20-80-8].

234 of 642

1
Figure 20-80-11
P-38120

P-38119 the bottom housing.
Remove the shaft seal (Item 2) [Figure 20-80-13].

Remove holder (Item 1) [Figure 20-80-11] from the
gears. Inspection

Figure 20-80-12 Clean all parts in clean solvent and use air pressure to
dry them. Do not use or paper because of small pieces of
material can get into the system and cause damage.
Inspect the drive gear and idler gear for rough surfaces
and wear.
1
2 Check the bushings in the end housings.
Replace the parts as needed.
P-38113
Remove the backup ring (Item 1) and seal ring (Item 2)

[Figure 20-80-12] from the gear holder.
Assembly: The seal ring (Item 2) [Figure 20-80-12] is

installed onto the gear holder first, followed by the
backup ring.

235 of 642

236 of 642
STEERING PUMP Figure 20-90-3

1
Figure 20-90-1
P-40164
Remove the steering wheel (Item 1) [Figure 20-90-3].

P-38015
Figure 20-90-4
Remove the steering wheel cover (Item 1) [Figure 20-90- 1

1
1].

Figure 20-90-2
1
1
1
2
P-38018
Remove the ten lower cover bolts (Item 1) [Figure 20-90-

4] and lower cover (Item 2) [Figure 20-90-4].
P-40163
Remove the nut and washer (Item 1) [Figure 20-90-2].
Installation: Tighten nut to 55-60 ft.-lb. (75-85 N•m)

torque.

237 of 642
STEERING PUMP (CONT’D) Figure 20-90-7
Removal And Installation (Cont’d) 1

1
Figure 20-90-5
1
1
2
2
P-40160

P-38082 7] and remove the instrument panel (Item 2) [Figure 20-
90-7].
Remove the harness connectors (Item 1) [Figure 20-90- Installation: Tighten bolts to 6-7 ft.-lb. (9-10 N•m) torque.
5]. Remove the cover (Item 2) [Figure 20-90-5].

Figure 20-90-8
Figure 20-90-6
1 1
P-38083
P-38004
Remove the ho ses (Item 1) [Figure 20-90-8] from the

Disconnect the ha rness connector (Item 1) [Figure 20- steering pump.
90-6].
NOTE: Mark the connectors for correct assembly.
IMPORTANT
damage the system.
I-2003-0888

238 of 642
STEERING PUMP (CONT’D)
Figure 20-90-9
P-38020
Remove the four steering pump mounting nuts and

washers (Item 1) [Figure 20-90-9].

Installation: Tighten nuts to 32-35 ft.-lb. (43-47 N•m)
torque.
Figure 20-90-10
P-38021
Remove the steering pump (Item 1) [Figure 20-90-10].

239 of 642
1. Bolt
2. End Cap
3. Spacer Washer
4. O-Ring
1
5. Geroler Assembly
6. Drive Shaft
7. Valve Plate
8. Spool
9. Sleeve 3 2
10. Springs
11. Drive Pin
4
12. Spool
13. Check Ball 5
14. Housing 6
15. Thrust Washer
16. Thrust Bearing
17. Guad Ring
4
18. Seal Housing
19. Seal 7

20. Ball Seat
21. Poppet 4
22. Spring
8 10
23. Plug
24. Ball Retainer
25. Washer
26. Spring Seat
21
23
22
26 4
25
23
9
13
20
11
22
24
23
24
13
14
15
16
12
15
17 13
4 13
20
18
19 22
23 24 MS1525

240 of 642
Disassembly
Figure 20-90-11
1
1
1
1
P-38076
2
Remove the two pr iority valve mounting bolts (Item 1)
P-38074 [Figure 20-90-13].
Remove the priority valve.

Remove the four nuts and washers (Item 1) [Figure 20-
90-11] and remove the steering shaft (Item 2) [Figure Figure 20-90-14
20-90-11].

1
Figure 20-90-12
P-38077
P-38075 Remove the five O-rings (Item 1) [Figure 20-90-14] from

the priority valve.
Mark the housing for correct assembly [Figure 20-90-

12].
IMPORTANT
damage the system.
I-2003-0888

241 of 642
Figure 20-90-15
1
1
2
3
4
2
5
P-38037
Mark the location of the metering spool (Item 1) [Figure

P-38081 20-90-17] and remove.
Figure 20-90-18
Remove the plug (Item 1) [Figure 20-90-15], washers
(Item 2) [Figure 20-90-15], spool (Item 3) [Figure 20-90-
15], spring (Item 4) [Figure 20-90-15] and valve cap

(Item 5) [Figure 20-90-15] from the housing. 1
Figure 20-90-16 1
P-38038
Remove the s ix end cap bolts and washers (Item 1)

[Figure 20-90-18].
P-38036
Mark the pump housing for correct assembly [Figure 20-

90-16].

242 of 642
Figure 20-90-19
1
P-38041
Remove the spacer washer (Item 1) [Figure 20-90-21].

P-38039
Figure 20-90-22
Remove the end cap (Item 1) [Figure 20-90-19].

1
Figure 20-90-20

1
P-38042
Remove the geroler assembly assembly (Item 1) [Figure

P-38040 20-90-22].
Remove and discard the O-ring (Item 1) [Figure 20-90-

20].

243 of 642
1
Figure 20-90-23
P-38045
Remove the valve plate (Item 1) [Figure 20-90-25].

P-38043
Figure 20-90-26

geroler assembly.
1

Figure 20-90-24
P-38046

housing.
P-38044
Remove the drive shaft (Item 1) [Figure 20-90-24].

244 of 642
1
Figure 20-90-27
P-38051
Remove the c heck ball (Item 1) [Figure 20-90-29] from

P-38047 each port.
Figure 20-90-30
Mark the location of the two ports (Item 1) [Figure 20-90-
27] for correct assembly.

Figure 20-90-28
P-38052
Remove the ball retainer (Item 1) [Figure 20-90-30].

P-38048
Remove the spool (Item 1) [Figure 20-90-28] from each

port.

245 of 642
Figure 20-90-31
3 2 1
P-38070
Remove the thick washer, (Item 1) [Figure 20-90-33],

P-38053 thrust bearing (Item 2) [Figure 20-90-33] and washer
(Item 3) [Figure 20-90-33] from the spool.
Remove the check ball (Item 1) [Figure 20-90-31]. Figure 20-90-34
Figure 20-90-32

2
1
3
P-38072
P-38069
Remove the drive pin (Item 1) [Figure 20-90-34].
Remove the control spool/sleeve assembly (Item 1)

[Figure 20-90-32] from the metering end of the housing
(Item 2) [Figure 20-90-32].
NOTE: When removing the spool, keep the drive pin

(Item 3) [Figure 20-90-32] horizontal. If the pin
becomes vertical, it may drop from the spool
and get caught in a n oil pa ssage inside the
housing.

246 of 642
Figure 20-90-35
1
2
P-38055
Remove the seal (Item 1) [Figure 20-90-37] and discard.

P-38073
Figure 20-90-38
Remove the s pool (Item 1) [Figure 20-90-35] from the

sleeve (Item 2) [Figure 20-90-35].

NOTE: If the spool and sleeve will not slide or rotate
within each other freely or in the housing,
they must be replaced.
1
Figure 20-90-36
1
P-38056
Remove the O-ring/quad ring (Item 1) [Figure 20-90-38]

and discard.
P-38096
Remove the springs (Item 1) [Figure 20-90-36] from the

spool.
NOTE: There are six springs positioned three per side

and back to back.

247 of 642
Figure 20-90-39
1
P-38062
Remove the spring (Item 1) [Figure 20-90-41].

P-38064
Figure 20-90-42
Remove the plug (Item 1) [Figure 20-90-39].
NOTE: The following procedures will be performed on

the second port (Item 2) [Figure 20-90-39]. 1
Figure 20-90-40
1
P-38061
Remove the poppet (Item 1) [Figure 20-90-42].
P-38063
Record the number of turns, while turning the plug (Item

1) [Figure 20-90-40] in to seat it. Record the number of
turns for correct assembly.
Remove the plug.

248 of 642
1
Figure 20-90-43
P-38067
Remove the check valve (Item 1) [Figure 20-90-45].

P-38060
Figure 20-90-46
Remove the check ball (Item 1) [Figure 20-90-43].

1
Figure 20-90-44

4 5
3
2
1
P-38068
Remove the O -ring (Item 1) [Figure 20-90-46] and

P-38066 discard.
Remove the plug (Item 1) [Figure 20-90-44], washer

(Item 2) [Figure 20-90-44], spring seat (Item 3) [Figure
20-90-44], spring (Item 4) [Figure 20-90-44] and poppet
(Item 5) [Figure 20-90-44] from the housing.

249 of 642
STEERING PUMP (CONT’D) Assembly
Inspection
Figure 20-90-47
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly, clean and lightly oil all parts.

2
Figure 20-90-49
1
P-38073
1
Inspect the spool (Item 1) [Figure 20-90-47] and sleeve

(Item 2) [Figure 20-90-47] for any damage or wear.
Replace as needed.

Figure 20-90-48
1 P-38068
Install the O-ring (Item 1) [Figure 20-90-49].
Figure 20-90-50
P-38098
Inspect the drive shaft (Item 1) [Figure 20-90-48] for

damage or wear.
P-38067
Install the check valve (Item 1) [Figure 20-90-50] and

tighten until fully seated.

250 of 642
Assembly (Cont’d)
Figure 20-90-51
1
5 4
P-38061
1
2
3 Install the poppet (Item 1) [Figure 20-90-53].
P-38066
Figure 20-90-54
Install the poppet (Item 1) [Figure 20-90-51], spring

(Item 2) [Figure 20-90-51], spring seat (Item 3) [Figure
20-90-51], washer (Item 4) [Figure 20-90-51] and plug

(Item 5) [Figure 20-90-51] into the port. 1
Figure 20-90-52
P-38062
Install the spring (Item 1) [Figure 20-90-54].
P-38060
Install the check ball (Item 1) [Figure 20-90-52] into the

port.
NOTE: The following procedures will be performed on

the second port.

251 of 642
Assembly (Cont’d)
Figure 20-90-55
1
1
P-38056
Install the quad ring/O-ring seal assembly (Item 1)

P-38063 [Figure 20-90-57].
Figure 20-90-58
Install the plug (Item 1) [Figure 20-90-55] the correct
number of turns recorded earlier.

Figure 20-90-56 1
P-38055
Install the seal (Item 1) [Figure 20-90-58].

P-38064
Install the plug (Item 1) [Figure 20-90-56].

252 of 642
Assembly (Cont’d)
Figure 20-90-59
P-38072
Install the drive pin (Item 1) [Figure 20-90-61].

P-38096
Figure 20-90-62
Install the springs (Item 1) [Figure 20-90-59] into the

spool.

NOTE: There are six springs and should be 3 1
positioned three per side and back to back.
Figure 20-90-60
1
2
P-38071
Install the thick washer (Item 1) [Figure 20-90-62], thrust

bearing (Item 2) [Figure 20-90-62] and washer (Item 3)
[Figure 20-90-62] onto the spool.
P-38073
Install the s pool (Item 1) [Figure 20-90-60] into the

sleeve (Item 2) [Figure 20-90-60].
NOTE: The spool should turn freely inside the sleeve.

253 of 642
Assembly (Cont’d)
Figure 20-90-63
1
2
1
P-38052
3
Install the check ball retainer (Item 1) [Figure 20-90-65]
P-38069 and tighten.
Figure 20-90-66
Install the control spool/sleeve assembly (Item 1) [Figure
20-90-63] into the metering end of the housing (Item 2)
[Figure 20-90-63].

1
NOTE: When installing the spool assembly keep the
drive pin (Item 3) [Figure 20-90-63] horizontal.
If the pin becomes vertical it ma y drop from
the spool and get caught in an oil passage
inside the housing.
Figure 20-90-64
1 P-38051
Install the check ball (Item 1) [Figure 20-90-66] in each

port.
P-38053
Install the check ball (Item 1) [Figure 20-90-64] in the

port.

254 of 642
Assembly (Cont’d)
Figure 20-90-67 1
P-38045
Install the valve plate (Item 1) [Figure 20-90-69].

P-38048
Figure 20-90-70
Install the spool (Item 1) [Figure 20-90-67] in each port. 3
Figure 20-90-68

1 1
2
P-38099
NOTE: The pin (Item 2) [Figure 20-90-70] must be

P-38046 parallel with the housing (Item 3) [Figure 20-
90-70].
Install the O-ring (Item 1) [Figure 20-90-68] in the Align the g roove (Item 1) [Figure 20-90-70] in the drive
housing. shaft with the drive pin (Item 2) [Figure 20-90-70] and
install the drive shaft.

255 of 642
Assembly (Cont’d)
Figure 20-90-71
1
P-38041
Install the spacer washer (Item 1) [Figure 20-90-73].

P-38043
Figure 20-90-74
Install the O-ring (Item 1) [Figure 20-90-71] on th e

geroler assembly.
1

Figure 20-90-72
2
2
P-38040
3 Install the O-ring (Item 1) [Figure 20-90-74].
P-38042
Align the marks on the housing and install the geroler

assembly (Item 1) [Figure 20-90-72] onto the valve plate
and drive shaft.
NOTE: The star valleys (Item 2) [Figure 20-90-72] must

be parallel with the housing (Item 3) [Figure
20-90-72].

256 of 642
2
Figure 20-90-75
3
4
1 2 5
P-38081
Install the plug (Item 1) [Figure 20-90-77], washer (Item

P-38038 2) [Figure 20-90-77], spool (Item 3) [Figure 20-90-77],
spring (Item 4) [Figure 20-90-77] and valve cap (Item 5)
[Figure 20-90-77] into the housing.
Align the ma rks made earlier and i nstall the en d cap
using the six bolts (Item 1) [Figure 20-90-75]. Do no t Figure 20-90-78
tighten the bolts at this time.

1
Figure 20-90-76
1
1
P-38077
P-38037 Install the five O-rings (Item 1) [Figure 20-90-78] onto

the priority valve.
Install the metering spool (Item 1) [Figure 20-90-76].

Tighten metering spool and bolts to 8-13 ft.-lb. (5.9-9.5
N•m) torque in a criss cross pattern.

257 of 642
Assembly (Cont’d)
Figure 20-90-79
P-38076
Install the priority valve (Item 1) [Figure 20-90-79] onto

the pump housing and tighten the two bo lts (Item 2)
[Figure 20-90-79] to 8 ft.-lb. (5.9 N•m) torque.

Figure 20-90-80
P-38074
Install the steering shaft onto the steering pump and

tighten the four studs (Item 1) [Figure 20-90-80] to 13 ft.-
lb. (9.5 N•m) torque.

258 of 642
TRAVEL PEDAL Figure 20-100-2
Stop the engine, engage the parking brake.

Remove the front floor panels. (See FLOOR PANELS on

Page 50-30-1.) 1 1
IMPORTANT P-38095

clean the work area before disassembly and keep all Remove the 4 mounting bolts (Item 1) [Figure 20-100-2].
tubelines and ports to keep dirt out. Dirt can quickly Installation: Tighten bolts to 18 to 19 ft.-lb. (24 to 26
damage the system. N•m) torque.
I-2003-0888
Remove the travel pedal.

Figure 20-100-1
1
P-38091
Remove the 4 hoses (Item 1) [Figure 20-100-1].

259 of 642
TRAVEL PEDAL (CONT’D)
1. Safety Tread
2. Retainer Clip 4
1
3. Pedal Angle Plate
4. Bolt 12 2
5. Pin 3
6. Nut
7. Set Screw 13
8. Adjustment Screw
9. Pedal 5
10. Washer 14
11. Mount Plate
12. Retainer Plate 6
15 4
13. Plunger Housing 2
7
14. Seal
6
15. O-ring 16
16. Plunger
17. Piston 8

18. Spring 2
19. spool 9
20. Plug 2
21. Housing
17 5
18 4
4
10
10
19
11
20
21
MS2112S

260 of 642
TRAVEL PEDAL (CONT’D) Figure 20-100-5
Figure 20-100-3 4
1 1 3
3
2
2
P-38160
Back the set screw (Item 1) o ut of the pin (Item 2).

P-38155 Remove the pin (Item 3) and pedal (Item 4) [Figure 20-
100-5].
Remove the 2 retainer clips (Item 1) and pins (Item 2) Installation: Algin the set screw (Item 1) with the hole in
(both sides).Remove the ped al angle plate (Item 3) the pin (Item 2) [Figure 20-100-5].
[Figure 20-100-3].

Figure 20-100-6
Figure 20-100-4
1
1
P-38161
P-38157
Remove the 4 bolts (Item 1) and the mount plate (Item 2)

Loosen the locknut (Item 1) and set screw (Item 2) [Figure 20-100-6].
[Figure 20-100-4].

261 of 642
Figure 20-100-7 1 3
2
P-38164
Remove the retainer plate (Item 1) and rod (Item 2) from

1
P-38162 the plunger housing (Item 3) [Figure 20-100-9].
Remove the 2 bolts (Item 1) from both plunger

assemblies (Item 2) [Figure 20-100-7].

NOTE: The plunger assemblies are under spring
pressure and may b ecome dislodged when
the bolts are removed.
Figure 20-100-8
P-38163
Remove the 2 plunger assemblies (Item 1) [Figure 20-

100-8].

262 of 642
Figure 20-100-10
1
P-38168
Remove the retainer (Item 1) [Figure 20-100-12] from

P-38165 the rod.
Figure 20-100-13
Figure 20-100-11

1
1
P-38169
P-38167
Remove the 2 spool assemblies (Item 1) [Figure 20-100-

Remove the O-ring (Item 1) and seal (Item 2) [Figure 20- 13].
100-10] from the plunger housing.
Installation: Make sure the lip (Item 1) [Figure 20-100-

11] on the s eal is installed to the i nside of the pl unger
body.

263 of 642
Figure 20-100-14
1
1
2
P-38172
Remove the 2 springs (Item 1) [Figure 20-100-16].

P-38170
Figure 20-100-17
Compress the spring (Item 1) to remove the r etainer

(Item 2) [Figure 20-100-14].

Figure 20-100-15
5
4 1
3 2
P-38173
Remove the 2 plugs (Item 1) [Figure 20-100-17].
P-38171
Remove the retainer (Item 1), piston (Item 2), spring

(Item 3) and w asher (Item 4) from the spool (Item 5)
[Figure 20-100-15].

264 of 642
TRAVEL PEDAL (CONT’D)
Figure 20-100-18
1
P-38174
Do NOT remove the 4 fit tings (Item 1) [Figure 20-100-

18] or the fittings and housing will be damaged.

265 of 642

266 of 642
HYDROSTATIC SYSTEM
HYDROSTATIC DRIVE MOTOR. . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4 SAFETY &
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-8 MAINTENANCE
HYDROSTATIC
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 SYSTEM
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-23
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-21 DRIVE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3 SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

ELECTRICAL
Pump Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 SYSTEM &
ANALYSIS
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 ENGINE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3 SERVICE
SPECIFICATIONS

267 of 642

268 of 642
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following Troubleshooting Chart is provided for
assistance locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
Problem Cause
Excessive noise in the hydrostatic pump. 1, 2, 3, 4, 5
Hydrostatic pump overheating. 1, 4, 6 7, 13
System not developing pressure. 1, 8, 9, 10
Loss of fluid. 11, 12
No drive in one direction. 5, 8, 9
Loss of hydrostatic power under load. 5, 8, 10, 17, 18
Loader moves with foot pedal in neutral. 14, 18
Slow or no drive. 5, 8, 9, 10, 15, 16, 17, 18

Key To Correct Cause
1. Low fluid in the reservoir.
2. Air in the system.
3. Incorrect hydraulic fluid.
4. Excessive internal wear.
5. Lack of charge pressure.
6. Oil cooler dirty or cooler fan not working.
7. Engine not being operated at correct RPM.
8. High pressure relief valve not working correctly.
9. Hydrostatic pump replenishing valve not working correctly.
10. Tow valve in open position.
11. Leaking tubelines.
12. Hydrostatic motor seal leaking.
13. Fluid temperature fan switch not working correctly.
14. Travel pedal not adjusted correctly.
15. Charge relief valve is not working correctly.
16. Hydraulic pump is not working correctly.
17. Hydrostatic motor is damaged.
18. Hydrostatic pump is damage.

269 of 642
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Replenishing Valve Function

IMPORTANT
The functions of the replenishing valves are:
Figure 30-10-1 clean the work area before disassembly and keep all
CHARGE OIL tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-088
Valve Moves for Charge

Oil Replacement
FUNCTION 1

Valve Stays on Seat to Hold
High Pressure for Drive
FUNCTION 2
B-2804
• To give replacement fluid to the low pressure side of

the hydrosttic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling: Function 1
• To keep high pressure fluid out of th e low pressure

side of the hydrostatic circuity: Function 2

270 of 642
OIL COOLER

IMPORTANT
Rotate the battery disconnect lever counterclockwise to clean the work area before disassembly and keep all
disconnect the battery from system. parts clean. Always use caps and plugs on hoses,
Remove the front and rear floor panels. (See FLOOR damage the system.
PANELS on Page 50-30-1.) I-2003-0888
1
1

P-38824 P-38823
Disconnect the h arness connector (Item 1) [Figure 30- Remove the two hoses (Item 1) [Figure 30-20-3].
20-1].
Figure 30-20-4
Figure 30-20-2
1
1
1
1
P-38827
P-38825
Remove the two front cooler mounting bolts (Item 1)

Remove the two hoses (Item 1) [Figure 30-20-2]. [Figure 30-20-4].
NOTE: Mark hoses for correct assembly. Installation: Tighten bolts to 18- 19 ft.-lb. (24-26 N•m)
torque.

271 of 642
OIL COOLER (CONT’D) Figure 30-20-7
Figure 30-20-5
P-38829
1
1
Remove the oil cooler (Item 1) [Figure 30-20-7].
P-38826
Remove the two r ear cooler mounting bolts (Item 1)

[Figure 30-20-5].

Figure 30-20-6
2 1
P-38828
Remove the two bracket mounting bolts (Item 1) [Figure

30-20-6] and remove the rear bracket (Item 2) [Figure
30-20-6].

torque.

272 of 642
OIL COOLER (CONT”D)
1. Cooler
2. Bracket
3. Bracket
4. Bolt
5. Bolt
6. Washer 5
7. Nut
1
7

6
7
4
B-19615

273 of 642
OIL COOLER (CONT”D) Figure 30-20-10
Disassembly
3
Figure 30-20-8
1 2
3
2 1
2
2 P-38832
Remove the harness (Item 1) [Figure 30-20-10] from the

P-38830 mounting tabs (Item 2) [Figure 30-20-10] and remove
the fan a ssembly (Item 3) [Figure 30-20-10] from the
cooler.
Remove the harness connector (Item 1) [Figure 30-20-8]
from temperature sensor (Item 2) [Figure 30-20-8]. Figure 30-20-11
Remove ground wire (Item 3) [Figure 30-20-8] and

mounting bolt.
Figure 30-20-9
1
1
1
P-38833
1 Remove the housing mounting bolt (Item 1) [Figure 30-

P-38831 20-11].
Remove the four fan assembly mounting bolts (Item 1)

[Figure 30-20-9].

274 of 642
Figure 30-20-12
1
1
1
P-38836
Remove the washer (Item 1) [Figure 30-20-14]. Inspect

P-38834 and replace as necessary.
Figure 30-20-15
Remove the two housing mounting bolts (Item 1) [Figure
30-20-12] and remove housing (Item 2) [Figure 30-20-
12].

Figure 30-20-13
1
1
P-38837
Remove the fi tting (Item 1) [Figure 30-20-15] from the

cooler.
P-38835
NOTE: Mark the fitting direction and location for
correct assembly.
Remove the temperature sensor (Item 1) [Figure 30-20-
13] from the cooler.

275 of 642
Figure 30-20-16
P-38840
1
Apply Loctite sealant 515 or equivalent to the fitting

P-38838 threads (Item 1) [Figure 30-20-18] and install into cooler.
Figure 30-20-19
Remove the fitting (Item 1) [Figure 30-20-16].
Assembly

Figure 30-20-17
P-38841
1
Install the washer (Item 1) [Figure 30-20-19] and apply

Loctite sealant 515 or equivalent to th e sensor threads
P-38839 (Item 2) [Figure 30-20-19] and install into the cooler.
Apply Loctite sealant 515 or equivalent to fitting threads

(Item 1) [Figure 30-20-17] and install into cooler.

276 of 642
Assembly (Cont’d)
Figure 30-20-20
1
1
1
3
3
2
3
P-38832
Place the fan assembly (Item 1) [Figure 30-20-22] on the

P-38834 cooler and install the harness (Item 2) [Figure 30-20-22]
into the mounting tabs (Item 3) [Figure 30-20-22].
Figure 30-20-21 Figure 30-20-23

1
1
1
1
P-38833 P-38831
Install the housing mounting bolts (Item 1) [Figure 30-20- Install the four mounting bolts (Item 1) [Figure 30-20-23].
20] and (Item 1) [Figure 30-20-21].
Installation: Tighten bolts to 11-12 ft.-lb. (15-17 N•m)
torque.

277 of 642
OIL COOLER (CONT”D)
Assembly (Cont’d)
Figure 30-20-24
P-38845
Install the harness connector (Item 1) [Figure 30-20-24]

to sensor. Install the ground wire and mounting bolt (Item
2) [Figure 30-20-24].

torque.

278 of 642
HYDROSTATIC DRIVE MOTOR Figure 30-30-2

disconnect the battery from system.

Page 50-30-1.) 1
Figure 30-30-1 1
P-38847
Figure 30-30-3
1 1
1

2
P-38846
Remove the two hoses (Item 1) [Figure 30-30-1] from

drive motor (Item 2) [Figure 30-30-1].
P-38848
IMPORTANT Remove the s ix drive motor mounting bolts (Item 1)

[Figure 30-30-2] and (Item 1) [Figure 30-30-3].
clean the work area before disassembly and keep all Installation: Tighten bolts to 55- 60 ft.-lb. (75-85 N•m)
parts clean. Always use caps and plugs on hoses, torque.
damage the system.
I-2003-0888

279 of 642
HYDROSTATIC DRIVE MOTOR (CONT”D)
Figure 30-30-4
P-38849
Slide the drive motor forward and remove [Figure 30-30-

4].

280 of 642
HYDROSTATIC DRIVE MOTOR (CONT”D)
1. SEAL
2. BEARING
3. HOUSING
4. O-RING
5. WASHER
6. KEYED COUPLER
7. SEAL RING
8. DRIVE LINK
9. WEAR PLATE
10. ROTOR
11. VANE
4 12. STATOR
13. MANIFOLD

14. RING
15. COMMUTATOR
1
16. END COVER
2
17. BOLT
3
5
5
1
5
2
5
2
6
6
9 2
7
10 7
8
11
12
7
13
7 14
2
17
15 7
16
B-19613

281 of 642
HYDROSTATIC DRIVE MOTOR (CONT”D) Figure 30-30-7
Disassembly
1
Figure 30-30-5
P-38852

P-38850 fitting. Inspect and replace as necessary.
Figure 30-30-8
Remove the shaft key (Item 1) [Figure 30-30-5].
Figure 30-30-6

1
P-38853
P-38851 Mark drive motor housing for correct assembly [Figure

30-30-8].
Remove the fittings (Item 1) [Figure 30-30-6].

282 of 642
Figure 30-30-9
1
P-38856
Remove the sealing ring (Item 1) [Figure 30-30-11].

P-38854
Figure 30-30-12
Remove the seven end cover bolts (Item 1) [Figure 30-

30-9].

Figure 30-30-10
1
P-38857
Remove the spacer (Item 1) [Figure 30-30-12].
P-38855
Remove the end cover (Item 1) [Figure 30-30-10].

283 of 642
Figure 30-30-13
1
2
1
P-38860

P-38858
Figure 30-30-16
Remove the sealing ring (Item 1). Remove the c ontrol

washer (Item 2) [Figure 30-30-13].

Figure 30-30-14
1
1
P-38861
Remove the sealing ring (Item 1) [Figure 30-30-16] from

valve plate.
P-38859

the control washer.

284 of 642
Figure 30-30-17
P-38864
Remove the spacer plate (Item 1) [Figure 30-30-19].

P-38862
Figure 30-30-20
Remove the g erotor assembly (Item 1) [Figure 30-30-

17].

NOTE: Keep the gerotor assembly together. If rollers 1
are removed install them back in the original
bore.
Figure 30-30-18
1
P-38865
Remove the multi-spline shaft (Item 1) [Figure 30-30-

20].
P-38863

gerotor.

285 of 642
HYDROSTATIC DRIVE MOTOR (CONT”D) Inspection
Disassembly (Cont’d) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-21 material can get into the system and cause damage.
Figure 30-30-23
2
1
P-38866
P-38872
Remove the sealing ring (Item 1) and thrust bearing (Item
2) [Figure 30-30-21].

Check the shaft (Item 1) [Figure 30-30-23] for wear or
Figure 30-30-22 damage in the spline and bearing surface areas. Replace
as needed.
Figure 30-30-24
1
P-38867
2
1
Remove the s haft (Item 1) from the ho using (Item 2)
P-38871
[Figure 30-30-22].
Inspect the shaft seal (Item 1), thrust bearing (Item 2)

and needle bearing (Item 3) [Figure 30-30-24] replace
as needed.

286 of 642
Inspection (Cont’d)
Figure 30-30-25
1
1 2
P-38859
Check the control washer (Item 1) [Figure 30-30-27] for

P-38869 wear or scratches. Replace as needed.
Figure 30-30-28
Inspect the outer shaft seal (Item 1) and roller bearing
(Item 2) [Figure 30-30-25] replace as needed.

Figure 30-30-26 1
P-38861
Check the valve plate (Item 1) [Figure 30-30-28] for wear

P-38863 or scratches. Replace as needed.
Check gerotor (Item 1) [Figure 30-30-26] for wear

scratches or cracks. If there is any defect in the gerotor,
the assembly must be replaced.

287 of 642
Figure 30-30-29
2
1 1
P-38872
Install the shaft (Item 1) into the housing (Item 2) [Figure

P-38856 30-30-30].
Figure 30-30-31
Check the end cover (Item 1) [Figure 30-30-29] for wear
or scratches. Replace as needed.

Assembly 1
2
IMPORTANT
damage the system.
P-38867
I-2003-0888
Clean and lightly oil all parts. Prior to assembly. Line up key way on shaft (Item 1) with center of the two
fitting bores (Item 2) [Figure 30-30-31].

288 of 642
Assembly (Cont’d)
Figure 30-30-32
2
1
P-38864
Install the spacer plate (Item 1) [Figure 30-30-34].

P-38866
Figure 30-30-35
Install the sealing ring (Item 1) and thrust bearing (Item 2)

[Figure 30-30-32].

Figure 30-30-33 1
P-38863
Install the sealing ring (Item 1) [Figure 30-30-35].
P-38865 Figure 30-30-36
Install the multi-spline shaft (Item 1) [Figure 30-30-33].
P-38862
Install the gerotor assembly (Item 1) [Figure 30-30-36].

289 of 642
Assembly (Cont’d)
Figure 30-30-37
1
P-38860
2 Install the valve plate (Item 1) [Figure 30-30-39].

P-38873
Figure 30-30-40
Rotate the gerotor gear so one lobe (Item 1) is in line with 1

the shaft key way (Item 2) using the center of the fitting
bores (Item 3) [Figure 30-30-37] for timing of m otor as

shown.
Figure 30-30-38
2
P-38859
Install the sealing ring (Item 1) into control washer (Item

2) [Figure 30-30-40].
P-38861
Install the s ealing ring (Item 1) [Figure 30-30-38] into

valve plate.

290 of 642
Assembly (Cont’d)
Figure 30-30-41 2 1
P-38856
Install the sealing ring (Item 1) into the end cover (Item 2)
P-38858 [Figure 30-30-43].
Figure 30-30-44
Install the sealing ring (Item 1) and control washer (Item
2) [Figure 30-30-41].

Figure 30-30-42 1
P-38855
Install the end cover (Item 1) [Figure 30-30-44].

P-38857
Install the spacer plate (Item 1) [Figure 30-30-42].

291 of 642
Assembly (Cont’d)
Figure 30-30-45
1
P-38851
Install the fittings (Item 1) [Figure 30-30-47].

P-38854
Figure 30-30-48
Install the seven bolts (Item 1) [Figure 30-30-45].
Installation: Tighten the bolts in a criss cross pattern to

45-55 ft.-lb. (61-75 N•m) torque.
1
Figure 30-30-46
P-38850
Install the shaft key (Item 1) [Figure 30-30-48].

2
P-38852
Install the washer (Item 1) onto the fitting. Apply Loctite

sealant 515 or equivalent to the fitting threads (Item 2)
[Figure 30-30-46].

292 of 642
HYDROSTATIC PUMP Figure 30-40-2
1
WARNING
immediately.
W-2145-0290
P-38276
IMPORTANT Remove the 2 hoses (Item 1) [Figure 30-40-2].
Figure 30-40-3

damage the system.
I-2056-0793
Drain the hydraulic reservoir. (See Replacing Hydraulic 1

Fluid on Page 10-120-3.)
Remove the floor panels. (See FLOOR PANELS on Page

50-30-1.)
Remove the gear pump. (See Removal And Installation

on Page 20-80-1.) P-38277
Mark the wires for correct installation.

Remove the 3 hoses (Item 1) [Figure 30-40-3].
Figure 30-40-1
Figure 30-40-4
P-38275
P-38278
Remove the 2 wires (Item 1) [Figure 30-40-1].
Mark the hoses for correct installation. Remove the hose (Item 1) [Figure 30-40-4].

293 of 642
HYDROSTATIC PUMP (CONT’D) Figure 30-40-7
Figure 30-40-5
1
P-38282
1
Remove the 2 bo lts (Item 1) [Figure 30-40-7] and
P-38279 remove the hydrostatic pump.
Figure 30-40-8
Figure 30-40-6

1
P-38283
P-38281 Lift the hoist and remove the hydrostatic pump [Figure
30-40-8].
Install a hoist (Item 1) [Figure 30-40-6] on the hydrostatic

pump.

294 of 642
HYDROSTATIC PUMP (CONT’D)
1. Charge Pump
2. O-ring
3. Alignment Pin
4. Bearing 10
16
5. Valve Plate 8
6. Replenishing Valve 15
11
7. Spool 18 14 10 5
8. Spring 2
9. Spring Seat 13 9
17 8 3
10. Plug
2 9 2
11. Washer
12. Poppet 8 7
13. Pin 12 15
6 4
14. Fitting 16
10
15. Jam Nut 14
16. Adjustment Screw 2
3 9 2 8
17. Back-up Ring

18. Metering Spool 11 8 9
19. Bolt 19 2
9 10
20. Ring Gear 3 1 2 7
10 7 15
21. Gear 2 16
22. Snap Ring 20 2 10
23. Coupler 21 9
24. Key 2 28 14
6 2 2
25. Bearing Race 3
13
26. Flange 7 8
12
27. Bearing 9 2 2 2
28. Manifold 10 13 10 10
8
8 2
2 11
10 19
11 10
9
10
8
2
22
23 10
24
27
25
22
26
11
19
11
19
MS-21195

295 of 642
Parts Identification (Cont’d)
1. Pump Housing
2. O-ring
3. Plug
4. Washer
5. Bolt
26
6. Shaft 5
7. Bearing 4
26 24
8. Snap Ring 8 26
9. Seal 27 2
7 25
10. Shaft Retainer 5 22 11
11. Spring
20 27
12. Cylinder Block 4
13. Pin
14. Retaining Ball 19 21 5 5
15. Retaining Ring 4 28
16. Piston 18 17
17. Swashplate 7 23

18. Plate 2 24
19. Actuator 22
20. Actuator Block 5 5
21. Bearing Race 21
22. Bearing Cage 17
23. Servo Housing 2 25
13 26
24. End Cover
8
25. Adjustment Screw
26. Nut 10
2
27. Spring Seat 9
28. Servo Piston 8
4
5 7
4
6
1
2
2
16
3
14 15
13
4
12
11
4
8
MS-21205

296 of 642
Disassembly
1
IMPORTANT
I-2003-0888
P-38494
Figure 30-40-9
Remove and discard the 6 o-rings (Item 1) [Figure 30-

40-11].
Figure 30-40-12

P-38492
1
With the pump on a work surface, mark the power limiter

housings for correct assembly [Figure 30-40-9].
P-38495
Figure 30-40-10

1
P-38493
Remove the 2 bolts and lock washers (Item 1) [Figure

30-40-10] and remove the power limiter.

297 of 642
Figure 30-40-13
1
1 1
P-38498

P-38496
Figure 30-40-16
Figure 30-40-14

1
P-38499
Remove the washers (Item 1) [Figure 30-40-16] from the

P-38497 plugs and replace as needed.

plugs and replace as needed.

298 of 642
Figure 30-40-17
1
2
1
P-38501
Remove and discard the o- ring (Item 1) [Figure 30-40-

P-38502 19] from the plug.
Figure 30-40-20
Figure 30-40-18

1 2
P-38504
P-38500
Slide the spool partially out of th e housing and remove

Remove the plug (Item 1) and spring (Item 2) [Figure 30- the shim pack (Item 1) [Figure 30-40-20].
40-17] & [Figure 30-40-18].
NOTE: Mark the housing for shim pack location.

299 of 642
Figure 30-40-21 5
4
3
2
1
P-38508
Remove the lube cooling adjusting screw (Item 1), pin

P-38505 (Item 2), spring seat (Item 3), spring (Item 4) and
metering spool (Item 5) [Figure 30-40-23].
Remove the s pool (Item 1) [Figure 30-40-21] from the Figure 30-40-24
manifold.

Figure 30-40-22
1
P-38507
P-38506 Remove and discard the o- ring (Item 1) [Figure 30-40-

24].
Before removing the lu be cooling adjusting screw (Item

1) [Figure 30-40-22] measure and record the correct
adjustment.

300 of 642
Figure 30-40-25
P-38511
Remove the adjusting screw (Item 1) [Figure 30-40-27].

P-38509
NOTE: Do not loosen the jam nut.
Remove the second manifold assembly [Figure 30-40- Figure 30-40-28

25].

Figure 30-40-26
P-38512
1
P-38510 Remove and discard the o- ring (Item 1) [Figure 30-40-

28].
Remove and discard the 6 o-rings (Item 1) [Figure 30-

40-26].

301 of 642
Figure 30-40-29
4
4
3 3
2 1 2
1
P-38515
Remove the plug (Item 1), washer (Item 2), retainer (Item
P-38513 3) and check valve assembly (Item 4) [Figure 30-40-31].
Figure 30-40-32
Remove the spring seat (Item 1), spring (Item 2), spring
seat/orifice (Item 3) and spool (Item 4) [Figure 30-40-
29].

Figure 30-40-30
P-38516
3
Remove the plug (Item 1) and washer (Item 2) [Figure
2 30-40-32].
1 P-38514
Remove the plug (Item 1), washer (Item 2) and pin (Item
3) [Figure 30-40-30].

302 of 642
1
Figure 30-40-33
3
2
1
P-38519
Remove the servo (Item 1) [Figure 30-40-35] from the

P-38517 pump housing.
Figure 30-40-36
Remove plug (Item 1), washer (Item 2) and orifice (Item
3) [Figure 30-40-33].

Figure 30-40-34
1
1
P-38520
1
Remove and discard the o- ring (Item 1) [Figure 30-40-
P-38518 36].
Remove the 6 bolts and lock washers (Item 1) [Figure

30-40-34].

303 of 642
Figure 30-40-37
1
1
1 P-38523
Remove the 4 bolts (Item 1) [Figure 30-40-39] from the

P-38521 servo end cap.
Figure 30-40-40
Before removing the adjustment screw (Item 1) [Figure
30-40-37] measure and record the correct adjustment.

Remove the adjustment screw (Item 1) [Figure 30-40-
37].
Figure 30-40-38
P-38527
1
Mark the servo housing for correct assembly [Figure 30-
40-40].
P-38522
Before removing the se rvo adjustment screw (Item 1)

[Figure 30-40-38] measure and record the correct
adjustment.
Remove the servo adjustment screw (Item 1) [Figure 30-

40-38].

304 of 642
Figure 30-40-41
P-38526
Remove and di scard the two back-up rings (Item 1)

P-38524 [Figure 30-40-43] from the housing.
Figure 30-40-44
Remove the servo piston assembly (Item 1) [Figure 30-
40-41] from the housing. 1
1

Figure 30-40-42
1
1
1
P-38528
Mark the housing for correct assembly.

P-38525
Remove the four bolts (Item 1) and remove the mounting
flange (Item 2) [Figure 30-40-44].
Remove and discard the o-ring (Item 1) [Figure 30-40-
42] from the servo piston.

305 of 642
Figure 30-40-45
1
P-38531
Remove the gear assembly (Item 1) [Figure 30-40-47].

P-38529
Figure 30-40-48
Remove and discard the o-ring (Item 1) [Figure 30-40-

45].

Figure 30-40-46 1
P-38532
Remove the coupler (Item 1) [Figure 30-40-48].
P-38530
Remove the bearing (Item 1) [Figure 30-40-46]. Replace

as needed.

306 of 642
Figure 30-40-49
1
1
P-38536
1
P-38533 fitting.
Figure 30-40-52
Mark the ho using and remove the four bolts (Item 1)
[Figure 30-40-49] and remove the charge pump.

1
Figure 30-40-50 3
4
2
P-38539
1 Remove the plug (Item 1), washer (Item 2), o-ring (Item
P-38535 3) and spring (Item 4) [Figure 30-40-52].
Remove the 2 fittings and washers (Item 1) [Figure 30-

40-50].

307 of 642
1
Figure 30-40-53
1
P-38541
Remove the replenishing valve (Item 1) [Figure 30-40-

P-38538 55].
Figure 30-40-56
Remove the r eplenishing valve (Item 1) [Figure 30-40-
53].

Figure 30-40-54
1
2 3 4
1
P-38542

P-38540
Remove the plug (Item 1), washer (Item 2), o-ring (Item
3) and spring (Item 4) [Figure 30-40-54].

308 of 642
Figure 30-40-57
1
P-38545
1
Remove the back-up ring (Item 1) and o-ring (Item 2)
P-38536 [Figure 30-40-59].
Figure 30-40-60
fitting.

Figure 30-40-58
1
1
P-38546
Before removing the adjustment screw (Item 1) [Figure

P-38544 30-40-60] measure and record the correct adjustment.
Remove the adjustment screw (Item 1) [Figure 30-40-

Remove the metering spool (Item 1) [Figure 30-40-58]. 60].

309 of 642
1
Figure 30-40-61
4 3
2
1
P-38652
Remove the o-ring (Item 1) [Figure 30-40-63] from the

P-38547 housing.
Figure 30-40-64
Remove the pin (Item 1), spring seat (Item 2), spring
(Item 3) and poppet (Item 4) [Figure 30-40-61].

1
Figure 30-40-62
P-38653

P-38548
Inspect both bearings (Item 1) [Figure 30-40-62] and

replace as needed.

310 of 642
Figure 30-40-65
1
P-38656
Remove the shaft assembly (Item 1) [Figure 30-40-67].

P-38654
Figure 30-40-68
Lay the housing on i ts side and remove the cylinder

block/piston assembly (Item 1) [Figure 30-40-65] from
the drive shaft.

Figure 30-40-66
P-38657
Remove the locator link and pin (Item 1) [Figure 30-40-

68].
P-38655
Remove the snap ring (Item 1) [Figure 30-40-66].

311 of 642
Figure 30-40-69
1
1
P-38660
Remove the swash plate bearing races (Item 1) [Figure

P-38658 30-40-71].
Figure 30-40-72
Remove the swash plate assembly (Item 1) [Figure 30-
40-69].

Figure 30-40-70
P-38661
Remove the actuator block (Item 1) [Figure 30-40-72]

P-38659 from the swash plate arm.
Remove the swash plate bearings (Item 1) [Figure 30-

40-70].

312 of 642
Inspection
Clean all parts in solvent and use air pressure to dry 1

them. DO NOT use cloth or paper as small pieces of
material can get into the system and cause damage.
Figure 30-40-73
1
2
P-38663
Check the swash plate bearings (Item 1) [Figure 30-40-

75] for wear and damage. Replace as needed.
Figure 30-40-76
P-38668

2
1
Check the we ar plate (Item 1) and charge pump gears
(Item 2) [Figure 30-40-73] for damage or wear.
Figure 30-40-74
P-38664
Check each piston (Item 1) and piston shoe (Item 2)

[Figure 30-40-76] for wear or scratches.
P-38662
Check the swash plate assembly surface, it must be

smooth and free of scratches [Figure 30-40-74].

313 of 642
Figure 30-40-77
2
P-38667
Inspect the shaft seal (Item 1). Replace if needed.

P18772 Remove and discard the o- ring (Item 2) [Figure 30-40-
79].
Check the c ylinder block bores for wear or scratches

[Figure 30-40-77].

If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.
Figure 30-40-78
P-38665
Check the shaft for wear or damage in the spline and

bearing areas [Figure 30-40-78].
Check the bearing for correct operation. If bearing

replacement is required, remove the s nap ring (Item 1)
and remove the bearing (Item 2) [Figure 30-40-78].

314 of 642
Assembly
IMPORTANT
1

damage the system.
I-2003-0888
P-38661
Clean and lightly oil all parts. Prior to assembly.
Figure 30-40-80 Install the actuator block (Item 1) [Figure 30-40-82] onto
the servo arm.
Figure 30-40-83

1
P-38660
Install the swash plate bearing races (Item 1) [Figure 30- P-38658
40-80] into the housing. Note the offset in each race.
Figure 30-40-81 Carefully install the swash plate (Item 1) [Figure 30-40-
83] into the housing.
P-38659
Assemble and lubricate the bearing cage (Item 1)

[Figure 30-40-81] and install on the bearing races.

315 of 642
Assembly (Cont’d)
Figure 30-40-84 1
P-38655
Install the snap ring (Item 1) [Figure 30-40-86].

P-38657
Figure 30-40-87
Install the locator link and pin (Item 1) [Figure 30-40-84].
Figure 30-40-85

1
P-38654
1 Install the cylinder block/piston assembly (Item 1)

P-38656 [Figure 30-40-87] over the drive shaft and onto the
swash plate.
Lubricate the o-ring (Item 1) and install the shaft

assembly (Item 2) [Figure 30-40-85].

316 of 642
Assembly (Cont’d)
Figure 30-40-88
1
1
2
3
4
2
P-38545
Install a new back-up ring (Item 1) [Figure 30-40-90] and

P-38547 o-ring onto the metering spool.
Figure 30-40-91
Install the poppet (Item 1), spring (Item 2), spring seat
(Item 3) and pin (Item 4) [Figure 30-40-88].

Figure 30-40-89
1
P-38543
Install the metering spool (Item 1) [Figure 30-40-91] into

1 the housing.
P-38546
Install the adjustment screw (Item 1) [Figure 30-40-89]

into the ho using to the c orrect adjustment recorded
earlier.

317 of 642
Assembly (Cont’d)
1
Figure 30-40-92
P-38541
Install the replenishing valve (Item 1) [Figure 30-40-94].

P-38536
Figure 30-40-95
Install the washer (Item 1) [Figure 30-40-92] onto the

fitting. 3 2 1

Figure 30-40-93
P-38540
1 Install the spring (Item 1), o-ring (Item 2), washer (Item 3)
and plug (Item 4) [Figure 30-40-95].
P-38542
Apply Loctite RC609 or equivalent to th e fitting (Item 1)

[Figure 30-40-93] and install.

318 of 642
Assembly (Cont’d)
Figure 30-40-96
P-38536
Install the was her (Item 1) [Figure 30-40-98] onto the

P-38538 fitting.
Figure 30-40-99
Install the replenishing valve (Item 1) [Figure 30-40-96].
Figure 30-40-97

4
1 2 3
1 P-38535
P-38539 Apply Loctite RC609 or equivalent to the fittings (Item 1)

[Figure 30-40-99] and install.
Install the spring (Item 1), o-ring (Item 2), washer (Item 3)
and plug (Item 4) [Figure 30-40-97].

319 of 642
Assembly (Cont’d)
1
Figure 30-40-100
2
P-38673
Install the o- ring (Item 1) [Figure 30-40-102] onto the

P-38671 housing.
Figure 30-40-103
Apply assembly grease to the valve plate.
Install the v alve plate onto the charge pump. Note the 1

1
slot (Item 1) must go around the pin (Item 2) [Figure 30-
40-100]. 1
Figure 30-40-101
1
1
P-38533
2
Carefully turn the charge pump assembly over and place
on the main housing.
Install the 4 bolts (Item 1) [Figure 30-40-103] and tighten

P-38670 to 90 ft.-lb. (122 N•m) torque.
For the timing to be correct the slot (Item 1) [Figure 30-

40-101] on the other side of the valve plate must be in
the position shown.
Install the o-ring (Item 2) [Figure 30-40-101].

320 of 642
Assembly (Cont’d)
1
Figure 30-40-104
P-38529
Install the o-ring (Item 1) [Figure 30-40-106] into the

P-38532 mounting flange.
Figure 30-40-107
Install the coupler (Item 1) [Figure 30-40-104].
2
Figure 30-40-105 2

1
1
2
2
P-38528
P-38531 Install the mounting flange (Item 1) and four bolts (Item 2)
[Figure 30-40-107]. Tighten the bo lts to 55 ft.-lb. (75
N•m) torque.
Apply assembly lube and install the gear assembly (Item
1) [Figure 30-40-105] over the coupler key.

321 of 642
Assembly (Cont’d)
Figure 30-40-108
P-38524
Lightly lubricate the ba ck-up rings in the housing and

P-38526 install the s ervo piston (Item 1) [Figure 30-40-110] into
the housing.
Install the new back-up rings (Item 1) [Figure 30-40-108] Figure 30-40-111
into the housing.

Figure 30-40-109
1 1
1
P-38523
P-38525 Install the 4 mounting bolts (Item 1) [Figure 30-40-111]

and tighten.
Install a new o-ring (Item 1) [Figure 30-40-109] on the

servo end cap.

322 of 642
Assembly (Cont’d)
2
Figure 30-40-112 3
1 1
P-38519
Apply Loctite 545 sealant or equivalent to t he mounting

P-38522 surface (Item 1) [Figure 30-40-114] on the servo
housing.
Install the servo adjustment screw (Item 1) [Figure 30- Align the actuator block (Item 2) with the servo piston
40-112] into the housing to the correct adjustment groove (Item 3) [Figure 30-40-114] and install the servo
recorded earlier.

housing.
Figure 30-40-113 Figure 30-40-115
1
1
P-38520 P-38518
Install the new o-ring (Item 1) [Figure 30-40-113] onto Install the 6 bolts and washers (Item 1) [Figure 30-40-
the servo housing. 115] and tighten to 14 ft.-lb. (20 N•m) torque.

323 of 642
Assembly (Cont’d)
Figure 30-40-116
2
4
1
1 3
2
3 P-38515
Install the check valve assembly (Item 1), retainer (Item

P-38517 2), washer (Item 3) and plug (Item 4) [Figure 30-40-118].
Figure 30-40-119
Install the orifice (Item 1), washer (Item 2) and plug (Item
3) [Figure 30-40-116].

Figure 30-40-117
1
1
2 2 P-38514
Install the pin (Item 1), washer (Item 2) and plug (Item 3)
P-38516 [Figure 30-40-119].
Install the washer (Item 1) and plug (Item 2) [Figure 30-

40-117].

324 of 642
Assembly (Cont’d)
Figure 30-40-120
1
2
3
4
P-38511
Install the adjusting screw (Item 1) [Figure 30-40-122]

P-38513 and tighten to 25 ft.-lb. (35 N•m) torque.
Figure 30-40-123
Install the spool (Item 1), spring seat/orifice (Item 2),
spring (Item 3) and spring seat (Item 4) [Figure 30-40- 1
120].

Figure 30-40-121
P-38510
Install the 6 o-rings (Item 1) [Figure 30-40-123].

1
P-38512

325 of 642
Assembly (Cont’d)
Figure 30-40-124
1
2
3
P-38508
Install the metering spool (Item 1), spring (Item 2), spring
P-38509 seat (Item 3), pin (Item 4) and adjusting screw (Item 5)
[Figure 30-40-126].
Install the second manifold onto the housing [Figure 30- Figure 30-40-127
40-124].

Figure 30-40-125
1 P-38506
P-38507 Tighten the adjusting screw (Item 1) [Figure 30-40-127]

into the housing to the c orrect adjustment recorded
earlier.

326 of 642
Assembly (Cont’d)
Figure 30-40-128 1
P-38501

P-38505 plug.
Figure 30-40-131
Lubricate and install the spool (Item 1) [Figure 30-40-
128] into the manifold.

Figure 30-40-129
1
2
P-38500
1
Install the spring (Item 1) and plug (Item 2) [Figure 30-
P-38504 40-131].
Install the shim pack (Item 1) [Figure 30-40-129] onto

the spool.
NOTE: Install the shim pack as recorded earlier.

327 of 642
Assembly (Cont’d)
Figure 30-40-132 2
P-38499
Install the washer (Item 1) onto the plug (Item 2) [Figure

P-38501 30-40-134].
Figure 30-40-135
plug.

Figure 30-40-133
1 1
2
P-38498
Install the plugs (Item 1) [Figure 30-40-135] into the

P-38502 manifold.
Install the spring (Item 1) and plug (Item 2) [Figure 30-

40-133].

328 of 642
Assembly (Cont’d)
Figure 30-40-136
P-38495
Install the fitting (Item 1) [Figure 30-40-138].

P-38497
Figure 30-40-139
Install the washer (Item 1) onto the plug (Item 2) [Figure

30-40-136].
1

Figure 30-40-137
1
1 1
P-38494
Install the 6 o-rings (Item 1) [Figure 30-40-139].
P-38496
Install the 5 plu gs (Item 1) [Figure 30-40-137] into the

housing.

329 of 642
Assembly (Cont’d)
Figure 30-40-140
1
P-38493
Install the top manifold (Item 1) with the washers and

bolts (Item 2) [Figure 30-40-140] tighten to 90 ft.-lb. (122
N•m) torque.

330 of 642
HYDROSTATIC TESTING Figure 30-50-2
Pump Adjustment
The testing of the hydrostatic pump must be done in the

following order: 1
CHARGE PRESSURE
FLUSHING VALVE
TORQUE LIMITER
All testing is done with the hydraulic oil at 150° F (66° C)
The hydraulic hoses, tubelines and fittings are 24° DIN

cone metric fittings.
To test the charge pressure, stop the engine and engage P-42707
the parking brake. Raise the machine and install

jackstands. (See LIFTING AND BLOCKING THE
With the park brake engaged, hydraulic fluid temperature
LOADER BACKHOE on Page 10-10-1.)
at 150° F (66° C), start the engine and set the engine to
1000 RPM. Record pressure on the gauge (Item 1)
[Figure 30-50-2]
WARNING The correct pressure should be 320 psi (2206 kPa).

Put jackstands under the front and rear axle before Stop the engine.
running the engine for service. Failure to us e
jackstands can allow the machine to fall or move and Figure 30-50-3
W-2461-0303
2
Remove the left front floor panel. (See Left Front Panel
Removal And Installation on Page 50-30-1.)
Figure30-50-1
1 1
P-42710
2
If the pressure is incorrect, loosen the jam nut (Item 1) on
the relief valve. Turn the ad justment screw (Item 2)
[Figure 30-50-3] clockwise to in crease the pressure or
counterclockwise to decrease the pressure.
P-42703
Tighten the jam nut (Item 1) [Figure 30-50-3].
Remove the plug (Item 1) [Figure30-50-1] from the Retest the charge pressure after adjustment.
charge port and install a 1000 psi (6895 kPa) gauge.
NOTE: If the charge pressure was adjusted the
Remove the plug (Item 2) [Figure30-50-1] from the flushing valve test must be performed. If no
forward travel test port and install a 1 0,000 psi (68950 adjustment was made continue to the Torque
kPa) gauge. Limiter Test.

331 of 642
HYDROSTATIC TESTING (CONT’D) Figure 30-50-5
Pump Adjustment (Cont’d) 3

1
Figure 30-50-4
P-42706
If the pressure drop is incorrect, locate the flushing valve

P-42707 adjustment (Item 1) [Figure 30-50-5] on the right side of
the hydrostatic pump facing forward.
To test the flushing valve, make sure the park brake is Loosen the ja m nut ( Item 2) and turn the adjustment
engaged, hydraulic fluid temperature is at 150° F (66° C), screw (Item 3) [Figure 30-50-5] counterclockwise to

start the engine and engage the press to drive. Set the increase the pressure drop ro clockwise to decrease the
engine to 1000 RPM. Record the pressure on the gauge pressure drop.
(Item 1) [Figure 30-50-4] in the charge port.
Tighten the jam nut (Item 2) [Figure 30-50-5]. Retest the
Apply slight pressure to the forward travel pedal (Item 2) flushing valve.
and release. The gauge (Item 1) [Figure 30-50-4] will
drop 30 psi (207 kPa) less than recorded pressure, then Figure 30-50-6
return to r ecorded pressure. The correct pressure drop
should be 30 psi (207 kPa).
Stop the engine.
3
1
P-42708
Locate the torque limiter adjustment (Item 1) [Figure 30-

50-6] on the bottom right side of the hydrostatic pump.
With the engine off, loosen the jam nut (Item 2) on the
torque limiter and turn the adjustment screw (Item 3)
[Figure 30-50-6] clockwise two full turns.

332 of 642
HYDROSTATIC TESTING (CONT’D)
Pump Adjustment (Cont’d)
Figure 30-50-7
P-42709
With the hydraulic fluid temperature at 150° F (6 6° C)

and the parking brake engaged, start the engine. Engage

the press to drive, set the engine to full RPM. Operate the
travel pedal (Item 1) in the forward travel position until the
maximum pump drive pressure is recorded on the gauge
(Item 2) [Figure 30-50-7].
With the engine running turn the torque limiter

adjustment screw (Item 3) counterclockwise until the
maximum drive is reduced by approximately 100 psi
(6895 kPa). Tighten the jam nut (Item 1) [Figure 30-50-
6].
Example: When driving into a p ile of material while

raising the lift arms, if the engine RPM drops and the
loader is underpowered, turn the Torque Limit Adjustment
OUT for less hydrostatic power and increased engine
RPM.
Example: When driving into a p ile of material while

raising the lift arms, the engine RPM does not lug down
and the l oader drive is underpowered turn the T orque
Limit Adjustment IN fo r more hydrostatic power and
decreased engine RPM.
Stop the engine.
Remove pressure gauges.
Install test port plugs. Remove the jackstands. Install left

front floor panel.

333 of 642

334 of 642
DRIVE SYSTEM
AXLE AND DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-26
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-7 SAFETY &
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-13 MAINTENANCE
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . 40-40-6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-19
Pinion Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 40-40-15
Pinion Group Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-18
Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . 40-40-14
DRIVE
Wheel Hub/Axle Assembly. . . . . . . . . . . . . . . . . . . . . . . . 40-40-35
SYSTEM
Wheel Hub/Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . 40-40-3
Wheel Hub/Axle Parts Identification. . . . . . . . . . . . . . . . . . 40-40-2
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1


ELECTRICAL
SYSTEM &
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 ANALYSIS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-4
Cable Removal And Installation. . . . . . . . . . . . . . . . . . . . . 40-10-2
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-1 ENGINE
SERVICE
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
SPECIFICATIONS

335 of 642

336 of 642
PARKING BRAKE Figure 40-10-3
Lever Removal And Installation
Figure 40-10-1 1
P-38616
Remove the pin retainer clip (Item 1). and washer (Item
2) [Figure 40-10-3].
P-36884 Figure 40-10-4
Block the rear wheels [Figure 40-10-1].

Figure 40-10-2
1
1
P-38617
Remove the pin (Item 1) [Figure 40-10-4].
P-38615
Release the parking brake lever (Item 1) [Figure 40-10-

2] as shown.

337 of 642
PARKING BRAKE (CONT’D) Figure 40-10-7
Lever Removal And Installation (Cont’d)

2
Figure 40-10-5
P-38620
Loosen jam nut (Item 1). Remove clevis bolt (Item 2)

P-38618 [Figure 40-10-7].
Installation: Do no t over tighten clevis bolt causing

Remove the three mounting bolts (Item 1) [Figure 40-10- clevis to deflect and bind.
5].

Figure 40-10-8
torque.
Figure 40-10-6
2
1
P-38621
Remove the clevis (Item 1) and jam nut (Item 2) [Figure

P-38619 40-10-8].
Remove the parking brake lever (Item 1) [Figure 40-10-

6].
Cable Removal And Installation
Block the r ear wheels and release brake lever. (See

“Lever Removal And Installation” on page 1.)
Remove the rear floor panel. (See Rear Panel Removal

And Installation on Page 50-30-2.)

338 of 642
Cable Removal And Installation (Cont’d)
Figure 40-10-9
1 2
P-38616
Remove the pin retainer clip (Item 1) and washer (Item 2)

P-38622 [Figure 40-10-11].
Figure 40-10-12
Remove the cable boot (Item 1) [Figure 40-10-9].
Figure 40-10-10

1
1
2
P-38617
P-38623 Remove the pin (Item 1) [Figure 40-10-12].
Remove the cable (Item 1) from the bracket (Item 2)

[Figure 40-10-10].

339 of 642
Cable Removal And Installation (Cont’d)
Figure 40-10-13
P-38626
Lower and remove the cable (Item 1) [Figure 40-10-15].

P-38624
Adjustment
Raise the cable boot (Item 1) [Figure 40-10-13]. Figure 40-10-16
Figure 40-10-14

1
P-32804
P-38625
Push parking brake lever (Item 1) forward and down to
disengage the parking brake. To adjust the parking brake
Remove the cable retainer clip (Item 1) [Figure 40-10- twist the handle [Figure 40-10-16]. Twisting the ha ndle
14]. clockwise will increase the force applied.

340 of 642
BRAKE CALIPER Figure 40-20-3
Lift and block the loader backhoe. (See LIFTING AND

BLOCKING THE LOADER BACKHOE on Page 10-10-1.)
2
NOTE: The bracket (Item 1) [Figure 40-20-1] must be
supported before removing the mounting
bolts.
Figure 40-20-1
1
1
P-40201
Remove the four mount bolts (Item 1). Remove the

bracket (Item 2) [Figure 40-20-3]
2
N•m) torque.

Figure 40-20-4
1
P-40199
Figure 40-20-2 1
2
P-40218
Remove the clevis bolt (Item 1) [Figure 40-20-4].
P-40200 Installation: Do not overtighten bolt causing clevis to

deflect and bind.
Remove the four bracket mount bolts (Item 2) [Figure

40-20-1] & [Figure 40-20-2].

torque.

341 of 642
BRAKE CALIPER (CONT’D) Figure 40-20-7
Figure 40-20-5
P-40221
Remove the hydrostatic drive motor (Item 1) [Figure 40-

P-40219 20-7] by sliding forward.
NOTE: Temporarily place the hydrostatic drive motor

Figure 40-20-6 on a support stand.

Figure 40-20-8
2
1
3
P-40220 1
P-40222
Remove the 6 dr ive motor mounting bolts (Item 1)
[Figure 40-20-5] & [Figure 40-20-6].
Rotate the brake disc (Item 1) to line up hole (Item 2) with
Installation: Tighten bolts to 55 to 60 ft.-lb. (75 to 85 lower caliper mount bolt (Item 3) [Figure 40-20-8].
N•m) torque. Remove the bolt.

342 of 642

2
Figure 40-20-9
1
2
P-40225
4 2
Position drive hub (Item 1) as shown. Remove the two
P-40223 brake disc mount bolts (Item 2) [Figure 40-20-11].
Figure 40-20-12
Rotate brake disc (Item 1) to line up h ole (Item 2) with
upper caliper mount bolt (Item 3). Remove the bolt and
caliper (Item 4) [Figure 40-20-9].

1
N•m) torque.
Figure 40-20-10
P-40226
Remove the brake disc (Item 1) [Figure 40-20-12]
1
P-40224
Remove the four hub mount bolts (Item 1) [Figure 40-20-

10].

N•m) torque.

343 of 642
BRAKE CALIPER (CONT’D)
1 Snap Ring
2 Screw
3 Link
4 Arm
5 Lever
6 Pin
7 Pad
8 Caliper
9 Bolt
10 Disc
11 Bushing

1
2
6 8 4
11
5
3
6
7
11
4
10
1
7
2 1 9
9
B-19693

344 of 642
Figure 40-20-13
1
1 1
P-40205
Inspect pins (Item 1) [Figure 40-20-15] for damage or

P-40202 wear. Replace as needed.
Figure 40-20-16
Remove the 2 snap rings (Item 1) [Figure 40-20-13].
Figure 40-20-14

1
1 1
P-40204
P-40203 Remove the linkage assembly (Item 1) [Figure 40-20-

16]. Inspect for damage or wear. Replace as needed.
Remove the 2 pins (Item 1) [Figure 40-20-14].

345 of 642
Figure 40-20-17
P-40205
1
1
Figure 40-20-20
Remove the 2 snap rings (Item 1) [Figure 40-20-17].
Figure 40-20-18

1 1
P-40208
1 1
P-40207 Remove the 2 arms (Item 1) [Figure 40-20-20]
NOTE: Mark location of arms for correct assembly.

Remove the 2 pins (Item 1) [Figure 40-20-18].

346 of 642

2
Figure 40-20-21
1
P-40211
1
1 Inspect bushing (Item 1) for damage or wear. Replace as
2 P-40209 needed. Record the number of shims used (Item 2)
[Figure 40-20-23] for correct assembly.
Inspect arms (Item 1) and caliper (Item 2) [Figure 40-20- Figure 40-20-24
21] for damage or wear. Replace as needed.

Figure 40-20-22
P-40212
P-40210 Remove brake pad (Item 1) [Figure 40-20-24].
Remove the bushing (Item 1) [Figure 40-20-22].

347 of 642
Figure 40-20-25 2
P-40215
Inspect bushing (Item 1) for damage or wear. Replace as

P-40213 needed. Record the number of shims (Item 2) [Figure
40-20-27] for correct assembly.
Inspect brake pad (Item 1) [Figure 40-20-25] for damage Figure 40-20-28
or wear. Replace as needed.

Figure 40-20-26
1
1
P-40216

348 of 642
Figure 40-20-29
P-40217
Inspect brake pad (Item 1) [Figure 40-20-29] for damage


349 of 642

350 of 642
BRAKE CALIPER Figure 40-21-3
Lift and block the loader backhoe. (See LIFTING AND

BLOCKING THE LOADER BACKHOE on Page 10-10-1.)
2
NOTE: The bracket (Item 1) [1] must be supported
before removing the mounting bolts.
Figure 40-21-1
1
1
P-40201
Remove the four mount bolts (Item 1) [Figure 40-21-3].

2 Remove the bracket (Item 2) [Figure 40-21-3]

torque.

Figure 40-21-4
1
P-40199
Figure 40-21-2
1
P-40218
Remove the clevis bolt (Item 1) [Figure 40-21-4].

P-40200
Installation: Do not overtighten bolt causing clevis to
deflect and bind.
Remove the four bracket mount bolts (Item 2) [Figure
40-21-1] & [Figure 40-21-2].

torque.

351 of 642
Figure 40-21-5
P-40221
Remove the hydrostatic drive motor (Item 1) [Figure 40-

P-40219 21-7] by sliding forward.
NOTE: Temporarily place the hydrostatic drive motor

Figure 40-21-6 on a support stand.

Figure 40-21-8
2
1
3
P-40220 1
P-40222
Remove the s ix drive motor mounting bolts (Item 1)
[Figure 40-21-5] & [Figure 40-21-6].
Rotate the brake disc (Item 1) [Figure 40-21-8] to line up
Installation: Tighten bolts to 55- 60 ft.-lb. (75-85 N•m) hole (Item 2) [Figure 40-21-8] with lower caliper mount
torque. bolt (Item 3) [Figure 40-21-8]. Remove the bolt.

352 of 642

2
Figure 40-21-9
1
2
P-40225
4 2
Position drive hub (Item 1) [Figure 40-21-11] as shown.
P-40223 Remove the two brake disc mount bolts (Item 2) [Figure
40-21-11].
Rotate brake disc (Item 1) [Figure 40-21-9] to line up Figure 40-21-12

hole (Item 2) [Figure 40-21-9] with upper caliper mount
bolt (Item 3) [Figure 40-21-9]. Remove the bolt and

caliper (Item 4) [Figure 40-21-9].
1
torque.
Figure 40-21-10
P-40226
Remove the brake disc (Item 1) [Figure 40-21-12]
1
P-40224
Remove the four hub mount bolts (Item 1) [Figure 40-21-

10].

torque.

353 of 642
1 Snap Ring
2 Screw
3 Link
4 Arm
5 Lever
6 Pin
7 Pad
8 Caliper
9 Bolt
10 Disc
11 Bushing

1
2
6 8 4
11
5
3
6
7
11
4
10
1
7
2 1 9
9
B-19693

354 of 642
Figure 40-21-13
1
1 1
P-40205

Figure 40-21-16
Remove the two snap rings (Item 1) [Figure 40-21-13].
Figure 40-21-14

1
1 1
P-40204
P-40203 Remove the linkage assembly (Item 1) [Figure 40-21-

16]. Inspect for damage or wear. Replace as needed.
Remove the two pins (Item 1) [Figure 40-21-14].

355 of 642
Figure 40-21-17
P-40205
1
1
Figure 40-21-20
Remove the two snap rings (Item 1) [Figure 40-21-17].
Figure 40-21-18

1 1
P-40208
1 1
P-40207 Remove the two arms (Item 1) [Figure 40-21-20]
NOTE: Mark location of arms for correct assembly.

Remove the two pins (Item 1) [Figure 40-21-18].

356 of 642

2
Figure 40-21-21
1
P-40211
1
1 Inspect bushing (Item 1) [Figure 40-21-23] for damage
2 P-40209 or wear. Replace as needed. Record the number of
shims used (Item 2) [Figure 40-21-23] for correct
assembly.
Inspect arms (Item 1) [Figure 40-21-21] and caliper
(Item 2) [Figure 40-21-21] for damage or wear. Replace Figure 40-21-24
as needed.

Figure 40-21-22
P-40212

357 of 642
Figure 40-21-25 2
P-40215
Inspect bushing (Item 1) [Figure 40-21-27] for damage

P-40213 or wear. Replace as needed. Record the number of
shims (Item 2) [Figure 40-21-27] for correct assembly.
Inspect brake pad (Item 1) [Figure 40-21-25] for damage Figure 40-21-28

Figure 40-21-26
1
1
P-40216

358 of 642
Figure 40-21-29
P-40217
Inspect brake pad (Item 1) [Figure 40-21-29] for damage


359 of 642

360 of 642
REAR AXLE

IMPORTANT
Install the boom lock. (See Engaging Boom Lock on
Page 10-140-2.) When repairing hydrostatic and hydraulic systems,
Stop the engine. Engage the parking brake. parts clean. Always use caps and plugs on hoses,
Remove the left front and rear floor panels. (See FLOOR damage the system.
PANELS on Page 50-30-1.) I-2003-0888

1
P-55404 P-53942
Using a floor jack raise the rear of the machine and install Remove the three hoses (Item 1) [Figure 40-30-3] from
jack stands in front of the dr ive motor mounting bracket the drive motor.
[Figure 40-30-1].
NOTE: Mark hoses for correct installation.
Figure 40-30-2
Release the parking brake.
Figure 40-30-4
1
P-55405
Remove the 5 lug nuts and washers (Item 1) [Figure 40-

P-55406
30-2] from each rear tire.
Remove both rear tires. Remove the brake cable clevis bolt (Item 1) [Figure 40-
30-4].
Installation: Tighten the lug nuts to 140 ft.-lb. (190 N•m)
torque.

361 of 642
REAR AXLE (CONT’D) Figure 40-30-7

1
Figure 40-30-5
P-55408
Remove the 2 nuts and washers (Item 1) [Figure 40-30-

P-55407 7] from both sides of the drive motor mounting bracket.
Installation: Tighten the b olts to 19 ft.-lb. (26 N•m)

Remove the 2 bolts (Item 1) and bracket (Item 2) [Figure torque.
40-30-5].

Figure 40-30-8
Figure 40-30-6
P-55409
P-55410
Remove the 2 rear axle mounting bolts (Item 1) [Figure

Install a hoist and lifting strap (Item 1) [Figure 40-30-6] to 40-30-8] from both sides of the rear axle.
lift and support the drive motor.
Installation: Tighten the bolts to 188 to 210 ft.-lb. (255 to
285 N•m) torque.

362 of 642
REAR AXLE (CONT’D)
Figure 40-30-9
P-55411
Lower the floor jack and hoist slowly. Roll the rear axle
out from under the machine [Figure 40-30-9].

363 of 642

364 of 642
AXLE AND DIFFERENTIAL
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Pinion or ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 10, 11, 14
Oil leakage 6, 8, 9, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

KEY TO CORRECT CAUSE
1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5 Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent

365 of 642
AXLE AND DIFFERENTIAL (CONT’D)
General Information
For photo clarity, the following axle procedures are done

with the complete axle assembly removed from the
machine, although the wheel hub, steering knuckle and
drive axle procedures may be done with the axle
assembly installed in the machine. For complete axle
repair, the following must be done.
Wheel Hub/Axle Parts Identification
1. Plug
2. Bolt
3. Pin

4. Flange
1 5. Lockwasher
4 2 6. Hub nut
2 5 7. Lock ring
8. Nut
6 9. Stud
8
9 10. Bearing
11. Hub
3
12. Spacer
11 13. Seal
7 14. Bushing
15. Axle shaft
10
10
12
13
14
15
B-23373

366 of 642
AXLE AND DIFFERENTIAL (CONT’D) Figure 40-40-3
Wheel Hub/Axle Disassembly
IMPORTANT
damage the system.
I-2003-0888
P-40078
Figure 40-40-1
Remove the axle shaft (Item 1) [Figure 40-40-3] from the

axle housing.
Figure 40-40-4

1
P-40076
Remove the 14 flange bolts (Item 1) [Figure 40-40-1].
Figure 40-40-2 P-40079
Remove the set screw and lock washer (Item 1) [Figure

40-40-4].
1
2
P-40077
Install 2 f lange bolts (Item 1) in th e location shown,

tighten the bolts equally to remove the flange (Item 2)
[Figure 40-40-2].

367 of 642
Wheel Hub/Axle Disassembly (Cont’d)
Figure 40-40-5
P-40082
1
Remove the outer bearing (Item 1) [Figure 40-40-7].
P-40080
Figure 40-40-8
Remove the hub nut (Item 1) [Figure 40-40-5]. 1

Figure 40-40-6

1
P-40083
Remove the hub assembly (item 1) [Figure 40-40-8].

P-40081
Remove the lock ring (Item 1) [Figure 40-40-6].

368 of 642
Wheel Hub/Axle Disassembly (Cont’d)

1
Figure 40-40-9
P-40088
Remove the inner bearing (Item 1) [Figure 40-40-11].

P-40091
Figure 40-40-12
Remove the bushing (Item 1) [Figure 40-40-9] if worn or

damaged.

Figure 40-40-10
1
P-40087
Remove the inner race (Item 1) [Figure 40-40-12].
P-40089 Figure 40-40-13
Remove the seal (Item 1) [Figure 40-40-10] from the

hub.
1
P-40084
Remove the outer race (Item 1) [Figure 40-40-13].

369 of 642
Differential Parts Identification
1. Shim
2. Bearing
3. Housing
4. Differential plate
5. Friction plate
6. Drive plate
7. Gear (pinion)
8. Washer
9. Gear
1 10. Shaft
2 11. Spider
12. Pin
3 13. Shaft
14. Cover
4 15. Bolt
4

4
8
4
4 9
8
5 10
5
5
5 9
6 11
7
4
10 12 4
8 4
13 4 14
9 7 4
6
5
9 5 15
5
5
8
2
1
B-23367

370 of 642
Differential Disassembly 2 1
Figure 40-40-14 1
1 1
P-40093

P-40092 2) [Figure 40-40-16].
Figure 40-40-17
Place the axle assembly on a secure work surface
[Figure 40-40-14].

Remove the wheel hub/axle (both sides). (See Wheel
Hub/Axle Disassembly on Page 40-40-3.)
Figure 40-40-15
P-40094
1
Remove the gasket (Item 1) [Figure 40-40-17] from the

axle housing.
P-40090
Remove the dr ain plug (Item 1) [Figure 40-40-15] and

drain fluid into an approved container and dispose of i n
an environmentally safe manner.

371 of 642
Differential Disassembly (Cont’d)
Figure 40-40-18
1 1
P-40098
Lift and remove the differential assembly [Figure 40-40-

P-40096 20].
NOTE: The bearing cup and shim (Item 1) [Figure 40-

Check and record the backlash of the differential [Figure 40-20] will be removed at this time. Do not mix
40-40-18]. parts from left to right.

Figure 40-40-19 Figure 40-40-21
2 2
1 1
2 2
P-40097 1
P-40099
Rotate the axle housing down, mark the location of the Remove the bearing (Item 1) [Figure 40-40-21] (both
bearing clamps (Item 1) and remove the 4 bolts (Item 2) sides) from the differential.
[Figure 40-40-19].
NOTE: Do not mix the bearings from left to right.
Remove the bearing clamps (Item 1) [Figure 40-40-19].

372 of 642
Figure 40-40-22
P-40102
Separate the differential housing [Figure 40-40-24].

P-65165
Figure 40-40-25
Support the di fferential assembly in a vise. Remove the

12 bolts (Item 1) and ring gear (Item 2) [Figure 40-40-
22].

Figure 40-40-23
1 P-40103
Remove the friction plates/differential plates and gear

from housing [Figure 40-40-25].
P-40101
Mark the differential housing (Item 1) [Figure 40-40-23]

for correct assembly.

373 of 642
Figure 40-40-26
1
2
P-40109
1
Remove the center shaft (Item 1) [Figure 40-40-28].

P-40104
Figure 40-40-29
Remove the friction plates/differential plates (Item 1) from

the gear (Item 2) [Figure 40-40-26].

Figure 40-40-27
P-40111
1
Remove the gear/thrust washer (both sides) [Figure 40-
40-29].
P-40108
Remove the center roll pin (Item 1) [Figure 40-40-27].

374 of 642
Figure 40-40-30
P-40122
Remove the spider shaft [Figure 40-40-32].

P-40115
Figure 40-40-33
Remove the roll pin [Figure 40-40-30] (both sides).
Figure 40-40-31

P-40123
Remove the side gear/thrust washer (both sides) [Figure

P-40118 40-40-33].
Remove the half shaft [Figure 40-40-31] (both sides).

375 of 642
Figure 40-40-34
P-40124
Remove the pinion gear (Item 1) [Figure 40-40-34].
Figure 40-40-35

1
P-40125
Remove the friction plates/differential plates (Item 1)

[Figure 40-40-35].

376 of 642
Differential Inspection
1
Figure 40-40-36
P-40114
Inspect the thrust washers (Item 1) [Figure 40-40-38] for

P-23942 damage or wear. Replace as needed.
Figure 40-40-37

P-23945
Inspect the pinion gears [Figure 40-40-36] & [Figure 40-

40-37] for broken or damaged teeth.
If either gear is damaged, replace all gears.

377 of 642
Pinion Group Parts Identification
1. Nut
2. Washer
3. O-ring
4. Flange
5. Cover
6. Seal
7. Bearing
8. Shim
9. Shim
10. Shim
11. Pinion shaft
12. Pinion gear 12
11

7 10
9
8
7
6
5
3
2
1
B-23362

378 of 642
Pinion Group Disassembly
Figure 40-40-39
P-65233
Remove the washer (Item 1) [Figure 40-40-41].

P-65231
Figure 40-40-42
Pry the p eened over nut [Figure 40-40-39] out of th e

shaft groove.

Figure 40-40-40
2
P-65232
1
P-65234
Remove the nut (Item 1) [Figure 40-40-40].
NOTE: Install 2 bolts (Item 2) [Figure 40-40-40]in the

drive flange to help keep from rotating.

379 of 642
Pinion Group Disassembly (Cont’d)
Figure 40-40-43
1
1
P-40133
Remove and discard the seal (Item 1) [Figure 40-40-45].

P-65239
Figure 40-40-46
Remove the drive flange (Item 1) [Figure 40-40-43].
Figure 40-40-44

1
P-40134

P-40132
Support the back of the pinion shaft and remove from the
housing using a soft hammer [Figure 40-40-44].

380 of 642
Pinion Group Disassembly (Cont’d)
Figure 40-40-47
P-40135

P-65158
Figure 40-40-50
Remove and record the s him pack from the bearing

[Figure 40-40-47].

NOTE: The shim pack may stay in the housing when 1
the bearing is removed.
Figure 40-40-48
P-65161
Remove the inner race (Item 1) [Figure 40-40-50].
P-65240
Remove the shim shaft (Item 1) [Figure 40-40-48].

381 of 642
AXLE AND DIFFERENTIAL (CONT’D) Pinion Group Inspection
Pinion Group Disassembly (Cont’d) Figure 40-40-53
Figure 40-40-51
1
P-40140
P-40138
Inspect the pinion gear (Item 1) and shaft splines (Item 2)
[Figure 40-40-53] for broken or damaged teeth or
Remove the bearing (Item 1) [Figure 40-40-51]. splines.
Figure 40-40-52

2 1
P-40139
Remove the shim (Item 1) from the shaft (Item 2) [Figure

40-40-52].

382 of 642
Pinion Group Assembly
IMPORTANT 2

damage the system.
I-2003-0888
P-65168
Figure 40-40-54
Install the bearing (Item 1) onto the false pinion tool (Item
2) [Figure 40-40-56].
Figure 40-40-57

1
P-40143
Install the outer race [Figure 40-40-54].
Figure 40-40-55 P-65167
Install the bearing/false pinion assembly (Item 1) [Figure

40-40-57] into the center housing.
P-40142
Install the inner race [Figure 40-40-55].
Before assembly, clean and lightly oil all parts.

383 of 642
Pinion Group Assembly (Cont’d)

2
2
Figure 40-40-58
1
1
2
2
P-65172
Install both bearing clamps (Item 1) and bolts (Item 2)

P-65238 [Figure 40-40-60].
Do not overtighten the bolts.

Install the outer bearing (Item 1) and lock nut (Item 2)
[Figure 40-40-58].

NOTE: Tighten the lock nut to eliminate any bearing
end play. DO NOT overtighten.
Figure 40-40-59
P-65171
Install the fal se differential tools [Figure 40-40-59] into

the axle housing (as shown).

384 of 642
Figure 40-40-61
P-40141
To determine the thickness of the shim or shims to be

P-65173 installed between the pinion and bearing, subtract the
value stamped on the pi nion (Item 1) [Figure 40-40-63]
from the value “X”.
Figure 40-40-62
Figure 40-40-64

1
B-23370
MS1199
Using a depth gauge (Item 1) [Figure 40-40-61] &

[Figure 40-40-62] measure through the reference hole in Select the shim [Figure 40-40-64] from the chart below.
the dummy pinion.
Measure distance “X” (distance between the axis of th e SHIM THICKNESS RANGE
differential bearings and the point at which the pinion Thick 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
head is supported, or base of the bearing [Figure 40-40-
62].

385 of 642

2
Figure 40-40-65
1
1
1
2
2
P-65238
1
1
Remove the lock nut (Item 1) and outer bearing (Item 2)
P-65172 [Figure 40-40-67].
Figure 40-40-68
Remove the 4 b olts (Item 1) and remove the bearing
clamps (Item 2) [Figure 40-40-65].

Figure 40-40-66
P-65167
Remove the bearing/false pinion assembly (Item 1)

P-65171 [Figure 40-40-68].
Remove the false differential tools from the housing

[Figure 40-40-66].

386 of 642
Figure 40-40-69
1 P-25694
Install the bearing (Item 1) [Figure 40-40-71] onto the

P-65168 pinion shaft until it is fully seated.
Figure 40-40-72
Remove the bearing (Item 1) [Figure 40-40-69] from the
false pinion.

Figure 40-40-70
P-65240
Install the pinion gear assembly into the center housing

P-25706 and install the spacer shim (Item 1) [Figure 40-40-72]
into the pinion.
Install the shims selected (Item 1) [Figure 40-40-70] onto NOTE: Install the shims (removed earlier) as a way to
the pinion shaft. determine the correct preload for the pinion
bearings.
NOTE: The beveled edge of the shims must go
towards the gear.

387 of 642
Figure 40-40-73 2
1
2
P-65235
1
Install the washer and nut (Item 1) [Figure 40-40-75] and
P-65237 gradually tighten the nut to 121 to 182 ft.-lb. (164 to 246
N•m) torque.
Install the outer bearing (Item 1) [Figure 40-40-73] onto NOTE: Install 2 bolts (Item 2) [Figure 40-40-75] in the
the pinion shaft. drive flange to help keep from rotating.

NOTE: Drive the outer bearing onto the shaft, have an Figure 40-40-76
assistant place a second hammer on the
pinion head to absorb the impact.
Figure 40-40-74
P-65236
1
Attach one end of a light rope to the drive flange and

P-65239 make 2 or 3 com plete wraps around the drive flange,
attach a spring scale perpendicular to the housing to
measure the rolling torque on th e bearings [Figure 40-
Install the drive flange (Item 1) [Figure 40-40-74] 40-76].
NOTE: Do not install the seal at this time. The preloading adjustment is determined by increasing
or decreasing the total shim value created by the spacer
and shims inserted onto the pinion shaft next to the outer
bearing.

388 of 642
Figure 40-40-77
MS1199
Select a shim [Figure 40-40-77] from the chart below

until there is 1.0 lb. (0,07 kg) of smooth and continuous

rolling torque measured on the spring scale.
SHIMS
Thick 0.10 0.25 0.30 0.50 26.50 26.53

389 of 642
Differential Assembly
Figure 40-40-78
P-40123
Install the si de gear/thrust washer (both sides) [Figure

P-40125 40-40-80].
Figure 40-40-81
Install the pl ates (Item 1) [Figure 40-40-78] into the
housing, beginning with a steel drive plate and
alternating between steel and friction.

1
NOTE: The thick washer must be on top (next to gear).
Figure 40-40-79
1
P-40122
Install the spider shaft (Item 1) [Figure 40-40-81]

between the side gears.
P-40124
Install the pinion gear (Item 1) [Figure 40-40-79] onto the

plate assembly.
NOTE: Make sure the plates remain in the correct

position.

390 of 642
Differential Assembly (Cont’d)
Figure 40-40-82
P-40111
1
Install the si de gear/thrust washer (both sides) [Figure

P-40121 40-40-84].
Figure 40-40-85
Install the half shaft (Item 1) [Figure 40-40-82] in th e
housing and through the side gear.

Figure 40-40-83
1
P-40109
Install the center shaft (Item 1) [Figure 40-40-85] in the

P-40115 housing through both side gears and spider shaft.
Align the roll pin hole and install the roll pin (Item 1)
[Figure 40-40-83] through the spider shaft side gear and
half shaft.
Repeat above procedure for the other side gear.

391 of 642
Figure 40-40-86
1 P-40103
Install the gear/plate assembly into the housing [Figure

P-40108 40-40-88].
Figure 40-40-89
Align the r oll pin hole in th e center shaft with the s pider
shaft and install the roll pin (Item 1) [Figure 40-40-86].

Figure 40-40-87
1
1
P-40101
Align the marks (Item 1) [Figure 40-40-89] and install the

P-40107 cover.
Install the plates (Item 1) [Figure 40-40-87] onto the

gear, beginning with the thick washer followed by a
friction plate and alternating between steel and friction.
NOTE: The thick washer must be next to the gear.

392 of 642
Figure 40-40-90
2
2 2
1
1
P-40098
1 Install the differential assembly into the axle housing

P-65165 along with both bearing cups (Item 1) and both shims
(Item 2) [Figure 40-40-92].
Support the differential assembly in a vise and position Figure 40-40-93

the ring gear (Item 1) [Figure 40-40-90].

Apply Loctite® 270 or equivalent to the 12 bolts (Item 2) 2
[Figure 40-40-90]. Install and tighten the bolts to 58 ft.-lb. 2
(78 N•m) torque. 1
1
Figure 40-40-91
2 2
P-40097
Install both bearing clamps (Item 1) as marked earlier

onto the bearing cup and install the 4 bolts (Item 2)
[Figure 40-40-93].
P-65179 NOTE: It may be necessary to use a soft hammer to

properly set the bearings in position.
Install the be aring (Item 1) [Figure 40-40-91] until it is

fully seated (both sides).

393 of 642
Figure 40-40-94
P-65236
Attach one end of a light rope to the drive flange and

P-40096 make 2 or 3 com plete wraps around the drive flange,
attach the spring scale to the opposite end of the rope.
Pull the scale perpendicular to the housing to measure
Position a magnetic-base dial gauge on the axle housing the rolling torque on the bearings. The value is 1.0 lb.
in the position shown [Figure 40-40-94]. Lock the pinion (0,07 kg) [Figure 40-40-95].
and move the ring gear. Record the backlash measured.

Repeat this procedure on two or more ring gear positions NOTE: All preloadings must be measured without the
to obtain an average value. seal.
The correct backlash value should be between 0.0059 to If the total preload is under the permissible range,
0.0098 in. (0.15 to 0.25 mm). increase the thickness of the shim equally on both sides
of the differential, while retaining the value of the pinion
To adjust the backlash value replace both shims, select a ring gear backlash.
shim from the chart below.
If the tot al preload is above the permissible range,
SHIM RANGE decrease the thickness of the shim equally on both sides
of the differential, while retaining the value of the pinion
Thick 4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 ring gear backlash.
Once the pinion/ring gear backlash has been determined Check the wear pattern of the pinion/ring gear teeth.
the total preload of the pinion ring gear bearings must be
measured, to verify that i t falls within the permissible
limits.

394 of 642
Figure 40-40-96
B-16059
Excessive contact on flank of tooth - adjust the backlash

B-16057 [Figure 40-40-98].
Figure 40-40-99
Correct Pattern - If pinion/ring gear has been properly
adjusted, wear pattern (contact) should be shown
[Figure 40-40-96].

2
Figure 40-40-97
1
1
P-40095
Once the wear pattern is correct, apply Loctite® 270 or

equivalent to the 4 b olts (Item 1) [Figure 40-40-99] and
B-16058 tighten to 78 - 85 ft.-lb. (105 - 115 N•m) torque.
Excessive contact on tooth edge - adjust the backlash

[Figure 40-40-97].

395 of 642
Figure 40-40-100
2
P-65234
Remove the lock nut and washer (Item 1) [Figure 40-40-

P-65146 102].
Figure 40-40-103
Remove and clean the cover (Item 1) [Figure 40-40-100]
and mounting surface on the axle housing (Item 2)
[Figure 40-40-99].

Install the drain plug (Item 2) [Figure 40-40-100].
Figure 40-40-101
1 2
2
1
2
P-65239
Remove the drive flange (Item 1) [Figure 40-40-103]
2
2
P-40093
Using a ne w gasket, apply Loctite® 542 or equivalent

to the bolts. Install the gasket and cover (Item 1) to
the axle housing and tighten the 9 bo lts (Item 2)
[Figure 40-40-101] to 28 ft.-lb. (39 N•m) torque.

396 of 642
Figure 40-40-104
P-65232
Install a new O-ring (Item 1) [Figure 40-40-106] onto the

1
P-65180 pinion shaft.
Figure 40-40-107
Install the new seal (Item 1) [Figure 40-40-104] into the
housing until it is seated 0.1377 in. (3,5 mm) in from the
flange end.

2
Figure 40-40-105
P-65235
1
Install the was her and nut (Item 1) [Figure 40-40-107]

and gradually tighten the nut to 121 to 182 ft.-lb. (164 to
P-65239 246 N•m) torque.
Remove the two bolts (Item 2) [Figure 40-40-107] from

Install the drive flange (Item 1) [Figure 40-40-105]. the drive flange.

397 of 642
Figure 40-40-108
P-65231
Stake the ring nut, using a hammer and punch [Figure

40-40-108].

398 of 642
Wheel Hub/Axle Assembly
Figure 40-40-109 1
P-40088
Lubricate and install the inner bearing (Item 1) [Figure

P-40086 40-40-111].
Figure 40-40-112
Install the inner bearing race in t he wheel hub [Figure
40-40-109].

1
Figure 40-40-110
P-40089
Install the seal (Item 1) [Figure 40-40-112].

P-40085
Install the outer bearing race in the wheel hub [Figure

40-40-110].

399 of 642
Wheel Hub/Axle Assembly (Cont’d)
Figure 40-40-113
P-40082
Lubricate and install the outer bearing (Item 1) [Figure

P-40091 40-40-115].
Figure 40-40-116
Install a new bushing (Item 1) [Figure 40-40-113] if worn
or damaged.

Figure 40-40-114
P-40081
Install the lock ring (Item 1) [Figure 40-40-116].

P-40083
Install the hub [Figure 40-40-114].

400 of 642
Wheel Hub/Axle Assembly (Cont’d)
Figure 40-40-117
P-40078
1
Install the axle shaft (Item 1) [Figure 40-40-119] into the
P-40080 axle housing aligning the shaft with the splines.
Figure 40-40-120
Install the hub nut (Item 1) [Figure 40-40-117] and
tighten.

NOTE: After the hub nut has been tightened, back the
nut off approximately 1/4 of a turn.
Figure 40-40-118
P-40076
Install the flange (Item 1) using the 14 bolts (Item 2)

[Figure 40-40-120].
Apply Loctite® 270 or equivalent and tighten to 25 to

P-40079 28 ft.-lb. (35 to 39 N•m) torque.
Install the set screw (Item 1) [Figure 40-40-118].

401 of 642

402 of 642
MAIN FRAME
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 50-150-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1 SAFETY &
MAINTENANCE
AXLE HUB (FRONT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . 50-110-3
Pivot Pin Bushing Removal And Installation . . . . . . . . . . 50-110-5
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
MAIN
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
FRAME
Backhoe Bucket Teeth Removal And Installation . . . . . . 50-190-1
Loader Bucket Teeth Removal And Installation . . . . . . . . 50-190-1

ELECTRICAL
ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 ANALYSIS
ENGINE SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 ENGINE
SERVICE
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
FLOOR PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1 SPECIFICATIONS

Left Front Panel Removal And Installation. . . . . . . . . . . . . 50-30-1
Rear Panel Removal And Installation . . . . . . . . . . . . . . . . 50-30-2
Right Front Panel Removal And Installation . . . . . . . . . . . 50-30-1
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Pivot Bushing Removal And Installation . . . . . . . . . . . . . 50-120-3
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . 50-90-2
GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
GRILL FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1


403 of 642
MAIN FRAME (CONT’D)
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Cab Mount Removal And Installation. . . . . . . . . . . . . . . . . 50-10-8
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200-1
SWING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

Boom Pivot Bushing Removal And Installation . . . . . . . . 50-170-1
Boom Swing Bushing Removal And Installation . . . . . . . 50-170-6

X-CHANGE™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

404 of 642
OPERATOR CAB Figure 50-10-2
Lower stabilizers flat to the ground.
Rotate the battery disconnect lever counterclockwise to 1 1

1 1
Remove the fenders. (See FENDER on Page 50-70-1.)

Page 50-20-1.)
P-36982
Remove the floor panels. (See FLOOR PANELS on Page
50-30-1.)
Remove the four roof mounting nut c overs (Item 1)
Remove the engine speed control. (See ENGINE SPEED [Figure 50-10-2].
CONTROL on Page 70-20-1.)
Figure 50-10-3
Remove the steering pump. (See Removal And

Figure 50-10-1
1
1
1 1
1
P-36983

P-38031
3].

Block the loader backhoe (Item 1) [Figure 50-10-1]. torque.

405 of 642
OPERATOR CAB (CONT’D) Figure 50-10-6
Figure 50-10-4
1
2
P-38029
Disconnect harness (Item 1) [Figure 50-10-6] and

P-36984 remove the cover (Item 2) [Figure 50-10-6].
Figure 50-10-7
Remove the roof (Item 1) [Figure 50-10-4].
Figure 50-10-5

1
2
P-38028
P-38030 Unhook harness (Item 1) [Figure 50-10-7] from the

operator cab. Remove mounting bolt (Item 2) [Figure 50-
10-7] (both sides).
Remove the six cover bolts (Item 1) [Figure 50-10-5].
Installation: Tighten bolts to 6-7 ft.-lb. (9-10 N•m) torque. torque.

406 of 642
Figure 50-10-8
1 1 1
1
P-36990
Remove the four travel pedal mounting bolts (Item 1)

P-38027 [Figure 50-10-10].

Remove the two housing mounting bolts (Item 1) [Figure torque.
50-10-8].

Figure 50-10-11
torque.
Figure 50-10-9
2
1
P-36992
Position travel pedal (Item 1) [Figure 50-10-11] as

P-38026 shown under operator cab.
Lift and position control valve housing (Item 1) [Figure

50-10-9] away from operator cab (Item 2) [Figure 50-10-
9].

407 of 642
Figure 50-10-12
1
P-36994
Position fuse box (Item 1) [Figure 50-10-14] under

P-36991 operator cab as shown.
Figure 50-10-15
Remove the four fuse box mounting bolts (Item 1)
[Figure 50-10-12].

Installation: Tighten bolts to 4- 5 ft.-lb. (5.5-6.5 N•m) 2
torque.
Figure 50-10-13
2
1
1
P-36995
Remove frame ground cable (Item 1) [Figure 50-10-15]

at the battery disconnect (Item 2) [Figure 50-10-15].
P-36993
Remove the two bol ts (Item 1) [Figure 50-10-13] and

remove the right side fuse panel bracket (Item 2) [Figure
50-10-13].
NOTE: Mark wires for correct reassembly.
Installation: Tighten bolts to 4- 5 ft.-lb. (5.5-6.5 N•m)

torque.

408 of 642
Figure 50-10-16
P-36998
Raise the dust cover (Item 1) [Figure 50-10-18].

P-36996
Figure 50-10-19
Remove the positive battery clamp (Item 1) [Figure 50-

10-16] from the battery.
2

1
Figure 50-10-17
P-36999
Remove the control lever mount bolt (Item 1) [Figure 50-

10-19]. Remove the control lever (Item 2) [Figure 50-10-
P-36997 19].
Installation: Tighten bolt to 4-5 ft.-lb. (5-6 N•m) torque.

Position positive clamp and ground cable under operator
cab as shown [Figure 50-10-17].

409 of 642
Figure 50-10-20
1
1
1
2
P-38032
1
Remove ground mounting bolt (Item 1) [Figure 50-10-
P-38000 22]. Remove connector (Item 2) [Figure 50-10-22] move
harness through operator cab opening.
Remove the three mounting bolts (Item 1) [Figure 50-10- Figure 50-10-23
20].

torque.
Figure 50-10-21
P-40198
Remove the three park brake mounting bolts (Item 1)

[Figure 50-10-23]. Remove the cable “E” clip (Item 2)
[Figure 50-10-23]. Remove the cable and park brake
P-38002 lever.

Lower control valve into opening in operator cab as torque.
shown [Figure 50-10-21].

410 of 642
Figure 50-10-24
1
1
P-38014
Install a chain and hoist to l ift and support operator cab

P-38007 [Figure 50-10-26].
Figure 50-10-27
Disconnect light harness (Item 1) [Figure 50-10-24].
Figure 50-10-25

1
P-38009
P-38025 Remove the cab mounting bolts (Item 1) [Figure 50-10-

27].
Secure harness (Item 1) [Figure 50-10-25] to operator Installation: Tighten bolts to 118-133 ft.-lb. (160-180
cab as shown (both sides). N•m) torque.

411 of 642
OPERATOR CAB (CONT’D) Cab Mount Removal And Installation
Removal And Installation (Cont’d) Figure 50-10-29
Figure 50-10-28
1 1
P-38023
P-38022A
With the operator cab removed, remove the four
mounting bolts (Item 1) [Figure 50-10-29].
Remove the operator cab [Figure 50-10-28].

torque.
Figure 50-10-30
P-38024
Remove the mount (Item 1) [Figure 50-10-30].
Replace as needed.

412 of 642
OPERATOR SEAT
Figure 50-20-1
P-35704

1].
Installation: Tighten bolts to 11-12.5 ft.-lb. (15-17 N•m)

torque.
Figure 50-20-2
1
P-35744

2].
Installation: Tighten bolts to 4- 5 ft.-lb. (5.5-6.5 N•m)

torque.
Remove the seat.

413 of 642

414 of 642
FLOOR PANELS Right Front Panel Removal And Installation
Left Front Panel Removal And Installation Figure 50-30-3
Figure 50-30-1
1
1
1
1
1
1
P-33312
P-33314
3].
1]. Figure 50-30-4

Figure 50-30-2
1
P-33313
P-33315
Remove the floor panel (Item 1) [Figure 50-30-4].

415 of 642
FLOOR PANELS (CONT’D)
Rear Panel Removal And Installation
Figure 50-30-5
P-35110
Remove the three mounting bolts (Item 1) [Figure 50-30-

5].

Figure 50-30-6
P-35111

416 of 642
GRILL
Page 10-20-1.)
Figure 50-40-1
P-33559

Remove the two screws and washers (Item 1) [Figure
50-40-1] (both sides).
Installation: Tighten the bolts to 7- 7.5 ft.-lb. (9.5-10.5

N•m) torque.
Figure 50-40-2
P-33560
Remove the grill [Figure 50-40-2]

417 of 642

418 of 642
GRILL FRAME Raise the h oist until the we ight of th e grill frame is
supported by the hoist.
Raise the lift arms and install an approved lift arm support Figure 50-50-3
Page 10-20-1.)
Figure 50-50-1
1
P-33563
Remove the two bolts (Item 1) [Figure 50-50-3] from the

grill frame. (both sides)

P-33561 Installation: The side covers must be in stalled before
tightening the bolts (Item 1) [Figure 50-50-3]. Tighten the
bolts to 55-60 ft.-lb. (75-85 N•m) torque.
Remove the two bolts (Item 1) [Figure 50-50-1] from the
grill frame. Figure 50-50-4
Installation: The side covers must be i nstalled before

tightening the bolts (Item 1) [Figure 50-50-1]. Tighten the
bolts to 7-7.5 ft.-lb. (9,5-10,5 N•m) torque.
Remove the side covers. (See ENGINE SIDE COVERS

on Page 50-60-1.)
Figure 50-50-2
P-33564
1
Remove the grill frame [Figure 50-50-4].
P-33562
Install a hoist and lifting strap (Item 1) [Figure 50-50-2]

on the grill frame.

419 of 642

420 of 642
ENGINE SIDE COVERS Figure 50-60-3
Page 10-20-1.)
1
Figure 50-60-1
1
P-33306
Remove the six side cover mounting bolts (Item 1)

[Figure 50-60-3].
Figure 50-60-4
P-33303

Release both engine cover latches (Item 1) [Figure 50-
60-1].
Figure 50-60-2
1 P-33307
Remove the side cover [Figure 50-60-4].
P-33305
Open the engine cover and put the support rod (Item 1)
[Figure 50-60-2] in the hole in the hood.

421 of 642

422 of 642
FENDER Figure 50-70-3
Figure 50-70-1
P-35708
Remove the fender [Figure 50-70-3].
P-36872
Remove the fo ur foot guard mounting bolts (Item 1)

[Figure 50-70-1]. Remove the foot guard (Item 2)
[Figure 50-70-1].

torque.
Figure 50-70-2
P-35707
Remove the four fender mount bolts (Item 1) [Figure 50-

70-2].
Installation: Tighten the bolts to 4-5 ft.-lb. (5.5-6.5 N•m)

torque.

423 of 642

424 of 642
ENGINE COVER Figure 50-80-3
Raise the lift arms and install the approved lift arm
1
support device.
Figure 50-80-1
P-35396
1
Remove the engine cover (Item 1) [Figure 50-80-3].

P-35397
Remove the engine cover bolts (Item 1) [Figure 50-80-1]

(both sides).
Figure 50-80-2
P-35395
Open the latch (Item 1) [Figure 50-80-2].

425 of 642

426 of 642
FUEL TANK Figure 50-90-2
Page 10-20-1.)


1
Page 50-30-1.)
P-36877
WARNING Remove plug (Item 1) [Figure 50-90-2].
Drain the fuel tank.

penetrate skin or eyes, causing serious injury or Installation: Tighten plug to 3 2-35 ft.-lb. (43-47 N•m)
death. Fluid leaks under pressure may not be visible. torque.

not use your bare hand. Wear safety goggles. If fluid Figure 50-90-3
W-2072-0496
Figure 50-90-1 1
P-38124
1 Place stands under the fuel tank [Figure 50-90-3].
P-36875 Remove the mounting bolts (Item 1) [Figure 50-90-3].
Remove wires (Item 1) [Figure 50-90-1] from sender.
NOTE: Mark hoses and wires for correct assembly.

427 of 642
FUEL TANK (CONT’D) Fuel Fill Screen Removal And Installation
Figure 50-90-4
P-36959
P-36879
Remove the fuel fill cap (Item 1) [Figure 50-90-5].
Remove the mounting bolts (both sides) (Item 1) [Figure Figure 50-90-6
50-90-4].

Remove the tank.

torque.
P-36960
Remove the fuel fill screen (Item 1) [Figure 50-90-6]

from the tank. Check the screen for damage and replace
if necessary.

428 of 642
LIFT ARMS

IMPORTANT
Remove the B ob-Tach. (See BOB-TACH on Page 50-
110-1.) When making repairs on hydraulic system, clean the
Remove the loader tilt cylinders. (See TILT CYLINDER clean. Always use caps and plugs on hoses,
on Page 20-30-1.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Lower the lift arms to the ground. I-2056-0793
Relieve hydraulic pressure by moving the loader control Figure 50-100-2

lever with the engine off.
WARNING 1


immediately.
W-2145-0290
P-33463
Figure 50-100-1
Remove the six hoses (Item 1) [Figure 50-100-2] from

the tubelines.
P-33462
NOTE: Mark the hoses for correct installation.
Remove the two lift cylinder hoses (Item 1) [Figure 50-

100-1] from the tubelines (Both sides).

429 of 642
LIFT ARMS (CONT’D) Figure 50-100-5
Figure 50-100-3
1 1
1
P-33467
2
1 Remove the plugs (Item 1) [Figure 50-100-5].
P-33464
Raise the engine cover.
Figure 50-100-4 Figure 50-100-6

1
1
1
P-33466 P-33461
Mark the tubelines for correct installation. Remove the bolt and nut (Item 1) [Figure 50-100-6] from
the lift arm pivot pins (both sides).
Remove the fo ur bolts (Item 1) [Figure 50-100-3] and
[Figure 50-100-4] from the tubline clamps and remove Installation: Tighten the bolts to 32-35 ft.-lb. (43-47 N•m)
the tubelines (Item 2) [Figure 50-100-3]. torque.
Installation: Tighten the bolts to 18-19 ft.-lb. (24-26 N•m) Lower the engine cover.
torque.

430 of 642
LIFT ARMS (CONT’D) Figure 50-100-9
Figure 50-100-7
P-33468

P-33488 100-9] from the lift cylinder mount pin (both sides).

Figure 50-100-8 torque.

Figure 50-100-10
P-33489
P-33469
Position the lifting straps [Figure 50-100-7] and [Figure
50-100-8] and chain hoist in the arrangement shown to
lift and support the lift arms. Remove the lift cylinder pivot pin (Item 1) [Figure 50-
100-10] (both sides).
Raise the hoist until the weight of the lift arm is supported
by the hoist.

431 of 642
LIFT ARMS (CONT’D)
Figure 50-100-11
P-33459
Remove the l ift arm pivot pin [Figure 50-100-11] (both

sides).

Figure 50-100-12
P-33542
Lift and remove the loader lift arm assembly [Figure 50-
100-12].

432 of 642
BOB-TACH Figure 50-110-3
Figure 50-110-1
P-33481
1
Remove the rod end pivot pin (Item 1) [Figure 50-110-3].

P-33471 (Both sides)
Figure 50-110-4
Tilt the Bob-Tach forward so it is parallel to the flo or, set
the Bob-Tach on blocks (Item 1) [Figure 50-110-1].

Figure 50-110-2
P-33482
1
Remove the tilt cylinder rod end (Item 1) [Figure 50-110-

P-33480 4].
Remove the retainer bolt (Item 1) [Figure 50-110-2] from

the pivot pin. (Both sides)

26 N•m) torque.

433 of 642
BOB-TACH (CONT’D) Figure 50-110-7
Figure 50-110-5
1
P-33485
Remove the Bob-Tach [Figure 50-110-7].

P-33483
NOTE: Always inspect the Bob-Tach pivot pin
bushings and seals in lift arms for wear or
Remove the retainer bolt and washer (Item 1) [Figure damage. Replace as needed.
50-110-5] from the Bob-Tach pivot pin (both sides).

Installation: Tighten the bolt and retainer nut to 32-35 ft.-
lb. (43-47 N•m) torque.
Figure 50-110-6
P-33484
Remove the p ivot pin (Item 1) [Figure 50-110-6] (both

sides).

434 of 642
BOB-TACH (CONT'D) Figure 50-110-10
Bob-Tach Lever And Wedge
Figure 50-110-8
1 P-33474
Remove the stop bolt (Item 1) [Figure 50-110-10] and

P-33471 nut.
Figure 50-110-11
Use the following procedure to remove and install the
Bob-Tach lever, spring, and wedge.

Tilt the Bob-Tach forward so it is parallel with the floor, set
the Bob-Tach on blocks (Item 1) [Figure 50-110-8].
Figure 50-110-9 1
5 P-33475
4
3
Remove the clevis assembly (Item 1) [Figure 50-110-11].
2
1
P-33473
Remove the lever mounting nut (Item 1) [Figure 50-110-

9], washer (Item 2) [Figure 50-110-9] spring (Item 3)
[Figure 50-110-9], lever (Item 4) [Figure 50-110-9] and
bolt (Item 5) [Figure 50-110-9].
Before installation of t he parts, put grease on the Bob-

Tach handle pivot (Item 6) [Figure 50-110-9]
Installation: Tighten the nut to 25-28 ft.-lb. (34-38 N•m)

torque.

435 of 642
BOB-TACH (CONT'D) Figure 50-110-14
Bob-Tach Lever And Wedge (Cont’d)
Figure 50-110-12
1
P-33479
1 Remove the wedge (Item 1) [Figure 50-110-14]

P-33476
Replace the wedge if it is worn, bent or damaged.
Loosen the bolt (Item 1) [Figure 50-110-12] on the clevis

assembly.

Figure 50-110-13
2
1
P-33477
Remove the bolt (Item 1) [Figure 50-110-13], handle

pivot (Item 2) [Figure 50-110-13], spring (Item 3) [Figure
50-110-13] and clevis (Item 4) [Figure 50-110-13].
Replace any worn or damaged parts as needed.
Before installation of the parts, put grease on the handle

pivot (Item 2) [Figure 50-110-13], and bolt (Item 1)
[Figure 50-110-13].
Reverse the removal procedure to install the Bob-Tach

lever and wedge assembly.

436 of 642
BOB-TACH (CONT'D)
Pivot Pin Bushing Removal And Installation
Figure 50-110-15
P-33486
Remove and replace the bushing (Item 1) [Figure 50-

110-15] with a driver tool and hammer.

Figure 50-110-16
P-33487
Using a dr iver tool, install the b ushing into the lift arm
[Figure 50-110-16].

437 of 642

438 of 642
FRONT AXLE Remove the roll pin (Item 1) [Figure 50-120-2] from the
front axle pivot pin. (Located on the backside of the front
Removal And Installation axle.)
Raise the lift arm and install an approved lift arm support Figure 50-120-3
Page 10-20-1.)
Remove the side covers. (See ENGINE SIDE COVERS 3

on Page 50-60-1.) 1
Remove the grill frame. (See GRILL FRAME on Page 50-

50-1.)
Remove the steering cylinder. (See Removal And 2

Figure 50-120-1 P-33579
Remove the nut ( Item 1) [Figure 50-120-3] and washer

(Item 2) [Figure 50-120-3].

Installation: Tighten the nut (Item 1) [Figure 50-120-3]
until there is no movement in or out on the pin (Item 3)
[Figure 50-120-3]. Tighten the nut until the hole in the pin
1 is aligned with the slots in the nut and the roll pin can be
installed.
Figure 50-120-4
P-33577
1
Lift the front of the loader backhoe and install jackstands
(Item 1) [Figure 50-120-1] under the main frame.
Remove the front wheel assemblies.
Figure 50-120-2
P-33580
Install the hoist and lifting straps (Item 1) [Figure 50-120-

4] on the front axle.
1 Raise the hoist until the weight of the front axle is

supported by the hoist.
P-33578

439 of 642
FRONT AXLE (CONT’D)
Figure 50-120-5
1
P-33581
Remove the front axle (Item 1) [Figure 50-120-5].

440 of 642
FRONT AXLE (CONT’D) Figure 50-120-8
Pivot Bushing Removal And Installation

1
Remove the front axle. (See AXLE HUB (FRONT) on
Page 50-130-1.)
2
Figure 50-120-6
1 3
P-33583
Remove the lock ring (Item 1) [Figure 50-120-8].
Installation: Align the tab (Item 2) [Figure 50-120-8] on

the lock ring with the groove (Item 3) [Figure 50-120-8]
P-33596 in the pin.

Figure 50-120-9
Straighten the locking tab (Item 1) [Figure 50-120-6] up
and out of the axle pivot pin lock nut.
1
Figure 50-120-7
2
1
3
P-33584

P-33582
Installation: Align the tab (Item 2) [Figure 50-120-9] in
the bushing with the groove (Item 3) [Figure 50-120-9] in
Remove the nut (Item 1) [Figure 50-120-7]. the pin.
Installation: Tighten the nut until the pi vot pin does not
move forward or back and the l ocking tab (Item 1)
[Figure 50-120-6] aligns with the notch in the nut.

441 of 642
FRONT AXLE (CONT’D) Figure 50-120-12
Pivot Bushing Removal And Installation (Cont’d)
Figure 50-120-10
P-33595
NOTE: Make sure the shaft (Item 1) [Figure 50-120-12]

P-33589 is fully seated in the front axle.
Figure 50-120-13
Set the axle assembly in a press [Figure 50-120-10].
1

Inspect the axle pivot pin bushing and replace as
needed. 2
Figure 50-120-11
P-33593
Use a hammer and punch (Item 1) [Figure 50-120-13] to

remove the front and rear bushings (Item 2) [Figure 50-
1 120-13] from the front axle.
P-33594
Installation: Turn the axle assembly (Item 1) [Figure 50-

120-11] over, and press the shaft (Item 2) [Figure 50-
120-11] into the front axle.

442 of 642
AXLE HUB (FRONT) Figure 50-130-3
The procedure for the left and right hubs is the same. The
left hub is shown.
Lower the lift arms to the work surface.
Figure 50-130-1
1
P-33630
1 Remove the cover (Item 1) [Figure 50-130-3].
Figure 50-130-4

P-33577
Raise the front of the loader backhoe and install

jackstands (Item 1) [Figure 50-130-1] under the main
frame.
Remove the front tire.
Figure 50-130-2
1
P-33631
Remove the cotter pin (Item 1) [Figure 50-130-4].
P-33629
Remove the two screws (Item 1) [Figure 50-130-2] (top

and bottom).

443 of 642
AXLE HUB (FRONT) (CONT’D) Figure 50-130-7
Figure 50-130-5
2
1
1
P-33640
Remove the inner bearing (Item 1) [Figure 50-130-7]

P-33632 from the shaft.
Figure 50-130-8
Installation: Tighten the nut, until the hub cannot be

rotated on the spindle, to seat the bearings. Loosen the 1
nut one notch (Item 2) [Figure 50-130-5] at a ti me until
the hub turns freely and the cotter pin can be installed.
Figure 50-130-6
P-33637
Remove the outer bearing (Item 1) [Figure 50-130-8]

from the hub.
P-33634
Remove the hub (Item 1) [Figure 50-130-6].

444 of 642
AXLE HUB (FRONT) (CONT’D)
Figure 50-130-9
P-33639
Remove the seal (Item 1) [Figure 50-130-9] and inner

race (Item 2) [Figure 50-130-9] from the hub.

Figure 50-130-10
P-33638
Wash the components in a clean solvent and air dry.
NOTE: Do not use compressed air to dry the

bearings. Completely fill the bearings with a
high quality lithium based grease. Add
additional grease in the cover and the inside
of the hub.

445 of 642

446 of 642
SPINDLE Figure 50-140-3
The procedure is the same for both right and left

spindles. The left spindle is shown.
Figure 50-140-1
P-33654
Remove the tie rod from the spindle [Figure 50-140-3].
1 Remove the front tire.
P-33577 Figure 50-140-4

Raise the front of the loader backhoe and install
jackstands (Item 1) [Figure 50-140-1] under the main
frame.
Figure 50-140-2
1
1
P-33617
Remove the two bolts (Item 1) [Figure 50-140-4] and

washers from the spindle cap.
2 Installation: Tighten the bolts to 4-5 ft.-lb. (5,5-6,5 N•m)

P-33651 torque.
Remove the nut (Item 1) [Figure 50-140-2] from the tie

rod.
Remove the cotter pin, nut and washer (Item 2) [Figure

50-140-2] from the tie rod.
Installation: Tighten the bolt to 140-155 ft.-lb. (190-210

N•m) torque.

447 of 642
SPINDLE (CONT’D) Figure 50-140-7

1
Figure 50-140-5
P-33620
Remove the retainer (Item 1) [Figure 50-140-7].

P-33618
Figure 50-140-8

1
Installation: Fill the cap with a high quality lithium base

grease.
Figure 50-140-6 3
1 2
P-33621
Loosen the nut (Item 1) [Figure 50-140-8].
Installation: Tighten the nut until the spindle does not

move up or down in the front axle. Ensure the spindle
P-33619 moves freely. Align the groove (Item 2) [Figure 50-140-8]
in the nut with the gr oove (Item 3) [Figure 50-140-8] in
the spindle to allow the retainer to be installed.
Remove the two b olts (Item 1) [Figure 50-140-6] from
the retainer.
Installation: Tighten the bolts to 4-5 ft.-lb. (5,5-6,5 N•m)

torque.

448 of 642
SPINDLE (CONT’D) Figure 50-140-11

1
Figure 50-140-9
P-33625
Remove the bearing (Item 1) [Figure 50-140-11] from

P-33623 the spindle.
Installation: Apply a high quality lithium based grease to

Support the spi ndle [Figure 50-140-9] and remove the the thrust bearing.
nut (Item 1) [Figure 50-140-9]. Remove the spindle.

Figure 50-140-12
Figure 50-140-10
P-33626
P-33624
Remove the thrust washer (Item 1) [Figure 50-140-12]

Remove the bushings (Item 1) [Figure 50-140-10] from and flat washer (Item 2) [Figure 50-140-12].
the front axle.

449 of 642

450 of 642
ARM Figure 50-150-3

1
Set the bucket flat on the ground.
Figure 50-150-1
P-35203
Remove the bolt (Item 1) [Figure 50-150-3] and nut.

Remove the pin (Item 2) [Figure 50-150-3] from the rod
end of the arm cylinder.
P-35200
torque.
Support the boom wiht a hoist (Item 1) [Figure 50-150-

1]. Retract the arm cylinder.
Figure 50-150-2
P-35201
Install a hoist on the arm [Figure 50-150-2].

451 of 642
ARM (CONT’D) Figure 50-150-5
WARNING
immediately.
W-2145-0290
P-35207
Figure 50-150-4
Remove the bolt (Item 1) [Figure 50-150-5] from the arm
pivot pin. (Both sides)

1 torque.

Remove the arm pivot pin (Item 2) [Figure 50-150-5].
Figure 50-150-6
P-35206
Relieve hydraulic pressure by moving the backhoe

control levers with the engine off.
Mark the hoses for correct installation.
Remove the h oses (Item 1) [Figure 50-150-4] from the

bucket cylinder. Install caps and plugs. P-35209
Raise the h oist (Item 1) [Figure 50-150-6] and remove

IMPORTANT the arm.

damage the system.
I-2003-0888

452 of 642
ARM (CONT’D)
Bushing Removal And Installation
Remove the arm. (See Removal And Installation on Page

50-150-1.)
Figure 50-150-7
P-35211

Remove the two bushings (Item 1) [Figure 50-150-7].
Installation: Fully seat the bushing (Item 1) [Figure 50-

150-7] in the bore of the arm. (Both sides)

453 of 642

454 of 642
BOOM Figure 50-160-2
Remove the arm. (See ARM on Page 50-150-1.)

1
Figure 50-160-1
P-35213
Mark the hoses for correct installation. Remove the

hoses (Item 1) [Figure 50-160-2].
P-35212 Install caps and plugs.
Figure 50-160-3
Lower the boom to the ground [Figure 50-160-1].

With the engine off, move the backhoe control levers to
1
WARNING
Hydraulic fluid escaping under pressure can have 2
P-35214
immediately.
W-2145-0290
Remove the bolt (Item 1) [Figure 50-160-3] and nut.

IMPORTANT torque.

damage the system.
I-2056-0793

455 of 642
BOOM (CONT’D) Figure 50-160-6
Figure 50-160-4
1 2 P-35175
Remove the bolt (Item 1) [Figure 50-160-6] and nut from

P-35215 the base end cylinder pivot pin (Item 2) [Figure 50-160-
6] of the boom cylinder.
Support the arm cylinder (Item 1) [Figure 50-160-4]. Installation: Tighten the bolt to 18-19 ft.-lb. (24-26 N•m)
Remove the pin (Item 2) [Figure 50-160-4]. torque.

Remove the cylinder. Figure 50-160-7
Figure 50-160-5
2
1
1
P-35176
P-35179
Remove the cylinder pin (Item 1) [Figure 50-160-7].
Install the c ylinder base end pivot pin (Item 1) [Figure

50-160-5].
Install the bolt (Item 2) [Figure 50-160-5] and nut.
Install a hoist (Item 3) [Figure 50-160-5] on the pin.
Raise the hoist to support the weight of the boom.

456 of 642
Figure 50-160-8
1 P-35174
Remove the bolt (Item 1) [Figure 50-160-10] from the

P-35177 bucket cylinder hose clamp (Item 2) [Figure 50-160-10].

Remove the bolt (Item 1) [Figure 50-160-8]. torque.

Remove the hose clamp.
torque.
Figure 50-160-11
Figure 50-160-9
P-35217
P-35178
Remove the bo lt (Item 1) [Figure 50-160-11] from the

Remove the pin (Item 1) [Figure 50-160-9]. arm cylinder hose clamp (Item 2) [Figure 50-160-11]
(both sides).

torque.
Remove the hose clamp (both sides).

457 of 642

1
Figure 50-160-12
1 P-35182
2
Slide the cylinder hoses (Item 1) [Figure 50-160-14]

P-35180 through the boom. Remove the boom.
Remove the bolt (Item 1) [Figure 50-160-12] and nut

from the boom pivot pin.

torque.
Remove the boom pivot pin (Item 2) [Figure 50-160-12].
Figure 50-160-13
P-35181
Lower the hoist and remove the boom cylinder (Item 1)

[Figure 50-160-13].

458 of 642
SWING FRAME
Boom Pivot Bushing Removal And Installation
Remove the boom. (See BOOM on Page 50-160-1.)
Figure 50-170-1
P-35196
Remove the b ushing (Item 1) [Figure 50-170-1] (both

sides).
Installation: Fully seat the bushings in the swing frame.

459 of 642
SWING FRAME (CONT’D) Figure 50-170-4
Remove the boom. (See BOOM on Page 50-160-1.) 2
Figure 50-170-2
1
1
P-35185
Remove the pin (Item 1) [Figure 50-170-4] using a slide

hammer (Item 2) [Figure 50-170-4] (both sides).
P-35183 Figure 50-170-5
Remove the bolt (Item 1) [Figure 50-170-2] (both sides).

Installation: Tighten the bolt to 18-19 ft.-lb. (24-26 N•m) 3
torque.
Figure 50-170-3
P-35191
Install the bo om cylinder pivot pin (Item 1) [Figure 50-

170-5].
1
Install the pivot pin retaining bolt (Item 2) [Figure 50-170-
5].
P-35184
Install a sling (Item 3) [Figure 50-170-5] on the pin.
Remove the retainer bolt (Item 1) [Figure 50-170-3] and

nut (both sides).

torque.

460 of 642
Figure 50-170-6
2
1
1
P-35188
Remove the two bolts (Item 1) [Figure 50-170-8].

P-35186
torque.
Remove the jam nut (Item 1) [Figure 50-170-6] from the
bottom pivot pin. Remove the plate (Item 2) [Figure 50-170-8].

Figure 50-170-7 Figure 50-170-9
P-35187 P-35189
Remove the lock nut (Item 1) [Figure 50-170-7]. Remove the pin (Item 1) [Figure 50-170-9].

461 of 642
Figure 50-170-10
1
P-35194
Remove the two bolts (Item 1) [Figure 50-170-12].

P-35192
torque.
Remove the jam nut (Item 1) [Figure 50-170-10] from the
top pivot pin. Remove the plate (Item 2) [Figure 50-170-12].

Figure 50-170-11 Figure 50-170-13
P-35193 P-35195
Remove the lock nut (Item 1) [Figure 50-170-11]. Remove the pivot pin (Item 1) [Figure 50-170-13].

462 of 642
SWING FRAME (CONT’D)
Figure 50-170-14
P-35198
Slide the hydraulic hose (Item 1) [Figure 50-170-14]

through the swing frame.

Remove the swing frame.

463 of 642
SWING FRAME (CONT’D) NOTE: Make sure that the bushing is ce ntered into
the casting hole and that it starts in the hole
Boom Swing Bushing Removal And Installation evenly and square.
The procedure is the same for both top and bottom pivot Figure 50-170-16
pin bushings. The top bushing is shown.
IMPORTANT 5
1
Do Not point (ha mmer) on the boom s wing bracket.
Excess pressure can cause the casting to crack.
I-2095-1195
2
Figure 50-170-15 3
4
P-35219
5
Put the washer (Item 1) [Figure 50-170-16] over the

2 flanged end of the bushing.

1
Put the spacer (Item 2) [Figure 50-170-16] and the
washer (Item 3) [Figure 50-170-16] over the bushing
hole casting. Center the spacer and the washer over the
3 bushing hole.
4 Install the bolt (Item 4) [Figure 50-170-16] through the

P-35218 washers, the spacer and the bushing. Install the nut (Item
5) [Figure 50-170-16].
Install a spacer (Item 1) [Figure 50-170-15] and washer Tighten the bolt and nut until the bushing is seated in the
(Item 2) [Figure 50-170-15] over the flanged end of the casting.
bushing.
The spacer (Item 1) [Figure 50-170-15] must be

centered over the bushing to avoid contact between the
bushing and the spacer during removal.
Install the was her (Item 3) [Figure 50-170-15] onto the

opposite end o f the bushing. This washer must be
centered on the bushing and must not contact the
casting.
Install the bol t (Item 4) [Figure 50-170-15] and the nut

(Item 5) [Figure 50-170-15] through the washers and the
spacer.
Installation: Tighten the bolt and nut to r emove the

bushing from the casting.
Apply a fi lm of grease to the outer diameter of th e

bushing and to the inner diameter of the casting.
Center the bushing on the casting hole.

464 of 642
X-CHANGE™ Figure 50-180-3

1
Remove the b ucket. (See the Operation & Ma intenance
Manual for the correct removal procedure.)
1
Figure 50-180-1
P-15087
Remove the washers (Item 1) [Figure 50-180-3].
Figure 50-180-4
P-33739
1

Support the boom with a hoist [Figure 50-180-1].
Figure 50-180-2
P-15086
Remove the plate (Item 1) [Figure 50-180-4].
P-15088
Remove the snap rings (Item 1) [Figure 50-180-2].

465 of 642
X-CHANGE™ (CONT’D) Figure 50-180-7
Figure 50-180-5
1
P-15083
Remove the washer (Item 1) [Figure 50-180-7].

P-15084
Figure 50-180-8
Remove the link (Item 1) [Figure 50-180-5].
Figure 50-180-6

1
1
P-15081
Remove the pin (Item 1) [Figure 50-180-8] and remove

P-15082 the X-Change™ from the arm.
Remove the snap ring (Item 1) [Figure 50-180-6].

466 of 642
BUCKET Loader Bucket Teeth Removal And Installation
Backhoe Bucket Teeth Removal And Installation Figure 50-190-3
Figure 50-190-1
1
P-35650
P-35226
Remove the two bol ts (Item 1) [Figure 50-190-3], nuts
and washers.
Remove the two bolts (Item 1) [Figure 50-190-1], nuts
and washers. Figure 50-190-4

torque.
Figure 50-190-2
P-35651
Remove the bucket teeth (Item 1) [Figure 50-190-4].
P-35199
Remove the bucket teeth (Item 1) [Figure 50-190-2].

467 of 642

468 of 642
STABILIZER Figure 50-200-3
Lower stabilizer to work surface. 2
Figure 50-200-1 1
P-40190

1
Figure 50-200-4
P-40188

Remove the cover bolt (Item 1) [Figure 50-200-1].
Figure 50-200-2
1 P-40191
Rotate the cylinder (Item 1) [Figure 50-200-4] up and

secure.
P-40189
Remove the pin retainer bolt (Item 1) [Figure 50-200-2].

torque.

469 of 642
STABILIZER (CONT’D) Figure 50-200-7
Figure 50-200-5
1
P-40194
Remove the nut and washer (item 1) [Figure 50-200-7].

P-40192
Installation: Tighten the nut until it is firmly seated. Do
not overtighten causing the frame to bend or deflect.
Support the st abilizer and remove the pi n retainer bolt
(Item 1) [Figure 50-200-5]. Remove the pin (Item 2) Figure 50-200-8
[Figure 50-200-5].

Installation: Tighten bolt to 18-19 ft.-lb. (24-26 N•m)
torque.
Figure 50-200-6 1
P-40195
Remove the pin retainer bolt (Item 1) [Figure 50-200-8]
1 Installation: Tighten bolt to 1 8-19 ft.-lb. (24-26 N•m)

P-40193 torque.
Remove the stabilizer pad (Item 1) [Figure 50-200-6].

470 of 642
STABILIZER (CONT’D)
Figure 50-200-9
P-40196
Figure 50-200-10

1
P-40197
Remove the stabilizer (Item 1) [Figure 50-200-10].

471 of 642

472 of 642
ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2 SAFETY &
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3 MAINTENANCE
Alternator Regulator Test With Voltmeter. . . . . . . . . . . . . . 60-30-4
Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Full Field Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-30-7 DRIVE
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . 60-30-12 SYSTEM
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-11
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-11
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

ELECTRICAL
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . 60-20-2 SYSTEM &
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3 ANALYSIS
CAB LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-50-1 ENGINE
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 60-50-3 SERVICE
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2 SPECIFICATIONS
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-14
Checking The Starter In The Loader . . . . . . . . . . . . . . . . . 60-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-13

473 of 642

474 of 642
Printable Version Click Here
WIRING SCHEMATIC
B100 (S/N 570011001 AND ABOVE)
(PRINTED OCTOBER 2002) 24 FUSE/RELAY CENTER BACK UP ALARM
E10 E9
V-0195 9
15 16 17 18 19 20 21 22 23 28 A A
C 020
X
B B
66
58 58
1 2 3 4 5
13
23
13
01
11
B
A
OPTION OPTION OPTION 9 03 9
CAB CAB LIGHTS 6 5 4 03 C 019
8 04
POSITION
85 85
POSITION
86 86 10
POSITION
B
A
EMPTY
EMPTY
EMPTY
3 2 1
15A 2 3
10
11 PRESSURE SWITCH
20A 15A 20A 20A 7.5A 20A 7.5A 15A 20A 15A 15A
7
46
12
30 87 30 87 7
FLASHING UNIT 1 5 6
40
12
15
48
46
84
31
27
65
82
26 or 43
3
25
7
OPTION LIGHTS 87A 87A
PRESSURE SWITCH
48
FILTER OIL PRESSURE
31
15
84
C 016
SWITCH A
85 B 4 5
B
A
C 015
85
C 017
AUXILIARY A
B
A
POWER SOCKET B
15
FUEL PUMP NOTE: THIS WIRE IS NOT
B
A
C 009 ON ALL MACHINES.
15
B
A
HORN SWITCH KILL SWITCH
40
41
HYD. OIL COOLER REAR REAR
SWITCH PRESS TO OPERATE
BUTTON
30b 8 8 D D 8
R 12 12 C C 12
C018
L 02 02 B B 02
M FAN MOTOR 30 6 6 6
26 or 43 A A
KILL SWITCH
25
59
80
8 27 15
FRONT C C C
73 73 49
A A A
C 006
C
D
B
A
57 49a
C 008 B B 57 B
FUEL
C
D
B
83
A
D D D
C 003
SOLENOID HYD. PRESSURE LIGHT
HYD. FILTR GLOW PLUGS E E
25
59
80
8
LIGHT F F
29 G G 29
30 H H 30
E
*
C 014 HOURS METER

E
*
WATER TEMPERATURE GAUGE ENGINE

H COOLANT
35
80
SENDER
Dealer Copy --t Not for Resale
29
36
30
- 21
HORN FRONT
+ V
FUEL QUANTITY GAUGE ENGINE OIL PRESSURE TIMER
59
SWITCH
3 30 36 29
R 4
CONTROL LIGHT
ALTERNATOR Y
41 D F 5 B
12 41 CONTROL LIGHT
FUEL SENDER G D 8 E G 4 IGNITION SWITCH
LOW OIL PRESSURE
7 B E 16 2 21
B 11 D C
C 002
3 A C 11 21 2
Y 16 C D
11 C A 3 4 37
HORN SWITCH G A
C 001
16 E B 7 FRONT 1 8 OFF
F E
5 F G 12
H F 1 RUN
55 H H 55 GLOW PLUG
17 B B 17
37 A H START
WORK LIGHTS FRONT

A 65
C 66
37 37
82 31
H
83 15 2
B
C 004
23 24
LEFT SIDE RIGHT SIDE D
SWITCH SWITCH E 30
WORKING LIGHTS WORKING LIGHTS G 60 22
55 55 FRONT REAR 40
F 29
GLOW PLUGS
WORK LIGHTS REAR 19 29
37
55
17 14 14 HR
C
D
D
C
B
B
A
C 007 C 005 50 36
C
D
D
C
B
B
A
13
13 2
C 013
35 A A
55
37
60
17
17
40
ALTERNATOR 13 B B 1
5 1 1 13
9 2
C 011
2
G
A
3 3 BATTERY C 012
22
BATTERY STARTER
DISCONECT A
M
(8-26-02) V-0195
475 of 642
WIRING SCHEMATIC
OPTION
B100 (S/N 570011001 AND ABOVE)
(PRINTED OCTOBER 2002)
V-0196
OPTIONS
PART OF STANDARD WIRING HARNESS 8
TURN AND ROAD LIGHTS E
2 D
21 C
4 G
C 001
1 F
37 A
TURN LIGHTS FRONT 17 B
60 40 H
61 SWITCH
61
SWITCH ROAD LIGHTS
ROAD LIGHTS FRONT WORKING LIGHTS
LEFT SIDE RIGHT SIDE REAR 65 A A 65
66 C C 66
ROAD LIGHTS REAR CHANGE OVER SWITCH
17 17 TURN LIGHTS H H 82
B B 83
C 004
60 40 D D
TURN LIGHTS E E
REAR 40 F G 60
60 G F 40

61 A A 61
17
55
60
37
40
17
60 D B 61
C 010
C
D
C
D
B
B
A
A
40 C C 40
C 007 C 005 61 60
B D
CAB
PART OF STANDARD WIRING HARNESS
27 C
73 A
57 B
HEATER MOTOR
D
C 003
57 FRONT WIPER SWITCH HEATER MOTOR
M 73
E
43 V F
29 G
73
M 30 H
A
B 57
C 006
C 43
D 82 REAR WIPER
43 V
M
WATER TEMPERATURE GAUGE
+ V
(8-26-02) V-0196
476 of 642
ELECTRICAL SYSTEM INFORMATION
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow ins tructions can
W-2003-0199
PROBLEM SOLUTION#
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

477 of 642
ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse Location
Description Figure 60-10-2
Figure 60-10-1
2 3 4 5
1
6 10
7 8 9
MS1403
P-33309
The electrical system is protected from overload by fuses
under the fuse panel cover [Figure 60-10-1].
The loader backhoe has a 12 volt, negative ground
alternator charging system. The electrical system is Remove the cover to check or replace the fuses.
protected by fuses located on the front panel and below

the operator seat [Figure 60-10-1]. The location and sizes are shown below and [Figure 60-
10-2].
The fuses will protect the electrical system when there is
an electrical overload. The reason of the overload must
REF DESCRIPTION AMP.
be found before starting the engine again.
1 Hyd. Cooling Fan 20
2 Front/rear horn 15
3 Auxiliary Outlet 20
4 Backup alarm 10
5 Wipers 15
6 Dash 7.5
7 Front/rear lights 20
8 Hyd. Filter 7.5
9 Glow plugs 15
10 Direction Indicators 10

478 of 642
BATTERY Figure 60-20-2
WARNING 2
Batteries contain acid which burns eyes and skin on

contact. Wear goggles, protective clothing and
1
rubber gloves to keep acid off body.
1
In case of acid contact, wash immediately with water.
In case of e ye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
P-32798
minutes.
If electrolyte is taken internally drink large quantities Remove the two bolts (Item 1) [Figure 60-20-2] and hold
of water or milk! DO NO T induce vomiting. Get down clamp (Item 2) [Figure 60-20-2].
prompt medical attention.
W-2065-1296
Remove the battery part way.

2
1
1 1 2
P-33780 P-32799
Remove the four bolts (Item 1) [Figure 60-20-1] and Always disconnect the negative (-) cable (Item 1) [Figure
remove the battery box cover (Item 2) [Figure 60-20-1]. 60-20-3] first to prevent sparks.
Disconnect the positive (+) cable (Item 2) [Figure 60-20-

3].
Remove the battery.

479 of 642
BATTERY (CONT’D) Servicing The Electrical System
Removal And Installation (Cont'd)
Figure 60-20-4
WARNING
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
P9589
Figure 60-20-6
Figure 60-20-5

P9588
P9590
The battery cables must be clean and the connections

Installation: Always clean the terminals and cable ends tight. Remove acid or corrosion from the bat tery and
when installing a new battery as shown in [Figure 60-20- cables with a s odium bicarbonate (baking soda) and
4] & [Figure 60-20-5]. water solution as shown in [Figure 60-20-6].
When installing the battery in the loader, do not touch any Clean the ter minals and cable ends as shown in fig ure
metal parts with the battery terminal posts. [Figure 60-20-4] and [Figure 60-20-5].
Connect and tighten the battery cables. Connect the Check the electrolyte level in the battery. Add distilled
negative (-) cable last to prevent sparks. water as needed.
Put battery saver P/N (6664458) or grease on the battery

terminals and cable ends to prevent corrosion.

480 of 642
BATTERY (CONT'D) Figure 60-20-8
Using A Booster Battery (Jump Starting)
If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator's seat and one person to co nnect and 1
disconnect the battery cables.
The key must be OFF. The booster battery must be 12

volt.
WARNING P-33539

contact. Wear goggles, protective clothing and Connect the end of the second cable to the negative (-)
rubber gloves to keep acid off body. terminal of the booster battery. Connect the other end of
the same cable (Item 1) [Figure 60-20-8] to the loader
In case of acid contact, wash immediately with water. backhoe frame near the engine.
In case of e ye contact get prompt medical attention
and wash eye with clean, cool water for at least 15 Start the engine.
minutes.

If electrolyte is taken internally drink large quantities
of water or milk! DO NO T induce vomiting. Get
prompt medical attention. WARNING
W-2065-1296
Keep arcs, sparks flames and lighted tobacco away
Remove the battery box cover. from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Figure 60-20-7
Do not jump s tart or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
1 connecting to a charger. Unplug c harger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.

W-2066-1296
IMPORTANT
P-33493
Damage to the alternator can occur if:
• Engine is operated with ba ttery cables
disconnected.
Connect the end of the first cable to the positive (+) • Battery cables are connected when using a fast
terminal of the booster battery. Connect the other end of charger or when welding on the loader. (Remove
the same cable (Item 1) [Figure 60-20-7] to the positive both cables from the battery.)
terminal on the loader backhoe battery. • Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

481 of 642
BATTERY (CONT'D)
Using A Booster Battery (Jump Starting) (Cont’d)
After the engine has started, remove the ground (-) cable
(Item 1) [Figure 60-20-8] first.
Remove the c able from the po sitive terminal (Item 1)

[Figure 60-20-7].

482 of 642
ALTERNATOR Description
Adjusting The Alternator Belt Figure 60-30-3
Stop the engine. Open the engine cover.

1
Remove the left side cover.
Figure 60-30-1 3
4 2
P-35312 P-35312A
The output terminal (Item 1) [Figure 60-30-3].

1
The battery or power sensing terminal (Item 2) [Figure
P-32730 60-30-3].

The ignition terminal (Item 3) [Figure 60-30-3].
Loosen alternator mounting and adjustment bolts (Item 1)
[Figure 60-30-1]. Open terminal not used in th e loader harness (Item 4)
[Figure 60-30-3].
Figure 60-30-2
Access hole for full field test (Item 5) [Figure 60-30-3].
P-32795
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force [Figure 60-30-2].
Tighten the adjustment and mounting bolts.

483 of 642
ALTERNATOR (CONT’D) Figure 60-30-5
Tests
Perform the following alternator tests in this order:
Alternator Output Test: Tests the alternator and regulator

output. 2
Full Field Test: Tests the maximum amperage output of

the alternator. 1
Alternator Regulator Test: Tests the regulator voltage

output.
Alternator Output Test P-35308
Rotate the battery disconnect lever clockwise to r estore

WARNING power from the battery.
With the parking brake engaged, start the engine and run
When an engine is running in an enclosed area, fresh at full RPM.
air must be added to avoid concentration of exhaust
fumes. If t he engine is stationary, vent the exhaust

The ammeter reading should be be tween 35 and 40
outside. Exhaust fumes contain odorless, invisible amps.
gases which can kill without warning.
W-2050-1285
If the ammeter reading is less than 35 amps d o the full
field test.
disconnect battery from system.
Disconnect the r ed wire (Item 1) [Figure 60-30-4] from

the alternator. Connect that wire to the negative (-) side
of the ammeter (Item 1) [Figure 60-30-5].
Connect the positive (+) side of the ammeter to the

output terminal at th e alternator (Item 2) [Figure 60-30-
5].
Figure 60-30-4
P-35305

484 of 642
ALTERNATOR (CONT’D) Alternator Regulator Test
Full Field Test Figure 60-30-7
With the parking brake engaged, start the engine and run
at full RPM.
Figure 60-30-6
1
1
P-35313
Disconnect the fue l stop solenoid connector (Item 1)

[Figure 60-30-7].
P-35311
Turn the lights on (if equipped) and crank the engine for

30 seconds to discharge the battery.
Place a small screw driver in the test port (Item 1)
[Figure 60-30-6] to provide a gr ound to the alternator Connect the fuel stop solenoid connector.
case. This will give maximum amperage output from the
alternator. With the parking brake engaged, start the engine and run
at full RPM.
NOTE: The Full Field Test should only last long
enough to get ammeter reading to prevent The ammeter reading should be ar ound 35 amps an d
damage to the alternator. slowly decrease with alternator output.
The ammeter reading should be above 35 amps. If ammeter reading is low or does not decrease with time,
replace the alternator’s regulator.
If the ammeter reading is low, repair or replace the
alternator. Rotate the battery disconnect lever counterclockwise to
Reconnect the alternator wires.

WARNING Rotate the battery disconnect lever clockwise to r estore
power from the battery.
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
NOTE: The alternator regulator test can also be run
fumes. If t he engine is stationary, vent the exhaust
using a voltmeter.
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-1285

485 of 642
ALTERNATOR (CONT’D)
Alternator Regulator Test With Voltmeter
Figure 60-30-8
P-35314
Connect the positive (+) voltmeter lead to the positive (+)

battery terminal (Item 1) [Figure 60-30-8].

Connect the negative (-) voltmeter lead to the negative (-
) battery terminal (Item 2) [Figure 60-30-8].
Start the engine, engage the parking brake and run at full
RPM.
The voltmeter should read between 13.9 and 14.7 volts.
If the voltmeter reading is not within this range, replace

the alternator’s regulator.

486 of 642
ALTERNATOR (CONT’D) Remove the alternator belt from the alternator.
Removal And Installation Figure 60-30-11
support device. (See Installing The Lift Arm Support
Device on Page 10-20-1.) 1
Open the engine cover, remove the cover from the le ft

side of the engine.

2
Figure 60-30-9
P-35309
Remove the adjusting bolt (Item 1) [Figure 60-30-11]

and mounting bolt and nut (Item 2) [Figure 60-30-11].
Remove the alternator.

1
P-35305
Disconnect the wiring harness (Item 1) [Figure 60-30-9]

from the alternator.
Remove the red wire (Item 2) [Figure 60-30-9].
Figure 60-30-10
P-35304
Loosen the alternator adjusting bolt (Item 1) [Figure 60-

30-10].

487 of 642
ALTERNATOR (CONT’D)
1. Nut 10. Rotor Assy. 19. Regulator

2. Pulley 11. Bearing 20. Screw
3. Spacer 12. Cover 21. Brush
4. Frame Assy. 13. Frame End 22. Spring
5. Stud 14. Nut 23. Screw
6. Bearing 15. Insulator 24. Screw
7. Plate 16. Nut 25. Brush
8. Screw 17. Bolt 26. Cover
9. Screw 18. Rectifier 27. Bolt
10
9
12
4 5
11
6

7
8
26
27
3 24
16 25
1
15
14 22 23
21
13
20
19
17 18

488 of 642
Pulley Removal And Installation
Remove the alternator from the machine. See “Removal

And Installation” on page 5.
Figure 60-30-12
P10051
2 Assembly: Tighten the p ulley nut [Figure 60-30-14] as

shown to 70-94 ft.-lb. (94-127 N•m) torque.
P10048

Wrap a V-belt in the alternator pulley and clamp the
pulley into a vise as s hown [Figure 60-30-12]. Do not
cover tighten vise.
Figure 60-30-13
P10050
Using a box end wrench (Item 1) [Figure 60-30-13] (22

mm) loosen and remove the nut (Item 1) [Figure 60-30-
12] while the pulley shaft (Item 2) [Figure 60-30-12] is
held firmly with a 6-point socket (Item 2) [Figure 60-30-
13] (10 mm).
NOTE: A six point box end wrench should be used, a

twelve point box end wrench may damage the
corners of the nut.

489 of 642

1
Figure 60-30-15
2
2
1
1
3
P10032
Remove the three screws (Item 1) [Figure 60-30-17] and

P10020 remove the regulator (Item 2) [Figure 60-30-17].
NOTE: The lengths of the screws are different, and

Remove the three screws (Item 1) [Figure 60-30-15], the must be marked prior to disassembly. If the
nut and insulator (Item 2) [Figure 60-30-15] and remove wrong screw is used, damage to the alternator
the end cover (Item 3) [Figure 60-30-15].

may occur.
Figure 60-30-16 Figure 60-30-18
2
1 1 1
1
1
2
1
P10031 P10033
Remove the two screws (Item 1) [Figure 60-30-16] and Loosen the four screws (Item 1) [Figure 60-30-18] that
remove the brush holder (Item 2) [Figure 60-30-16]. hold the rectifier lead wires. Unwrap and straighten the
rectifier lead wires from the screws, and lift the r ectifier
(Item 2) [Figure 60-30-18] from the stator.

490 of 642

2 1
Figure 60-30-19
1 2
2 1
P10037
Support the alternator housing (Item 1) [Figure 60-30-

P10034 21] on blocks.
With the nut (Item 2) [Figure 60-30-21] on the p ulley

Remove the two bolts (Item 1) [Figure 60-30-19] and two shaft, tap the rotor out of th e bearing. A p ress may be
nuts (Item 2) [Figure 60-30-19]. needed if the bearing is stuck to the rotor shaft.

Figure 60-30-20 NOTE: Care should be used not to damage the fan,
slip ring, etc.
Figure 60-30-22
2
1
P10036
Remove the four screws (Item 1) [Figure 60-30-22] and

remove the retainer plate (Item 2) [Figure 60-30-22].
P10035
Using a p uller (Item 1) [Figure 60-30-20], remove the

rear housing as shown in [Figure 60-30-20].

491 of 642

1
Figure 60-30-23
P10042
Remove the bearing (Item 1) [Figure 60-30-25]from the

P10039 rotor shaft, using a puller (Item 2) [Figure 60-30-25].
NOTE: A vise with padded jaws may be used to

Support the alternator housing (Item 1) [Figure 60-30- secure the rotor assembly. Do not over
23] on blocks, and press the bearing from the housing. tighten the vise.

Figure 60-30-24
P10040
Assembly: Press a ne w bearing in the housing [Figure

60-30-24].

492 of 642
Rotor Continuity Test
Figure 60-30-26
P10041
Measure the slip ring shaft [Figure 60-30-28].

P10043
Standard measurement is 0.57 inches (14,45n mm)
allowable limit is 0.55 inches (14,0 mm).
Touch the probes to the slip rings [Figure 60-30-26].
Check the slip ring for stained or rough surfaces, use fine
The ohmmeter should read approximately 2.9 ohms.

sandpaper to clean shaft.
If there is no continuity, replace the rotor. Stator Continuity Test
Figure 60-30-27 Figure 60-30-29
P13179 P13177
Check the continuity across the slip rings (Item 1) Check the continuity across each of the four leads of the
[Figure 60-30-27] to the c ore of the rotor (Item 2) stator coil with an ohmmeter [Figure 60-30-29].
[Figure 60-30-27] with an ohmmeter.
If there is no continuity, replace the stator.
If there is continuity, replace the rotor.

493 of 642
Rotor Continuity Test (Cont’d)
Figure 60-30-30
1
2
P1
P2
P4 P3
P10047
Test 3: Touch the positive (+) test probe (Item 1) [Figure

P13178 60-30-32] to the ground terminals, touch the (-) negative
test probe (Item 2) [Figure 60-30-32] to the P1, P2, P3
and P4 terminals. There should be a reading.
Check the c ontinuity across each stator coil lead to th e
core (Frame Assembly) with an ohmmeter [Figure 60- Test 4: Reverse the positions of the test probes from test
30-30]

3, there should be no reading.
Rectifier Continuity (Diode) Test Brush Length
Figure 60-30-31 Figure 60-30-33
1
2
P1
P2
P4
P3
P10046 P10044
Test 1: Touch the positive (+) test probe (Item 1) [Figure Measure the l ength of th e brush protruding from the
60-30-31] to the positive terminal. Touch the negative (-) brush holder [Figure 60-30-33].
test probe (Item 2) [Figure 60-30-31] to the P1, P2, P3
and P4 terminals. There should be no reading. Standard measurement is 0.41 inches (10,5 mm)
allowable limit is 0.18 inches (4,5 mm).
Test 2: Reverse the positions of the test probes from Test
1, there should be a reading.

494 of 642
STARTER Installation: Tighten the starter mounting bolts to 25-28
ft.-lb. (34-38 N•m) torque.
Checking The Starter In The Loader
Stop the engine and open the engine cover.
NOTE: The starter is removed from the loader for
Remove the left side cover. clarity.
Rotate the battery disconnect lever counterclockwise to The key switch must be in the OFF position.
disconnect battery from system
The battery must be at full charge.
Make note of the wiring connections on the s tarter to
ensure correct installation. The cable connections on the ba ttery must be clean and
tight.
Figure 60-40-1
Figure 60-40-3
1
2

2 1
P-35109
P9975
Disconnect the plug (Item 1) [Figure 60-40-1] and three

wires (Item 2) [Figure 60-40-1] from the starter. Connect a jumper wire between battery terminal (Item 1)
[Figure 60-40-3] and the solenoid terminal (Item 2)
Figure 60-40-2 [Figure 60-40-3].
If the starter turns but does not turn the e ngine, the
starter drive has a defect.
1
P-35303
Remove the starter mounting bolts (Item 1 & 2) [Figure

60-40-2].
Remove the starter.

495 of 642
STARTER (CONT’D)
Checking The Starter In The Loader (Cont’d)
Figure 60-40-4
2
1
P9976
Connect a jum per wire between the battery terminal

(Item 1) [Figure 60-40-4] and motor terminal (Item 2)
[Figure 60-40-4].

If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

496 of 642
STARTER (CONT'D)
1. Bearing 9
2. Armature 7
3. Bearing
4. Frame 5 6 8
5. Brush Spring
6. Brush Holder
4
7. Cover 12. Gasket
8. Bolt 3 13. Switch
9. Bolt 14. Nut
10. Bolt 2
15. Washer
11. Cover 1 16. Nut
17. Washer
18. Roller
19. Retainer
10 20. Idler Gear
11
21. Ball
15 12 22. Spring
14

16
18 17
19
20 13
15
16
23 14
22
21
36
35
34
33
32 23. Housing
26
25 24. Screw
24 25. Washer
30 26. O-ring
28
29 27. Housing
28. O-ring
31 29. Snap Ring
29 30. Collar
27 31. Pinion Gear
32. Spring seat
33. Spring
34. Clutch
35. Spring
36. Pinion Shaft
D-2297

497 of 642
STARTER (CONT'D) Figure 60-40-7
Disassembly
Figure 60-40-5
1
N-15021
Remove the fr ame (Item 1) [Figure 60-40-7] from the

N-15019 magnetic switch.
Figure 60-40-8
Remove the cable (Item 1) [Figure 60-40-5] from the
magnetic switch.

Mark the frame and magnetic switch (Item 2) [Figure 60-
40-5]
Figure 60-40-6 2
1
1
N-15022
1
Remove the screws (Item 1) [Figure 60-40-8] from the
1 brush cover (Item 2) [Figure 60-40-8].

N-15020
Remove the bolts (Item 1) [Figure 60-40-6].

498 of 642
Disassembly (Cont'd)
Figure 60-40-9
1 1
1
N-15025
3 Remove the bearings (Item 1) [Figure 60-40-11] from

N-15023 both ends of the armature.
Figure 60-40-12
Using a needle nose pliers, pull the brush springs (Item
1) [Figure 60-40-9] back and remove the brushes (Item
2) [Figure 60-40-9].

NOTE: The brushes are non-replaceable. If the
brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
positive brushes).
Remove the brush holder (Item 3) [Figure 60-40-9] from

the end of the armature.
Figure 60-40-10 1 1
N-15026
1 Remove the bolts (Item 1) [Figure 60-40-12] from the

starter housing.
N-15024
Remove the armature (Item 1) [Figure 60-40-10] from

the frame.

499 of 642
3
Figure 60-40-13
2
N-15029
Remove the idler gear (Item 1) [Figure 60-40-15], rollers

1
N-15027 (Item 2) [Figure 60-40-15] and retainer (Item 3) [Figure
60-40-15].
Remove the starter housing (Item 1) [Figure 60-40-13] Figure 60-40-16

from the magnetic switch.

Figure 60-40-14
N-15042
1
N-15028 In order to remove the snap ring from the pinon shaft, a
tube 0.605 inches (15,4 mm) in diameter by 2.0 inches
(50,8 mm) in length is needed [Figure 60-40-16].
Remove the ball (Item 1) [Figure 60-40-14] from the
pinion shaft.

500 of 642
Figure 60-40-17
N-15047
1 Remove the snap ring (Item 1) [Figure 60-40-19].

N-15045
Figure 60-40-20
Install the tube (Item 1) [Figure 60-40-17] in over the

running clutch.

Figure 60-40-18 2
3 1
4
1
N-15053
2
Remove the collar (Item 1) [Figure 60-40-20], pinion
(Item 2) [Figure 60-40-20] spring (Item 3) [Figure 60-40-
N-15046 20] and spring seat (Item 4) [Figure 60-40-20].
Press down on the starter carrier (Item 1) [Figure 60-40-

18] to extend the pinion shaft. Press down on the pinion
(Item 2) [Figure 60-40-18].
Press the collar (Item 3) [Figure 60-40-18] down to gain

access to the snap ring.

501 of 642
Figure 60-40-21
1 2
N-15035

N-15033 starter housing.
Figure 60-40-24
Remove the pinion shaft (Item 1) [Figure 60-40-21], and
spring (Item 2) [Figure 60-40-21] from the starter drive.

Figure 60-40-22
1
1
N-15030
Remove the spring (Item 1) [Figure 60-40-24] from the

Remove the over running clutch (Item 1) [Figure 60-40-

22].

502 of 642
STARTER (CONT'D) Inspection And Repair
Disassembly (Cont'd) Figure 60-40-27
Figure 60-40-25
1 1
B-14455
N-15031
Inspect the brush cover for discoloration, indication the
starter has been overheated.
Remove the bo lts (Item 1) [Figure 60-40-25] from the
magnetic switch cover. Inspect the pinion teeth for wear and damage.

Figure 60-40-26 Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-27]. A s hort circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
3 2 1 Figure 60-40-28
N-15032
Remover the cover (Item 1) [Figure 60-40-26], gasket

(Item 2) [Figure 60-40-26] and switch (Item 3) [Figure
60-40-26].
N-15036
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to t he armature core [Figure 60-40-28]. There
should be no c ontinuity. If there is continuity, the
armature is grounded and must be replaced.

503 of 642
Inspection And Repair (Cont'd)
Figure 60-40-29
1
B-14460
Measure the segment mica depth (Item 1) [Figure 60-40-

N-15037 31].
Service Limit - 0.008 inch (0,2 mm)

Armature Winding Continuity Test: Use a c ircuit tester,
touch the probes to two commutator segments [Figure If it is worn, replace the armature.
60-40-29]. There should be continuity at any point. If

there is no continuity, the wi nding is open-circuited, Check the commutator surface for burned spots which
replace the armature. usually indicates an open -circuit, and c orrect it us ing
#400 sand paper.
Figure 60-40-30
Figure 60-40-32
B-14458
N-15039
Commutator Run-Out Test: check the commutator run-

out as shown in [Figure 60-40-30]. Check the field windings for wear and damage.
Service Limit - 0.020 inch (0,4 mm) Check all the connections for clean and tight solder
joints.
If the commutator exceeds the service limit, repair as
needed. Field Winding Ground Test: Using a c ircuit tester, touch
one probe to th e field winding end of th e brush and the
other probe to the surface of the frame [Figure 60-40-
32]. There should be no continuity. If there is continuity,
the field windings are grounded.
Replace the field windings.

504 of 642
STARTER (CONT'D) should be no continuity. If there is continuity, replace or
repair.
Inspection and Repair (Cont'd)
Figure 60-40-35
Figure 60-40-33
N-15043
N-15040
Inspect the over clutch (Item 1) [Figure 60-40-35], it

Field Windings Continuity Test: Using a ci rcuit tester, must rotate freely in the direction of the starter rotation
touch one probe to th e wire and the other probe to the and lock in the opposite rotation.
brush [Figure 60-40-33]. There must be c ontinuity. If

there is no continuity, the fi eld windings are open-
circuited. Replace the yoke if the field windings have an
open circuit.
Figure 60-40-34
N-15059
Inspect the brushes for wear and damage.
Replace the brush holder or yoke assembly if the

brushes are worn or damaged.
Check brush spring, for damage or rust. Replace as

needed.
Brush Holder Insulation Test: Use a c ircuit tester, touch

one probe to the positive brush holder plate and the other
probe to th e holder plate [Figure 60-40-34]. There

505 of 642
Inspection and Repair (Cont'd)

50
The following tests should be done without the armature C
assembly. Install the magnetic switch in the switch
housing.
M.T. . . . Main Terminal to which the main cable from
the battery is connected.
C..... C-Terminal to which the wire from the field
windings is connected.
50 . . . . 50-Terminal to which the wire from the start-
ing switch or stator relay is connected. M.T.
B-14470
NOTE: Each test should be performed a short time (3
to 5 seconds) to prevent the magnetic switch
winding from burning. Each test should be Hold-In Test: With the same conditions as in th e pull-in
performed with 12 volts. test, open the connecting Terminal C [Figure 60-40-37].
The pinion should remain in the engaged position.
Figure 60-40-36
Figure 60-40-38
50
50

C
C
M.T. M.T.
B-14471
B-14469
Pull-In Test: Connect the wires as shown in [Figure 60-

40-36]. When connecting Terminal C and M.T. are Return Test: With the s ame conditions as in the hold-in
closed, the pinion should engage. test, open the connecting Terminal 50 [Figure 60-40-38].
The pinion should return immediately.

506 of 642
STARTER (CONT'D)
No Load Test
Figure 60-40-39
Ammeter
50
M.T.
Starter B-14440
The following test should be done after reassembling the

starter:

Clamp the starter in a v ise. Using a 1 2 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the 50 terminal [Figure 60-40-39]. Connect
the negative wire tot he starter body. Using a jumper wire,
connect the 50 terminal to the main terminal.
The starter should show smooth and s teady rotation

immediately after the pinion is engaged. It should draw
less than the specified current.
Service Limit - 220 Amp. Maximum Draw

507 of 642
Assembly
Figure 60-40-40
1
1 2 3
N-15030
Install the spring (Item 1) [Figure 60-40-42] on the

Figure 60-40-43
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.

Install the switch plunger (Item 1) [Figure 60-40-40],
gasket (Item 2) [Figure 60-40-40] and c over (Item 3)
[Figure 60-40-40] on the switch housing.
1
Figure 60-40-41
N-15035
Install the O-ring (Item 1) [Figure 60-40-43] in the starter

1 housing.
1
N-15031
Install the bolts (Item 1) [Figure 60-40-41].

508 of 642
Assembly (Cont'd)
Figure 60-40-44
1
N-15042
In order to install the pinion and snap ring on the pinion

N-15034 shaft, a tube (Item 1) [Figure 60-40-46] 0.605 inch (15,4
mm) in diameter by 2.0 inches (50,8 mm) in length is
needed.
Install the over running clutch (Item 1) [Figure 60-40-44]
in the starter housing. Figure 60-40-47

Figure 60-40-45
1 2
1
N-15044
N-15033
Install the tube (Item 1) [Figure 60-40-47] in the ov er
running clutch.
Install the spring (Item 1) [Figure 60-40-45] and pinion
shaft (Item 2) [Figure 60-40-45] in the over running
clutch.

509 of 642
Assembly (Cont'd)
Place the starter drive on the bench, and press down on

the starter drive housing. 1
Figure 60-40-48
N-15056
Install the pinion (Item 1) [Figure 60-40-50].
Figure 60-40-51
N-15054
1

Install the spring seat (Item 1) [Figure 60-40-48] on the
pinion shaft.
Figure 60-40-49
N-15057
Install the collar (Item 1) [Figure 60-40-51].
N-15055
Install the spring (Item 1) [Figure 60-40-49].

510 of 642
Assembly (Cont'd)
Figure 60-40-52
1
1
N-15041
Install the rollers (Item 1) [Figure 60-40-54] in th e

N-15047 retainer.
Figure 60-40-55
Install the snap ring (Item 1) [Figure 60-40-52]. Pull the
collar (Item 2) [Figure 60-40-52] over the snap ring.
1

Figure 60-40-53
N-15029
1
Install the roller/retainer assembly (Item 1) [Figure 60-
N-15058 40-55] on the starter housing.
Install the idler gear (Item 2) [Figure 60-40-55] over the

With the pinion shaft extended, extend and release the roller/retainer assembly.
pinion (Item 1) [Figure 60-40-53]. The pinion must return
to the fully retracted position.

511 of 642
Assembly (Cont'd)
Figure 60-40-56
1
1
N-15026
Install the two bol ts (Item 1) [Figure 60-40-58]. Tighten

1 the bolts to 60-104 in.-lb. (7-12 N•m) torque.
N-15028
Figure 60-40-59
Install the ba ll (Item 1) [Figure 60-40-56] in the pinion
shaft.

Figure 60-40-57
1 2
N-15025
1 Install the bearings (Item 1 & 2) [Figure 60-40-59] on

N-15027 both ends of the armature.
Install the starter drive (Item 1) [Figure 60-40-57] on the

magnetic switch.

512 of 642
Assembly (Cont'd)
Figure 60-40-60
1
2
N-15049
Install the fr ame (Item 1) [Figure 60-40-62] over the

N-15048 armature.
NOTE: Make sure the tab (Item 2) [Figure 60-40-62] on

Install the ar mature (Item 1) [Figure 60-40-60] in the the frame is aligned with t he slot in the
magnetic switch housing. magnetic switch housing.

Figure 60-40-61 Figure 60-40-63
3
1
1
N-15050 N-15051A
Install the new O -rings (Item 1) [Figure 60-40-61] on Install the brush holder (Item 1) [Figure 60-40-63] on the
both ends of the frame. armature.
Using a needle nose pliers, pull the spring (Item 2)

[Figure 60-40-63] back and install the brushes (Item 3)
[Figure 60-40-63].

513 of 642
Assembly (Cont'd)
Figure 60-40-64
1 N-15019
Install the cable (Item 1) [Figure 60-40-66] on th e

N-15052 terminal. Tighten the terminal to 4 -7 ft.-lb. (5-9 N•m)
torque.
Install the brush cover and screws (Item 1) [Figure 60-

40-64].

Figure 60-40-65
N-15020
Install the thru bolts (Item 1) [Figure 60-40-65]. Tighten

the bolts to 60-104 in.-lb. (7-12 N•m) torque.

514 of 642
CAB LIGHTS Figure 60-50-3
Bulb Removal And Installation
Figure 60-50-1
2
P-36797
1 Support the lamp assembly (Item 1) [Figure 60-50-3].

P-36795 Remove both connectors (Item 2) [Figure 60-50-3] and
remove the lamp.
Carefully remove the lamp guard (Item 1) [Figure 60-50- NOTE: Mark the wires for correct assembly.
1].

Figure 60-50-4
Figure 60-50-2
2 1
2
1 1
P-36798
P-36796
Remove the bulb retainer clip (Item 1) [Figure 60-50-4].

Remove the two screws (Item 1) [Figure 60-50-2] and
lamp retainers (Item 2) [Figure 60-50-2].

515 of 642
CAB LIGHTS (CONT’D)
Bulb Removal And Installation (Cont’d)
Figure 60-50-5
P-36799
Remove the bulb (Item 1) [Figure 60-50-5] from the lamp

housing.

Figure 60-50-6
P-36800
Installation: Align the tangs (Item 1) [Figure 60-50-6] on

the lamp housing with the notches (Item 2) [Figure 60-
50-6] on the bulb. Insert the bulb.
NOTE: Do not touc h the glass part of the bulb, a ny

dirt or oil will shorten the service life of the
bulb.

516 of 642
CAB LIGHTS (CONT’D) Figure 60-50-9
Housing Removal And Installation
Remove the bu lb. See “Bulb Removal And Installation”

on page 1.
1
Figure 60-50-7
P-36909
Remove the nut (Item 1) [Figure 60-50-9].
Figure 60-50-10
P-36907

Remove the harness (Item 1) [Figure 60-50-7] from the
lamp housing.
Figure 60-50-8
P-36910
Remove the housing (Item 1) [Figure 60-50-10] from the

operators cab.
P-36908
Remove the nut cover (Item 1) [Figure 60-50-8].

517 of 642

518 of 642
FUEL LEVEL SENDER Figure 60-60-3

Page 50-30-1.)
Figure 60-60-1
P-36880
Raise the sender unit holder out of the tank [Figure 60-
60-3].
NOTE: Lower arm down in tank to remove sender.

P-36875
Figure 60-60-4

Remove the wires (Item 1) [Figure 60-60-1].
Figure 60-60-2
P-36882
2
Remove the sender unit [Figure 60-60-4].
P-36876
Remove the bolts (Item 1) [Figure 60-60-2] from the

sender unit.
Installation: Tighten bolts to 2 -2.5 ft.-lb. (2.5-3.5 N•m)

torque.
Remove the bolts (Item 2) [Figure 60-60-2] from sender

unit holder.
Installation: Tighten bolts to 7-7.5 ft.-lb. (9.5-10.5 N•m)

torque.

519 of 642

520 of 642
INSTRUMENT PANEL Figure 60-70-3
Figure 60-70-1
1
P-40164
Remove the steering wheel (Item 1) [Figure 60-70-3]

P-40162
Figure 60-70-4
Remove the steering wheel cover (Item 1) [Figure 60-70- 1

1] 1

Figure 60-70-2
1
1
1
2 P-40158
Remove the ten lower cover bolts (Item 1) [Figure 60-70-

4] and lower cover (Item 2) [Figure 60-70-4].
P-40163
Installation: Tighten nut to 55-60 ft.-lb. (75-85 N•m)

torque.

521 of 642
INSTRUMENT PANEL (CONT’D) Figure 60-70-7
Figure 60-70-5
1 P-40161
Remove the instrument panel (Item 1) [Figure 60-70-7]

P-40159
Disconnect the instrument panel connectors [Figure 60-

70-5]

NOTE: Mark the connectors for correct assembly.
Figure 60-70-6
1
1
P-40160
Remove the tw o panel mounting bolts (Item 1) [Figure

60-70-6].

522 of 642
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
SAFETY &
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1 MAINTENANCE
Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-60-1

Checking Engine Compression . . . . . . . . . . . . . . . . . . . . . 70-60-1
Checking Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Checking Fuel Injector, Nozzles. . . . . . . . . . . . . . . . . . . . 70-60-11 DRIVE
Checking Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2 SYSTEM
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-60-6
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . 70-60-8
Fuel Injector Nozzles Removal And Installation. . . . . . . . . 70-60-9
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . 70-60-4
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . 70-60-3
Thermostat Removal And Installation . . . . . . . . . . . . . . . 70-60-12
Water Pump Removal And Installation . . . . . . . . . . . . . . 70-60-13

ELECTRICAL
SYSTEM &
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 ANALYSIS
Cable Removal And Installation. . . . . . . . . . . . . . . . . . . . . 70-20-2
ENGINE
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1 SERVICE
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . 70-100-1
FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 SPECIFICATIONS

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

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ENGINE SERVICE CONT’D
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . 70-80-1

Camshaft Removal And Installation . . . . . . . . . . . . . . . . . 70-80-20
Checking Crankshaft Journal And Block Bearing . . . . . . 70-80-36
Checking Crankshaft Journal And Main Bearing . . . . . . . 70-80-37
Checking Engine Cylinder Bore . . . . . . . . . . . . . . . . . . . . 70-80-33
Checking Piston Top Clearance. . . . . . . . . . . . . . . . . . . . 70-80-13
Checking The End Play Of The Crankshaft . . . . . . . . . . . 70-80-39
Checking The Piston And Connecting Rod . . . . . . . . . . . 70-80-30
Combustion Chamber Removal And Installation . . . . . . . 70-80-18
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . 70-80-31
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-32
Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-38
Crankshaft Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-39
Crankshaft Front Seal Removal And Installation . . . . . . . . 70-80-5
Crankshaft Removal And Installation . . . . . . . . . . . . . . . . 70-80-34
Cylinder Head Disassembly And Assembly. . . . . . . . . . . 70-80-14
Cylinder Head Removal And Installation . . . . . . . . . . . . . 70-80-12
Engine Speed Control Plate Removal And Installation . . . 70-80-6
Engine Timing Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-80-40
Exhaust Manifold Removal And Installation. . . . . . . . . . . . 70-80-7

Fuel Camshaft Gear And Governor Shaft Gear . . . . . . . . 70-80-41
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . 70-80-22
Governor Fork Lever Removal And Installation . . . . . . . . 70-80-28
Governor Shaft Removal And Installation . . . . . . . . . . . . 70-80-25
Idler Gear And Camshaft Gear . . . . . . . . . . . . . . . . . . . . 70-80-41
Idler Gear And Fuel Camshaft Gear . . . . . . . . . . . . . . . . 70-80-41
Idler Gear Removal And Installation . . . . . . . . . . . . . . . . 70-80-19
Idle Limit And Fuel Limit Adjustment . . . . . . . . . . . . . . . . . 70-80-7
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . 70-80-24
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . 70-80-3
Piston Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-30
Piston Ring Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-31
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-32
Push Rod Removal And Installation . . . . . . . . . . . . . . . . 70-80-10
Rocker Arm Removal And Installation . . . . . . . . . . . . . . . . 70-80-9
Servicing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 70-80-15
Tappet Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-11
Timing Gear Backlash, Idler Gear And Crankshaft . . . . . 70-80-40
Timing Gear Case Cover Removal And Installation. . . . . . 70-80-1
Valve Cover Removal And Installation . . . . . . . . . . . . . . . . 70-80-8
Water Flange Removal And Installation. . . . . . . . . . . . . . 70-80-11
RUBBER DRIVE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

524 of 642
ENGINE SERVICE CONT’D
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

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526 of 642
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 23, 24, 25, 26, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51

Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

527 of 642
TROUBLESHOOTING (CONT'D)
Chart (Cont'd)

1. Battery capacity low. 28. Worn valve and seat.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the oil pan.
6. Fuel tank empty. 33. Switch is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is stuck open.
9. Plugged fuel filter. 36. Relief valve is stuck closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect alignment of flywheel.

17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Plugged breather pipe.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect high pressure fuel lines. 53. Broken valve spring.
27. Worn cylinder bores.

528 of 642
ENGINE SPEED CONTROL Remove washers and friction plates (Item 2) [Figure 70-
20-2].
Figure 70-20-3

Remove the seat.
Figure 70-20-1
1
P-35382
1
Remove rotating plate (Item 1) [Figure 70-20-3].
Figure 70-20-4

1
P-35379
Remove the friction adjusting nut an d washer (Item 1)

[Figure 70-20-1].
Installation: Do not over tighten the friction nut. 1
Figure 70-20-2
P-35384
2 Remove the four engine speed control mounting bolts

(Item 1) [Figure 70-20-4].
P-35380
Remove engine speed control lever and tr avel stop

washers as an assembly (Item 1) [Figure 70-20-2].
NOTE: Mark the position of all washers and friction

plates for correct assembly.

529 of 642
ENGINE SPEED CONTROL (CONT’D) Figure 70-20-6
Figure 70-20-5
1 1
P-35103
2
Remove the cable clevis pin (Item 1) [Figure 70-20-6].
P-35383
Figure 70-20-7
Remove the control lever assembly (Item 1) [Figure 70-

20-5] from the cable (Item 2) [Figure 70-20-5].

NOTE: The cable is threaded into t he engine speed
control housing.
1
Cable Removal And Installation
Raise the lift arms and install the approved support

device.
Rotate the battery disconnect lever counterclockwise to P-35104

Remove the seat. (See OPERATOR SEAT on Page 50- Loosen cable jam nut (Item 1) [Figure 70-20-7]. Remove
20-1.) the cable from mounting bracket.
Remove the e ngine speed control lever. See “Removal NOTE: Intake air hose is removed for photo clarity.
And Installation” on page 1.
Remove the cable.
Open engine cover. Remove right engine side cover.

530 of 642
MUFFLER Figure 70-30-3
Raise the lift arm and install the approved lift arm support
device.
Figure 70-30-1
2 P-35386
Remove the muffler [Figure 70-30-3].

P-35394
Remove the e xhaust clamp (Item 1) [Figure 70-30-1]

and remove the two mounting bolts (Item 2) [Figure 70-
30-1].
Figure 70-30-2
P-35392
Remove the ou tlet exhaust pipe clamp (Item 1) [Figure

70-30-2].

531 of 642

532 of 642
AIR CLEANER Figure 70-40-3
Housing Removal And Installation
device. (See Installing The Lift Arm Support Device on 1
Page 10-20-1.)
Remove the engine side cover from the right side.
Figure 70-40-1
P-35090

3].
1
Remove the air cleaner housing from the machine.

P-33288
Loosen the ho se clamp (Item 1) [Figure 70-40-1] and

remove the hose from the intake.
Figure 70-40-2
P-35089
Loosen the ho se clamp (Item 1) [Figure 70-40-2] and

remove the hose from the air cleaner housing.

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534 of 642
RADIATOR Figure 70-50-3

1
Page 10-20-1.)
Drain the coolant from the radiator. (See ENGINE

COOLING SYSTEM on Page 10-90-1.)

50-1.)
2
Remove the air cleaner housing. (See AIR CLEANER on
Page 70-40-1.) P-35096
Figure 70-50-1
Remove the pin clip (Item 1) [Figure 70-50-3] and
mounting bolt (Item 2) [Figure 70-50-3] from each side of
the radiator.
Remove the radiator.

1
P-35094
Loosen the upper radiator hose clamp (Item 1) [Figure

70-50-1] and remove the hose.
Figure 70-50-2
P-35095
Loosen the lower radiator hose clamp (Item 1) [Figure

70-50-2] and remove the hose.

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536 of 642
ENGINE COMPONENTS AND TESTING Figure 70-60-2
Checking Engine Compression
The tools listed will be nee ded to do the fol lowing

procedure:
MEL10630-Engine Compression Kit
MEL1546-Compression Test Adapter
Warm the engine.
Clean the area around the fuel injection pump and the
fuel injectors thoroughly.
P-33348
Remove the fuel injector nozzels from the engine. (See
Fuel Injector Nozzles Removal And Installation on Page
70-60-9.) Connect the compression gauge to the adapter [Figure
70-60-2].
Figure 70-60-1
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 se conds
each time and take the average reading.
1

The correct compression for the eng ine is 412-469 PSI
(2840,7-3233,8 kPa) with no more than 10% difference
between the cylinders.
P-33287
Install the compression adapter (Item 1) [Figure 70-60-1]

in the cylinder head.

537 of 642
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-60-5
Checking Glow Plugs
Figure 70-60-3
P13106
Touch one probe to the end of the glow plug and the
P13101 other probe to the body of glow plug [Figure 70-60-5].
The reading must be 0.9 ohms. If the resistance is

Disconnect the e ngine harness wire and glow plug infinite, the coil of the glow plug is broken and must be
connecting strap (Item 1) [Figure 70-60-3]. replaced.

Figure 70-60-4 Repeat the procedure for each glow plug.
Replace each glow plug as needed. (See Glow Plug

P13102
Use an ohmmeter to check the glow plugs [Figure 70-60-

4].

538 of 642
Glow Plug Removal And Installation
Rotate the battery disconnect switch to counterclockwise

to disconnect the power supply from the battery.
Figure 70-60-6
1
P13104
Loosen and remove the glow plugs (Item 1) [Figure 70-

60-8].
Installation: Tighten the glow plugs to 5-10 ft.-lb. (6,8-

P-33282 13,6 N•m).

Figure 70-60-9
Disconnect the engine harness wire (Item 1) [Figure 70-
60-6] from the glow plug.
Figure 70-60-7
1 1 1
P-4307
2
Photo [Figure 70-60-9] shows the glow plug assembly
P13101 removed from the engine. Inspect the glow plugs and
replace when necessary.
Remove the nuts (Item 1) [Figure 70-60-7] from the top

of each glow plug.
Remove the glow plug connecting strap (Item 2) [Figure

70-60-7].

539 of 642
Fuel Shut-Off Solenoid Removal And Installation
Figure 70-60-10
P13109
Remove the solenoid from the engine [Figure 70-60-12]

P-35101 and replace if needed.
Disconnect the engine wiring harness (Item 1) [Figure

70-60-10] from the fuel shut-off solenoid.

Figure 70-60-11
P-35296
Remove two mounting bolts (Item 1) [Figure 70-60-11]

from the fuel shut-off solenoid.
NOTE: Engine is removed for photo clarity.

540 of 642
Checking Fuel Injection Pump
The injection pump contains parts which have a very

close tolerance and its operation has a d irect effect on 3
the performance of the engine. Be sure to clean the area
around the injection pump and injectors before removal
to prevent contamination from dirt.
WARNING 2
Diesel fuel or hydraulic fluid unde r pressure can 1

P13138
Use a piece of cardboard or wood to find le aks. Do Connect a pressure gauge (Item 1) [Figure 70-60-13] to
not use your bare hand. Wear safety goggles. If fluid the long leg of the test tubeline (Item 2) [Figure 70-60-
enters skin or eyes, get immediate medical attention 13] and tighten.
W-2072-0496
Connect the short leg of the tubeline to the fitting at the
fuel injection pump (Item 3) [Figure 70-60-13].

procedure: Rotate the engine, with the starter, to increase the
pressure 1990-2133 PSI (13721-14707 kPa).
MEL1237-Adapter Fuel Line
MEL1173A-Pressure Gauge With the pressure at 1990-2133 PSI (13721-14707 kPa),
it should hold this for 5 seconds or more.
To check the initial discarge pressure, remove the high
pressure tubelines from the fuel injection pump. (See If the time is less than the allowable limit, replace the
Fuel Injection Pump Removal And Installation on Page injection pump.
70-60-6.)

541 of 642
ENGINE COMPONENTS AND TESTING (CONT’D) 60-15] when removing or tightening the high
pressure fuel lines.
Fuel Injection Pump Removal And Installation
Installation: Tighten the high pressure fuel line nuts to
Stop the engine and open the engine cover. 18-25 ft.-lb. (24-33 N•m).
Let the engine cool and clean the area around the Figure 70-60-16
injection pump and injectors thoroughly.
Figure 70-60-14
1
2 2 P13119

P13101 Remove the high pressure fuel lines (Item 1) [Figure 70-
60-16] from the engine.
Disconnect the high pressure fuel lines (Item 1) [Figure Remove the fuel shut-off solenoid (Item 2) [Figure 70-60-
70-60-14] from the fuel injectors. 16]. (See Fuel Shut-Off Solenoid Removal And
NOTE: Hold the banjo fitting nuts (Item 2) [Figure 70-
60-14] when removing or tightening the high Figure 70-60-17
pressure fuel lines.
Installation: Tighten the h igh pressure fuel line nuts to 1

18-25 ft.-lb. (24-33 N•m). 1
1
Figure 70-60-15 1
1
1 1
P13126
Remove the six mounting bolts (Item 1) [Figure 70-60-

2 17] from the intake manifold. Remove the intake manifold
from the engine.
P13105
Installation: Replace the manifold gasket. Tighten the
mounting bolts to 16-20 ft.-lb. (22-27 N•m) torque.
Disconnect the high pressure fuel lines (Item 1) [Figure
70-60-15] from the fuel injectors.
NOTE: Hold the banjo fitting nuts (Item 2) [Figure 70-

542 of 642
Fuel Injection Pump Removal And Installation

(Cont’d)
2
Figure 70-60-18
1
2
2
P13128
1
Installation: The fuel rack pin (Item 1) [Figure 70-60-19]

on the injection pump must be aligned with the notch
P13127 (Item 1) [Figure 70-60-20] located inside the injection
pump chamber. Use the throttle lever (Item 2) [Figure
70-60-20] on the side of th e injection pump chamber to
Disconnect the fuel inlet hose (Item 1) [Figure 70-60-18] align the notch.
from the injection pump.

Figure 70-60-21
18] from the top of the injection pump.
Installation: Tighten the mounting bolts to 16 -20 ft.-lb.

(22-27 N•m) torque.
Figure 70-60-19
P13130
Install the s him(s) (Item 1) [Figure 70-60-21] on the

injection pump mounting surface. For information on
number of shims used (See Fuel Injection Pump Timing
on Page 70-60-8.)
P13129
Install the injection pump in the engine.
Remove the injection pump from the engine [Figure 70-

60-19].

543 of 642
ENGINE COMPONENTS AND TESTING (CONT’D) Turn the flywheel counterclockwise until fuel flows from
the delivery valve holder and into the plastic tube.
Fuel Injection Pump Timing
Continue rotating the engine slowly until the fuel begins
to rise in the plastic tube (Item 1) [Figure 70-60-22].
IMPORTANT Figure 70-60-23
Do not attempt to maintain or adjust unless you are

trained and have the correct equipment.
I-2028-0289
Timing the injection pump is done by changing the

number of shims between the in jection pump and the
injection pump mounting surface.
Remove the engine assembly. (See ENGINE on P age

1
70-70-1.)
Remove flywheel housing. (See FLYWHEEL HOUSING

on Page 70-90-1.)
P-35295
Remove starter. (See STARTER on Page 60-40-1.)

Disconnect the high pressure fuel lines from the injection At this point look at the timing mark (located on the
pump and the injectors. (See Fuel Injection Pump flywheel) for proper alignment (Item 1) [Figure 70-60-23]
Removal And Installation on Page 70-60-6.) When the timing mark is aligned as shown the timing is
correct for the injection pump, which is 18°-20° degrees
Remove the fu el injectors. (See Fuel Injection Pump B.T.D.C.
Figure 70-60-24
Remove the fuel shut-off solenoid. (See Fuel Shut-Off
Solenoid Removal And Installation on Page 70-60-4.)
Figure 70-60-22
P13130
Add or subtract shim(s) (Item 1) [Figure 70-60-24] as

P13132 needed to adjust the fuel delivery timing.
Install a short plastic tube (Item 1) [Figure 70-60-22] in Shims are available in thickness of 0.20 mm, 0 .25 mm
the number one cylinder port of the injection pump. The and 0.30 mm. Combine these shims for adjustments.
tube should fit tight in the port and point upward.
Addition of shim(s) (0.0020 inch, 0.05 mm) delays the
Move the fuel lever on the injection pump to full fuel injection timing by approximately 0.5 degree.
position (or full throttle).
Reduction of shim(s) (0.0020 inch, 0.05 mm) advances
the injection timing by approximately 0.5 degree.
544 of 642
ENGINE COMPONENTS AND TESTING (CONT’D) NOTE: Hold the banjo fitting nuts (Item 2) [Figure 70-
60-25] when removing or tightening the high
Fuel Injector Nozzles Removal And Installation pressure fuel lines.

18-25 ft.-lb. (24-33 N•m).
WARNING Figure 70-60-26
death. Fluid leaks under pressure may not be visible. 1
W-2072-0496
These are some engine problems caused by damaged

injector nozzles.
2
The engine is hard to start or will not start
Engine operation is not smooth. P13105
The engine will not idle correctly.

Bad engine performance.
The engine exhaust smoke is black, white or blue. Disconnect the high pressure fuel lines (Item 1) [Figure
70-60-26] from the injection pump.
Remove the injector nozzles from the engine and test the
injectors only after engine performance shows that there NOTE: Hold the delivery valve holder nuts (Item 2)
may be damage. [Figure 70-60-26] when removing or
tightening the high pressure fuel lines.
Stop the engine and open the engine cover.
Let the engine cool and clean the area around the 18-25 ft.-lb. (24-33 N•m).
injection pump and injectors thoroughly.
Figure 70-60-27
Figure 70-60-25
2
P13119
P13101
Remove the high pressure tubelines [Figure 70-60-27].

Disconnect the high pressure fuel lines (Item 1) [Figure
70-60-25] from the fuel injectors.

545 of 642
ENGINE COMPONENTS AND TESTING (CONT’D)
Fuel Injector Nozzles Removal And Installation

(Cont’d)
Figure 70-60-28
2 2
2
P13121
Remove the fuel return hoses (Item 1) [Figure 70-60-28]

from the banjo fittings.

Remove the three banjo fitting nuts (Item 2) [Figure 70-
60-28] from the fuel injector nozzles.
Remove the banjo fittings from the fuel injectors.
Figure 70-60-29
P13120
Remove the fuel injector nozzles from the engine [Figure

70-60-29].
Installation: Tighten the injectors to 22-36 ft.-lb. (29-49

N•m) torque.

546 of 642
Checking Fuel Injector, Nozzles

procedure:
OEM 1064-Injector Nozzle Tester

OEM 1065-Accessory Set
Figure 70-60-30
1
2 A-2513
Connect the injector nozzle to the te ster with the nozzle

in the down position [Figure 70-60-31].
Slowly operate the hand lever of the test pump until the
3 injector nozzle vavle opens. The pressure must be 1990-
2133 PSI (13721-14707 kPa).

B-14862A If the pressure is not correct, disassemble the injector
nozzle and add or remove spacers (Item 1) [Figure 70-
60-30].
NOTE: You can adjust the release pressure of the
injector nozzle by adding or removing NOTE: When assembling the injector nozzle, tighten
spacers (Item 1) [Figure 70-60-30] from the top the nozzle nut (Item 3) [Figure 70-60-30] to 36-
of the nozzle spring (Item 2) [Figure 70-60-30]. 51 ft.-lb. (49-69 N•m) torque. Any higher
The release pressure must be 1990-2133 PSI torque will cause slow action of the valve.
(13721-14707 kPa).
Check for inside leakage. Operate the hand lever until
the pressure is almost enough to open the injector valve.
Make a record of th e pressure. Release the ha nd lever.
WARNING Check the pressure decrease to 10 seconds. The nozzle
has damage if the pressure decrease is more than 740
PSI (5162 kPa) in 10 seconds.
W-2072-0496

547 of 642
Checking Fuel Injector, Nozzles (Cont’d)

1
Figure 70-60-32
2
Spring
CORRECT WRONG
Pressure
Pin
Holder
Nozzle
Body
Needle
Valve
P13267
Remove thermostat (Item 1) [Figure 70-60-34] and

A-2621 replace if necessary.
Always replace the thermostat gasket (Item 2) [Figure

Check the spray pattern of the n ozzle for the following 70-60-34].
conditions [Figure 70-60-32].

Fuel comes out the side of the nozzle.
Has fuel drops coming from the nozzle.
Has a flow (solid stream) coming from the nozzle.
Any of the above conditions show a defect or a dirty

injector nozzle. Clean the nozzle that does not operate
correctly and check again.
Thermostat Removal And Installation
Figure 70-60-33
P-35094
Remove the two b olts (Item 1) [Figure 70-60-33] from

the thermostat housing.
Installation: Tighten bolts to 87-100 in.-lb. (9,8-11,3

N•m) torque.

548 of 642
Water Pump Removal And Installation 1
Figure 70-60-35
1
1
1
1 1
1 1
1 P13265
2
Remove the seven mounting bolts (Item 1) [Figure 70-
P13013 60-36] from the water pump.
Installation: Tighten the mounting bolts to 87-100 in.-lb.

Remove the four mounting bolts (Item 1) [Figure 70-60- (9,8-11,3 N•m) torque.
35] from the belt pulley (Item 2) [Figure 70-60-35] and
remove the pulley from the water pump.

Remove the water pump from the engine.
NOTE: The bolts may vary in length. Keep the bolts in Check the wa ter pump for wear and replace if ne eded.
their original location. Thoroughly clean the area between the water pump and
the block flange.
Install a ne w water pump gasket and install the water

pump.

549 of 642

550 of 642
ENGINE Figure 70-70-3
support device. (See Installing The Lift Arm Support
Device on Page 10-20-1.)
Figure 70-70-1
1
1
P-35092
Remove the clamp (Item 1) [Figure 70-70-3] and remove

the exhaust pipe.
Figure 70-70-4
P-32800

Rotate the battery disconnect switch (Item 1) [Figure 70-
70-1] to the position shown, to d isconnect the power
supply from the battery. 2

50-1.)
Remove the air cleaner housing. (See AIR CLEANER on 1

Page 70-40-1.)
Remove the radiator. (See RADIATOR on Page 70-50-1.) P-35100
Figure 70-70-2
Disconnect the engine temperature wire (Item 1) [Figure
70-70-4].
Disconnect the wire (Item 2) [Figure 70-70-4] from the

glow plugs.
NOTE: Mark all wires for correct installation.
P-35093

2] from the exhaust manifold.

551 of 642
ENGINE (CONT’D) Figure 70-70-7
Figure 70-70-5
P-35103
Remove the engine speed control cable (Item 1) [Figure

P-35101 70-70-7].
Figure 70-70-8
Disconnect the wiring harness connector (Item 1) [Figure
70-70-5] from the fuel shutoff solenoid.

Figure 70-70-6
1
P-35104
1
Loosen the j am nut (Item 1) [Figure 70-70-8] and

P-35102 remove the engine speed control cable.
NOTE: Mark the location of the jam nut for correct

Loosen the ho se clamp (Item 1) [Figure 70-70-6] and assembly.
remove the fuel line.
NOTE: Install caps and plugs.

552 of 642
Figure 70-70-9 1
P-35107
Disconnect the two wires (Items 1) [Figure 70-70-11]

P-35117 from the alternator.
Figure 70-70-12
Remove the ground strap (Item 1) [Figure 70-70-9].
Figure 70-70-10

1
1
P-35108
P-35105 Disconnect the wire (Item 1) [Figure 70-70-12] from the

oil pressure sending unit.
Remove the fu el return line (Item 1) [Figure 70-70-10]

from the tee fitting.
NOTE: Install caps and plugs.

553 of 642
Figure 70-70-13
P-35113
1
Remove the hydrostatic pump mounting bolt (Item 1)
P-35109 [Figure 70-70-15] (both sides).
Figure 70-70-16
Disconnect the two wires (Item 1) [Figure 70-70-13] from
the starter.

Remove the two front floor panels. (See FLOOR
PANELS on Page 50-30-1.)
Figure 70-70-14
P-35115
Using a ch ain and h oist, lift and support the engine

[Figure 70-70-16].
P-35112
Using a c hain and hoist, lift and support the h ydrostatic

pump assembly [Figure 70-70-14].

554 of 642
ENGINE (CONT’D) Mount Replacement
Figure 70-70-17
P-35301
P-35116
With the engine removed, remove the bottom motor
mount nut (Item 1) [Figure 70-70-19].
Remove the two engine mounting bolts (Item 1) [Figure
70-70-17] from each side of the engine. Figure 70-70-20

Figure 70-70-18
P-35302
P-35119
Remove the mount (Item 1) [Figure 70-70-20].
Lift and remove the engine assembly [Figure 70-70-18]. Replace as needed.

555 of 642

556 of 642
RECONDITIONING THE ENGINE Figure 70-80-3
Timing Gear Case Cover Removal And Installation

1 1
Figure 70-80-1
1
1
1
1
1
1
1
1
1
1
1 P13270
NOTE: The bolts may vary in length. Keep the bolts in

P13266 their original location.

Remove crankshaft pulley bolt (Item 1) [Figure 70-80-1]. from the timing case cover, and remove the cover.
Installation: Tighten crankshaft pulley bolt to 101-116 ft.-

Installation: Tighten the mounting bolts to 7.2-8.3 in.-lb.
lb. (137-157 N•m) torque. (9,8-11,3 N•m) torque.
Figure 70-80-2 Clean the surface of timing cover.
Figure 70-80-4
P13268
1
P13271
Remove the crankshaft pulley (Item 1) [Figure 70-80-2]
from the crankshaft.
Remove the timing cover gasket (Item 1) [Figure 70-80-
Installation: When installing the crankshaft pulley on the 4].
crankshaft, align the ti ming marks (Item 2) [Figure 70-
80-2].

557 of 642
RECONDITIONING THE ENGINE (CONT’D) Figure 70-80-7
Timing Gear Case Cover Removal And Installation 1

(Cont’d)
Figure 70-80-5
P13279
1
Installation: Install the timing case cover, then install the
1 1 crankshaft collar with the tapered side (Item 1) [Figure
P13272 70-80-7] toward the O-ring.
Figure 70-80-8
Remove the O-rings (Item 1) [Figure 70-80-5] from the
timing case cover.

1
Figure 70-80-6
P13276
1
NOTE: The idle adjustment spring (Item 1) [Figure 70-

P13345 80-8] is located inside the timing case cover.
Be careful not to da mage. Replace if
necessary. (See Idle Limit And Fuel Limit
Remove the crankshaft collar (Item 1) [Figure 70-80-6] Adjustment on Page 70-80-7.)
from the crankshaft.
NOTE: The collar may stay in the gearcase cover,

when the cover is removed.
Remove the O-ring (Item 2) [Figure 70-80-6] from the

crankshaft and replace with a new O-ring.

558 of 642
Oil Pump Removal And Installation
Remove timing gear case cover. (See Timing Gear Case

Cover Removal And Installation on Page 70-80-1.)
1
Figure 70-80-9
1
1
P13275
2
Replace the front crankshaft seal (Item 1) [Figure 70-80-
1 11].
1
1 Figure 70-80-12
P13272

from the back of the oil pump.

(7,9-12,8 N•m) torque.
Remove the rear cover (Item 2) [Figure 70-80-9].
Figure 70-80-10
P13317
Measure the clearance between the lobes of the inner

rotor and the outer rotor with a feeler gauge [Figure 70-
80-12].
The clearance between inner rotor and outer is 0.0024-

1
0.0071 inch (0,06-0,18 mm), with an allowable limit of
0.0118 inch (0,3 mm). If the clearance exceeds the
allowable limit, replace the oil pump rotor assembly.
P13273
Remove the oil pump rotor assembly (Item 1) [Figure 70-

80-10] and check for wear.

559 of 642
Oil Pump Removal And Installation (Cont’d)
Figure 70-80-13
P13272
Install the oil pump cover (Item 1) [Figure 70-80-15] and

P13316 tighten the cover bolts to 70-113 in.-lb. (7,9-12,8 N•m
torque.
Measure the clearance between the outer rotor and th e Figure 70-80-16
pump body with a feeler gauge [Figure 70-80-13].

The clearance between outer rotor and the pump body is 1
0.0039-0.0071 inch (0,100-0,180 mm) with an allowable
limit of 0.0213 inch (0,54 mm). If the clearance exceeds
the allowable limit, replace the oil pump rotor assembly.
Figure 70-80-14
P13273
Remove the cover and measure the width of the pressed

plastic gauge (Item 1) [Figure 70-80-16].
The end clearance between the i nner rotor and the oil
pump cover should be 0.0098-0.0295 inch. (0,025-0,75
P13273 mm) with an allowable limit of 0.0089 inch. (0,225 mm).
If the c learance exceeds the allowable limit, replace the

Put a strip of plastic gauge (Item 1) [Figure 70-80-14] oil pump rotor assembly.
onto the rotor face.

560 of 642
Crankshaft Front Seal Removal And Installation
Figure 70-80-17
1
P-13278
Remove the crankshaft collar (Item 1) [Figure 70-80-19].

P13266
Figure 70-80-20
Remove the crankshaft pulley bolt (Item 1) [Figure 70-

80-17] and remove the crankshaft pulley.

Installation: Tighten crankshaft pulley bolt to 101-116 ft.-
lb. (137-157 N•m) torque.
2
Figure 70-80-18 1
P13277

crankshaft.
1
Remove the front seal (Item 2) [Figure 70-80-20] from
the timing gear case cover.
P13268
Replace the seal.
When installing the c rankshaft pulley on the crankshaft, Replace the O-ring.
be sure the timing marks are aligned (Item 1) [Figure 70-
80-18].

561 of 642
Crankshaft Front Seal Removal And Installation

(Cont’d)
Figure 70-80-21
1
1 2
P-35300
Remove the speed control plate from the mounting bolts

and unhook the governor spring (Item 1) [Figure 70-80-
P13279 23] from the governor compensation lever (Item 2)
[Figure 70-80-23].
Install the crankshaft collar with the tapered side (Item 1) Check the return spring (Item 3) [Figure 70-80-23] and
[Figure 70-80-21] toward the O-ring.

internal parts for wear and replace if needed.
Engine Speed Control Plate Removal And Installation Figure 70-80-24
Figure 70-80-22
1 1
P13285
P-35298
Remove start spring (Item 1) [Figure 70-80-24].
Remove the mounting bolts and nuts (Item 1) [Figure 70- Check for wear and replace if needed.
80-22] from the engine speed control plate.
Installation: Tighten mounting bolts and nuts to 87-100

in-lb. (9,8-11,3 N•m) torque.

562 of 642
Idle Limit And Fuel Limit Adjustment

1
Figure 70-80-25
P13286
2
Remove the ex haust manifold from the engine and

P-35102 remove the exhaust manifold gasket (Item 1) [Figure 70-
80-27] from the engine.
The idle limit adjustment (Item 1) [Figure 70-80-25] and Installation: Replace the exhaust manifold gasket.
the fuel limit adjustment (Item 2) [Figure 70-80-25] have Tighten the mounting nuts to 12 -14 ft.-lb. (16-19 N•m)
sealed caps.

torque.
NOTE: See your authorized Kubota dealer for proper

adjustment before removing the caps.
Exhaust Manifold Removal And Installation
Figure 70-80-26
1
1
P-35299
Remove the mounting nuts (Item 1) [Figure 70-80-26]

from the exhaust manifold.

563 of 642
Valve Cover Removal And Installation
Remove the air cleaner assembly (See AIR CLEANER

on Page 70-40-1.)
Figure 70-80-28
2
1
1
P13293
Remove the breather element plate (Item 1) [Figure 70-

80-30].
Remove the breather element (Item 2) [Figure 70-80-

P-35093 30].

Check element and clean or replace as needed.
Remove the nuts (Item 1) [Figure 70-80-28] from the
valve cover.
Installation: Tighten valve cover nuts to 5. 1-6.5 in.-lb.

(6,9-8,8 N•m) torque.
Remove the valve cover.
Figure 70-80-29
1 1
P13295
Remove the mo unting bolts (Item 1) [Figure 70-80-29]

from the breather oil shield (Item 2) [Figure 70-80-29].

(2,7-4,1 N•m) torque.

564 of 642
Rocker Arm Removal And Installation
Figure 70-80-31
1 1 1
2
P13312
Remove the rocker arm shaft washers (Item 1) [Figure

P13288 70-80-33].
Remove the rocker arm assembly (Item 2) [Figure 70-

Remove the engine. (See ENGINE on Page 70-70-1.) 80-33] from the rocker arm shaft.
Remove the valve cover. (See Valve Cover Removal And

Figure 70-80-34
Remove the th ree mounting nuts from the rocker arms

bracket (Item 1) [Figure 70-80-31], and remove the
rocker arms from the head.
Figure 70-80-32
P13308
1
Measure the outside diameter of the rocker arm shaft.
[Figure 70-80-34].
The measurement should be 0. 4714-0.4718 inch

P13311 (11,973-11,984 mm) in diameter.

the rocker arm shaft.

565 of 642
RECONDITIONING THE ENGINE (CONT’D) Make sure the piston is on top dead center when making
the adjustment and adjust the clearance to 0 .005-0.007
Rocker Arm Removal And Installation (Cont’d) inch (0,12-0,18 mm).
Figure 70-80-35 Push Rod Removal And Installation
Figure 70-80-37
1 1 1
P13314
P13291
Measure the inside diameter of the rocker arm [Figure
70-80-35].

Remove the six push rods (Item 1) [Figure 70-80-37].
(12,000-12,018 mm) in diameter. NOTE: Mark the push rods to prevent interchanging
when installing.
The clearance between the r ocker arm shaft and the
rocker arm should be 0.00 6-0.0018 inch (0,016-0,045 Check for wear and replace if needed.
mm) with an allowable limit 0.0039 (0,10 mm).
If the me asurement exceeds the allowable limit replace

the rocker arm or rocker arm shaft.
Figure 70-80-36
1 1 1
P13289
Installation: Tighten the three rocker arm mounting nuts

(Item 1) [Figure 70-80-36] to 16-20 ft.-lb. (22-27 N•m)
torque.
Adjust the valve clearance using a feeler gauge (Item 2)

[Figure 70-80-36].

566 of 642
RECONDITIONING THE ENGINE (CONT’D) Water Flange Removal And Installation
Tappet Removal And Installation Figure 70-80-39
Figure 70-80-38
1 1 1 1
1
1
P13296
P13294
39] from the engine head.
Remove the six tappets (Item 1) [Figure 70-80-38] from
the crankcase. Remove water flange from the head.

NOTE: Mark the tappets to prevent interchanging Installation: Replace the water flange gasket as needed.
when installing. Tighten the mounting bolts to 87- 100 in.-lb. (9,8-11,3
N•m) torque.
Check the tappets for wear. The inside diameter of the
tappet guide is 0.787-0.7882 inch (20,000-20,021 mm).
The outside diameter of the tappet is 0.7858-0.7866
(19,959-19,980 mm).
The clearance between the tappet and the guide is

0.008-0.0024 inch (0,020-0,062 mm) with an allowable
limit 0.0028 inch (0,07 mm).
If wear exceeds the allowable limit, replace the tappets.
NOTE: If the tappets have to be changed because of

excess wear. Check the camshaft for wear
and replace if ne eded. (See Camshaft

567 of 642
Cylinder Head Removal And Installation
Removal
Figure 70-80-40
1 1 1
1
1 1
A-2773
Put oil on the cylinder head bolts and tighten to 47-51 ft.-
1 1 lb. (64-69 N•m) torque. Use the tightening sequence as
shown in [Figure 70-80-42]. Allow the head to set for at
P13290 least a 1/2 hour. Then check the torque of the head bolts
again using the sequence shown in [Figure 70-80-42].
Remove the fourteen mounting bolts (Item 1) [Figure 70-

80-40] and remove the head.
Installation
Figure 70-80-41
2
1
P13403
Clean the head and the block.
Replace the head gasket (Item 1) [Figure 70-80-41] and

O-ring (Item 2) [Figure 70-80-41].

568 of 642
Checking Piston Top Clearance 1 1
Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 70-80-12.)
Figure 70-80-43
2 2
1
1
1 P13300
Figure 70-80-45
2
2
P13297 1

Bring the piston (Item 1) [Figure 70-80-43] to top dea d
center.
Fasten a 0.06 inch (1,5 mm) diameter by 0.20-0.28 inch

(5,1-7,1 mm) piece of solder (Item 2) [Figure 70-80-43]
to four spots on the piston with grease.
Put the piston to bottom dead center.

P13299
Install the cylinder head and ti ghten the cylinder head
bolts to s pecification. (See Cylinder Head Removal And
Installation on Page 70-80-12.) Remove the cylinder head and measure the sq ueezed
solder wire (Item 1) [Figure 70-80-44] & [Figure 70-80-
Turn the crankshaft until the piston goes over top dead 45].
center.
The top clearance between the pis ton and the hea d
should be 0.0217-0.0276 inch (0,55-0,70 mm).
If the measurement is not within specified value, check

the oil clearance of the c rankpin journal and the piston
pin. (See Crankshaft Removal And Installation on Page
70-80-34.) Also check the oil clearance between the
crankshaft journals and the crankshaft bearings. (See
Checking Engine Cylinder Bore on Page 70-80-33.)

569 of 642
RECONDITIONING THE ENGINE (CONT’D) Assembly
Cylinder Head Disassembly And Assembly Install the valves.
Disassembly Put oil on the valve seal and install the valve seal on the
valve.
Figure 70-80-46
Install the valve spring and the retainer.
1 Install the spring collet and the valve cap.
P13302
Figure 70-80-47

Spring
Collets
Cap
Valve Seal
P13303
Retainer
Using a valve compression tool (Item 1) [Figure 70-80-

46], remove the valve cap and the valve spring collet
[Figure 70-80-47].
Remove the seal on the valve and remove the valve from
the cylinder head.
Repeat this procedure for all valves.

570 of 642
RECONDITIONING THE ENGINE (CONT’D) The correct width of the valve seat for both intake and
exhaust, is 0.083 inch (2,1 mm). The seat angle is 45° for
Servicing The Cylinder Head the exhaust valve and 60° for the intake valve.
Clean the surface of the cylinder head. Figure 70-80-50
Figure 70-80-48 C Valve Contrating

A D Width
0.083” (2,1 mm)
B
D Uncorrected
Corrected Surface of
Surface of Valve Seat
A-45° cutter
1 Valve Seat
B-15° cutter
C-65° or 70° cutter
D-45° valve surface
MC-2185
P13298
Use the following steps to grind the valve seats [Figure
70-80-50].
Put a straight edge on the cylinder head [Figure 70-80-

48]. Item A-Use a 45° cutter to grind the surface of the valve
seat.
Put a feeler gauge (Item 1) [Figure 70-80-48] between
the straight edge and the surface of the cylinder head. Item B-Use a 15° cutter to grind the front surface of the
valve seat.
The maximum distortion of the cylinder head surface is ±
0.0019 inch (± 0.05 mm). Item C-Use A 65° or 70° cutter to grind the rear surface of
the valve seat to finish the seat of a 0.083 inch (2,1 mm)
If the measurement is more than the specification, width.
remove the combustion chambers (See Combustion
Chamber Removal And Installation on Page 70-80-18.), Item D-Grind the valve surface to a 45° angle.
then grind the cylinder head.
Clean the surface of the valve seat area.
Figure 70-80-49
P13306
Measure the width of the valve seat [Figure 70-80-49].

571 of 642
RECONDITIONING THE ENGINE (CONT’D) The measurement must be 0.0014-0.0025 inch (0,035-
0,065 mm). Replace the valve guide and valves as
Servicing The Cylinder Head (Cont’d) needed.
Figure 70-80-51 Figure 70-80-53
P13305 P13301
Install the valve in the seat and check the depth [Figure Measure the valve spring [Figure 70-80-53]. The length
70-80-51]. of the spring must be 1 .457-1.476 inch (37,0-37,5 mm).

Replace the valve spring if it does not meet the
The specification for the depth of the valve is 0.0020- specification.
0.0060 (-0,05-0,15 mm). Allowable limit 0.016 inch (0,4
mm). Figure 70-80-54
NOTE: If the measurement is mo re than the

specifications add the correct thickness
washer under the valve spring to keep the
correct tension on the spring.
Clean the valve guide.
Install the valve in the cylinder head.
Figure 70-80-52
1 P13304
Check the valve spring with a square to make sure it is

straight [Figure 70-80-54]. Replace the spring if it is not
straight.
P13310
Install a dial indicator gauge (Item 1) [Figure 70-80-52].
Measure the clearance of the valve guide and the valve.

572 of 642
RECONDITIONING THE ENGINE (CONT’D)
Servicing The Cylinder Head (Cont’d)
Figure 70-80-55
A-2759
Put the valve spring in a tester [Figure 70-80-55].
Push down on the spring 1.22 inches (31 mm). The

compression load must be 26.4 lbs. (11,97 kg). Replace
the valve spring if it does not meet these specifications.

573 of 642
Combustion Chamber Removal And Installation
Figure 70-80-56
1 1 1
1 P13290
Remove the combustion chamber by using a blunt punch

P13305 through the injector ports (Item 1) [Figure 70-80-58]. Tap
the punch with a ham mer and remove the combustion
chamber.
Locate the combustion chamber (Item 1) [Figure 70-80-
56] in the head. Figure 70-80-59

NOTE: Mark the combustion chambers so they do
not get interchanged between cylinders.
Figure 70-80-57
1
2
1
1
P13467
2 P13467
Grind the cylinder head.

3
B-15124 Grind the same amount of material from the combustion
chamber at points (Item 1 & 2) [Figure 70-80-59].
Locate the notch on the combustion chamber edge (Item Installation: Install two 9 mm dowels in the h ead bolt
1) [Figure 70-80-57] (inset). Scribe a line (Item 2) holes (Item 3) [Figure 70-80-57]. Place a s traight edge
[Figure 70-80-57] at that point on the cylinder head for against the dowels and scribe a line (Item 4) [Figure 70-
locating purposes. 80-57].
Align the no tch on the combustion chamber (Item 1)

[Figure 70-80-57] with the scribe line on the head (Item
4) [Figure 70-80-57], and install the chamber.

574 of 642
Idler Gear Removal And Installation

1
Figure 70-80-60
1
P13346
Remove the mo unting bolts (Item 1) [Figure 70-80-62]

P13345 from the idler shaft.
Remove the shaft.

Remove the timing gear case cover. (See Timing Gear
Case Cover Removal And Installation on Page 70-80-1.) Figure 70-80-63

Remove the crankshaft collar (Item 1) [Figure 70-80-60]
and O-ring (Item 2) [Figure 70-80-60].
Figure 70-80-61
P13368
2
With a micrometer measure the outside diameter of th e
idler gear shaft (Item 1) [Figure 70-80-63].
P13343
(25,967-25,980 mm).
the idler gear shaft.
Remove the flat washer.
Remove the idler gear (Item 2) [Figure 70-80-61].

575 of 642
RECONDITIONING THE ENGINE (CONT’D) Remove the mounting bolts from the camshaft mounting
plate.
Idler Gear Removal And Installation (Cont’d)
Figure 70-80-64 (9,8-11,3 N•m) torque.
Remove the camshaft.
1 Figure 70-80-66
2
P13365
2
Check the inside diameter of the idler gear bushing (Item
1) [Figure 70-80-64]. The measurement should be
P13367
1.0236-1.0244 inch (26,000-26,021 mm), with an

allowable limit of 0.0039 inch (0,10 mm).
Check the key (Item 2) [Figure 70-80-66] from the
If the clearance exceeds the allowable limit, replace the camshaft.
busing.
Check the camshaft gear (Item 1) [Figure 70-80-66] and
Align the o il hole in bushing (Item 2) [Figure 70-80-64] the key way in the gear and the camshaft for wear and
with oil hole in sprocket, when installing the new bushing. replace if needed.
Camshaft Removal And Installation
Remove the tappets from the block. (See Tappet

Figure 70-80-65
P13344
Align the holes (Item 1) [Figure 70-80-65] in the gear on

the camshaft with the mounting plate bolts.

576 of 642
Figure 70-80-67
P13347
Figure 70-80-70
P13363
Support the camshaft with V-blocks [Figure 70-80-67].
Measure the height of the intake and exhaust cams at

their highest point with a micrometer.
The measurement should be:

Intake 1.1339 inch (28,80 mm)
Allowable Limit 1.1319 inch (28,75 mm)
Exhaust 1.1417 inch (29,00 mm)
Allowable Limit 1.1398 inch (28,95 mm)
P13348
If the measurement is less than the allowable limit

replace the camshaft. Measure the cylinder block bore inside diameter for the
camshaft with an inside micrometer [Figure 70-80-69] &
Figure 70-80-68 [Figure 70-80-70].
P13351
Measure the camshaft journal outside diameter (Item 1)

[Figure 70-80-68] with a micrometer. The measurement
should be 1.4147-1.3799 inch (35,934-35,050 mm).

577 of 642
RECONDITIONING THE ENGINE (CONT’D) Installation: Tighten the mounting bolts to 89-100 in.-lb.
(9,8-11,3 N•m) torque.
Remove the fuel camshaft from the block.
Figure 70-80-71
Figure 70-80-73
2
P13364
P13366
Check the camshaft alignment by supporting the

camshaft in V-blocks. Set a dia l indicator with its tip on Remove the three mounting bolts (Item 1) [Figure 70-80-
the center journal at a right angle [Figure 70-80-71].

73] from the injection pump gear (Item 2) [Figure 70-80-
73].
Rotate the c amshaft on the V-blocks and get th e
misalignment, which is half of the measurement. Installation: Tighten the mounting bolts to 89-100 in.-lb.
(9,8-11,3 N•m) torque.
The measurement should be 0.0004 inch (0,01 mm).
Figure 70-80-74
If the misalignment exceeds the allowable limit, replace
the camshaft.
Fuel Camshaft Removal And Installation
Figure 70-80-72
4
1
2 1
3
P13369
Remove the fuel cam (Item 1) [Figure 70-80-74] and the

cam washer (Item 2) [Figure 70-80-74] from the
camshaft gear.
P13349
Installation: When installing the fuel cam and washer to
the cam shaft gear align the t iming marks (Item 3)
Remove the two mounting bolts (Item 1) [Figure 70-80- [Figure 70-80-74] on the fuel cam with the timing marks
72] and remove the fuel camshaft stop (Item 2) [Figure (Item 4) [Figure 70-80-74] on the camshaft gear.
70-80-72].

578 of 642
Fuel Camshaft Removal And Installation (Cont’d)
Figure 70-80-75
2
P13370
Remove the nut (Item 1) [Figure 70-80-75] from the

camshaft.

Installation: Tighten the nut to 43 -51 ft.-lb. (58,3-69,2
N•m) torque.
Remove the injection pump gear (Item 2) [Figure 70-80-

75] from the fuel camshaft.
Figure 70-80-76
P13373
Check the key (Item 1) [Figure 70-80-76] and the

keyways in the gear and on the shaft for wear and
replace if needed.
Check the bearings (Item 2) [Figure 70-80-76] for wear

and replace as needed.

579 of 642
Oil Pan Removal And Installation

2
Figure 70-80-77
1 1
1 1
1 P13318
Clean the oil pickup tube screen (Item 1) [Figure 70-80-

P13309 79].
Check the O-ring (Item 2) [Figure 70-80-79] and replace

Remove the oil pan mounting bolts (Item 1) [Figure 70- if worn.
80-77], and remove the oil pan.

Use care not to d amage O-ring when installing the oil
Installation: Tighten pan mounting bolts to 87-100 in.-lb. pickup tube.
(9,8-11,3 N•m) torque, in a di agonal order from the
center. NOTE: Clean the surface of the oil pan and the block
thoroughly. And apply a new liquid gasket to
Figure 70-80-78 the oil pan before installing.
P13313
Remove the mounting bolt (Item1) [Figure 70-80-78] and

remove the oil pickup tube (Item 2) [Figure 70-80-78].

580 of 642
Governor Shaft Removal And Installation

1
Figure 70-80-80
P13352
Remove the governor shaft assembly (Item 1) [Figure

P13357 70-80-82] from the front of the block.
Figure 70-80-83
Remove the fuel camshaft plug (Item 1) [Figure 70-80-
80] from the block.

Figure 70-80-81
1
1 2
P13362
NOTE: The set screw (Item 1) [Figure 70-80-83] must

P13358 be removed to remove the rear governor shaft
bearing.
Remove the snap ring (Item 1) [Figure 70-80-81] from Check the governor gear bushing (Item 2) [Figure 70-80-
the governor shaft. 82] and replace if needed.

581 of 642
Governor Shaft Removal And Installation (Cont’d)
Figure 70-80-84
P13379
Check the p arts from the governor shaft for wear and
P13360 replace if needed [Figure 70-80-86].
Figure 70-80-87
Remove the set screw (Item 1) [Figure 70-80-84] from
the block

Figure 70-80-85 1
1
P13371
Remove the g overnor gear holder and governor gear

P13359 (Item 1) [Figure 70-80-87] from the governor shaft.
NOTE: The bearing must be driven out toward the

front of the block.

582 of 642
Figure 70-80-88
2 3
2 1
P13377
Remove the governor weight holder (Item 1) [Figure 70-

P13378 80-90] from governor shaft.
Remove the governor sleeve (Item 2) [Figure 70-80-90]

Remove the g overnor gear (Item 1) [Figure 70-80-88] and thrust washer (Item 3) [Figure 70-80-90] from
from the gear holder (Item 2) [Figure 70-80-88]. governor shaft.

Figure 70-80-89 Check all parts and replace if needed.
1
2
3 2
3 1 P13374
Remove the governor weight shafts (Item 1) [Figure 70-

80-89] from the governor weights (Item 2) [Figure 70-80-
89].
Remove the governor weights.
Remove the rollers (Item 3) [Figure 70-80-89] from the

governor weights.

583 of 642
Governor Fork Lever Removal And Installation
Figure 70-80-91
1 2 1
P13356
Remove the fork lever cover and gasket from the block.
P13285
Remove the governor fork lever collar (Item 1) [Figure
70-80-93] from the block.
Remove the speed control plate. (See Engine Speed
Control Plate Removal And Installation on Page 70-80- Figure 70-80-94
6.)

Remove the fue l injection pump. (See Fuel Injection 2
Pump Removal And Installation on Page 70-60-6.) 1
Figure 70-80-92
3
2
P13353
Remove the go vernor fork lever shaft (Item 1) [Figure

1 70-80-94] and outer bearing (Item 2) [Figure 70-80-94],
using a met ric tap [Figure 70-80-94] screwed into the
P13354 threads of the fork lever shaft for leverage.
Remove the fork compensating lever and fork lever from

Remove the two mounting bolts (Item 1) [Figure 70-80- the block.
92] from fork lever shaft cover (Item 2) [Figure 70-80-92]

584 of 642
Figure 70-80-95
P13355
Remove the inside governor fork lever bearing (Item 1)

[Figure 70-80-95].

Figure 70-80-96
P13372
Check the parts for wear and replace as needed [Figure

70-80-96].
NOTE: The washer (Item 1) [Figure 70-80-96] goes

between the fork [Figure 70-80-96] and the
fork compensating lever (Item 3) [Figure 70-
80-96] when being installed.

585 of 642
RECONDITIONING THE ENGINE (CONT’D) Checking The Piston And Connecting Rod
Piston Removal And Installation Figure 70-80-99
Figure 70-80-97
1
1
2
1
2
P13398
P13381
Measure the piston hole with an inside micrometer
[Figure 70-80-99].
Remove the connecting rod bolts (Item 2) [Figure 70-80-
97]. The specifications are 0.8661-0.8687 inch (22,000-

22,013 mm). The allowable wear limit is 0.8673 inch
Installation: Tighten bolts to 30- 34 ft.-lb. (41-46 N•m) (22,03 mm).
torque.
Figure 70-80-100
Figure 70-80-98
2
1
1
4
3 P13401
P13400
Measure the piston pin (Item 1) [Figure 70-80-100] with

Remove the piston rings (Item 1) [Figure 70-80-98] from a micrometer and the c onnecting rod bushing (Item 2)
the piston. [Figure 70-80-100] with an inside micrometer.
Remove the p iston (Item 2) [Figure 70-80-98] from the The specifications for the outside diameter of the piston
connecting rod (Item 3) [Figure 70-80-98] by removing pin are 0.8662-0.8666 inch (22,002-22,011 mm).
the piston pin (Item 4) [Figure 70-80-98].
The specification for the inside diameter of th e
connecting rod bushing are 0.8671-0.8677 inch (22,025-
22,040 mm).
The clearance between the piston pin and the connecting

rod bushing is 0.0006-0.0015 inch (0,014-0,038 mm) with
an allowable limit of 0.0059 (0,15 mm).
586 of 642
RECONDITIONING THE ENGINE (CONT’D) Piston Ring Gap
Connecting Rod Alignment Figure 70-80-102
Figure 70-80-101
P13402
B-4067
Put the piston ring in the engine cylinder [Figure 70-80-
102]. Use a piston to push the ring to the lower part of the
NOTE: Check the I.D. of the connecting rod small end cylinder liner.
bushing, because it is used for this check,
make sure it is not worn. (See Checking The

Measure the r ing gap with a fee ler gauge (Item 1)
Piston And Conne cting Rod on Pa ge 70-80- [Figure 70-80-102].
30.)
The specifications are as listed below:
Install the piston pin into the connecting rod.
Top Ring 0.0098-0.0157 inch (0,25-0,40 mm)
Install the connecting rod on the connecting rod Second Ring 0.0098-0.0157 inch (0,25-0,40 mm)
alignment tool [Figure 70-80-101]. Oil Ring 0.0098-0.0157 inch (0,25-0,040 mm)
Put a gauge over the piston pin and move it against the
face plate. The allowable wear limit for all the rings is 0.0492 inch
(1,25 mm).
If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the If the r ing gap exceeds the al lowable limit, replace the
face plate. ring.
The allowable wear limit is 0.0020 inch (0,05 mm).
If the measurement exceeds the allowable limit, replace

the connecting rod.

587 of 642
RECONDITIONING THE ENGINE (CONT’D) If the clearance still exceeds the allowable limit after
replacing the ring, replace the piston.
Piston Ring Installation
Figure 70-80-103
3
B-3614
P13393
Remove the carbon from the ring grooves in the piston.
Install the r ings on the piston [Figure 70-80-103].

Position the top r ing so the gap is not lined up wi th the
piston pin. Position the other rings so there is a gap every
90°.
NOTE: The top ring (Item 1) [Figure 70-80-103] (Inset)

is a 1/2 flat key stone type ring and must be
installed with the flat side toward the bottom
of the piston as shown.
NOTE: The second ring (Item 2) [Figure 70-80-103]

(inset) must be installed with the notch down
as shown.
NOTE: The oil ring (Item 3) [Figure 70-80-103] (inset)

must be installed as shown.
NOTE: Measure the clearance between the ring and

the ring groove in the piston, with a feeler
gauge.
The clearance between compression ring (Item 2)

[Figure 70-80-103] and the ring groove is 0.0033-0.0044
inch (0,085-0,112 mm) with an al lowable limit of 0. 0079
inch (0,20 mm).
The clearance between the oil ring (Item 3) [Figure 70-

80-103] and the ring groove is 0.008-0.0021 inch (0,020-
0,055 mm) with an allowable limit of 0.0 059 inch (0,15
mm).
If the clearance exceeds the allowable limit, replace the

ring.

588 of 642
RECONDITIONING THE ENGINE (CONT’D) Checking Engine Cylinder Bore
Connecting Rod Installation Figure 70-80-106
Install the connecting rod to the piston.
Figure 70-80-104
P13384
Figure 70-80-107
P13393
Figure 70-80-105

1
P13382
Use a micrometer to measure the inside diameter of the

P13396 cylinders [Figure 70-80-106] & [Figure 70-80-107].
To find the maximum wear, measure the inside diameter

NOTE: The arrow (Item 1) [Figure 70-80-104] on the of the cylinder in three different locations. The inside
piston must point in the direction of the diameter specification is 2.9921-2.9929 inches (76,000-
numbers (Item 1) [Figure 70-80-105] on the 76,019 mm). The allowable wear limit is 0.0059 inch
connecting rod and the connecting rod cap. (+0,15 mm).
The alignment arrow and numbers must be
installed pointing oppos ite of the camshaft NOTE: When the cylinder has more wear than the
and in the same cylinder it was removed from. specifications the block can be bored and
honed one time. The oversize cylinder inside
diameter is +0.0197 inch (+0,5 mm). Be sure to
use the correct oversize piston and rings to
match the cylinder.

589 of 642
Crankshaft Removal And Installation 1

1
Remove the engine from the loader. (See Removal And
Installation on Page 70-70-1.) 1
2
Remove engine starter. (See STARTER on Page 60-40-
1.) 1
1
Remove engine flywheel. (See FLYWHEEL on Page 70-
100-1.) 1
Remove the engine cylinder head. (See Cylinder Head 1 1

1 P13380
Remove the e ngine oil pan. (See Oil Pan Removal And
Remove the nine mounting bolts (Item 1) [Figure 70-80-
Remove the p istons. (See Piston Removal And 109] from the crankshaft bearing case cover (Item 2)
Installation on Page 70-80-30.) [Figure 70-80-109].
Figure 70-80-108 Installation: Tighten the mounting bolts to 87-100 in.-lb.

(9,8-11 N•m) torque.

Figure 70-80-110
1 1
1
P13381
Remove the two main bearing mounting bolts (Item 1) P13375

[Figure 70-80-108].
Installation: Tighten the m ounting bolts to 36 -40 ft.-lb. Remove the crankshaft from the rear of the engine
(49-53,9 N•m) torque. [Figure 70-80-110].
Check the gasket (Item 1) [Figure 70-80-110] and

replace.

590 of 642
Crankshaft Removal And Installation (Cont’d)
Figure 70-80-111
1
1 1 2
1
2
1 1 1
2
1 1
P13387
1
1 Mark the main bearing caps (Item 1) [Figure 70-80-113].
P13386
Remove the main bearing cap bolts (Item 2) [Figure 70-
80-113].
Remove the eight mounting bolts (Item 1) [Figure 70-80-
111] from the crankshaft bearing case cover and remove Installation: Tighten the main bearing cap bolts to 22-25
the cover.

ft.-lb. (24,4-34,3 N•m) torque.
Figure 70-80-112 NOTE: Since diameters of main bearings vary, install

the caps back on the bearings as t hey are
removed. Install them in the order they were
marked from the gear case side. When
installing the main bearing cap assemblies
face the mark (FLYWHEEL) on the
assemblies, toward the flywheel end of the
crankshaft.
1
Figure 70-80-114
1
2
P13388
Replace the crankshaft bearing case cover gasket (Item

1) [Figure 70-80-112]. 1
Replace the oil seal (Item 2) [Figure 70-80-112]. 1
1
P13397
Check the thrust bearings (Item 1) [Figure 70-80-114],

located on the rear main bearing only, and replace if
worn.
NOTE: When replacing the thrust bearings be sure to

install the oil groove facing outward.
591 of 642
Checking Crankshaft Journal And Block Bearing
Figure 70-80-115
1
P13391
The outside diameter of the crankshaft number one

P13385 journal (Item 1) [Figure 70-80-117] is 1.8872-1.8878 inch
(47,934-47,950 mm).
Measure the i nside diameter of the fr ont crankshaft The oil clearance between the crankshaft and the
bearing (Item 1) [Figure 70-80-115]. crankshaft bearing is 0.0013-0.0045 inch (0,034-0,114

mm) with an allowable limit of 0.0079 inch (0,2 mm).
Figure 70-80-116
P13383
The crankshaft bearing inside diameter is 1.8891-1.8917

inch (47,984-48,048 mm).

592 of 642
Checking Crankshaft Journal And Main Bearing
Figure 70-80-118
P13394
Remove the bolts and remove the main bearing cap and
P13395 measure with the plastic gauge scale [Figure 70-80-
120], to get oil clearance.
Clean the crankshaft journal and crankshaft bearing. The oil clearance between crankshaft and crankshaft
number two bear ing is 0.0013-0.0037 inch (0,034-0,095
Put a str ip of pl astic gauge (Item 1) [Figure 70-80-118]

on the main bearing.
The oil clearance between the crankshaft and crankshaft
Figure 70-80-119 number three bearing is 0.0013-0.0037 inch (0,034-0,095
1
The oil clearance between the crankshaft and crankshaft
number four bearing is 0.0013-0.0039 inch (0,034-0,098
If the c learance exceeds the allowable limit, replace the

crankshaft bearing.
P13392
Install the main bearing cap (Item 1) [Figure 70-80-119]

on the main bearing.

593 of 642
Crankshaft Removal And Installation (Cont’d)
Figure 70-80-121
3 2 1
P13383
Measure the connecting rod bearings [Figure 70-80-122]

P13391 & [Figure 70-80-123]. The measurement should be
1.5750-1.5768 inches (40,004-40,050 mm).
The measurement for the outside diameter of crankshaft Figure 70-80-124

number two jou rnal (Item 1) [Figure 70-80-121] and
crankshaft number three journal (Item 2) [Figure 70-80-

121] is 1.8872-1.8878 inch (47,934-47,950 mm).
The crankshaft bearing inside diameter for number tow

and three journals are 1.8891-1.8909 inch (47,984-
48,029 mm).
The measurement for the outside diameter of the

crankshaft number four journal (Item 3) [Figure 70-80-
121] is 2.0041-2.0449 inch (51,921-51,940 mm).
The crankshaft bearing inside diameter for number four

journal is 2.0462-2.0480 inches (51,974-52,019 mm).
P13390
Connecting Rod Journal
Figure 70-80-122 Measure the connecting rod journals [Figure 70-80-124].
The measurement should be 1.5732-1.5738 inches

(39,959-39,975 mm).
The oil clearance between the crankpin and the crankpin

bearing is 0.0011-0.0036 (0,029-0,091 mm) with an
allowable limit of 0.0079 inch (0,2 mm).
P13399

594 of 642
RECONDITIONING THE ENGINE (CONT’D) Crankshaft Alignment
Checking The End Play Of The Crankshaft Figure 70-80-126
Move the crankshaft toward the crankshaft pulley end.
Figure 70-80-125
P13389
Support the crankshaft with V-blocks and set a dial

P13376 indicator on one of the center journals at a right angle
[Figure 70-80-126].
Set a dial indicator (Item 1) [Figure 70-80-125] to the

Rotate the crankshaft on th e V-blocks and get the
crankshaft. misalignment (half of the measurement).
Measure the end play by pushing the crankshaft toward The measurement should be 0.0008 inch (0,02 mm).
flywheel end.
If the misalignment exceeds the allowable limit, replace
The end play should be between 0.0059-0.0122 inch the crankshaft.
(0,15-0,31 mm) with an allowable limit of 0.0197 inch (0,5
mm).
If the me asurement exceeds the allowable limit replace

the thrust bearings. (See Crankshaft Removal And

595 of 642
RECONDITIONING THE ENGINE (CONT’D) Align the timing marks between the idler gear and the
crankshaft (Item 2) [Figure 70-80-128], the camshaft
Engine Timing Installation (Item 3) [Figure 70-80-128] and the fuel camshaft (Item
4) [Figure 70-80-128].
Figure 70-80-127
Timing Gear Backlash, Idler Gear And Crankshaft
Figure 70-80-129
3
2
4
1
P13346 2
Install the crankshaft (Item 1) [Figure 70-80-127]. (See

P13271
Crankshaft Removal And Installation on Page 70-80-34.)

Install the camshaft (Item 2) [Figure 70-80-127]. (See Set a dial indicator (lever type) with its tip on a gear tooth
Camshaft Removal And Installation on Page 70-80-20.) of the idler gear (Item 1) [Figure 70-80-129].
Install the gov ernor shaft (Item 3) [Figure 70-80-127]. Hold the crankshaft gear (Item 2) [Figure 70-80-129] and
(See Governor Shaft Removal And Installation on Page move the idler gear.
70-80-25.)
Check the amount of movement on the dial indicator.
Install the fuel camshaft (Item 4) [Figure 70-80-127].
(See Fuel Camshaft Removal And Installation on Page The measurement should be 0.0013-0.0045 inch (0,032-
70-80-22.) 0,115 mm) with an allowable limit of 0.00 59 inch (0,15
mm).
Figure 70-80-128
If the backlash exceeds the allowable limit, check the oil
clearance between idler gear shaft and the i dler gear
bushing. (See Idler Gear Removal And Installation on
Page 70-80-19.)
3
4 If the clearance is within the allowable limit, replace the
idler gear.
P13269
Install the idler gear (Item 1) [Figure 70-80-128] on the

idler shaft. (See Idler Gear Removal And Installation on
Page 70-80-19.)

596 of 642
RECONDITIONING THE ENGINE (CONT’D) If after replacing the camshaft gear the backlash exceeds
the allowable limit check the fuel camshaft bearings.
Idler Gear And Camshaft Gear (See Fuel Camshaft Removal And Installation on P age
70-80-22.)
Figure 70-80-130
Fuel Camshaft Gear And Governor Shaft Gear
Set a dial indicator (lever type) with its tip on a gear tooth
1
of the governor shaft gear (Item 4) [Figure 70-80-130].
3
Hold the fuel camshaft gear (Item 3) [Figure 70-80-130]
and move the fuel camshaft gear.
2
4 Check the amount of movement on the dial indicator.
The measurement should be 0.0012-0.0046 inch (0,030-

mm).
P13271 If backlash exceeds the allowable limit replace the

governor shaft gear.
Set a dial indicator (lever type) with its tip on a gear tooth If after replacing the governor shaft gear the backlash
of the camshaft gear (Item 1) [Figure 70-80-130]. exceeds the allowable limit check the gov ernor shaft

bearings. (See Governor Shaft Removal And Installation
Hold the idler gear (Item 2) [Figure 70-80-130] and move on Page 70-80-25.)
the camshaft gear.

mm).
If backlash exceeds allowable limit replace the camshaft

gear.
If after replacing the camshaft gear the backlash exceeds

the allowable limit check the camshaft bearing. (See
Camshaft Removal And Installation on Page 70-80-20.)
Idler Gear And Fuel Camshaft Gear
Set a dial indicator (lever type) with its tip on a gear tooth
of the fuel camshaft gear (Item 3) [Figure 70-80-130].
Hold the idler gear (Item 2) [Figure 70-80-130] and move

the fuel camshaft gear.

mm).
If backlash exceeds the allowable limit replace the fuel

camshaft gear.

597 of 642

598 of 642
FLYWHEEL HOUSING Figure 70-90-3
Remove the engine assembly. (See Removal And

NOTE: Set engine assembly on a secure work

surface.
Remove starter. (See STARTER on Page 60-40-1.)
Figure 70-90-1
P-35286
Remove flywheel housing from the engine [Figure 70-

90-3].

P-35284
Install a lifting bracket and hoist to lift and support the

flywheel housing [Figure 70-90-1].
Figure 70-90-2
P-35285
Loosen and remove the nine flywheel housing mount

bolts [Figure 70-90-2].
Installation: Tighten the two bolts (Item 1) [Figure 70-

90-2] to 40-45 ft.-lb. (54-61 N•m) torque. Tighten the
remaining mounting bolts to 20-23 ft.-lb. (27-31 N•m)
torque.

599 of 642

600 of 642
FLYWHEEL Ring Gear Removal And Installation
Removal And Installation NOTE: The lead chamfer on ring gear tooth must face
the starter.
Remove the engine. (See Removal And Installation on
Page 70-70-1.) Figure 70-100-2
Remove the flywheel housing. (See FLYWHEEL

HOUSING on Page 70-90-1.) 1
Remove the rubber drive coupler. (See RUBBER DRIVE

COUPLER on Page 70-110-1.)
Mark the location of the flywheel for correct installation.
Figure 70-100-1
1
P-35293
The ring gear (Item 1) [Figure 70-100-2] on the flywheel

is an i nterference fit. Heat the ring gear enough to
expand it and hit it with a hammer to remove it evenly.
Clean the outer surface of the flywheel to give it a smooth

fit.
P-35292 Clean the new ring gear and heat it to a ma ximum

temperature of 428°F (220°C).
Remove the six flywheel mounting bolts (Item 1) [Figure Fit the ring gear over the flywheel. Make sure the gear is
70-100-1]. Remove the flywheel. on the seat correctly.
Installation: Apply Loctite #242 or equivalant to the bolts

and tighten to 40-43 ft.-lb. (54-59 N•m) torque.

601 of 642

602 of 642
RUBBER DRIVE COUPLER Disassembly
Removal And Installation Figure 70-110-3
Remove the engine. (See Removal And Installation on

Page 70-70-1.) 1
Remove the flywheel housing. (See FLYWHEEL

HOUSING on Page 70-90-1.)
Figure 70-110-1
1
1
1
P-35289
Put the coupler assembly in a vise and remove the three

bolts (Item 1) [Figure 70-110-3].
1 Figure 70-110-4

P-35287
Remove the three drive coupler mounting bolts (Item 1)

[Figure 70-110-1]. Remove the coupler.
Installation: Apply (Loctite 242) or equivalent to the bolts

and tighten to 25-30 ft.-lb. (34-40 N•m) torque.
Figure 70-110-2
2
P-35294
Remove the drive coupler (Item 1) [Figure 70-110-4]

from the rubber housing (Item 2) [Figure 70-110-4].
Inspect the drive coupler (Item 1) [Figure 70-110-4] for

damage and replace as needed.
P-35288
NOTE: When the drive coupler is installed correctly

the recessed part of the coupler (Item 1)
[Figure 70-110-2] is in position shown.

603 of 642
RUBBER DRIVE COUPLER (CONT’D)
Figure 70-110-5
P-35290
Inspect the rubber housing [Figure 70-110-5] and

damage and replace as needed.

Install the drive coupler into the rubber housing, apply
(Loctite #242) or equivalent to the bolts and tighten to 25-
30 ft.-lb. (30-40 N•m) torque.

604 of 642
TURBOCHARGER
NOT AVAILABLE AT TIME OF PRINTING

605 of 642

606 of 642
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 DRIVE
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 SYSTEM
Grinding Specifications for the Crankshaft. . . . . . . . . . SPEC-20-5
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2

ELECTRICAL
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 SYSTEM &
ANALYSIS
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . SPEC-50-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
ENGINE
LOADER BACKHOE SPECIFICATIONS . . . . . . . . . . . . . SPEC-10-1 SPECIFICATIONS
SERVICE
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Loader Backhoe Dimensions . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
LOADER BACKHOE TORQUE. . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-40-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-1

SPEC-01 Service Manual
607 of 642

SPEC-02 Service Manual
608 of 642
LOADER BACKHOE SPECIFICATIONS
Loader Backhoe Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.

SPEC 10-01 Service Manual
609 of 642
LOADER BACKHOE SPECIFICATIONS (CONT’D)
Performance
REF. B100
Rated Operating Capacity (SAE) 1600 lbs. (726 Kg)
Tipping Load (SAE Rating) (ISO) 3200 lbs. (1452 Kg)
Operating Weight 4865 lbs. (2203 kg)
Travel Speed 5.0 MPH (8 km/hr.)
Controls
Vehicle Steering Direction is controlled with steering wheel

Loader Hydraulics
Lift and Tilt Controlled by lever
Front Auxiliary Controlled by lever
Rear Auxiliary (Option) Controlled by lever.
Engine Hand lever throttle: Key-type starter switch and shutdown.
Starting Aid Glow plugs-Automatically activated by key switch, with light on
Instrument Panel.
Parking Brake Controlled by lever.

Engine
Make/Model Kubota/D1105
Fuel/Cooking Diesel/Liquid (Antifreeze mixture)
Horsepower (SAE Net) 25.0 HP (18,6 kW)
Number of Cylinders Three
Displacement 69 cu. in. (1,13 L)
Lubrication Gear Pump Pressure System W/Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable cartridge
Ignition Diesel-Compression
High Idle RPM 850-950 RPM
Low Idle RPM 3200 RPM

610 of 642
Hydraulic System
B100
Pump Capacity @ 2615 Engine RPM (std) 10.7 GPM (40,5 L/min.
System Main Relief 2320-2900 PSI (17500 kPa)
Hydraulic Cylinders
Bore Diameter:
Boom Cylinder 2.5 (63)
Bucket Cylinder 2.5 (63)
Arm Cylinder 2.5 (63)
Lift Cylinder 2.5 (63)
Stabilizer Cylinder 2.2 (55)
Steering Cylinder 2.2 (55)
Swing Cylinder 2.2 (55)
Tilt Cylinder 2.2 (55)
Rod Diameter:
Bucket Cylinder 1.4 (36)

Arm Cylinder 1.4 (36)
Stabilizer Cylinder 1.2 (30)
Tilt Cylinder 1.2 (30)
Stroke:
Bucket Cylinder 15 (380)
Arm Cylinder 15 (380)
Stabilizer Cylinder 13 (330)
Tilt Cylinder 15 (380)

611 of 642
Electrical
B100
Alternator Belt Driven, 90 amp., open
Battery 12 volt, 1000 cold cranking amps. @ 0°F. (-18°C);
180 minute reserve capacity
Starter 12 volt, Gear Type; (1,0 Kw)
Instrumentation Gauges: Hourmeter, Fuel, Engine Coolant Temperature.
Warning lights: Fuel Level, Glow Plugs, System Voltage, Engine Coolant
Temperature, Engine Oil Pressure, Hydraulic Oil Temperature,
Engine Air Filter & Hydraulic Filter.
Drive System
Main Drive Hydrostatic rear wheel drive

Transmission/Final Drive Hydrostatic
Capacities

Fuel 14.5 gals. (55 L)
Engine Oil W/Filter 4.3 qts. (4 L)
Hydraulic/Hydro. Reservoir 13.5 gals. (51 L)
Hydraulic/Hydro. System 13.5 gals. (51 L)
Tires
Front 23 x 8.5-12,6 Ply rating

Rear 10.0 x 75-15.3,8 Ply rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire.
DO NOT mix brands of tires used on the same loader

612 of 642
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Engine Compression
@ 200 to 300 RPM (Operating Temperature) 412-469 PSI (2841-3234 kPa)

Fuel Injection Nozzles
Opening Pressure 1990-2133 PSI (13721-14707 kPa)

Fuel Tightness Nozzle Seat Dry Nozzle at 1848 PSI (12742 kPa)
Fuel Injection Pump
Fuel Tightness Plunger

Limit Permitted 2133 PSI (14707 kPa)
Fuel Tightness of Delivery Valve 10 sec: initial pressure drop from 2133-1990 PSI (14707-13721 kpa)
Limit Permitted 5 sec: initial pressure drop from 2133-1990 PSI (14707-13721 kpa)
Injection Timing 18.0-20.0 degrees B.T.D.C.

Cylinder Head
Cylinder Distortion Limit 0.0020” (0,05 mm) in 4” (100 mm)

of the length of the cylinder head surface.
Thickness of Gasket 0.0413-0.0453” (1,05-1,15 mm)
Thickness of Gasket Shim 0.0079” (0,2 mm)
Top Clearance 0.0217-0.0453” (1,05-1,15 mm)
Compression 412-469 PSI (2840-3234 kPa)
Head Bolt Torque 48-51 ft.-lb. (65-69 N•m)
Valves
Valve Seat Width 0.0835” (2,12 mm)

Valve Seat Angle Intake 60 degrees
O.D. of Valve Stem Exhaust 0.2740-0.2746” (6,960-6,975 mm)
I.D. of Valve Guides 0.2760-0.2765” (7,010-7,025 mm)
Clearance Between Valve Stem & Guide 0.0014-0.0025” (0,035-0,065 mm)
Limited Permitted 0.004” (0,1 mm)
Depth of Valve 0.035-0.043” (0,9-1,1 mm)
Limit Permitted 0.51” (1,3 mm)
Valve Clearance (Cold) 0.0057-0.0072” (0,145-0,185 mm)

SPEC-20-01 Service Manual
613 of 642
ENGINE SPECIFICATIONS (CONT’D)
parentheses.
Valve Springs
Free Length 1.457-1.476” (37,0-37,5)

Fitted Length 1.22” (31,0 mm)
Load to Compress To Fitted Length 26.4” lbs. (11,98 kg)
Limit Permitted 22.5 lbs. (10,2 kg)
Limit Permitted for Spring being Straight 0.039” (1,0 mm)
Rocker Arms
O.D. of Rocker Arm Shaft 0.4714-0.4718” (11,973-11,984 mm)

I.D. of Rocker Arm Bushings 0.4724-0.4731” (12,000-12,018 mm)
Clearnace Between Rocker Arm & Bushing 0.0006-0.0018” (0,016-0,045 mm)
Camshaft

O.D. of Camshaft Bearing Journal 1.4147-1.3799” (35,934-35,950 mm)
I.D. of Camshaft Bearing 1.4173-1.4183” (36,000-36,025 mm)
Clearance Between Camshaft Bearing & Journal 0.0020-0.0036” (0,050-0,091 mm)
Alignment of the Camshaft 0.0004” (0,01 mm)
Cam Lobe Height Intake 1.1339” (28,80 mm)
Exhaust 1.1417” (29,00 mm)
Limit Permitted Intake 1.1319” (28,75 mm)
Exhaust 1.1398” (29,95 mm)
Gear Backlash 0.0013-0.0045” (0,032-0,115 mm)
Cylinders
Cylinder Liner I.D. 3.2677-3.2686 (83,0-83,022)

Allowable Limit +0.0059 (+0,15)
Oversized Cylinder Liner I.D. 3.2874-3.2883 (83,5-83,522)
Allowable Limit +0.0059 (+0,15)

614 of 642
ENGINE SPECIFICATIONS (CONT'D)
parentheses.
Piston Rings
Ring Gap, Top Ring 0.0118-0.0177” (0,30-0,45 mm)

Ring Gap, 2nd Ring 0.0118-0.0177” (0,30-0,45 mm)
Ring Gap, Oil Ring 0.0098-0.0157” (0,25-0,40 mm)
Side Clearance of Ring Groove:
Top Ring Can not measure accurately
2nd Ring 0.0033-0.0048” (0,081-0,122 mm)
Oil Ring 0.0008-0.0021” (0,020-0,055 mm)
Pistons
I.D. of Piston Bosses 0.8611-0.8687 (22,002-22,011 mm)

Limit Permitted
O.D. of Piston Pin 0.8662-0.8666” (22,002-22,011 mm)
I.D. of Connecting Rod Bushing (Small End, Fitted) 0.8671-0.8677” (22,025-22,040 mm)

Clearance Between Piston Pin & Bushing (New Engine) 0.0006-0.0015” (0,014-0,038 mm)
Service Parts 0.0006-0.0026” (0,015-0,066 mm)
Connecting Rod Alignment
Oversize Piston 0.020” (0,5 mm)
Crankshaft
Crankshaft Alignment 0.0008” (0,02 mm)

O.D. of Crankshaft Journal #1 1.8872-1.8878” (47,934-47,950 mm)
I.D. of Crankshaft Bearing #1 1.8892-1.8917” (47,984-48,048 mm)
Oil Clearance Between Crankshaft Journal & Bearing #1 0.0013-0.0045” (0,034-0,114 mm)
O.D. of Crankshft Journal #2 1.8872-1.8878” (47,934-47,950 mm)
O.D. of Crankshaft Journal #3 2.0441-2.0449” (51,921-51,940 mm)

615 of 642
parentheses.
Oil Pump
Oil Pressure @ Rated RPM 28-64 PSI (196-441 kPa)

Limit Permitted 21.3 PSI (147.1 kPa)
Oil Pressure @ Idle Speed 7 PSI (49 kPa)
Clearance Between Inner and Outer Rotor 0.0024-0.0071” (0,06-0,18 mm)
Clearance Between Outer Rotor & Pump Body 0.0039-0.0071” (0,10-0,18 mm)
End Clearance Between Rotor & Cover 0.0098-0.295” (0,025-0,75 mm)
Thermostat
Opening Temperature (Starting) 157°-162°F (69.5°-72.5°C)

(Fully Open) 203°F (95°C)

616 of 642
Grinding Specifications for the Crankshaft
If the standard-size bearing cannot be used due to excessive wear of the crankpin and crank journals, use undersize or
oversize bearings.
3
1
3
2
A A

4
B-5928
Undersize and Oversize Bearings
If the standard size bearing cannot be employed due to excessive wear of the crankpin and crank journal, employ
undersize or oversize bearings.
For under size or oversize bearing use, use the precautions noted below.
1. Grind the crankpin corner (1) and journal corner (2) with a wheel which has specified round corner and width without
shoulder.
Item 1 .1102-.1260 inch (2.8-3.2 mm)

Item 2 .0906-.1063 inch (2.3-2.7 mm)
2. Be sure to chamfer the oil hole (3) circumference to .04-.06 inch (1,5 mm) radius with an oil stone
3. The crankpin (4) must be fine-finished to higher than (.8-S).
4. The crank journal (5) must be fine-finished to higher than (.8-S).
5. The crank journal side surface (C) must be fine-finished to higher than (.8-S).

617 of 642
ENGINE SPECIFICATIONS (CONT’D)
Grinding Specifications for the Crankshaft (Cont’d)
If the standard-size bearing cannot be used due to excessive wear of the crankpin and crank journal, use undersize or
oversize bearings.
Ref. SIZE CODE NUMBER DESCRIPTION DIMENSION MARK

-0.008 in. 16241-2391-1 Crankshaft Bearing #1 1.8793-1.8799 in. 020US
-0,2 mm (0.2 minus) 47,734-47,750 mm
-0,4 mm (0.4 minus) 47,534-47,550 mm
-0,2 mm (0.2 minus) 47,734-47,750 mm
A
-0,4 mm (0.4 minus) 47,534-47,550 mm
-0,2 mm (0.2 minus) 51,721-51,740 mm
-0,4 mm (0.4 minus) 51,521-51.540 mm

-0.008 in. 16241-2397-1 Crank pin Bearing 1.5653-1.5659 in. 020US
-0,2 mm (0.2 minus) 39,759-39,775 mm
B
-0.008 in. 16241-2398-1 Crank pin Bearing 1.5574-1.5581 in. 040US
-0,2 mm (0.4 minus) 39,559-39,575 mm
-0.008 in. 19202-2397-1 Thrust Bearing 2 (0.2 +) 1.1102-1.1122 in. 0.20 OS
-0,2 mm 15521-2396-1 Thrust Bearing 1 (0.2 +) 28,20-28,25 mm
C
-0.008 in. 19202-2398-1 Thrust Bearing 2 (0.4 +) 1.1181-1.1201 in. 0.40 OS
-0,2 mm 15521-2396-1 Thrust Bearing 1 (0.4 +) 28,40-28,45 mm

618 of 642
LOADER BACKHOE TORQUE
Specifications
ITEM FT.-LB. N•M

Air Cleaner Mounting Bolts
Alternator Pulley Nut 50 68
Arm Cylinder Pivot Pin Retainer Bolt
Axle Hub Mounting Bolt
Bob-Tach Pivot Pin Bolts 190 260
Bob-Tach Lever Pivot Bolt 25-28 34-38
Boom Cylinder Pivot Pin Retainer Bolts
Bucket Cylinder Pivot Pin Retainer Bolt
Camshaft Retainer Plate Bolts 7-8 9-11
Connecting Rod Bolts 30-34 41-46
Crankshaft Pulley Nut 101-116 137-157
Cylinder Head Bolts 48-51 64-69
Drive Coupler Mounting Bolts 25-28 34-37
Engine Mounting Bolts
Floor Panel Mounting Bolts
Flywheel Bolts 40-43 54-59

Front Axle Pivot Nut
Fuel Camshaft Retainer Plate Bolts 7-8 9-11
Fuel Tank Mounting Bolts
Glow Plug 15-18 20-24
Grill Frame Mount Bolts
High Pressure Fuel Lines 18-25 24-33
Hydraulic Reservoir Mounting Bolts
Hydraulic Filter Housing Mounting Bolts
Hydrostatic Motor Mounting Bolts
Hydrostatic Pump Mounting Bolts
Idler Gear Shaft Bolts 7-8 9-11
Injection Pump Mounting Bolts & Nuts 17-20 23-27
Injection Nozzles 36-51 46-69
Injector Nozzle Body 43-58 59-79
Main Bearing Mounting Bolts 36-40 49-54
Main Bearing Cap Bolts 22-25 29-34
Main Relief Valve 35-40 47-54
Operator Cab Fastening Nuts
Rear Bearing Case Cover Bolts 13-15 18-20
Seat Belt Fastening Bolts
Seat Mounting Bolts
Seat Bar Pivot Bolts 25-28 34-38
Steering Linkage Bolts
Steering Linkage Lock Nuts
Tilt Cylinder Pivot Pin Retainer Bolt
Timing Gearcase Cover Bolts 13-17 18-23
Travel Pedal Mounting Bolts
Wheel Nuts 140 190

619 of 642

620 of 642
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
3-4 ft.-lb.
M 5 x 0.8
(4-5 N•m)
6-7 ft.-lb. 6-9 ft.-lb.
M 6 x 1.0
(8-9 N•m) (8-12 N•m)
6-9 ft.-lb. 11-16 ft.-lb. 18-25 ft.-lb.
M 8 x 1.25
(8-12 N•m) (15-22 N•m) (24-34 N•m)
13-18 ft.-lb. 22-30 ft.-lb. 36-50 ft.-lb.
M 10 x 1.25
(18-24 N•m) (30-41 N•m) (49-68 N•m)
22-30 ft.-lb. 40-54 ft.-lb. 69-87 ft.-lb.
M 12 x 1.25
(30-41 N•m) (54-73 N•m) (94-118 N•m)
36-50 ft.-lb. 58-80 ft.-lb. 116-137 ft.-lb.
M 14 x 1.5
(49-68 N•m) (79-108 N•m) (157-186 N•m)

621 of 642

622 of 642
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not available, use 10W-30 or 10W-40
SAE Motor Oil (5W-30 for 0°F [-18°C] and Below).
DO NOT use automatic transmission fluids in the loader or permanent damage to the transmission will result.
WARNING
W-2072-0496
When temperatures below zero degree F (-18°C) are common, the loader must be kept in a warm building. Extra warm-

up time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and
it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by
TRANS light ON) can cause transmission damage in less than 60 seconds.
WARNING
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the

hydrostatic oil mus t be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285

623 of 642
T190 Bobcat Loader Backhoe

624 of 642
CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion

625 of 642

626 of 642
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Revision No: B100-1

Date: October 7 2002
Product: Bobcat Loader
Model: B100
Manual No: 6901844 (7-02)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN CHANGE DECRIPTION
Entire service manual - Entire service manual - Updated and new information
including hydraulic and including hydraulic and
electrical schematics - electrical schematics -
Dated 7-02 Dated 10-02
Printed in U.S.A.
627 of 642
B100 Bobcat Backhoe Loader

2 Service Manual
628 of 642
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: B100-2

Date: November 1, 2002
Product: Bobcat Loader Backhoe
Model: B100
Manual No: 6901844 (10-02)

20-01 through 20-04 20-01 through 20-04 Revised text
20-60-1 & 20-60-2 20-60-1 through 20-60-28 Revised text
40-01 & 40-02 40-01 & 40-02 Revised text
40-21-1 through 40-21-10 Added text
50-01 & 50-02 50-01 & 50-02 Revised text
Printed in U.S.A.
629 of 642

2 Service Manual
630 of 642
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: B100-3

Date: March 1, 2003
Model: B100
Manual No: 6901844 (10-02)

ALPHABETICAL INDEX ALPHABETICAL INDEX Revised text
10-50-1 & 10-50-2 10-50-1 & 10-50-2 Revised text
20-01 through 20-04 20-01 through 20-04 Revised text
20-50-1 through 20-50-18 20-50-1 through 20-50-18 Revised text
30-01 & 30-02 30-01 & 30-02 Revised text
30-10-1 & 30-10-2 30-10-1 & 30-10-2 Revised text
60-01 & 60-02 60-01 & 60-02 Revised text
SPEC 10-1 through SPEC 10-4 SPEC 10-1 through SPEC 10-4 Revised text
Printed in U.S.A.
631 of 642

2 Service Manual
632 of 642
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: B100-4

Date: April 1, 2003
Model: B100
Manual No: 6901844 (10-02)

10-10-1 & 10-10-2 10-10-1 & 10-10-2 Revised text
10-70-1 & 10-70-2 10-70-1 & 10-70-2 Revised text
30-01 & 30-02 30-01 & 30-02 Revised text
Printed in U.S.A.
633 of 642
Machine Name
2 Operation & Maintenance Manual
634 of 642
ROUTE TO
ATTENTION
PARTS MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: B100-5

Date: November 1, 2005
Model: B100
Manual No: 6901844 (7-02)

TAKE OUT PUT IN CHANGE DESCRIPTION
20-50 20-50 Revised text


40-40 Added text
Printed in U.S.A.
635 of 642
636 of 642
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
Revision No: B100-6

Date: 23 March 2006
Model: B100
Manual No: 6901844 (7-02)
B100 Service Manual (P/N 6901844) Dated (3-06) contains updated service information which replaces the
previous B100 Service Manual (P/N 6901844) Dated (7-02).
Printed in U.S.A.
637 of 642
638 of 642
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: B100-7

Date: May 15, 2011
Model: B100
Manual No: 6901844 (5-11)
The following Sections are a revision to the above Service Manual.
COVER

HYDRAULIC / HYDROSTATIC SCHEMATICS
ELECTRICAL SCHEMATICS
Printed in U.S.A.
639 of 642
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ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
Revision No: B100-8

Date: 15 June 2012
Model: B100
Manual No: 6901844 (5-11)

The following Sections are a revision to the above Service Manual.
COVER
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642 of 642

B100 6901844 enUS SM

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B100

Dealer Copy -- Not for Resale

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

6901844 (6-12) Printed in U.S.A. © Bobcat Company 2011

CORRECT CORRECT CORRECT

B-10731a B-16639 B-16527

Dealer Copy -- Not for Resale

B-16570 B-16517 B-16696

WRONG WRONG WRONG

B-16571 B-16572 B-6589

AIR CLEANER ........................................................ 70-01 HYDROSTATIC TESTING.......................................30-01

CAB LIGHTS........................................................... 60-01 PARKING BRAKE....................................................40-01

Dealer Copy -- Not for Resale

GEAR PUMP .......................................................... 20-01 TILT CYLINDER ......................................................20-01

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

Dealer Copy -- Not for Resale

B100 Bobcat Loader Backhoe

2. The seat belt must be 10. Safety treads must be in good

Dealer Copy -- Not for Resale

5. Foot pedal must return to 13. Inspect for fuel, oil or

6. Check for correct function of 14. Lubricate the loader backhoe.

7. The parking brake must 15. Check the condition of the

B100 Bobcat Loader Backhoe

19. Inspect for loosen or broken 22. Recommend to t he owner

Dealer Copy -- Not for Resale

B100 Bobcat Loader Backhoe

B100 Bobcat Loader Backhoe

Dealer Copy -- Not for Resale

• The Loader Backhoe Operator Training Course is

B100 Bobcat Loader Backhoe

The dealer and owner/operator review the recommended

Dealer Copy -- Not for Resale

B100 Bobcat Loader Backhoe

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

Dealer Copy -- Not for Resale

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

B100 Bobcat Loader Backhoe

B100 Bobcat Loader Backhoe

Always use the serial number of the loader backhoe Figure 3

Loader Backhoe Serial Number

The engine serial number is located on the valve cover at

Dealer Copy -- Not for Resale

The loader backhoe serial number plate is located under

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module B-16315

B100 Bobcat Loader Backhoe

Dealer Copy -- Not for Resale

B100 Bobcat Loader Backhoe

ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

BACKHOE BOOM LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1