Bobcat 520 - 530 Service Manual

5 5
2 3
0 3
Service
Manual
5
3
0
6566532 (11–94) Printed in U.S.A. Melroe Company 1987

MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
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-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-11799 B-15231 B-15280

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-6590 B-6580 B-6589

B-16102 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 loader 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 acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can 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 rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
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. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805
FORWARD PREVENTIVE
MAINTENANCE
This manual gives instructions for:
1. Correct service and adjustment of the Bobcat Loader.
2. Overhaul instructions of the engine, loader hydraulic/hydrostatic system and HYDRAULIC

mai nframe parts. SYSTEM
See the Owner's Manual for operating instructions (Starting Procedure, Regular Checks,
Basic Maintenance, etc.).
Make a complete inspection of these items after completion of service or repair: HYDROSTATIC
SYSTEM
1. Check the hydraulic fluid level, engine oil level, fuel supply, and coolant level.
2. Look for any sign of fuel, oil or hydraulic fluid leaks.
3. Complete lubrication of the machine.

DRIVE
SYSTEM
4. Check the battery condition, electrolyte level and cables.
5. Check the air cleaner system for damage or leaks. Check the element and replace if
necessary.
6. Check the electrical system. MAIN FRAME
7. Check the warning lamps.
8. Check the tires for wear and correct pressure.
9. Check the Bob·Tach attachment for condition. Check the wedges for damage or
ELECTRICAL
wear.
SYSTEM
10. Check all safety items for condition (Operator Enclosure, Seat Belt, Safety Treads,
Lamps, Parking Brake, etc.).
11. Make a visual inspection for loose or broken parts or connections.

ENGINE SERVICE
12. Operate the loader, and check operation of drive system and hydraulic system. (520, 530)
Tell the owner if any of the above items are in need of repair.
ENGINE SERVICE
(533)
CONTENTS
ALPHABETICAL INDEX .10-1 TECHNICAL

ELECTRICAL SYSTEM 6-1 DATA
ENGINE SERVICE (520/530) 7-1
ENGINE SERVICE (533) 8-1
HYDRAULIC SYSTEM 2-1
HYDROSTATIC SYSTEM 3-1 ALPHABETICAL
MAIN FRAME 5-1 INDEX
DRIVE SYSTEM 4-1
PREVENTIVE MAINTENANCE 1-1
TECHN ICAl DATA 9-1
SAFETY INSTRUCTIONS
AWARNING
Instructions are necessary before operating or servicing machine. Read 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. Failure
to follow instructions can cause injury or death.
W-2003-1289
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete in structions have been given to the new owner and that the machine
is in safe operating condition .
• The Operation & Maintenance Manual delivered with the loader gives operating information as wel l as rou ti ne mainte·
nance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator's Handbook fastened to the operator cab. Its brief instructions are conven ient to the
operator. The handbook is available from your dealer in English edition or a combination English, French, German , Italian,
Dutch & Spanish edition.
• The EMI Safety Manual delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from you r dealer for use by mechanics to do shop-type service and
repair work.
• The Skid-Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader.
AWARNING IMPORTANT
Warnings on the machine and In the This notice identifies procedures
manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause Injury or damage to the machine.
death. 1- 2019-0284
W-2044-1285
A Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this
symbol follow the safety message to avoid personal injury or death.
520, 530 & 533 Loader

v Service Manual
SAFETY INSTRUCTIONS (Cont'd)
• Wear tight fitting cloth ing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.
• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• The engine compartment and eng ine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.
• Check all electrical wirfng 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 fo r 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 not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti-freeze.
• Do not use ether or starting fluids on thi s engine. It has glow plugs. These starting aids can cause explosion and injure
you or bystanders.
• Always clean the loader and disconnect the battery before doing any welding . Cover rubber hoses, battery and all other
fl ammable parts. Keep a fire extinguisher near the loader when weld ing. Have good ventilation when grinding or welding
painted parts . Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
• Stop the engine and let it cool before adding fuel. No (>moking!
• Use the procedu re in the Operation & Maintenance or Service Man uals for connecting the battery.
• Use the procedure in the Operation & Maintenance or Service Manuals for cleaning the spark arrestor muffler.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
520, 530 & 533 Loader

vi Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
MAINTENANCE
Paragraph Page
Number Number
AIR CLEANER 1-5 1-4

BOBCAT SERVICE SCHEDULE 1-3 1-3
BOB-TACH 1-21 1-13
CHANGING ENGINE OIL AND
F I LTE R (520/530) 1-10 1-6
CHANGING ENGINE OIL AND FILTER (533) 1-11 1-7
ELECTRICAL SYSTEM 1-14 1-9
ENGINE COOLING SYSTEM (520/530) 1-12 1-8
ENGINE COOLING SYSTEM (533) 1-13 1-8
ENGINE LUBRICATION SYSTEM 1-9 1-6
ENGINE SERVICE 1-4 1-4
FI~AL DRIVE TRANSMISSION (CHAINCASE) 1-18 1-11
FUEL FILTER 1-8 1-5
FUEL SYSTEM SERVICE 1-7 1-5
HYDRAULIC FILTER REPLACEMENT 1-17 1-11
HYDRAU LlC/HYDROSTATIC FLU ID 1-16 1-10
HYDRAULIC SYSTEM 1-15 1-10
INTRODUCTION 1-1 1-1
LUBRICATION OF LOADER 1-20 1-12
PIVOT PINS 1-22 1-13
PREVENTIVE MAINTENANCE 1-2 1-3
TIRE MAINTENANCE 1-19 1-12
1-1 INTRODUCTION
1-1.1 Symbols
This sYmbol is on the machine and used

in this manual for an identification of
warning. When this symbol is shown, look
for possible danger to personnel. Carefully Serial
read and follow the instructions on this
symbol.
Fig. 1-1 Loader Serial Number

This symbol is used as an identification
for possible damage to equipment when
you work on a specific part of the
machine. Carefully read and follow the
instructions on this sYmbol.
1-1.2 Serial Number Identification

~
It is important to make oorrect reference to the serial number of the loader when you
make repairs or are ordering parts. Early or later models (identification made by "Lot")
sometimes use different parts, or it may be necessary to use a different procedure in
~
"
cQ)
~
I
Serial Number
doing a specific job. Make reference to the parts manual for identification information. (5201530)
1-1.3 Loader Serial Number
The plate for the serial number of the loader is inside the left upr[ght (Fig. 1-1).
The serial number is made up as follows:
M 11001
I Production Sequence
I Plant Location
Model, Engine Type Fig. 1-2 Engine Serial Numbers
1-1.4 Engine Serial Number
The Kohler (520/530) engine serial number is located on the blower housing, at the right
side of the engine (Fig. 1-2).
The ISUZU engine (533) engine serial number is on the left side of the engine, above the
injection pump (Fig. 1-2).
520, 530, 533 Loader
·1-1· Service Manual
1-1.5 Pre-Delivery Inspection ClARK
The pre-delivery inspection is used to make sure that the loader is in correct operating
condition when delivery is made to the dealer.
.
The pre-delivery inspection also helps to let the factory know when something is wrong
with the loader.
All items on the inspection form (Fig. 1-3) must be completed according to
specifications in this manual.
1-1.6 30 Hour Inspection

Fig. 1-3 Pre-Del ivery Inspection
The 30 hour inspection must be completed soon after the first 30 hours of loader
operation.
ClARK
30 MOUII Ol'[IIATlONAL .. SEII'IltE II'ISPlCflON
... ,,".'-" .,"

]
"-,,,,,",, ,
The purpose of the 30 hour inspection is as follows: .w~, ""',"'0. _, _~"~".m _~ ... WO,
,x, ....,. "._. " •• ' _dod .....' ...... _. do,.,h

.~~ .... ', ....... _H,""" ""_ ~". "" ''''_'
(1) For adjustment and inspection after first work period.
(2) To correct wrong maintenance and operating methods.

"""" '·""'1- ','.
..
~ :::~":.~:: ..:..-;::.::~:'" ". .- I
(3) To show correct service procedures to customers.
All items on the 30 hour inspection form (Fig. 1-4) must be completed by the mechanic
according to specifications in this manual.
When the 30 hour inspection is completed, the form must be signed by:
(1) The mechanic completing the inspection.
(2) Dealer person Fig. 1-4 30 Hour Inspection
(3) Owner or operator
520, 530, 533 Loader

-1-2- Service Manual
1 - 2 PREVENTIVE MAINTENANCE
Maintenance work must be done at regular intervals. Failure to do this will cause
damage and failure to the machine or its engine. The service schedule is a guide to
maintenance of the Bobcat loader. Do not change this schedule unless to shorten the
intervals during very hot, cold, dirty conditions that can cause corrosion.
HOURS
0 0
..... 0 0 0
0
0 0
eX;, It) 0 0 0
1 - 3 BOBCAT SERVICE SCHEDULE ..... N M .....
ITEM SERVICE REQUIRED
Engine Air Cleaner Clean dust cup. Inspect condition of system.
Engine Oil Check and add oil as necessary.
Engine Cooling System Check coolant level in coolant recovery tank. Add
coolant when low. R"emove any debris from radiator
grill area.
Tires Inspect for damage and check tire pressure.
All Pivot Points Add lubricant to all fittings (12).
Indicators, etc. Check for correct operation of all indicators,

switches, lights.
Operator Guard Check condition and holding bolts.
Seat Belt Check condition of straps and buckle and replace if

defective.
Safety Decals Check for missing or damaged decals. Replace as

necessary.
Hydraulic Fluid Check level and add recommended fluid if needed.
Engine Oil & Filter Replace oil and filter.
Battery Check cables.
Control Pedals & Steering Check operation. Make repairs and adjustments as
needed.
Bob-Tach Inspect locking levers and wedges for condition and

operation.
I Governor Lubrication
Brakes
Check oil level and add as needed.
Check operation. Make adjustment as needed.
Chaincase Fluid Check level. Add fluid if needed.
Engine Cylinder Head Tighten to correct torque after first 100 hours. Also
Bolts (533) adjust valve tappets.
Engine Air Filter System Inspect system for leaks. Replace element, if
needed.
I Spark Arrestor Muffler Clean carbon from the muffler.
Hydraulic Filter Replace element.
Engine Air Housing (5201 Remove and clean housing and cooling fins.
530)
Engine Fuel Filter Replace element or clean as necessary.
Injection Pump Oil (533) Replace oil in injection pump reservoir.
Engine Ignition System Check points and timing. Replace spark plugs.
(520/530)
Chaincase Replace fluid.
Hydraulic System Replace fluid and filter. Clean inlet screen and vent.
520, 530, 533 Loader

Revised Mar 79 -1-3- Service Manual
1-4 ENGINE SERVICE
The rear door must be opened to

service the engine. Pull the door latch
to the left to open the door (Fig. 1 - 5).
NOTE: The 530; SIN 12291 & up
and 533; SIN 12121 & up
loaders have a rear door stop
(Fig. 1-6al. The door stop
will hold the rear door open
while servicing the engine. Be
sure to disengage the door
stop before closing the rear
door. C-I024
Fig. 1-6 Air Cleaner

-
IMPORTANT
Fig. 1-5 Releasing the Rear Door
Door must be closed when
operating loader.
1-5 AIR CLEANER SYSTEM (Fig.

1-61
Regular maintenance of the air cleaner
system is very important for good
engine performance and long service
life.
Service as follows: (Fig. 1 - 7)
(1) Remove dust cup and clean
each day.
(2) Make replacement of element
only when necessary. To check for
need of replacement, hold an
illuminated flashlight inside the
element. If light can not be seen
through element or if element has
I
holes in it, replacement is
necessary (Fig. 1 - 8).
Be sure the inlet of the air Fig. 1-6a Rear Door Stop Fig. 1-7 Removing Air Cleaner Elemen+
NOTE cleaner has the rubber elbow
installed. It helps prevent
water from getting into the air
cleaner.
Be sure to clean the inside of the
housing before installing a new
element. Make sure that the gasket
(Fig. 1 - 6, Item 1) is correctly in place
and the arrow on the end of the cover is
pointing up.
(3) Check complete air inlet
system and replace any parts
which have a defect.
(4) Check the operating condition
of the system, as follows:
a. Run the engine at idle.
Remove the rubber elbow, if
installed.
b. Hold a piece of wood over
©):)
the inlet pipe of the air cleaner
(Fig. 1 -9). The engine must
slow down then stop.
Fig. 1-8 Checking Element with Flashlight Fig. 1 - 9 Checking Air Cleaner System
520, 530, 533 Loader

c. If the engine does not stop, the system has a leak. Check the system
and make repairs as necessary.
NOTE: Look for a leak in the air cleaner hose or the crankcase breather hose.
1-6 FUEL SYSTEM
Use only regular grade or lead-free gasoline in the 520/530 engine.

Use No.2 diesel fuel in 533 engine (#1 during cold weather [below + 20 0 F -6CI).
A visual check will show the fuel level in the tank.
Never add fuel to the loader when the

AWARNING engine is running or is hot!
1 - 7 FUEL SYSTEM SERVICE
Remove the filler cap to service the fuel tank as follows: (Fig. 1 -10 & 1 -11) Fig. 1-10 Fuel Filling (520)
(1) Ignition must be in off position and engine must be cooled.
(2) Add fuel only in an area which has good air movement and is free from
sparks. (NO SMOKING.)
(3) Use a clean approved safety container to add fuel to the fuel tank.
(4) Lower the spill guard (Fig. 1 -10).
(5) Use only clean fuel to fill the tank.
(6) Be sure to tighten the cap on the filler pipe.
Be sure the air inlet hose (Fig. 1-11) is
IMPORTANT in place to prevent moisture (rain,

snow, etc.) from entering the air
cleaner system.
1-8 FUEL FILTER

The 520 and 530 loader has a fuel filter installed next to the shut-off valve on the
fuel tank (Fig. 1 -12).
To check or replace the filter element:
(1 ) Close shut-off valve (1 ) for fuel.
NOTE: Some of the 530 & 533 Fig. 1-11 Fuel Tank Cap (530, 533)
loaders did not have manual

shut-off valves installed. Be
sure to install the fuel shut-off
if it does not have one (See
Parts Manual or microfiche for
parts).
(2) Loosen the tubeline nut (2)
and disconnect the tubeline.
Turn the element to remove it from
the shut-off valve.
Put air pressure through the
element in the direction of the
arrow. (Air must have free
passage.)
When you install a new element,
make sure that the arrow point is in
direction of the carburetor (Fig.
1-12). Fuel Filter
(3) Tighten the tubeline nut, open 8-2921
the fuel shut-off valve and check
for leaks.
Fuel Filter (520, 530) Fig. 1-.13 Fuel Filter (533)
520, 530, 533 Loader

The 533 fuel system uses a "turn on" filter element, installed on the left side of the
engine (Fig. 1 -13).
To replace the element:
Close the shut-off valve for fuel (Fig. 1 -12, Item 1).
(2) Turn the filter element counterclockwise to remove it.
i3) Clean the element contact area on the filter housing.
(4) Put oil on the rubber gasket and turn the new element clockwise to install
it. Use your hand to tighten the element until it is hand tight.
(5) Open the shut-off valve for fuel.
(6) Loosen the screw to let air out of the system (Fig. 1 -13, Item 1).
(7) Engage the starter and turn the engine until fuel flows freely from the
loosened screw, then tighten the screw. Fig. 1-14 Checking Engine Oil (520. 530)
Start the engine and let it run for several minutes. Then check for leaks.
1-9 ENGINE LUBRICATION SYSTEM
Check the oil level every 4 hours during the first 50 hours of operation. Check the oil
level daily after the first 50 hours of operation.
To check the oil level, stop the engine and remove the dipstick at the left side of the
engine on the model 520/530 loader (Fig. 1 -14). The dipstick on the 533 loader is
at the right side of the engine (Fig. 1 -15), early models (left side on current
models).
Oil level must be kept between the "L" (Low) and "F" (Full) marks on the dipstick.
Do not overfill - - - oil level must not exceed the "F" mark. Use good quality
detergent motor oil which meets recommended API Service Classifications (See
chart).
Use oil of proper SAE viscosity for expected temperature conditions at the time of
starting, not for the highest temperature expected during the working day (See chart
on page 1 - 7).
1 -10 CHANGING ENGINE OIL & FILTER (520/530)

Engine Oil Check (533)
The engine oil & filter should be
replaced after every 50 hours of
operation.
Remove the drain plug (Fig. 1 -16)

when the engine is hot. Let oil flow fully
out for several minutes.
Use a 1 " size socket or box end wrench

to remove the oil filter (Fig. 1 -17). Put
an open reservoir or rags under filter
area to catch leaking oil.
Clean the filter contact area before

installing a new element.
Fig. 1-16 Oil Drain Plug (520, 530) Remove Oil Filter Element (520, 530)
520, 530, 533 Loader

Put oil on the gasket before installing the element. Turn the element on until it is
hand tight and use the socket or box end wrench to tighten the element an additional
1/4 to 1/2 turn.
Install the drain plug and remove the oil filler cap. Fill with 4 quarts (3,8 U of oil of
the correct specification (See chart).
Start the engine and let it run for a few minutes and check for leaks at the filter.
Check the oil level again and add oil, if needed, to bring the level to the "F" mark on
the dipstick.
NOTE: Do not overfill the crankcase.
RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)
CO -34 -29 -23 -18 -13 +38
Fig. 1-18 Oil Filter Location (533)
FO -30 -20 -10 0 +10+20 +30+40+50+60 +70+80+90 +100

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
(GASOLINE: USE API CLASSIFICATION SE)
(DIESEL: USE API CLASSIFICATION CD)
1 -11 CHANGING ENGINE OIL AND FILTER (533)

D·1379R
Change the engine oil and filter after every 50 hours of operation. Fig. 1 -18a Oil Drain (533)
Remove the drain plug when the engine is hot. Let oil flow for several minutes.
Use a filter wrench to remove the oil filter (Fig. 1 -18). Place an open reservoir or
rags under filter area to catch leaking oil.
Clean the filter contact area and put on the gasket before installing the element. Turn
I
the element on until it is hand tight.
NOTE: Be sure to check the engine oil drain for a leak which is caused by engine
vibration (SIN 11339 & below). When there is a leak, you can install a new
tubeline assembly (See Parts Manual or microfiche for parts).
Install the drain plug and remove the oil filler cap (Fig. 1 -1 5). Fill with 3.4 quarts
(3,2 U of oil of correct specification (See chart).
Start the engine and let it run for a few minutes. Then stop the engine and check for
leaks at the filter.
NOTE: To check engine oil. the dipstick cap must touch the dipstick tube. To get
the proper oil level. DO NOT tighten the dipstick in the tube.
Check the oil level and add oil, if needed, to bring the level to the "F" mark on the
dipstick.
NOTE: Do not overfill the crankcase.
520, 530, 533 Loader

Revised Mar 79
1-12 ENGINE COOLING SYSTEM
(520/530)
The oil cooler grill and engine cylinder

cooling fins must be kept clean and free
of foreign material or overheating of
engine will result.
AWARNING
Wear safety goggles when cleaning
with air hose.
Use air pressure or water spray to clean Fig. 1-19 Cleaning Oil Cooler Grill (520,530)
oil cooler grill area (Fig. 1-19).
Remove the shrouding on the engine to clean the cooling fins. Be sure to wear safety
goggles when using water spray or air pressure to clean cooling fins.
Use a hard brush and scraper tool to remove hard deposits on the cooling fins (Fig.
1-20). The oil cooler can be removed for better cleaning.
NOTE: Do not use a scraper on the oil cooler.
Be sure to replace all covers after deaning.
Never operate the engine with any part of

IMPORTANT the shrouding removed.
1-13 ENGINE COOLING SYSTEM (533)
The radiator grill area must be kept clean and free of foreign material or the engine will Fig. 1-20 Cleaning Cooling Fins (520, 530)
become too hot.
Keep the blower fan clean and free from debris (Fig. 1-21).
AWARNING
Use safety goggles when cleaning
the grill area with air pressure.
Check coolant level daily at the coolant

recovery tank (F ig. 1-22). Correct tank
level is 1/3 full when the engine is cold
and 2/3 full when the engine is warm.
Add coolant at the recovery tank only. Fig. 1-21 Blower & Housing (533) Fig. 1-22 Coolant Recovery Tank (533)
520, 530, 533 Loader

3/16" (5 mm)
AWARNING
Do not remove the radiator cap
to check coolant level unless
the engine is cold.
To protect against freezing in cold

climate, add anti-freeze as necessary. A·2626
The cooling system must be made Fig. 1-23 Alternator Belt Tension
empty and flushed clean once each
year. Fill with new, clean coolant,
containing a rust inhibitor.
,
IMPORTANT Never operate the engine with any part
of the blower shrouding removed.
Check the water pump and alternator belt tension and adjust when necessary. The
correct belt tension is 3/16" (5 mm) with a little amount of finger pressure at the
center of the belt span (Fig. 1-23).
1 - 14 ELECTRICAL SYSTEM
The 520/530 loader is equipped with a 12 volt, 15 amp, flywheel generator charge
system. (See Section 6 for wiring diagram.)
The 533 loader uses a 12 volt, 37 amp, belt driven alternator charge system. (See
Section 6 for wiring diagram.)
Service the electrical system as follows:
(1 ) Check the battery electrolyte level and if it is low, fill to the mark with
distilled water. (Not required on "Maintenance Free" type battery.)
(2) Keep the battery cables and
terminals clean and tight. Remove
acid corrosion with a baking soda
and water solution. Coat the
terminals with grease to prevent
corrosion build up.
To remove the battery, pull back and
lift up on the holddown lever (Fig.
1-24). On later model loaders remove
nuts and clamp. Use a carrystrap to lift
the battery out of the engine
compartment.
Be sure to fasten the battery in place
with the holddown lever or clamp when
installing.
NOTE: On the 520; all 530; 11080 &
below and 533; 11165 &
below. the battery hold down
can bend. Install a new hold-
down rod which has been heat
treated. (See Parts Manual or
microfiche for parts) (PIN has
not been changed).
(3) Check for worn or loose
wiring. Fig. 1-24 Battery Hold Down Fig. 1-24A Battery Hold Down
520. 530. 533 Loader

1 -1 5 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITRY
The loader hydraulic and hydrostatic D YELLOW 'CHARGf PRES,URr SLf'Pl Y
D RED HIGH PRESSUREc
systems use fluid from the same o OK BLUE 'LOW PHE~SURl
CJ GREt N . CASE DRAN
hydraulic fluid reservoir. o LT BLUE 'STROK£O CtjARG/:. PRES'>URE
o ORANGE 'FLlJD Rf'>e:R'vOIR (SUCTION)
~, LINE CONTINUES
The engine driven vane pump moves

fluid to the control valve to give power
to the lift and tilt cylinders (Fig. 1 - 25).
Fluid also goes from the control valve

to the hydrostatic transmission pumps
to be used to give power to the drive
system.
The 10 micron hydraulic filter is

installed at the right side of the engine
compartment (Fig. 1-26). This filter
cleans the fluid for the hydrostatic foIYDRAULIC
FLUID
transmission. PR£SSURE
SE"-OER
45 PSI
The oil cooler (Fig. 1 - 27) cools the
I
fluid before it returns to the inlet of the
vane pump.
Be sure the hydraulic hoses for

NOTE the oil cooler are in the
position as shown in figure
1-27 to prevent damage to
the hoses.
E-1l39
1 -1 6 HYDRAULIC/HYDROSTATIC Fig. 1-25 Hydraulic Flow Diagram

FLUID
Use only 10W-40 SE motor oil in

Bobcat hydraulic reservoir. When the
starting temperature is below -10 0 F
[-23 0 Cl use 5W-30 SE motor oil in the
hydraulic system.
IMPORTANT .--;'-ii:--:- Filter

Element
Never use automatic

transmission fluid in the Bobcat B-2657
hydraulic system.
Fig. 1-26 10 Micron Filter
1 -16.1 Checking and Adding Fluid
To check the fluid level in the hydraulic

reservoir:
(1 ) Put the loader on a level

surface.
(2) Open the lower valve on the

side of the reservoir (Fig. 1 -28,
B-2236R
Item 1). If no fluid flows, close the
valve. Fig. 1 - 27 Hydraulic Oil Cooler (520, 530)
520, 530, 533 Loader

(3) Open the upper valve (F ig.
1-28, Item 2). Remove the reservoir
fill cap (Fig. 1-29) and add
recommended fluid. When the fluid
flows from the upper valve, close
the valve and install the fill cap.
1-16.2 Hydraulic/Hydrostatic Fluid

Replacement
Remove the fluid from the hydraulic

reservoir and replace it with new approved
fluid after every 1000 hours of operation,
or sooner, if the fluid is dirty.
To remove flu id from the reservoir:
(1) Remove the hose from the

outlet elbow on the oil cooler (long
hose) and put the end into a clean
Fig. 1-28 Hydraulic Reservoir Level Check
reservoir (Fig. 1-30).
(2) A fte r a II flu id has been

removed, connect the hose to the cooler.
(3) Remove the spring cI ip and remove the screen from the reservoir filler pipe
(Fig. 1-31). Wash the screen in clean solvent and install it in the filler pipe. (Clean
the reservoir screen only when necessary.)
(4) Open the upper valve at the side of the reservoir (Fig. 1-28, Item 2). Add
recommended fluid (about 4 gallons [15 Ltrs.l) to the reservoir. When fluid flows
at the open valve, close the valve and install the filler cap.
1-17 HYDRAULIC FILTER REPLACEMENT
Replace the hydraulic filter element after every 100 hours of operation, or sooner, if
necessary (indicated by illuminated "tran" light).
To replace the element:
(1) Remove the element (Fig. 1-32). (Use an open reservoir to catch leaking
fluid.)
(2) Clean the element contact area

of the filter housing.
(3) Put oil on the rubber gasket

on the new filter element.
Fig. 1-'-30 Draining Reservoir (520, 530)
(4) Install the element. Tighten it

until it is hand tight only.
(5) Start the loader engine and

check for leaks.
1-18 FINAL DRIVE TRANSMISSION

(CHAINCASE)
The chaincase is the housing for the final

drive sprockets and chains. The chaincase
is filled with the same fluid as the
hydrau lic/hydrostatic transmission.
To check the fluid level: B·2235
Fig. 1-31 Removing Filler Pipe Section Fig. 1-32 Remove Hydraulic Oil Filter
(1) Put loader on a level surface.
520, 530, 533 Loader
·1-11- Service Manual
(2) Remove the plug, located at
the front of the chaincase housing
(Fig. 1-33).
(3) Add recommended fluid into

the hole until the fluid is level with
the hole. Install the plug.
(4) To remove fluid from the

chaincase, put the rear end of the
loader on blocks and remove the
fluid through the opening in the
front end of the chaincase. Fig. 1-33 Chaincase Check. Fill, Drain Plug
1-19 TIRE MAINTENANCE C·1965
Check the tires regularly for wear, damage Fig. 1-34 Tire Rotation
and correct pressure (See specification,

page 8-3).
1-19.1 Tire Rotation
Tires must be rotated (front to rear, rear

to front, Fig. 1-34) for even wear.
When tires are installed new, install them

two per each side of the loader.
Do not put fluid (ballast) in the tires on

this loader.
Check the wheel fastening bolts or nuts

often and make sure that they are tight GREASE
GASOLINE TANK
(Seee specifications, page 8-3).
1-20 LUBRICATION OF LOADER
For good performance, lubricate the

loader regu larly as specified in the serv ice
schedu Ie on page 1-3.
Figure 1-35 shows the location of the

grease fittings on the Bobcat loader.
Use a good quality lithium based,

multi-purpose grease when servicing the
loader with lubricant. Add lubricant until
it comes out of the area being serviced.
Also, lubricate the seat rails (Fig. 1-36AI

to make easy movement for seat 6553967
adjustment. Fig. 1-35 Lubrication Points
520, 530, 533 Loader

Add oil to the oil hole in the steering
control shaft (Fig. 1 -36). Use regular Add Lubricant
motor oil for this purpose. Remove the
seat and seat pan to reach the steering
mechanism.
1-21 BOB-TACH
Check the Bob-Tach regularly (See

service schedule, page 1-3) for
condition and wear.
When the levers are in the "locked"

position (Fig. 1-37), the wedges must
extend through the slots in the
attachment (Fig. 1 -38).
NOTE: Some Bob-Tachs will not fit in- B-2135

to mounting frame of attach-
ments (Example: Pallet Fork Fig. 1-36 Lubrication Steering Shaft Fig_ 1-36A Seat Rails
and Angle Broom). Grind 1/4"
(6,35 mm) of material from
each side of the Bob-Tach
(Fig. 1-37).
1 - 22 PIVOT PINS
All pivot points (lift arm, Bob-Tach and

cylinder) use pins which are held in
place by lockbolts (Fig. 1-39).
Check lockbolt nuts for tightness. (See Remove

the "Service Schedule" for interval of Material
check.) Here
D-1380
Fig. 1-37 Bob-Tach
Fig. 1-38 Locking Wedges Pivot Pin Lockbolt
520, 530, 533 Loader

1-23 FUEL INJECTION PUMP
RESERVOIR (533)
The oil reservoir level in the injection

pump muSl: be checked every 100 hours.
To check level: (Fig. 1-40)
(1) Remove the check plug (F ig.

1-40, Item 1).
(2) If no oil can be seen at the

opening, remove the breather on top
of the pump (Item 2).
(3) Add oil of same specification

as recommended for engine (See
chart). Add until oil flows out of
check opening.
(4) Install the breather and the

check plug.
Every 300 hours replace oil as follows:
(1) Remove the plug at the

bottom of the pump (Item 3) and
let out the oil.
(2) After all oil has been removed,

install plug. Remove the level check
plug (Item 1).
(3) Remove the breather (Item 2)

and fill the reservoir to check plug
level with new oil, according to
engine oil spec chart. Install the
breather and the plug.
Injection Pump
520, 530, 533 Loader

HYDRAULIC SYSTEM
Paragraph Page
Number Number
CHECKING CONTROL VALVE AND CYLINDERS 2-8 2-6 HYDRAULIC

CHECKING OUTPUT OF VANE PUMP 2-6 2-4 SYSTEM
CHECKING RELIEF VALVE 2-5 2-4
CONTROL VALVE REPAIR 2-10 2-7
GENERAL INFORMATION 2-2 2-1
HYDRAULIC CIRCUIT 2-1 2-1
HYDRAULIC CYLINDER REPAIR 2-9 2-6
PROBLEM ANALYSIS CHARTS 2-4 2-3
TROUBLESHOOTING HYDRAULIC SYSTEM 2-3 2-2
VANE PUMP REPAIR 2-7 2-5
520, 530, 533 Loader

Service Manual
2-1 HYDRAULIC CIRCUIT (Fig. 2-1)
520 HYDRAULIC CIRCUITRY
Fluid is added to the Bobcat by removing

the vented cap and filling through the
screen installed in the tank. There are two
valves on the side of the reservoir for
checking the fluid level.
(1) A specific amount of fluid

from the hydrostatic motors, and
fluid from the reservoir goes into
the port block to keep the hydraulic
system full of fluid.
,.,.
(2) Fluid goes from the pump to
the control va Ive.
(3) When the control s are activated

the cylinders move until they reach
the end of their length, then the
hydraulic relief valve opens to '.If---~
protect the system from too high
,Ir-_ _ _ _ __
pressure. t
(4) All oil from the control valve

I.
',~-
goes to the hydraul ic filter, and
then to the hydrostatic drive system.
(5) A by·pass valve installed in the

port block will open whenever there
is an over limit of oil pressure. The
higher pressure can be caused by: Fig. 2-1 Hydraulic Circuit
(1) Cold fluid too thick to flow
through the fi Iter element. (2) 0 irty
filter. (3) Added flow of fluid (lowering lift arms or moving bucket back).
(6) A restrictor orifice is installed in the hydraulic filter tubeline to limit oil flow
and protect the filter from too high oil pressure.
Restrictor orifice locations are shown in figure 2-1;
Location A . Machine SIN 12,300 & Up (520, All 530 & 533)
Location B . Machine SIN 12,299 & Below (520)
Mark a Line On Nut

and Adaptor Before Torquing
2-2 GENERAL INFORMATION
2-2.1 Keeping Parts and Work Area Clean
When making repairs on the hydraulic system keep all parts completely clean. Use caps
and plugs to keep dirt out of tubelines and openings.
Misalignment of Marks Shows
Amount to Tighten (See Chart)
Put only clean oil in reservoir. Be sure the screen for the reservoir filler tube is in the
correct location.
2-2.2 37 0 Flare Connections
To tighten flare fittings, use this method:
(1) Tighten the nut u nti I the flame is in contact with the seat.
A·1897
(2) Make a line from the nut to the adapter (Fig. 2-2).
Fig. 2-2 Tightening Flared Fitting
520, 530, 533 Loader

-2-1b- Service Manual
(3) Use this chart to find amount of tightening for fittings:
Fitting Thread Size Rotate Number of Hex Flats
9/16 - 18 2
3/4 - 16 2
7/8 - 14 1-1/2 - 2
1-1/16 - 12 1
1-5/16 - 12 3/4 - 1
(4) Use a wrench to turn the fittings to the correct number of flats shown in chart Fig. 2-3 Straight Tread Seal
above. Loosen the fitting and tighten again. (The first tightening action is for
alignment and the second is for correct torque).
(5) Check the fitting for leakage. If there is leakage, remove the fitting and look
for damage.
2-2.3 Straight Thread O-ring Connections
These connections seal by compression of the D-ring. To tighten D-ring fittings, use this
method:
(1) Loosen the nut and slide the washer and D-ring against the thread (Fig. 2-3).
Put oil on the D-ring.
(2) Tighten the fitting in place by hand. If the fitting is an elbow turn the elbow
until it is in alignment with the tubeline or hose.
Fig. 2-4 Seal in Place
(3) Hold the fitting with a wrench. Use another wrench to tighten the jam nut
(Fig. 2-4). The D-ring must fit into the space as shown.
(4) If the fitting is not turned in correctly, the D-ring will have damage and the
fitting will leak (Fig. 2-5).
2-2.4 Tubelines and Hoses
Make replacement of any tubelines which has damage, or the restriction to size can cause
heat and slow hydraulic action. A replacement of hoses must be made when they have
wear or damage. Use correct clamps to hold the hoses and tubelines in position.
2-3 TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM
PROBLEM CHART CORRECTION

Fig. 2-5 Wrong Installation
Slow hydraulic or no hydraulic A Check control linkage and fluid

power on all circuits. level. Check release pressure and
pump output.
Slow hydraulics or no hydraulic B Check control linkage, cylinder

on one circuit. condition. Check valve section for
leakage.
Cylinders move with controls in B Check cylinder condition. Check

neutral position (See Note A). valve section for leakage. Check
for tubeline leakage.
A_ If the spool is not free, turn the spool 180 0 in its location or loosen the control
valve from the frame and tighten the bolts evenly, a small amount at a time.
520, 530, 533 Loader

HYDRAULIC PUMP
Checking Output of the Pump
Use these tools listed for the following Procedure:
MEL - 10003 - Hydraulic Tester

MEL - 10006 - Hydraulic Test Kit
A WARNING
Put jackstands under the front axles and rear
corners of the frame before running the engine 8-5257
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W-2017-0286 B
This test will determine the acceptable flow of the
hydraulic pump. A hydraulic tester is required that will
measure flow, temperature and pressure.
NOTE: Make sure that all the air is removed from the
system before beginning the test. Air in the
system can give an inaccurate test.
Remove the hose between the outlet of the hydraulic

pump and the inlet of the hydraulic control valve [A].
Connect the inlet of the tester to the outlet of the hydraulic

pump [A]. 8-5299
Connect the outlet of the tester to the inlet of the hydraulic
control valve [A].
NOTE: Make sure that the restrictor valve on the

c
tester is fully open.
Start the engine and run at low RPM. Make sure that the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected backwards.
Increase the engine RPM to full RPM.
Warm the hydraulic fluid to 140 0 F. (60 0 C.) by turning the

restrictor knob on the tester to about 1000 PSI (6895
kPa). do not exceed system relief pressure.
Open the restrictor on the tester and record free flow

(GPM at full RPM). 8-5296
Disconnect any attachment from the auxiliary quick

couplers and operate the auxiliary control lever. Record
the high pressure (PSI) and the flow (GPM) at full RPM.
The high pressure flow must be at least 80% of free flow.
0/0 = --'-H;..;..;IG=H..:....P'::::-'R='"::E::-:S:-"S~U"':::R~E-:'-F:":::LO"=W':-'::-'"(G=P...;;.M;.;.L)_ X 100

FREE FLOW (GPM)
A low percentage may indicate a failed hydraulic pump,

or it may be caused by air in the system. Make sure that
all the air is removed from the system.
Make reference to your Model loader, in the Technical

Service Guide, for the system relief pressure and full
RPM specifications. the system relief pressure must be
per specifications before test is run.
520,530 & 533 Loader
Added Sept. 96 -2-2a- Service Manual
®
520,430,533 Loader
Service Manual
2-4 PROBLEM ANALYSIS.
CHART A
SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ALL CIRCUITS
Check Check Control Check Release Check Output

If If If
Fluid ~ linkage Adjustment Pressure Of Vane Pump
~ Full """"Good . . . . -Good ......
level & Free Movement (Sec. 2-5) (Sec. 2-6)
I
If
low
f
I
If Not
Correct
t ,I
If Not
Correct
I
If Not
Correct
t
Make Repairs
Make Corrections Remove, Clean &
Add
Inspect Relief As Needed
Fluid As Needed
Valve (Sec. 2-5.1) (Sec. 2-7)
CHART B
SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ONE CIRCUIT
ONL Y. CYLINDERS MOVE WITH CONTROLS IN NEUTRAL POSITION.
Check Control Check Condition Remove, Clean &

linkage Adjustment
& Free Movement
~
If
Correct • Of Cylinders
(Sec. 2-8.1)
~Good
If
• Inspect Control
Valve (Sec. 2-10)
I
If Not Correct
I
If Bad
I
If Bad
~ + ~
Make Repairs
Make Repair Make Repair
Or Replacement
Or Adjustment Or Replacement
As Needed
As Needed As Needed
(Sec. 2-9)
520, 530, 533 Loader

2-5 CHECKING RELIEF VALVE
NOTE: Hydraulic checks are made using

a hydraul ic tester. The tester
gives flow and pressure
measurements and has a flow
control va Ive. Release pressure
setting can also be checked with
a pressure gauge connected to
the hose which has pressure. The
machine must be put on blocks
when making tests.
2-5.1 To Check Release Pressure
(1) Activate all controls to release

hydraulic pressure.
(2) Connect a tester or pressure

gauge to the auxiliary connections as
shown in figure 2-·6. The tester also
Fig. 2-6 Testing Hydraulic System
can be can nected to the tilt cy Iinder
hoses.
NOTE: The flow control on the tester must be fully opened.
(3) Start the engine and run it at full throttle.
(4) Activate the hydraulic control which will put pressure on the hose connected
to the tester. Read the pressure (See Section 8 for correct pressure).
2-5.2 Relief Valve Removal and Replacement
(1) Activate the controls to release pressure from the hydrau lie systems.
(2) Remove the relief valve assembly from the control valve (Fig. 2-7).
(3) Remove the snap ring from the end of the valve and lift the parts out (Fig.
2-8, Item 10). Clean and make an inspection of all parts.
Be sure to assemble the relief valve parts

correctly. Wrong assembly of these parts
can cause pump damage (Fig. 2-8). Relief Valve Removal
(4) Install the relief valve (Fig. 2-20, Item 16) with new a-rings (Items 13 & 15)
and back-up washer (Item 14).
(5) Check release pressure again. If

pressure is not correct after cleaning,
a new relief valve must be installed.
After installing a new relief valve,
check the release pressure again.
2-6 CHECKING OUTPUT OF VANE

PUMP
(1) Lift the loader and put it on

jack stands. Remove the wheels and
the seat assembly.
(2) Connect the hydraulic tester to

the system as shown in figure 2-9.
Fully open the flow control valve
on the tester. Fig. 2-8 Relief Valve AssemblY Fig. 2-9 Checking Output of Vane Pump
520, 530, 533 Loader

-2--4- Service Manual
Use caution when turning the flow
control valve. There is no relief valve in
the hydraulic circuit for protection to the
system when tester is connected this way.
(3) Start the engine and run it at full throttle. Close the flow control valve slowly.
Read the flow on the gauge (See Section 8 for correct flow), If the flow is less
than specifications, hydraulic pump repairs are needed.
2-7 VANE PUMP REPAIR
2-7.1 Removal Fig. 2-10 Removing Port Block
(1) Remove the seat and the shield above the transmission area.
(2) Disconnect the hose from the reservoir and the vane pump at the port block.
Put a cap on the hose to keep the fluid in the system.
(3) Remove the hex plug from the top of the port block and use a long link socket to
remove the large screw which holds the port block in place (Fig. 2-10).
(4) Remove the two screws which hold the vane pump and lift the pump out of
the Bobcat.
2-7.2 Disassembly
Put the pump in a vise (Fig. 2-11). Put a

long mark on the side of the pump to
Fig. 2-11 Marking Pump
help in alignment of parts during
assembly. Remove the bolts which hold
the pump together and make a separation
of all the parts. Body
2-7.3 Inspection
Clean all the parts thoroughly. Check the

areas shown for wear, scratches and other
damage (Fig. 2-121.
2-7.4 Assembly (Fig. 2-13)

t
Pressure
Ring
Plate Rotor
NOTE: Install new O-rings and put oil B·2104
on all the parts during assembly.
Fig. 2-12 Vane Pump Wear Areas
(1) Put the pump housing in vise.

Install a new D-ring in groove (Fig.
2-13, Item 1).
Vane
(2) Install the center ring (Item 2).
Put pins (Item 3) through the ring
and into the pump body. Install the
vanes and rotor. Be sure the round
edge of each vane is toward the
outside of the pump. Arrow must
point in direction of pump rotation.
(3) Install the pressure plate (Item
4) and spring (Item 5) over the ring.
Put a new D·ring (Item 6) on the
pressure plate. Install the cover and A·1900
fasten it with bolts.
Fig. 2-13 Vane Pump
520, 530, 533 Loader

2-7.5 Pump Installation
(1) Install a new O-ring on the pump and put the pump in position on the
hydrostatic pump assembly. Fasten the pump with bolts.
(2) Fasten the hoses and port block to the pump. Fill the reservoir with clean,
recommended fluid.
NOTE: No special "start-up" procedure is needed when installing only the vane pump.
2-8 CHECKING CONTROL VALVE AND CYLINDERS
Wear in the control valve or spools will cause: (1) Hydraulic cylinders to move when the
controls are in neutral position. (2) Loss of hydraulic power. Check condition of the
hydraulic cylinders by following the procedures given on the next page. If the cylinders ~ B.28~?
are good, the defect is probably in the control valve. LEFT SIDE
2-8.1 To Check Lift Cylinders Fig. 2-14 Disconnect Lift Cylinder Hose
(1) Lower the lift arms fully.
(2) Put the machine on blocks and remove the wheels. Activate the controls to
release hydraulic pressure.
(3) Open the rear door. Disconnect the hoses which go to the lift cylinders (Fig.
2-14 and 2-15). Install plugs in the tubelines.
(4) Start the Bobcat and push the toe of the lift pedal.
(5) If hydraulic fluid leaks from the open hoses, (continuous floW) remove the cylinder
from the side with the leak, for repair.
2-8.1 To Check the Tilt Cylinder

(1) Tilt the Bob-Tach all the way back. 852
RIGHT SIDE
Fig. 2-15 Disconnect Lift Cylinder Hose
(2) Put the machine on jackstands and remove the wheels.
(3) Disconnect the hose which goes to the top (Base End) of the tile cylinder (Fig.
2-16). Put a plug in the hose.
(4) Start the engine. Push the heel of the tilt pedal. If a continuous flow of fluid
leaks from the open connection on the cylinder, the cylinder needs repair.
2-9 HYDRAULIC CYLINDER REPAIR
NOTE: Repair procedure for the tilt and lift cylinder is similar.
Be sure to support the lift arms or Bob-Tach

I
to prevent them from falling
AWARNING when a cylinder is removed.
B·2853
2-9.1 Removal and Installation Fig. 2-16 Disconnect Tilt Cylinder Hose
(1) Activate the controls to release pressure in the system.

Cylinder
(2) Disconnect the hoses from the cYlinder.
(3) Remove the bolts and pins which hold the cylinder in position.
Installation is the reverse of removal.
2-9.2 Disassembly and Repair
(1) Remove the cylinder head with a spanner wrench (Fig. 2-17).
(2) Pull the rod and piston assembly from the case. ·Spanner
Wrench A-1896
(3) Remove the nut from the end of the rod. Slide the piston and O-ring off the
Fig. 2-17 Cylinder Head Removal
rod.
520, 530, 533 Loader
(4) Check the cylinder rod for scratch marks or other damage. Remove small Stone
defects by grinding (Fig. 2-18).
(5) Check the cylinder housing and piston for damage.

I
(6) Put new seal parts on the cylinder rod, piston and cylinder head.
(7) If there is a sharp edge on the end of the rod, remove the edge with a file
and slide the cylinder head over the rod (Fig. 2-19). Install the piston and tighten
the nut to correct torque (See Section 9).
(8) Slide the piston and rod assembly into the housing and tighten the head with
a spanner wrench. PI·1221b
2-10 CONTROL VALVE REPAIR
Fig. 2-18 Removing Marks
Be sure that lift arms are fully down and Bob-Tach
is fastened fully back before
AWARNING removing control valve tube lines.
2-10.1 Removal
(1) Remove the seat and shield above the transmission area.
(2) Disconnect the control linkage and hydraulic tubelines from the control valve.
(3) Remove the two bolts which hold the control valve and lift the valve out of the
Bobcat.
2-10.2 Disassembly and Inspection (All Sections) (Fig. 2-20)
PI·1221a
NOTE: Be sure to put the spools back in their original bores.
Fig. 2-19 Beveling the Shoulder
12
/
6~.r--------- // ,/'
17~' 6')1' L-------:)O\
29 -;rf P' ll-d ~
):::Y ,<::::1/, 6
27-A 28-@ @
23 26}~ 27~' (:{' \ 17
--~ -, 23- 26 }iT " 18
24_~~' 2 I ~ @~ 30
I / -""18 4__ ~ jf / \ 19
'~--25 K --18 /0'\ 18
~ ~--23 ~\ 20
°--
#l 25
')2 \
22
23 21 C·2012
Fig. 2-20 Control Valve Assembly
520, 530, 533 Loader

(1) Remove the screws wh ich hold
the boot assembly on the valve
body (Fig. 2-21).
(2) Push the lift spool in until it is

in the detent position.
NOTE: This is necessary to prevent the

spring and bolts from falling out.
(3) Turn the caps off the end of

the valve body and slide the spools
out (F ig. 2 -22).
B·2855
B·2898
(4) Remove the spacers from the Fig. 2-21 Removing Rubber Boots Fig. 2-22 Removing Spools
bores (Fig. 2-23).
(5) Remove the relief valve

assembly (Fig. 2-24, Item 1). (See
Paragraph 2-5.2 for relief valve
service.)
(6) Remove the load check valves

(Fig. 2-24, Item 2).
(7) Remove the O·rings (Fig.

2-25).
(8) Check the spools and bores for

wear or scratch marks.
2-10.3 Assembly of Valve Fig. 2-23 Remove Spacers from Bores Fig. 2-24 Relief Valve Removal
Use all new O-rings and put hydraulic

fluid on all parts during assembly.
Lift Spool Repair

o
(1) Put a cloth around the spool
and cap to hold the spring and balls
in position. Pull the cap from the
spool.
(2) Assemble by installing the

spring with the balls on each end.
Slide the cap over the spool to hold
the parts in place (F ig. 2-26).
B·2904 B·2896
(3) Be sure the restriction washer

Fig. 2-25 Removing G-Ring, Fig. 2-26 Float Detent Assembly
is installed correctly in the rear port
of the lift section (F ig. 2-27).
NOTE: Check the "Detent". "it will

normally take 20 to 100 Ibs. of oI
force to disengage the "Detent". I
B·2903
Fig. 2-27 Install Flow Restriction Washer

520, 530, 533 Loader
ADJUSTMENT OF PEDAL LINKAGE
This Corner of Pedal
Must Align With Top Edge
Several problems are caused when the pedal support does not have the correct
adjustment. The lift arms or bucket may raise, lower or tilt too slow or the spool in
the control valve may not go to the centered position for neutral.
Adjust the linkage so the pedals will not touch the floor when you tilt them fully
back. Each valve must move the full length of it's stroke when you push the heel or
toe of the pedal.
To adjust the pedal supports:
(1) Loosen the 2 bolts on the pedal support (Fig. 2 - 28).

B-3032
(2) Move the support and pedal to give correct adjustment. Fig. 2-28 Pedal Adjustment
(3) Tighten the locknuts on the pedal support.
2 - 11 HYDRAULIC HOSES
2 - 11 .1 Hydraulic Hose Protection
On some of the 530 and 533 loaders, the hydraulic hoses come in contact with the
rear door hinge when the door is opened. Install a bolt and a bushing in the right hand
upright at the location directly in front of the door hinge (Fig. 2 - 28). Drill a 5/16"
(7,937 mm) hole at the location as shown in figure 2- 28 and install a 3/8" (9,525
mm) 10 x 2-3/4" (69,85 mm) long bushing, 5/16" x 3-1/2" bolt and locknut.
Bushing is Installed
Between Door Hinge and
Hydraulic Hoses
/
/
/
-
/
/
~Bushing
Bolt
~
...L
I
2-1/2" (63,5 mm)
,
B-3166
Fig. 2-28 Installing Bushing for Hydraulic Hose Protection
520, 530, 533 Loader

Added Mar 79 -2-9- Service Manual
2 - 12 QUICK-COUPLERS
2 -12.1 Restriction In The Quick-Couplers
If there is not enough oil flow through the quick-couplers there will be high back
pressure, on the hydraulic system, and slow attachment operation.
The adaptor on the male quick-coupler has a "taper" end which can cause the
restriction in the hydraulic oil flow and over-heating. Remove the quick-coupler (Fig.
2-29) and the adaptor and cut away the "taper" about 3/16" (4.76 mm) (Fig.
2 - 30). Do not cut the threads on the adaptor.
Fig. 2 - 29 Removing The Quick-Coupler
Remove
3/16"
14,76 mm)
,------..,
----.- I ~j On This
End Only
'"
/ - - - ----I ~
-
~ - - ~--- f- -p
\.-J
A-2704
Fig. 2 - 30 Quick-Coupler Adaptor
520, 530, 533 Loader

Added January 1980 -2-10- Service Manual
SYSTEM OPERATIONS
• 520, 530, 533 HYDRAULIC/HYDROSTATIC SYSTEM
(Open Center .System)
(Chart # PI 2499, 2500 or 2501)
The oil flows by gravity from the reservoir 0 to the port

block 0 which is on top of the hydraulic pump O. Return oil from
the bypass valve e and the oil cooler 4D join with reservoir oil to
supply oil to the hydraulic pump O. "Case drain" oil from the
48 flows through the bearing of the hydrostatic
hydrostatic pumps
pumps e and also supplies oil to the hydraulic pump O.
The hydraulic pump e is a "vane type" pump and is driven by a

shaft through the hydrostatic pumps 48. The oil goes from the
• hydraulic pump 0
The hydraulic control valve
valve
through the control valve
to the hydraulic control valve
e
e
49 .
has a pilot operated main relief
4D . When all three spools are in neutral position, the oil goes
and out to the "Tee" fitting. If one of
the spools is activated, the oil goes out the respective port and to
either the base end, or the rod end of.the hydraulic cylinder(s). As the
oil goes into one end of the cylinder(s), return oil comes from the
- opposite end of the cylinder(s) and back into the control valve
When the cylinder reaches the end of the stroke, the oil flow stops and
e.
causes hydraulic pressure to increase. When the pressure reaches the
setting of the relief valve G it opens and lets the oil bypass the
hydraulic circuit (internally) and goes out the "Tee" fitting. When this
happens, there, is no oil going to the down-stream sections of the
control valve e. If you let the spool go back to the neutral position,
then there is oil available for the other sections. Two sections of the
control valve e can be used at the same time if the main relief
valve G is not open.
• The oil which goes to the "Tee" fitting on the control valve
two places, one is to the hydraulic filter «Ii) and
CD will go
to the bypass
6566161 (2-81)-21C -1-

valve e. The normal flow of oil is through the hydraulic
filter G) and to the hydrostatic pumps e.
The hydraulic
filter G) has a bypass valve e
to allow oil flow when it cannot go
through the filter element (plugged).
When the oil gets to the hydrostatic pumps e, it activates the high
pressure replenishing valves 8. As the pressure increases the
replenishing valves 8 open and let oil into the hydrostatic
pumps e, for replenishing, lubrication and cooling. This oil is called
"charge oil". The hydrostatic pumps e do not need the full volume
of the charge oil so there is extra oil. This extra oil goes through the
other side of the "Tee" fitting to the charge bypass valve e. When
the pressure reaches the setting of the charge bypass valve e and if
opens and lets this extra oil go back to the inlet of the hydraulic
pump O.
There are two hydrostatic pumps e and two hydrostatic
motors e. One pump and one motor work together as a pair to drive
one side of the machine. The other pump and motor work as a pair to
drive the opposite side of the machine.
When the replenishing valves 8 open and charge oil goes into the
hydrostatic pumps e, the flow becomes "drive loop oil". When the
steering levers are in neutral, the hydrostatic pumps e and the
hydrostatic motors e are not working but do have charge pressure.
When the steering levers are moved; the swashplates in the
hydrostatic pumps e are angled and oil is pumped out of the
pressure side of the hydrostatic pumps 0 to the hydrostatic
motors e.
This flow of oil is called "drive pressure". Drive pressure is much
higher than charge pressure causing the high pressure replenishing
valves8 to close 'allowing the flow of oil to go to the hydrostatic
motors 8.
When the machine is driven with the bucket down, into a pile of dirt,
there is resistance causing high pressure oil in the drive loop. There is a
relief valve built into the high pressure replenishing valves 8. This
relief valve releases the high pressure in the drive loop. When the relief
valve opens the extra oil goes from the drive loop to the charge loop to
-2-
be used again. If the oil pressure gets above the setting of the relief
valves, the pressure could break tubelines, damage the hydrostatic
pumps e or the hydrostatic motors O. There are four high
pressure replenishing valves 8 ' two for each side of the hydrostatic
pumps e. One is forward travel and one is for reverse travel.
The hydrostatic motors 0 are a "geroller type" and have a built in

shuttle (pin and balls) that meters oil to the oil cooler e. The oil
flows from the oil cooler e to the port block e located on top of
the hydraulic pump G. The shuttle (pin and balls) operates when the
steering levers are moved. When the hydrostatic pumps e, forces
drive pressure oil to the hydrostatic motors 0, one ball in the shuttle
is forced tight against its' seat. As the ball is forced against the seat it
moves the shuttle pin and pushes the ball on the other end of the pin
off its' seat. Low pressure oil is then metered out through case drain to
the oil cooler e. When the direction of the steering levers are
changed, the shuttle (pin and balls) move so the opposite ball is seated
but low pressure oil continues to be metered out through case drain
and to the oil cooler e. The open center system will allow oil flow to
the oil cooler e from the hydrostatic motors 0 in neutral position
because both balls cannot seat at the same time. The pin is longer than
the seat area to allow this.
-3-
HYDRAULIC FLOW CHART
520 (All) (
530 (SIN 13,999 & Below)

533 (SIN 12,999 & Below)
520 (ALL)
• OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
530 (SIN 13,999 & Below)
533 (SIN 12,999 & Below) • HYDRAULIC OIL PUMP, 8 GPM [30,3 LIm] at 2500 RPM
o OIL RESERVOIR-.-I • PORT BLOCK
G) o BY-PASS VALVE, 55-75 PSI [379-517 kPa]
•
OIL COOLER • TEMPERATURE SWITCH, 230°F [110°C]
HYDROSTATIC o Lin CYLINDERS

P
• •
•
G
TILT CYLINDER
PRESSURE SWITCH, 23-27 PSI [158-186 kPa]
FILTER, 10 Micron
(
o G) RESTRICTOR
BY-PASS VALVE
G MAIN RELIEF, 1500-1600 PSI [10342-11032 kPa]
SWITCH.
•
TEMPERATURE
SWITCH o
Lin
48
At Valve (1575-1675 PSI [10859-11549 kPa]
Measured at Aux. Quick Couplers)
HYDRAULIC CONTROL VALVE
G) ORIFICE
TERG «0 FILTER BY-PASS, 30 PSI [206 kPa] (530 & 533 Only)
G) OIL COOLER
RESTRICTOR G)
o HYDROSTATIC PUMP
G CONTROL
HYDRAULIC
VALVE
•
_
RED - - - - - - - High Pressure
BLUE - - - - - - Low Pressure
• GREEN - - - - - Case Drain & Reservoir
G
.............
MAIN RELlEF-
•
TILT
CYLINDER
ORANGE - - - -Charge Pressure
PI-2499
HYDROSTATIC FLOW CHART
Neutral Position (Open Center System)
520 (All)
530 (SIN 13,999 & Below)
533 (SIN 12,999 & Below)
HYDROSTATIC FLOW CHART HYDROSTATIC.
Neutral Position (Open Center System)
520 (All)
o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
530 (SIN 13,999 & Below) OIL

o
RESIERVI~IR-_
•
e
CHARGE RELIEF, Non-Functional
HIGH PRESS. RELIEF VALVES, 3000 PSI [20685 kPa]
533 (SIN 12,999 & Below)
o
•
PORT BLOCK
e BY-PASS VALVE, 55 - 75 PSI [379 - 517 kPa]
OIL COClILER
A HYDROSTATIC
W PUMP
e o HYDRAULIC OIL PUMP, 8 GPM [30,3 LIm] at 2500 RPM
HIGH PRESSURE • TEMPERATURE SWITCH, 230°F [l1o,°C]

CHARGE A
RELIEF V
RELIEF VALVES
e PRESSURE SWITCH, 23-27 PSI [158-186 kPa]
PORT BLOCK • HYDROSTATIC MOTOR

o G!) FILTER, 10 Micron
• • MAIN RELIEF, 1500-1600 PSI [10342-11032 kPa]

At Valve (1575-1675 PSI [10859-11549 kPa]
• HYDRAULIC CONTROL VALVE

G ORIFICE
TEMPERATURE
SWITCH
G FILTER BY-PASS, 30 PSI [206 kPa] (530 & 533 Only)
FILTER
G!) AHYDROSTA
• •
e
_
OIL COOLER
HYDROSTATIC PUMP
RED - - - - - - - High Pressure
V MOTOR
_ BLUE - - - - - - Low Pressure
ORIFICEG) _ GREEN - - - - - Case Drain & Reservoir
ORANGE - - - -Charge Pressure
FILTER.
BY-PASSW
•
HYDRAULIC
CONTROL V~
MAIN RELIEF.
PI· 2500
Forward Position (Open Center System)
520 (All)
530 (SIN 13,999 & Below)
533 (SIN 12,999 & Below)
Forward Position (Open Center System)
520 (All)
•
HYDROSTATIC
MOTOR o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
530 (SIN 13,999 & Below) • CHARGE RELIEF, Non·Functional
G)
533 (SIN 12,999 & Below)
..
OIL RESERVOIR
. . HIGH PRESS. RELIEF VALVES, 3000 PSI [20685 kPa]
.•
e
PORT BLOCK
BY·PASS VALVE. 55·75 PSI [379·517 kPa]
OIL COOLER
49 o HYDRAULIC OIL PUMP, 8 GPM [30,3 LIm] at 2500 RPM
HYDROSTATIC
PUMP o TEMPERATURE SWITCH, 230°F [110°C]
e PRESSURE SWITCH, 23 • 27 PSI [158 ',186 kPa]
• HYDROSTATIC MOTOR
G) FILlER, 10 Micron
( G MAIN RELIEF, 1500 • 1600 PSI [10342 • 11032 kPa]
At Valve (1575 • 1675 PSI [10859 • 11549 kPa]
BY·PASSA
VALVE V Measured at Aux. Quick Couplers)
L1CO
OIL PUMP ,
o HYDRAULIC CONTROL VALVE
G) ORIFICE
TEMPERATURE
SWITCH e FILTER BY·PASS, 30 PSI [206,9 kPa] [530 & 533 Only]
o G) OIL COOLER
49 HYDROSTATIC PUMP
HYDROSTATIC RED· •••••• High Pressure
MOTOR
•
IiiIiI BLUE· ••••• Low Pressure
~- ORIFICE G) _ GREEN· •••• Case Drain & Reservoir
CJ ORANGE· •• ·Charge Pressure
HYDRAULIC
CONT;L~LF::::::::;
MAIN RELIEF
G PI·2501
SYSTEM OPERATIONS
~~ 520, 530, 533 HYDRAULIC/HYDROSTATIC SYSTEM

(Closed Center System)
• bobcat (Chart # PI 2502, 2503 or 2504)
The oil flows by gravity from the 0 to the port

reservoi;
block • which is on top of the hydraulic pump 0 . Return oil from
the bypass valve. and motor case drain join with reservoir oil to
supply oil to the hydraulic pump o. "Case drain" oil from the
hydrostatic pumps CD flows through the bearing of the hydrostatic
pumps 0 and also supplies oil to the hydraulic pump 0 .
The hydraulic pump 0 is a "vane type" pump and is driven by a
shaft through the hydrostatic pumps CD . The oil goes from the
)
hydraulic pump 0 to the hydraulic control valve 49 .
The hydraulic control valve 49 has a pilot operated main relief
valve CD . When all three spools are in neutral position, the oil goes
out the respective port and to either the base end, or the rod end of the
hydraulic cylinder(s). As the oil goes into one end of the cylinder(s),
return oil comes from the opposite end of the cylinder(s) and back into
the control valve 49. When the cylinder reaches the end of the
stroke, the oil flow stops and causes hydraulic pressure to increase.
When the pressure reaches the setting of the relief valve CD it opens
and lets the oil bypass the hydraulic circuit (internally) and goes out
the "Tee" fitting. When this happens, there is no oil going to the
down-stream sections of the control valve 49 .If you let the spool go
back to the neutral position, then there is oil available for the other
sections. Two sections of the control valve 49 can be used at the
same time if the main relief valve CD is not open.
The oil which goes to the "Tee" fitting on the control valve 49 will go
) two places, one is through the protective orifice CD) into the oil
cooler 0 and to the bypass valve • in the port block • . The
hydraulic filter CD has a bypass valve e to allow oil flow when it
6566162 (2 ·811· 21C -1- Printed in U.S.A .
cannot go through the filter element (plugged).
When the oil gets to the hydrostatic pumps 41), it activates the
replenishing function of the high pressure relief valves • . As the
pressure increases the replenishing valves. open and let oil into the
hydrostatic pumps 41) , for replenishing, lubrication and cooling . This
oil is called" charge oil" . The hydrostatic pumps 41) do not need the
full volume of the charge oil so there is extra oil. This extra oil goes to
the charge relief valve 8 and through the other side of the "Tee"
fitting to the charge bypass valve • . When the pressure reaches the
setting of the charge bypass valve. it opens and lets this extra oil
go back to the inlet of the hydraulic pump O.
There are two hydrostatic pumps ell) and two hydrostatic
motors • . One pump and one motor work together as a pair to drive
one side of the machine. The other pump and motor work as a pair to
drive the opposite side of the machine.
When the replenishing valves. open and charge oil goes into the
hydrostatic pumps ell) , the flow becomes "drive loop oil". When the
steering levers are in neutral, the hydrostatic pumps ell) and the )
hydrostatic motors. are not working but do have charge pressure .
When the steering levers are moved, the swash plates in the
hydrostatic pu~ps 41) are angled and oil is pumped out of the
pressure side of the hydrostatic pumps ell) to the hydrostatic
motors • . This flow of oil is called ."drive pressure". Drive pressure
is much higher than charge pressure causing the high pressure
replenishing valves. to close allowing the flow of oil to go to the
hydrostatic motors • .
When the machine is driven with the bucket down, into a pile of dirt,
there is resistance causing high pressure oil in the drive loop. There is a
relief valve built into the high pressure replenishing valves • . This
relief valve releases the high pres~ure in the drive loop. When the relief
valve opens the extra oil goes from the drive loop to the charge loop to
be used again . If the oil pressure gets above the setting of the relief
valves, the pressure could break tubelines, damage the hydrostatic
pumps ell) or the hydrostatic motors. . There are four high
pressure replenishing valves • ' two for each side of the hydrostatic
)
pumps ell) . One is forward travel and one is for reverse travel.
·2·
The hydrostatic motors 0 are a "geroller type" and have a built in
shuttle that meters oil to the port block 0 .The oi l flows to the port
block 0 located on top of the hydraulic pump 0 . The shuttle
operates when the steering levers are moved. When the hydrostatic
pumps e. forces drive pressure oil to the hydrostatic motors 0 .
the shuttle is forced in one direction. Low pressure oil is then metered
out through case drain to the port block 0 . When the direction of
the steering levers are changed. the shuttle moves toward the
opposite side and low pressure oi l continues to be metered out to the
port block O. There is an orifice 0 in the case drain line to help
dampen the shuttle movement.
-3-
HYDRAULIC FLOW CHART (
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above)
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above) o
OIL RESERVOIR---..I
o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
• PORT BLOCK
• BY-PASS VALVE. 78-97 PSI [537-668 kPa]
G)
HYlllROliTATIC PUMP
o HYDRAULIC OIL PUMP, 8 GPM [30,3 LIm] at 2500 RPM
G
FILTER BY-PASS
•
PORT DLu•.,n
•
o
o
TEMPERATURE SWITCH, 230°F [110°C]
LIFT CYLINDERS
TILT CYLINDER
49
o PRESSURE SWITCH, 23 - 27 PSI [158 - 186 kPa]
OIL COOLER
.-...!..!.---- BY-PASS VALVE.
o RESTRICTOR
~~------ HYDRAULICO G) MAIN RELIEF, 1500 - 1600 PSI [10342 - 11032 kPa]
TEMPERATURE OIL PUMP , At Valve (1575 - 167~ PSI [10859 - 11549 kPa]
SWITCH Measured at Aux. QUick Couplers)
PRESSURE SWITCH • 0 G HYDRAULIC CONTROL VALVE
o ~--- LIFT CYLINDERS ~
W OIL COOLER
o G FILTER BY-PASS, 72 PSI [496 kPa]

RESTRICTOR «D FILTER, 10 Micron
G) HYDROSTATIC PUMP
_ RED - - - - - - - High Pressure
_ BLUE - - - - - - Low Pressure
HYDRAULIC _ GREEN - - - - - Case Drain & Reservoir
CONTROL VALVE .......... ,------, I - - ~ CJ ORANGE - - - -Charge Pressure
G 0
I ----TILT CYLINDER
MAIN RELIEF
G) PI·2502
HYDROSTATIC FLOW CHART (
Neutral Position (Closed Center System)

530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above)
Neutral Position (Closed Center System)
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above) o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
o
OIL RESERVOIR
.CHARGE RELIEF, 45-65 PSI [310-448 kPa]
eHIGH PRESS. RELIEF VALVES, 3000 PSI [20685 kPa]
A HYDROSTATIC _
V MOTOR epORT BLOCK
OBY-PASS VALVE, 55 - 75 PSI [379 - 517 kPa]
o HYDRAULIC OIL PUMP, 8 GPM [30,3 Um] at 2500 RPM
•
FILTER
BY-I"A:!Io~
e
I!!!I!!!!!!!!~"- HIGH PRESSURE
CHARGEaRELIEF VALVES
GTEMPERATURE SWITCH, 230°F [110°C]
• PRESSURE SWITCH, 23-27 PSI [158-186 kPa]
/
RELIEF V
,
o HYDROSTATIC MOTOR
- , ,,
\
G)ORIFICE
OIL COOLER G MAIN RELIEF, 1500-1600 PSI [10342-11032 kPa]
At Valve (1575-1675 PSI [10859-11549 kPa]
1~iii.1' FILTER 48HYDRAULIC CONTROL VALVE

G) TEMPERATURE G) FILTER, 10 Micron
SWITCH
_OIL COOLER
HYDROSTATIC
MOTOR ~
G
•
.FILTER BY-PASS, 72 PSI [496 kPa]
fDHYDROSTATIC PUMP
. . RED - - - - - - - High Pressure
HYDRAULIC . . BLUE - - - - - - Low Pressure
_ GREEN - - - - - Case Drain & Reservoir
CONTROL VALVE D ORANGE - - - -Charge Pressure
48
MAIN RELIEF
PI·2503
G
Forward Position (Closed Center System)
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above)
Forward Position (Closed Center System)
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above)
GOIL RESERVOIR, System Cap.: 5 Gal. [19 L)
G
OIL e CHARGE RELIEF, 45 • 65 PSI [310 - 448 kPa]
RESERVOIR
.HIGH PRESS. RELEF VALVES, 3000 PSI [20685 kPa]
OPORT BLOCK
G)
FILTER BY.PASii
HYDROSTATIC
S iiiiii.p:~ PUMP
•
_ _fill'" HIGH PRESSURE
CHARGE A RELIEF VALVE
RELIEF V
eBY-PASS VALVE. 55 - 75 PSI [379 -
o
517 kPa]
HYDRAULIC OIL PUMP, 8 GPM [30,3 Um] at 2500 RPM
.TEMPERATURE SWITCH, 230°F [110°C]
_
OIL COOLER
PORT
r--''''--, BLOCK
0
HYDRAULIC 0
o
o
PRESSURE SWITCH, 23 - 27 PSI [158 - 186 kPa)
HYDROSTATIC MOTOR
OIL PUMP • G)ORIFICE
BY.PASSe G MAIN RELIEF, 1500 - 1600 PSI [10342 • 11032 kPa)

VALVE At Valve (1575 • 1675 PSI [10859 - 11549 kPa]
0HYDRAULIC CONTROL VALVE
AHYDROSTATIC TEMPERATURE A
V MOTOR SWITCH V G) FILTER, 10 Micron
ORIFICE G) _OIL COOLER
G) FILTER BY·PASS, 72 PSI [496 kPa]
HYDRAULIC
CONTROL VALVE
o HYDROSTATIC PUMP
o _ RED· - •••• - High Pressure

I I BLUE - - • - •• Low Pressure
_ GREEN· •• - - Case Drain & Reservoir
MAIN RELIEF PI -2504 ORANGE· - - ·Charge Pressure
G
HYDROSTATIC SYSTEM
Paragraph Page
Number Number
BY-PASS VALVE REPAIR 3-5 3-4

HYDROSTATIC CIRCUIT 3-1 3-1
HYDROSTATIC MOTOR RENEWAL AND
INSTALLATION 3-8 3-7
HYDROSTATIC MOTOR REPAIR 3-9 3-7
REMOVAL AND INSTALLATION OF PUMP HYDROST ATIC
SYSTEM
ASSEMBLY 3-6 3-4
REPAIR OF HYDROSTATIC PUMP ASSEMBLY 3-7 3-5
REPLENISHING VALVES 3-4 3-4
STEERING LINKAGES 3-10 3-11
TROUBLESHOOTING CHART 3-2 3-1
520, 530, 533 Loader

Service Manual
3 HYDROSTATIC SYST£M 520/530 a 533
HYDROSTATIC CIRCUITRY
3-1 HYDROSTATIC CIRCUIT (Fig. 3-1) FORWARD POSITION
o ORANGE CHAf<GE PRES~ SIYPLY
o RED ' HIGH PRESSURE
Fluid from the hydraulic control valves CJ BLUE ' LON PRESSLHE
U GRE!:N SUPPLY (RESER\oQIR) /l. CASE DRAIN
goes to the hydrostatic filter and then to
the hydrostatic pumps. If the pressure to C:::::::=:=)' LINE CONTINUES
the filter is too high (oil too thick, as in

cold weather starting), the by·pass valve in
the port block will open and let fluid
return to the inlet of the hydraulic pump.
Fluid which goes to the hydrostatic
pumps keeps the lines from the pumps to
the motors full of fluid. Fluid enters the
system through the replenishing valves.
Fluid which leaks (internally) from the
pumps returns to the hydraulic vane
pump, through an internal passage.
Fluid which leaks internally from the
hydrostatic motors goes to the oil cooler.
From the oil cooler, the fluid returns to
the inlet of the hydraulic (vane) pump.
If the pressure of the fluid supply to the
hydrostatic pumps is too low (filter is
dirty or one of the pumps has wear). the
pressure switch at the filter wi II close and
illuminate the "Trans" light on the dash
panel.
PI·2327
If the fluid becomes too hot, the switch
at the port block will close and illuminate Fig. 3-1 Hydrostatic Circuitry I
the "Trans" light.
There is a restrictor orifice (Fig. 3-2) which protects the filter from damage from sudden
increases in pressure. This orifice is in location at the control valve end of the filter
tubeline (1) on 520 SIN 12,299 and below. On 520 SIN 12,300 and above and all 530,
533's, the orifice is located at the inlet tubeline to the 10 micron filter (2).
3-2 TROUBLESHOOTING CHART
PROBLEM CHART NO CORRECTION
No drive on one side in one None Check for hydraulic leaks. Check
direction. steering linkage, check
replenishing valves (Sec. 3-4.11.
No drive on either side. A Check fluid level and steering

linkages, make replacement of
filter, inspect by· pass. Check vane
Restrictor
pump. Check restrictor.
(Late Models)
No drive, one side, both B Check linkage. Check for pump
directions. or motor damage.
Machine does not move in a C Check dia. and size of tires

straight Ii ne. steering linkage, see Chart B.
NOTE: If the "Trans" light is illuminated, check which sender is actuating the light by
removing the wire at the pressure sender switch. If the light is still illuminated,
the temperature sender is actuating the light because fluid is too hot. If the light
goes out when the pressure sender wire is removed it is an indication of loss of
hydrostatic charge pressure.
" Restrictor
(Early Modelsl B-2286
Fig. 3-2 Restrictor At Filter Inlet
520, 530, 533 Loader

·3-1b· Service Manual
CHART A
NO DRIVE ON EITHER SIDE
If "Trans"
Check Turn Ignition Start Engine &
Fluid Level
If
Correct Switch "On"
Light
Comes On
• Run At 1/2 Throttle
If Light Does
If Low
Not Come On
+
Add Make Repair To Install
Fluid Light System New Filter
If Light Is On
Remove, Clean &

Check Inspect By-Pass
Vane Pump Valve (Sec. 3-5).
If Light Goes Out
If Light Is On
If Good
iF
t
Hydrostatic Pump
Has Defect. Remove,
Make Repairs Check Clean & Inspect
If Good
To Controls Pump Drive Pump And Motor
(Sec. 3-6 & 3-8).
CHART B
NO DRIVE: 1 SIDE, BOTH DIRECTIONS
If Light
Check Steering If Turn Ignition If Light.. Start Engine & I-Is Off.- Hydrostatic Motor
r--
Linkage Good Switch "On" Is On Run At 1/2 Throttle 'But No Has Defect
Drive
I
If Not
Correct
t ,
If Light
Is Not On
,I
If Light
Stays On
,It
NOTE: If Either
Make Repairs The Pump or Motor
Repair Electrical Hydrostatic Pump
As Needed Has Damage, Remove,
(Sec. 3-10) System Has A Defect
Clean & Inspect
Both Units.
520 Loader
-3-2 Service Manual
CHART C
BOBCAT DOES NOT MOVE IN A STRAIGHT LINE
Check Size
& Pressure
Of Tires
If
Correct
.. Check Steering
Linkage
(Sec_ 3-101
If
Correct
... Go To
Chart B
I
If Not Correct
I
If Not Correct
t t
Change Tire Make
Or Pressure Repairs
As Needed As Needed
CHART D
BOBCAT OVERHEATS
Check If Hydraulic
Check
Check
Fluid Level
_ If
Correct
~ Check & Clean
Oil Cleaner
_If~
Clean
Controls Are Being
Held Out of
- If
Not
~ "Temp Sender"
(Sec. 1-111
Neutral Position
I I
If Low If So
t
Loader Is
Add Fluid Not Being
Operated Correctly
-3-3-
3-4 REPLENISHING VALVES
3-4.1 Checking the Replenishing

Valves (Fig. 3-3)
If there is a loss of drive in one direction

on one side, check as follows:
(1) Remove and exchange the
location of the two valves for the
side which has the drive problem.
The valves are located on each side
of the valve plate, near the pump,
for the drive on the same side. If
I
I
I
.... _--, I
Seat Area
t
there is no loss of drive in the A·2380
opposite direction, one of the
Fig. 3-4 Valve Seating Area
valves has a defect and needs ,,
replacement.
Q
NOTE: Do not lose the small pin in the ,
end of each valve.
(2) If exchanging the valves does I
not change which side loses power
or drive, remove all four valves and
wipe them dry.
cD
(3) Put a coloring fluid on the
valves and let them dry (Fig. 3-4).
Replenishing
(4) Use a needle nosed pliers to High Pressure
install the valve into the hole. Relief Valves
Install the valve lightly in the seat
and turn it very little. 8·1608
Fig. 3-3 Replenishing Valves
(5) Remove the valve and check the contact area of valve. If the contact area
of valve does not show sign of full contact around the seat area, the seat in the
valve plate has defect. The valve plate must be replaced.
3-5 BY-PASS VALVE REPAIR
If the "TRANS" indicator light continues to goON or OFF, and you do not notice any
poor hydrostatic performance, the by-pass valve can be the problem. The poppet
does not fit correct against seat and must be replaced. (See Parts Manual or
microfiche for parts.)
(1) Disconnect the hose from the control valve to the port block. Slide the
spring and poppet out of the port block (Fig. 3-5).
(2) Check the spring poppet and

its seat for damage or binding.
(3) Assembly is the reverse of

disassembly.
3 - 6 REMOVAL AND INSTALLATION

OF PUMP ASSEMBLY
(1) Activate the controls to

raelease the hydraulic pressure.
(2) Disconnect the hose from the

reservoir at the vane pump. Put
covers on the openings.
(3) Remove the two bolts which

hold the vane pump to the
hydrostatic pump assembly. Slide
8·3127
the vane pump, with hoses, away
from the hydrostatic pump. Fig. 3-5 By·Pass Valve Removal
520, 530, 533 Loader

(4) Remove the engine (See
Section 7).
(5) Disconnect the steering linkage

at the steering levers. Disconnect all
other hoses to the hydrostatic pump
assembly. Put covers on all openings,
to keep dirt out.
(6) Remove the two bolts which
.. ,
hold the pump assembly to the
frame and lift the pump assembly
out of the Bobcat. Weight of the
pump assembly is about 90 Ibs. (41
kg).
.".
. .,.,.-- "",-
-
Installation is the reverse of removal. Be
-- ,
". ..~.
sure to use a new O·ring between the

vane pump and hydrostatic pump B·2894
assembly.
Fig. 3-6 Remove Coupling Assembly
3-7 REPAIR OF HYDROSTATIC PUMP

ASSEMBLY
NOTE: Be careful to keep dirt out of

hydrostatic system. Dirt will
cause serious damage.
Do not use parts from one pump for

repair of another pump.
3-7.1 Pump Disassembly
(1) Remove steering linkage and

head shield.
(2) Remove coupling assembly

(F ig. 3-6) from pump with puller. B·2902 B·2987
(3) Remove bolts hold ing the Fig. 3-7 Remove Pump From Valve Plate Fig. 3-8 Remove Coupling from Valve Plate
pump housing to the valve plate.
Remove the pumps from the valve
plate (Fig. 3-7). Remove the spline
coupling from the valve plate (F ig.
3-8).
NOTE: The disassembly and assembly

procedure for both pumps is
similar but there is not a shaft
seal in the front (right side
drivel pump.
(4) Remove the small snap ring

(Fig. 3-9) to remove the race.
Remove the rotating group from the
housing.
(5) Remove the large snap ring

(Fig. 3-10) which holds the shaft
and bearing in position. Use a soft 8-2895
hammer to remove the shaft from
the housing. Fig. 3-9 Remove Small Snap Ring Fig. 3-10 Remove Large Snap Ring
520, 530, 533 Loader
(6) Remove the pintle seal plate
(Fig. 3-11). Remove the two bolts
which hold the pintles in the yoke.
Remove the pintles, together with
a-rings and cloth seals (Fig. 3-12).
Lift the swashplate out of the
housing.
NOTE: A puller can be used to remove

the pintle bearings if necessary. B-290l B-2886
There is a key between the
longer pintle shaft and the yoke. Fig. 3-11 Remove Pintle Seal Plate Fig. 3-12 Remove Pintles
Wear Area
(7) Use a hammer and punch to
remove the shaft seal (F ig. 3-13).
(8) Check all parts for wear,

scratch marks or other damage (Fig.
3-14, 3-15 & 3-16). If the
swashplate bearings need
replacement, use a puller to remove
them. Be careful not to cause
damage to the parts. B-2887 A-2304
Fig. 3-13 Remove Shaft Seal Fig. 3-14 Valve Plate Wear
3-7.2 Assembly
Use a seal installation tool (Fig. 3-17) to install the new seal (See Section 8, "Special
Tools"). Put hydraulic fluid on parts during assembly. Install new seals and a-rings.
This Dimension Must Be Maintained On All

Nine Shoes Within 0.001 Inch.
L--
/-~
Shoe Faces Slides
Shoe Must Swivel Smoothly on Ball.
on Swash Plate
End Play Must Not Exceed 0.003 Inch. A-1850
Fig. 3-15 Rotating Group Fig. 3-16 Piston Shoe
520, 530, 533 Loader

3-8 HYDROSTATIC MOTOR SHAFT SEAL INSTALLATION
REMOVAL AND INSTALLATION
NOTE: All
(1) Put the machine on jack-
stands. Remove the cover from Dimensions
under the motor (Fig. 3-18). In Inches.
Driver--...
(2) Let hydraulic fluid out of the
chaincase. Remove the foot rests,
seat assembly, shield and
chaincase covers.
(3) Make a separation of the front
drive chain at the white connector
link. If chain does not have a
connector link. Put paint on the I Sea
1!
new connector link for future
identification. Do not use the old
connector link again.
(4) Disconnect the hoses to the 4.000
!
hydrostatic motor and put covers
on the hoses to keep dirt out. , 0.500
(5) Remove the bolts which hold o.375 ~ 0.125
the motor to the chain case. Tilt the
motor to one side to release the
t
e=a,;.= F==?,
+
tension on the rear drive chain,
R
t
then remove the motor (Fig.
3-19).
3-8.1 Installation
I
Installation is the reverse of removal.
Be sure to use a new o-ring between
the motor and the chaincase. On the
520; SIN 13246 & belo.w and 533;
SIN 11060 & below, use new twelve
point bolts if not installed.
Fig. 3-17 Seal Installation Tool
A-1851
Fig. 3-19 Remove Motor
3-9 HYDROSTATIC MOTOR REPAIR
3-9.1 Disassembly and Inspection ...

I "'
I "'"'
(1 ) Remove the nut and use a "' "'
puller to remove the sprocket from "' "' B
the motor shaft. "' "'
"' "'
(2) Remove the bolts which hold
the end cover to the motor. Use a
soft hammer to make a separation
"' "'
"' "'
" .
I'~
of the end cover and sleeve "-25
protector (Fig. 3-20).
(3) Remove the internal parts
from the motor (Fig. 3-21).
30
.~
)
B·2876 C-2013
Fig. 3-20 Remove End Cap Fig. 3-21 Hydrostatic Motor Breakdown
520, 530, 533 Loader

(4) Slide the coupling shaft from
the housing (Fig. 3-22).
(5) Remove the seal from the

housing (Fig. 3-23). Remove the
snap ring and seal parts under the
outside seal (Fig. 3-24).
(6) Use a press to carefully push

against the thrust washer to remove
the needle bearings (Fig. 3-25).
NOTE: Remove these bearings only if 8·2841 8-2877

they have wear or damage.
Install new bearings if the old Fig. 3-22 Remove Coupling Shaft Fig. 3-23 Remove Seal
bearings are removed.
(7) Clean and check all parts for

scratch marks, wear and damage
(Fig. 3-26).
Be sure the inside ball is free. Move the

motor housing to hear the inner ball. Do
not remove the larger, press fit ball (F ig.
3-21, Item 1).
3-9.2 Assembly
(1) Clean all parts thoroughly and

8-2842 8-2872
install new seals and a·rings. Put
hydraulic fluid on the parts during Fig. 3-24 Remove Snap Ring & Seal Parts Fig. 3-25 Remove Needle Bearings
assembly.
(2) Use a seal installation tool. Install the rubber sealing ring inside the collar of
the tool, with numbered side toward the chamfer (Fig. 3-27).
(3) Put the installation collar into the housing with the chamfer toward the
housing (Fig. 3-27).
(4) Put the installation sleeve into the collar and push the seal into the housing Wiper
(F ig. 3-27). Seal
\
Snap Q Spacer
Ring ------.,~ • _ /
..l..,
Manifold
In~~~::on _I 1
~
,
I
I
<C>
),
Shim
I
Wear Plate
~
Installation
Collar
Rubber Sealing
Ring
Manifold Plate 8·2875 A-2522

Geroter Section (Stator & Roller)
Fig. 3-26 Wear Areas Fig. 3-27 Install Sealing Ring
520, 530, 533 Loader

(5) Remove installation sleeve
and collar.
(6) Install shim on seal, then

install spacer and snap ring (Fig.
3-27).
NOTE: Be sure tapered edge of snap

the snap ring is towards
the spacer.
(7) Install wiper seal (Fig.

3-27). B-2869
(8) Install thrust bearings and Fig. 3-28 Install Thrust Bearings Fig. 3-29 Install Wide Shaft Bearing
races (Fig. 3-28).
(9) Install wide shaft bearings

(Fig. 3-29). Push on numbered
side only. The distance from
machined surface of the housing to
the numbered side of the bearing
must be 2.4-2.42 inches
(60,96-61,47 mm) (Fig. 3-30).
(10) Install the narrow shaft

bearing by pushing on the
numbered side. Distance from the
machined surface'of the hbusing to
the numbered side of the bearing
mus~ be .150-.210 inches
(3,81-5,334 mm). Fig. 3-30 Check Bearing Location
(11) Put the housing in a vise. Put

tape over the key slot on the shaft
to prevent seal damage. Install the
shaft in the housing.
NOTE: Be sure to measure the length

of the shuttle pin (Fig. 3-321.
The correct length is,
minimum 1.455 inchs (36,95
mml and maximum 1.495
inches (37,97 mm). Replace
the shuttle pin when it is not
in this specification range.
(1 2) Put the sealing ring in the

groove in the housing with the Install Ball and Pin
bevel side up (Fig. 3-31). Install
the ball and pin in the housing (Fig.
3-32).
(13) Install the drive link in the

coupling shaft (Fig. 3-33). Be
sure that the hole in the drive link is
in alignment with the hole in the
side of the coupling shaft.
(14) Install the thrust bearing over

the shaft (Fig. 3-34).
NOTE: Alignment bolts can be used

to aid in assembly.
(15) Install the wear plate over

Install Thrust Bearing Install Wear Plate
the shaft (Fig. 3-35).
520, 530, 533 Loader
Revised Mar. 79
(16) Install the stator ring and the
rotor assembly (Fig. 3-36).
(17) Install the manifold plate (Fig.

3-37).
(18) I nsta II the manifold (Fig.

3-38).
(19) Install commutator and special

sealing ring with flat side out (Fig.
3-39).
Fig. 3-36 Install Stator Ring & Rotor Fig. 3-37 Install Manifold Plate
(20) Install the commutator (Fig.
3-40).
(21) Put grease on the seal ing ring

and install the sleeve protector (Fig.
3-41).
(22) Install the sealing ring on the

end cover and put the cover on the
housing and protector sleeve. Fasten
the cover with bolts and tighten the
bolts evenly to 50 ft.-Ibs. (67,8 Nm)
torque.
Fig. 3-38 Install Manifold Fig. 3-39 Install Commutator Ring
Fig. 3-40 Install Commutator Fig. 3-41 Install Sleeve Protector
520, 530, 533 Loader

3-10 STEERING LINKAGE
3 -1 O. 1 Adjustment (Old Style Linkage)
(1) Put the machine on jackstands.
Be sure that the tires are off the floor

AWARNING and are not hitting jackstands.
I NOTE: The nuts that hold the steering linkage can become loose (Fig. 3-43,
Item 1). Tighten the nut to 25 - 28 ft.-Ibs. (33,8 - 37,9 Nm) torque. Fig. 3-42 Loosen Pintle Arm Stops
(2) Disconnect the steering levers from the control rod.
(3) Start the engine and run it at idle RPM. Adjust the rear pintle arm first.
Loosen the pintle arm stops (Fig. 3-42, Item 1 I. Adjust the pintle arms (Item 2)
so that the axles do not turn. Slide the stops against the pintle arms and tighten
the bolts.
(4) The centering spring (Fig.
3-44, Item 1) must have enough
force to hold the pintle arms in the
neutral position. Adjustment to the
spring is made by turning the nut
(Item 21.
NOTE: Current production loaders

(530; SIN 12034 & above
and 533; $/N 12000 &
above) have improved steering
linkage and pedal control
parts. You can replace these
parts with "improved"
parts. (See your Parts Manual
or microfiche for parts.)
3 -10.2 Adjustment (New Style
Linkage)
To adjust for neutral position (Fig.

D-1283
3-45).
Fig. 3-43 Steering Controls
(1) Put the machine on
jackstands.
AWARNING
Be sure that the tires are off the
floor and are not hitting
jackstands.
(2) Move the left steering lever

until the tires do not turn (neutral).
Adjust rear pintle bar so that the
bar is tight against both lobes of
8-2828
pintle lever and tighten the bolt
first to 28 ft.-Ibs. (38 Nml torque. Fig. 3-44 Centering Spring Assembly
520, 530, 533 Loader

(3) Move the steering lever
forward and backward and let the Left Steering Right Steering
pump return to neutral position. If Bar Bar
the pump does not return to
neutral, make adjustment again.
There must not be any space
between the bar and the lobes.
(4) Move right steering lever until

the tires do not turn (neutral).
Adjust the front pintle bar so that
the bar is tight against both lobes
of the pintle lever and the pump is Bar Centering
Lever Bar
still in neutral. Tighten both lobes Strip
to 28 ft.-Ibs. (38 Nm) torque.
(5) Move both steering levers

C·2431
forward and backward and let
them return to neutral. Fig. 3-45 Adjusting Neutral Position
(6) Check to see that there is no clearance between the bars and the lobes.
Make adjustment if necessary.
(7) Tighten the bolts that hold the steering linkages to the pintle levers to 12
ft.-Ibs. (16 Nm) torque. Install new locknuts on each bolt and tighten to 23 ft.-
Ibs. (31 Nm) torque.
NOTE: The nuts at the front end of steering linkages go toward the center of
machine.
(8) Tighten two bolts at the front end of the steering linkages to 12 ft.-Ibs. (16
Nm) torque.
(9) Install new locknuts on these bolts and tighten to 23 ft.-Ibs. (31 Nm)
torque.
(10) Install the seat and seat plate.
(11) Remove jackstands and lift arm stop and lower lift arms.
520. 530. 533 Loader

DRIVE SYSTEM
Paragraph Page
Number Number
AXLES AND BEAR INGS 4-2 4-1

BRAKE PAD REPLACEMENT 4-3 4-3
DRIVE CHAINS 4-1 4-1
DRIVE
. SYSTEM
520, 530, 533 loader

Service Manual
4 FINAL DRIVE
4-1 DRIVE CHAINS
The drive chains are endless. (Do not have Front Cover
I
connector links.) A separation of the
cha ins can be made if needed. If chain
separation is necessary, use a new press-on
connector link when installing again. Put
paint on the connector link for future
identification.
4-1.1 Chain Replacement
(1) Put machine on jackstands.
(2) Remove seat assembly and

transmission shield.
(3) Remove the covers from the

chai ncase (F ig. 4-11.
(4) Check the chain for connector

link. If there is no connector link,
separation of the chain can be made
at any link.
E-1138R
(5) Install the new chain over the
sprockets. Use a new connector link Fig. 4-1 Remove Chaincase Covers
when connecting the chain together.
(6) Install the chaincase covers,

transmission shield and seat
assembly. Add hydraulic fluid to the
chaincase reservoir if fluid level is
low.
4-2 AXLES & BEARINGS

Axle Nut
4-2.1 Removal Procedure For All Four
B-2814
Axles Is Similar
Fig. 4-2 Remove Bolt & Washer Fig. 4-3 Remove Axle
NOTE: Chain separation is not necessary

for axle removal.
(1) Put the machine on jackstands.
(2) Remove the bolt and washer

from the end of the axle (F ig. 4-21.
Remove the wheel.
(3) Use a slide hammer to pull the

axle from the machine (Fig. 4-3).
(4) Remove the inside bearing cone

with a long punch, if bearing B-2840
replacement is necessary (F ig. 4-4). Fig. 4-4 Remove Bearing Cone
520, 530, 533 Loader

(5) Use a puller to remove the
outer bearing cone (Fig. 4-5).
(6) Use a puller to remove the

bearing from the axle shaft if either
the bearing or seal have defects (Fig.
4-6).
(7) Clean and check all parts

thoroughly for wear or damage.
4-2.2 Assembly and Installation
(1) Install a new seal on the shaft

with the open side toward the
chaincase. Lubricate the seal with
grease.
(2) Use a press to push the bearing
onto the shaft (Fig. 4-7). B·2885
Fig. 4-5 Remove Outer Bearing Cone Fig. 4-6 Remove Axle Bearing
(3) The outer and inner bearing
races can be pulled into position by
using a long bolt and washers.
(4) Put the sprocket into the

chaincase and put the chain in
position on the sprocket.
Press
NOTE: The wide sprocket hub must be
toward the inside in the front of
Bearing
the loader and toward the
outside at rear of the loader.
(5) I nstall the axle in the housing

and install the bearing and sprocket.
(6) Install the inner halves of the

installation tool (Fig. 4-8).
(7) Install the outer halves of the

installation tool (F ig. 4-9). B-2810
~
(8) Install the spring on the Fig. 4-7 Install Outer Beari!1g
f~i
installation tool (Fig. 4-10).
(9) Use a hammer to hit the axle

until the installation tool is in I B-2770
contact with both the axle flange
Fig. 4-8 Install Inner Halves of Tool
and axle housing.
(10) Remove the installation tool.
(11) Tighten the axle bolt to pull

the seal and inner bearing into
position (F ig. 4-2) (See Section 8
Technical Data for torque
specificat ions).
(12) If the chain was separated

during axle removal, install the chain
and connector link.
(13) I nstall the covers on the

chaincase and install the transmission
shield !lnd seat assembly. Fig. 4-9 Install Outer Halves of Tool Fig. 4-10 Install Spring on Tool
520, 530, 533 Loader

4-3 BRAKE PAD REPLACEMENT (Fig.
4-11)
(1 ) Remove the seat assembly,

transmission shield and
transmission covers. Disconnect
the linkage from the brake lever. Front Panel______ ,
(2) Install the pucks into the
block (Fig. 4-11, Item 1). Install
the last puck into puck retainer and
-----..~ ,~ _ _-Pedal
put into the block.

(3) Put oil on the a-ring and put
~V -----1
the a-ring on the cam. Install the
cam in the block from the top (Fig.
Brake Leve~
~ t,~~/i---------- I!~
~ i i/ \ ~r~---~ i
4 - 1 1 , Item 2).
(4) Install the brake/puck block
on the transmission cover. Install
Rear Cover t i i!I~~_-;" - -~ -
bolts and tighten &Fig. 4-11, -............. ~--" r--_ 7 '
~ -- ---' ront Cover
Item 3). Puck ~
(5) Put the brake/puck assembly Retainer 0---~ Cam
and transmission cover over the
brake discs. \
h
~l'¥'
••• _-6 __ CaUp.. Assembly
if pu!.s @~ @
(6) Turn the cam counterclock-
wise with a vice-grip pliers to force
the pucks against the discs.
(7) While holding the pucks
against the discs, align the
transmission cover so that the
discs are centered between the
sprocket teeth.
(8) Align the gasket and install
V
Discs D-1328R
cover bolts and tighten to 20 ft.- Fig. 4-11 Brake Pad Replacement
Ibs. (27 Nm) torque.
(9) Be sure pucks are tight
against discs; then install brake
lever on the cam with the lever as
far clockwise as possible (against the right pump mount).
(10) Install front cover and angle bracket and tighten bolts to 20 ft.-Ibs. (27
Nm) torque (Fig. 4-11, Item 4).
(11) Install bar and bolt on the cam (Fig. 4-11, Item 5) and tighten bolt to 70
ft.-Ibs. (95 Nm) torque.
NOTE: Be sure that the lever and bar are at right angle from each other and that the
bar is parallel with transmission wall (Fig. 4-12).
(12) Assemble brake pedal and

rod (Fig. 4-11, Item 6).
(13) Install brake pedal on front
cover.
(14) Install brake rod into hole in
brake lever.
(1 5) Install nut (big nut) and lock
nut onto brake rod (Fig. 4-11,
Item 7).
(16) Connect one end of the
spring to bar on the cam. Connect
other end to angle bracket on front
cover.
(17) Adjust the brake rod nut (big
nut) for 1/4" freeplay between nut
and brake lever and turn lock nut
against the nut (big nut).
(18) Check pedal operation in
locked and unlocked position.
(19) Install front plate, seat and Fig. 4-12 Brake Pad Adjustment
seat plate.
520, 530, 533 Loader
MAIN FRAME
Paragraph Page
Number Number
BOB-TACH 5-3 5-2

REMOVAL OF FUEL TANK AND
HYDRAULIC RESERVOIR .. 5-4 5-4
REMOVAL OF ROPS ..... 5-1 5-1
REPLACEMENT OF PIVOT PINS 5-2 5-1
MAIN
FRAME
520, 530, 533 Loader

Service Manual
5 MAIN FRAME
5-1 REMOVAL OF ROPS (Operator

Guard) (Fig. 5-1)
(1) Stop the engine and activate

the hydraulic controls to release
hydraulic pressure in the system.
(2) Fasten a chain hoist to the

ROPS.
(3) Remove the two (2) bolts from

the front corners of the ROPS.
(4) Remove the two (2) bolts from

the rear corners of the ROPS.
Fig. 5-1 Remove The ROPS
(5) Disconnect the wiring harness.
(6) Lift the ROPS from the

Bobcat.
I
I
II
G...l
I
AWARNING '*
~
I
I
I
~
n
Be sure to install holddown bolts
and washers when installing the
ROPS (Fig. 5-21.
D·1369R
Fig. 5-2 Install Holddown Bolts
5-2 REPLACEMENT OF PIVOT PINS

(Fig. 5-3)

the hydraulic controls to release
hydraulic pressure in the system.
(2) Fasten a chain hoist to the lift

arms.
(3) Remove the bolt in the pivot

pin.
8-2801
(4) Use a punch and hammer to
remove the pivot pins. Fig. 5-3 Liftarm Removal
520, 530, 533 Loader

_ - - - - - Bushing
This Sleeve used on

early 520 models only
(Kit #6555534)
\7
I
-'ClI-D-~ Bushing
./
D-1467
Fig. 5-4 Bushing Replacement
5 - 2.1 Bushing Replacement
There are bushings in the lift arm pivots

only (Fig. 5-4).
The bushings must be removed and

installed with a bushing driver of the
correct size. Be sure that the grease
hole in the lower pivot bushing is
aligned with the grease fitting. Push the
upper pivot bushing in until it is even Weld Both
with the outside of the collar. LH and RH
Sides of Lift Arms
AWARNING
Release the hydraulic pressure Fill in With
and use a good support to hold Weld On
the cylinders and lift arms Corner Openings
before removing any pivot pin. (Both Sides)
Weld Under This Weld On Four Sides

There may be a failure of welds on the Edge Along The (2 On the Inside)
lift arm crossbar on the early 520 Crossbar (2 On the Outside)
Bobcats. Remove the lift arms and
make a continuous weld as shown in
figure 5-4a. Corner Opening
Fill With Weld
NOTE: Weld the crossbar at each
junction and fill in the corner
openings with weld so it be-
comes a solid piece. Fig.5-4a Lift Arm Weld (520)
520, 530, 533 Loader

5-3 BOB-TACH
5-3.1 To Check the Wedges (Fig.

5-51
(1 I Install an attachment on the

Bobcat.
(2) Engage the locking levers.
(3) Replace the wedges if they do

not extend at least 1/4 inch (6,5
mm) through the notches in the
attachment (Fig. 5- 5).
(4) Check that the locknut is tight

(Fig. 5-6).
NOTE: There is no adjustment for the

Bob-Tach wedges.
Fig. 5 - 5 Checking Bob·Tach Wedges Fig. 5-6 Check Locknut
520, 530, 533 Loader

Revised Mar 79 -5-2a- Service Manual
5-3.2 Removal of Bob-Tach (Fig.
5-7)
(1) Lower the lift arms and Bob-

Tach to the ground.

hydraulic controls to release
hydraulic pressure from the
system.
(3) Remove the pivot pin from the

rod end of the tilt cylinder.
B-2791 B·3062
(4) Remove the bolts and Fig. 5-7 Removal of Bob-Tach Fig. 5 - 8 Remove Bob-Tach Pin
washers from the Bob-Tach pivot

pins.
NOTE: Early 520 loader used a

straight (not tapered) pin, kit
#6555534 should be installed
on these loaders.
(5) Use a hammer and punch to

push the pivot pins into the Bob-
Tach frame (Fig. 5-8).
(6) Remove the Bob-Tach.
To install Bob-Tach, remove the grease Fig. 5 - 9 Installing Bob-Tach Pins
fittings and use a thin punch to push

the pivot pins out of Bob-Tach frame
(Fig. 5-9).
5-3.2a Bob-Tach Over-Center Stop
Install mechanical stops on the Bob-

Tach and lift arms when the Bob-Tach
goes over-center when tilted fully
forward.
Install the kit (PIN 6560898) to

prevent damage to the tilt cylinder
parts (Fig. 5-9a). D-1488
Fig. 5-9a Bob-Tach Over-Center Stops
520, 530, 533 Loader
Revised April 79 -5-3- Service Manual
5-4 REMOVAL OF FUEL TANK AND
HYDRAULIC RESERVOIR
(1) Remove the seat assembly.
(2) Remove the cover (Fig. 5-10).
(3) Let fluid out of the tank or

reservoir. (See Section 1 for
removing hydraulic fluid.)
(4) Disconnect the tubeline or hose

to the tank or reservoir. Put covers
on ali openings to keep dirt out. '/
(
c:'~
(5) Remove the tank or reservoir.
(6) When installing tank or

reservoir, be sure the cushions are in
correct positio n.
Hydraulic
Reservoir Tank
Fuel Tank
Reservoir
(533)
System
Fig. 5-10 Removal of Fuel and Hydraulic Reservoir Tanks
520, 530, 533 Loader

ELECTRICAL SYSTEM
Paragraph Page
Number Number
CHECKS & REPAIRS OF THE ELECTRICAL

SYSTEM (520/530) 6-3 6-8
CHECKS & REPAIRS OF THE ELECTRICAL
SYSTEM (533) . 6-5 6-9
ELECTRICAL CIRCUITRY 6-1 6-1
GENERATOR SERVICE 6-6 6-10
PROBLEM ANALYSIS CHARTS 6-2 6-1
REPAIR OF THE STARTER 6-7 6-12
STARTER 6-4 6-8
ELECTRICAL
SYSTEM
520, 530, 533 Loader

Service Manual
6 ELECTRICAL SYSTEM
Solenoid
6 - 1 ELECTRICAL CIRCUITRY
There are three basic electrical circuits

in the loader electrical system. They
are:
(1) The starting circuit (switch,

solenoid, battery and starter) (Fig.
6-1).
(2) The ignition circuit (points,

spark plugs, coil and attached
wiring). (See Section 7, "520 and
530 Loaders".)
Switch
B·2275
Fig. 6-1 Starting Circuit (Simplifiedl
Battery
AWARNING
Before making repairs on the
electrical circuits, disconnect
the battery ground cable.
Generator
Rectifier /Regulator
The 520 and 530 loader has a 12 volt,
1 5 amp. flywheel alternator charge
system. (See figure 6 - 3 and 6 - 4 for
wiring diagrams.) B-2274
Fig. 6-2 Charging Circuit (Simplified)
The 533 loader has a 12 volt, 37 amp, belt driven alternator charge system. (See
figure 6- 5 for wiring diagram.)
NOTE: If the fuses on your 530 or 533 Bobcat are not in the dash panel, there are
I parts available to put the fuses in the dash panel for better access.
(See your Parts Manual or microfiche for the parts.)
6 - 2 PROBLEM ANALYSIS CHARTS
See the charts for diagnosis of electrical problems (Page 6 - 7).
Chart A: Battery does not keep charge.
Chart B: Starter will not turn engine.
The charts give the correct order for finding problems and making repairs.
520,530,533 Loader
Circuit
Breaker
/ AMP
Gauge
..--- Engine Oil
Ignition
Hydraulic Pressure
Switch
Switch
/'
-Cr""'- - ~- -')-~1
Transmission
Oil
Hour Meter
Spark
\;"
~ ...
\
\
Engine
Oil
__ ,,,-"pressure
f -----
Eng. Temp.
0-1287
E-1159R
Fig. 6-3 Electrical System (520 Loader)
520, 530, 533 Loader

Revised February 80 6-2- Service Manual
Front
---~
Rear
Light
1
Switch
/
Instru ment Box
Spark Plug
Wire
Ammeter
I
,, I
c_ I
Stator I
I E·1183
- - _1
E·1188
Fig. 6-4 Electrical System (530 Loader}
520, 530S, 533 Load er

Revised February 80 -6-3- ervice Manual
Front Lights
--.~\
Rear
Light
l "
"
"
\). . ~ . J)
"
,/ 0"
Hour Meter
I
i
Hydro Pressure
Switch
Batte~ __________ ~
E-1l66
E-1l88
Fig. 6-5 Electrical System (533 Loader)
520, 530, 533 Loader

-- -----,
~~ ~.r
o ,
f!! '. i
! I
I ~!,l
'" m .,
t - , ""'- 80J ~l _
!r~lj[1 J~ ~ ~
-----~:-l
~g
I ,,
L____ ----i~~~ ~ 0, I" ~

--I:1';; C)
,,1 ;"."
~l: 2:
'i
~
' __
o 9i:_Jme 11
~
'Vll-31IHM---'/
r'--:--c;;;'39N't1!lO'i31IH .....
/ ~
~.h
r=--=='="=-=~gt: =~~
:::E
w
l:
o
en
...J
«
o
Ii:
t;
W
...J
W
Fig. 6-6 Electrica I Schematic (530 Loaded
520, 530, 533 Loader

ELECTRICAL SCHEMATIC
~"
HAIlNES'.
CONNECTOR
~A~_~~_O" ~'~_"="CCO"-'
I
o _ _ _ __ -~
"'~,
GROUIC)
ENGINE
WATER
TEMPERATURE
" Jrr---r---
I
" -------/.....F()
I rr~----"'::S=':"-;;-~4FJ ALTERNATOR
~,:":,"_ _ _ _ _L
R f f i - - I -_ _ _ _ __
LIGHT
SWITCH
FEEOFOR
FU!;EO ..cCESSORIES
IHORNI
SCHEMATIC
Fig. 6-7 Electrical Schematic (533 Loaderl
520, 530, 533 Loader

CHART A
BATTERY WILL NOT HOLD A CHARGE
Charge Battery
Completely & Check
Condition With
A Hydrometer
If
-Good·
Check Condition
Of Battery
Terminals & Wiring
And Fuse
- If
Good . Check A.C.
Voltage
(See Sec. 6-3)
- If
Good
.. Install New
Rectifier/
Regulator
If Bad If Bad
I
If Not Correct
t ~
Install New Make Repairs
Install New
Battery As
Stator
Needed
CHART B
STARTER WILL NOT TURN EI\1GII'JE
Check Condition
Of Battery With - If
Good
... Check Wires
For Damage - If
Good
. Connect Jumper
Wire Across
If
- Engine......
r-::, .
Make Repairs
To Starter
A Hydrometer Solenoid (Sec. 6-5) Does Not (Sec. 6-4.3)
Turn
If Bad If Bad
I
If Engine
I
I
Turns If Starter Turns
t t t But Engine
Does Not Turn
Put Charge
In Battery Make Repairs Install New T
Check Charging As Needed Solenoid
System Install New
(See Chart A)
Starter Drive
(Sec. 6-6)
520, 530, 533 Loader

6-3 CHECKS AND REPAIRS OF THE
ELECTRICAL SYSTEM (520 & 530)
6-3.1 Checking A.C. Voltage
(1) Put the machine on jackstands

and remove the wheels.
(2) Disconnect the stator wires

from the rectifier and connect them
to the A.C. voltmeter (Fig. 6-8).
(3) Start the engine and let it run

at maximum RPM. The voltage must
be 28 or more volts. If the voltage
Fig. 6--8 Check AC Voltage Fig. 6-9 Remove Flywheel Nut
is less than 28 volts, replace the
stater. If the voltage is over 28 volts, the stator is good.
6-3.2 Alternator Repair
The alternator is located behind the engine flywheel.
6-3.3 Replacement of the Stator
(1) Remove the blower housing.
(2) Hold the flywheel with a piece of wood and remove the nut (Fig. 6-9).
(3) Use a puller (Fig. 6-10) to remove the flywheel.
(4) Remove the screws that hold the stator (Fig. 6-11).
(5) Install the new stator. Install the flywheel and blower housing. (See Section 8
for correct torque for the flywheel nut.
6-4 STARTER
6-4.1 To Check the Starter
NOTE: Before checking the starter, be sure the battery has full charge and all electrical
C-2334
connections are good.
(1) Put the machine on iackstands. Remove the wheels. Fig. 6-10 Remove Flywheel
(2) Connect a large wire between the two large terminals on the solenoid (Fig.
6-12).
(3) If the starter turns rapidly, it

has no defect but the solenoid can
have a defect.
6-4.2 Removal of Starter
(1) Disconnect the ground cable

from the battery.
(2) Disconnect the wire from the

starter.
(3) Remove the solenoid from the

starter.

8-2907
the starter and remove the starter.
Fig. 6-11 Remove Stator Fig. 6-12 Checking Starter
520, 530, 533 Loader

(5) When installing the starter,
connect the battery ground wire
last.
6-4.3 Disassembly and Repair
(1) Pull the rubber cap off the end -~-N\!1-@ - ~

of the starter shaft. Use two
wrenches to remove the nut on the
end of the shaft (Fig. 6-13).
(2) Remove the starter drive B-2862

parts as shown (Fig. 6-14).
Fig. 6-13 Remove Shaft Nut Fig. 6-14 Remove Starter Drive Parts
(3) Put a mark on the side of the

starter housing and end plates for
an aid in assembly.
(4) Remove the long bolts and

make a separation of the housing
and end plates.
(5) Check the condition of the

brushes. If the brushes are less
than 5/16" (8 mm) in length,
install new brushes (Fig. 6-15).
B-2878 B-2860
(6) Check the commutator (Fig.
6 -16) and check the armature in Fig_ 6-15 Check Brushes Fig_ 6-16 Check Commutator
a growler.
(7) Check all the parts of the

starter for damage. Add lubricant
to the bushings and assemble the
parts in reverse order of
disassembly.
NOTE: Do not put lubricant on the

starter drive splines.
6-5 CHECKS AND REPAIRS OF THE

ELECTRICAL SYSTEM (533)
6-5.1 To Check the Wiring
(1) Turn the switch key to "on".

Connect a voltmeter from the
chassis to: (Fig. 6 -17)
No. 1 generator connection
No.2 generator connection
"Bat" connection
(2) If any of these connections

show zero voltage, the wiring has
defect. Find the defect and make B-2 11 3
repair. Then check the voltage
again. Fig. 6 - 1 7 Alternator
520, 530, 533 Loader

6-5.2 To Check the Generator Output Test Hole
(1 ) Put the machine on jack-
stands.
(2) Disconnect the negative

battery cable. Connect an ammeter
in line with the "Sat." terminal of
the generator, and connect the
battery cable.
(3) Lower the electric charge in

battery. (Turn the engine with the A-22Il
B-2113 6-2655
starter, connect lights, etc.)
Fig. 6-18 Checking Regulator Fig. 6 - 1 Sa "Pre-Heat" Position
(4) Start the engine and run at full
throttle. The indication on the
ammeter must be within 10
amperes of the rating mark on the
generator.
(5) If the indication is correct, the

generator is good. If the indication
is high or low, check the regulator.
6 - 5.3 To Check the Regulator o;od. ~/JS

(1) Leave the ammeter , ....-- - -6- - --.
connected as in Paragraph 6-14. ,{ "
~s
T'-'" ,
(2) Lower the electric charge in
"'~H.at 'nd;ca'o,
battery. (Turn th·e engine with the
starter, connect lights, etc.)
(3) with the engine running at full
ft'
throttle, connect the generator
field to the chassis with a small
screwdriver or wire (Fig. 6-18). Fuse
(4) Check the ammeter. The Starter Switch
indication must be within 10 6-3140R
amperes of the rating mark on the
generator. If the indication is Fig. 6-1Sb Pre-Heat Indicator Installation & Wiring Circuitry
correct, the regulator probably has

a defect. If the indication is not
correct, the problem is in the diode Pre-Heat Indicator
trio, the rectifier, the stator or the Connecting Bar
rotor.
6-5.4 To Check the Engine Pre-Heat Lt. Blue/Black
(1) Turn the starter switch to the

"pre-heat" position (Fig. 6-18al.
__-----Diode
(2) If the indicator is "ON" White Wire
(glows), the circuit is good.
(3) The pre-heat indicator must

be installed as shown in figure
6-18b and 6-18c. Starter Switch
(4) The diode must be installed as

shown for the glow plug to operate 4" Jump Wire
6-2943
when the starter switch is in the
"start" position. Fig. 6 - 1Sc Pre-Heat Wiring Circuitry
520, 530, 533 Loader

6-6 GENERATOR SERVICE
6-6.1 Removal of the Generator
(1 ) Disconnect the negative battery cable.
(2) Disconnect the wires from the generator.
(3) Remove the two bolts that hold the generator in place and remove the
generator.
(4) Installation is the reverse of removal.

C·1959
6-6.2 Disassembly Fig. 6 - 1 9 Separate Housing
(1) Put a mark across each housing half for correct alignment during assembly.
(2) Remove the pulley from the shaft.
(3) Remove the four bolts which hold the case together.
(4) Use a screwdriver to separate each half of the housing (Fig. 6-19). Slide
the rotor out of the housing.
(5) Remove the nuts which hold the three stator wires to the housing. Remove
the stator.
(6) Disconnect the diode trio.
520. 530. 533 Loader

Added Mar 79 -6-10a- Service Manual
6-7.2 Checking the Starter
Armature
CORRECT
(1) Make a visual check of the commutator for rough or burned surface and if
necessary, polish with a fine sand paper. Turn the commutator in a lathe if it is
rough or taper wear is over maximum.
Standard outside diameter 1.73" (41 mm)
Minimum allowable diameter 1.61" (41 mm)

B-3009
Fig. 6-27 Aramture Undercut
Measure the outside diameter of the commutator at several locations with an outside
micrometer and compare the highest micrometer indication with lowest indication to
find the amount of wear. Correction is necessary if the amount of wear is beyond
the value indication for need of servicing.
Value indication for need of

servicing above .016" (0.44 mm)
Finishing accuracy .002" (0.05 mm)
B-2988
(2) Measure the depth of the undercut mica on the commutator (Fig. 6-27). Fig. 6-28 Armature Insulation Test
Correction is necessary, if the measured values are beyond the value indication for
need of servicing.
Value indication for need of

servicing above .008" (0.2 mm)
Standard depth .020" .. 031" (0.5 - 0.8 mm)
(3) Armature coil insulation test:
Test for insulation between the commutator segments using a growler tester (Fig. B-2990
6-28). If the light of the growler illuminates, the coils are poorly insulated and the
armatu re needs replacement. Fig. 6-29 Armature Coil Short Test
(4) Testing of the armature coils for shorts:
Put the armature on the growler and turn the armature on the growler slowly while
holding a hacksaw blade or a strip of steel over the sections of the armature core
(Fig. 6-29). If there is vibration of the hacksaw blade or a strip of steel, or if it is
pulled, the armature coils are shorted and the armature needs replacement.
(5) Armature coil continuity test:
Make a continuity test between the commutator sections using a growler (Fig.
6-30). If the light of the growler does not illuminate when the tester wires are
connected across the commutator sections, the coil circuit is open and armature
needs replacement.
B-2989
Fig. 6-30 Armature Coil Continuity Test
520, 530, 533 Loader

Field Coils
(1) Measure the insulation resistance between the field coils and yoke, using a
megger meter (Fig. 6-31).
Standard insulation resistance 1M or higher
If the test indication shows poor insulation, find the cause for por insulation or
grounding by making the test with the cores removed one at a time.
(2) Make a conductor test on the four field coils using a tester (Fig. 6-32).
If the indication between the coil leads show resistance, replace the field coils. B·2995
Brushes and Brush Holder Fig. 6 - 31 Field Coil Insulation Tnst
(1 ) Check the brushes for wear, damage and broken wires and replace the
parts if defect is found.
Brush information
Standard Brush Length Limit for use
.710"(18mm) .472" (12 mm)
Check the brushes for broken springs, corrosion, distortion or weak tension.
Replace parts with defects, as necessary .
Standard spring tension . 031" (0.8 kg)
B·2994
(2) Clean the brush holders to remove carbon and check for insulation
between the brush holders and the mounting plate (Fig. 6-33). Fig. 6 - 32 Field Coil Continuity Test
Solenoid Operating Test
(1) The magnetic switch is normal if the plunger is pulled hard when 12V
power is applied between the C and M terminals and returns smoothly when the
power is removed.
NOTE: When the starter solenoid is fastened to the engine. vibration can cause
failure. Move the solenoid to the engine mounting frame. Also be sure the
connections on the solenoid have insulation covers.
6-8 CHECKING ELECTRICAL WIRING
(1) Check all wires for broken insulation and replace any bad wires.
(2) The electrical connector (between the ROPS and the mainframe) can get
Fig. 6 - 33 Check Brush Holders
corrosion. Put a sealant (water resistant) on the connector before installing.
(See the Parts Manual (or microfiche) for the part number of the sealant).
6-9 STARTER SUPPORT BRACKET
1Install a support bracket (Fig. 6-34) at the lower through bolt of the starter and the
right front engine mount if there is a failure of the starter mount. (See Parts Book or
Microfiche for correct PIN).
Fig. 6 - 34 Starter Bracket
520, 530, 533 Loader

Revised February 80
ENGINE SERVICE (520/530)
Paragraph Page
Number Number
CARBURETOR REPAIR 7-3 7-3

CHECKS AND ADJUSTMENTS 7-2 7-2
ENGINE 7-5 7-5
OIL PUMP AND RELIEF VALVE 7-8 7-7
PISTONS, RODS, CRANKSHAFT 7-9 7-7
REPAIR OF THE ENGINE 7-6 7-5
REPAIR OF THE GOVERNOR 7-4 7-4
TIMING COVER, TIMING GEARS, CAMSHAFT 7-7 7-6
TROUBLESHOOTING THE ENGINE 7-1 7-1
ENGINE SERVICE
(520, 530)
520, 530, 533 Loader

Service Mamlal
7-1 TROUBLESHOOTING THE ENGINE (520/530)
PROBLEM CAUSE CORRECTION PAGE
Engine will not turn with starter. Battery charge low. Increase charge in 'battery, find 6-2
cause for charge loss.
Cables loose or dirty. Clean and tighten cables. 6-2
Starter defect, solenoid or wiring. Check starting circuit. Make 6-3

repairs as needed.
Engine turns with starter, but is Wrong starting procedu reo See Owner's Manual for correct -
difficult to start. procedure.
No fuel in tank. Add fuel, if needed. -
Vent in fuel filler cap has Clean as needed. -

restriction.
Dirt or water in fuel system. Make repairs as needed. -
Defect in carburetor. Make repairs as needed. 7-3
Hole in fuel line. Make repairs as needed. -
Choke not closing completely. Make adjustment of linkage. -
Ign ition system has defect. Check and make repairs as 7-3
needed.
Wrong oil in engine. See Oil Specifications. 9-1
Engine has lost compression. Overhaul the engine. 7-5
Engine has overheated. Clean cool ing system, check 1-6

ignition.
Engine has little power or runs Defect in ignition system. Make repairs as needed. 7-3
rough.
Dirt or water in fuel system. Clean and make repairs as -

needed.
Choke not open. Check choke linkage. -
Governor adjustment is wrong. Check and make adjustment if 7-2

needed.
Dirty air cleaner. Check air cleaner. 1-4
Engine has lost compression. Overhaul the engine. 7-5
Engine overheats. Cooling system is dirty. Clean cooling system. 1-6
Engine air housing cover damaged Check air housing covers. -

or missing.
Ignition system set wrong. Engine Check ignition timing. Operate 7-3
is overloaded. loader with engine at full
throttle.
520, 530, 533 Loader

Revised Mar 79
7-2 CHECKS AND ADJUSTMENTS
NOTE: All engine specifications can be found in Section 9.
7-2.1 Oil Pressure
(1) Remove the sender from the engine and install a pressure gauge in the opening
(Fig. 7-1).
(2) Put the machine on jackstands. Start and run the engine until it is at operating
temperature.
(3) Check the oil pressure at idle RPM. (See Specifications, Section 9, For Correct
Pressure).
(4) Make adjustment of pressure Fig. 7-1 Checking Oil Pressure
by loosening the jam nut under No.

1 cylinder (Next to the Flywheel)
and turning the screw in or out
(Fig. 7-2).
I
ACORN SE LF LOC KI NG NUT
LOCK NUT I
7-2.2 Valve Clearance "-... :
NOTE:
(1)
Make adjustment of tappets with
engine cold.
Remove the covers from

valve chambers.
the
Eart~
-i-i (
modets have acorn nut.
I ADJUSTING
I SCREW
(2) Turn the crankshaft until there

PI-1908
is a maximum amount of clearance
between the valve and tappet. Check Fig. 7-2 Oil Pressure Adjustment
the clearance with a feeler gauge
(Fig. 7-3).
Valve-Tappet Clearance
(3) If the clearance is wrong, turn
the screw on the end of the tappet
until it is correct. (See Section 9 for
correct clearance.)
7-2.3 Compression
NOT E : Check compression with the

engine hot.
(1) Remove both spark plugs.
(2) Open the throttle and choke PI-1911

fully. Remove the coil high voltage Fig. 7-3 Valve Clearance Adjustment
wires.
(3) Install the compression gauge in the cylinder to be checked.
(4) Turn the engine several times with the starter. Check the gauge. (See
Specifications, Section 9).
7-2.4 Adjustment of the Carburetor
NOTE: Adjustment to the carburetor is to be made only when the ignition system is
correct.
7-2.5 Throttle and Governor Linkage (Fig. 7-4)
Speed Stop
(1) Put the machi ne on jackstands. Screw
(2) Disconnect the throttle linkage between the carburetor and governor arm. Hold
the throttle on the carburetor fully open, and hold the governor arms against the B-2282
stop (F ig. 7 -4). Adjust the length of the throttle linkage so it will fit.
Fig. 7-4 Throttle & Governor Linkage
520, 530, 533 Loader

(3) Push the throttle control fully ahead. The speed stop screw must be against
the stop. If not, make adjustment of the stop screw at the throttle control lever
(Fig. 7-5).
(4) Start the engine and let it run at idle RPM. Turn the screw for idle adjustment
to get the fastest idle RPM (Fig. 7-6). Then make adjustment of the idle RPM
screw for correct low idle RPM.
(5) Run the engine at full throttle and engage the auxiliary control or move the
Bob·Tach fully back to put a load on the engine. Turn the main fuel adjustment in
or out for smooth engine operation.
(6) Disengage the aux il iary control and check the high ·id Ie RPM. Turn the speed
RPM stop screw to get correct RPM. Fig. 7-5 Throttle Lever Stops
(7) Engage and release the auxiliary control at full engine RPM. If governor action
for engine RPM changes is not smooth, connect the governor spring to a lower hole
on the governor arm. If the engine RPM rapidly becomes slower, move the spring to
a higher hole in governor arm.
(8) If the location of the spring was changed, check the high idle RPM again.
7-2.6 Ignition System Adjustment

Main Fuel
(1) Install new ignition points and turn the engine until maximum point gap is Adjustment
reached. PI·1905
Fig. 7-6 Carburetor Adjustment

(2) Make an adjustment of the gap to .020" (.51 mm) (Fig. 7-7).
(3) Put Bobcat on jackstands.
(4) Remove the cover for the timing sight hole (Fig. 7-8) and turn the flywheel
until the "SP" mark is in the timing sight hole. Put a chalk mark on the "SP" mark
on the flywheel.
(5) Start the engine and run it at minimum of 1200 RPM. Use a timing light to
check the alignment of the "SP" mark with the sight hole.
(6) If alignment is not correct, loosen the 2 bolts on the governor and turn the
governor until timing is correct. Stop the engine and tighten the 2 bolts.
(7) Check adjustment of the idle RPM. Fig. 7-7 Adjust Points
7-3 CARBURETOR REPAIR
7-3.1 Removal
(1) Disconnect the hoses and linkage from the carburetor.
(2) Remove the bolt and two nuts which hold the carburetor to the engine.
Installation is the reverse of removal. Be sure to check adjustment of the linkage and
mixture screws after installation. Use a new gasket. Fig. 7-8 Timing Engine
520, 530, 533 Loader

,i
7-3.2 Disassembly and Inspection
(Fig. 7-9)
MIIIN FUEL
____ NEEDLE
(1 ) Remove both mixture screws
and springs.
(2) Remove the plug from the

float bowl. Remove the bowl from
~
the carburetor body. CARBURETOR
BODY
(3) Remove the float pin, float
and needle from the carburetor
body.
~ FUEL INLET
~7NEEDLE
(4) Remove the seat from the
& SEAT
carburetor body.
BOWL GASKET
~
(5) Clean all parts thoroughly. Do
not remove the throttle or choke
shafts. BAFFLE
(6) Check the float for bends and

damage.
(7) Check the end of the needle

valve for wear or damage.
7-3.3 Assembly
PI·1912
NOTE: Use all new gaskets during Fig. 7~ Carburetor Assembly

assembly.
(1) Install a new needle and seat assembly in the carburetor body.
(2) Put a new bowl gasket and baffle gasket in position. Put the float in
position to install the float pin.
(3) Turn the carburetor so the bottom is up. The float must be parallel to the
gasket surface of the carburetor body. If it is not, bend the tab on the float to
adjust the float position.
(4) Install the bowl with a new gasket installed on the plug.
NOTE: When gravity flow of fuel to the carburetor continues when the ignition
B-2883
switch is off (All 520 &. 530, SIN 12138 &. 8elow) install the parts for the
fuel shut-off (Solenoid Activated). When the engine continues to run after Fig. 7-10 Remove Points
the switch is turned off (Dieseling), install the carburetor with the "Anti-
Dieseling" solenoid. (The choke linkage must be replaced with a choke
cable kit) (See Parts Manual or Microfiche for Parts).
7-4 REPAIR OF THE GOVERNOR
7-4.1 Removal
(1) Disconnect the hoses and linkage from the governor.
(2) Remove screws which hold the governor in position and lift it off the
engine. Remove the shrouding from the right cylinder to reach the lower bolt.
(3) Remove the crankcase breather.
Remove the ignition point cover, ignition points and push rod (Fig. 7 -10).
520. 530. 533 Loader

Revised Oct. 80 -7-4- Service Manual
7 - 4. 2 Installation
Remove the plug from the top of the

governor adapter and ignition timing
sight hole cover. Turn the flywheel so
the D.C. mark can be seen. Install the
governor so the bevel on the gear is in
alignment with the hole in the governor
adapter (Fig. 7 - 1 1). Check the
adjustment of the timing, governor
linkage and carburetor
NOTE: On the 530 loader with engine

SIN 9224060 & up there may
be too much oil consumption
when engine has a small
amount of hours. Remove the
oil tube, elbow and adapter
that goes from the engine
block to the governor. Install
1/8" NPT plugs in the holes
which will prevent oil from
going into the carburetor
through the breather hose.
7-5 ENGINE
7 - 5.1 Removal and Installation of the

Engine
NOTE: If the engine is to be tested

out of the machine, a plate
must be installed on the pump
drive end to keep the oil in
8·2293
the engine.
Fig. 7 -11 Timing Marks
(1) Remove the battery.
(2) Remove the muffler.
(3) Disconnect the throttle and choke linkage.
(4) Disconnect the fuel line, air filter hose and wire harness.
(5) Fasten a chain or other support to hold the pump assembly and remove the
bolts which hold the pump to the engine adapter.
(6) Remove the bolts which hold the engine block to the engine adapter.
(7) Slide the engine out of the rear of the Bobcat (Weight is approximately 200
Ibs. [100 kgl]).
Installation is the reverse of removal. Be sure to install a new gasket between the
pump and pump drive housing.
Fig. 7 -12 Transmission Support

Use a chain or other support to hold the end of the pump for correct alignment during
engine installation (Fig. 7 -12).
7-6 REPAIR OF THE ENGINE
7-6.1 Flywheel
NOTE: It is not necessary to remove the engine for flywheel replacement.
Remove the shrourding and the nut from the end of the flywheel. Attach a puller on
the four bolt holes to remove the flywheel from the craankshaft (See Paragraph
6-3.3, Section 6(.
Check the flywheel for broken cooling fins, loose magnets, cracks or keyway
damage. Also check the keyway in the crankshaft for damage.
1 00 not try to replace the ring gear. If the ring gear teeth are damaged, .replace the
complete flywheel. The side with the bevel on the teeth must be toward the engine
(Fig. 7 -13).
Fig. 7 -13 Ring Gear Installation
520, 530, 533 Loader

Revised July 79
7-6.2 Repair of the Valves and Guides
(1) Remove the engine.
(2) Remove the shrouding, cylinder

heads, manifold and valve chamber
covers. Turn the crankshaft and
check the amount of valve lift. If
not enough, the cam is worn and
needs replacement. (See Section 8
for Specifications).
(3) Use a valve spring compressor

to remove the valve springs (F ig.
7-141.
NOTE: There are valve rotators under

the exhaust valve springs. The
exhaust valve springs are shorter.
The dose coils on the springs
must be towards the cylinder
heads.
(4) Check the clearance between

the valves and guides. If over
maximum, push the guides out and
install new guides. Use a reamer in
the new guide to make it the
correct size.
(5) Check the exhaust valve seats PI-1910

for wear, distortion or cracks. Use a
Fig. 7-14 Remove Valve Springs & Locks
valve seat tool to remove old seats,
if necessary.
NOT E : Only exhaust seats can be

removed.
(6) Grind the valves and seats. Use grinding compound to check that valves are
fitted correctly and seat has correct width.
7-7 TIMING COVER, TIMING GEARS, CAMSHAFT
7-7.1 Timing Cover
(1) Remove the air housing for the flywheel.
(2) Remove the bolts which hold the timing cover in position and slide it off the
crankshaft.
(3) When installing the timing cover, note the two special bolts. Install and tighten
these two bolts first (Fig. 7-15).
7-7.2 Timing Gears
While the timing cover is off the engine, the gears can be removed. The camshaft gear is
removed by putting a block of wood between the gear teeth and removing the nut from
the camshaft. Then the gear will slide off.
THIRD
Remove the snap ring from the end of the crankshaft and the crankshaft gear will slide HOLE UP
off.
If the oil pump gear is bad, make a replacement of the complete pump.
NOTE: Be sure that the crank and cam gear marks are in alignment (Fig. 7-16). Fig. 7-15 Timing Gear Cover Installation
520, 530, 533 Loader

-7-6· Service Manual
7 - 7.3 Camshaft and Tappets
The gear cover must be removed to

remove the camshaft gear. Remove all
0.1 the bolts which hold the gear cover
plate in place. Remove the cylinder
heads and valves. Turn the camshaft to
push the tappets out of the way and
slide the shaft out of the engine.
NOTE: If the camshaft is worn, also

replace the tappets. To replace
the tappets, the oil pan must
be removed.
7 - 8 OIL PUMP AND RELIEF VALVE
The relief valve for oil pressure is under Fig. 7 -16 Alignment of the Crank and Cam Gear Marks
the No.1 cylinder (Fig. 7 -17). The oil
pressure is adjusted by loosening the
jam nut and turning the screw with an
allen wrench. Oil pressure is checked
with engine idling and oil at operating
temperature. If the oil pressure can not
be adjusted, either the bearings or the
pump has a defect.
If oil pump has a defect, a replacement

must be made. To remove the pump,
remove the oil pan and take off the
strainer. Then, remove the flywheel
and gear cover. Remove 2 bolts which
hold the pump in place and lift out the
pump (Fig. 7 -18).
7 - 8.1 Adjust Gear Clearance for

Engine Oil Pump
Fig. 7 -16a Adjusting Oil Pump Gear With Feeler Gauge
When installing the oil pump on the

520 and 530 engine, it is important to
adjust the clearance between the oil
pump gear and the crankshaft gear.
The clearance between the gears is
.005" to .009" (0,127 to 0,228 mm).
A feeler gauge or a dial indicator can be
used.
To Set Clearance With Feeler Gauge:
(1) After oil pump is installed, do

not tighten the mounting bolts.
(2) Use a .007" (0,177 mm)

feeler gauge and adjust the
clearance between the oil pump
and crankshaft gear (Fig. 7 -16a). A·2642
Tighten the mounting bolts. Fig. 7 - 1 6b Adjusting Oil Pump Gear With Dial Indicator
520, 530, 533 Loader

(3) Check the clearance at two other locations (120 0 from each other) to be
sure the clearance is correct.
(4) If one or more locations do not have the same clearance, loosen the bolts
and adjust the clearance until all three locations have the same clearance.
To Set Clearance With Dial Indicator:
(1) After oil pump is installed, do not tighten the mounting bolts.
(2) Mount a dial indicator on the engine (Fig. 7 ~ 16b). Be sure the dial
indicator arm is against one of the gear teeth. Zero the dial indicator.
(3) Adjust the clearance by moving the oil pump backward and forward until
the clearance is between .005" to .009" (0,127 to 0,228 mm), tighten the
mounting bolts.
(4) Check the clearance at two other locations (120 0 from each other) to be
sure the clearance is correct.
Fig. 7 ~ 18 Remove Oil Pump
(5) If one or more locations do not have the same clearance, loosen the bolts
and adjust the clearance until all three locations have the same clearance.
7~9 PISTONS, RODS, CRANKSHAFT
(1) Remove the engine, flywheel, oilpan, strainer and oil pump.
(2) Put marks on the rods and caps. The caps, rods and pistons must be
installed in the original bores.
NOTE: The notch on the cap and notch on the rod must be together.
(3) Remove the rod bolts and caps and slide the pistons out of the engine (Fig.
7~ 19).
(4) Remove the adapter and bearing plate and the snap ring from the end of the
crankshaft. Slide the bearing plate, with bearing, off the engine.
(5) Slide the crankshaft out of the engine. Be careful to prevent damage to the C-2339
bearing in the engine block.
Fig. 7 ~ 19 Remove Piston & Connecting Rod
520,530,533 Loader
Revised Mar 79 -7~8-
Service Manual
(6) Check the following:
a. Crankshaft: keyway, diameters, round condition.
b. Rods: condition of bearing surfaces.
c. Pistons: scratch marks, ring groove clearance, cracks or damage.

PATTERN
d. Cylinder Block: condition of bearings, cylinder walls. AFTER REBORING
Use a cylinder hone to correct surface on the cylinder walls (Fig. 7-20). Check the
clearance between the piston and cylinder wall. If it is over maximum, check the
book for available sizes.
"" PI1907
If new bearing inserts are installed in block, push the bearing even with outside
Fig. 7 - 20 Using Hone on Cylinder
surface of the block. Be sure oil holes in bearings are in alignment with holes in
block.
Install the new rings on the pistons (Fig. 7-22) (See instructions on ring package.).
The early Kohler engines use connecting rods with 3/8" rod bolts. The later Kohler
engines now use 5/16" rod bolts. The old style connecting rod with the 3/8" bolt
must be tightened to 300 in.-Ibs. (34 Nm( torque. The new style connecting rod
with 5/16" bolt must be tightened to 200 in.-Ibs. (23 Nm) torque.
NOTE: Too much torque on the new style connecting rod bolts will cause seizure
of the connecting rod cap to the crankshaft.
7 - 1 0 CYLINDERHEADS
PI 1904
Use new gaskets, Put the head in position and install the bolts, make sure washers
are used. Tighten bolts to 35 ft.-Ibs. (47.5 Nm) torque in the correct sequence as Fig. 7 - 21 Checking Ring Gap
shown in figure 7-23.
7-11 INTAKE AND EXHAUST MANIFOLD Bevel Up
Put heavy flat washerslor spacers on the manifold where the bolts are used to fasten
the manifold and side baffles to engine. Put on the intake and exhaust manifold,
install the bolts and tighten to 25 ft.-Ibs. (33.9 Nm) torque.
7 - 1 2 ENGINE HEAT SHIELD
1
On all 520 loaders and 530 with (SIN 14119 & Below), a new corrective heat shield
must be installed before any weather enclosure is installed on the RaPS. See Service
Bulletin·#530-005 or current Parts Manual for kit part no. for new corrective heat
shield.
Fig.7-22 Piston & RlIlgs
Never use loader models 520 and 530

with S.N 4981-M-11 001 to SIN
4994-M-14198 with enclosed cabs
unless corrected with shield kit PIN
6561963.
The corrective shield must be used to

deflect poisonous engine exhaust
gases with carbon monoxide away
from enclosed operator cabs.
Exhaust gases can kill. Always use

with adequate ventilation and keep
A·2678
exhaust system tight with no leaks.
Fig. 7-23 Head Torque Sequence
520, 530, 533 Loader

Revised December 1979 -7-9- Service Manual
ENGINE SERVICE (533)
Paragraph Page
Number Number
ASSEMBLY OF ENGINE 8-13 8-11

CAMSHAFT 8-10 8-11
CLEANING AND INSPECTION 8-3 8-3
CRANKSHAFT BEARINGS 8-8 8-10
CYLINDER BLOCK 8-6 8-7
DISASSEMBLY AND ASSEMBLY OF
ROCKER SHAFT 8-4 8-3
DISASSEMBLY, INSPECTION AND ASSEMBLY
OF THE OIL FILTER 8-15 8-15
DISASSEMBLY, INSPECTION AND ASSEMBLY
OF THE 01 L PUMP 8-14 8-15
DISASSEMBLY OF ENGINE 8-2 8-1
DISASSEMBLY OF THE CYLINDER HEAD 8-5 8-4
ENGINE OVERHAUL 8-1 8-1
FLYWHEEL AND RING GEAR 8-9 8-11
INJECTION NOZZLES 8-17 8-17
INJECTION PUMP 8-18 8-18
MANIFOLD ASSEMBLY 8-12 8-11
PISTON AND PISTON RING ASSEMBLIES 8-7 8-8
TIMING GEAR 8-11 8-11
WATER PUMP 8-16 8-16
ENGINE SERVICE
(533)
520, 530, 533 Loader

Service Manual
8 DIESEL ENGINE (533)
8-1 ENGINE OVERHAUL
Check the following to see if the engine

needs an overhau I.
(1) Check the compression pressure

in the cylinders:
Run the engine until the coolant

reaches 750 C. Remove the injector
nozzles. To check compression
pressure in cylinders, engage the
sta rter to turn the engi ne at a
minimum of 250 RPM. The throttle
valve must be fully open.
If the compression pressure is lower

than 300 PSI (2068 kPa) the engine
needs an overhau I.
(2) Check oil consumption
High oil oonsumpation indicates

worn piston rings and valve guides.
(3) Check fuel consumption
High fuel consumption is an

indication of defect in the valves.
(4) Engine makes noise.
Noise in engine is an indication of

loose parts because of wear or other
damage.
8-2 DISASSEMBLY OF ENGINE
Remove the oil from the engine

crankcase, and remove coolant from the
cooling system.
Fig. 8-1 Fuel I njection Pump

(11 Disconnect the fuel pipe at the
connections on the fuel fi Iter and
on the injection pump (Fig. 8-1,
Item 1).
(2) Remove the bolts which hold the fuel filter and remove the fuel filter
assembly.
(3) Disoonnect and remove the injection tubelines.
(4) Disconnect and remove the leak-off tubeline from the injectors.
(5) Remove the oil filter assembly and disconnect the tubeline that gives oil
pressure for the shaft of the rocker arm.
(6) Remove the bolts which hold the timing gear cover and remove the injection
pump (Fig. 8-2).
(7) Remove the fuel injectors.
(8) Remove the indicator switch for oil pressure.
(9) Remove the bolts from the adjustment plate for the generator and the bolt for
lower mounting and remove the generator.
Remove Injection Pump
520, 530, 533 Loader

(10) Remove the blower, sheave and
belt.
(11) Remove the bolts that hold the

starter and remove the starter.
(12) Remove the dipstick and

remove the muffler and manifold
assembly.

the water pump and remove the
water pump.
(14) Bend the washer on the bolt

Fig. 8-3 Remove Crankshaft Sheave Fig. 8-4 Remove Rocker Assembly
for the crankshaft sheave. Take out
the bolt and use a puller to remove
the sheave (Fig. 8-3).
(15) Remove the timing gear cover.
(16) Remove the idle gear.
(17) Remove the Cover for the rocker arms. Remove the rocker assembly (Fig.
8-4).
NOTE: Turn each bolt in the rocker assembly 1/4 turn at a time until all of the bolts
are loose.
(18) Pull out the push rods and remove the cylinder head and gasket.
NOTE: Turn each bolt in the cylinder head 1/4 turn at a time until all the bolts are
Fig. 8-5 Remove Oil Pan
loose.
(19) Remove the crankcase and the oil pan together (Fig. 8-5).
NOTE: If the crankcase will not come away from the cylinder body, put a screwdriver
into the grooves in the crankcase to remove.
(20) Disconnect the pipe at the connection on the cylinder body side. Remove the
bolts and remove the oil pump assembly from the cylinder body.
(21) Remove the bolts from the thrust plate of the camshaft and remove the
camshaft (Fig. 8-6).
NOTE: Be careful not to make a scratch on the camshaft bearings.
(22) Remove the front plate from the engine.

Fig. 8-6 Remove Camshaft
(23) Use a magnetic tool to remove the tappets from the bottom of the engine
(Fig. 8-7).
(24) Remove the connecting·rod

caps and push out the piston and
rod assemblies through the top of
the engine (Fig. 8-8).
NOTE: 1. Remove carbon from the

upper part of the cylinder wall
before removing the piston and
rod assembly.
NOTE: 2. Make a note of the cylinder

number of each rod and bearing
cap that is removed, so that B·2835
each will be installed in the Fig. 8-7 Remove Valve Tappets Fig. 8-8 Remove the Piston
correct order.
520, 530, 533 Loader
(25) Bend the 3 lock plates and remove the bolts that hold the flywheel. Remove
the flywheel (Fig. 8-9).
NOTE: Loosen the flywheel bolts in diagonal sequence.
(26) Remove the flywheel housing.
NOTE: 1. When removing the bolts from the bearing caps on the crankshaft, loosen
them evenly, a little amount at a time.
NOTE: 2. Do not cause damage to the oil seal in the cap for the rear bearing.
NOTE: 3. Keep the bearings and bearing caps in order so that each will be installed in
correct location.
Fig. 8-9 Remove the Flywheel
(27) Remove the crankshaft pilot bearing.
(28) Remove the crankshaft bearings, caps and bearings.
(29) Remove the thrustwashers and crankshaft (Fig. 8-10).
8-3 CLEANING AND INSPECTION
(1) Wash and clean all parts to remove dirt, carbon, oil, grease or rust.
(2) Inspect the cylinder body and cylinder head for damage.
(3) Clean all oil openings in the parts with compressed air and check that each
opening is free from restriction.
B-2834
(4) Remove carbon from the pistons, cylinder head and valves carefully, to prevent Fig. 8-10 Remove the Crankshaft
scratches.
(5) Put a cylinder number mark on the valves, bearings, pistons, connecting rods so
that each will be installed in correct location.
8-4 DISASSEMBLY AND ASSEMBLY OF ROCKER SHAFT
8-4.1 Disassembly
(1) Remove the snap ring from each end of the rocker shaft. Remove the springs,
rocker arms, rocker shaft brackets and rocker shaft (F ig. 8-11).
NOTE: Keep the rocker arms from each cylinder separate so that they will be installed
in correct location.
A-2512
(2) Assemble the parts in the Fig. 8-11 Remave the Rocker Arm & Shaft
reverse order of disassembly.
Inspection
(1) Measure the outside diameter

of the rocker shaft with micrometer
(Fig. 8-12). (See Specifications
Section.)
Replace the rocker arms shaft if the

measurement is over the limit.
(2) Measure the inside diameter of

the bushings with a micrometer.
I nstall new bushings if the
A-2510 A·2520
measurements for wear are over the
limit (Fig. 8-13). Fig. 8-12 Measuring Rocker Arm Shaft Fig. 8-13 Rocker Arm
520, 530, 533 Loader

(3) Check the wear of the faces of
the rocker arms that are in contact
with the valve stem. Replace the
rocker arms if the amount of wear
is over maximum. Remove small
scratch marks on the curved face of
the rocker arms, by grinding (Fig.
8-14).
8-5 DISASSEMBLY OF THE CYLINDER

HEAD
A·2524 B-2849
(1) Disconnect the glow plug
Fig. 8-14 Grinding Rocker Arm Fig. 8-15 Remove the Valve Springs
wiring at the connectors and remove
the glow plugs.
NOTE: Put the cylinder number mark on the valves so that each will be installed in the
correct location.
(2) Use a valve spring compressor to remove valve springs and remove the split
collar, valve springs and valve (Fig. 8-15).
(3) Remove the valve seals from the valve guides.
(4) Use a tool to force the valve guides out toward the bottom of the cylinder
head (Fig. 8-16).
NOTE: If the hot plugs are to be removed, follow Steps 5 through 7.
(5) Put a cylinder number mark on each of the hot plugs.

Fig. 8-16 Remove Valve Guides
(6) Put a rod, 1/4" (5-7 mm) diameter, into the nozzle hole in the cylinder head.
Use a hammer to force out the hot plug (Fig. 8-17).
NOTE: 1. Hold rod so that it is against the upper edge of the hole with threads, as
shown in figure 8-17.
(7) Do not hit the hot plug with the rod, or damage to the heat shield can result.
8-5.1 Inspection
(1) Carefully remove carbon from the bottom of the cylinder head. Check the
cylinder head for cracks and damage. (Use a magnetic process for crack detection or
red color check)'
B-3003
NOTE: When removing carbon from the lower face of the cylinder head, be careful to
prevent scratch marks of the valve seat areas. Fig. 8-17 Remove the Hot Plug
(2) Check the lower surface of the cylinder head for distortion, in six directions,
using a straight edge and a feeler gauge. If the amount of distortion is more than
.008" (0.2 mm), correct by grinding so that maximum amount of distortion is
within .0012" (0.05 mm).
(3) Check the joining face of the intake and exhaust manifolds for distortion, in
the same manner as for checking the cylinder head. If the amount of distortion is
more than .016" (0.4 mm), correct by grinding so that maximum amount of
distortion is with in .0012" (0.05 mm).
8-5.2 Inspection of the Combustion Chambers
(1) Remove all carbon from the combustion chambers (Fig. 8-18). Check the heat
A-2521
shield and hot plug holes in the combustion chambers, for damage.
Fig. 8-18 Remove Carbon
520, 530, 533 Loader

(2) Check the hot plug fitting areas for cracks and damage and make replacement
of the cylinder head assembly if there is any damage condition to the cylinder head.
High spots or pieces on the hot plug seat area can cause poor fitting of the hot
plug.
L Clearance
8-5.3 Inspection of the Valves and Valve Guides
(1) Check for amount of wear of the valve stems in the valve guides (Fig. 8-19).
(2) Use a micrometer to measure the outside diameter of the valve stems at
locations A, Band C (Fig. 8-20).
PI·2096
Fig. 8-19 Check Valve Stem Wear
8-5.4 Inspection and Correction of the

Valve Seats
(1) Check the valve seats for Valve stem end

wrong contact or damage and
/
co rrect or replace as necessary.
Before correcting the valve seat,
check the valve gu ide and install a
new guide, when necessary.
(2) Cut the valve seat using seat

cutters of correct specification so c B
that the contact width is correct
(Fig. 8-21 & 8-22).
PI·2077
NOTE: When cutting the valve seat use Fig. 8-20 Measure Outside Diameter of Valve Stem;
a guide rod of correct diameter.
(3) If the amount of valve seat

depth is over the value indication
for need of servicing, replace the
valve seat insert (Fig. 8-23).
(4) Procedure for replacement of

the valve seat insert.
a. Use an oxy·acetylene Valve guide must be

cutting and welding torch to free from wear,
inclination and
heat the opposed 2 portions of out·of·round.
the inner face of the valve seat
insert until red hot (700 .
'\ PI·2095 PI·2098
800 0 C). Let the insert cool for
3 to 5 minutes. Use a Fig. 8-21 Using Val-ve Seat Cutters Fig. 8-22 Cutting to Correct Contact Width
screwdriver to remove the
va Ive seat inse rt.
b. Remove carbon and metal

deposit from the insert bores
in the cylinder head. Measure
the diameters of the insert
bores and select the inserts
according to the specifications
section.
(5) Press the insert all the way

into the bottom of the insert bore.
Then grind the seat face.
Fig. 8-23 Check for Correct Valve Seat Depth

520, 530, 533 Loader
(6) Check the head and stem of
the intake and exhaust valves for
wear, pointed pieces and distortion
and replace as necessary. Also check
and install a new valve if the
thickness of the valve head is less
than the limit (F ig. 8-24).
(7) Use a valve grinder to correct

the seat face of the valves to an
angle of 45 0 . Correct the valve stem
end as necessary. Thickness of valve head
(8) Put valve grinding compound B·2101 B·285!

on the seat face of the valve and Fig. 8-24 Check New Valve Fig. 8-25 Grinding the Valve Seat
use a grinding tool to grind the
valve seat (Fig. 8-25).
(9) When valve grinding is complete, check that valve contact width is within the
specifications and that the contact is correctly centered on the valve seat.
NOTE: Too wide contact width will cause carbon deposits between valve and seat. Too
narrow contact width will increase the wear of the parts.
8-5.5 Inspection of the Valve Springs Deviation of valve springs from vertical
(1) Make a visual check of the valve springs for damage. Put the valve spring on a Limit for use (mm) 1.04" (1,0 mm
surface plate and check the amount of deviation of the valve spring from vertical,
using a square. Install a new spring if the amount of deviation from vertical is over
the limit (Fig. 8-26).
(2) Check the tension of the valve springs with a spring tester. Install new valve
springs if the measured value is over the limit (Fig. 8-27).
8-5.6 Inspection of the Push-Rods and Tappets

Free
length
(1) Check the push-rods for wear or bending. Replace worn or bent push-rods.
(2) Check the face of the tappets in contact with the push-rods for wear. Replace
any tappets which have a defect.
Measure the outside diameter of the tappets with a micrometer. Install new tappets P[·2119
if the amount of reduction in the outside diameter is over the limit (Fig. 8-28). Fig. 8-26 Check Valve Springs
8-5.7 Installation of the Hot Plugs
(1) Align the round part of the hot plug with the groove in the cylinder head and
install the hot plug into position by
hitting the ci rcumference of the hot
plug, carefully, with a brass hammer.
(2) Hold a soft metal plate with

smooth surface on the hot plug to
protect the face of the hot plug
from damage.
(3) Use a hydraulic press to press

the hot plug fully into position,
slowly. Use a maximum pressure of
4 tons.
NOTE: Avoid the use of over-maximum

pressure.
A·2525
Fig. 8-27 Check Valve Spring Tension Fig. 8-28 Check Valve Tappet
520, 530, 533 Loader

(4) After the new hot plug has been installed, grind the end of the hot plug until
it is even with the cylinder head face (Fig. 8-29).
8-5.8 Assembly of the Valve System
(1) Push the valve guide into position from the upper face of the cylinder head
(Fig. 8-30 & 8-31).
(2) Install the oil seal on the valve guide.
NOTE: Install the oil seal carefully, to prevent distortion.
(3) Install the valve springs and valve spring seat. Flush
B-3004
(4) Compress the va Ive springs with the valve spri ng compressor and install the Fig. 8-29 Grind New Hot Plug to Fit
locks for the valve stem.
(5) Install the manifold gasket and manifold assembly.
8-6 CYLINDER BLOCK
8-6.1 Inspection of the Cylinder Block

for Cracks
(1) Check the cylinder block for

cracks by the magnetic or red color
method (F ig. 8-32).
8-6.2 Distortion of the Cylinder Block

Upper Surface
Standard value for

ass~mbly . . . . Below .002" (0,05 mm)
Value for need of
servicing . . . . Below .008" (0,2 mm)
Fig. 8-30 Valve Guide Location (Cross Section)

8-6.3 Correction of Cylinder Bores
(1) Use a cylinder bore gauge to

measure the cylinder bore at the
upper, middle and lower locations of
the cylinder in two directions: (1)
In line with the crankshaft. (2) At a
right angle to the cran kshaft.
Cut the cylinders to oversize if the

amount of wear is over the standard
value, or if the cylinder wall is
damaged.
(2) When measurements are taken,

find the piston oversize according to
largest bore diameter. Use a
micrometer to measure the outside
diameter of pistons at the base, in
the direction' of side thrust, at
normal room temperature (20 0 C).
C-2340
Fig. 8-31 Install Oil Seal Valve Guide Fig_ 8:-32 Check the Cylinder Block
520, 530, 533 Loader

To find the bore diameter needed for hone operation, use the following formula:
Cylinder bore diameter after hone operation = P +C- H +E
P: Piston outside diameter
C: Piston clearance
H: Amount for hone operation
E: Error in bore finish
(3) Measure the cylinder bore diameter after hone operation is complete.
B-3012
NOTE: Cylinder bores, after hone operation, must be held within .0008" (0,02
Fig. 8-33 Remove Piston Snapring
mm) of each other.
8 - 7 PISTONS AND PISTON RING ASSEMBLIES
8 - 7 . 1 Disassembly
(1) Use a piston ring expander tool to remove the piston rings from the piston.
NOTE: Keep the piston rings separate, in the sequence of the cylinder numbers.
(2) Use a snap ring pliers to remove the piston pin snap rings (Fig. 8 - 33).
(3) Heat the piston to 120 - 140 0 F (50 - 60 0 C) and remove the piston pin (Fig.
8-34).
NOTE: Keep the piston, piston pin and connecting-rod from each cylinder in
separate groups in the sequence of the cylinder numbers, to be sure of Fig. 8-34 Remove Piston Pin
assembly into their original positions.
8 - 7 . 2 Inspection of Pistons
(1) Make a visual check of the pistons for scratch marks, cracks or seizure and
replace any found to have defect.
(2) Use an outside micrometer to measure the outside diameter of the piston at
the base, at a right angle to the piston pin hole. Measure the cylinder bore
diameter at the base of the piston, with a cylinder bore gauge.
Then, compare the measured values to find the piston clearance. The standard
clearance is .004" - .005" (0,104 - 0, 124 mm) at 68 0 F (20 0 C).
NOTE: When installing new piston rings on the pistons without cutting new
cylinder sizes, measure the piston ring gaps with the piston rings held
at the lower point of the cylinder (Fig. 8- 35). Fig. 8-35 Check Piston Ring Gap
8-7.3 Inspection of Piston Ring Clearance
(1) Use a feeler gauge to measure the clearance between the piston ring and
ring groove in the piston. Take measurements at several locations around the
circumference ofthe piston (Fig. 8 - 36). (See Specifications Section.)
8 - 7.4 Assembly of Piston and Connecting-Rods
(1) Heat the piston to about 190 - 250 0 F (70 - 1 20 0 C). Align the small-end
hole of the connecting-rod with the piston pin hole and install the piston pin.
NOTE: Assemble the connecting-rod with the piston so that the side of the
connecting-rod with the cylinder number mark is toward the camshaft side
of the engine.
(2) Install the snap rings. Fig. 8-36 Check Piston Ring Clearance
520,530, 533 loader

(3) Use a ring expanding tool to
assemble the piston rings on the
piston (Fig. 8-36A).
NOTE: 1. The 1st compression ring is

chamfered.
NOTE: 2. Install the 3rd compression

ring with undercut side down.
NOTE: 3. Assemble the 1 st oil ring to

the piston with the expander
ring.
Fig. 8-36A Piston Ring Arrangement Fig. 8-37 Check Connecting Rod AI ignment
8-7.5 Connecting-Rods
(1) Check the connecting-rods for

bending, distortion and damage.
Check for alignment between the big-end and small-end.
If the amount of wrong alignment or distortion is over the value limit for servicing,
correct or replace the connecting-rod (Fig. 8-37). (See Specifications Section.)
(2) The normal clearance between the piston pin and the small-end bushing is such
that the lubricated piston pin can be pushed into the bushing with finger pressure.
Replace either the piston pin or bushing if the pin fits too loose into the bushing.
8-7.6 Clearance Between the Small-End Bushing and Piston Pin

Fig. 8-38 Check Sideplay
Standard Clearance Limit for use
below .0005" (0,013 mm) below .002" (0,05 mm)
(3) Assemble the connecting-rod on the crankshaft and use a feeler gauge to
measure the side clearance between the connecting-rod big-end and the crankpin.
Replace the connecting-rod if the clearance is over the limit (Fig. 8-38).
8-7.7 Clearance Between the Big-End Bearing and Crankpin
Standard clearance Limit for use
.008-.010" (0,2-0,25 mm) above .014" (0,35 mm)
(4) When a new bushing is fitted into the connecting-rod small-end, make the inner A-2509
face smooth with a reaming tool according to the piston pin diameter.
Fig. 8-39 Check Weight of Piston Assemblies
(5) When installing a new connecting-rod, piston or piston pin, measure the weight
of the replacement parts. Make necessary adjustment by grinding or selection of
parts, so that weight of each piston and connecting-rod assemblies is held within 15
grams of each other (Fig. 8-39).
8-7 _8 Connecting-Rod Bearings
(1) Check the connecting-rod bearings for wear, poor contact, sign of seizure or
loss of tension and replace if defect is found.
Install the connecting-rod bearing and bearing cap and tighten the bearing cap bolts
to a torque of 58 ft.-Ibs. (79 Nm). Then, measure the inside diameter of the bearing
with a cylinder bore gauge (Fig. 8-40).
B-2991
(2) If the oil clearance has increased because of wear in the crank pins, have the
crankpins cut to a smaller size and install smaller size connecting-rod bearings. Fig. 8-40 Measure Rod Bearing
520, 530, 533 Loader

8-7.9 Connecting-Rod Bearing Oil Clearance
To measure oil clearance:
(1) Wipe and clean the bearings and crankpins to remove dust and oil.
(2) Install a piece of plasti-gauge over the crankpin or bearing in the direction of
the axis of the crankshaft.
(3) Install the connecting-rod bearing cap and tighten the bearing cap bolts to the
correct torque.
NOTE: Do not move the crankshaft or connecting-rods when making this check.
(4) Remove the bearing cap bolts and bearing cap.

Fig. 8-41 Check Width of Plastic-Gauge
Remove flattened plasti-gauge and check width of plasti-gauge against the scale
printed on the instructions (Fig. 8-41 I.
NOTE: 1. Never try to file the bearings or install shims to adjust the oil clearance.
NOTE: 2. Check that the oil clearance is within specifications before installing the
piston and connecting-rod.
NOTE: 3. Have the crankpins cut to size indicated in the specifications section when
installing smaller size bearings.
8-8 CRANKSHAFT BEARINGS
(1) Check the crankshaft bearings and install them using the same method as used
for installing connecting-rod bearings.
(2) Have the crank journals ground to size indicated in specifications section when
installing smaller size bearings.
8-8.1 Crankshaft
(1) Visually check the crank journals, crankpins and oil seal fitting faces for
damage or wear and check the oil passages for restriction.
(2) Use a micrometer to measure the outside diameter of the crank journals and
crankpins. Take measurements at several locations on the crank journals and
crankpins to find the amount of wear (Fig. 8-421. Fig. 8-42 Check Crank Journals
If the amount of wear is more than .002" (0,05 mm), have the crank journals and
crankpins cut to size indicated in the specifications section and· install smaller size
bearings.
(3) Check the crankshaft for axial alignment and correct if the amount measured is
beyond the amount indicating a need for servicing (Fig. 8-431. (See Specifications
Section.)
NOTE: To check the crankshaft for axial alignment:

1) Put the crankshaft on V blocks at each end and hold the point of a dial
indicator in contact with the center journal.
2) Slowly turn the crankshaft one full turn and read the dial indicator.
(1/2 of the indication corresponds to actual crankshaft alignment).
(4) Use a feeler gauge to check the crankshaft thrust clearance at the center
bearing. If the measured value is over the limit, install oversize thrust bearing. (See
Specifications Section.)
NOTE: Install the thrust bearing so that the side with the oil groove is toward the
crankshaft thrust face. Fig. 8-43 Check for Axial Alignment
520, 530, 533 Loader

'-8-10- Service Manual
8-9 FLYWHEEL AND RING GEAR
(1) Check the ring gear for wear or damage. If wear to the ring gear teeth is in
one area, the ring gear may be removed, turn 180 0 degrees and installed again. Heat
is used to fit the ring gear to the flywheel, and it can be removed or installed again
by heating.
8-10 CAMSHAFT
(1) Check the camshaft journals, cam lobes and oil pump drive gear for wear or
damage.
(2) Use a micrometer to measure the height of the cam lobes.

B·2996
Replace the camshaft if the amount of reduction in the height of cam lobes is over Fig. 8-44 Check Camshaft Journal
the limit or if cam surfaces are found to have bad damage. Small scratch marked on
the cam surfaces can be removed with polishing stone.
(3) Use a micrometer to measure the diameter of the camshaft journals (See
Specifications Section.)
Replace the camshaft if the amount of wear is over the value indicating need for
servicing (F ig. 8-44).
(4) Measure the camshaft end play with a feeler gauge. Install a new thrust plate if
the measured value is over the value indicating need for servicing (See Specifications
Section).
To measure the camshaft end play: (Fig. 8-45)

B·3001
Install the gear on the camshaft and push the thrust plate against the cam gear. Use
a feeler gauge to measure the clearance between the thrust plate and journal. Fig. 8-45 Check Camshaft Endplay
8-11 TIMING GEAR
(1) Check the timing gears for wear and damage. Replace the timing gears if any
defect is found.
(2) Measure the clearance between the timing gears, using a feeler gauge or dial
indicator. Replace the timing gears if the amount of clearance is over maximum
specifications.
8-12 MANIFOLD ASSEMBLY
(1) Check the intake manifold for cracks, corrosion or damage. Correct or replace
the manifold as necessary.
(2) Check contact surfaces of the intake and exhaust manifolds for distortion.
Replace the part or correct by grinding if the amount of distortion is over the limit
for servicing. (See Specifications.)
8-13 ASSEMBLY OF ENGINE
8-13.1 Specia I Cautions
(1) Wash and clean disassembled parts, such as, the oil ports, bearings, pistons,
cylinders, etc.
(2) Put engine oil on the cylinder walls and the bearings and pistons.
(3) Install new gaskets at the time of assembly. Use a liquid gasket where it is
necessary to prevent oil leakage.
(4) Check the oil clearances and other clearances when assembling the parts.
(5) Tighten the bolts and studs to the correct specifications.
520, 530, 533 Loader

8-13.2 Assembly
(1) Install the upper half of the crankshaft bearing and thrust bearings on the
cylinder block (Fig. 8-46).
NOTE: Install the thrust bearings so that the side with the oil groove is away from the
crankshaft bearing.
(2) Put a thin layer of sealant on the connecting areas of the No. 1 and No. 3
bearing caps. Install the bearing caps.
(3) Install and tighten the bolts in the bearing caps to the specified torque.
(4) When the crankshaft is correctly installed, check the crankshaft for correct end
clearance (See Specifications). Fig. 8-46 Install Crankshaft Bearings
(5) Install the gasket on the No. 1 and No. 3 bearing caps. Put sealant on the
inner surface of the gasket and install the gasket ev~nly into the groove in the
bearing cap. Hold it with fingers for about 5 minutes (Fig. 8-47). Be sure the
gasket is 0 . 0.002 inch (0-0,05
mm) beyond the end of the bearing
cap.
(6) Put a thin layer of silicone

Cylinder body
rubber-base sealant on the outer
circumference of the rear oil seal.
Fill the clearance between the lips Crankshaft

of the oil seal with grease. Install
the oil seal. Setting tool
(7) Install the rear plate. ., ...
18) Fasten the flywheel to the ",Hammer

/ ' ,
crankshaft and tighten the bolts in , "
diagonal sequence to the specified

Grease
torque. Bend the lock plates over
the bolt heads (Fig. 8-48).
(9) Set the piston ring gaps so that

their gaps are 180 degrees apart
from each other. PI-2097
Fig. 8-47 Install Gasket on Bearing Caps

NOTE: Put engine oil on the cylinder
walls and around the pistons and
piston rings.
(10) Use a piston ring compressor tool to install the piston and connecting-rod
assembly. The front mark on top of the piston must be toward the water pump end
of the engine.
NOTE: The piston and connecting-rod assemblies must be installed so that the cylinder
number mark (on the connecting-rod) is toward the camshaft side.
(11) Install and tighten the connecting-rod bearing cap bolts to specifications, Then,
check connecting-rod end clearance. (See Specifications Section.)
NOTE: When the cap bolts for the connecting-rod bearings are tightened, check that the
crankshaft turns smoothly.
(12) Install the engine front plate,
NOTE: Before installing, put cement on the surface of the engine front plate in contact
with the cylinder body and injection pump and put the gasket in place.
(13) Install the tappets into position from the oil pan side, Fig. 8-48 Install the Flywheel
520, 530, 533 Loader
NOTE: Put engine oil on the tappets
and install them before installing
the camshaft.
(14) Install the camshaft. Then,

install the thrust plate on the
cylinder block.
(15) Install the oil pump assembly

and connect the oil pipes (F ig.
8-49).
NOTE: Fully tighten the oil pipe

connections.
Fig. 8--49 Install Oil Pump Fig. 8-50 Install Timing Gears
(16) Install the oil pan on the
crankcase and fasten the crankcase
to the cylinder block.
NOTE: 1. Put cement on the upper

and lower surfaces of the
crankcase, both sides of the oil "y" Marks
pan gasket and No. 1 and No. 3
bearing cap gaskets for the
crankshaft.
NOTE: 2. Let cement dry for 10 . 30

minutes.
Tighten the 4 bolts around the

bearing caps. Tighten the
remainder of the bolts evenly in
sequence, then finish tightening
the 4 bolts.
(17) Install the timing gears (Fig.

8-50).
NOTE: Install the idler gear thrust collar

"z" Marks
on the idler shaft and install the
timing gears so that the "X" and
"y" marks are in alignment (Fig.
8-50A).
(18) Install the cylinder head.
"X" Marks
(19) First tighten the cylinder head
bolts to 20 - 35 ft.-Ibs. (25 - 45
Nm) torque, in sequence, starting
with those at the center. Then,
Fig. 8-50A Timing Gear Alignment
tighten them further, to a torque of
45 ft.-Ibs. (60 Nm). Then tighten
them to the last torque of 60
ft.·lbs. (80 Nm) (Fig. 8-51).
NOTE: Put engine oil on the cylinder head bolts before installation.
(20) Connect the oil tube line for the rocker shaft.
(21) Install the push-rods.
(22) Install the rocker shaft assembly.
(23) Adjust the valves for correct clearance.
NOTE: Valve clearance adjustment is made with the engine cold. (See Specifications
Section). Fig. 8-51 Install Cylinder Head
520, 530, 533 Loader

Method of Adjustment
[1] Turn the engine and stop it when the exhaust valve on the No.2 cylinder is ready
to open. [2] Align the Top-mark on the crank sheave with the pointer on the timing gear
cover. (Piston in the No. 1 cylinder is now at the top center [TOC] on the compression
stroke.)
[3] Hold the engine stationary and adjust the intake and exhaust valve clearances on the
No.1 cylinder. [4] Adjust the intake valve on the No.2 cylinder.
[5] Turn the crankshaft one complete revolution so that the piston of the No.2 cylinder
is at the bottom center on the intake stroke. [6] Hold the engine stationary and adjust
the exhaust valve clearance on the No.2 cylinder.
(24) Install the crankshaft front oil seal on the timing gear cover and fasten the
cover with screws.
NOTE: Fill the space between the lips of oil seal with grease before installing the oil
seal.
(25) Install the injection pump and fasten it with the long bolts for the timing gear
cover. Fig. 8-52 Timing Injection Pump
NOTE: Align the mark "z" on the injection pump gear with the mark "z" on the
camshaft gear and install the cover (Fig. 8-52).
(26) Install the crankshaft sheave on the crankshaft and tighten the bolt. Bend part
of the washer over the head of the bolt.
NOTE: Put a thin layer of oil on the counterbore for the oil seal on the sheave, before
install ing the sheave.
(27) Install the injection nozzles and tighten the bolts to one-half the specified
torque.
NOTE: 1. Use corrugated washer and nozzle washer when installing the injection
nozzles. Corrugated washer must be so installed that the side of the washer with
the groove is up (Toward Nozzle) (Fig. 8-53).
2. Turn the nozzles so that the injection pipe connection is down. Nozzle assy
- Nozzle washer
. Corrugate washer
(28) Install the rocker arm cover. Heat shield
Hot J>lug
(29) Install the manifold gasket and muffler/manifold. Install the lifting hook at the
J-
rear end of engine.
(30) Install the thermostat and thermostat housing. Fasten the thermostat housing
and lifting hook with the bolts.
PI-2082
(31) Install the water pump assembly.
Fig. 8-53 Install Injection Nozzles
(32) Install the blower.
(33) Install the generator fastening bracket and the coolant temperature switch.
Install the generator and bolts. 3/16" (5 mm)
(34) Install the belt for the generator and water pump. Adjust the belt tension for
1/4" (5 mm) movement and tighten the generator bolts (Fig. 8-54).
(35) Install "0" ring on the oil filter and fasten the oil filter assembly to the
cylinder block.
(36) Connect the Injection tubelines and tighten the fastening bolts for the injection
nozzles to the correct torque. (See "Specifications", Section 9.)
(37) Connect the leak-off tubel ines to the injector nozzles.

A-2626
(38) Install the starter. Fig. 8-54 Adjust Belt Tension
520, 530, 533 Loader

8-14 DISASSEMBLY, INSPECTION AND
ASSEMBLY OF THE OIL PUMP (Fig.
8-55)
1- ~-2
1
J
(1) Disconnect the oil pipe (Fig.
8-55A).
(2) Remove the strainer case and

pump cover. Then, remove the vane. /'
(3) Remove the pin which holds

the pinion.
(4) Pull out the pin and remove

the rotor.
Fig. 8--55A Disconnect the Oil Pipe
(5) Remove the rotor shaft.
(6) Assemble the parts in the

reverse order of disassembly.
(7) When assembling operation is

completed, check that the rotor
shaft turns smoothly.
8-14.1 Inspection
(1) Make a visual check of the

vane, rotor and pinion gear for 16-
w ea r. I nstall new parts if the
amount of wear is over C·2344
specifications.
Fig. 8--55 Oil Pump Assembly
(2) Measure the clearance between
the rotor, vane and cover. (See
Specifications Section.) Make ~)';;/ ~
replacement of either the rotor or ~(r:J
the vane if the measured amount is
over the limit for servicing (Fig.
8-56). \ "
~~~{r:J
(3) Use a feeler gauge to measure C-2337
the tip clearance between the rotor
and vane. Make replacement of the Fig. 8-56 Check for Oil Pump Wear
rotor assembly if the measured
clearance is over the standard limit
(Fig. 8-57).
B-2986
(4) Measure the clearance between
the rotor shaft and pump body. Fig. 8--57 Check Rotor & Vane Clearance
Replace the parts if the clearance is
over the limit for servicing (Fig.
8-58).
8-15 DISASSEMBLY, INSPECTION AND

ASSEMBLY OF THE OIL FILTER
ASSEMBLY
8-15.1 Disassembly and Assembly (Fig.

8-59)
(1) Remove the oil filter assembly

and remove the filter element by
turning it counterclockwise.
(2) Remove the relief valve and

overflow valve. Fig. 8--58 Check Oil Pump & Rotor Clearance Fig. 8--59 Oil Filter Assembly
520, 530, 533 Loader
(3) Assemble the parts in the
reverse order of disassembly. Install
the element by turning it on hand
tight.
NOTE: Replace the filter element and

gasket after every 50 hours of
operation (Each oil change).
8-15.2 Inspection
(1) The relief valve and overflow

valve cannot be disassembled. Make
a visual check of these valves for
damage or other defect condition B·3010
and replace the valve if defect is
Fig. 8-60 Water Pump Assembly
found.
(2) To check the relief valve opening pressure, proceed as follows: Connect a
pressure gauge to the oil gallery at a point closest to the oil filter and check valve
opening pressure with engine running.
8-16 WATER PUMP (Fig. 8-60)
Narne of Parts
Ref. Name Ref. Name
1. Pulley center 7. Seal unit

2. Pump body 8. Impeller B-2997
3. Setscrew, spring washer 9. Gasket
4. Screw plug 10. Cover Fig. 8-61 Loosen Bearing Setscrew
5. Bearing unit 11. Screw
6. Thrower
8-16.1 Disassembly of the Water Pump (Fig. 8-60)
(1) Remove the rear cover from the body and loosen the bearing setscrew (Fig.
8-61).
(2) Remove the pulley center using a puller (F ig. 8-62).
(3) Remove the shaft and impeller from the body using a bench press (Fig. 8-63).
NOTE: The impeller is made of cast iron. Do not use hammer to remove it.
8-16.2 Inspection
(1) Check the disassembled parts for wear, cracks or other damage and replace the Fig. 8-62 Remove Pulley Center
pump if defect is found.
(2) Check the shaft for straight condition.
(3) Check for loose bearing unit. Replace the bearing unit if the bearing unit is
loose by more than .008" (0,2 mm).
8-16.3 Assembly (Fig. 8-60)
(1) Install the thrower (Item 6) and seal unit (Item 7) on the bearing seat location
on the shaft.
NOTE: Install the seal unit so that the side with the spring is toward the impeller.
(2) Install the shaft in the water pump body from the pulley side. Use a bench
A·2528
press and align the screw hole in the water pump body with screw hole for the
outer bearing race (Fig. 8-64). Fig. 8-63 Remove Shaft and Impeller
520, 530, 533 Loader
(3) Use a be nch press to install the
impeller on the shaft.
a. There must be a clearance

of about .040" (1 mm)
between the rear face of the
impeller and the inner face of
the pump body.
b. St a nd ard clearance
between outer circumference
of the impeller and pump
body is .047 - .051" 0,2-1,3
A-2523
mm) (Fig. 8-65). B-2999
Fig. 8-64 Install Pump Impeller Shaft Fig. 8-65 Impeller & Pump Body Clearance
(4) Use a bench press to install the
pulley center (Fig. 8-66).
(5) Tighten the setscrew and install

the rear cover.
(6) When assembly operation is

completed, check that fan center
turns smoothly.
8-17 INJECTION NOZZLES
The nozzles have an injection orifice size Fig. 8-66 Install Pulley Center
of .039" (1 mm) in diameter and have
the spray angle of 4 0 degrees. Fuel
injection pressure (breaking pressure) is set to 1720 PSI (11860 kPa) by an adjustment
screw (Fig. 8-68, Item 5).
To remove the nozzles:
(1) Remove the high and low pressure tubelines.
(2) Use a wrench to remove the nozzle holder and nozzle assembly.
Diesel fuel under pressure can go through

the skin and cause injury. Keep your
hands away from the nozzle spray area.
(1) Install the nozzle on a nozzle tester and put pressure of 1435 PSI (9880 kPa)
continuously and check for sign of leakage (F ig. 8-67).
(2) Increase the testing pressure to 4300 PSI (29640 kPa) by turning the
adjustment screw in and check the time taken for pressure to decrease from 3580
PSI (24700 kPa) to 2860 PSI (19760 kPa).
A-2513
If the time is less than 5 seconds, install new nozzle assembly. Fig. 8-67 Testing Nozzle
520, 530, 533 Loader

8-17.2 Disassembly of the Nozzle Holder
Assembly (Fig. 8-68) 3
(1) Fasten the body of the nozzle 8 910 11 12 13
14
holder (Item 4) in a vise and c..::::::::::::ff!\.rrr?Tn;:,,/ II / 1/ / 1516 )7
remove the cap nut, (Item 14) being
careful not to put a scratch on the
@OO= I
O@~
I
nozzle holder.
(2) Remove the nut and

adjustment screw (Item 11 & 12) and
take out the washers, nozzle spring
and the push rod (Item 7, 8, 9 &
C·2345
10).
Fig. 8-68 Nozzle and Holder Assembly
(3) Remove the nozzle nut (Item
1) and take out the nozzle
assembly (Item 2), then remove the
bushing (Item 3). Keep the nozzle
assembly in clean kerosene or diesel
fuel.
(4) Remove the inlet connector assembly together with the gasket (Item 10) and
take out the edge filter (Item 6).
8-17.3 Inspection of the Nozzle and Nozzle Holder Assemblies
(1) Wash the needle valve and nozzle body in kerosene or diesel fuel. Tilt the
nozzle body to an angle of 60 0 from vertical and check that the need Ie valve sl ides
out smoothly. If the needle valve is not free or if its sliding movement is very
loose, replace the nozzle assembly.
a. Check the seat area and the tip on the need Ie valve for wear. Replace the
nozzle if it is worn. Fig. 8-69 Remove Injector Fuel Lines
(2) Nozzle holders.
a. Check the thread areas of the nozzle holders for wear or damage. Replace the
nozzle assembly if a defect is found.
b. Check the nozzle springs for weak condition, corrosion or damage.
c. Check the push·rods for bending and the surface in contact with the needle
valve for wear and magnet effect.
d. Check the upper surface and needle valve seat area on the nozzle body for
wear or scratch marks.
8-17.4 Assembling the Nozzle
Assemble the nozzle in the reverse order of disassembly and note the following: Fig. 8-70 Remove Injection Pump
(1) Wipe and clean the contact areas of the nozzle and body of the nozzle holder
to remove any oil. Install the nozzle into the body of the nozzle holder and tighten
the nozzle nut.
Install NEW gaskets at the time of assembly.
8-18 INJECTION PUMP
8-18.1 Removal of Pump
(1) Remove the fuel supply line and high pressure tubelines to the injectors (Fig. 8-69).
(2) Remove the six bolts which hold the injection pump to the engine. (These bolts
are on the timing gear cover).
(3) Remove the injection pump (Fig. 8-70).

520, 530, 533 Loader
8-18.2 To Remove the Pump Drive Gear
(1) Remove the nut and lockwasher from the injection pump shaft (F ig. 8-71).
(2) Use a gear puller to remove the gear.
8-18.3 To Install the Pump Drive Gear
(1) Insert the key and align the key groove on the gear with the key groove on
the pump shaft when installing the gear.
(2) Install the lockwasher and nut. Tighten the nut to 40 ft.·lbs. (54 Nm) torque.
B·2979
8-18.4 Installation and Timing of Injection Pump
Fig. 8-71 Remove Pump Drive Gear
(1) Remove the cover from the hole for visual timing of the injection pump gear
(Fig. 8-72).
(2) Install the injection pump and gear so that the "Z" marked tooth on the
pump gear is between the two "Z" marked teeth on the camshaft gear.
(3) Tighten the fastening bolts for the injection pump to 12 ft.-Ibs. (16 Nm)
torque.
(4) Check to see that the timing mark on the pump flange (Fig. 8-73) is in
alignment with the mark on the pump mounting bracket. If the marks are not in
alignment, loosen the three fastening nuts and turn the pump to adjust until marks
are in correct alignment.
A·2506
Fig. 8-72 Timing Injection Pump Gear
Fig. 8-73 Timing the Injection Pump
520, 530, 533 Loader

TECHNICAL DATA
Paragraph Page
Number Number
DEISEL ENGINE TORQUE SPECIFICATIONS (533) 9-7 9-4

ITS, CLEARANCES, ADJUSTMENTS (520/530) 9-12 9-5
FITS, CLEARANCES, ADJUSTMENTS (533) 9-13 9-6
FUEL SPECIFICATIONS 9-1 9-1
GASOLINE ENGINE TORQUE SPECIFICATION
(520/530) 9-6 9-4
GENERAL TORQUE SPECIFICATION 9-14 9-9
HYDRAULIC/HYDROSTATIC SYSTEM 9-10 9-4
HYDRAULIC MOTOR TORQUE SPECIFICATIONS 9-9 9-4
HYDROSTATIC PUMP TORQUE SPECIFICATION 9-8 9-4
LOADER SPECIFICATIONS (520/530) 9-3 9-2
LOADER SPECIFICATIONS (533) 9-4 9-3
LOADER TORQUE SPECIFICATIONS 9-5 9-4
LUBRICANTS 9-2 9-1
SEAL INSTALLING TOOL 9-11 9-5
TECHNICAL
DATA
520, 530, 533 Loader

Service Manual
9 SPECIFICATIONS
9-1 FUEL SPECIFICATIONS
Gasoline Engine - Regular or low-lead gasoline with minimum octane rating of 85.
Diesel Engine - #2 Diesel fuel. Use No. 1 Diesel fuel in temp. below + 20F (-6C).
9-2 LUBRICANTS
9-2.1 Gasoline Engine (520/530)
-34 -29 -23 -18 -13 -7 -1 +4 +10 +15 +21 +27 +32 +38
FO -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
(API SERVICE CLASSIFICATION SC)

TEMPERATUER RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
AWARNING Do not overfill engine crankcase!
9-2.2 Diesel Engine (533)
-34 -29 -23 -18 -13 -7 -1 +4 +10 +15 +21 +27 +32 +38
FO -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
(API SERVICE CLASSIFICATION CC)

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
9-2.3 Hydraulic System
If the system oil level is low or the oil is being changed, use 10W-30 or 10W-40 engine
oil (Classification SE) oil when filling the reservoir.
System Capacity: Approximately 5.5 gallons (21 Liters)
Reservoir Capacity: 3.5 gallons (13 Liters)
9-2.4 Chaincase
Fill with 10W-30 or lOW-40 engine oil.
Capacity: Approximately 4 gallons (15 Liters)
520, 530, 533 Loader

9-3 LOADER SPECIFICATIONS (520/530)
/
/
,/,-~I
I
'"
970
t
127.5
,'" ~:/:Z~t;.~.,r--' ", (3238)
'~'1-_-_-__-_-_-_'-';_;-=...-_7---,
, I
, I
72.5
(1841)
(1199)
PI·1BS7
PI·1857
Dimensions are given for loader equipped with dirt Where applicable,
bucket and may vary with other bucket types. All specifications conform to
dimensions are shown in inches. Respective metric ICED & SAE standards
dimensions are given in millimeters enclosed by and are subject to change
parentheses. without notice.
9-3.1 Operating Specifications Bore and Stroke . . . . . . . . 3.5 x 3" Cylinders . Doubleacting
(88,0 x 76,2 mm)
Operating Weight . 3075 Ibs. (1396 kg) Displacement .. . 57.7 in. 3 (946 cm 3 ) Function Tilt Lift
Rated Capacity. .. 800 Ibs. (363 kg) Cooling System . . . . . . . Forced Air Bore 3.0 (76,20) 2.G (50,80)
Cycle Times: Air Filter . . . . . Replaceable dry type Stroke 12.4 (314,96) 22.2 (563,88)
Lift ... .4.0 sec. Crankcase Ventilation .. Internal Breathing Rod 1.50 (38,10) 1.25 (31,75)
Lower .. . 3.0 sec.
Tilt ... .2.5 sec. 9-3.3 ELECTRICAL 9-3.5 POWER TRAIN
Rollback .. 2.0 sec.
Travel Speed .0 - 5.5 MPH (8,9 Km/hr) Generator ... 15 amp. flywheel generator Transmission ... Both sides independent.
Controls: with external rectifier Infinitely variable hydrostatic
Vehicle .. . Steering, direction, speed Starter ... 12 volt gear drive with remote primary drive. Single chain reduction
controlled by two hand levers. R.H. lever solenoid fi nal drive.
moves sideways to control auxiliary Fuses. . 2, 30 ampere, on the dash panel
hydraulic circuit. & at coil 9-3.6 CAPACITIES
Loader . . . . . . Hydraulic lift and tilt Battery. . . . . . . . . . . . . . . . . 12 vo It
controlled by left and right foot Circuit Breaker .. On indicator lamps and Fuel Tank . . . . . . · . . . . 10 gal. (38 L)
pedals. hr. meter Chaincase · . . . . .4 gal. (15 L)
9-3.4 HYDRAULIC SYSTEM Hydraulic Reservoir .3.5 gal. (System: 5.5
gal. [21L])
Pump . . . . . . . Engine driven vane-type Engine Oil · .... .4 qt. (3,8 L)
9-3.2 ENGINE System Design . Series - open center valve
System Release Pressure . . . . . 1500 psi 9-3.7 TIRES
Make and Model . . . . . . . . Kohler K582 (10343 kPa)
Type . . . . . . . . . . .2 cylinder, opposed Pump Volume, @ 2500 RPM .. 8.33 gpm Standard.. .5.70 x 15,55 psi (379 kPa)
Fuel . Leaded or non-leaded gasoline with (32 l/min.) Flotation.. . . . . . 8.50 x 15,33 . 37 psi
minimum octane rating of 85 Hydrostatic Charge Pressure .. 55 - 75 psi (240 kPa)
Horsepower . . . . . . . 19 Bhp (14,3 Kw) (379 - 517 kPa)
at 2500 RPM Filters .. 10 micron for hydrostatic drive.
Maximum Torque .40.8 ft.-Ibs. (55,3 Nm) Filter screen in reservoir fill for
at 2200 RPM hydraulic system.
520, 530, 533 Loader

9-4 LOADER SPECIFICATIONS (533)
~1------~4
/ / 1
/ 1
_ 1,'-_,
1
127.5
~'::r:-o.~/! " (3238)
"~I '
' ..- - - - - I - - J
" , \
\
"~)-:------r~~
1
72.5
85
(2159)
(1841)
PI·2218
Dimensions are given for loader equipped with dirt Where applicable,
bucket. And may vary with other bucket types. All specifications conform to
dimensions are shown in inches. Respective metric ICED & SAE standards
dimensions are given in millimeters enclosed by and are subject to change
parent heses. without notice.
9-4.1 Operating Specifications Maximum Torque ... 40 ft.-Ibs. (54 Nm) Cylinders ... Doubleacting
at 2000 RPM
Operating Weight .. 3300 Ibs. (1500 kg) Bore and Stroke . . . . . . . 3.38 x 3.30" Function Tilt Lift
Rated Capacity . . . . . . 800 Ibs. (363 kg) (86 x 83 mm) Bore 3.0 (76,20) 2.0 (50,80)
Cycle Time: Displacement . . . . . . . . . 60 in. 3 (1 L) Stroke 12.4 (314,96) 22.2 (563,88)
Lift . . . . . . . . . . . . . . . . . 4.0 sec. Cooling System . . . . . . . . . . . . Liquid Rod 1.50 (38,10) 1.25 (31,75)
Lower . . . . . . . . . . . . . . . . 3.0 sec. Air Filter . . . . . . . Replaceable dry type
Tilt . . . . . . . . . . . . . . . . . 2.5 sec. Crankcase Ventilation . External Breathing 9-4.5 POWER TRAIN
Rollback . . . . . . . . . . . . . . 2.0 sec.
Travel Speed .. 0 - 5.5 MPH (8,9 Km/hr) 9-4.3 ELECTRICAL Transmission ... Both sides independent.
Controls: I nfinitely variable hydrostatic
Vehicle . . . . Steering, direction, speed Generator . . . . . . . . . 37 ampere, open primary drive. Single chain reduction
controlled by two hand levers. R.H. lever Starter . . . . . . . . . . . 12 volt gear drive final drive.
moves sideways to control auxiliary Battery . . . . . . . . . . . . . . . . 12 volt
hydraulic circuit. Fuse . . . . . . . . . . . . . . On dash panel 9-4.6 CAPACITIES
Loader . . . . . . Hydraulic lift and tilt
controlled by left and right foot Fuel Tank . . . . . . . . . . 11 gal. (41,6 L)
pedals. 9-4.4 HYDRAULIC SYSTEM Chaincase . . . . . . . . . . . .4 gal. (15 L)
Hydraulic Reservoir . . . . . . . 3.5 (13 L)
Pump . . . . . . . Engine driven vane-type (System: 5.5 gal. [21 LJ)
System Design . Series - open center valve Engine 0 il . . . . . . . . . . 4 qts. (3,8 L)
System Release Pressure . . . . 1500 psi Cooling System . . . . . . 10 qts. (94,6 L)
(10343 kPa)
9-4.2 ENGINE Pump Volume, @ 2500 RPM .. 8.33 gpm 9-4.7 TIRES
(32 l/min.)
Make and Model . . . . . . . ISUZU 2AA 1 Hydrostatic Charge Pressure .. 55 - 75 psi Standard . . . . 5.70 x 15,55 psi (379 kPa)
Type . . . . . . . . 2 cylinder diesei engine (379 - 517 kPa) Flotation . . . . . . . . 8.50 x 15,33-37 psi
Fuel . . . . . . . . . . . . . . . . #2 Diesel Filters .. 10 micron for hydrostatic drive. (240 kPa)
Horsepower . . . . . . . . 19 Bhp (14 Kw) Filter screen in reservoir fill for
at 2500 RPM hydraulic system.
520, 530, 533 Loader

9 - 5 LOADER TORQUE SPECIFICATIONS
The following special torque specs must be used on the 520, 530 & 533 loaders:
Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-85ft.-lbs. (95-120Nm)

Axle-to-SprocketBolts . . . . . . . . . . . . . . . . . 240- 300ft.-lbs. (325.4-406,8 Nm)
Bolts through Rubber Pump, Engine Mounts and
Operator Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35ft.-lbs.(47,5Nm)
UprightFrame-to-AxleHousing . . . . . . . . . . . . 95-120ft.-lbs. (128,8-162,7 Nm)
Steering LinkageSpring . . . . . . Tighten bolt until spring is 2.5" - 2.75" (63, 5- 70 mm)
long with levers in neutral position.
Hydraulic Cylinder Piston Nuts: . . . . . . . . . . . . Lift 11 0-1 20ft.-lbs. (149 -163 Nm)
Tilt 21 0 - 260 ft.-Ibs. (285 - 382 Nm)
MotortoSprocketNut . . . . . . . . . . . . . . . . . . . . . 300-400ft.-lbs. (407 - 542 Nm)
SplineAdapterScrew . . . . . . . . . . . . . . . . . . . . . . 20-25ft.-lbs.(27, 1-33,9Nm)
Motor-to-Transmission Fastening Nuts . . . . . . . . . . . . 70- 85 ft.-Ibs. (9 5-1 20 Nm)
AlternatorSheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . 40- 60ft.-lbs. (54- 81 Nm)
Pumpto Engine Fastening Nuts . . . . . . . . . . . . . . . . . . . 65- 70ft.-lbs. (81 - 9 5 Nm)
I
Pum p High Pressure "Banjo" Fittinqs
(HollowScrew) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150ft.-lbs. (203Nm)
9-6 GASOLINE ENGINE TORQUE SPECIFICATIONS (520/530)
PumpCouplertoShaft . . . . . . . . . . . . 30-35ft.-lbs. (40.7 - 47,5 Nm)

Flywheel Retaining Nut . . . . . . . . . . . 115 ft.-Ibs. (155,9 Nm)
Camshaft Retaining Nut . . . . . . . . . . . 40 ft.-Ibs. (54,2 Nm)
Oil Pan Screws . . . . . . . . . . . . . . . . . 30 ft.-Ibs. (40,7 Nm)
Manifold Screws . . . . . . . . . . . . . . . 25 ft.-Ibs. (33,9 Nm)
Closure Rlate Screws . . . . . . . . . . . . 30 ft.-Ibs. (40,7 Nm)
Connectrng Rod * * with 3/8" bolts .. . 300 in.-Ibs. (34Nm)
Connecting Rod * * with 5/1 6" bolts .. 200 in.-Ibs. (23 Nm)
Spark Plug . . . . . . . . . . . . . . . . . . . 20 ft.-Ibs. (27,1 Nm)
I
Cylinder Head Bolts . . . . . . . . . . . . .
* * Lightly oiled treads
35 ft.-Ibs. (47,5 Nm)
9 - 7 DIESEL ENGINE TORQUE SPECIFICATIONS (533)
Crankshaft Bearing Cap Bolts ....... 120 ft.-Ibs. (163 Nm)

Flywheel to Crankshaft Bolts . . . . . . . . 58 ft.-Ibs. (79Nm)
Connecting Rod Bearing Cap Bolts . . . . 58 ft.-Ibs. (79 Nm)
Camshaft Thrust Plate Bolts . . . . . . . . 50 ft.-Ibs . (68 Nm)
Crankshaftto Block Bolts . . . . . . . . . . 15 ft.-Ibs. (20Nm)
Oil Pan Bolts .................. 6 ft.-Ibs. (8Nm)
Cylinder Head Bolts . . . . . . . . . . . . . . 60 ft.-Ibs. (80Nm)
Rocker Arm Assembly Bolts ........ 20 ft.-Ibs. (27 Nm)
Crankshaft Pulley Bolt . . . . . . . . . . . . 108 ft.-Ibs. (146 Nm)
Injection Nozzle Holding Bolts . . . . . . . 54 ft.-Ibs. (73Nm)
9 - 8 HYDROSTATIC PUMP TORQUE SPECIFICATIONS
AII3/8 Assembly Bolts . . . . . . . . . . . . 42 ft.-Ibs. (57 Nm)

Couplerto Shaft . . . . . . . . . . . . . . . . 20 - 25 ft.-Ibs. (27 - 34 Nm)
9 - 9 HYDRAULIC MOTOR TORQUE SPECIFICATIONS
Motor Assembly Bolts . . . . . . . . . . . . 45 - 55 ft.-Ibs. (61 -75 Nm)

SprockettoMotorNuts . . . . . . . . . . . 300 - 400 ft.-Ibs. (407 - 542 Nm)
9 - 10 HYDRAULlC/HYDROST ATIC SYSTEM
Vane Pump Flow at 2500 RPM

and 1000 PSI (6895kPa) . . . . . . . . . . . . . . . . . . 8.1 gpm 1/min. (30,66 L/Min.)
Hydraulic Release Pressure . . . . . . . . . . . . . . 1 500-1 600 PSI (10340-11030 kPa)
HydraulicFilterElement . . . . . . . . . . . . . . . . . . 1 Om nominal, without bypass valve
Release Pressure at Bypass Valve at Full
EngineRPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-83PSI(460-570kPa)
RossMotorShaftEnd Play. . . . . . . . . . . . . . .. .005- .025 in. (0, 127 -0,635 mm)
520,530,533 Loader
Revised July 79 -9-4- Service Manual
9-11 SEAL INSTALLING TOOLS
Axle Seal Installing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN 6558009

Pump Seal Installing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacture Locally
Motor Seal Installing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN 6558458
Motor Sprocket Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN 6559551
9-12 FITS, CLEARANCES, ADJUSTMENTS (520/530)
9-12.1 Engine
Ignition Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .018 - .022 (,46 - ,56)

Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .025" (,6)
Compression at Cranking Speed . . . . . . . . . . . . . . . . 100 - 120 PSI (689 - 827 kPa)
High Idle at no Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2700 RPM
Low Idle at no Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM
Oil Pressure (@ Idle RPM) . . . . . . . . . . . . . . . . . . . . . 40 - 50 PSI (276 - 345 kPa)
9-12.2 Cylinder Bore
INCHES MILLIMETERS
New Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.500 88,9

Wear Diameter (Maximum) . . . . . . . . . . . . . . . . . . . . 3.503 88,976
Taper (Maximum) . . . . . . . . . . ........... . 0.0015 0,038
Out-of-Round (Maximum) . . . . . . . . . . . . . . . . . . . . . 0.005 0,127
9-12.3 Crankshaft
End Play . . . . . . 0.004-0.010 0,1 02-1 ,254

Crankpin - New Diameter . . . . . . . . . . . . . . . . . . . . . 1.625 41,275
Crankpin - Maximum Out-of-Round . . . . . . . . . . . . . . . 0.0005 0,013
Crankpin - Maximum Taper . . . . . . . . . . . . . . . . . . . 0.001 0,025
Crankshaft Sleeve Bearing-R unning Clearance 0.0015-0.005 0,038-0,127
9-12.4 Camshaft
End Play . . . . . 0.017-0.038 0,432-0,965

Shaft to Bearing Clearance .. 0.0005-0.0035 0,013-0,089
9-12.5 Connecting Rod
Big End - Maximum Wear Diameter 1.627 41,326

Rod to Crankpin - Maximum Clearance . . . . . . . . 0.0035 0,089
Small End - New Diameter . . . . . . . . . . . . . . . . . . 0.87585 22,246
Rod to Piston Pin - Clearance . . . . . . . . . . . . . . . . . . 0.0003.{).0008 0,008-0,020
Side Play on Crankpin . . . . . . . . . . . . . . . . . . . . . . , 0.005-0.014 0,127-0,356
9-12.6 Piston, Pin & Rings
Thrust Face * - Maximum Wear Diameter 3.4945 88,760

Thrust Face* to Bore - Maximum Clearance . . . . . . . . . 0.007-0.010 0,178-0,254
Ring - Maximum Side Clearance. . . . . . . . . . . . . . . . . 0.006 0,152
Ring - End Gap in Used Bore . . . . . . . . . . . . . . . . . . 0.030 0,762
Pin to Boss Clearance (Loose) .. . . . . . . . . . . . . . . 0.0005 0,013
Pin to Rod Clearance . . . . . . . . . . . . . . . . . . . . . 0.0003-0.0008 0,008-0,020
9-12.7 Valves, Guides, Tappets
Intake Valve to Tappet - Cold Clearance . . . . . . . 0.008-0.010 0,203-0,254

Exhaust Valve to Tappet - Cold Clearance . . . . . . 0.017-0.020 0,432-0,508
Valve Lift - Zero Lash . . . . . . . . . . . . . . . . . . 0.324 8,230
Intake Valve Stem to Guide - Max. Clearance ... . 0.0045 0,114
Exhaust Valve Stem to Guide-Max. Clearance. . . . . 0.0065 0,165
Tappet Clearance in Guide . . . . . . . . . . . . . . . . . . . . 0.0012-0.0023 0,030-0,058
Guide Interference F it in Block . . . . . . . . . . . . . . . . . 0.0005-0.002 0,013-0,051
Guide Ream Diameter . . . . . . . . . . . . . . . . . . . . . . . 0.312-0.313 7,9248-7,950
Valve Seat Angle (Degrees) .................. . 45 0
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . .030" ,762
*Measured just below oil ring at right angles to pin.
520, 530, 533 Loader

9-13 FITS, CLEARANCES, ADJUSTMENTS (533)
9-13.1 Cylinder Compression (@ 250 RPM) . . . . (Minimum) 284 PSI (1945 kPa)
9-13.2 Valves
Intake valves open <:t (B.T.D.C.) . 11 0

I ntake valves close at (A.B.D .C.) . 49 0
Exhaust valves open at (B.T.D.C.) 51 0
Exhaust valves close at (A.B.D.C.) .90
Valve clearances (intake valves) (mm) ... .018" (,45 mm)
Valve clearances (exhaust valves) (mm) .018" (,45 mm)
9-13.3 Fuel Injection Timing ... 180 B.T.D.C.
9-13.4 Injection Pressure .1706 PSI (11762 kPa)
9-13.5 Glow Plugs
Voltage (V) Current (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5V, 5.5A
9-13.6 Starting Motor:
Voltage (V) Output (KW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V, 1.2KW
9-13.7 Generator:
Voltage (V) Capacity (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12VAC, 37A
9-13.8 Oil Pump
Lubricating Method Pressurized Circulation
Oil pump type Trochoid type
Oil pump delivery

Pump speed: 1400 rpm
Pressure of delivery: 57 PSI (393 kPa)
Oil temperature: 50 0 C
Oil filter type Full-flow type with paper element
Relief valve opening pressure 64 PSI (441 kPa)
9-13.9 DIMENSIONAL SPECIFICATIONS
9-13.10 Cylinder Head
Distortion of Cylinder Head Face, standard . . . . . . . . . . . . . . . . " .122" (3,1 mm)

Limit for use above .142" (3,6 mm)
Rocker Arm Shaft Diameter, normal ........ . .748" (19 mm)

Limit for use .742" (18,85 mm)
Clearance between Rocker Arm

Shaft and Bushing, standard ..... " .0016" (,04 mm)
Limit for use .008" (,2 mm)
Valve Stem Diameter, normal. . . . . . . . . . . . . . . . .. . . . . . . . . . .315" (8 mm)

Limit for use .310" (7,88 mm)
Clearance between Valve Stem and Valve Guide Intake Exhaust
(Standard Valve) .002" (,05 mm) .003" (,08 mm)

(Limit for use) .008" (,02 mm) .010" (,25 mm)
520, 530, 533 Loader
Valve Contact with Seat (Intake & Exhaust)
Standard contact width . . . . . . . . . . . . . . . 047" - .059" (1,2 - 1,5 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . above .079 (2 mm)
Valve Seat Depth, normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 (3,1 mm)

Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .142 (3,6 mm)
Valve Clearances
Intake and Exhaust (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . .018" (,45 mm)
Valve Seat Inserts
Insert Bore Insert Outside

Diameter Diameter
Intake 1.575" - 1.576" (40 - 40,03 mm) 1.579" - 1.580" (40,11 - 40,13 mm)
Exhaust 1.339" - 1.340" (34 - 34,03 mm) 1.343" - 1.344" (34,11 - 34,13 mm)
Thickness of Valve Head, standard .05" (1,3 mm)

Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .039" (1 mm)
Valve Spring Deviation (From Vertical) . . . . . . . . . . . . . . . . . . . . . . .039" (1 mm)
Valve Spring Tension
Free Length Tension (Length - 1.30" [33 mml )

Standard 1.535" (39 mm) 29.3 - 33.7 Ibs. (13,3 - 15,3 kg)
Limit for use 1.48" (37,7 mm) 24.9 Ibs. (13,3 kg)
9-13.11 Cylinder Block
Distortion of Upper Surface, standard .002" (,05 mm)

Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008" (,2 mm)
Cylinder Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.386" (86 mm)

Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .016" (,4 mm)
9-13.12 Piston Rings
Gap Clearance, 1st, 2nd & 3rd Compression Rings

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . · .. .008" - .016" (,2 - ,4 mm)
Limit for use . . . . · . . . . . . . . . . .079" (,2 mm)
1st & 2nd Oil Rings

Standard . . . . . . . . . . . . . . . .. .004" - .012" (,1 - ,3 mm)
Ring Groove Clearance, 1st Compression Ring

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .. .002" - .003" (,045 - ,075 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012" (,3 mm)
2nd & 3rd Compression Rings

Standard . . . . . . . . . . . . . . . . . . . .001" - .002" (,030 - ,060 mm)
Limit for use . . . . · . . . . . . . . . . .012" (,3 mm)
1st & 2nd Oil Rings

Standard . . . . . . . . . . . . . . . . . . . . . . . . . .. .0008" - .002" (,020 - ,054 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .006" (,15 mm)
9-13.13 Connecting Rods
Alignment between big end and small end (Per 3.94" [100 mml)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below .002" (,05 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . above .006" (,15 mm)
520, 530, 533 Loader

Piston Pin Clearance
Standard . . . . . . .0003" .. 0001" (,008 - ,020)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .002" (,05 mm)
Big End & Crankpin Side Clearance

,Standard . . . . . . . . . . . . . . . · .. 008" - .010" (,18 - ,30 mm)
,Limit for use . . . . . . . . . . . . . . . . . . . · . . . . . . above .014" (,35 mm)
Connecting Rod Bearing & Crankpin Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . .0016" (,04 mm)
Limit for use .. . . . . . · . . .. .005" (,12 mm)
9-13.14 Crankshaft
Crankpin Outside Diameters
Bearing Size Crankpin Size
Standard 2.087"(53 mm)

Undersize .010" (,25 mm) 2.077~' (52,75 mm)
U/S .020" (,50 mm) 2.067" (52,50 mm)
U/S .030" (,75 mm) 2.057" (52,25 mm)
U/S .040" (1 mm) 2.047" (52 mm)
Crankshaft Bearing Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .. .001" - .Ocxt.' (,029 - ,085 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . agave .005" (,12 mr.1)
Crankshaft Journal Outside Diameters
Bearing Size Journal Size
Standard 2.756" (70 mm)

U/S .010" (,25 mm) 2.746" (69,75 mm)
U/S .020" (,50 mm) 2.736" (69,SO mm)
U/S .030" (,75 mm) 2.726" (69,25 mm)
U/S .040" (1 mm) 2.716" (69 mm)
Crankshaft Run-Out
Standard . . . . . . . . . . . . . . . . . . . · . . . . . . below .001" (,03 mm)
Limit for use . . . . . . . . . . . . . . . . · . . . . . . above .002" (,06 mm)
Crankshaft Thrust (End Play) Clearance

Standard . . . . . . . . . . . . . . . . . . . . . . . . .004" (,10 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .019" (,30 mm)
9-13.15 Camshaft
Height of Cam Lobes

Standard . . . . . . . . . . . . . . . . . 1.319" (33,5 mm)
Limit for use . . . . . . . 1.303" (33,1 mm)
Camshaft Journal Diameter

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.890" (48 mm)
Limit for use .. . . . . . . . . . . . . . . . . 1.874" (47,6 mm)
Camshaft End Play

Standard . . . . . · . . .. .003" (,08 mm)
Limit for use .. · .. above .008" (,2 mm)
9-13.16 Timing Gears
Standard Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004" (,1 mm)

Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .above .012" (,3 mm)
520, 530, 533 Loader

-9-8· Service Manual
9-13.17 Manifolds
Face Distortion
Standard ... .002" (.05 mm)
Limit for use . .008" (.2 mm)
9-13.18 Oil Pump
Clearance between Rotor, Vane & Cover

Standard . . . . ..... .0008" .. 003" (,02 - ,07 mm)
Limit for use . . . . . . . . . . . . . . . . . . .006" (.15 mm)
Rotor and Vane Tip Clearance

Standard (Maximum) . . . . . .0009" - .005" (,02 - ,13 mm)
9-13.19 GeneratorlWater Pump Belt Tension 3/8" (15 mm) deflection
9-13.20 Injection Nozzle Breaking Pressure .. 1720 PSI (11860 kPa)
9-13.21 Injection Nozzle Spray Angle . . . . . . . . . . . . . 4 degrees
9-14 GENERAL TORQUE SPECIFICATIONS
For standard fasteners on the loader use the following chart of general torque specs (Page
9-10).
NOTE: Weld·on studs use grade 2 lubricated specifications.
520, 530, 533 Loader

STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc phosphate
coating. Bolts purchased from Clark that have zinc phosphate coating are specified by the
letter "H" following the part number.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
INCH. .250 80-90 110-120

lBS. (9-10) (13-14)
(Nm)
.3125 180-200 215-240
(21-23) (24-27)
.375 25-28 35-40
(34-38) (48-54)
.4375 40-45 60-65
(54-61) (82-88)
.500 65-70 90-100
(88-95) (125-135)
.5625 90-100 125-140
(125-135) (170-190)
.625 125-140 175-190
(170-190) (240-260)
FOOT .750 220-245 300-330
lBS. (300-330) (410-450)
(Nm)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)
520. 530. 533 Loader

DECIMAL AND MILLIMETER EQUIVALENTS
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 - 0.015625- 0.397 33/64 - 0.515625-13.097
1/32 .03125 - 0.794 17/32 .53125 -13.494
3/64 -.046875- 1.191 35/64- .546875-13.891
1/16 .0625 - 1.588 9/16 .5625 -14.288
5/64 - .078125- 1.984 37/64- .578125-14.684
3/32 .09375 - 2.381 19/32 .59375 -15.081
e 5/32
7/64 - .109375- 2.778
.1250 - 3.175
9/64 - .140625- 3.572
.15625 - 3.969
e 21/32
39/64- .609375-15.478
41/64 -
.6250 -15.875
.640625-16.272
.65625 -16.669
11/64- .171875- 4.366 43/64- .671875-17.066
3/16 .1875 - 4.762 11/16 .6875 -17.462
13/64- .203125- 5.159 45/64- .703125-17.859
7/32 .21875 - 5.556 23/32 .71875 -18.256
e 9/32
15/64 - .234375- 5.953
.2500 - 6.350
17164 - .265625- 6.747
.28125 - 7.144
19/64- .296875- 7.541
e 25/32
47/64- .734375-18.653
.7500 -19.050
49/64- .765625-19.447
.78125 -19.844
51/64- .796875-20.241
5/16 .3125 - 7.938 13/16 .8125 -20.638
21/64 - .328125- 8.334 53/64 - .828125-21.034
11/32 .34375 - 8.731
e
27/32 .84375 -21.431
13/32
23/64 - .359375- 9.128
.3750 - 9.525
25/64 - .390625- 9.922
.40625 -10.319
27/64- .421875-10.716
e 29/32
55/64- .859375-21.828
.8750 -22.225
57/64 - .890625-22.622
.90625 -23.019
59/64 - .921875-23.416
7/18 .4375 -11.112 15/16 .9375 -23.812
29/64 - .453125-11.509 61/64 - .953125-24.209
15/32 .46875 -11.906 31/32 .96875 -24.606
e 1 mm =
31/64 - .484375-12.303
.03937"
.5000 -12.700
0 .001" =
63/64- .984375-25.003
.0254 mm
1.000 -25.400
U.S. TO METRIC CONVERSION
TO CONVERT INTO MULTIPLY BY

LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centi meters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Milimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot-pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1. Subtract 32 0
2. Multiply by 5/9
520. 530. 533 Loader

ALPHABETICAL INDEX
Page
Number
ALPHABETICAL INDEX 10-1,10-2
ALPHABETICAL
INDEX
520, 530, 533 Loader

Service Manual
10 ALPHABETICAL INDEX
Subject Page SUbject Page
A.C. Voltage, check (520/530) ... .6-2 Hydraulic Circuit .2-1

Air Cleaner . . . . . . . . . . · 1-4 Hydraulic Cylinder, repair . . . .2-6
Alternator, repair (520/530) .6-2 Hydraulic Filter Replacement 1-11
Axles and Bearings .4-1 Hydraulic/Hydrostatic Fluid . 1-10
Hydraulic Reservoir, removal .5-4
Block, caution . · 1-1 Hydraulic System . . . . . . . 1-10
Block, warning . · 1-1 Hydraulic System, troubleshooting .2-2
Bob-Tach . . . . . 1-13, 5-2 Hydrostatic Circuit . . . . . .3-1
Brake Pad, replacement . . . .4-3 Hydrostatic Motor, removal .3-7
Bushing, replacement .5-2 Hydrostatic Motor, repair . .3-7
By-Pass Valve, repair .3-4 Hydrostatic Pump, removal .3-4
Hydrostatic Pump, repair .. .3-5
Camshaft (533) . . . . . . . . . . . . . . 8-11 Hydrostatic System, troubleshooting .3-1
Camshaft & Tappets (520/530) . . . . . .7-7
Carburetor, adjustment (520/530) .7-2 Ignition, adjustment (520/530) .7-3
Carburetor, repair (520/530) . 7-3 Injection Nozzles (533) .. 8-17
Combustion Chambers (533) .8-4 I njection Pump . . . . . 8-18
Compression, check (520/530) .7-2
Connections, straight thread .2-2 Lift Cylinder, checking .2-6
Connecting Rods (533) .. . .8-8 Lubricants . . . . . . . . . .9-1
Control Valve, repair . . . . .2-7 Lubrication of Loader . 1-12
Crankshaft (520/530) ... . .7-7
Crankshaft Bearings (533) . 8-10 Maintenance, preventive .1-3
Cylinder Block (533) . . . . .8-7 Manifold Assembly (533) 8-11
Cylinder Head, disassembly (533) .8-4
Oil Filter (533) . . . . . . 8-15
Dimensional Specifications . .9-6 Oil Filter, changing (533) · 1-7
Drive Chains . . . . . . . . . .4-1 Oil Filter, changing (520/530) .1-6
Oil Pressure, check (520/530) . .7-2
Electrical System . . . . . . 1-9 Oil Pump (520/530) .7"-7
Electrical System (520/530) .6-1 Oil Pump (533) 8-15
Electrical System (533) .6-9 Operator Guard, removal .5-1
Engine (520/530) .. . .7-5
Engine (533) . . . . . . . 8-1 Pistons (520/530) . .7-7
Engine, assembly (533) 8-11 Pistons (533) . . . . .8-7
Engine, disassembly (533) . .8-1 Piston Rings (533) .8-7
Engine Cooling System (520/530) . 1-8 Pivot Pins . . . . . . 1-13
Engine Cooling System (533) ... . 1-8 Pivot Pin, replacement . .5-1
Engine Lubrication System · 1-6 Pre-Delivery Inspection . · 1-2
Engine Oil, changing (520/530) .1-6 Problem Analysis, hydraulic .2-3
Engine Oil, changing (533) · 1-7 Problem Analysis, electrical .6-1
Engine Service . . . . . . . . . . · 1-4
Engine, troubleshooting (520/530) . 7-1 Regulator, check (533) ... 6-10
Release Pressure, checking . .2-4
Final Drive Transmission . . . . . . 1-11 Relief Valve (520/530) .. . · .7-7
Fits, Clearances, adjustments (520/530) . 9-5 Relief Valve, checking . . . . . . . . · .2-4
Fits, Clearances, adjustments (533) .9-6 Relief Valve, removal & replacement .2-4
Flare Connections . . . . . . . . .2-1 Replenishing Valves . . . . . . . . .3-2
Flywheel (520/530) . . . . . . . .. 7-5 Rocker Shaft, disassembly (533) .8-3
Flywheel and Ring Gear (533) 8-11 Rods (520/530) .. .7-7
Fuel Filter . . . . . . . . . . . . 1-5
Fuel Injection Pump Reservoir (533) 1-14 Seal Installing Tool .9-5
Fuel Specifications . 9-1 Serial Number, engine . . . · 1-1
Fuel System . . . . . .1-5 Serial Number, identification · 1-1
Fuel System Service. . 1-5 Serial Number, loader .. · 1-1
Fuel Tank, removal . . 5-4 Service Schedu Ie . .1-3
Starter (520/530) ... . · .6-2
Generator, check output (533) 6-10 Starter, repair . . . . . . 6-12
Generator Service (533) 6-10 Stator, replacement (520/530) .6-2
Governor Linkage (520/530) . 7-2 Steering Linkage . . . . . . . . . 3-11
Governor Repair (520/530) .7-4 Specifications, capacities (520/530) .9-2
Specifications, capacities (533) .. . . . . . . 9-3
Hot Plugs (533) .8-6 Specifications, electrical (520/530) . . . . . . . 9-2
520, 530, 533 Loader
10-1 ALPHABETICAL INDEX (Cont'd)
Subject Page Subject Page

Specifications, electrical (533) . . . . .9-3
Specifications, engine (520/530) .. .9-2
Specifications, engine (533) . . . . . .9-3
Specifications, engine torque (520/530) .9-4
Specifications, engine torque (533) . . . . 9-4
Specifications, general torque . . . . . . . . . . . . . . . . 9-9
Specifications, hydraulic (520/530) . . . . . . . . 9-2
Specifications, hydraulic (533) .. .9-3
Specifications, hydrau lie/hydrostatic .9-4
Specifications, hydraulic motor torque .9-4
Specifications, hydrostatic pump torque. .9-4
Specifications, loader torque . . . . . . . .9-4
Specifications, operating (520/530) . . . . . .9-2
Specifications, operating (533) . . . . . . . .9-3
Specifications, power train (520/530) .9-2
Specifications, power train (533) . . . . . . .9-3
Specifications, tires (520/530) .9-2
Specifications, tires (533) .9-3
Thirty Hour Inspection .. .1-2

Throttle Linkage (520/530) .7-2
Tilt Cylinder, checking . .2-5
Timing Cover (520/530) .7-6
Timing Gears (520/530) .7-6
Timing Gears (533) .. . 8-11
Tire Maintenance . . . . 1-12
Tubelines and Hoses .2-2
Valve Clearances (520/530) .7-2

Valve Guides (533) .8-5
Valve Seats (533) . .8-5
Valve Springs (533) .8-6
Valve System (533) .8-7
Valves (533) . . . . .8-5
Valves & Guides, repair (520/530) .7-6
Vane Pump, checking .2-4
Vane Pump, repair .. .2-5
Water Pump (533) ... 8-16
520, 530, 533 Loader

.. • bobcat
530-001
20 MARCH 79
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER
Product ATTENTION
520 AND 530 SERIES
520, 530 & 533 ALL
6556407 (10-78)
SUBJECT: SHUTTLE PIN ON THE MOTOR (ROSS MOTOR PIN

12012, 12021 OR 12024)
PROBLEM:
Loss of drive on one side of the loader.
CAUSE:
The shuttle pin (PIN 6512304) is too short and the edge of the case drain port can
hold it in an open or closed position.
CORRECTION:
Remove the motor from the loader (Make reference to the Service Manual). Remove
the shuttle pin from the motor housing. Measure the pin length. The minimum length
is 1.455 inches (36,95 mm) and the maximum length is 1.495 inches (37,97 mm).
Replace the shuttle pin when it is not in this specification range.
Put the revised pages in your 520, 530 and 533 Service Manual (PIN 6556407
[10-78]).
REMOVE PUT IN
3-9,3-10 Revised Mar. 79 - 3-9, 3-10
POLICY:
Melroe will give compensation for the part (PIN 6512304) and labor which is
needed to repair the loaders in warranty which have had a failure due to the shuttle
pin.
EXPIRATION DATE:
31 Dec. 79
BUL~TUS
Refer To
Bulletin No.ls) Printed in U.S.A. NON CURRENT D-
W
• bobcat
__.... _ .. _!;i;30~.J)Q~
Buil€ltln
24 APRIL 79
Di:lte
-SERVICE BULLETIN-
ROUTE TO
Product BOBCAT LOADER
...................• -.~-~~.~. ATTENTION
Mode! 530 & 533
530 - 12348 & Below

.............................................. 533
.. - 12121 & Below SALES
tit
D
D
_~o.~~~·,,_._v ,,~··.·
----
..- - -.•.
6556407
BJECT: BOB- TACH OVER-CENTER STOP KIT
PROBLEM:
The tilt cylinder is damaged when using tilt hydraulics.
CAUSE:
The Bob-Tach goes over-center when tilted fully forward.
CORRECTION:
Install the stops from the kit (PIN 6560898).
Order the kit from Chicago Central Parts.
This Service Bulletin includes one page which is to be put in the 520, 530 & 5S3
Service Manual (6556407 [10-78]).
REMOVE PUT IN
5-3,5-4 Revised 5-3, 5-4
POLICY:
This kit is available ,as a DealerlCustomer option only. Melroe will not give warranty
compensation for parts or labor.
Refer To BULLETIN STATUS

Bulletin No.ls) Printed in U.S.A. NON CURRENT D
CIIARK Melroe
Division ~ 530-003
"bobcat
15 MAY 79
-SERVICE BULLETIN-
ROUTE TO
. BOBCAT LOADER ATTENTION
6556407
REVISION TO THE SERVICE MANUAL
The attached pages are a revision to the 520, 530 and 533 Service Manual (PIN
6556407 [10-78)). There are 24 pages to this bulletin, be sure you have them all.
The list of the following Service Bulletins have been added or are in the Service
Manual.
Bltn. No. Date Bltn. No. Date Bltn. No. Date
76-20 Aug 76 039 Dec 77 074 Oct 78

76-20 Sept 76 041 Jan 78 075 Oct 78
009 Mar 77 044 Mar 78 077 Oct 78
014 May 77 045 Apr78 080 Nov 78
016 Aug 77 046 Apr 78 082 Nov 78
018 Aug 77 054 May 78 089 Dec 78
020 Sept 77 060 Oct 78 091 Nov 78
022 Oct 77 064 Aug 78 092 Nov 79
026 Sept 77 068 Sept 78 097 Jan 79
028 Oct 77 070 Sept. 78
032 Nov 77 073 Oct 78
Remove the following pages in the Service Manual and put in the revised or added
pages, on the back of this page:

Bulletin No.(s) Printed in U.S.A. NON CURRENT D
REMOVE PUT IN
1-3, 1-4 Revised 1 - 3, Revised 1 - 4
1-5,1-6 Revised 1-5, 1-6
1-7,1-8 Revised 1-7, 1-8
1-9,1-10 Revised 1 - 9, Revised 1 - 1 0
1-13,1-14 Revised 1 - 1 3, 1 - 1 4
Added 2-9
3-3,3-4 3-3, Revised 3-4
3-7,3-8 Revised 3-7, 3-8
3-11 Revised 3-11, Added 3-12
4-3 Revised 4-3
5-1,5-2 5-1, Revised 5-2
Added 5-2a
6-1,6-2 Revised 6-1,6-2
6-9,6-10 Revised 6 - 9, Revised 6 - 1 0
Added 6-1 Oa
6-13,6-14 6 - 1 3, Revised 6 - 1 4
7-1,7-2 Revised 7 - 1, 7 - 2
7-3,7-4 7-3, Revised 7-4
7-5,7-6 Revised 7-5, 7-6
7-7,7-8 Revised 7 - 7, Revised 7 - 8
Added 7-9
8-7, 8-8 8-7, Revised 8-8
9-3,9-4 9-3, Revised 9-4
Added 9-10, Added 9-11
~ 530-004
• bobcat 31 JULY 79
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER
ATTENTION
520, 530 and 533
SALES MANAGER
6556407 ......................................... ~~--
REVISION TO THE SERVICE MANUAL
The attached pages are a revision to the 520, 530 and 533 Service Manual (PIN
6556407 [10-78). There are three pages to this Service Bulletin.
Remove the following pages in the Service Manual and put in the revised pages.
Remove Put In
Revised Mar 79 7-5,7-6 Revised June 79 7-5, 7-6

Added 7-9 Revised June 79 7 - 9
9-3, Revised Mar 7-9,9-4 9-3, Revised June 79, 9-4

Melroe
Division ~ 530-005
"bobcat 8 JANUARY 1980
.. SERVICE BULLETIN"
SAFETY NOTICE
ROUTE TO
BOBCAT LOADER
ATTENTION
520, 530
520'8 (ALL) 530'8 (SIN 14119 & Below)
6556407 [10-78] (520, 530, 533 Service Manual)
HEAT SHIELD FOR ENGINE
PROBLEM:
Poisonous engine exhaust gases with carbon monoxide accumulate in operator com-
partment if the operator compartment is enclosed. This problem was identified by a
Warning Notice of 19 Oct. 79 mailed to owners.
CAUSE:
Original heat shield allows excess exhaust gases to blow towards operator space
which is not adequately ventilated if operator compartment is enclosed.
CORRECTION:
Never use loader with enclosed operator enclosure unless corrective shield kit (PIN
6561963) is installed. Order kit from Chicago Central Parts. Install warning decal
(PIN 6561960), which is supplied with kit, on upper left side of loader panel behind
seat. After corrective shield is installed put correction notice decal (PIN 6561961),
supplied with kit, on the warning decal.
POLICY:
Melroe will give warranty compensation for cost of parts and 4 hours labor for in-
stallation of the new heat shield on machine serial numbers listed above with any
type of weather enclosure installed.
EXPIRATION DATE: Indefinite
The attached page is a revision to the 520, 530, 533 Service Manual (PIN
6556407 [10-78)).
REMOVE PUT IN
7-9 Revised 7-9
Refer To
Bulletin No.ls)
Printed in U.S.A.
BULLETIN STATUS
NON CURRENT o
CUARK Melroe
Division ~( 530-006
"bobcat
29 JANUARY 80
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER ATTENTION
520 AND 530 SERIES
........................................................
6556407
THE RESTRICTION OF OIL THROUGH THE QUICK-COUPLERS
PROBLEM:
Not enough oil flow through the quick-couplers (high back pressure, slow operation
of the attachment).
CAUSE:
The adapter which connects the quick-coupler has a restriction.
CORRECTION:
Remove the male quick-coupler and adaptor and cut the "taper" from the end of the
adaptor (See Page 2-10, Fig. 2-30),
This Service Bulletin includes one page which is to be put in the 520, 530 & 533
Service Manual (6556704 [10-78]).
REMOVE PUT IN
2-9 2 - 9, Added 2 - 1 0
POLICY:
Melroe will give warranty compensation for 112 hour labor to remove the "taper"
from the adaptor.
EXPIRATION DATE:
31 May 1980

Melroe
Division -OJ(
--bobcat
530-007
26 FEBRUARY 80
-SERVICE BULLETIN-
AFFECT!
ROUTE TO
Mode! 520 & 530
'ocl
6556407
o
su SUPPORT BRACKET FOR THE STARTER
PROBLEM:
Failure at the starter mounting.
CAUSE:
Not enough support for the starter.
CORRECTION:
Install the support bracket (PIN 6561936). Fasten the support bracket to the lower
through bolt on the starter and the right front engine mounting bolt. (See Page
6~ 14, Fig. 6~34).
Order the bracket from Chicago Central Parts.
The attached pages are a revision to the 520, 530 & 533 Service Manual
(6556407 [10-78]).
Remove the following pages in the Service Manual and put in the revised or added
pages.
REMOVE PUT IN
Revised Mar. 6~ 1, 6~2 Revised Mar. 6~1, Revised Jan. 6~2

6~3, 6~4 Revised Jan. 6~3, 6~4
6~ 13, Revised Mar. 6~ 14 6~ 13, Revised Jan. 6~ 14
POLICY:
Melroe will give warranty compensation for the part (PIN 6561936) and flat rate
labor for Bobcats which have starter failure within 1 year from date of delivery to the
original owner.
EXPIRATION DATE:
31 DECEMBER 80
BULLETIN STATUS
Refer To
Melroe
Division ~(
"bobcat
28 OCTOBER 80
-SERVICE BULLETIN-
ROUTE TO
520, 530
ENGINE CARBURETOR AND CHOKE CONTROL
PROBLEM:
Engine continues to run after the key switch is turned off.
CAUSE:
Carburetor does not have a fuel shut off solenoid.
CORRECTION:
Replace carburetor 6512225 with carburetor 6514854 which has a fuel shut off
solenoid.
Replace the rod controlled choke linkage with a cable controlled choke (Kit PIN
65619961.
The fuel solenoid carburetor has the choke lever on the left side and cannot be
connected to the rod controlled choke linkage.
The cable controlled choke will fully open and close the choke and give better
assistance in cold weather starting.
The cable controlled choke cannot be installed on machines with carburetor part
number 6512225 installed because the choke lever is on the right side of the
carburetor, and will result in interference with the governor control.
The attached pages are a revision to the 520, 530 & 533 Service Manual (P/N
6556407 [10-7811.
Remove the following pages in the Service Manual and put in the revised pages.
REMOVE PUT IN
7-3, Revised Apr. 7-4 7-3, Revised Oct. 7-4
POLICY:
Melroe offers this for installation at the dealer/customer option and will not give
warranty compensation for parts or labor.
BULLETIN STATUS
Refer To
MELROE
INGERSOLL-RAND
SERVICE MANUAL
-- r ., bobcat ®
530-9
Revision Number
10 September 1996
Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER 0
SERVICE MANAGER 00
Model __~5=2=W~53~0~/5~3~3~________________________ SALES MANAGER 0
Manual No. 6556407 (10-78)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 520,530,533 Service Manual PIN 6556407.
Take out the pages shown and put in the revised pages as follows:
TAKEOUT PUTIN
2-2a (Added September 96)
Prinh>rt in I I !'-.

Bobcat 520 - 530 Service Manual

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Bobcat 520 - 530 Service Manual

Transféré par

Droits d'auteur :

Formats disponibles

5 5

6566532 (11–94) Printed in U.S.A. Melroe Company 1987

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

B-11799 B-15231 B-15280

B-6590 B-6580 B-6589

1. Correct service and adjustment of the Bobcat Loader.

2. Overhaul instructions of the engine, loader hydraulic/hydrostatic system and HYDRAULIC

2. Look for any sign of fuel, oil or hydraulic fluid leaks.

3. Complete lubrication of the machine.

6. Check the electrical system. MAIN FRAME

7. Check the warning lamps.

8. Check the tires for wear and correct pressure.

11. Make a visual inspection for loose or broken parts or connections.

ALPHABETICAL INDEX .10-1 TECHNICAL

520, 530 & 533 Loader

520, 530 & 533 Loader

AIR CLEANER 1-5 1-4

This sYmbol is on the machine and used

Fig. 1-1 Loader Serial Number

1-1.2 Serial Number Identification

1-1.3 Loader Serial Number

The serial number is made up as follows:

Model, Engine Type Fig. 1-2 Engine Serial Numbers

1-1.4 Engine Serial Number

1-1.6 30 Hour Inspection

30 MOUII Ol'[IIATlONAL .. SEII'IltE II'ISPlCflON

... ,,".'-" .,"

,x, ....,. "._. " •• ' _dod .....' ...... _. do,.,h

(1) For adjustment and inspection after first work period.

(2) To correct wrong maintenance and operating methods.

(1) The mechanic completing the inspection.

(2) Dealer person Fig. 1-4 30 Hour Inspection

(3) Owner or operator

520, 530, 533 Loader

Engine Oil Check and add oil as necessary.

Tires Inspect for damage and check tire pressure.

All Pivot Points Add lubricant to all fittings (12).

Indicators, etc. Check for correct operation of all indicators,

Operator Guard Check condition and holding bolts.

Seat Belt Check condition of straps and buckle and replace if

Safety Decals Check for missing or damaged decals. Replace as

Hydraulic Fluid Check level and add recommended fluid if needed.

Engine Oil & Filter Replace oil and filter.

Battery Check cables.

Bob-Tach Inspect locking levers and wedges for condition and

Check operation. Make adjustment as needed.

Chaincase Fluid Check level. Add fluid if needed.

I Spark Arrestor Muffler Clean carbon from the muffler.

Hydraulic Filter Replace element.

Engine Fuel Filter Replace element or clean as necessary.

Injection Pump Oil (533) Replace oil in injection pump reservoir.

Chaincase Replace fluid.

520, 530, 533 Loader

The rear door must be opened to

Fig. 1-6 Air Cleaner

1-5 AIR CLEANER SYSTEM (Fig.

520, 530, 533 Loader

1-6 FUEL SYSTEM

Use only regular grade or lead-free gasoline in the 520/530 engine.

Never add fuel to the loader when the

1 - 7 FUEL SYSTEM SERVICE

Be sure the air inlet hose (Fig. 1-11) is