463 6903711 SM 8-07 PDF

Service
Manual
Dealer Copy -- Not for Resale

S/N 538911001 & Above
S/N 539011001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6903711 (8-07) Printed in U.S.A. © Bobcat Company 2007

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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
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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 70-01 INSTRUMENT PANEL.............................................60-01

AIR CLEANER SERVICE ....................................... 10-01
ALTERNATOR ........................................................ 60-01 LIFT ARMS ..............................................................50-01
AUXILIARY CONTROL LOCKBOLT....................... 10-01 LIFT ARM BY-PASS VALVE ....................................20-01
LIFT ARM SUPPORT DEVICE ............................10-01
BATTERY................................................................ 60-01 LIFTING AND BLOCKING THE LOADER...............10-01
BICS™ SYSTEM (WITH PRESS LIGHTS ................................................................60-01
TO OPERATE BUTTON) ...................................... 60-01 LOADER SPECIFICATIONS ............................. SPEC-01
BICS™ SYSTEM CONTROLLER.......................... 60-01 LUBRICATING THE LOADER.................................10-01
BOB-TACH ............................................... 10-01, 50-01

MAIN RELIEF VALVE ..............................................20-01
CHAINCASE ........................................................... 40-01 MUFFLER................................................................70-01
CHARGE PRESSURE ............................................ 30-01
CONTROLS ............................................................ 20-01 OIL COOLER ....................................................... 30-01
CONTROL PANEL .................................................. 30-01 OPERATOR CAB .........................................10-01, 50-01
CONVERSIONS ............................................SPEC-01 OPERATOR SEAT...................................................50-01
COOLING FAN ....................................................... 70-01
CYLINDER (LIFT) ............................................... 20-01 PARKING BRAKE....................................................40-01
CYLINDER (TILT) ............................................... 20-01 PIVOT PINS ............................................................10-01
DRIVE BELT ........................................................... 30-01 RADIATOR ..............................................................70-01

DRIVE COMPONENTS .......................................... 40-01 REAR DOOR ...........................................................50-01
REAR WINDOW ..................................................50-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 RECONDITIONING THE ENGINE ..........................70-01
ENGINE ................................................................. 70-01 REMOTE START SWITCH ................................. 10-01
ENGINE COMPONENTS AND TESTING .............. 70-01
ENGINE COOLING SYSTEM ................................. 10-01 SEAT BAR RESTRAINT SYSTEM ..........................10-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 SEAT BAR ...............................................................50-01
ENGINE MOUNTING BRACKET............................ 70-01 SEAT BAR SENSOR ...............................................60-01
ENGINE SPECIFICATIONS ...........................SPEC-01 SERVICE SCHEDULE ............................................10-01
ENGINE SPEED CONTROL .................................. 70-01 SPARK ARRESTOR MUFFLER..............................10-01
STARTER ................................................................60-01
FINAL DRIVE TRANSMISSION (CHAINCASE) ..... 10-01 STEERING ..............................................................30-01
FLYWHEEL ......................................................... 70-01
FUEL SYSTEM ....................................................... 10-01 TIRE MAINTENANCE .............................................10-01
FUEL TANK............................................................. 50-01 TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK ...................................................60-01
HYDRAULIC CONNECTION SPECS ................SPEC-01 TRANSPORTING THE LOADER ............................10-01
HYDRAULIC CONTROL VALVE............................. 20-01 TROUBLESHOOTING ............................................70-01
HYDRAULIC FILTER .............................................. 20-01
HYDRAULIC FLUID SPECIFICATIONS ............SPEC-01
HYDRAULIC PUMP ................................................ 20-01
HYDRAULIC RESERVOIR ..................................... 20-01
HYDRAULIC SYSTEM INFORMATION.................. 20-01
HYDRAULIC/HYDROSTATIC SYSTEM ................. 10-01
HYDROSTATIC MOTOR .....................................30-01
HYDROSTATIC PUMP ........................................30-01
HYDROSTATIC SYSTEM INFORMATION ......... 30-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

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

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

SYSTEM
DRIVE
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
MAINFRAME
MAIN
s
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
SYSTEM AND
SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SERVICE
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader excavator mechanic. It provides necessary servicing and adjustment procedures for
the Bobcat loader and its component parts and systems. Refer to the for operating instructions, starting procedure, daily
checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Melroe approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good

condition.
4. The seat bar and pedal 12. Safety treads must be in good
interlocks must be correctly condition.
adjusted, clean and
lubricated.
5. Check lift arm suport device, 13. Check for correect function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers and foot 15. Inspect for fuel, oil or

pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct funtion of 16. Lubricate the loader.

the work lights.
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17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to

service.
21. Inspect for loose or broken

parts or connections.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the

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

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
• The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI SSL-0206 SM
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

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

Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM
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SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

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

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

or hot components can contact flammable material,

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

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

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

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

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

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

SMOKING!
SI SSL-0206 SM
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Bobcat Loader Serial Number
Figure 2
P-37954
The engine serial number is located on the engine fuel

injection pump [Figure 3].
DELIVERY REPORT

Figure 4
P-4399
The loader serial number plate is located on the inside of

the operator cab on the right fender and in front of the
seat [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
Model/ Engine Version Production Sequence
(Series)
B-16315
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
4].
FACTORY OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

* TIRES - Flotation tires (Optional) are shown. bobcats are base-equipped with standard tires.
† BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator
cab as shown. Extra insulated cab is available as an option (Reduced noise level).
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BOBCAT LOADER IDENTIFICATION
OPERATOR
HANDBOOK
◆OPERATING LIGHTS
SEAT BAR
OPERATOR
GRAB SEAT
HANDLES
STEERING
LEVER
SAFETY TREAD
STEPS
†BUCKET TILT CYLINDER

B-19678
•OPERATOR CAB
(ROPS/FOPS)
◆OPERATING LIGHT
UPRIGHTS
LIFT ARM SUPPORT

REAR DEVICE
DOOR
LIFT ARMS
LIFT CYLINDER
TIRES*
B-19679
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SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . 10-140-1 MAINTENANCE
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-1 DRIVE
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1 SYSTEM
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

ELECTRICAL
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 SYSTEM &
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3 SERVICE
Fuel Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-4
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1 SPECIFICATIONS

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-2
Replacing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . . 10-120-2
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Disengaging The Lift Arm Support Device. . . . . . . . . . . . . 10-20-2
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . 10-20-1
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Continued On Next Page
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SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . 10-200-1

Foot Pedal Clean Out . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Adjusting The Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC
SECTION) UNLESS OTHERWISE SPECIFIED.
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LIFTING AND BLOCKING THE LOADER Figure 10-10-2
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow instructions can
cause injury or death [Figure 10-10-1].
P-34920
W-2003-0199
Figure 10-10-1 Always park the loader on a level surface.
Put a floor jack under the rear of the loader [Figure 10-
10-2].
Lift the rear of the loader and install jackstands [Figure

10-10-2].
Figure 10-10-3
B-7023A
Procedure
WARNING P7289
Put jackstands under the front axles and rear corners

of the frame before running the engine for service. Put the floor jack under the front of the loader [Figure 10-
Failure to use jackstands can allow the machine to 10-3].
fall or move and cause injury or death.
W-2017-0286
Lift the front of the loader and put jackstands under the
loader frame.
NOTE: Make sure the jackstands do not touch the

tires.
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LIFT ARM SUPPORT DEVICE Figure 10-20-2
Engaging The Lift Arm Support Device
WARNING P-19460
Never work on a machine with the lift arms up unless

Lower the lift arm support device on top of the lift cylinder.
the lift arms are secured by an approved lift arm
Fasten the free end of the spring (Item 1) [Figure 10-20-
support device. Failure to use an approved lift arm
2] to the lift arm support device so there will be no
support device can allow the lift arms or attachment
interference with the support device engagement.
to fall and cause injury or death.
W-2059-0598
With the operator in the seat, seat belt fastened and seat

bar lowered, start the engine. Press the green PRESS
Figure 10-20-1 TO OPERATE Button.
Figure 10-20-3
1
P-19458
P-9800
Put jackstands under the rear corners of the loader.
Disconnect the spring from the lift arm support device Raise the lift arms until the lift arm support device drops
retaining pin (Item 1) [Figure 10-20-1], hold the support onto the lift cylinder (Item 1) [Figure 10-20-3].
device and remove the retaining pin.
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move both pedals until both
pedals lock.
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LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-6
Engaging The Lift Arm Support Device (Cont’d)
WARNING
Service lift arm support device if damaged or if parts 1
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Figure 10-20-4 P-9807
Connect the spring from the lift arm support device to the
tubeline bracket (Item 1) [Figure 10-20-6] on the lift
arms.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine. Press the green PRESS

TO OPERATE Button.
Raise the lift arms a small amount and the spring will lift
1 the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine.
P-9808 Raise the seat bar and move pedals until both pedals
lock.
Install the retaining pin (Item 1) [Figure 10-20-4] into the Disconnect the spring from the bracket.
rear of the lift arm support device below the cylinder rod.
Figure 10-20-7
Disengaging The Lift Arm Support Device
Figure 10-20-5
1
1 P-19458
P-9808 Raise the support device into storage position and insert
pin through lift arm support device and bracket (Item 1)
[Figure 10-20-7].
Remove the retaining pin (Item 1) [Figure 10-20-5] from
the lift arm support device. Connect spring to pin [Figure 10-20-7].
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OPERATOR CAB Raising The Operator Cab
Description Stop the loader on a level surface. Put the lift arms all the
way down.
Install jackstands under the rear of the loader frame.

WARNING Open the rear door. (See REAR DOOR on Page 50-70-
1.)
Before the cab or the lift arms are raised for service,
jackstands must be put under the rear corners of the
If the lift arms must be up while raising the cab, install the
frame. Failure to use jackstands can allow the
lift arm support device. (See Engaging The Lift Arm
machine to tip backward causing injury or death.
W-2014-0895
Support Device on Page 10-20-1.)
Remove the two fasteners (Item 1) [Figure 10-30-1] at

Figure 10-30-1 the front (both sides) of the operator cab.
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless

instructed to do so by Bobcat. Changes to the cab
1 can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299
Figure 10-30-2
P-37953
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer
if the operator cab has been damaged. The seat belt
must be worn for roll over protection.
ROPS/FOPS Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level 1.
Level 1 - Protection from falling bricks, small concrete

blocks and hand tools encountered in operations such as
P-19462
highway maintenance, landscaping, and other
construction site services.
Stand on the ground. Lift slowly until operator cab is all
Check with your dealer if the operator cab has been the way up [Figure 10-30-2].
changed.
The operator cab will lock in the raised position
The operator cab fastening nuts (Item 1) [Figure 10-30-
1] must be tightened to 40-50 ft.-lb. (54-68 N•m) torque.
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OPERATOR CAB (CONT’D) REMOVE YOUR HAND FROM THE HOLE BEFORE
LOWERING THE OPERATOR CAB
Lowering The Operator Cab
Stand on the ground and pull down on the operator cab.
Avoid slippery surfaces when lowering the cab.

WARNING NOTE: Guide the operator cab over the fastening
bolts to prevent thread damage.
The cab must be held to prevent falling while hand is
in access hole.
W-2205-0695
Figure 10-30-5
Figure 10-30-3
1
1

P-37953
P-34927 Install the cab washers and nuts. Tighten the nuts (Item
1) [Figure 10-30-5] (both sides) to 40-50 ft.-lb. (54-68
N•m) torque.
Figure 10-30-4
P-34928
Hold the operator cab. Release the locking mechanism

by pushing the lever (Item 1) [Figure 10-30-3] inward
from the locked position and lifting the lever until it stays
in the unlocked position [Figure 10-30-4].
The pin (Item 2) [Figure 10-30-3] must be retracted from

the hole in the upright before lowering the operator cab.
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OPERATOR CAB (CONT’D) Figure 10-30-7
Emergency Exit
The front opening on the operator cab and rear window

provide exits.
Figure 10-30-6
1 P-19463
Exit throught the rear of the cab [Figure 10-30-7].
P-9829

Pull on the tag (Item 1) [Figure 10-30-6] at the top of the
rear window to remove the rubber cord.
Push the rear window out of the rear of the operator cab.
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TRANSPORTING THE LOADER Adjusting The Bumper
Procedure Figure 10-40-2
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
P-19457
Figure 10-40-1
P-9926
P-9927

Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].
SUPPORT B-6198
Fully lower any bucket or attachment. Stop the engine.
Engage the parking brake.
Be sure the transport and towing vehicles are of
adequate size and capacity. Fasten chains at the front using the slots in the axle
gussets [Figure 10-40-2]. The counterweight is removed
A loader with an empty bucket or no attachment must be (Inset) to show clarity. DO NOT operate the loader with
loaded backward onto the transport vehicle [Figure 10- counterweight removed.
40-1].
Figure 10-40-3
The rear of the trailer must be locked or supported
[Figure 10-40-1] when loading or unloading the loader to
prevent the front end of the trailer from raising up.
P-37626 P-37627
P-37626 P-37628
Fasten the rear of the loader as shown [Figure 10-40-3].
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TOWING THE LOADER Figure 10-50-2
Procedure
IMPORTANT
Do not push or pull the machine at more than 2 MPH
(3,2 km/h) or for a distance of more than 25 feet (7,6
meters) with the towing tool in place.
I-2017-0389
Figure 10-50-1
P-21493
P-39207
Install the tow valves in the fitting holes [Figure 10-50-2].
Figure 10-50-3

1
1
P-39206
Be sure the transport and towing vehicles are of

adequate size and capacity.
To prevent damage to the loaders hydrostatic system, a P-21497

tow valve is available for towing the loader short distances
at slow speeds. (Example: Moving the loader onto a
transport vehicle.) Tighten the jam nut (Item 1) [Figure 10-50-3] to 20-25 ft.-
lb. (27-34 N•m) torque.
A tow valve is available from your dealer and must be
installed before towing the loader.
Raise the operator cab.(See Raising The Operator Cab

on Page 10-30-1.)
Clean the area around the hydrostatic pumps.
Remove the charge pressure tubeline and fittings (Item

1) [Figure 10-50-1] from the front side of the hydrostatic
pumps.
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TOWING THE LOADER (CONT’D)
Procedure (Cont’d)
Figure 10-50-4
When flats are vertical

loader can be towed
P-21496
Turning the tow valves so the flats are vertical as shown

(Item 1) [Figure 10-50-4] will release the relief valves

and the check valves in the hydrostatic pumps and allow
the loader to be moved.
The towing chain (or cable) must be rated at 1-1/2 times

the weight of the loader. (See LOADER
SPECIFICATIONS on Page SPEC-10-1.)
Turn the key switch to ON and press the traction lock

override button.
If the electrical system is not functioning, contact your

Bobcat loader dealer. (Part of the brake system must be
disassembled to move the loader.)
Remove the tow valves and install the fittings and charge
tubelines before operating the loader.
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REMOTE START Figure 10-60-1
Procedure
WARNING 1
2
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
W-2017-0286
P-59192
WARNING Remove the protective cap from the remote start

connector on the loader.
Connect the adapter harness to the remote start and
connect the adapter harness to the remote start
connector (Item 1) [Figure 10-60-1].

W-2059-0598
Turn the key (Item 2) to start the engine.
The tools listed will be needed to do the following

procedure:
MEL1429-2 Remote Start Kit
6734387 Adapter Harness
The Remote Start is required when the operator cab is in

the raised position for service or the service technician
needs to start the engine.
The remote start is required when the service technician

is adjusting the steering linkage and checking the
hydraulic/hydrostatic system.
Lift and block the loader. (See Procedure on Page 10-10-

1.)
Open the rear door of the loader.
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SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service
schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read

and understand the Operation & Maintenance Manual and signs (decals) on
machine. Follow warnings and instructions in the manuals when making
WARNING repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-1285
SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED 8-10 50 100 250 500 ■1000
Engine Air Cleaner Empty the dust cup & replace the filter as needed.
Engine Oil Check the engine oil level and add oil as needed.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level in recovery tank.
Add coolant as needed.
Tires Check for damaged tires and correct air pressure.
Indicators, Gauges, & Check for correct operation of all indicators, gauges & lights (Opt.).
Lights (Opt.)

Seat Belt, Seat Bar Check the condition of the seat belt. Check the seat bar & pedal interlocks for cor-
rect operation. Clean dirt and debris from moving parts.
Safety Signs (Decals) and Check for damaged sign (decals) and safety treads. Replace any signs or safety
Safety Tread treads that are damaged or worn.
Lift Arms and Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Engine Fuel Filter Remove the water from the filter.
Hydraulic Fluid, Hoses Check fluid level and add as needed. Check for damage and leaks. Repair or
and Tubelines replace as needed.
Bobcat Interlock Control Check BICS™ System Controller functions. Clean dirt, debris or objects from under
System (BICS™) or behind seat as required.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Control Pedals & Steering Check for correct operation. Repair or adjust as needed.
Bob-Tach Check locking levers & wedges for condition & operation.
Wheel Nuts ❑Check for loose wheel nuts & tighten to 40-45 ft.-lb. (54-61 N•m) torque.
Parking Brake Check operation.
Alternator Belt Check belt tension and adjust as needed.
Engine Oil and Filter Replace oil and filter. (See Oil Chart on Page 10-110-1.)
Hydraulic Filter Element Replace Filter Element.
Spark Arrestor Muffler Clean the spark chamber.
Drive Belt Clean the spark chamber.
Steering Lever Pivots Lubricate grease fittings and oil hole in the steering shaft.
Engine Fuel Filter Replace the filter element.
Hydraulic Reservoir Replace the breather cap.
Breather
Final Drive Trans (Chain- Replace the fluid.
case)
Hydraulic/Hydrostatic •Replace the fluid.
Reservoir
❑ Check wheel nut torque every 8 hours for the first 24 hours.
• Also replace hydraulic/hydrostatic filter element when the transmission warning light stays on for five minutes
after the hydraulic fluid is at operating temperature.
■ Or every 12 months.
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AIR CLEANER SERVICE Figure 10-80-2
Replacing Filter Element
Figure 10-80-1
2
1
P-34934
2 Remove the outer filter element (Item 1) [Figure 10-80-2]

P-34933A
Figure 10-80-3
(See SERVICE SCHEDULE on Page 10-70-1) for the

interval to service the air cleaner system.

Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all
connections are tight.
NOTE: Before replacing the filter element, push the

button on the condition indicator (Item 1)
[Figure 10-80-1]. Start the engine, then stop 1
the engine. If the red ring does not show, do
not replace the filter element.
Replace the outer filter element only when the red ring P-34935
shows in the window of the condition indicator [Figure
10-80-1].
Remove the inner filter element (Item 1)[Figure 10-80-3].
Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator Clean the inside of the filter housing.
window after the outer filter has been replaced.
Install the inner element, if required.
Release the two fasteners (Item 2) [Figure 10-80-1] to
remove the cover. Clean any debris or dust from the Install the outer element.
cover.
Install the cover and engage the two fasteners.
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ENGINE COOLING SYSTEM Cleaning The Cooling System
Checking The Coolant Level
Figure 10-90-1
WARNING
Use safety goggles when using air or water under
pressure. Do not use cold water to clean a hot
engine. Failure to obey warnings can cause serious
injury.
W-2064-1285
Open the rear door.
1 Use air pressure or water pressure to remove the debris

in the area of the radiator and oil cooler.
If debris is a problem, check with your dealer about the

P-37947 special debris screens.
WARNING

Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
Check the cooling system every day to prevent

overheating, loss of performance or engine damage.
Open the rear door.
The coolant recover tank (Item 1) [Figure 10-90-1] is

located above the radiator.
The coolant level in the recovery tank must be between

the maximum and minimum mark when engine is cool.
NOTE: The loader is factory filled with propylene

glycol coolant. DO NOT mix propylene glycol
with ethylene glycol.
Add premixed coolant; 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylenen glycol mixed with

one gallon of water is the correct mixture of coolant to
provide a -34° F (-37° C) freeze protection.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
NOTE: Coolant testing strips are available for

checking the coolant condition. (See your
Bobcat loader dealer.)
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ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-4
Replacing The Coolant
Figure 10-90-2
1
2
1
P-37948
Remove the radiator cap (Item 1) [Figure 10-90-4].

P-37926
Turn the valve counterclockwise to open the drain valve
(Item 2) [Figure 10-90-4].
Open the rear door.

Install the drain hose (Item 1) [Figure 10-90-2] on the
valve outlet.
Figure 10-90-3
P-37949
Install the drain hose into a clean container (Item 1)

[Figure 10-90-3].
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FUEL SYSTEM Filling The Fuel Tank
Fuel Specification
Figure 10-100-1
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
2
Figure 10-100-2
1
P-34922
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.

1
The following is a suggested blending guideline which
should prevent fuel gelling problems:
P-34921
Temp. F°/ C° No. 2 No.1
+15° (-9° ) 100% 0%
Down to -20° / (-29° ) 50% 50% Remove the fuel fill cap (Item 1) [Figure 10-100-2].
Below -20° / (-29° ) 0% 100%
Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
We recommend an operator contact their fuel supplier for free movement of air and no open flames or sparks. NO
local recommendations. SMOKING .
The fuel gauge (Item 1) [Figure 10-100-1]and the fuel Install and tighten the fuel fill cap (Item 1) [Figure 10-
shut off valve (Item 2) [Figure 10-100-1] are located on 100-2].
the right side of the loader.
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FUEL SYSTEM (CONT’D)
Filling The Fuel Tank (Cont’d)
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 10-100-3
WRONG

B-6108
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FUEL SYSTEM (CONT’D) Figure 10-100-5
Fuel Filter
WARNING
1
W-2103-1285
Drain Water:
P-37924

service interval when to remove the water from the fuel Loosen the drain (Item 1) [Figure 10-100-5] at the
filter. bottom of the filter element to drain water from the filter.
Close the drain.
Figure 10-100-4
Open the shut-off valve (Item 1) [Figure 10-100-4] to turn
on the fuel supply.

OFF Replace Fuel Filter:

1 service interval when to replace the fuel filter.
Clean the area around the fuel filter.
ON Close the shut-off valve (Item 1) [Figure 10-100-4].
Remove the fuel filter [Figure 10-100-5].
P-34923 NOTE: Be sure the filter gasket is removed with the

old fuel filter.
Turn the fuel shut-off valve (Item 1) [Figure 10-100-4]
Install the new filter element and hand tight.
clockwise to shut off the fuel supply.
Open the shut-off valve (Item 1) [Figure 10-100-4].
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FUEL SYSTEM (CONT’D)
Removing Air From The Fuel System

WARNING
Figure 10-100-6
W-2103-1285
1
Figure 10-100-7
P-37923
After replacing the fuel filter element or when the fuel

tank has run out of fuel, air must be removed from the

fuel system before starting the engine.
Open the rear door. The engine must be cool.

P-34929
Open the vent plug (Item 1) [Figure 10-100-6].
Open the valve (Item 1) [Figure 10-100-7] on the injector
Operate the hand pump (priming bulb) (Item 2) [Figure pump and squeeze the hand pump several times until
10-100-6] until fuel flows from the vent plug with no air fuel flows from the valve.
bubbles.
Close the valve (Item 1) [Figure 10-100-7].
Close the vent plug.
Lower the operator cab. (See Lowering The Operator
With the operator in the seat, seat belt fastened, seat bar Cab on Page 10-30-2.)
lowered, and parking brake engaged, start the engine.
Start the engine.
NOTE: If engine fails to start, remove air from the fuel
injection pump as follows:
Put jackstands under the rear of the frame. (See

Procedure on Page 10-10-1.)
Raise the operator cab.(See Raising The Operator Cab

on Page 10-30-1.)
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ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil (See SERVICE SCHEDULE on Page 10-70-1) for the
service interval for replacing the engine oil filter.
Figure 10-110-1
Run the engine until it its at operating temperature. Stop
the engine.
Figure 10-110-2
1
P-37927
Check the oil every day.

P-37950

Stop the engine and remove the dipstick (Item 1) [Figure
10-110-1].
Open the rear door and remove the cap from the end of
Keep the oil level between the marks on the dipstick. the hose. Drain the oil into a container [Figure 10-110-
2].
Use a good quality motor oil that meets API Service
Classification of CD or better. (See Oil Chart below.) Figure 10-110-3
Oil Chart
RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
C°
P-37928
Remove the filter (Item 1) [Figure 10-110-3].
Clean the filter housing surface. Put clean oil on the

F° gasket of the new filter. Install the filter and hand tighten.
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES Install and tighten the cap on the drain hose.
MUST USE API CLASSIFICATION CD, CF4, CG4)
*Can be used ONLY when available with appropriate
diesel rating.
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ENGINE LUBRICATION SYSTEM (CONT’D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-4
P-37929
Turn the oil fill cap (Item 1) [Figure 10-110-4] counter

clockwise the remove the cap.

Fill to capacity. (See Capacities on Page SPEC-10-4.)
Start the engine and let it run for about 5 minutes. Check
for leaks ant the filter. Check the oil level. Add oil until
the level is at the FULL mark on the dipstick. Install the
oil fill cap (Item 1) [Figure 10-110-4].
NOTE: DO NOT overfill the crankcase.
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HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-1
Checking And Adding Fluid
1
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496 P-37930
Use only recommended fluid in the hydraulic system. Open the rear door. Remove the dipstick (Item 1)
(See Hydraulic System on Page SPEC-10-3.) [Figure 10-120-1].
Stop the loader on a level surface. Lower the lift arms The fluid level is correct if the fluid is between the marks
and tilt the Bob-Tach fully back. on the dipstick.

Stop the engine. NOTE: The dipstick may indicate an incorrect level of
fluid when first removed because of
expansion or contraction of oil in the fill tube.
Always (1) remove the dipstick, (2) wipe the
dipstick, (3) insert the dipstick again and (4)
re-check the fluid level.
If fluid is needed, remove the dipstick (Item 1) [Figure

10-120-1] and add fluid to the reservoir until the level is
correct.
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HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Replacing The Hydraulic/Hydrostatic Fluid
Hydraulic/Hydrostatic Filter Replacement (See SERVICE SCHEDULE on Page 10-70-1) for the
service interval to replace the fluid. The fluid must also
be replaced if it becomes contaminated and after any
major repairs.
WARNING Stop the engine. Open the rear door.
Fluid such as engine oil, hydraulic fluid, coolants,
Remove the fill cap/dipstick.
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
Figure 10-120-3
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local,
state and federal regulations for the correct disposal.
W-2067-0499
Figure 10-120-2
1 1

P-37980
Loosen the nut (Item 1) [Figure 10-120-3] which fastens

the fill tube to the loader frame.
P-37931 Loosen the clamp at the fill tube, turn the fill tube down to
drain the fluid from the reservoir [Figure 10-120-3].
(See SERVICE SCHEDULE on Page 10-70-1) for the After the fluid is removed, put the fill tube in the correct
correct service interval. position, tighten the hose clamp and tighten the bolt.
Stop the engine. Open the rear door. Raise the operator Replace the hydraulic filter element.
cab. (See Raising The Operator Cab on Page 10-30-1.)
Clean the area around the filter housing. Add Hydraulic/Hydrostatic fluid to the reservoir. (See
Checking And Adding Fluid on Page 10-120-1.)
Remove the filter element (Item 1) [Figure 10-120-2].
Do Not over fill the reservoir.
Clean the surface of the filter housing where the filter
element seal contacts the filter housing.
Put grease on the seal of the filter element, install the

element and hand tighten only.
Lower the operator cab.
Start the engine and operate the loader through the

hydraulic and hydrostatic functions. Stop the engine.
Check the fluid level and add fluid the the reservoir as
needed.
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FINAL DRIVE TRANSMISSION (CHAINCASE)
The chaincase contains the final drive sprockets and the

chains and is filled with the same type of fluid as is used
in the hydraulic system. (See Hydraulic System on Page
SPEC-10-3.)
Checking And Adding Oil
Figure 10-130-1

P-7561
Put the loader on a level surface. Remove the plug at the

front of the chaincase (Item 1) [Figure 10-130-1]. If the
fluid can be reached with the tip of your finger through the
hole, the level is correct.
Add fluid through the check plug hole until the fluid flows
from the hole. Install and tighten the plug.
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AUXILIARY CONTROL LOCKBOLT
Procedure
Figure 10-140-1
P-37932
The Auxiliary control has a lockbolt (Item 1) [Figure 10-

140-1] that must be removed to use the optional auxiliary

hydraulics.
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
Remove the nut and bolt (Item 1) [Figure 10-140-1] from

the right hand steering lever.
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BOB-TACH Figure 10-150-2
Inspection And Maintenance
WARNING 1
Bob-Tach wedges must extend through the holes in

attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-1
P-19495
The wedges must extend through the holes in the

1 attachment mounting frame (Item 1) [Figure 10-150-2].
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage. Replace any parts that are damaged, bent, or

missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on

P-19494 Page 10-70-1) and (See LUBRICATING THE LOADER
on Page 10-160-1).
Move the Bob-Tach lever (Item 1) [Figure 10-150-1] to

engage the wedges. The levers and wedges must move
freely.
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LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1
1
P-19456
Lift Arm Pivot Pin (Item 1-Both sides) [Figure 10-160-3].

P-34924
Figure 10-160-4
Lubricate the loader as specified in the SERVICE

SCHEDULE Contents, Page 10-01 for the best

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

Bobcat loader.
1
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
Base End Lift Cylinder (Item 1-Both sides) [Figure 10- P-37985
160-1].
Figure 10-160-2 Rod End Tilt Cylinder (Item 1) [Figure 10-160-4].
P-19455
Rod End Lift Cylinder (Item 1-Both sides) [Figure 10-

160-2].
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LUBRICATING THE LOADER (CONT’D) Figure 10-160-7
Procedure (Cont’d)
1
Figure 10-160-5
P-39056
Steering shaft pivot bearings (Item 1) [Figure 10-160-7]

P-7552 (Both sides).
NOTE: If the steering levers do not move freely, (See

Base End Tilt Cylinder (Item 1) [Figure 10-160-5]. STEERING on Page 30-30-1) to disassemble
and lubricate the mechanism.

Figure 10-160-6
P-19417
Bob-Tach pivot pins (Item 1) [Figure 10-160-6] (Both

sides).
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TIRE MAINTENANCE Tire Inflation
Wheel Nuts
See the SERVICE SCHEDULE Contents, Page 10-01 for

the service interval to check the wheel nuts. The correct
WARNING
torque is 50-55 ft.-lb. (68-75 N•m) torque.
Do not inflate tires above specified pressure. Failure
Tire Rotation to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
Check the tires regularly for wear, damage and pressure. W-2078-1285
(See SPECIFICATIONS Page SPEC-01 for the correct
tire pressure.)
Figure 10-170-1
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
Tires are to be repaired only by an authorized person

using the proper procedures and safety equipment. Tires

and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
B-9976 lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
Rear tires usually wear faster than front tires. To keep pressure frequently to avoid over inflation.
tire wear even, move the front tires to the rear and rear
tires to the front [Figure 10-170-1].
It is important to keep the same size tires on each side of

the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
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SPARK ARRESTOR MUFFLER
(See SERVICE SCHEDULE on Page 10-70-1) for correct

service interval. Do not operate the loader with a
WARNING
defective exhaust system.
Never use machine in atmosphere with explosive
Cleaning Procedure dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles. WARNING
Failure to obey can cause serious injury.
W-2011-1285 When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
WARNING W-2006-0284
Start the engine.

When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust

Have a second person (wearing safety goggles) hold a
fumes. If the engine is stationary, vent the exhaust
block of wood over the outlet of the muffler (with the
outside. Exhaust fumes contain odorless, invisible
engine running) for about 10 seconds.
gases which can kill without warning.
W-2050-1285
Stop the engine and install the plug. Close the rear door.
Figure 10-180-1
IMPORTANT
This loader is factory equipped with a U.S.D.A.
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation.
1
If this machine is operated on flammable forest,
brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
P-37933 and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442
PRC.
Stop the engine. Open the rear door.
Make reference to local laws and regulations for
Remove the plug (Item 1) [Figure 10-180-1] from the spark arrestor requirements.
bottom of the muffler. I-2022-0595
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PIVOT PINS
Procedure
Figure 10-190-1
P-19288
Figure 10-190-2

1
P-34926
All pivot pins, lift arms, and cylinders have a large pin
held in position with lockbolts and retainer (Item 1)
[Figure 10-190-1] & [Figure 10-190-2].
Check that the lockbolts are tightened to 8-10 ft.-lb. (11-

13 N•m) torque.
Do not over-tighten.
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SEAT BAR RESTRAINT SYSTEM Seat Bar Maintenance
The seat bar restraint system has a pivoting seat bar with Figure 10-200-1
arm rests and has spring loaded interlocks for the lift and
tilt control pedals. The operator controls the use of the
seat bar. The seat bar in the down position helps to keep
the operator in the seat. The interlocks require the
operator to lower the seat bar in order to operate the foot
pedal controls. When the seat bar is up, the lift and tilt
pedals are locked when returned to the neutral position.
WARNING
AVOID INJURY OR DEATH
The Seat Bar System must lock the lift and tilt foot
pedals or hand controls in neutral when the Seat Bar
is up. Service the system if controls do not lock
correctly.
W-2263-0597
Seat Bar Inspection

Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the green PRESS TO OPERATE P-9790
Button. Operate each foot pedal to check both the lift

and tilt functions. Raise the lift arms until the bucket is
Figure 10-200-2
about 2 feet (600 mm) off the ground.
Raise the seat bar, try to move each pedal. The pedals
must be firmly locked in neutral position. There must be
no motion of the tilt (bucket) or the lift arms when the
pedals are pushed.
Pull the seat bar down, press the green PRESS TO

OPERATE Button and lower the lift arms. Operate the lift
pedal. While the lift arms are going up, raise the seat bar
and the lift arms should stop.
Lower the seat bar, Press the green PRESS TO

OPERATE Button, lower the lift arms and put the bucket
flat on the ground. Stop the engine. Raise the seat bar
P-37951
and operate the foot pedals to be sure that the pedals are
firmly locked in the neutral position. Unbuckle the seat
belt. (See SERVICE SCHEDULE on Page 10-70-1) and on
the loader for correct service interval.
Clean any debris or dirt from the moving parts [Figure

10-200-1] & [Figure 10-200-2].
Inspect the linkage bolts and nuts for tightness. The

correct torque is 25-28 ft.-lb. (34-38 N•m).
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SEAT BAR RESTRAINT SYSTEM (CONT’D)
Seat Bar Maintenance (Cont’d)
If the seat bar system does not function correctly, check

for free movement of each linkage part. Check for
excessive wear. Adjust pedal control linkage. Replace
parts that are worn or damaged. Use only genuine
Bobcat replacement parts.
Foot Pedal Clean Out
Figure 10-200-3

P-37952
Clean any debris from around the foot pedals. Debris will
fall out through the holes under the pedals (Item 1)
[Figure 10-200-3].
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HYDRAULIC SYSTEM
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Control Pedals Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-90-2
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2 SAFETY &
Pedal Interlock Linkage Removal And Installation. . . . . . . . . . . . . . . . 20-90-1 MAINTENANCE
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Checking The Lift Cylinder(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
SYSTEM
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 DRIVE

Checking The Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SYSTEM
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1

Auxiliary Pivot Bracket Disassembly And Assembly . . . . . . . . . . . . . .20-40-25
Auxiliary Pivot Bracket Removal And Installation . . . . . . . . . . . . . . . .20-40-25

ELECTRICAL
Anti Cavitation/Check Valves Removal And Installation . . . . . . . . . . . 20-40-11
SYSTEM &
Auxiliary Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . .20-40-21
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . .20-40-21 ANALYSIS
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . .20-40-3
BICS™ Valve, Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-6 ENGINE
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . .20-40-2
SERVICE
BICS™ Valve, Pressure Differential Valve Removal And Installation . .20-40-3
BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
BICS™ Valve, Solenoid Removal And Installation . . . . . . . . . . . . . . . 20-40-4
BICS™ Valve, Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
SPECIFICATIONS
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Lift And Tilt Lock Block Removal And Installation . . . . . . . . . . . . . . . 20-40-12
Lift Spool And Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Lift Spool And Detent Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-14
Lift Spool And Detent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-13
Lift Spool Detent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-18
Load Check Valves Removal And Installation . . . . . . . . . . . . . . . . . . . .20-40-9
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . .20-40-9
Port Relief/Anti-Cavitation Valve Removal And Installation . . . . . . . . .20-40-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-6
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .20-40-12
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-24
Tilt Spool Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . .20-40-20
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-19
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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 20-70-2
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Checking The Output Of The Pump. . . . . . . . . . . . . . . . . . 20-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BY-PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Checking The Main Relief Valve With Auxiliaries. . . . . . . . 20-30-2
Checking The Main Relief Valve Without Auxiliaries . . . . . 20-30-1

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463 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 538911001 AND ABOVE
(PRINTED DECEMBER 2004)
V-0638legend
LEGEND
1 RESERVOIR CAPACITY:. .5.3 Qts. (5,0 L) 14 FILTER - BICS CONTROL VALVE
System Capacity:. . . . . . . 16.0 Qts. (15,14 L)
2 HYDRAULIC FILTER: 15 CHECK VALVE - BICS CONTROL VALVE
with 46 PSI (3,2 Bar) by-Pass
16 SOLENOID ACTIVATED DIRECTIONAL
3 CHARGE PRESSURE SWITCH: CONTROL VALVE - BICS CONTROL
17-21 PSI (1,2-1,4 Bar)
17 PULL BUTTON ACTIVATED
4 TEMPERATURE SWITCH
DIRECTIONAL CONTROL VALVE - LIFT
225-232 degrees F.
ARM BY PASS
(108-111 degrees C.)
5 RELIEF VALVE - CHARGE: 18 PILOTED ACTIVATED DIRECTIONAL
85 PSI (5,9 Bar) CONTROL VALVE - LIFT CONTROL
6 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDRAULIC/ 19 PILOTED ACTIVATED DIRECTIONAL
HYDROSTATIC MOTOR CONTROL VALVE - TILT CONTROL

7 VARIABLE CAPACITY DISPLACEMENT
20 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDRAULIC/
HYDROSTATIC PUMP CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
8 HYDRAULIC PUMP:
Gear Type . . . 9.8 GPM (37,1 L/min.) 21 FLOW DIVIDER ADJUSTMENT VALVE
at 3000 RPM
9 RELIEF/REPLENISHING VALVE - HIGH 22 PILOTED ACTIVATED DIRECTIONAL
PRESSURE: 3000 PSI (207 Bar) CONTROL VALVE - FLOW CONTROL
SPOOL
10 RELIEF VALVE - MAIN: Two Stage
System Relief 2000 PSI (138 BAR) 23 CHECK VALVE - BUCKET POSITION
Auxiliary Relief at Front Quick Couplers VALVE
3000 PSI (207 BAR)
24 PILOTED ACTIVATED DIRECTIONAL
11 LOAD CHECK VALVE CONTROL VALVE - UNLOADING
SPOOL
12 RELIEF/ANTICAVITATION VALVE -
PORT . . . . . . . . . 3500 PSI (241 Bar)
at High Engine RPM
13 ANTI CAVITATION VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-0638legend (12-2-04)
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HYDRAULIC
463 HYDRAULIC/HYDROSTATIC SCHEMATIC FILTER
S/N 538911001 AND ABOVE BUCKET POSITION VALVE (OPTIONAL)
S/N 539011001 AND ABOVE 2
(PRINTED DECEMBER 2004) D
V-0638 23
DRIVE MOTOR
MALE
(FRONT AUXILIARY
QUICK COUPLERS)
21
6
3
FEMALE
A
4
OIL COOLER
20 C
5
22
HYDROSTATIC PUMPS 24
7 HYDRAULIC CONTROL VAVLE B
9 TILT CYLINDER
AUXILIARY
9 SPOOL
INLET 11
9
9
BICS CONTROL VALVE
7
13 Dealer Copy -- Not for Resale
P2 B1
19
8 TILT
INLET OUTLET CYLINDER
SPOOL
11
LIFT CYLINDERS
13
P1 L1
DRIVE MOTOR
6
LIFT 18
CYLINDER
SPOOL
12
11
PP
16
10 14 15
14
PT
17
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
Printed in U.S.A. 1 V-0050 (3-26-01)
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HYDRAULIC SYSTEM INFORMATION
MC 2340 (6-2-98)
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HYDRAULIC SYSTEM INFORMATION (CONT’D)
MC 2340-2 (6-2-98)
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MC 2340-3 (6-2-98)
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Troubleshooting Chart
The following troubleshooting chart is provided for

assistance in locating and correcting problems which are
WARNING
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel Check for correct function after adjustments, repairs
only. or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are 1, 3
operating.
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral 4
position.
The lift arms come down with the pedal in the neutral position 4, 9, 10, 11

KEY TO CORRECT THE CAUSE
1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See Specifications on Page SPEC-50-1.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
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CYLINDER (LIFT) Figure 20-20-3
Checking The Lift Cylinder(s)
Open the rear door.

1
Figure 20-20-1
1
P-39098
Disconnect the hose (Item 1) [Figure 20-20-3] from the

lift cylinder base end port.
P-19327 Install a plug in the hose and tighten the plug.
Lower the seat bar, engage the parking brake and start

Remove the nut (Item 1) [Figure 20-20-1] from the base the engine. Loaders without seat sensors press the
end pin retainer (left side shown). green PRESS TO OPERATE button.
Figure 20-20-2 Push the top (toe) of the lift pedal until system relief
pressure is reached.
There should be no leaks at the base end port.
If there is leakage from the open base end port of the lift
cylinder, remove the lift cylinder for repair. (See Removal
And Installation on Page 20-20-2.)
Install the cylinder(s) in the reverse order.
WARNING
P-39097
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
Use a slide hammer to remove the pivot pin (left side penetrating the skin. This can cause serious injury
shown) [Figure 20-20-2]. and possible death if proper medical treatment by a
physician familiar with this injury is not received
Pull the cylinder forward. Mark the hoses for correct immediately.
reassembly. W-2145-0290
Check only one cylinder at a time.
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CYLINDER (LIFT) (CONT’D) Lower the left cylinder into the fender [Figure 20-20-5].
Removal And Installation Figure 20-20-6
Fully lower the lift arms.
Stop the engine. Pull up on the lift arm by-pass control

and move the lift pedal to release the hydraulic pressure.
Raise the seat bar. Engage the parking brake. Raise the 1
operator cab. (See Raising The Operator Cab on Page
10-30-1.)
Figure 20-20-4
P-19290
1 Remove the bolt (Item 1) [Figure 20-20-6] to remove the

cover and pivot pin from the right lift cylinder.
Installation: Tighten the bolt to 18-20 ft.-lb. (24-27 N•m)

torque.
Remove the cover and pivot pin [Figure 20-20-6].

P-19288
Figure 20-20-7
Install a lifting strap around the center of the lift arms

crossmember, fasten the strap to a chain hoist and the lift
arms slightly as shown [Figure 20-20-4].
Remove the rod end retainer bolt (Item 1) [Figure 20-20-

4] from the left cylinder.

torque.
Remove the retainer and the rod end pin [Figure 20-20-
4].
Figure 20-20-5
P-19324
Lower the right lift cylinder onto the fender [Figure 20-20-
7].
P-19325
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CYLINDER (LIFT) (CONT’D) Figure 20-20-10
Removal And Installation (Cont’d)
Figure 20-20-8 1
P-39098
Pull the cylinder forward to remove the hose (Item 1)

P-19327 [Figure 20-20-10] from the base end and the hose (Item
2) [Figure 20-20-10] from the rod end. Mark the hoses
for correct reassembly.
Open the rear door.
Install the cylinder(s) in the reverse order.

Remove the nut (Item 1) [Figure 20-20-8] from the base
end pin retainer (left side shown).

torque.
Figure 20-20-9
P-39097
Use a slide hammer to remove the pivot pin (left side

shown) [Figure 20-20-9].
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CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Tube
2. Case
7
3. Nut
4. Piston
5. Ring 5
6. O-Ring 4
7. Spacer
8. O-Ring 6
9. Washer
10. Head
11. Seal 3 13
12. Seal 8
13. Rod
12
1
11
2 10
8
9
8

B-6942
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Disassembly And Assembly 4

2 3
Use the following tools to disassemble and assemble the
cylinder:
1
MEL 1074 - O-ring Seal Hook
MEL 1396 - Seal Installtion Tool
MEL 1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder. P-7428
Put the base end of the cylinder in a vise.

Remove the head and the rod assembly from the cylinder
Figure 20-20-11 [Figure 20-20-12].
Put the rod end in a vise.
Remove the nut (Item 1) [Figure 20-20-12], piston (Item

2) [Figure 20-20-12], spacer (Item 3) [Figure 20-20-12]
and head (Item 4) [Figure 20-20-12].
Installation: Lift: tighten the nut to 300 ft.-lb. (407 N•m)

torque.
Figure 20-20-13
P-7429
2
Use a spanner wrench to loosen the head [Figure 20-20- 1

11].
P-7430
Remove the seal (Item 1) [Figure 20-20-13] and O-ring

(Item 2) [Figure 20-20-13] from the piston (Item 3)
[Figure 20-20-13].
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Disassembly And Assembly (Cont’d)
Figure 20-20-14
2
1
P-7424
Install a new seal on the tool and slowly stretch it until it

P-7422 fits the piston (Item 1) [Figure 20-20-16].
Allow the seal the stretch for 30 seconds before installing

Remove the thick O-ring (Item 1) [Figure 20-20-14] and it on the piston.
the back-up washer (Item 2) [Figure 20-20-14] from the

groove in the head. Remove the thin O-ring (Item 3) Use a ring compressor to compress the seal to the
[Figure 20-20-14]. correct size. Leave the piston in the compressor for
about three minutes.
Figure 20-20-15
Figure 20-20-17
2
1
3
P-7426
P-7427
Remove the wiper seal (Item 1) [Figure 20-20-15], and

rod seal (Item 2) [Figure 20-20-15]. Install the rod seal on the rod seal tool [Figure 20-20-17].
Remove the O-ring (Item 3) [Figure 20-20-15] from the
NOTE: During installation the O-ring side of the seal
rod seal.
must be toward the inside of the cylinder.
Wash the cylinder parts in solvent and air dry them.
Rotate the handles to collapse the rod seal.
Inspect the cylinder for nicks, scratches or other damage.
Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during

installation.
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CYLINDER (LIFT) (CONT’D)
Figure 20-20-18
P-7425
Install the rod seal in the head [Figure 20-20-18].

Install the wiper seal with the wiper toward the outside of
the head.
Assemble the cylinder(s) in the reverse order.
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CYLINDER (TILT) Removal And Installation
Checking The Tilt Cylinder Tilt the Bob-Tach fully forward until it rests on the floor.
Stop the engine. Raise the seat bar. Stop the engine and raise the seat bar.
Engage the parking brake.
WARNING Figure 20-21-2
Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-21-1
1
2 P-37983

Remove the bolt (Item 1) [Figure 20-21-2] and the
retainer (Item 2) [Figure 20-21-2] from the Bob-Tach and
tilt cylinder rod end pivot pin.
1 Installation: Tighten the bolt to 18-20 ft.-lb. (24-27 N•m)

torque.
Remove the pivot pin from the Bob-Tach.

P-19273
Figure 20-21-3
Disconnect the hose (Item 1) [Figure 20-21-1] from the

base end of the tilt cylinder.
Install a plug in the hose and tighten the plug. 1
Lower the seat bar, engage the parking brake and start
the engine.
Push the bottom (heel) if the tilt pedal until system relief
pressure is reached.
1
There should be no leaks from the base end of the port.
If there is leakage from the open port of the tilt cylinder, P-19273
remove the cylinder for repairs.
Remove the hoses (Item 1) [Figure 20-21-3] from the tilt

cylinder fittings.
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CYLINDER (TILT) (CONT’D) Figure 20-21-5
Figure 20-21-4 1
2
P-19282
1
Remove the pivot pin (Item 1) [Figure 20-21-5] from the

P-19278 tilt cylinder base end and the lift arm frame.

retainer (Item 2) [Figure 20-21-4] from the base end of

the tilt cylinder.
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CYLINDER (TILT) (CONT’D)
1. Tubeline
2. Case
3. Nut
4. Piston
5. Seal
11
6. O-Ring
7. Bolt 7
11
8. Clamp
9. Nut 1
10. O-Ring
11. Seal
12. Head 2 13
13. Rod 8 11
14. Seal
3 10
14
4 9
12

5
C-1808
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Disassembly And Assembly 4

2 3
Use the following tools to disassemble and assemble the
cylinder:
1
MEL 1074 - O-ring Seal Hook
MEL 1396 - Seal Installation Tool
MEL 1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder. P-7428
Put the base end of the cylinder in a vise.

Remove the head and the rod assembly from the cylinder
Figure 20-21-6 (Item 1) [Figure 20-21-7].
Put the rod end in a vise.
Remove the nut (Item 1) [Figure 20-21-7], piston (Item 2)

[Figure 20-21-7], spacer (Item 3) [Figure 20-21-7] and
head (Item 4) [Figure 20-21-7]
Installation:Lift: Tighten the nut to 250 ft.-lb. (339 N•m)

torque.
Figure 20-21-8
P-7429
2
Use a spanner wrench to loosen the head [Figure 20-21- 1

6].
P-7430
Remove the seal (Item 1) [Figure 20-21-8] and O-ring

(Item 2) [Figure 20-21-8] from the piston (Item 3) [Figure
20-21-8].
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Figure 20-21-9
2
1
P-7424
Install a new seal on the tool and slowly stretch it until it

P-7422 fits the piston (Item 1) [Figure 20-21-11].
Allow the seal the stretch for 30 seconds before installing

Remove the thick O-ring (Item 1) [Figure 20-21-9] and it on the piston.
the back-up washer (Item 2) [Figure 20-21-9] from the

groove in the head. Remove the thin O-ring (Item 3) Use a ring compressor to compress the seal to the
[Figure 20-21-9]. correct size. Leave the piston in the compressor for
about three minutes.
Figure 20-21-10
Figure 20-21-12
2
1
3
P-7426
P-7427
Remove the wiper seal (Item 1) [Figure 20-21-10],and

the rod seal (Item 2) [Figure 20-21-10]. Install the rod seal on the rod seal tool [Figure 20-21-12].
NOTE: During installation the O-ring side of the seal
rod seal.
must be toward the inside of the cylinder.
Wash the cylinder parts in solvent and air dry them.
Rotate the handles to collapse the rod seal.
Inspect the cylinder for nicks, scratches or other damage.
Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during

installation.
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CYLINDER (TILT) (CONT’D)
Figure 20-21-13
P-7425
Install the rod seal in the head [Figure 20-21-13].

Install the wiper seal with the wiper toward the outside of
the head.
Assemble the cylinder(s) in the reverse order.
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MAIN RELIEF VALVE Check the hose routing, from the tester, for clearance
while doing this procedure.
Checking The Main Relief Valve Without Auxiliaries
Sit in the operator seat, lower the seat bar and fasten the
NOTE: The following procedure is for checking the seat belt.
main relief valve only. Use this procedure
when it is known that the hydraulic pump is in Start the engine and run at low RPM. Push the bottom
good working condition. If the hydraulic (heel) of the right foot pedal to retract the tilt cylinder.
pump is not working correctly, refer to
checking the output of the hydraulic pump. Check for hydraulic leaks. Be sure the tester is showing
(See Checking The Output Of The Pump Page flow.
20-60-1.)
Increase the engine speed to full RPM.
procedure: Push the bottom (heel) of the right foot pedal until the
system relief pressure is reached.
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit The correct pressure for the main relief valve is 2000 PSI
(13788 kPa).
Lift and block the loader. (See Procedure Page 10-10-1.)
If the relief valve pressure is not correct, stop the engine.
Figure 20-30-1 Replace the main relief valve. (See Page 20-30-3.)
When the test is complete return the foot pedal to neutral

position, reduce the engine RPM to idle.
1 Stop the engine.
WARNING
P-19273
W-2017-0286
Disconnect the rod end hydraulic hose (Item 1) [Figure

20-30-1] from the tilt cylinder.
Connect the IN port of the hydraulic tester to the rod end

hydraulic hose (Item 1) [Figure 20-30-1].
Connect the OUT port of the hydraulic tester to the rod

end of the tilt cylinder port. (Where the hydraulic hose
was disconnected.)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
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MAIN RELIEF VALVE (CONT’D) Open the restrictor (Item 3) [Figure 20-30-2] fully
(counterclockwise) before testing the relief valve.
Checking The Main Relief Valve With Auxiliaries
NOTE: The following procedure is for checking the

main relief valve only. Use this procedure
when it is known that the hydraulic pump is in
IMPORTANT
good working condition. If the hydraulic
pump is not working correctly, refer to The hydraulic tester must be in the fully open
checking the output of the hydraulic pump. position before you start the engine.
I-2024-0284
(See Checking The Output Of The Pump Page
20-60-1.)
Remove the auxiliary hydraulics lock bolt. (See
NOTE: The main relief valve is not adjustable. Procedure Page 10-140-1.)
The tools listed will be needed to do the following Figure 20-30-3

procedure:
MEL 10003 - Hydraulic Tester

MEL 10006 - Hydraulic Test Kit
Lift and block the loader. (See Procedure Page 10-10-1.)

WARNING
fall or move and cause injury or death. P-34925
W-2017-0286
Start the engine and run at low idle RPM. Push the right
Figure 20-30-2 steering lever all the way to the right to engage the front
auxiliary hydraulics detent [Figure 20-30-3].
Increase the engine speed to full RPM. Watch the flow

meter on the hydraulic tester to make sure the flow is
3 correct.
There should be 9.8 GPM (37.1 L/min.) free flow.

2
Slowly turn the restrictor control knob (Item 3) [Figure
20-30-2], on the tester, until the main relief valve opens.
Record the pressure reading. The correct pressure for
the main relief valve is 3000 PSI (20682 kPa).
1
P-39079
WARNING
Connect the IN port of the hydraulic tester to the bottom
(female) quick coupler (Item 1) [Figure 20-30-2] on the When the engine is running during service, the
loader. steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Connect OUT port of the hydraulic tester to the top death.
(male) quick coupler (Item 2) [Figure 20-30-2] on the W-2006-0284
loader.
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MAIN RELIEF VALVE (CONT’D) Figure 20-30-5
Removal And Installation

1 1
Page 10-30-1.)
Figure 20-30-4
2 1
P-39096
Remove the o-rings (Item 1) [Figure 20-30-5] and back-

up washer (Item 2) [Figure 20-30-5]. Install new o-rings
and back-up washer.
P-37916

Clean the area around the control valve. Remove the
pilot hose (Item 1) [Figure 20-30-4] from the main relief
valve. Remove the main relief valve (Item 2) [Figure 20-
30-4].
Installation: Tighten the main relief valve to 35-40 ft.-lb.

(47-54 N•m) torque.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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HYDRAULIC CONTROL VALVE Figure 20-40-3
BICS™ Valve Removal And Installation
Figure 20-40-1
1
1
1 1 1
1 1 1
1
2
1 P-37723
Remove and discard the four large O-rings (Item 1)

P-37724 [Figure 20-40-3] and the small O-ring (Item 2) [Figure
20-40-3] from the top of the control valve.
Remove the control valve from the loader. (See Removal Install new O-rings during assembly.

Remove the six mounting bolts (Item 1) [Figure 20-40-1]
to remove the BICS™ valve from the control valve. Note
the bolt locations.
Figure 20-40-2
P-37722
Remove the BICS™ valve assembly from the top of the

control valve [Figure 20-40-2].
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HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve, Lift Arm By-Pass Orifice Removal And
Installation
BICS™ Valve Removal And Installation (Cont’d)
Figure 20-40-5
Figure 20-40-4
6
3
1 2 2
5 4 1
P-37726
P-37724
The lift arm by-pass orifice is located in the port with the
Install the six mounting bolts [Figure 20-40-4]. 90° fitting (Item 1) [Figure 20-40-5]. The pressure
differential/check valve (Item 2) [Figure 20-40-5] must be

The chart below lists the correct torque specifications removed to remove the fitting (Item 1) [Figure 20-40-5].
and tightening sequence when reinstalling the BICS™
valve assembly to the control valve. Thoroughly clean Figure 20-40-6
and dry the bolts and the threads in the valve. Use liquid
adhesive LOCTITE #242 or equivalent.
STEP TORQUE SEQUENCE

1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb.
1,2,3,4,5 &6 1
(21,5-23,7 N•m)
3* 190-210 in.-lb.
(21,5-23,7 N•m)
*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for

every bolt or repeat step 3.
P-37728
Use a flat blade screw driver to remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-6] from the BICS™
valve.
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HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-9
BICS™ Valve, Lift Arm By-Pass Orifice Removal And

1
Installation (Cont’d)
Figure 20-40-7
1 2
2
2
N-18690
Remove the O-rings (Item 1) [Figure 20-40-9] and the

back-up rings (Item 2) [Figure 20-40-9] from both the tilt
P-37729 pressure differential valve.
Install new O-rings and back-up rings during assembly.

Check the condition of the orifice (Item 1) [Figure 20-40-

7] and replace if needed. BICS™ Valve, Check Valve Removal And Installation
The orifice hole must be 0.0785 inch (1.994 mm) Figure 20-40-10
diameter.
BICS™ Valve, Pressure Differential Valve Removal

And Installation
Figure 20-40-8 1
P-37725
Remove the check valve (Item 1) [Figure 20-40-10].
Installation: Tighten the valve to 22 ft.-lb. (30 N•m)

P-37724 torque.
Remove the two pressure differential valves (Item 1)

[Figure 20-40-8] from the BICS™ valve.
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HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve, Solenoid Removal And Installation
BICS™ Valve, Check Valve Removal And Installation Figure 20-40-13

(Cont’d)
Figure 20-40-11
1
2
1
P-37730
N-18684 Remove the mounting nut (Item 1) [Figure 20-40-13]

from the solenoid stem.
Remove the O-rings (Item 1) [Figure 20-40-11] and the Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

back-up ring (Item 2) [Figure 20-40-11] from the check
valve. Remove the coil.
Install new O-rings and back-up ring on the check valve. Figure 20-40-14
Figure 20-40-12
1
P-37731
P-8956
Remove the O-rings (Item 1) [Figure 20-40-14] from
both ends of the coil.
Clean and inspect the screen (Item 1) [Figure 20-40-12]
on the end of the valve.
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HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve, Solenoid Testing
BICS™ Valve, Solenoid Removal And Installation Figure 20-40-17

(Cont’d)
Figure 20-40-15
P9175
P-37732 Use a test meter to measure the coil resistance [Figure

20-40-17]. Coil wires do not have polarity. Correct
resistance for the coil is 7-10 ohms.
Remove the solenoid stem (Item 1) [Figure 20-40-15].

Raplace the test meter with 12 volt power. You can see
Installation: Tighten the solenoid stem to 22 ft.-lb. (29.8 and hear the spool shift.
N•m) torque.
Figure 20-40-16
3
2
1
N-18694
Remove the O-rings (Item 1) [Figure 20-40-16] and

back-up washers (Item 2) [Figure 20-40-16] from the
solenoid stem.
Clean the solenoid stem in solvent and dry with

compressed air.
Inspect the solenoid stem for wear and replace if it is

showing excessive wear.
NOTE: The screen (Item 3) [Figure 20-40-16] may be

cleaned with solvent. If it is torn or worn
replace the solenoid stem.
Apply oil to the new O-rings and back-up washers and

install on the solenoid stem.
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HYDRAULIC CONTROL VALVE (CONT’D) Removal And Installation
BICS™ Valve, Identification Chart
Figure 20-40-18
2 3
5 WARNING
1 B-20380 support device can allow the lift arms or attachment
Item 463AF W-2059-0598
1 Tilt Cylinder Rod End Lock Valve
2 Lift Cylinder Base End Lock Valve Install jackstands under the rear corners of the loader.

3 Orifice (See Procedure on Page 10-10-1.)
4 Solenoid
5 Check Valve Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the center control shield and the steering lever

covers. (See Control Shield And Steering Lever Panels
Removal And Installation on Page 30-20-1.)
Remove the steering levers. (See Lever Removal And

Installation on Page 30-30-1.)
Thoroughly clean the control valve area.
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Figure 20-40-19 3
2 2
1
1
1
P-39072
Remove the tilt tublines (Item 1) [Figure 20-40-21] and

1 1 P-39064 the auxiliary tubelines (Item 2) [Figure 20-40-21] from
the control valve.
Remove the hair pins and the fastener links (Item 1) Remove the pilot hose (Item 3) [Figure 20-40-21] from
[Figure 20-40-19] from the three spools in the control the control valve.

valve spool.
Figure 20-40-22
Figure 20-40-20
1
1 1
P-39071
P-39073
Remove the left rear mounting bolt (Item 1) [Figure 20-

Remove the lift tubelines (Item 1) [Figure 20-40-20] from 40-22] from the control valve.
the control valve.
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HYDRAULIC CONTROL VALVE (CONT’D) Identification Chart
Removal And Installation (Cont’d) Item 463AF

A1 Lift Cylinder Base End
Figure 20-40-23
A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function
1 C3 Load Check Valve/Auxiliary Function
D1 Lift Spool Detent
D2 Centering Spring Tilt Spool
D3 Auxiliary Spool Detent
E1 Port Relief/Anti-Cavitation Valve
E2 Anti-Cavitation/Check Valve
F1 Anti-Cavitation/Check Valve
F2 Plug
P-39065 G1 Lift Spool
G2 Tilt Spool
G3 Auxiliary Spool
Remove the nut (Item 1) [Figure 20-40-23] from the
MR Main Relief Valve
mounting bracket on the right front corner of the control

valve
Lift and pull the control valve forward to remove it from AUXILIARY
the loader. LIFT
D3 TILT
D1
D2
E2 E1
A3 A2 A1
C3 C2 C1
OUTLET
B3 B2 B1 INLET
F2 F1
G3
G2 G1 MR
B-20379
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Disassembly And Assembly

1
See Identification Chart on Page 20-40-8 for the control
valve parts assembly.
2
3
IMPORTANT
4
N-20078
damage the system.
I-2003-0888
Remove the load check plug (Item 1) [Figure 20-40-25],
Mark each valve section and spool so that the parts will spring (Item 2) [Figure 20-40-25], and poppet (Item 3)
be returned to their original bore during assembly. [Figure 20-40-25].
Use bolts to fasten the control valve to a work bench for All poppets have an orifice (Item 4) [Figure 20-40-25].
easier disassembly and assembly.

Main Relief Valve Removal And Installation
Load Check Valves Removal And Installation
NOTE: The main relief valve is non-adjustable.
Figure 20-40-24
Figure 20-40-26
1
1
1
P-37723 1
P-37733
Remove the BICS™ valve assembly from the control

valve. (See BICS™ Valve Removal And Installation on Remove the main relief valve adapter fitting (Item 1)
Page 20-40-1.) [Figure 20-40-26].
Remove and discard the four large O-rings (Item 1)

[Figure 20-40-24] and the small O-ring (Item 2) [Figure
20-40-24] from the top of the control valve. Install new O-
rings during assembly.
Loosen the load check plug (Item 3) [Figure 20-40-24].
Assembly: Always use new O-rings. Tighten the plugs

to 35-40 ft.-lb. (47-54 N•m) torque.
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HYDRAULIC CONTROL VALVE (CONT’D) Port Relief/Anti-Cavitation Valve Removal And
Installation
Main Relief Valve Removal And Installation (Cont’d)
Figure 20-40-29
Figure 20-40-27
1 P-37735
P-37785
Remove the Port Relief/Anti Cavitation valve (Item 1)

Remove the O-ring from the main relief valve adapter [Figure 20-40-29].
fitting (Item 1) [Figure 20-40-27].

Assembly: Always use new O-rings and back-up
Figure 20-40-28 washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
Figure 20-40-30
1
2
P-37734
P-37736
Remove the main relief valve (Item 1) [Figure 20-40-28]
from the control valve.
Remove the O-rings (Item 1) [Figure 20-40-30], and
Remove the O-rings and back-up washers (Item 2) back-up washer (Item 2) [Figure 20-40-30] from the Port
[Figure 20-40-28] from the main relief valve. Relief/Anti-Cavitation valve.

washers (Item 2) [Figure 20-40-28]. Tighten to 35-40 ft.-
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Anti Cavitation/Check Valves Removal And

Installation
Figure 20-40-31
1 P-37739
Remove the Anti Cavitation/Check valve (Item 1) [Figure

20-40-33] from the lift cylinder rod end port.
P-37737
Figure 20-40-34
Remove the Anti Cavitation/Check valve (Item 1) [Figure

20-40-31] from the tilt cylinder base end port.
1
Figure 20-40-32
P-37738
2
Remove the O-rings (Item 1) [Figure 20-40-34], and
back-up washer (Item 2) [Figure 20-40-34] from the Anti
P-37738 Cavitation/Check valve.

Remove the O-rings (Item 1) [Figure 20-40-32], and washer. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
back-up washer (Item 2) [Figure 20-40-32] from the Anti
Cavitation/Check valve.

washer. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
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HYDRAULIC CONTROL VALVE (CONT’D) Lift And Tilt Lock Block Removal And Installation
Rubber Boot Removal And Installation Figure 20-40-37
Figure 20-40-35
1
P-37754
P-37752
Remove the lift and tilt lock block [Figure 20-40-37].
Remove the two screws (Item 1) [Figure 20-40-35] from

the rubber boot retainer.

Assembly: Tighten the screws to 90-100 ft.-lb. (10,2-
11,3 N•m) torque.
Figure 20-40-36
2 2
P-37753
Remove the rubber boots (Item 1) [Figure 20-40-36] and

boot retainers (Item 2) [Figure 20-40-36].
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Lift Spool And Detent Removal
Figure 20-40-38
1
2
2
1
P-37758
1
Remove the screws (Item 1) [Figure 20-40-40] from the

P-37756 detent bonnet. Remove the detent bonnet (Item 2)
[Figure 20-40-40] from the detent bonnet. Remove the
detent bonnet.
The tool listed will be needed to do the following
procedure:

MEL 1278 - Detent Tool
IMPORTANT
MEL 1285 - Detent Spring Tool
The detent assembly has small springs and balls. Do
Remove the lift and tilt lock block. (See Page 20-40-12.) not lose these parts during disassembly and
assembly.
Remove the O-ring (Item 1) [Figure 20-40-38] and I-2012-0284
bushing (Item 2) [Figure 20-40-38].
Figure 20-40-41
Figure 20-40-39
3
1
2
P-37759
P-37757
Wrap a rag around the detent assembly (Item 1) [Figure

Remove the end cap (Item 1) [Figure 20-40-39]. Use a 20-40-41]. This will prevent the detent balls and spring
screw driver to remove the snap ring (Item 2) [Figure 20- from being lost when the detent sleeve is removed.
40-39]. Remove the washer (Item 3) [Figure 20-40-39].
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Lift Spool And Detent Removal (Cont’d)
Figure 20-40-42
2 1
3 1
P-37762
2
Remove the spool seal (Item 1) [Figure 20-40-44] from
P-37760 the linkage end of the control valve.
Lift Spool And Detent Disassembly

Remove the detent sleeve (Item 1) [Figure 20-40-42],
detent balls (Item 2) [Figure 20-40-42], and spring (Item Figure 20-40-45

3) [Figure 20-40-42].
Figure 20-40-43
1 1
N-18915
P-37761 Put the linkage end of the spool assembly [Figure 20-40-
45] in a vise.
Remove the spool assembly and seal (Item 1) [Figure Install MEL 1285 Spring Compressor Tool (Item 1)
20-40-43]. [Figure 20-40-45] on the spring assembly.
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Lift Spool And Detent Disassembly (Cont’d)
Figure 20-40-46
P-7278
Lift Spool Only: Remove the stud from the end of the
N-18916 spool [Figure 20-40-48].
Figure 20-40-49
Put a rag around the detent assembly (Item 1) [Figure
20-40-46] to prevent losing the two detent balls when the

detent adapter is removed.
NOTE: Be careful when removing the detent adapter 1

from the centering spring, the spring is under
pressure.
Use an allen wrench (Item 2) [Figure 20-40-46] to 2

remove the detent adapter.
Figure 20-40-47
2 N-18920 P-7443
1
Removal of plastic plug.
• Make a center point in the plug using a 3/16 inch drill.
• Drill a hole all the way through the plug using a 7/64
3 inch tap drill.
• Turn a 6-62 tap into the plug [Figure 20-40-49]. Pull

4 the tap and plug out of the spool. BE CAREFUL, do
P7280 not break the tap.
• Clean all the debris from the inside of the spool bore.
Remove the detent adapter (Item 1) [Figure 20-40-47]
from the adapter retainer (Item 2) [Figure 20-40-47]. Assembly: Install the new plastic plug (Item 1) [Figure
20-40-49] and O-ring (Item 2) [Figure 20-40-49].
Remove the detent spring (Item 3) [Figure 20-40-47] and
detent balls (Item 4) [Figure 20-40-47].
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Lift Spool And Detent Assembly
Figure 20-40-50
1
N-18968
0.600”
(15,2 mm)
Install the detent balls and spring into the detent adapter
B-9973 (Item 1) [Figure 20-40-52]. Hold the detent balls in
position with the tool and install the detent adapter into
the end cap [Figure 20-40-52].
Install the stud and leave 0.600 inch (15,2 mm) past the
end of the spool [Figure 20-40-50]. Figure 20-40-53

NOTE: DO NOT US LOCTITE ON THE STUD
THREADS. DO NOT EXCEED 70 in.-lb. (8 N•m)
torque during stud installation. Excess
torque may cause spool distortion resulting in
sticky spool operation.
NOTE: Put grease on all detent component surfaces

before assembly. 1
Figure 20-40-51
N-19004
Install the MEL 1285 Compression Spring Tool (Item 1)

1 [Figure 20-40-53] over the washer, spring, collar, and
detent adapter.
NOTE: Be careful when installing the assembly in the

spring tool, the assembly is under spring
pressure.
N-18967
Install the collar (Item 1) [Figure 20-40-51] in a vise. DO

NOT overtighten the vise.
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Lift Spool and Detent Assembly (Cont’d)
Figure 20-40-54
1
N-19007
Install the detent balls and spring in the adapter. Hold the
N-18917 detent balls in place with the detent pliers (Item 1)
[Figure 20-40-56].
Install the spool seal (Item 1) [Figure 20-40-54] and the Figure 20-40-57
back-up washer (Item 2) [Figure 20-40-54] on the spool.

NOTE: The larger diameter of the seal surface must
be installed toward the inside of the control
valve.
Figure 20-40-55
1
1
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-57] on

the detent adapter.
While holding the detent balls in position with the tool,

N-19005 push the detent adapter into the end cap [Figure 20-40-
57]
Install the spring assembly on the lift spool hand tight

[Figure 20-40-55].
Remove the spring tool. Check the alignment of the

detent adapter and the washer.
NOTE: The adapter must fit in the center of the washer

(Item 1) [Figure 20-40-55].
Tighten the detent adapter to 90-100 in.-lb. (10,2-11,3

N•m) torque.
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Lift Spool Detent Installation
Figure 20-40-58
2 2
1
P-37756
2
Install the bushing (Item 1) [Figure 20-40-60] and the O-
P-37758 ring (Item 2) [Figure 20-40-60] in the linkage end of the
control valve.
Install a new spool seal in the linkage end of the control Figure 20-40-61
valve. Install the spool assembly [Figure 20-40-58] in

the control valve.
1
Install the detent bonnet (Item 1) [Figure 20-40-58] and
the mounting screws (Item 2) [Figure 20-40-58].
Installation: Tighten the screws to 90-100 in.-lb. (10,2-

11,3 N•m) torque. 2
Figure 20-40-59
P-37753
1
3
2
Install the lift and tilt lock block (Item 1) [Figure 20-40-61]
on the control valve.
Install the rubber boots (Item 2) [Figure 20-40-61] and

the screws on the lift and tilt lock block.
P-37757
Install the washer (Item 1) [Figure 20-40-59], the snap

ring (Item 2) [Figure 20-40-59], and the end cap (Item 3)
[Figure 20-40-59] on the detent bonnet.
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Tilt Spool Removal And Installation
Figure 20-40-62
1 1
1
P-37764
Remove the end cap mounting screws (Item 1) [Figure

P-37754 20-40-64] and remove the end cap (Item 2) [Figure 20-
40-64] from the tilt spool centering spring.
Remove the lift and tilt lock block (Item 1) [Figure 20-40- Assembly: Tighten the mounting screws to 90-100 in.-lb.
62] from the control valve. (See Lift And Tilt Lock Block (10,2-11,3 N•m) torque.

Figure 20-40-65
Figure 20-40-63
1
1
P-37765
P-37763
Remove the spool and centering spring assembly from

Remove the bushing (Item 1) [Figure 20-40-63] and the the control valve [Figure 20-40-65].
O-ring (Item 2) [Figure 20-40-63] from the tilt spool
linkage end.
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Tilt Spool Disassembly And Assembly 1

2
Figure 20-40-66 3
4
1
6 5
N-18944
Inspect the adapter (Item 1) [Figure 20-40-68], the collar

N-18942 (Item 2) [Figure 20-40-68], the spring (Item 3) [Figure
20-40-68], the washer (Item 4) [Figure 20-40-68], the
bushing (Item 5) [Figure 20-40-68], and the spool seal
Put the linkage end of the spool in a vice and install the (Item 6) [Figure 20-40-68].
MEL 1285 Compression Spring Tool (Item 1) [Figure 20-

40-66] Figure 20-40-69
Figure 20-40-67
1
1
P-37766
N-19014
Remove the spool seal (Item 1) [Figure 20-40-69] from
the linkage end of the control valve.
Remove the bolt (Item 1)[Figure 20-40-67] holding the
centering spring to the spool. Assembly: Always use a new spool seal.
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3

N•m) torque.
Remove the spring tool from the centering spring

assembly. Remove the back-up washer and spool seal.
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Auxiliary Spool Removal And Installation 4

5
Figure 20-40-70
3
2 1
1
4
3
P-37770
1 Remove the centering spring assembly (Item 1) [Figure

P-37767 20-40-72], the detent retainer (Item 2) [Figure 20-40-72],
the housing (Item 3) [Figure 20-40-72], the seal retainer
(Item 4) [Figure 20-40-72], and the spool seal (Item 5)
Remove the screws (Item 1) [Figure 20-40-70] and the [Figure 20-40-72].
rubber boot (Item 2) [Figure 20-40-70] from the linkage

end of the control valve. Auxiliary Spool Disassembly And Assembly
Remove the spool seal retainer (Item 3) [Figure 20-40- Figure 20-40-73
70], and the O-ring (Item 4) [Figure 20-40-70] from the
control valve. 1
Assembly: Tighten the screws to 90-100 in.-lb. (10,2-

11,3 N•m) torque.
Figure 20-40-71
1
P-37771
Wrap a rag (Item 1) [Figure 20-40-73] around the detent

1 ball retainer and the centering spring. Slowly remove the
retainer from the balls.
P-37768
Remove the two mounting screws (Item 1) [Figure 20-

40-71] and the detent cap (Item 2) [Figure 20-40-71].
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Auxiliary Spool Disassembly And Assembly (Cont’d)
Figure 20-40-74
1 P-37779
2
P-37772 adapter (Item 2) [Figure 20-40-76] from the centering
spring assembly. Check the condition of the bolt and
adapter.
The detent retainer must be installed over the spool
detent balls in the position shown [Figure 20-40-74]. The Figure 20-40-77

deeper counter bore end of the retainer (Item 1) [Figure
20-40-74] goes on the spool first and will rest against the
centering spring plate (Item 2) [Figure 20-40-74].
2
3 1
Figure 20-40-75
P-37778
NOTE: Be careful when removing the assembly from

the spring tool, the assembly is under spring
P-37773 pressure.
Check the condition of the collar (Item 1) [Figure 20-40-

Put the linkage end of the spool in a vice and install the 77], the spring (Item 2) [Figure 20-40-77], and the
MEL 1285 Compression Spring Tool (Item 1)[Figure 20- washer (Item 3) [Figure 20-40-77].
40-75].
Use an allen wrench (Item 2) [Figure 20-40-75]. to

remove the bolt holding the centering spring assembly on
the spool.
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3

N•m) torque.
Remove the assembly from the spool.
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Auxiliary Spool Disassembly And Assembly (Cont’d)
Figure 20-40-78
P-37780
Install the detent retainer (Item 1) [Figure 20-40-80] on

P-37777 the spool
Figure 20-40-81
Remove the detent adapter (Item 1) [Figure 20-40-78].

Installation: Tighten the adapter to 90-100 in.-lb. (10,2-
11,3 N•m) torque. 1
Figure 20-40-79
P-37781
Install the first set of detent balls and spring in the

adapter. Hold the detent balls in place with the detent
pliers (Item 1) [Figure 20-40-81] while installing the
P-37776 detent retainer.
Remove the stud (Item 1) [Figure 20-40-79] from the end

of the spool.
Installation: The stud will bottom in the spool during

assembly.
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HYDRAULIC CONTROL VALVE (CONT’D) Spool Seal Installation
Auxiliary Spool Disassembly And Assembly (Cont’d) To install new spool seals when the centering spring (tilt
spool) or other detent assembly (lift spool) are not
Figure 20-40-82 removed from the spool, use the following procedure:
Check the seal surface area (in the control valve) for rust,
corrosion, scratches, etc. Correct any irregularities
before continuing.
Install the back-up washer on the spool.

1
Figure 20-40-84
P-37782
Install the second set of detent balls and spring in the

adapter. Hold the detent balls in place with the detent 1

pliers (Item 1) [Figure 20-40-82] while installing the
detent retainer.
Figure 20-40-83
CD-15080
Put plastic material on the valve spool [Figure 20-40-84].
Put clean oil on the spool seal. Install the spool seal
(Item 1) [Figure 20-40-84] on the spool being careful not
to damage the seal on the sharp edges.
Remove the plastic material and install the spool into the
control valve.
P-37783
Remove the spool seal (Item 1) [Figure 20-40-83].
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HYDRAULIC CONTROL VALVE (CONT’D) Auxiliary Pivot Bracket Disassembly And Assembly
Auxiliary Pivot Bracket Removal And Installation Figure 20-40-87
Figure 20-40-85
P-39075
P-39064
The plastic bushing (Item 1) [Figure 20-40-87] is
inserted from the bottom of the flange as shown.
Remove the hair pin (Item 1) [Figure 20-40-85] and the
link from the auxiliary spool on the control valve. Figure 20-40-88

Figure 20-40-86
1
1
P-39076
P-39074
Remove the two nuts (Item 1) [Figure 20-40-88] to
remove the flange from the bracket.
Remove the bolt (Item 1) [Figure 20-40-86] to remove
the bracket assembly. Installation: Tighten the nuts to 25-28 ft.-lb. (34-38 N•m)
torque.
torque.
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LIFT ARM BY-PASS VALVE Figure 20-50-2

1
Put jackstands under the rear corners of the loader.
WARNING
1
Before the cab or the lift arms are raised for service,
jackstands must be put under the rear corners of the
frame. Failure to use jackstands can allow the
machine to tip backward causing injury or death. 1
W-2014-0895
P-37941
Figure 20-50-1
Remove the tubelines (Item 1) [Figure 20-50-2] to
remove the by-pass body assembly.
Install plugs on the tubelines.

2 2 Figure 20-50-3
2 2
P-37934 2

on Page 10-30-1.)
1
Remove the two mounting bolts (Item 1) [Figure 20-50-
1] securing the valve body to the control shield.
P-37942
Remove the control shield mounting bolts (Item 2)
[Figure 20-50-1].
Install the valve body in a vise and remove the valve
(Item 1) [Figure 20-50-3]
The valve body can be removed from the mounting

bracket by removing the two mounting nuts (Item
1)[Figure 20-50-3] and bolts.
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LIFT ARM BY-PASS VALVE (CONT’D)
Disassembly And Assembly (CONT’D)
Figure 20-50-4
P-37944
Remove the o-rings (Item 1) [Figure 20-50-4], and the

back-up washer (Item 2) [Figure 20-50-4] from the valve.

Assembly: Always use new o-rings and back-up
washers during assembly.
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HYDRAULIC PUMP Figure 20-60-2
Checking The Output Of The Pump Example: Tester

Connection
procedure:
Reservoir
MEL1429 - Remote Start Switch
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
NOTE: The relief pressure must be per specification

before the output test is performed.
Hydraulic Pump
Hydraulic Control
WARNING Valve
Put jackstands under the front axles and rear corners 3

B-16917
W-2017-0286

Figure 20-60-1
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
A sample tester connection is shown in picture [Figure

2 3 20-60-2].
Start the engine and run at low RPM. Make sure the
tester is connected correctly. If no flow is indicated on
the tester, the hoses are connected wrong. With the
1 hoses connected correctly, increase the engine speed to
P-39104 full RPM*.
Warm the hydraulic fluid to 140° F (60° C) by turning the

Lift and block the loader. (See Procedure on Page 10- restrictor control (Item 1) [Figure 20-60-1] & [Figure 20-
10-1.) 60-2] on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1] control and record the free flow (GPM) at full RPM.
from the hydraulic pump. Connect the OUTLET hose
from the tester to the hose (Item 1) [Figure 20-60-1].
Connect the INLET hose (Item 2) [Figure 20-60-1] from

the tester to the OUTLET fitting on the hydraulic pump.
Open the restrictor control (Item 3) [Figure 20-60-1] fully

(counterclockwise) before testing the relief valve.
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HYDRAULIC PUMP (CONT’D) NOTE: The engine and hydrostatic pump assembly
must be moved to the right to remove the
Checking The Output Of The Pump (Cont’d) hydraulic pump.
Remove the auxiliary hydraulics lock bolt and push the Remove the hydraulic reservoir. (See Removal And
right steering lever all the way to the right (detent) (See Installation on Page 20-80-1.)
Checking The Main Relief Valve With Auxiliaries on Page
20-30-2.) to engage the auxiliary hydraulics (attachment Figure 20-60-3
must be disconnected from the front auxiliary couplers).
The fluid pressure will go over main relief. If the pressure
is not to specifications, first adjust the main relief valve.
(See Main Relief Valve Removal And Installation on Page
20-40-9.) Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.
HIGH PRESSURE FLOW (GPM)

%= x100
FREE FLOW (GPM)
A low percentage indicates a failed pump.
* Refer to SPECIFICATIONS Section for system relief 1 2

pressure, RPM, and Hydraulic pump capacity (GPM).
P-37648

Loosen the left engine mounting bolt (Item 1) [Figure 20-
60-3], and remove the right engine mounting bolt (Item 2)
[Figure 20-60-3].
IMPORTANT Figure 20-60-4
damage the system.
I-2003-0888
WARNING
support device. Failure to use an approved lift arm P-39092

to fall and cause injury or death. Loosen the clamp (Item 1) [Figure 20-60-4] to remove
W-2059-0598
the suction hose from the hydraulic oil reservoir fill tube.
Raise the lift arms and install the lift arm support device. NOTE: Removing the battery will make gear pump
(See Engaging The Lift Arm Support Device on Page 10- removal and installation easier. (See Removal
20-1.) And Installation on Page 60-20-1.)
Stop the engine and raise the seat bar.
Lift and block the loader. (See Procedure on Page 10-

10-1.) Raise the operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
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HYDRAULIC PUMP (CONT’D) Figure 20-60-7
Figure 20-60-5
P-37809
1
Remove the bolt (Item 1) [Figure 20-60-7] and washer

P-37918 from the hydrostatic pump pulley.

Remove the bolts (Item 1) [Figure 20-60-5] from the torque.
steering lever linkage. Remove the linkage from the

hydrostatic pumps. Figure 20-60-8
Remove the two nuts (Item 2) [Figure 20-60-5] from the

pivot mounting bracket.
Remove the speed control linkage from the pivot.
Figure 20-60-6
P-37656
Remove the nut (Item 1) [Figure 20-60-8] from the right

1 side hydrostatic pump mounting bolt.
Remove the rubber mount, washers, and reinstall the

P-19123 bolt. Tighten the bolt to pull the hydrostatic pump
assembly to the right to allow clearance for hydraulic
pump removal.
Remove the nut (Item 1) [Figure 20-60-6] from the left
side hydrostatic pump mounting bolt. Remove the
mounting bolt.
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HYDRAULIC PUMP (CONT’D)
Figure 20-60-9
P-37919
Remove the outlet hose (Item 1) [Figure 20-60-9] from

the top of the hydraulic pump.

Remove the two hydraulic pump mounting bolts (Item 2)
[Figure 20-60-9] (top and bottom).

torque.
Remove the hydraulic pump and the coupler.
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HYDRAULIC PUMP (CONT’D)
1
3
4
11
5 6 13
7

8
9 10
12
B-13927A
Ref. Description
1 BOLT
2 SEAL
3 WASHER
4 COVER
5 O-RING
6 BACK-UP RING
7 WASHER
8 SEAL
9 PLATE
10 COVER
11 GEAR
12 GEAR
13 BODY
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1 1
IMPORTANT
2 2
damage the system.
I-2003-0888
P-19834
Figure 20-60-10
Remove the eight bolts (Item 1 & 2) [Figure 20-60-11]

from the pump.
Assembly: Tighten the bolts 25-28 ft.-lb. (33-38 N•m)

torque.

NOTE: Use new washers under bolts (Item 1) [Figure
20-60-11] during assembly.
Remove the pump from the vise.
Figure 20-60-12
P-19833
1 2
NOTE: Always use new o-rings, gaskets, and seals 3
when assembling the hydraulic pump.
Put the hydraulic pump in the vise.
Put a mark across the housing of the pump for correct

assembly (Item 1) [Figure 20-60-10].
P-19835
Remove the front cover (Item 1) [Figure 20-60-12] from

the pump.
Remove the o-ring (Item 2) [Figure 20-60-12] from the

front cover.
Remove the pressure plate (Item 3) [Figure 20-60-12]

from the pump.
NOTE: Only the Seal Kit is available for the hydraulic

pump. If any other parts are worn, replace the
pump assembly.
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Disassembly And Assembly (Cont’d) 1

2
Figure 20-60-13
3 2 1
P-19838
Remove the pump body (Item 1) [Figure 20-60-15] from

P-19836 the rear cover of the pump.
Remove the o-ring (Item 2) [Figure 20-60-15] from the

Remove the back-up ring (Item 1) [Figure 20-60-13] and rear cover.
seal (Item 2) [Figure 20-60-13] from the pressure plate

(Item 3) [Figure 20-60-13]. Check the pump body and rear cover for wear.
Check the pressure plate for wear. Figure 20-60-16
Figure 20-60-14 3
4
1 2
P-19839
P-19837
Remove the seal (Item 1) [Figure 20-60-16] and washer
(Item 2) [Figure 20-60-16] from the front cover (Item 3)
Remove the pump gears [Figure 20-60-14]. [Figure 20-60-16].
Check the gears for wear [Figure 20-60-14]. NOTE: If the front cover is equipped with a seal and
washer they can be removed and discarded.
The seal and washer are for factory testing
purposes only. Current cover will also be
equipped with a drain hole (Item 4) [Figure 20-
60-16].
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HYDRAULIC FILTER Figure 20-70-2
Block Removal And Installation
WARNING
Failure to use jackstands can allow the machine to 1
W-2017-0286
Put jackstands under the front and rear of the loader. P-37921
(See Procedure on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab Remove the drain hose (Item 1) [Figure 20-70-2] from
on Page 10-30-1.) the front hydrostatic pump housing and the filter block.
Figure 20-70-3
WARNING

the lift arms are secured by an approved lift arm 2
1
W-2059-0598
Figure 20-70-1
P-37922
1 Disconnect the electrical connector from the charge

pressure switch (Item 1) [Figure 20-70-3] and the
temperature sender (Item 2) [Figure 20-70-3].
P-37920
Remove the hose (Item 1) [Figure 20-70-1] from the filter

block.
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HYDRAULIC FILTER (CONT’D) Figure 20-70-6
Block Removal And Installation (Cont’d)
Figure 20-70-4
P-39077
Remove the temperature sender (Item 1) [Figure 20-70-

P-19412 6] from the filter block.
Figure 20-70-7
4] from the outside of the fender.

Remove the hydraulic filter block.
Block Disassembly And Assembly
Figure 20-70-5
1
3
2
1
P-19889
Remove the charge pressure switch (Item 1) [Figure 20-

70-7] from the filter block fitting.
P-39044
Remove the fitting (Item 1) [Figure 20-70-5], the charge

pressure spring (Item 2) [Figure 20-70-5] and the poppet
(Item 3) [Figure 20-70-5].
Clean and inspect the parts. Replace as needed.
Install a new o-ring on the plug.
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HYDRAULIC RESERVOIR Figure 20-80-2
Install jackstands under the rear corner of the loader.

(See Procedure on Page 10-10-1.)
Remove the fluid from the hydraulic reservoir. (See

Replacing The Hydraulic/Hydrostatic Fluid on Page 10- 2
120-2.)

on Page 10-30-1.)
1
Remove the control shield and steering lever panels.
(See Control Shield And Steering Lever Panels Removal P-19039
Remove the steering levers. (See Lever Removal And Remove the return hose (Item 1) [Figure 20-80-2] from
Installation on Page 30-30-1.) the hydraulic reservoir.
Figure 20-80-1 Remove the nut (Item 2) [Figure 20-80-2] and bolt from
the hydraulic reservoir holding strap.

NOTE: The nut and bolt holding the other end of the
strap is located in front of the gear pump.
Remove the hydraulic reservoir.
P-19038
Remove the filter return hose (Item 1) [Figure 20-80-1]

from the fitting located on the right side of the hydraulic
reservoir.
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CONTROLS Figure 20-90-2
Pedal Interlock Linkage Removal And Installation 2

Figure 20-90-1
1
3 1
2
P-7198

P-7207 bottom bolt on the interlock and pedal.
Installation: The bottom slot (Item 2) [Figure 20-90-2] &

Remove the nut (Item 1) [Figure 20-90-1] from the top [Figure 20-90-3] on both interlock bars must be toward
bolt on the interlock. the rear of the pedal.

Remove the spring (Item 2) [Figure 20-90-1] from the Always check for free movement of the interlock after
bolt and interlock. assembly.
Installation: Tighten the interlock nut to 80-90 in.-lb. (9- Figure 20-90-3
10 N•m) torque.
Remove the nut (Item 3) [Figure 20-90-1] and plastic

washer from the interlock bolt.
Remove the bolt from the outside of the fender.

2
NOTE: Note the location of the interlock parts during
removal for assembly purposes. There is a
plastic washer which must be installed on
each side of the interlock bar during
assembly.
P-7211
Remove the interlock assembly [Figure 20-90-3].
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CONTROLS (CONT’D) Pedal Adjustment
Control Pedals Removal And Installation When installing the pedal and interlock, align them by
moving the interlock forward or backward in the slot in
Figure 20-90-4 the fender.
P-7202
Remove the bottom nut, washers and bolt from the

interlock and pedal [Figure 20-90-2].

Remove the bolt (Item 1) [Figure 20-90-4] from the
linkage pivot.
Remove the pedal from the linkage
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HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
SAFETY &
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 MAINTENANCE
Control Shield And Steering Lever Panels Removal And
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Tension Pulley And Spring Removal And Installation . . . . 30-70-1
HYDROSTATIC
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 SYSTEM
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

ELECTRICAL
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-60-3 SYSTEM &
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 ANALYSIS
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1 ENGINE

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 SERVICE
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

SPECIFICATIONS
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Lever Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 30-30-3
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . 30-30-1
Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . 30-30-5
Pintle Arm Removal And Installation . . . . . . . . . . . . . . . . . 30-30-4

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HYDROSTATIC SYSTEM INFORMATION
WARNING
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2, 3, 4, 5, 19
No drive on one side in both directions. 2, 3, 5, 6, 7, 8
The loader does not move in a straight line. 2, 3, 4, 6, 7, 8, 9, 10, 19
the hydrostatic system is overheating. 4, 11, 12, 13, 14, 15
The oil light comes on. 16, 17, 18

1. The hydrostatic system has a fluid leak.

2. The steering linkage needs adjustment.
3. The high pressure relief valve(s) are defective.
4. The shuttle valve in the hydrostatic motor has a defect.
5. The balance plate in the hydrostatic motor seals are defective.
6. The hydrostatic pumps have a defect.
7. The final drive chain is broken.
8. The hydrostatic motor has a defect.
9. The tires do not have the correct tire pressure.
10. The tires are not the same size.
11. The hydrostatic fluid is not at the correct level.
12. The oil cooler has a restriction (Externally or Internally).
13. The temperature sending switch is not operating correctly.
14. The control valve is not operating correctly.
15. The loader is not being operated at the correct RPM.
16. The sender has a defect.
17. There is low charge pressure.
18. The charge relief has a defect.
19. Steering lever is obstructed.
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CONTROL PANEL Figure 30-20-1
Control Shield And Steering Lever Panels Removal

And Installation
2 3
WARNING 3

of the frame before running the engine for service. 1
W-2017-0286
P-37934
Hold the lock nut and remove the lift arm by-pass knob
(Item 1) [Figure 30-20-1].
Remove the lock nut and rubber washer (Item 2) [Figure

30-20-1] from the BICS™ valve block.

Remove the four mounting bolts (Item 3) [Figure 30-20-
1] from the control shield.
WARNING Remove the control shield.
Figure 30-20-2
1
W-2059-0598
1
Open the rear door.
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10-
10-1.)

on Page 10-30-1.) P-37940
Remove the two bolts (Item 1) [Figure 30-20-2] from the

steering lever panels. Remove the panels.
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STEERING Figure 30-30-2
Lever Removal And Installation

1
WARNING
Failure to use jackstands can allow the machine to 2
3
W-2017-0286
P-37941
WARNING Disconnect the tubelines (Items 1) and the hose (Item 2)

from the lift arm bypass valve assembly (Item 3)
[Figure 30-30-2].
Remove the lift arm bypass valve assembly

Figure 30-30-3
W-2059-0598
20-1.)

on Page 10-30-1.)
Remove the control shield and steering panels. (See

Figure 30-30-1
1
P-39088
Disconnect the pilot hose (Item 1) [Figure 30-30-3] from

1 the main valve.
P-39087
Remove the nuts and bolts (Item 1) [Figure 30-30-1]

from the steering linkage.
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STEERING (CONT’D) Figure 30-30-6
Lever Removal And Installation (Cont’d)
Figure 30-30-4
1
P-39056
1
Remove the bolts (Item 1) [Figure 30-30-6] from the
P-39054 pivot bearings (right side). Hold the nuts from inside the
fender.
Remove the nut (Item 1) [Figure 30-30-4] from the Remove the bearing (Item 2) [Figure 30-30-6].
auxilliary hydraulics cable bolt (if equipped).

Figure 30-30-7
Remove the cable.
Figure 30-30-5
1
1 P-39058
P-39052 When removing the right side bearing, watch for shims
(Item 1) [Figure 30-30-7]. Remove the shims.
Remove the nuts (Item 1) [Figure 30-30-5] from the pivot Remove the steering lever assembly from the loader.
bearings (right side). Hold the bolts from outside the
fender.
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STEERING (CONT’D) Linkage Adjustment
Lever Disassembly And Assembly Figure 30-30-9
Figure 30-30-8
2 2
3 1
1
P-37809
1 5 3 P-39059
1.)
Remove the bearings (Item 1) [Figure 30-30-8] from the
shaft. Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
Remove the steering levers (Item 2) [Figure 30-30-8]
from the shaft. Install the Remote Start Switch. (See Procedure on Page
10-60-1.) Start the engine and run at a slow RPM.
Check the plastic bushings (Item 3), shims (Item 4) and
the washers (Item 5) [Figure 30-30-8] for damage or Hold the nuts (Item 1) [Figure 30-30-9] and turn the bolts
wear and replace as necessary. so the centering springs just touch the pin (Item 2)
[Figure 30-30-9] and the adjustment bolt heads.
Assembly: Lightly lubricate the steering shaft during
assembly. If the wheels are turning (creeping), move the steering
lever to stop the creeping. Locate the correct side of the
centering spring where the adjustment is to be made.
WARNING Turn the bolt out a small amount until the wheels stop
turning.
Move the steering lever forward and backward and let the
transmission return to neutral position. If the
transmission does not return to the neutral position,
W-2017-0286
repeat the adjustment.
Repeat steps for the other side.
Lower the operator cab. (See Lowering The Operator

Cab on Page 10-30-2.)
Remove the jackstands from the loader frame.
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Pintle Arm Removal And Installation
WARNING 2
Never work on a machine with the lift arms up unless 1

W-2059-0598
P-39095
Put jackstands under the rear of the frame. (See
Use pliers to remove one of the spring ends from the
Raise the lift arms and install the lift arm support device. bracket (Item 1) [Figure 30-30-11]. Remove the spring.
20-1.) Loosen the pintle arm clamping bolt (Item 2) [Figure 30-
30-11].

on Page 10-30-1.) Use a small gear puller and remove the assembly from
the shaft of the hydrostatic pump.
Remove the steering linkage from the pintle arm.
NOTE: Do not use a screwdriver to pry the pintle arm
Figure 30-30-10 off, it will cause damage to the seal retainer.
2 1
2
P-39094
Remove the adjustment nuts and bolts (Item 1) [Figure

30-30-10] from the centering spring.
Remove the spring retainer brackets (Item 2) [Figure 30-

30-10].
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Pintle Arm Disassembly And Assembly
Figure 30-30-12
P-7481
Put the pintle arm in a vise and use a hammer to drive

P-7479 the bushing (Item 1) [Figure 30-30-13] into position.
Install the pintle arm on the hydrostatic pump in the

Put the pintle arm on a vise and use a hammer to drive reverse order.
the bushing (Item 1) [Figure 30-30-12] from the pintle

arm. Adjust the steering linkage. (See Linkage Adjustment on
Page 30-30-3.)
Replace the bushing if damaged.
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HYDROSTATIC MOTOR Figure 30-40-1

1
1
WARNING
W-2017-0286
P-9903
Remove the motor cover bolts (Item 1) [Figure 30-40-1]

from the outside of the loader.
Pull the cover outward and free from the slots under the
frame.

WARNING IMPORTANT
Never work on a machine with the lift arms up unless When repairing hydrostatic and hydraulic systems,
the lift arms are secured by an approved lift arm clean the work area before disassembly and keep all
support device. Failure to use an approved lift arm parts clean. Always use caps and plugs on hoses,
support device can allow the lift arms or attachment tubelines and ports to keep dirt out. Dirt can quickly
to fall and cause injury or death. damage the system.
W-2059-0598 I-2003-0888

10-1.)
20-1.)
Remove the wheels from the side of the loader where the
motor is to be removed.

on Page 10-30-1.)
Remove the control shield and steering panels. (See

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HYDROSTATIC MOTOR (CONT’D) NOTE: Mark the hoses for installation purposes.
Removal And Installation (Cont’d) Remove the parking brake cover from the chaincase.
(See Chaincase Cover Removal And Installation on Page
Figure 30-40-2 40-30-1.)
1 NOTE: Always use caps and plugs on hoses and

fittings during disassembly and assembly.
Remove the high pressure hoses (Item 1) [Figure 30-40-

2], and the drain hose (Item 2) [Figure 30-40-2] from the
3 motor. Cap and plug the hoses and fittings.
Remove the four motor mounting bolts (Item 3) [Figure

30-40-2].
2 Installation: Lift the drive sprocket to align it with the

motor splines. Be sure the O-ring is installed on the
motor flange during installation. Tighten the bolts to 90-
P-7493 100 ft.-lb. (123-135 N•m) torque.

7
6
2 4
8 9
1
11
19 10
5 1
3
18
1. O-ring 19 17
2. Plate, Valve 13 16 1
3. Valve 19
4. Plate, Balancing 12 12 15
5. Seal, Inner 14
6. Seal, Outer
7. Plug 12 1
8. Pin
9. Spring
10. Housing
11. Bolt
12. Seal
13. Housing
14. Shaft & Bearing Assembly
15. Plate, Wear
16. Shaft, Long
17. Geroler
18. Shaft, Short
19. Ball D-1635
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HYDROSTATIC MOTOR (CONT’D) Figure 30-40-4
Disassembly
IMPORTANT
damage the system.
I-2003-0888
B-6472
Figure 30-40-3
Lift the valve house straight up [Figure 30-40-4]. If done

carefully the balance ring assembly and valve will stay on
3 1 the valve plate.
Figure 30-40-5

2 4
B-7382
B-6464
NOTE: Clean the outside of the motor before

disassembly. Keep all the parts of the motor
clean.
B-6402
Put the motor in a vise, holding it by the mounting flange
with the shaft down [Figure 30-40-3]. Put a mark across
the motor housing for correct assembly. Remove the 3 inch (76 mm) diameter O-ring from the
valve housing [Figure 30-40-5].
Remove the four bolts from the motor [Figure 30-40-3].
Installation: Tighten the bolts to 37 ft.-lb. (50 N•m)

torque in the sequence shown [Figure 30-40-3].
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Disassembly (Cont’d)
Figure 30-40-6
B-6400
Remove the balance ring assembly [Figure 30-40-8].

B-6401
Figure 30-40-9
Remove the pins and springs from the valve housing

[Figure 30-40-6].

Figure 30-40-7
Balance Plate
Outer
Outer
Seal
Seal
Case Drain
Pin B-8733
Fitting Inner Seal Pin B-3046
Remove the inner face seal from the balance plate

[Figure 30-40-9]. Remove the spring.
B-9971
Installation: Put grease on the inner seal during
assembly.
Remove the case drain fitting from the valve housing
[Figure 30-40-7].
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Figure 30-40-10
Balance Plate
Outer
Outer
Seal B-9925
Seal
Remove the valve drive [Figure 30-40-12].

Pin B-8732
Inner Seal Pin B-3046
Figure 30-40-13
Remove the outer face seal [Figure 30-40-10].

Installation: Put grease on the outer seal during
assembly.
Figure 30-40-11
B-9928
Remove the valve plate [Figure 30-40-13].
Remove the 3 inch diameter O-ring from the valve plate

[Figure 30-40-13].
B-9927
Remove the valve [Figure 30-40-11].
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Disassembly (Cont’d) Wear Plate
Figure 30-40-14
B-6374 B-6396
Remove the wear plate [Figure 30-40-16].

B-9926
Remove the shaft face seal (Item 1) [Figure 30-40-16]
from the wear plate.
Remove the geroler [Figure 30-40-14]. Make sure the
rollers are kept in place. Remove the 3 inch diameter O-ring from the bearing

housing.
Figure 30-40-15
Figure 30-40-17
B-9924
B-6373
Remove the drive shaft [Figure 30-40-15].

Remove the shaft and bearing assembly from the
Remove the 3 inch diameter O-ring (Item 1) [Figure 30- housing [Figure 30-40-17].
40-15] from the wear plate.
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HYDROSTATIC MOTOR (CONT’D) Inspection
Disassembly (Cont’d) Before the motor is assembled, check the following

items:
Figure 30-40-18
Figure 30-40-19
Dust
Seal
Shaft Seal
B-6372 B-6395
B-6394
Remove the dust seal from the housing [Figure 30-40-

18]. Check the geroler for wear or scratches [Figure 30-40-

19].
Remove the shaft seal from inside the housing [Figure
30-40-18]. Figure 30-40-20
NOTE: The shaft and bearing assembly are not sold

as individual parts. Replace as a unit.
B-6392
Check the geroler rollers [Figure 30-40-20].
Check the rotor.
NOTE: Put all the rollers back in their original

position.
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Inspection (Cont’d)
Figure 30-40-21
B-6389
Check the balance plate [Figure 30-40-23].

B-6391
Check the valve drive shaft and maintenance shaftfor
wear.
Check the valve plate for wear or scratches [Figure 30-
40-21]. Figure 30-40-24

Figure 30-40-22
B-6388
B-6390
Check the end plate for scratches [Figure 30-40-24].
Check the valve [Figure 30-40-22]. Check all the contact surfaces. Replace any parts that
have scratches or are worn.
Clean all the parts in solvent and use air pressure to dry
the parts. DO NOT use cloth or paper because some
material may get into the hydrostatic system and cause
damage. DO NOT use sandpaper or a file to remove
scratches on any of the parts.
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Assembly
IMPORTANT
Use grease such as Dow Corning #44 or Vaseline
petroleum jelly to hold seals, O-rings and bearings in
position during assembly.
I-2010-0597
Figure 30-40-25
B-6386
Install the dust seal [Figure 30-40-27] as shown in (Item

8) [Figure 30-40-26].
Figure 30-40-28

B-6387
Figure 30-40-26
1 2 1. Shaft
2. Shaft Seal B-6385
3. Wear Plate
4. Seal
3 5. Shaft & Bearing Use a press to install the bearing and shaft assembly in
6. Shaft Seal the housing [Figure 30-40-28],
5 7. Bearing Housing
4 8. Dust Seal Lubricate and install the 3 inch diameter O-ring on the
7
9. Back-Up Washer bearing housing.
9
NOTE: You can use alignment studs for easier
8 assembly of the motor.
6 B-9931
NOTE: Always use a NEW seal kit when assembling

the hydrostatic motor.
Install the back-up washer and use a press to install the

shaft seal (Item 9) [Figure 30-40-26] in the bearing
housing [Figure 30-40-25].
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Assembly (Cont’d)
Figure 30-40-29
B-9924
Lubricate the 3 inch diameter O-ring (Item 1) [Figure 30-

B-6396 40-31].
Install the drive in the housing [Figure 30-40-31].

Install the shaft face seal (Item 2) [Figure 30-40-26] in
the wear plate [Figure 30-40-29].

Figure 30-40-30
B-6374
Install the wear plate [Figure 30-40-30].
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HYDROSTATIC MOTOR (CONT’D) The timing of the motor controls the direction of the
rotation of the drive shaft of the motor. The timing parts
Assembly (Cont’d) are as follows [Figure 30-40-33]:
Figure 30-40-32 Geroler Ring (Item 1)

Valve Drive (Item 2)
Valve Plate (Item 3)
Valve (Item 4)
Find the largest opening between the geroler star and the
geroler ring and mark the outside of the geroler ring at
the location [Figure 30-40-33].
Install the valve drive in the geroler (Item 2) [Figure 30-

40-33].
Lubricate the 3 inch diameter O-ring and install it on the

valve plate.
B-9926 Align the notch on the outside of the valve plate with the
notch on the geroler ring [Figure 30-40-33]. Install the
valve plate (O-ring side toward the geroler) on the
Align the notch on the outside of the geroler with the geroler.
notch on the wear plate. Install the geroler against the

wear plate. Hold the rollers in the geroler while installing Align the slot opening in the valve plate with the largest
it [Figure 30-40-32]. opening of the geroler.
Figure 30-40-33 NOTE: If you can see a roller (in the geroler) in all the
Rotate Valve Clockwise holes of the valve plate the motor is timed
1/2 Tooth To Engage Spline wrong.
Any One of the Openings Align the valve on the valve plate so that any one of the
on the Valve openings is in alignment with the open slot in the valve
plate and the largest opening of the geroler [Figure 30-
40-33]. Turn the valve CLOCKWISE 1/2 tooth to engage
the drive.
Largest Opening
Valve 4
3
2
1 Valve Plate
Pressure
Relief Hole (3) Geroler
Star
Geroler
Ring
B-9972
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Assembly (Cont’d)
Figure 30-40-34
Balance
Outer Ring Outer
Seal Seal
Inner B-6401
Seal
Install the pins and springs in the valve housing [Figure

B-9930 30-40-36].
Lubricate the 3-inch diameter O-ring and install on the

Lubricate the inner and outer seals and install the seals valve housing.
on the balance ring [Figure 30-40-34].

Align the pin grooves in the balance ring with the pins in
the valve housing. Install the balance ring assembly in
the housing.
IMPORTANT Figure 30-40-37
Install the seals in the position as shown or the
motor will not operate correctly. Do not force or bend
the seals. Any damage to these seals will have a
direct effect on the motor operation.
I-2098-1295
Figure 30-40-35
B-6370
Case Drain Put your finger through the port in the valve housing to
Fitting hold the balance ring in position [Figure 30-40-37].
Seal NOTE: You must feel a spring action of the balance

ring after the valve housing is installed.
B-9971
Install the seals and the case drain fitting on the valve
housing [Figure 30-40-35].
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CHARGE PRESSURE Figure 30-50-2
Checking
WARNING
fall or move and cause injury or death. 1
W-2017-0286
Figure 30-50-1 P-39099
Connect the pressure gauge into the sender port of the

filter port block (Item 1) [Figure 30-50-2].
Start the engine and run at full RPM. The pressure must
be 75-85 PSI (241-586 kPa) minimum with no hydraulic
action.

Stop the engine.
Figure 30-50-3
1
P-37638
The tools listed are needed to complete the following

procedure: 2 3
MEL1173a - Test Kit

1
1.)

on Page 10-30-1.) P-39100
Disconnect the electrical connector (Item 1) [Figure 30-

50-1] from the charge pressure switch. If the pressure is not correct, check the charge pressure
poppet (Item 1) [Figure 30-50-3], the spring (Item 2)
Remove the charge pressure switch from the filter port [Figure 30-50-3], by removing the fitting (Item 3) [Figure
block. 30-50-3] .
Disconnect the pressure gauge.
Install and tighten the charge pressure switch.
Reconnect the electrical connector to the charge pressure switch.
Remove the jackstands from under the loader frame.

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HYDROSTATIC PUMP
Rear Pump Front Pump

Hydraulic Pump End Drive End
28
25
26 24 25
27
26
23 24
25
25
20 23
16 10 9
19 17 20 10 9
14 13 19 17
13
22
14
21 18 22
18
15 21

16
8 30 16 15 7
8
14
13 14 4
11 1213
11
9 5 5 9 4 6
10 12 6 4 10 5 4
29 1 5 2
3 1
B-15896 B-15895
Ref. Description Ref. Description

1 Ring, Retaining 16 Bearing
2 Seal 17 Swash Plate
3 Washer 18 Key
4 Ring, Retaining 19 Thrust Plate
5 Race, Bearing 20 Rotating Group
6 Bearing, Thrust 21 Gasket
7 Shaft, Drive 22 Valve Plate
8 Bearing 23 Bearing
9 Bolt 24 End Cover
10 Cover 25 Relief Valve
11 Seal 26 Coupler
12 Crush Ring 27 O-Ring
13 Race, Bearing 28 Bolt
14 O-Ring 29 Spacer
15 Housing 30 Shaft
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HYDROSTATIC PUMP (CONT’D) Figure 30-60-1
WARNING P-37812
Never work on a machine with the lift arms up unless Remove the bolts (Item 1) [Figure 30-60-1] from the
the lift arms are secured by an approved lift arm hydrostatic pump.
support device can allow the lift arms or attachment Figure 30-60-2
W-2059-0598

NOTE: The engine and hydrostatic pumps are
removed from the loader as an assembly.
1
Remove the engine and pump package. (See Removal
Remove the drive belt. (See Removal And Installation on

Page 30-70-1.)
Remove the pump pulley. (See Tension Pulley And

Spring Removal And Installation on Page 30-70-1.)
P-37811
Use the following procedure to remove the
hydrostatic pumps:
Remove the bolts (Item 1) [Figure 30-60-2] from the left
mounting bracket.
Remove the hydrostatic pump assembly.
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1 2
IMPORTANT
damage the system.
I-2003-0888
P-37800
NOTE: Always use new O-rings, gaskets, and seals
during assembly.
Remove the high pressure relief valves (Item 1 & 2)
Figure 30-60-3 [Figure 30-60-4] located on the top side of the
hydrostatic pumps.
1 NOTE: Mark the locations for correct installation.

Figure 30-60-5
P-37813
1 2
3] to remove the mounting bracket, hydraulic gear pump
and coupler. P-37801
Installation: Tighten the mounting bolts to 25-28 ft.-lb.

(34-38 N•m) torque. Check the condition of the high pressure relief valves
(Item 1 & 2) [Figure 30-60-5].
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Figure 30-60-6
2
P-37802
1 2
Remove the bolt (Item 1) [Figure 30-60-8] to remove the
P-37888 right centering spring bracket and crossbrace (Item 2)
[Figure 30-60-8] .
Remove the high pressure relief valves (Item 1 & 2) Figure 30-60-9
[Figure 30-60-6] located on the bottom side of the

hydrostatic pumps.
NOTE: Mark the locations for correct installation. 1

3
Figure 30-60-7
2 2
P-37803
1 2 Remove the charge tubeline (Item 1) [Figure 30-60-9]

from the pumps.
P-37799 Remove the bolts (Item 2) [Figure 30-60-9] connecting

the hydrostatic pumps. Once the bolts are removed, the
left centering spring mount (Item 3) [Figure 30-60-9] can
Check the condition of the high pressure relief valves be removed.
(Item 1 & 2) [Figure 30-60-7].
Installation: Tighten the bolts to 27-31 ft.-lb. (37-42 N•m)
torque.
NOTE: The pump sections will be classified as front

and rear for the disassembly and assembly
procedure. The pulley section is the front
section.
Separate the pumps.
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Figure 30-60-10
2
P-37805
Remove the end cover from the rear pump [Figure 30-
P-37804 60-12].
Remove and discard the gasket (Item 1) [Figure 30-60-

Remove the coupler (Item 1) [Figure 30-60-10], remove 12]. Remove the valve plate (Item 2) [Figure 30-60-12].
and discard the O-ring (Item 2) [Figure 30-60-10].

Figure 30-60-13
NOTE: The internal parts for the pumps are basically
the same. Any differences will be clarified
during the procedure.
Figure 30-60-11 2
1
1
1
P19790
The valve plate metering slots (Item 1) [Figure 30-60-13]

identify the direction of the rotation group.
P-37806
Check that the surface (Item 2) [Figure 30-60-13] is
smooth and free of grooves. If grooves can be felt with a
Remove the bolts (Item 1) [Figure 30-60-11] from the fingernail, replace the valve plate.
rear pump end cover.

torque.
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Figure 30-60-14
Dowel 2
Numbered
End
.075” .110”
(2,79 mm) 1
(1,91 mm) ‘
3
P-19801
Before removing the piston assembly (Item 1) [Figure

B-15893 30-60-16] mark one piston in the piston block.
Remove the piston assembly, remove the piston (Item 2)

If the needle bearing is replaced in the end plate, the [Figure 30-60-16], and install it in the piston block in the
numbered end of the bearing must face the valve plate marked location.

side of the end plate, [Figure 30-60-14].
This procedure assures pistons will be relocated in their
Install the bearing to the dimensions shown [Figure 30- original locations.
60-14].
Check the piston assemblies, the spiders, the spider
Figure 30-60-15 pivot (Item 3) [Figure 30-60-16], and the piston block for
excess wear.
Figure 30-60-17
Shoe Piston
Shoe Must Swivel

P-19791 Smoothly On Ball
Remove the rotating group carefully from the housing so

A-01850
as to retain the piston in the piston block [Figure 30-60-
15].
Check that the shoe swivels freely in each piston
assembly [Figure 30-60-17].
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Figure 30-60-18 Drain

Hole
1
1
P-19816
Remove the retaining ring (Item 1) [Figure 30-60-20]

P-19793 from the rear pump housing.
Use a small press to remove the driveshaft from the rear

Check the face (Item 1) [Figure 30-60-18] of the piston pump.
block for excessive wear or scratches.

Figure 30-60-21
NOTE: DO NOT lap the face of the piston block.
NOTE: The piston block usually requires no further 2 1

3
disassembly unless the pins or the block 4
spring are damaged.
Figure 30-60-19
P-19804
The rear pump drive shaft will have a spacer (Item 2)

[Figure 30-60-21] under the snap ring (Item 1) [Figure
30-60-21].
P-19802 Remove the bearing snap ring (Item 3) [Figure 30-60-21]

and remove the bearing and thrust washers (Item 4)
[Figure 30-60-21].
Before assembling the rotation group position the
retaining ring (Item 1) [Figure 30-60-19] to hold the pins. Check the bearing, thrust washers, and drive shaft for
wear.
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2
1
Figure 30-60-22
1 1
P-19809
The bearing cup (Item 1) [Figure 30-60-23] may come

P-19805 off with the cover plate.
The crush ring (Item 2) [Figure 30-60-23] needs removal

To remove the swash plate from the housing, remove the only when the cover, the swash plate assembly, or the
screws (Item 1) [Figure 30-60-22] from the control shaft housing assembly is replaced.

cover plate.
A shim kit is then required to replace the crush ring. See
Installation: Tighten the bolts to 29 ft.-lb. (39.9 N•m) your Parts book for the kit number.
torque.
Figure 30-60-24
If needed use screwdrivers in the notches to pry the
cover loose.
Remove and discard the O-ring.
P-19808
Use a small press (Item 1) [Figure 30-60-24] to remove

the seal from the cover plate.
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2
Figure 30-60-25
1 1
P-19811
Remove the cover plate [Figure 30-60-27].

P-19807
The bearing cup (Item 1) [Figure 30-60-27] in the cover
plate is a press fit and not removable.
Use a small press (Item 1) [Figure 30-60-25] to install
the new seal in the cover plate. Lubricate the new shaft Remove and discard the O-ring (Item 2) [Figure 30-60-

seal before assembling onto the swash plate control 27].
shaft.
NOTE: The swash plate control shaft will fit out either
Figure 30-60-26 side of the pump housing. Be sure to note on
which side of the housing the control shaft
protrudes before removing the swash plate.
Figure 30-60-28
1
1
P-19810
1
Remove the bolts (Item 1) [Figure 30-60-26] to remove
the cover plate from the opposite side of the housing.
P-19812
Installation: Tighten the bolts to 29 ft.-lb. (39.3 N•m)

torque. To remove the swash plate, first use a small press to
remove the drive shaft needle bearing from the housing.
Slide the swash plate (Item 1) [Figure 30-60-28] toward

the control shaft side and lift it from the pump housing.
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Figure 30-60-29
1
1
2
2
P-19814
1
P-19813 front pump end cover.

Remove the thrust plate (Item 1) [Figure 30-60-29] from torque.
the swash plate.

The thrust plate is reversible and either side may face the Remove the internal parts and check for wear as done for
swash plate. the rear pump.
Check the thrust plate for wear. It must be replaced if the Figure 30-60-32
rotating group is replaced.
Remove and replace the bearings (Item 2 [Figure 30-60-

29] if needed.
Install the swash plate in the reverse order.
Figure 30-60-30
1
Numbered End Flange End Of Housing
Of Bearing
.07”
(1,78 mm) P-19815
Remove the retaining ring (Item 1) [Figure 30-60-32]

from the front pump housing.
Use a small press to remove the drive shaft.

B-15692A
The seal is located only in the front pump housing and

will come out with the shaft removal.
If the needle bearing is replaced in the housing, the
numbered end of the bearing must face away from the
housing and be pressed to the dimension shown [Figure
30-60-30].
NOTE: The swash plate must have no or very little

side clearance and must be able to be pivoted
with the force of 45 in.-lb. (5,1 N•m) or less.
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HYDROSTATIC PUMP (CONT’D)
Figure 30-60-33
2
1
P-19817
Remove the seal (Item 1) [Figure 30-60-33] and washer

(Item 2) [Figure 30-60-33] from the drive shaft.

Installation: Lubricate the lip of the seal during
assembly. The lip of the seal must face the inside of the
pump housing.
Figure 30-60-34
2 1
P-19818
Remove the retaining ring (Item 1) [Figure 30-60-34], the

bearing and thrust washers (Item 2) [Figure 30-60-34].
Check the bearing, thrust washers, and drive shaft for

wear.
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DRIVE BELT Tension Pulley And Spring Removal And Installation
Removal And Installation Figure 30-70-3
Figure 30-70-1
1
P-37751
P-37809
NOTE: Remove the engine and pump assembly from
the loader. (See Removal And Installation on
Put jackstands under the rear of the loader. (See Page 70-80-1.)

Use a wrench to lift the tension pulley (Item 1) [Figure
Raise the operator cab. (See Raising The Operator Cab 30-70-3]. Remove the drive belt.
on Page 10-30-1.)
Figure 30-70-4
Remove the bolt and washer (Item 1) [Figure 30-70-1]
from the pulley. 2
Use a pry bar to lift the tension pulley. 1
Figure 30-70-2 3
P-37750
1
Use the wrench to turn the tension pulley clockwise to
install a wooden block (Item 1) [Figure 30-70-4]
between the flywheel and the tension pulley arm. Rest
P-37810 the pulley against the wooden block.
Remove the bolt (Item 2) [Figure 30-70-4] and washer.

Remove the belt (Item 1) [Figure 30-70-2] from the
pulley. Lower the pulley slowly onto a wooden block. Install two 5/16 inch x 2.5 inch bolts in the holes (Item 3)
[Figure 30-70-4]. Attach flanged 5/16 inch nuts to the
bolts on the backside of the pulley.
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DRIVE BELT (CONT’D) Figure 30-70-7
Tension Pulley And Spring Removal And Installation

(Cont’d)
Figure 30-70-5
1 2
1
P-37744
Pull the shaft (Item 1) [Figure 30-70-7] from the spring

and mounting brackets.
P-37748
Installation: Align the spring with the slot in the shaft
(Item 2) [Figure 30-70-7].
Install a small wheel puller (Item 1) [Figure 30-70-5] and

remove pulley from shaft. Figure 30-70-8
Figure 30-70-6
P-37743
P-37747
Remove the spring and tube (inside spring) from the
mounting bracket [Figure 30-70-8].
Hold the tension pulley arm tightly and remove the wood
block. Rotate the arm (Item 1) [Figure 30-70-6] Installation: Install the spring hook (with the tube inside
counterclockwise to release the spring tension. the spring) in the mounting bracket.
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DRIVE BELT (CONT’D)
Tension Pulley And Spring Removal And Installation

(Cont’d)
Figure 30-70-9
1
1
P-37740
Remove the bearing mounting bolts (Item 1) [Figure 30-

70-9] and spacers (Item 2) [Figure 30-70-9].
Check the parts for damage and replace as needed.
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OIL COOLER
Stop the engine and open the rear door.
Remove the radiator assembly from the loader. (See

Remove the radiator from the assembly. (See Removal

Figure 30-80-1
1 1

P-37553
Remove the mounting bolts (Item 1) [Figure 30-80-1] to

remove the oil cooler from the assembly.
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DRIVE SYSTEM
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Chaincase Cover Assembly And Disassembly . . . . . . . . . 40-30-1
Chaincase Cover Removal And Installation. . . . . . . . . . . . 40-30-1 SAFETY &
Removing Oil From The Chaincase. . . . . . . . . . . . . . . . . . 40-30-1 MAINTENANCE
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Axle Hub Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-2
Drive Chain Removal And Installation . . . . . . . . . . . . . . . . 40-20-8
Installing The Bearing Races . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Installing The Inner Bearing And Axle Sprocket. . . . . . . . . 40-20-7
Removing And Installing The Axle Bearing . . . . . . . . . . . . 40-20-4
Removing The Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
Removing The Bearing Races . . . . . . . . . . . . . . . . . . . . . . 40-20-5
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 DRIVE

Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1 SYSTEM

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE ELECTRICAL
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC SYSTEM &
SECTION) UNLESS OTHERWISE SPECIFIED. ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
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PARKING BRAKE Figure 40-10-2
Disc Removal And Installation 1
Figure 40-10-1
P-7226
Remove the brake disc (Item 1) [Figure 40-10-2].

P-7224
Reverse the procedure to install the parking brake disc.
Remove the chaincase cover. (See Chaincase Cover


Use snap ring pliers to remove the snap ring (Item 1)
[Figure 40-10-1] from the cluster sprocket.
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DRIVE COMPONENTS Figure 40-20-1
Axle Hub Removal And Installation 1

2
WARNING
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395
Axle Hub Puller Tool P-7519

Slide Hammer
MEL 1525 - Seal Driver Tool
Install a nut on one wheel stud and strike the nut with a
NOTE: The procedure is the same for the front and hammer to remove the stud (Item 1) [Figure 40-20-1].
rear axles. The front axle will be used for the
procedure. Installation: Support the flange of the axle hub and
install the stud with a hammer. Use a hydraulic press if
Loosen the axle hub mounting bolt, use the following available for this procedure.

procedure:
Install the puller tool (Item 2) [Figure 40-20-1] on the
Before lifting and blocking the loader, loosen the hub axle hub bolt.
mounting bolt.
Turn the threaded rod of the puller to remove the axle
NOTE: If the axle and bearings are being replaced, hub from the axle.
loosen the sprocket mounting bolt inside the
chaincase before lifting and blocking the
loader.
Installation: Install thread adhesive LOCTITE #242 to

the bolt threads and tighten the axle hub mounting bolt to
175-190 ft.-lb. (240-255 N•m) torque.

10-1.)
Remove the front wheel from the loader.
Installation: Tighten the wheel mounting nuts to 40-45

ft.-lb. (54-61 N•m) torque.
Loosen the axle bolt 2-4 turns.
One of the wheel studs must be removed to position a

puller for axle removal.
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DRIVE COMPONENTS (CONT’D) Clean the seal area and inspect the shaft for wear.
Axle Hub Removal And Installation (Cont’d) NOTE: If the shaft is damaged or worn, an axle repair
sleeve kit is available from Melroe Parts Sales
Figure 40-20-2 in Chicago or remove the axle. (See Removing
The Axle on Page 40-20-3.)
Lubricate the seal lips before installation.
Put the axle seal over the axle and into the axle tube.
1 Figure 40-20-4
P-7508
Remove the key [Figure 40-20-2] from the axle.

Axle Seal Removal And Installation
Remove the axle hub. (See Axle Hub Removal And

P-7513
Figure 40-20-3 Install MEL 1525 seal driver tool (Item 1) [Figure 40-20-
4] over the end of the axle and against the seal.
Hit the seal driver tool with a hammer [Figure 40-20-4].
Figure 40-20-5
P-7507
Drill a small hole in the axle seal [Figure 40-20-3].
Install a slide hammer (Item 1) [Figure 40-20-3] with a P-7515

screw tip end in the drilled hole on the seal.
NOTE: More than one hole may need to be drilled in Drive the seal (Item 1) [Figure 40-20-5] into the axle tube
the seal for removal. until the seal tool is against the axle tube.
If installed correctly, the axle seal will be slightly recessed

Remove the axle seal.
in the axle tube after installation.
Installation: Use MEL1525 - seal driver to install the seal Reverse the removal procedure to install the axle hub
in the axle housing. and wheel on the loader.
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DRIVE COMPONENTS (CONT’D) Figure 40-20-6
Removing The Axle
WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-7522
The tools listed are needed for the following procedure:
NOTE: A box end wrench should be used to loosen
MEL 1202A - Axle Bearing Service Tool
the bolt (Item 1) [Figure 40-20-6]. The wrench
Slide Hammer
must be ground to fit between the two axle
bolts.
NOTE: The procedure is the same for the front and
rear axle. The front axle procedure will be
Remove the axle hub. (See Axle Hub Removal And
shown.

Remove the hydrostatic motor. (See Removal And
20-1.)

10-1.)

on Page 10-30-1.)

(See Control Shield And Steering Lever Panels Removal

Remove the oil from the chaincase. (See Removing Oil

From The Chaincase on Page 40-30-1.)
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DRIVE COMPONENTS (CONT’D) Removing And Installing The Axle Bearing
Removing The Axle (Cont’d) Figure 40-20-8
Figure 40-20-7
P-7494
P-7518
Install a bearing puller (Item 1) [Figure 40-20-8] between
the bearing and the tapered flange for the hub. Be sure
Install the axle puller (Item 1) [Figure 40-20-7], loosen the bearing puller makes good contact with the inner race
the sprocket bolt as much as possible, and pull the axle of the bearing.

out until the sprocket bolt stops the travel.
Put the axle and the bearing puller in the hydraulic press
Repeat the procedure until the sprocket bolt is free from [Figure 40-20-8].
the axle. Remove the sprocket and bearing from the
axle. Press the bearing off the mounting surface of the axle.
Installation: Apply grease to the axle bearing before Be sure to hold onto the axle during removal. The
installation. bearing will slide freely along the axle shaft when the
bearing is free of the mounting surfaces.
Installation: Apply a small amount of liquid adhesive
(LOCTITE #242) to the bolt threads and tighten the bolt Figure 40-20-9
to 175-190 ft.-lb. (238-257 N•m) torque.
Remove the axle from the tube.
P-7496
Press the bearing from the splined end of the axle

[Figure 40-20-9].
Installation: Apply grease to the bearing before

installation.
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Removing And Installing The Axle Bearing (Cont’d)
Figure 40-20-10
3 4
P-7498
2
Press the bearing until it is fully seated on the mounting

P-7495 surface at the hub end of the axle [Figure 40-20-11].
Removing The Bearing Races

Installation: Use a piece of round tube (Item 1) [Figure
40-20-10] to install the bearing on the axle shaft. The Use the tools provided in the MEL 1202A Axle Bearing

inside diameter of the tube should be slightly larger than Service Set for bearing cup removal and installation. A
the inside diameter of the bearing race (for axle diameter slide hammer is also necessary for this procedure.
clearance) and must make contact with only the inner
race during installation. Figure 40-20-12
Use the same bearing puller (Item 2) [Figure 40-20-10]

to install the bearing on the axle.
Put the tube (Item 1) [Figure 40-20-10] on the bearing

puller (Item 2) [Figure 40-20-10].
Put the bearing (Item 3) [Figure 40-20-10] on the tube as

shown.
Put the splined end of the axle shaft (Item 4) [Figure 40-
20-10] in the bearing and press the bearing onto the axle.
Be sure to hold the axle during installation. It will slide

freely along the axle shaft after the splined end has P-7510
passed through the fbearing until it reaches the bearing
mounting surface on the hub end of the axle.
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-12].
Hit the long rod with a hammer to remove the inner

bearing cup from the axle tube [Figure 40-20-12].
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Removing The Bearing Races (Cont’d)
Figure 40-20-13
P-7511
1 Use the slide hammer to remove the bearing cup from

P-7509 the axle tube [Figure 40-20-14].
To remove the outer bearing cup, put the bearing cup tool
(Item 1) [Figure 40-20-13] on the slide hammer.

Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-13].
After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-13] on the tool.
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DRIVE COMPONENTS (CONT’D) Put the installation tool (Item 1) [Figure 40-20-16] in the
axle tube with the threaded rod through the hole in the
Installing The Bearing Races tool.
Figure 40-20-15 Secure the tool to the threaded rod with a nut [Figure 40-
20-16].
Hold the inside nut (Item 3) [Figure 40-20-15] with a

wrench and tighten the outside nut as shown in photo
[Figure 40-20-16].
Tighten the nut until the bearing cup is seated.
3 Figure 40-20-17
2
1
P-7497
Figure 40-20-16

1
P-7516
2 Install the outer bearing cup, install the installation tool

1 (Item 1) [Figure 40-20-17] and tighten the nut until the
bearing is seated.
Installing The Inner Bearing And Axle Sprocket
P-7492 Apply grease to the axle bearing before installation.
Install and hold the bearing in the inner race while sliding
Use the bearing cup installation tool (Item 1) [Figure 40- the axle in the tube and through the bearing.
20-15] & [Figure 40-20-16] and the long threaded rod
(Item 2) [Figure 40-20-16] from the service set to install Apply a small amount of liquid adhesive (LOCTITE #242)
the inner and outer bearing cups. to the bolt threads.
Put the inner bearing cup in the axle tube (Item 2) Install the washer and bolt in the sprocket, align the
[Figure 40-20-15]. sprocket splines with the axle splines worth the axle
splines. Continue to install the axle in the sprocket in the
Put the installation tool (Item 1) [Figure 40-20-15] in the sprocket while threading the bolt in the axle.
axle tube.
Tighten the bolt to 175-190 ft.-lb. (238-257 N•m) torque.
Install the long threaded rod (Item 2) [Figure 40-20-16]
into the axle tube with the threaded rod through the
installation tool (Item 1) [Figure 40-20-15].
Secure the tool to the threaded rod with a nut (Item 3)

[Figure 40-20-15].
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Drive Chain Removal And Installation
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
P-7514
10-1.)
Remove the cluster sprocket (Item 1) [Figure 40-20-18]
Raise the lift arms and install the lift arm support device. from the drive chains.
20-1.) Figure 40-20-19

on Page 10-30-1.)


Remove the brake disc. (See Disc Removal And

Remove the axle hub. See Axle Hub Removal And P-7512
Installation on Page 40-20-1.
Remove the hydrostatic motor. (See Removal And Remove the drive chain and axle sprocket from the
Installation on Page 30-40-1.) chaincase [Figure 40-20-19].
Remove the axle. See Removing The Axle on Page 40- NOTE: Installing an old or new chain will be easier if
20-3. the above removal procedure is followed.
NOTE: Due to the small area in the chaincase,

assemble a new chain on a bench before
installation, using a chain compression tool.
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CHAINCASE Remove the control shield and steering lever panels.
Removing Oil From The Chaincase And Installation on Page 30-20-1.)
Figure 40-30-1 Figure 40-30-2
2
2
2 2
P-7490 P-39060
Remove the plug located in front of the chaincase (Item Disconnect the electrical harness for the parking brake.
1) [Figure 40-30-1].

Remove the steering levers assembly. (See Lever
Use a transfer pump [Figure 40-30-1] to remove the oil Removal And Installation on Page 30-30-1.)
from the chaincase into a clean container.
Remove the mounting bracket bolts (Item 1) [Figure 40-
Installation: Add oil to the chaincase through the check 30-2] from the brake solenoid.
plug hole. ((See LOADER SPECIFICATIONS on Page
SPEC-10-1.) Remove the mounting bolts (Item 2) [Figure 40-30-2]
from the chaincase cover.
NOTE: Oil can also be removed or added through the
chaincase cover. Chaincase Cover Assembly And Disassembly
Chaincase Cover Removal And Installation Figure 40-30-3
WARNING
Never work on a machine with the lift arms up unless 1 1
W-2059-0598
Raise the loader arms and install the lift arm support
device. (See Engaging The Lift Arm Support Device on P7227
Page 10-20-1.)
Put jackstands under the rear of the loader. (See Remove the four bolts (Item 1) [Figure 40-30-3] from the
Procedure on Page 10-10-1.) brake disc guide block.
Raise the operator cab. (See Raising The Operator Cab Assembly: Put liquid adhesive (LOCTITE 242) on the
on Page 10-30-1.) bolt threads for the disc guide block. Tighten the bolts to
65-70 ft.-lb. (88-95 N•m) torque.
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CHAINCASE (CONT’D) Figure 40-30-5
Chaincase Cover Assembly And Disassembly

(Cont’d) REAR OF LOADER
Figure 40-30-4
1
1
2 3
MC-2327
1
Assembly: The guide blocks (Item 1) [Figure 40-30-5]
have angled slots (Item 2) [Figure 40-30-5] which must
P-7228 be parallel to each other when installed in the disc guide
(Item 3) [Figure 40-30-5]. When installed in the
chaincase cover correctly the top of both slots must be
Remove the four mounting bolts (Item 1) [Figure 40-30- toward the rear of the loader. Put liquid adhesive

4] from the disc guides. (LOCTITE #242) on the bolt threads for the disc guide.
Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque.
Installation: Install a new gasket (Item 2) [Figure 40-30-

4] under the cover during assembly.
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MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Lever And Wedge Removal . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 SAFETY &
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 MAINTENANCE
Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-40-3
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 DRIVE
SYSTEM
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-20-3
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1


REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1 MAIN FRAME
REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 ENGINE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 SERVICE
SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1 SPECIFICATIONS

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SEAT BAR Figure 50-10-3
Figure 50-10-1
P-9544
2 2
Turn the bolt (Item 1) [Figure 50-10-3] into the clevis five
P-9543 turns (both sides).
Installation: Adjust the clearance between the bolt head

Lower the seat bar (Item 1) [Figure 50-10-1] so the (Item 2) [Figure 50-10-2] and the seat bar tab (Item 3)
compression springs (Item 2) [Figure 50-10-1] will be in [Figure 50-10-2] to 1/16 inch (1,58 mm).

a down position.
Figure 50-10-4
Figure 50-10-2
2
3
1
1/16”
(1.58 MM)
1
P-9541
P-9542A P-9542
Remove the retaining pin (Item 1) [Figure 50-10-4] and

Loosen the adjustment lock nut (Item 1) [Figure 50-10-2] clevis pin (both sides).
(both sides).
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SEAT BAR (CONT’D) Figure 50-10-7
Figure 50-10-5
2
1
1
P-9554
3
Remove the mounting bolt and nut (Item 1) [Figure 50-

P-9548
10-7] and remove the mounting bracket (Item 2) [Figure
50-10-7] (both sides).
Disconnect the wiring harness connector (Item 1) [Figure Installation: Tighten the mounting bolt and nut (Item 1)
50-10-5] (left side). [Figure 50-10-7] to 180-200 in.-lb. (21-23 N•m) torque.

Remove the seat bar mounting bolt (Item 2) [Figure 50- Figure 50-10-8
10-5] (both sides).
Remove the sensor mounting bolt (Item 3) [Figure 50-

10-5] (left side).
Figure 50-10-6 22”

(558 mm)
P-7587
NOTE: Hook a 3/16 inch diameter rod, 22 inches (558

mm) long, in each end as shown [Figure 50-
10-8]. Pulling the seat bar together and
P-9547
holding it at the pivot holes with the 3/16 inch
rod, will make removal and installation easier.
Installation: Make sure the two tabs (Item 1) [Figure 50-

10-6] are located in the slot in the operator cab.
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Figure 50-10-9
2
2
1
P-9932
1
To prevent damage, use cardboard (Item 1) [Figure 50-
P-9930
10-11] and duct tape (Item 2) [Figure 50-10-11] to
protect the cab during removal and installation.
Use a clamp (Item 1) [Figure 50-10-9] to hold one side of Figure 50-10-12
the seat bar against the side screen.

Install the rod (Item 2) [Figure 50-10-9] in the pivot hole.
Figure 50-10-10
2
3 1
P-9933
Position the seat bar in the recess of the left side of the
cab (Item 1) [Figure 50-10-12]. Position the left side
P-9931
pivot end of the seat bar between the cab and the grab
handle (Item 2) [Figure 50-10-12].
Use a wooden 2 x 4, installed with one end against the Lift straight up on the right side of the seat bar (Item 3)
other side screen to pry the seat bar together [Figure 50- [Figure 50-10-12].
10-10].
Continue to lift on the right side of the seat bar and allow
Install the rod (Item 1) [Figure 50-10-10] in the seat bar the left side to rotate between the cab and the grab
pivot hole. handle. Lift the right side of the seat bar until it clears the
right side screen of the cab.
Remove the wooden 2 x 4.
Reverse the above procedure to install the seat bar into
Remove the C-clamp. the operator cab.
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Assembly
Figure 50-10-13
7 6 3 2 1
5 1
4 3 2
Right Side
of Seat Bar
Left Side P-7332
of Seat Bar
8 5 4
Assemble the parts as shown for the right side of the seat
P-3284
bar pivot assembly [Figure 50-10-14].
Mounting Bolt - (Item 1).

Assemble the parts as shown for the left side of the seat Pivot Bushing - (Item 2).
bar pivot assembly [Figure 50-10-13]. Keyed Plastic Bushing - (Item 3).

Washer - (Item 4).
Mounting Bolt - (Item 1). Mounting Bolt - (Item 5).
Washer - (Item 2).
Keyed Plastic Bushing - (Item 3). Tighten the mounting bolt to 180-200 in.-lb. (21-23 N•m)
Magnetic Bushing Assembly - (Item 4). torque.
Sensor Bracket - (Item 5).
Pivot Bushing - (Item 6).
Mounting Bolt - (Item 7).
Sensor Mounting Bolt - (Item 8).
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OPERATOR CAB Figure 50-20-2

1
Figure 50-20-1
P-34932
Disconnect the electrical harnesses (Item 1) [Figure 50-

20-2] From the operator cab.
Remove the gas cylinder from the operator cab. (See

Gas Cylinder Removal And Installation on Page 50-20-
3.)

P-37960
Put jackstands under the rear corners of the loader. (See


on Page 10-30-1.)
Install a lift strap through the grab handles and connect

the lift strap to a chain hoist to support the operator cab
[Figure 50-20-1].
Release the lock pin.
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Figure 50-20-3
2
1
1
P-37947
Disconnect the ground wire (Item 1) [Figure 50-20-3]

from the operator cab.

Figure 50-20-4
P-37962
Install a lift strap through the fuel fill access hole (Item 1)
[Figure 50-20-5] in the operator cab.
Use a chain connected to the two lift straps (Item 1 & 2)

[Figure 50-20-5] and remove the operator cab.
1
Reverse the procedure to install the operator cab.
P-34926
Remove the nuts (Item 1) [Figure 50-20-4] from the U-

bolts (both sides).
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Gas Cylinder Removal And Installation
WARNING
The cab must be held to prevent falling while hand is
in access hole.
W-2205-0695
WARNING P-19399

Pull the clip (Item 1)[Figure 50-20-7] enough to clear the
base end ball of the cylinder.
Figure 50-20-8
W-2059-0598

Figure 50-20-6
P-19400
1
Rotate the cylinder to remove it from the ball (Item 1)

P-19398 [Figure 50-20-8]

Raise the lift arm and install the arm support device.
20-1.)

on Page 10-30-1.)
Turn the clip (Item 1) [Figure 50-20-6] to remove it from

the hole in the base end of the cylinder.
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OPERATOR CAB (CONT’D)
Gas Cylinder Removal And Installation (Cont’d)
Figure 50-20-9
P-19330
Hold the nut under the fender and remove the bolt (Item
1) [Figure 50-20-9] from the rod end of the cylinder.

Remove the cylinder.
Reverse the procedure to install the gas cylinder.
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OPERATOR SEAT Figure 50-30-2


on Page 10-30-1.)
Figure 50-30-1
1 P-37982
1
Lower the operator cab and remove the two front

mounting bolts (Item 1) [Figure 50-30-2] from the seat
mount.
Remove the operator seat.

P-37955
Remove the rear bolts (Item 1) [Figure 50-30-1] from the

seat mount.
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BOB-TACH Figure 50-40-3
Removal
1
Figure 50-40-1
P-37984
1 Remove the pivot pin (Item 1) [Figure 50-40-3] from the

P-37985 tilt cylinder and the Bob-Tach.
Figure 50-40-4
Tilt the Bob-Tach forward so it is parallel to the floor. Put
blocks under the Bob-Tach and lower the Bob-Tach onto

the blocks (Item 1) [Figure 50-40-1]. 1
Figure 50-40-2
P-19279
Remove the grease fitting (Item 1) and slightly loosen the

bolt (Item 2) [Figure 50-40-4].
1 2 P-37983
Cover the grease fitting hole with a rag and strike the
pivot pin bolt with a hammer to loosen the tapered pin.
Remove the retainer bolt (Item 1) from the rod end pivot
pin retainer (Item 2) [Figure 50-40-2]. Repeat the procedure for the other side.
Installation: Tighten the retainer bolt to 18-20 ft.-lb. (24- Remove the Bob-Tach.
27 N•m) torque.
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BOB-TACH (CONT’D) Figure 50-40-7
Installation
Figure 50-40-5
2 1 P-37983
Install the pin retainer (Item 1) and the retainer bolt (Item
P-19279 2) [Figure 50-40-7].
Tighten the bolt (Item 2) [Figure 50-40-7] to 18-20 ft.-lb.

Push the pivot pin into the Bob-Tach fully and install the (24-27 N•m) torque.
grease fitting.

Align the Bob-Tach pivot pin with the lift arm hole (both
sides).
Add grease to the fitting (Item 1) [Figure 50-40-5] to

force the pivot pin into the lift arm hole.
Install the bolt (Item 2) [Figure 50-40-5] in the pivot pin.

Tighten the bolt to 90-100 ft.-lb. (125-135 N•m) torque.
Figure 50-40-6
P-37984
Align the tilt cylinder rod end with the bushings in the
Bob-Tach and install the pin (Item 1) [Figure 50-40-6].
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Seal Removal And Installation
Figure 50-40-8
1
1
2
P-19280
Remove the seal (Item 1) [Figure 50-40-9] from the Bob-

P-19281 Tach. Check the condition of the seal and replace as
needed.
Remove the Bob-Tach. (See Removal on Page 50-40-1.) NOTE: Install the seal with the lip facing outward.

Remove the grease fitting from the pivot pin grease NOTE: There is a plug located at the bottom of the
chamber (Item 1) [Figure 50-40-8]. bore in each Bob-Tach bushing. The plug
helps contain the grease inside the bushing
Install the Bob-Tach mounting bolt (Item 2) [Figure 50- and is a very low service item. See your
40-8] in the pivot pin and remove the pivot pin. dealer if service is required.
Check for wear and damage. Replace the pivot pins as

needed.
Installation: Push the pivot pin into the Bob-Tach frame.

Position the end of the pin flush with the end of the Bob-
Tach bushing (Item 3) [Figure 50-40-8].
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Lever And Wedge Removal

2
Use the following procedure to remove and install the
Bob-Tach lever, spring, and wedge.
Figure 50-40-10 1
P-19286
1
4 Remove the spring, bolts, and clevis assembly (Item 1)

[Figure 50-40-12].
Remove the wedge (Item 2) [Figure 50-40-12] from the

P-19284 Bob-Tach frame.

Always replace bent or broken wedges.
Remove the lever mounting bolt and nut (Item 1), washer
(Item 2), spring (Item 3) and lever (Item 4) [Figure 50-40- Figure 50-40-13
10].
Installation: Tighten the nut to 25-28 ft.-lb. (34-38 N•m)

torque. 4
Figure 50-40-11
3
1
1
P-19287
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) ,
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
assembly in the vise. Loosen and remove the bolt (Item
P-19285 1) [Figure 50-40-13] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.

Use a punch and hammer, remove the roll pin (Item 1)
[Figure 50-40-11] from the Bob-Tach wedge and spring, Reverse the removal procedure to install the Bob-Tach
bolt, and clevis assembly. Lever and Wedge.
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LIFT ARMS Figure 50-50-2
Figure 50-50-1
1
P-19293
Remove the auxiliary tubeline clamps (Item 1) [Figure

P-19288 50-50-2] (if equipped).
Use caps and plugs in the fittings during the procedure.

Put jackstands under the front and rear corner of the
loader. (See Procedure on Page 10-10-1.) Figure 50-50-3

Remove the Bob-Tach. (See Removal on Page 50-40-1.)
Start the engine and raise the lift arms to allow jackstands 1
to be placed under the lift arm crossmember. Have a
second person install the jackstands. Lower the lift arms
until the lift arms rest on the jackstands. Stop the engine.
Install a sling (Item 1) [Figure 50-50-1] around the lift

arm crossmember and use a chain hoist to support the lift
arms.
Remove the tilt cylinder. (See Removal And Installation

on Page 20-21-1.)
Remove the bolt (Item 2) [Figure 50-50-1] from the rod P-19292
end pivot pin retainer on the left lift cylinder. Remove the
retainer and the pivot pin.
Remove the auxiliary tubelines (Item 1) [Figure 50-50-3]
from the auxiliary coupler bulkhead fittings.
Lower the cylinder to the fender.
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LIFT ARMS (CONT’D) Figure 50-50-6
Figure 50-50-4
1
1
2
2
P-34926

P-37981 upright pivot pin retainer (both sides).
Remove the retainer (Item 2) [Figure 50-50-6].

Remove the rod end pivot pin bolt (Item 1) [Figure 50-
50-4] from the right lift cylinder. Remove the pivot pin. Figure 50-50-7

Lower the cylinder to the fender.
Remove the nut (Item 2) [Figure 50-50-4] from the tilt

cylinder tubeline cover.
Remove the tubeline clamps from the right lift arm.
Figure 50-50-5
P-19321
Use a slide hammer to remove the pivot pin from the

upright (both sides) [Figure 50-50-7].
P-19323
Wrap the lifting strap around the lift arm as shown

[Figure 50-50-5] (both sides) and attach it to the chain
hoist.
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LIFT ARMS (CONT’D)
Figure 50-50-8

P-37963
Use the chain hoist to remove the lift arms from the
loader [Figure 50-50-8].
Use the reverse procedure to install the lift arms on the

loader.
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REAR WINDOW Installation
Removal Figure 50-60-3
Figure 50-60-1
P19418
P-19465
Clean the area before installing the rubber moulding.
Remove the locking tab (Item 1) [Figure 50-60-1] from Install the rubber molding (Item 1) [Figure 50-60-3]
the groove in the window moulding. around the edge of the rear opening in the operator cab.

Cut off the excess moulding.
Figure 50-60-2
Figure 50-60-4
P-19464
P-19419
Use a plastic stick (Item 1) [Figure 50-60-2] (to pry the

window from the moulding. Apply liquid soap on the rubber cord to make installation
easier. Install the rubber cord (Item 1) [Figure 50-60-4]
into the moulding on the inside of the operator cab.
Install the safety tag in the top center of the cord.
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REAR WINDOW (CONT’D) Figure 50-60-7
Installation (Cont’d)
Figure 50-60-5
P-19422
Use a plastic stick (Item 1) [Figure 50-60-7] to position

P-37939 the locking tab into the groove to secure the window in
the moulding.
Apply liquid soap in the rubber moulding to make Tapping the window corners will help seat the window in
installation easier. Install the window from the outside of the moulding.

the operator cab [Figure 50-60-5]
Work the window downward until the window is fully

seated in the lower portion of the moulding [Figure 50-
60-5].
Figure 50-60-6
P19421
Use a plastic stick (Item 1) [Figure 50-60-6] under the

moulding lip to guide the window into the moulding
groove.
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REAR DOOR Figure 50-70-2
Open the rear door.

1
Figure 50-70-1
1
P-39232

Disconnect the wire harnesses (Item 1) [Figure 50-70-1]
from the loader electrical harness.
P-39233
Install a lifting strap (Item 1) [Figure 50-70-2] through the

slots in the rear door.
Remove the hinge pins (Item 2) [Figure 50-70-2] from

the door hinges.
Remove the door from the loader.
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FUEL TANK Figure 50-80-2


on Page 10-30-1.)
1 1
Figure 50-80-1
P-34931

fuel tank mounting strap.
Remove the fuel tank from the loader.

1
2

P-34930
Remove the hose clamps (Item 1 & 2) [Figure 50-80-1]

to remove the fuel supply and return lines.
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ELECTRICAL SYSTEM & ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Belt Removal And Installation . . . . . . . . . . . . . . . . . . . 60-30-2 SAFETY &
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3 MAINTENANCE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . 60-20-3 DRIVE
SYSTEM
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON) . . . . . . . 60-80-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) 60-80-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . 60-80-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . 60-80-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . 60-80-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2

ELECTRICAL
BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2 ANALYSIS
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . 60-10-1 ELECTRICAL

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2 SYSTEM &
Fuel Shutoff Timer and Fuel Pull Solenoid Locations . . . . . . . . . 60-10-2 ANALYSIS
Fuse And Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
SPECIFICATIONS
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 60-60-3
Front Lights Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Lights Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

BICS™ Controller Seat Bar Sensor Circuit Test . . . . . . . . . . . . . 60-90-5
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
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ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-12
Checking The Starter In The Loader . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

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CAB HARNESS - 6732922
TO OPTIONS
463 WIRING SCHEMATIC C 6430 6420 1 F
C453
B 6530 6520 2 B 1830
C452
1130
A 1130 4 A 1250
4420 5 D 6640
C423
A A 4420
2720 3 6650
B E
B 2420 1790 6
TO TAILGATE C 1180
(PRINTED DECEMBER 2004) B 2600 BUCKET POSITION
ACCESSORY
V-0636 VALVE
ACCESSORY
F
(If Equipped)
C454
C
6665920
E 6540
D 6440
A 6330
LIGHT SWITCH
1220
6733734 1 LEFT FRONT
1250
2210 2
6640 HEADLIGHT (2A)
2640 2610
6670 6110 2750
BACKUP 2650
3 2760
7100 1 1 7100
ALARM LEFT TURN SIGNAL REAR WORK LAMP (2A)
7110 EURO LIGHT
SWITCHES 2120 2 2 2120 LIGHT INDICATOR (1A) 4 5
CONNECTOR 2630 6200 6350
RIGHT FRONT
6650 2640 REAR 6
6610
6360
HEADLIGHT (2A)
E 1180
6680 2650 TAIL 2760
6120
A 6670 LAMP (1A)
C215
6733735 6840 2770
RIGHT TURN SIGNAL
B 6680 6340
LIGHT INDICATOR (1A)
RED = RED 7100 B B 7100
BACKUP C 6610
RNG = ORANGE
BLK = BLACK WIRES CONNECT BY LETTER BATTERY FEED 1000-1999 RED, RED/WHT, RNG ALARM 1780 A A 1780 D 6360
LBL = LIGHT BLUE ACROSS CONNECTORS GROUND 2000-2999 BLK F 2620 LIGHT 6850 LIGHT
DBL = DARK BLUE
6330
C207
C206
A B MONITORING 3000-3999 LBL
LGN = LIGHT GREEN
T G 2780 2780 G
V
DGN = DARK GREEN B A HYDRAULIC 4000-4999 LGN
YEL = YELLOW ATTACHMENT CONTROLS 5000-5999 YEL I 1860 1860 I
PNK = PINK VOLTMETER
LIGHTS 6000-6999 PNK 6330 A A 6330 S 6669664
WHT = WHITE COOLANT
TO HANDLE FOR 6664886
BRN = BROWN ACCESSORIES 7000-7999 WHT TEMPERATURE
SOME CONNECTOR HORN 2620
TAN = TAN HORN GAUGE HOURMETER
BODIES NOT SHOWN FOR ENGINE 8000-8999 TAN 2730
PUR = PURPLE (If Equipped)
C109
B 7200 7200 B B 7200 6669663 3420 H 1780
GRY = GRAY DRAWING CLARITY COMMUNICATION 9000-9999 PUR 6660294
A 1770
1860
Temp. Sender 6658818
t
3200 C C 3200 3200
ENGINE COOLANT
C119
SENDER
1750 D D 1750 1750
ENGINE
WARNING LIGHT
MAINFRAME HARNESS - 7105457 TRANS. OIL A A 3420 3420 E
C110
E 3420 1760
PRESSURE 6631010 Switch
B B 3010
3500 G G 3500
SWITCH ENGINE OIL 6820
C C 3410
C201
6670705 PRESSURE SWITCH 3500
3400 F F 3400 3400

TRANS. OIL TEMPERATURE
SWITCH 6820
6632633
TRANSMISSION
TRACTION
WARNING LIGHT
LOCK
22 22 4600 4600
A OVERRIDE
12 12 1940 1940
B A 4600 A A SWITCH
B 1940 B B 6674220
15 15 3910 3910 C
10 10 3920 3920 D C 3910 A A RED
C305
SEAT BAR
20 20 3900 3900 E D 3920 B B BLK SENSOR
23 23 4500 E 3900 C C DGN
4 4 1850
BICS
C420
2410 3 6 2850
HYDRAULIC
A B
A B
CONTROLLER 1 1 4410 4430 LOCK SOLENOID
C448
2 5 BRAKE
4500 F F 4500
SWITCH
16 16 2100 4400 A
1 4 1820
2110 B 1850 G G 1850
4130 C
REMOTE START
4220 D CONNECTOR
1920
1870 Dealer Copy -- Not for Resale
E
F
C114
1290 G
xxx ohm
3 3 4200 4210 A A HOLD TRACTION LOCK
C425
2200 C C SOLENOID
1860
5 5 4110
B XXXXXX
8 8 1810 4100 B PULL xxx ohm
1900 1910 1910 1840 H H 1840
DIODE
1 J
1800 J 1800
C162
6675149 GLOW PLUG SWITCH OFF
1 RUN
6665318
8520 K K 8520 8520 START 1800
1 2 B ST
R 1260
BAT 1230
1820
FUEL PULL 3
2060
SOLENOID
6670602 4 5
2000 L L 2000 1840
FAN 1 FAN 2 GLOW PLUG
1060
ALTERNATOR A B A B 6 1810 1830
12.3 ohm
0.38 ohm
I
C115 C116 IGNITION SWITCH
FUEL 1230 M M 1230
A B A B HR SHUTOFF
HOLD
PULL
2600 TIMER
2100 2610 T11
8110
2810
8120
2820
2000
2240
STARTER
2420
2720 A B C C B A 1220 N N 1220
2200 2400 A B C
2410
3010
B
8210 C117 C118 C101
S A B C C B A
2050
A B C - 2210
T12
2010 P P
1890
1240
2240
2250
1270
1930
1210
+
1930
1270
2250
2810 2210
8210
2820
8520
AUXILIARY
2060 POWER
SOCKET
1000
GROUNDS DIODE
FUSE 6
FUSE 5
25A
25A
BICS
1220
1250
1210
1810 8100
C164
1110
A 1730 10 A
BATTERY CABLE
1880
8200
1830
1240
4120
4100
FUSE 1
1930
8100
GLOW
8500
1120
8510
SWITCHED COOLING PLUG TRACTION
Power Plug
Accessory POWER FAN STARTER
1770 LOCK
Fuel Pull
FUSE 10
FUSE 12
FUSE 11
87A 87 86 87A 87 87A 87 86 87A 87 86
Engine
Lights
86
1730
FUSE 9
25 A
86 87 87A
25 A
15 A
10 A
(Accessory Fused and
C105
Switched) A 1720 1720 25 A 30 85 30 85 30 85 30 85

85 30
TO OPTIONS FUSE 2
B 2050
2090
1010
2010
2040
1020
1280
2030
1120
2040
2260
1260
Gauge
2030
2260
1750
1200
FUSE 4
FUSE 7
40 A
25 A
10 A
FUSE 3
FUSE / RELAY
CENTER
FUSE 5 FUSE 1 FUSE 9

FAN 1 BICS POWER PLUG
20A 10A SWITCH 10A

1010
FUSE 6 FUSE 2
POWER FUSE 10
FAN 2 ACCESSORY LIGHTS
- + 1020
20A 25A 25A 1030

1000
FUSE 7 FUSE 3 FUSE 11 1050
GLOW PLUGS GAUGE ENGINE
1200
40A 10A GLOW TRACTION 15A
FAN STARTER
FUSE 8 FUSE 4 PLUG LOCK FUSE 12
TRACTION L OC K FUEL PULL BATTERY
25A 25A
V-0636 (12-1-04)
Printed in U.S.A.
219 of 372
463 WIRING SCHEMATIC
OPTIONS A
B
OPEN
OPEN
C
S/N 538911001 AND ABOVE D
OPEN
OPEN
S/N 539011001 AND ABOVE E OPEN
OPEN
F
(PRINTED DECEMBER 2004) G 1290
V-0637 H OPEN
EUROPEAN ONLY J OPEN
K OPEN
L 1920 1290 G
HORN RIGHT LEFT
REAR REAR M 1870 1870 F
(Optional) TO ENGINE TO REMOTE
TAILLIGHT TAILLIGHT N OPEN 1920 E
B START
C109
RNG/DBL LICENSE Power B 2320 2300 Ground
Supply P OPEN 4220 D CONNECTOR ON
RNG A E A C B D F PLATE E F C B D A A 1610
For Kit Q OPEN 4130 C MAIN FRAME
LIGHT
HORN HARNESS - C702 C701 25 A
R OPEN
2110 B HARNESS
1620
2310
Fuse
6708506 or 6709526 E A C B D F E F C B D A S OPEN 4400 A
T OPEN
U OPEN
87A 87 86
LBL/WHT
V OPEN
PNK
PNK
BLK
BLK
TO ENGINE W OPEN
TO ATTACHMENT HORN TO REMOTE
SKI CONTROL TO ENGINE
START TOOL
C441
B DBL RNG/WHT A C109 A OPEN

B BRN/YEL D
A WHT RNG/DBL 30 85 B 2110
BLK B
C454
C 4400
PNK A 1740 1
D 4220
REAR AUX. TURN SIGNAL F
1600
1730
C YEL/LGN DGN B E 4130
C
C457
C453
B YEL/RED BRN A BRN/DGN E F OPEN

REMOTE START
A RNG YEL C ACCESORY 1 G OPEN
TO ENGINE TAILGATE HARNESS - 6707509 ADAPTER HARNESS

HARNESS
TO ATTACHMENT
LEFT HANDLE To Starter
6734387
(If Equipped) 6736214 B Terminal
TO CAB
B TO OPTIONS
DOME LIGHT
A SWITCH
C215
C
C608
BACKUP ALARM A RED
B
C105
2710
SWITCHES D B BLK
1710 A
BLK BEACON
C609
A A BRN/RED E A OPEN
TO ENGINE OR
- B B BLK F DOME LIGHT B 2710
C105
BLK BLK BLK B STROBE

C 4200 4800 C
C441
RNG A
+ RNG D 4100 4700 B
BEACON/STROBE HARNESS - 6708318 E 4300 1710 A
BACKUP ADDITIONAL POWER
CONNECTOR F 4400
ALARM BOOM
C717
B OPEN
BLK
CONNECTOR G
C457
4300 A
BLK A H OPEN
4400 B
J OPEN
BACKUP ALARM HARNESS - 6708739 EUROPEAN ONLY K OPEN
L OPEN
M OPEN ATTACHMENT
LEFT RIGHT
CLEARANCE CLEARANCE
BEACON
OR
N
P
OPEN
OPEN
CONTROL HARNESS
BLK
(WORK LIGHT) (WORK LIGHT) BLK

LEFT LAMP LAMP
STROBE
6727870
BEACON RIGHT
OR TURN
LAMP TURN
B A STROBE LAMP
BLK
BLK
C607 B A
PNK
FRONT WIPER
LEFT B A C608 WATER BOTTLE PUMP HAZARD SWITCH
TURN RIGHT TO CAB
TURN B A M BEACON SWITCH 1140
LAMP TO CAB FRONT WIPER
LAMP 1190
BLK
BRN/RED E SWITCH
5 2
F 5 2 1760
BLK BRN/RED E
C215
3
C BLK F 1
C215
TO OPTIONS 6 4 5
DGN B C 6 4 3 1 2
D DGN B C608
YEL A PNK D B A 6 4 3 1
6000
YEL A FRONT WIPER
6700
2745
2755
6420
6640
JV FLASHER LIGHT HARNESS - 6710905 MOTOR
2745
7310
2710
1110
2750
2765
1780
4-WAY FLASHER HARNESS - 6709530 V

7310
7210
TO MAINFRAME DIODE M
HARNESS
3 2000
1 6420
C452
2 6520 6520 C B
EUROPEAN ONLY 4 1130 2755 B C
6 1720 7160 A A
WIRES CONNECT BY LETTER
5 4420 BUCKET
ACROSS CONNECTORS
6650
LEFT RIGHT POSITION
BEACON SWITCH
A B CLEARANCE CLEARANCE OR 6
BLK
BLK
BLK
BLK
B A (WORK LIGHT) (WORK LIGHT) STROBE 5

LAMP LAMP
1140
LEFT 4
TURN RIGHT
LEFT RIGHT 3
1130
LAMP TURN
SOME CONNECTOR HEADLIGHT HEADLIGHT 1 2
LAMP
BODIES NOT SHOWN L
B A B
DBL
1420
PNK
FOR DRAWING CLARITY X
A
RED = RED C716 1150 1180
C216
RNG = ORANGE B A F OPEN FLASHER
BLK = BLACK C 6700
ACCESSORY HARNESS
TO CAB
BATTERY FEED 1000-1999 RED, RED/WHT, RNG LBL = LIGHT BLUE E 6650
GROUND 2000-2999 BLK
DBL = DARK BLUE BRN/RED E E 6640
MONITORING 3000-3999 LBL
LGN = LIGHT GREEN
BLK F 6729789
C215
DGN = DARK GREEN TO CAB
DBL C
HYDRAULIC 4000-4999 LGN YEL = YELLOW HARNESS
ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK DGN B
LIGHTS 6000-6999 PNK
WHT = WHITE PNK D
BRN = BROWN YEL A
ACCESSORIES 7000-7999 WHT TAN = TAN
ENGINE 8000-8999 TAN PUR = PURPLE
COMMUNICATION 9000-9999 PUR GRY = GRAY
HEADLIGHT HARNESS - 6707672
V-0637 (12-1-04)
Printed in U.S.A.
220 of 372
ELECTRICAL SYSTEM INFORMATION
WARNING
The Following Troubleshooting Chart Is Provided For
Assistance In Locating And Correcting Problems Which Check for correct function after adjustments, repairs
Are Most Common. Many Of The Recommended or service. Failure to make correct repairs or
Procedures Must Be Done By Authorized Bobcat Service adjustments can cause injury or death.
Personnel Only. W-2004-1285
PROBLEM CAUSE
Battery loses charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is defective.

4. The ground is not correct in the electrical system.
5. The alternator has a defect.
6. Engine seizure.
7. Starter has a defect.
8. Wiring or solenoid has a defect.
9. Fuse has a defect.
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ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Switches Location
Description Figure 60-10-3
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
1
Figure 60-10-1
P-34970
The electrical system is protected by 11 fuses and five

relay switches located in the engine compartment
[Figure 60-10-3].

the cover.
Figure 60-10-4
P-39013
The loader has a 12 volt, negative ground alternator

charging system [Figure 60-10-1].
Fuel Shutoff Timer and Fuel Pull Solenoid Locations
Figure 60-10-2
P-34972
The decal (Item 1) [Figure 60-10-4] located in the cover

specifies the fuse sizes used in the various electrical
circuits and shows the relay switch locations and
description.
1
P-59247
Raise the operator cab to access the fuel pull solenoid

(Item 1) and the fuel shutoff timer (Item 2) [Figure 60-10-
2] located on the front side of the engine.
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BATTERY Figure 60-20-2

1 1
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
P-39009
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Remove the nuts (Item 1) [Figure 60-20-2] from the
W-2065-1296 battery holddown clamp and remove the clamp.
Figure 60-20-3
WARNING

Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60° F (16° C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.

W-2066-1296 1
P-39085
Figure 60-20-1
Loosen the nut (Item 2) [Figure 60-20-3] which fastens
the hydraulic fill tube to the frame, and move out of the
way.
Remove the battery from the loader and set on the floor.
P-39008
Open the rear door.
Disconnect the negative (-) cable (Item 1) [Figure 60-20-

1] from the battery.
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BATTERY (CONT’D) Figure 60-20-6
Figure 60-20-4
P-9590
Always clean the terminals and cable ends when

P-39010 installing a new battery[Figure 60-20-5] and [Figure 60-
20-6].
Remove the positive (+) cable from the battery [Figure When installing the battery in the loader, do not touch any
60-20-4]. metal parts with the battery terminal posts.

Use the reverse procedure to install the battery. Connect and tighten the battery cables. Connect the
negative (-) cable last to prevent sparks.
Servicing
Figure 60-20-7
Figure 60-20-5
P-9588
P-9589
The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [Figure 60-20-7].
Clean the terminals and cable ends as shown in [Figure

60-20-5] and [Figure 60-20-6].
Check the electrolyte level in the battery. Add distilled

water as needed.
Put battery saver (P/N 6664458) or grease on the battery

terminals and cable ends to prevent corrosion.
463 Bobcat Loader
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BATTERY (CONT’D) Figure 60-20-8
Using A Booster Battery (Jump Starting)
WARNING 2
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and 1
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
P-39011
minutes.
If electrolyte is taken internally drink large quantities Figure 60-20-9

of water or milk! DO NOT induce vomiting. Get
prompt medical attention. 2
W-2065-1296
1

WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
P-39012
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. Connect the end of the first cable (Item 1) [Figure 60-20-
8] to the positive (+) terminal of the booster battery.
Battery gas can explode and cause serious injury. Connect the other end of the same cable (Item 1) [Figure
W-2066-1296 60-20-9] to the positive (+) terminal for the starter.
If it is necessary to use a booster battery to start the Connect the end of the second cable (Item 2) [Figure 60-
engine, BE CAREFUL! There must be one person in the 20-8] to the negative (-) terminal of the booster battery.
operator’s seat and one person to connect and Connect the other end of the second cable (Item 2)
disconnect the battery cables. [Figure 60-20-9] to the engine frame mount.
The ignition must be in the OFF position. The booster Keep the cables away from moving parts. Start the
battery to be used must be 12 volt. engine. (See Cold Temperature Starting Condition,
Operation & Maintenance Manual.)
After the engine has started, remove the ground (-) cable
(Item 2) [Figure 60-20-9] first.
Remove the cable from the starter.
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ALTERNATOR Figure 60-30-2
1
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove 1
both cables from the battery.) 2
• Extra battery cables (booster cables) are
P-39013
connected wrong.
I-2023-1285
Remove the bolts (Item 1) [Figure 60-30-2] and harness
Figure 60-30-1 retaining bolt (Item 2) [Figure 60-30-2] to remove the
alternator shield and the alternator.
Figure 60-30-3

2
1
P-39014
Open the rear door. Disconnect the negative (-) battery P-39015
cable.
Move the protective cover and disconnect the red wire Loosen the adjustment bolts and move the alternator so
(Item 1) [Figure 60-30-1] from the alternator. there is 1/4 inch (6 mm) movement between the pulleys
with 15 pounds (67 N) of force (Item 1) [Figure 60-30-3].
Disconnect the wiring harness connector (Item 2) [Figure
60-30-1] from the alternator. Tighten the adjustment bolts.
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ALTERNATOR (CONT’D) Alternator Belt Removal And Installation
Adjusting The Alternator Belt Open the rear door. Disconnect the negative (-) battery
cable.
Loosen the alternator adjustment bolts (Item 1 & 2)
Figure 60-30-4 [Figure 60-30-4].
Move the alternator ahead to loosen and remove the

alternator belt from the pulleys.
P-39013

Loosen the bolts (Item 1 & 2) [Figure 60-30-4] to adjust
the alternator.
Figure 60-30-5
P-39015
Move the alternator so there is 1/4 inch (6 mm)

movement between the pulleys with 15 pounds of force
[Figure 60-30-5].
Tighten the adjustment bolts.
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ALTERNATOR (CONT’D) Figure 60-30-7
Description
Figure 60-30-6
3
1
P-39017
Check and record the battery voltage [Figure 60-30-7].

P-39230
Figure 60-30-8
The output terminal (Item 1) [Figure 60-30-6].

2

The battery or power sensing terminal (Item 2) [Figure
60-30-6]. 1
The ground connection (Item 3) [Figure 60-30-6].
Alternator Output Test
WARNING
P-39204
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust Start the engine and run at half speed. Use a volt meter
outside. Exhaust fumes contain odorless, invisible to check the alternator output.
gases which can kill without warning.
W-2050-1285
Touch the positive probe (Item 1) [Figure 60-30-8] to the
power connection and touch the negative probe (Item 2)
Lift and block the loader. (See Procedure on Page 10-10- [Figure 60-30-8] to the ground connection at the
1.) alternator.
In the no load test (lights off, heater off, etc.), the volt
meter reading should be at least .5 volt to 2 volts over the
recorded battery voltage.
If the volt meter reading is less than .5 volts or more than

2 volts, repair or replace the alternator.
In the full load test, turn all accessories on in the loader,

(lights, heater, etc.) The volt meter reading should be at
least .5 volt over the recorded battery voltage.
If the voltage reading is less than .5 volt over the

recorded battery voltage, repair or replace the alternator.
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STARTER Figure 60-40-2
Disconnect the negative (-) cable from the battery. 2
Installation: Make note of the wiring connections on the

starter to ensure correct installation.
Figure 60-40-1
1
3
P-9975
1
Connect a jumper wire between battery terminal (Item 1)
and the solenoid terminal (Item 2) [Figure 60-40-2].
If the starter turns but does not turn the engine, the
3 starter drive has a defect.

Figure 60-40-3
2
P-39018
Remove the rubber cover from the solenoid terminal

(Item 1) [Figure 60-40-1].
Remove the positive (+) wires (Item 2) [Figure 60-40-1]

from the starter.
Remove the solenoid wire (Item 1) [Figure 60-40-1].

2
Remove the starter mounting bolt (Item 3) [Figure 60-40-
1] and negative (-) cables. 1
P-9976
Remove the starter.
Installation: Tighten the starter mounting bolts to 25-28 Connect a jumper wire between the battery terminal
ft.-lb. (34-38 N•m) torque. (Item 1) and the motor terminal (Item 2) [Figure 60-40-3].
Checking The Starter In The Loader If the starter turns, the defect is in the solenoid.
NOTE: The starter is removed from the loader for If the starter does not turn, the starter is defective.
clarity.
The key switch must be in the OFF position.
The battery must be at full charge.
The cable connections on the battery must be clean and

tight.
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STARTER (CONT’D)
1. Bearing
2. Armature 7
3. Bearing
4. Frame 5 8 9
6
5. Brush Spring
6. Brush Holder
4
7. Cover
8. Bolt
9. Bolt
10. Bolt 3
11. Cover 2
12. Gasket
13. Switch
14. Nut
15. Washer
16. Nut
17. Washer 10
18. Roller 1
19. Retainer 12
15

20. Idler Gear
21. Ball 14
22. Spring 11
23. Housing
16
24. Screw
25. Washer 18 13
26. O-Ring 19
20
27. Housing
28. O-Ring 16
29. Snap Ring
30. Collar 14
23
31. Pinion Gear
15
32. Spring Seat 22
33. Spring 21
34. Clutch 36
35. Spring
36. Pinion Shaft
35
34
33
32
26
25 29
24 31
30
29
28
27
D-2297
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STARTER (CONT’D) Figure 60-40-6
Disassembly
Figure 60-40-4
1
1
N-15021
Remove the frame (Item 1) [Figure 60-40-6] from the

N-15019 magnetic switch.
Figure 60-40-7
Remove the cable (Item 1) [Figure 60-40-4] from the
magnetic switch.

Mark the frame and magnetic switch (Item 2) [Figure 60-
40-4] for ease of assembly.
2
Figure 60-40-5
N-15022
1 Remove the screws (Item 1) from the brush cover (Item

2) [Figure 60-40-7].
1
Remove the cover (Item 2) [Figure 60-40-7].
N-15020
Remove the bolts (Item 1) [Figure 60-40-5].
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Figure 60-40-8
1
1
1 N-15025
3 Remove the bearings (Item 1) [Figure 60-40-10] from

N-15023 both ends of the armature.
Figure 60-40-11
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 60-40-

8].
NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder 1
(for the negative brushes) and yolk (for the
positive brushes). 1
Remove the brush holder (Item 3) [Figure 60-40-8] from

the end of the armature.
Figure 60-40-9
N-15026
1 Remove the bolts (Item 1) [Figure 60-40-11] from the

starter housing.
N-15024
Remove the armature (Item 1) [Figure 60-40-9] from the

frame.
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Figure 60-40-12
N-15029
Remove the idler gear (Item 1), rollers (Item 2) and

1
N-15027 retainer (Item 3) [Figure 60-40-14].
Figure 60-40-15
Remove the starter housing (Item 1) [Figure 60-40-12]
from the magnetic switch housing.

Figure 60-40-13
N-15042
1
In order to remove the snap ring from the pinion shaft, a
N-15028 tube 0.605 inches (15,4 mm) in diameter by 2.0 inches
(50,8 mm) in length is needed [Figure 60-40-15].
Remove the ball (Item 1) [Figure 60-40-13] from the

pinion shaft.
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Figure 60-40-16
N-15047
1 Remove the snap ring (Item 1) [Figure 60-40-18].

N-15045
Figure 60-40-19
Install the tube (Item 1) [Figure 60-40-16] in the over

running clutch.

Figure 60-40-17 2
3 1
4
1 N-15053
2
Remove the collar (Item 1), pinion (Item 2), spring (Item
3) and spring seat (Item 4) [Figure 60-40-19].
N-15046
Press down on the carrier (Item 1) to extend the pinion

shaft. Press down in the pinion (Item 2) [Figure 60-40-
17].
Press the collar (Item 3) [Figure 60-40-17] down to gain

access to the snap ring.
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Figure 60-40-20
1 2
N-15035

N-15033 starter housing.
Figure 60-40-23
Remove the pinion shaft (Item 1) and spring (Item 2)
[Figure 60-40-20] from the starter drive.

Figure 60-40-21
1 1
N-15030
Remove the spring (Item 1) [Figure 60-40-23] from the

Remove the over running clutch (Item 1) [Figure 60-40-

21].
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STARTER (CONT’D) Inspection And Repair
Disassembly (Cont’d) Inspect the brush cover for discoloration, indicating the
starter has been overheated.
Figure 60-40-24
Inspect the pinion teeth for wear and damage.
Figure 60-40-26
N-15031

B-14455
magnetic switch cover.

Figure 60-40-25 Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-26]. A short-circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-citcuited must be replaced.
3 2 1 Figure 60-40-27
N-15032
Remove the cover (Item 1), gasket (Item 2) and switch

(Item 3) [Figure 60-40-25].
N-15036
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-27]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.
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Inspection And Repair (Cont’d)
Figure 60-40-28
1
B-14460
Measure the segment mica depth (Item 1) [Figure 60-40-

N-15037 30].
Service Limit - 0.008 inch (0,2 mm)

Armature Winding Continuity Test: Use a circuit tester,
touch the probes to two communicator segments [Figure If it is worn, replace the armature.

60-40-28]. There must be continuity at any point. If there
is no continuity, the winding is open-circuited, replace the Check the commutator surface for burned spots which
armature. usually indicates an open-circuit, and correct it using
#400 sand paper.
Figure 60-40-29
Figure 60-40-31
B-14458
N-15039
Commutator Run-Out Test: Check the commutator run-

out as shown in [Figure 60-40-29]. Check the field windings for wear and damage.
Service Limit - 0.020 inch (0,4 mm) Check all the connections for clean and tight solder
joints.
If the comutator exceeds the service limit, repair as
needed. Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
other probe to the surface of the frame [Figure 60-40-
31]. There should be no continuity. If there is continuity,
the field windings are grounded.
Replace the field windings.

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Inspection And Repair (Cont’d)
Figure 60-40-32 1
N-15043
Inspect the over running clutch (Item 1) [Figure 60-40-

N-15040 34], it must rotate freely in the direction of the starter
rotation and lock in the opposite rotation.
Field windings Continuity Test: Use a circuit tester, touch The following tests should be done without the armature
one probe to the wire and the other probe to the brush assembly.
[Figure 60-40-32]. There must be continuity. If there is

no continuity, the field windings are open-circuited.
M.T......Main Terminal to which the main cable from the
Replace the yoke if the field windings have an open-
circuit. battery is connected.
Inspect the brushes for wear and damage. C.........C-Terminal to which the wire from the field
windings connected.
Replace the brush holder or yoke assembly if the
brushes are worn or damage. 50.......50-Terminal to which the wire from the starting
switch or stator relay is connected.
Check brush springs, for damage or rust. Replace as
needed. NOTE: Each test should be performed a short time (3
to 5 seconds) to prevent the magnetic switch
Figure 60-40-33
winding from burning. Each test should be
performed with 12 volts.
N-15059
Brush Holder Insulation Test: Use a circuit tester, touch

one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-40-33]. There
should be no continuity. If there is continuity, replace or
repair.
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STARTER (CONT’D) No Load Test
Inspection And Repair (Cont’d) The following test should be done after reassembling the
starter:
Figure 60-40-35
Figure 60-40-37
50
C
50
C
M.T.
M.T.
B-14471
B-14469
Pull-In Test: Connect the wires as shown in [Figure 60-

40-35]. When connecting Terminal C and M.T. are Return Test: With the same conditions as in the hold-in

closed, the pinion should engage. test, open the connecting terminal 50 [Figure 60-40-37].
the pinion should return immediately.
Figure 60-40-36
Figure 60-40-38
50 Ammeter
C
50
M.T.
M.T.
B-14470
Starter B-14440
Hold-In Test: With the same conditions as in the pull-in

test, open the connecting Terminal C [Figure 60-40-36]. Clamp the starter in a vise. Using a 12 volt battery and
The pinion should remain in the engaged position. ammeter, connect the positive wire of the battery, and the
ammeter to the 50 terminal [Figure 60-40-38]. Connect
the negative wire to the starter body. Using a jumper
wire, connect the 50 terminal to the main terminal.
The starter should show smooth and steady rotation

immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit - 220 Amp. Maximum Draw.
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Assembly
Figure 60-40-39
1 3 1
2
N-15030
Install the spring (Item 1) [Figure 60-40-41] on the

Figure 60-40-42
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running

clutch, and idler gear rollers.
Install the switch plunger (Item 1), gasket (Item 2) and

cover (Item 3) [Figure 60-40-39] on the switch housing.
Figure 60-40-40 1
1
N-15035
Install the O-ring (Item 1) [Figure 60-40-42] in the starter

1 housing.
N-15031
Install the bolts (Item 1) [Figure 60-40-40].
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Assembly (Cont’d)
Figure 60-40-43
N-15042
In order to install the pinion and snap ring on the pinion

N-15034 shaft, a tube (Item 1) [Figure 60-40-45] 0.605 inch (15,4
mm) in diameter by 2.0 inches (50,8 mm) in length is
needed.
Install the over running clutch (Item 1) [Figure 60-40-43]
in the starter housing. Figure 60-40-46

Figure 60-40-44
1 2
1
N-15044
N-15033
Install the tube (Item 1) [Figure 60-40-46] in the over
running clutch.
Install the spring (Item 1) and pinion shaft (Item 2)
[Figure 60-40-44] in the over running clutch.
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Assembly (Cont’d)
Figure 60-40-47
1
N-15056
Install the pinion (Item 1) [Figure 60-40-49].

N-15054
Figure 60-40-50
Place the starter drive on the bench, and press down on

the starter drive housing. 1

Install the spring seat (Item 1) [Figure 60-40-47] on the
pinion shaft.
Figure 60-40-48
N-15057
Install the collar (Item 1) [Figure 60-40-50].
N-15055
Install the spring (Item 1) [Figure 60-40-48].
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Assembly (Cont’d)
Figure 60-40-51
1
1
N-15041
Install the rollers (Item 1) [Figure 60-40-53] in the

N-15047 retainer.
Figure 60-40-54
Install the snap ring (Item 1). Pull the collar (Item 2)
[Figure 60-40-51] over the snap ring.
1

Figure 60-40-52
N-15029
1
Install the roller/retainer assembly (Item 1) [Figure 60-
N-15058 40-54] on the starter housing.
Install the idler gear (Item 2) [Figure 60-40-54] over the

With the pinion shaft extended, extend and release the roller/retainer assembly.
pinion (Item 1) [Figure 60-40-52]. The pinion must
return to the fully retracted position.
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Assembly (Cont’d)
Figure 60-40-55
1
1
N-15026
1 Install the two bolts (Item 1) [Figure 60-40-57]. Tighten

N-15028 the bolts to 60-104 in.-lb. (7-12 N•m) torque.
Figure 60-40-58
Install the ball (Item 1) [Figure 60-40-55] in the pinion
shaft.

Figure 60-40-56
1 2
N-15025
1 Install the bearings (Items 1 & 2) [Figure 60-40-58] on

N-15027 both ends of the armature.
Install the starter drive (Item 1) [Figure 60-40-56] on the

magnetic switch.
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Assembly (Cont’d)
Figure 60-40-59
1 2
N-15049
Install the frame (Item 1) [Figure 60-40-61] over the

N-15048 armature.
NOTE: Make sure the tab (Item 2) [Figure 60-40-61] on

Install the armature (Item 1) [Figure 60-40-59] in the the frame is aligned with the slot in the
magnetic switch housing. magnetic switch housing.

Figure 60-40-60 Figure 60-40-62
1 3
1
N-15050 N-15051A
Install the new O-rings (Item 1) [Figure 60-40-60] on Install the brush holder (Item 1) [Figure 60-40-62] on the
both ends of the frame. armature.
Using a needle nose pliers, pull the spring (Item 2) back

and install the brushes (Item 3) [Figure 60-40-62].
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Assembly (Cont’d)
Figure 60-40-63
1 N-15019
Install the cable (Item 1) [Figure 60-40-65] on the

N-15052 terminal. Tighten the terminal nut to 4-7 ft.-lb. (5-9 N•m)
torque.
Install the brush cover and screws (Item 1) [Figure 60-

40-63].

Figure 60-40-64
N-15020
Install the thru bolts (Item 1) [Figure 60-40-64]. Tighten

the bolts to 60-104 in.-lb. (7-12 N•m) torque.
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INSTRUMENT PANEL Figure 60-50-3
Figure 60-50-1
P-7184
Pull the right instrument panel down and disconnect the

P-3995 wire harness connectors from the panel. Remove the
panel [Figure 60-50-3].
Pry the rubber light mount (optional) loose from the Figure 60-50-4
operator cab (both sides) [Figure 60-50-1].

Figure 60-50-2
P-39019
P-3955 Repeat steps [Figure 60-50-1] and [Figure 60-50-2].

Pull the left instrument panel down and disconnect the
wire harness connectors from the panel. Remove the
Lower the light (optional) from the operator cab and panel [Figure 60-50-4].
locate the three instrument panel mounting bolts (Item 1)
[Figure 60-50-2] (both sides). Reverse the removal procedure to install the instrument
panel.
Remove the three mounting bolts (Item 1) [Figure 60-50-
2].
Installation: Do not overtighten the instrument panel

mounting bolts to prevent stripping of the threaded holes
in panels.
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LIGHTS Figure 60-60-3
Front Lights Removal And Installation
Figure 60-60-1 1
P-3955
Pull the light down and remove the three mounting bolts
P-3956 (Item 1) [Figure 60-60-3] from the instrument panel.
Disconnect the front light connector from the instrument

The front lights are mounted in the upper corners of the panel. Remove the front light from the operator cab.
operator cab [Figure 60-60-1].

Figure 60-60-4
Figure 60-60-2
P-7416
P-3995

Pry the rubber light mount free from the operator cab 60-4] to remove the light from the rubber light mount.
[Figure 60-60-2].
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LIGHTS (CONT’D) Rear Lights Removal And Installation
Front Lights Removal And Installation (Cont’d) Figure 60-60-6
Figure 60-60-5
2
1
4
3
1
2 P-7447
P-7414
Remove the light from the rubber mount.
Turn the bulb (Item 1) [Figure 60-60-5] and remove it Push the work bulb (Item 1) [Figure 60-60-6] in and turn
from the cover (Item 2) [Figure 60-60-5]. it counterclockwise to remove it from the socket.

60-6] from the cab harness.
Remove the screw (Item 3) [Figure 60-60-6] to remove

the work light socket from the rear light.
Remove the screws (Items 3 & 4) [Figure 60-60-6] to

remove the rear light.
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LIGHTS (CONT’D) Figure 60-60-9
Cab Light Removal And Installation
Figure 60-60-7
1
1
P-39023
1
1
Remove the mounting bolts (Item 1) [Figure 60-60-9] to
P-39021 lower the instrument panel.
Figure 60-60-10
The cab light is mounted in the upper left rear corner of
the operator cab [Figure 60-60-7]. Remove the two

mounting screws (Item 1) [Figure 60-60-7] to remove the
light cover.
Figure 60-60-8
1 1
2 2
P-37423
Disconnect the electrical connectors (Item 1) [Figure 60-

60-10] from any switches in the light housing.
3 P-39022
Lower the cover to access the light bulb (Item 1) [Figure

60-60-8]. The switch can be replaced by removing the
wires from the terminals (Item 2) [Figure 60-60-8] and
unscrewing the switch (Item 3) [Figure 60-60-8] from the
light cover.
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BICS™ SYSTEM CONTROLLER
Troubleshooting Guide
WARNING
The following troubleshooting guide os provided for
aassistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Power indicator light does not come ON. 1, 2, 3, 6
All indicator lights flashing. 4
One of the indicator lights flashing. 5
Intermittent idicator lights. 6, 7, 8, 9
Key ON, Seat bar down, push the Press to Operate Button. The System Activated, Valve And 10
Traction indicator lights do not come ON.
SOLUTION SUGGESTIONS

1. Check that ignition switch ON.
2. Check BICS 10 amp. fuse.
3. Check wiring and connections. Make sure the connector is securely connected to the controller. Pull on
connector to check.
4. Look at indicator light windows, if they are milky white in appearance it is most likely caused by moisture
in the controller. Allow to dry or replace the controller.
5. Refer to BICS controller troubleshooting chart. (See Troubleshooting Chart on Page 60-80-2.)
6. Check wire connections to make sure connectors are locked into place.
7. Check pins in connectors for pins pushed back or bent.
8. Move the system wiring back & forth to try to find area that may be causing the intermittent connection.
9. Use sensor tester MEL 1428 to isolate problem between sensor and controller and wiring.
10. Check the wiring connections. Remove the left instrument panel and check the Push to Operate Button
with an Ohmmeter at the two pin connector.
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BICS™ SYSTEM CONTROLLER (CONT’D) Figure 60-70-2
NOTE: Photo’s may be different but the procedure is

the same for all models. 1

on Page 10-30-1.)
Figure 60-70-1
P-39084
1
2
IMPORTANT
Be sure the connector to the BICS system controller

are correctly engaged in the controller when
P-7186A
installing the controller. An audible snap can be
heard when the connector is correctly installed. Try
to pull the connector out of the controller, if it cannot
The controller mounting bolts are located on the back of be removed it has been correctly installed [Figure 60-
the operator cab [Figure 60-70-1]. 70-3].
I-2087-1095
Remove the top mounting bolt (Item 1) [Figure 60-70-1]
from the controller. Figure 60-70-3
Loosen the two lower mounting bolts (Item 2) [Figure 60-

70-1].
NOTE: The operator seat is removed in photo [Figure

60-70-2] for clarity purposes only. The seat 2
does not need to be removed to remove the
controller.
Slide the controller (Item 1) [Figure 60-70-2], up and

remove it from the back of the operator cab.
1
Disconnect the electrical harness from the controller and P-4707
remove the controller from the loader.
NOTE: Install the harness connector (Item 1) [Figure

60-70-3] into the controller (Item 2) [Figure 60-
70-3] before installing the controller.
Installation: Tighten the controller mounting bolts 80-90

in.-lb. (9-10 N•m) torque.
Reverse the procedure to install the controller.
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BICS™ SYSTEM (WITH PRESS TO OPERATE Inspecting The Seat Bar Sensor (Engine RUNNING)
BUTTON)
4. Sit in the operator’s seat. Lower the seat bar.
Inspecting The BICS™ Controller (Engine STOPPED - Engage the parking brake pedal. Fasten seat belt.
Key ON)
5. Start the engine and operate at low idle. Press the
green PRESS TO OPERATE Button. While raising
the lift arms, raise the Seat Bar fully. The lift arms
WARNING should stop. Repeat using the tilt function.
AVOID INJURY OR DEATH NOTE: The auxiliary hydraulic functions are not
The Bobcat Interlock Control System (BICS™) must affected by the Bobcat Interlock Control
deactivate the lift, tilt and traction drive functions. If it System (BICS™).
does not, contact your dealer for service. DO NOT
modify the system. Inspecting The Traction Lock (Engine RUNNING)
W-2151-0394
6. Fasten the seat belt, disengage the parking brake
pedal, press the green PRESS TO OPERATE Button
Figure 60-80-1
and raise the Seat Bar fully. MOve the steering levers
slowly forward and backward. The Traction lock
should be engaged. Lower the Seat Bar. Press the
1 green PRESS TO OPERATE Button.
2
7. Engage the parking brake pedal and move the

3 steering levers slowly forward and backward. The
Traction Lock should be engaged.
4
5
Inspecting The Lift Arm By-Pass Control
8. Raise the lift arms 6 feet (2 meters) off the ground.

Stop the engine.
Turn, pull, and hold the by-pass control knob to lower the
P-4242
lift arms.
1. Sit in the operator’s seat. Turn key ON, lower the seat
bar and disengage the parking brake pedal. Press
the green PRESS TO OPERATE Button. All five
BICS controller lights should be ON (Items 1, 2, 3 ,4
& 5) [Figure 60-80-1].
2. Engage the parking brake pedal and raise the seat

bar fully. System Activated (Item 1), Seat Bar (Item
2), Valve (Item 3) and Traction lights (Item 4) [Figure
60-80-1] should be OFF.
NOTE: Record what lights are blinking (if any) and

number of blinks. See Troubleshooting Chart
on Page 60-80-2.
3. Exit the loader and press Traction Lock Override

button. Traction light (Item 4) [Figure 60-80-1]
should be ON. Press override button again and
Traction light (Item 4) [Figure 60-80-1] should be
OFF.
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BICS™ SYSTEM (WITH PRESS TO OPERATE
BUTTON) (CONT’D)
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
Effect on Flashing Indicator Means System Problem

Operation (See Your Bobcat Dealer for Service)
of Loader
Indicator When Light is Number Of
Light Light ON Light Off OFF Flashes Cause
System PRESS TO PRESS TO Lift, tilt and 2 System activated circuit shorted
Activated OPERATE OPERATE traction functions to battery voltage.*
button not activated button not activated will not operate. 3 System Activated circuit shorted
to ground.
Seat Bar Seat Bar Down. Seat Bar Up. Lift, tilt and 2 Seat bar sensor circuit shorted to
traction functions battery voltage.*
will not operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Control Valve Lift and tilt 2 Valve output circuit shorted to
Can Be Used. Cannot Be Used. functions will not battery voltage.*
operate. 3 Valve output circuit shorted to

ground.
3 Valve output circuit is not
grounded.
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is
moved forward moved forward and moved forward open.
& backward. backward. and backward. 2 Traction lock hold coil circuit
shorted to battery voltage.*
3 Traction lock hold coil shorted
to ground.
4 Traction lock pull coil circuit is
open.
shorted to battery voltage.*
shorted to ground.
Power BICS Controller BICS Controller is Lift, tilt and
is operating not operating traction functions N/A N/A
correctly. correctly. will not operate.
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is
shorted to system voltage.
NOTES:
(1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF.
in Preventive Maintenance section.
If one of the lights stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
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SEAT BAR SENSOR
WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5, 6
1. Check controller power indicator light. It must be ON.
2. Check sensor wire connection.
3. Use the BICS sensor tester MEL1428 to check sensor and controller.
4. Check for loose hardware.

5. Check keyed bushing to make sure magnet collar rotates with seat bar.
6. Check Magnet collar magnets for contamination such as metal particles.
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SEAT BAR SENSOR (CONT’D) Figure 60-90-3
Seat Bar Sensor Test
Use Sensor Tester (MEL1428) for the following

procedure:
Disconnect the short adapter test leads if connected.
Figure 60-90-1 2
P-4698
1
The toggle switch (Item 2) [Figure 60-90-3] can be in

either the Absent or Present position.
The power light (Item 1) [Figure 60-90-3] will illuminate,

if the light is not on, check the tester or wiring harness.

P-39048 Figure 60-90-4
Disconnect the seat bar sensor connector (Item 1)

[Figure 60-90-1].
Figure 60-90-2 1
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-90-4] should illuminate.
P-39047 Raise the seat bar. The Sensor Test light (Item 1)
[Figure 60-90-4] should go off.
Connect Sensor Tester (Item 1) [Figure 60-90-2] in line If the above tests fail, there is a problem with the seat bar
as shown to the seat bar sensor connectors. sensor.
Turn the key to the ON position. DO NOT START THE Disconnect the Sensor Tester.
ENGINE.
Replace the Seat Bar Sensor. (See Removal And
If the above tests pass, run BICS controller seat bar

circuit test. (See BICS™ Controller Seat Bar Sensor
Circuit Test on Page 60-90-5.)
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SEAT BAR SENSOR (CONT’D)

IMPORTANT
Figure 60-90-5
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Figure 60-90-7
1
P-39048
Disconnect the seat bar sensor connector (Item 1)

[Figure 60-90-5].

P-3247
Figure 60-90-6
Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [Figure 60-90-7] of
the operator cab as shown.
P-3246
Remove the mounting bolt (Item 1) [Figure 60-90-6] from

the pivot bushing.
Installation: Tighten the mounting bolt to 25-28 ft.-lb.

(34-38 N•m) torque.
Remove the sensor mounting bolt (Item 2) [Figure 60-

90-6] and nut.
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SEAT BAR SENSOR (CONT’D)
Pull the seat back and remove the assembly as follows:
Figure 60-90-8
3 6 2 1
Left Side
5 of Seat Bar
4
P-3284

NOTE: The sensor assembly [Figure 60-90-8] is
shown removed from the operator cab for
clarity purpose only. The sensor assembly
can be removed without removing the seat
bar from the operator cab.
Remove the pivot bushing mounting bolt (Item 1) [Figure

60-90-8] and the washer (Item 2) [Figure 60-90-8] from
the pivot bushing (Item 3) [Figure 60-90-8].
Installation: Tighten the pivot bushing mounting bolt to

180-200 in.-lb. (21-23 N•m) torque.
Remove the pivot bushing (Item 3) [Figure 60-90-8],

sensor (Item 4) [Figure 60-90-8], magnet (Item 5)
[Figure 60-90-8] and plastic bushing (Item 6) [Figure 60-
90-8] from the seat bar.
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar

sensor.
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SEAT BAR SENSOR (CONT’D) NOTE: The sensor test light (Item 3) [Figure 60-90-10]
is activated by the seat bar. It will be off with
BICS™ Controller Seat Bar Sensor Circuit Test the seat bar up or on with the seat bar down.
Use Sensor Tester (MEL1428) For the following Figure 60-90-11

procedure:
Disconnected the short adapter test leads if connected.
Figure 60-90-9
1
P-39049
1
The seat bar light (Item 1) [Figure 60-90-11] on the BICS
controller should illuminate.

P-39047
Figure 60-90-12
Figure 60-90-10
3
1
2
1
P-4699
P-4703
Move the toggle switch (Item 1) [Figure 60-90-12] on the
sensor tester to the Absent position.
Disconnect the seat bar sensor connector and connect
the Sensor Tester (Item 1) [Figure 60-90-9] inline as The seat bar light (Item 1) [Figure 60-90-11] should go
shown to the seat bar sensor connectors. off.
Turn the key to the ON position. DO NOT START THE If the tests above fail, there is a problem with the BICS™
ENGINE. system controller or the wiring harness
If there is no power light (Item 1) [Figure 60-90-10] on

the sensor tester, check the testor or wiring harness.
Power light illuminated, move the toggle switch (Item 2)

[Figure 60-90-10] on the sensor tester (Item 1) [Figure
60-90-10] to the Present position.
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TRACTION LOCK
WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
W-2004-1285
PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of traction lock. 8, 9, 10
1. Check that controller power indicator light is ON.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 25 amp. fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses.

(See Fuse And Relay Switches Location on Page 60-10-2.)
5. To test the solenoid, the pull coil should be .4 to .5 ohms and the hold coil 10.5 to 11.0 ohms.
6. Check the brake solenoid and cover mounting hardware for the correct torque.
7. Remove the brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
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TRACTION LOCK (CONT’D) solenoid toward the rear of the loader when installed
correctly. (See inset photo [Figure 60-100-1].)
Figure 60-100-2
1
WARNING
AVOID INJURY OR DEATH
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking 4
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat 2
Company parts if repair is necessary.
W-2165-0100
3
P-39051
Put jackstands under the rear of the loader.
Raise the loader operator cab. (See Raising The Remove the electric solenoid/mounting bracket assembly
Operator Cab on Page 10-30-1.) (Item 1) [Figure 60-100-2] from the chaincase cover.

Remove the center shield. (See Control Shield And Remove and inspect the compression spring (Item 2)
Steering Lever Panels Removal And Installation on Page [Figure 60-100-2] for wear and damage. Replace if
30-20-1.) necessary. The spring may also stay with the shaft when
the electric solenoid and bracket are removed from the
Figure 60-100-1 chaincase.
Installation: Install the compression spring (Item 2)

1 [Figure 60-100-2] on the collar located on the electric
solenoid.
Remove the traction lock assembly (Item 3) [Figure 60-

100-2] from the chaincase.
2
P-4712 Check the gasket (Item 4) [Figure 60-100-2] condition
and replace as needed.
P-39050
Remove the Do Not Modify sta-strap (P/N 6665527) from

the electric solenoid connector (Item 1) [Figure 60-100-
1].
Installation: Install a new Do Not Modify sta-strap (P/N

6665527) in the electric solenoid connector.

1] from the electric solenoid mounting bracket.
Installation: Tighten the mounting bolts 25-28 ft.-lb. (34-

38 N•m) torque. Be sure the solenoid mounting bracket
is installed in the same position. The solenoid mounting
surface has a slight angle which tips the top of the
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TRACTION LOCK (CONT’D)
IMPORTANT
Failure to use LOCTITE may allow the traction lock
assembly to loosen up which can cause damage to
the traction lock system.
I-2090-1095
Figure 60-100-3

3
1
P-7025
Remove the shaft mounting bolt (Item 1) [Figure 60-

100-3], washer and spring from the assembly shaft (Item
2) [Figure 60-100-3]. Remove the wedge (Item 3)
[Figure 60-100-3] and inspect all parts for damage or
wear. Replace if necessary.
Installation: Thoroughly clean and dry the shaft

mounting bolt (Item 1) [Figure 60-100-3], the shaft (Item
2) [Figure 60-100-3], and wedge (Item 3) [Figure 60-
100-3]. Use LOCTITE #242 when assembling these
parts to the traction lock assembly.
Refer to ELECTRICAL SYSTEMS & ANALYSIS, Page

60-01 for the traction lock inspection procedure.
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ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

SAFETY &
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 MAINTENANCE
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-70-1

Engine Compression Test Procedure . . . . . . . . . . . . . . . . 70-70-8 DRIVE
Fuel Injector Nozzles Checking . . . . . . . . . . . . . . . . . . . . . 70-70-4 SYSTEM
Fuel Injector Nozzles Installation . . . . . . . . . . . . . . . . . . . . 70-70-7
Fuel Injector Nozzles Removal . . . . . . . . . . . . . . . . . . . . . 70-70-6
Fuel Injection Pump Check . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-1
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . 70-70-8
Glow Plugs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7

ELECTRICAL
SYSTEM &
ENGINE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . 70-100-1 ANALYSIS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 ENGINE

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 SERVICE
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

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ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 70-110-21
Checking Crankshaft Journal And Block Bearing . . . . . . . . . . . 70-110-36
Checking Engine Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-33
Checking Piston Top Clearance. . . . . . . . . . . . . . . . . . . . . . . . . 70-110-14
Checking The Crankshaft Journal And Main Bearing . . . . . . . . 70-110-37
Checking The End Play Of The Crankshaft . . . . . . . . . . . . . . . . 70-110-39
Checking The Piston And Connecting Rod . . . . . . . . . . . . . . . . 70-110-30
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-31
Combustion Chamber Removal And Installation . . . . . . . . . . . . 70-110-18
Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-38
Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Crankshaft Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-39
Crankshaft Front Seal Removal And Installation . . . . . . . . . . . . . 70-110-6
Crankshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-110-33
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Engine Speed Control Plate Removal And Installation . . . . . . . . 70-110-7

Engine Timing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Governor Fork Lever Removal And Installation . . . . . . . . . . . . . 70-110-28
Governor Shaft Removal And Installation . . . . . . . . . . . . . . . . . 70-110-25
Exhaust Manifold Removal And Installation. . . . . . . . . . . . . . . . . 70-110-8
Governor Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-7
Idle Limit And Fuel Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . 70-110-8
Idler Gear And Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-41
Idler Gear And Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Idler Gear And Injection Pump Shaft Gear . . . . . . . . . . . . . . . . 70-110-41
Idler Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-110-19
Injection Pump Shaft And Governor Shaft Gear . . . . . . . . . . . . 70-110-41
Injection Pump Shaft Removal And Installation . . . . . . . . . . . . . 70-110-23
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-110-24
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Piston Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-110-29
Piston Ring Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-31
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Push Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-110-11
Rocker Arm Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-110-10
Servicing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Start Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-8
Tappet Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-110-12
Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-110-1
Timing Gear Case Cover Removal And Installation. . . . . . . . . . . 70-110-2
Valve Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-110-9
Water Flange Removal And Installation. . . . . . . . . . . . . . . . . . . 70-110-12
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-110-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
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TROUBLESHOOTING
Chart
WARNING
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30, 31, 32, 58
Difficult to start. 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28, 30, 31, 32, 58
No power from the engine. 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 30, 31, 32
Engine is mis-firing. 8, 9, 10, 11, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 30, 31, 32
Too much fuel consumption. 11, 13, 14, 16, 18, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Black exhaust. 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Blue/White exhaust. 4, 16, 18, 19, 20, 24, 26, 30, 32, 33, 34, 44, 54
Low oil pressure. 4, 35, 36, 37, 38, 39, 41, 42, 32, 56
Engine knocking. 9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 35, 44, 45, 57
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 34, 44, 57

Vibration. 13, 14, 20, 24, 25, 28, 29, 32, 44, 47
High oil pressure. 4, 37, 40
Overheating. 11, 13, 14, 16, 18, 19, 23, 24, 44, 46, 48, 49, 50, 51, 52, 55
Too much crankcase pressure. 24, 30, 32, 33, 44, 53
Poor compression. 11, 19, 24, 27, 28, 30, 31, 32, 33, 45, 57
Start and stop. 10, 11, 12
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TROUBLESHOOTING (CONT’D)
Chart (Cont’d)

1. Battery capacity low. 30. Worn cylinder bores.
2. Bad electrical connection. 31. Worn valves and seats.
3. Faulty starter motor. 32. Broken, worn or sticking piston rings.
4. Incorrect grade of oil. 33. Worn valve stems and guides.
5. Low cranking speed. 34. Overly full air cleaner.
6. Fuel tank empty. 35. Worn or damaged bearings.
7. Faulty stop control operation. 36. Not enough oil in the oil pan.
8. Plugged fuel line. 37. Gauge is not correct.
9. Faulty fuel lift pump. 38. Oil pump worn.
10. Plugged fuel filter. 39. Pressure relief valve is open.
11. Restriction in the air cleaner. 40. Pressure relief valve is sticking closed.
12. Air in the fuel system. 41. Broken relief valve spring.
13. Faulty fuel injection pump. 42. faulty suction pipe.
14. Faulty fuel injectors. 43. Plugged oil filter.
15. Incorrect use of the glow plugs. 44. Piston seizure.
16. Glow plugs not working. 45. Incorrect piston height.
17. Broken fuel injection pump drive. 46. Damaged fan.

18. Incorrect fuel pump timing. 47. Faulty engine mounting.
19. Incorrect valve timing. 48. Faulty thermostat.
20. Poor compression. 49. Restriction in the water jacket.
21. Plugged fuel tank vent. 50. Loose fan belt.
22. Incorrect type or grade of fuel. 51. Plugged radiator.
23. Exhaust pipe restriction. 52. Faulty water pump.
24. Cylinder head gasket leaking. 53. Plugged breather pipe.
25. Overheating. 54. Valve stem seals damaged.
26. Cold running. 55. Coolant level low.
27. Incorrect valve tappet adjustment. 56. Plugged oil pump pipe strainer.
28. Sticking valves. 57. Broken valve springs.
29. Incorrect high pressure tubelines. 58. Auxiliary Hydraulics in Detent.
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ENGINE SPEED CONTROL Removal And Installation
Adjustment Remove the mounting bolt and nut (Item 2) [Figure 70-
20-1], and the tension spring from the speed control
mounting bracket.
WARNING Remove the lever and fiber washer between the lever
and the fender.
Installation: Tighten the mounting bolt until the speed
control lever moves forward and backward at a
comfortable tension.
W-2059-0598
Remove the speed control rod (Item 3) [Figure 70-20-1]
from the lever.
Figure 70-20-1 Figure 70-20-2
1 2

1 1
P-7212 P-37918
Install jackstands under the rear of the loader. (See Lift the rod (Item 1) [Figure 70-20-2] to remove the
Procedure on Page 10-10-1.) speed control rod from the lever.
20-1.)

on Page 10-30-1.)
Remove the center shield and left steering lever panel.

Mark the position of the two adjustment bolts and nuts

(Item 1) [Figure 70-20-1] for installation purposes.
Move the bolts as needed to adjust the engine speed.
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MUFFLER Figure 70-30-3
Open the rear door.
Figure 70-30-1
P-37808

muffler mounting bracket.
P-34970 Remove the muffler.

Remove the bolts (Item 1) [Figure 70-30-1] from the fuse
panel bracket. Set the bracket aside to gain access to
the muffler bolts.
Figure 70-30-2
1
1
P-62025

muffler flange.
Installation: Torque bolts to 17.4-20.3 ft-lbs (23.5-27.5

N•m).
Installation: Use a new gasket (Item 2) [Figure 70-30-2]

between the exhaust manifold and the muffler flange.
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AIR CLEANER Figure 70-40-3
Removal And Installation 2

Figure 70-40-1 1
P-34933
1
Loosen the two bolts (Item 1) [Figure 70-40-3] located in

P-34974 the air cleaner housing mounting bracket.
Remove the condition indicator (Item 2) [Figure 70-40-3]

Loosen the clamp (Item 1) [Figure 70-40-1] from the from the fitting.
intake manifold hose.

Remove the air cleaner housing from the loader.
Remove the hose from the intake manifold.
Figure 70-40-2
P-34975
Loosen the clamp (Item 1) [Figure 70-40-2] from the air

cleaner hose and remove the hose.
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RADIATOR Figure 70-50-3
Open the rear door.
Drain the coolant from the engine. (See Replacing The

Coolant on Page 10-90-2.)
1
Figure 70-50-1
P-37551
1
Remove the outler hose (Item 1) [Figure 70-50-3] from
the radiator.
Figure 70-50-4

P-37546
Remove the hose (Item 1) [Figure 70-50-1] from the left

side of the oil cooler. 1
Figure 70-50-2
P-37550
1 Remove the inlet hose (Item 1) [Figure 70-50-4] from the

radiator.
P-39157
Remove the hose (Item 1) [Figure 70-50-2] from the right

side of the oil cooler.
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RADIATOR (CONT’D) Figure 70-50-7
Figure 70-50-5
1
1 1
1
P-37552

P-37548 the radiator from the assembly.
Loosen the right side mounting nuts (Item 1) [Figure 70-

50-5].

Figure 70-50-6
1
1
P-37549
Loosen the left side mounting nuts (Item 1) [Figure 70-

50-6].
Slide the radiator to the rear to remove the carriage bolts

from the frame. Remove the radiator assembly.
Reverse the procedure to install the radiator assembly.
Remove the radiator assembly from the loader.
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COOLING FAN Figure 70-60-3
WARNING
1 1
W-2059-0598
P-37553
Open the rear door.
Figure 70-60-1 Remove the mounting bolts (Item 1) [Figure 70-60-3] to

remove the oil cooler.

1
P-37547
Remove the cooling fan connectors (Item 1) [Figure 70-

60-1] from the loader harness.
Figure 70-60-2
P-37546
Remove the mounting screws (Item 1) [Figure 70-60-2]

to remove the fan.
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ENGINE COMPONENTS AND TESTING Connect the short leg of the tubeline to the fitting at the
fuel injection pump (Item 3) [Figure 70-70-2].
Fuel Injection Pump Check
With the starter, rotate the engine to increase the
The tools listed will be needed to do the following pressure to 1991 PSI (137,3 Bar). Align the plunger with
procedure: TDC.
MEL 1237 - Adapter Fuel Line The pressure should hold at 1849-1991 PSI (127,5-137,3
MEL1173-1 - Pressure Gauge Bar), for 5 seconds or more.
Figure 70-70-1 If the time is less than the allowable limit, replace the
injection pump.
Fuel Injection Pump Removal And Installation
3 IMPORTANT
3 2 1 Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

P-39268
NOTE: The engine cylinder sequence and firing order

IMPORTANT
is 1,2,3 as shown in [Figure 70-70-1]. Number Never steam clean or put cold water on an injection
1 is at the gear case end of the engine. pump while the engine is running or while it is hot. If
you do it will cause serious damage to the injection
To check the initial discharge pressure, remove a high pump.
pressure tubeline (Item 3) [Figure 70-70-1] from the fuel I-2135-0997
injection pump.
Loosen the other end of the tubeline at the injector, so

that the tubeline can be turned away from the fitting.
Figure 70-70-2
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Thoroughly clean the area around the injection pump.

3
Use these tools for the following procedure:
2 MEL 1270 - Fuel Line Removal Tool

MEL1271 - Delivery Valve Removal Tool
1
B-8235
Connect a pressure gauge (Item 1) to the long leg of the

test tubeline (Item 2) [Figure 70-70-2] and tighten.
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ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-5
Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 70-70-3
1
B-14423
Lift the injection pump while moving it to align the pin

(Item 1) [Figure 70-70-5] in the control rack with the slot
P-39272 in the engine block to remove the pump.
Installation: When the injection pump is installed, make

Remove the injector nozzle tubelines (Item 1) [Figure sure the pin (Item 1) [Figure 70-70-5] on the control rack

70-70-3] from the injection pump and the injectors. is correctly installed in the fork lever. If the slot is not
installed correctly, the engine will run over a maximum
Installation: Tighten the tubelines to 18.1-25.3 ft.-lb. speed and serious damage can result.
(24.5-34.3 N•m) torque.
NOTE: Make sure the same number of shims are
Figure 70-70-4 installed under the injection pump. The shims
are used for engine timing.
3
3
3
1
P-39268
Disconnect the fuel inlet hose (Item 1) [Figure 70-70-4]

and the fuel return hose (Item 2) [Figure 70-70-4].
Remove the four bolts (Item 3) [Figure 70-70-4] from the

injection pump.
Installation: Tighten the four nuts to 17-20 ft.-lb. (23-27

N•m) torque.
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Fuel Injection Pump Timing
Figure 70-70-6
1
B-10007
Timing the fuel injection pump is done by changing the

P-39272 number of shims between the injection pump and the
injection pump mounting surface (Item 1) [Figure 70-70-
8].
Remove the high pressure tubelines (Item 1) [Figure 70-
70-6] from the injection pump and the injectors. Addition or reduction of shim .002 inches (.05 mm) will

delay or advance the injection timing by approximately
Figure 70-70-7 0.5°. The timing of the pump will be later when a shim is
added, and earlier when a shim is removed.
Move the fuel lever on the injection pump to full fuel

position (or full throttle).
1
Turn the flywheel clockwise slowly until the fuel starts to
rise in the plastic tube (Item 1) [Figure 70-70-7].
Figure 70-70-9
P-13132 1
Install a short plastic tube (Item 1) [Figure 70-70-7] in the

fitting of the number 1 cylinder port. Point the tube up.
NOTE: The fuel must be in the tube (Item 1) [Figure

70-70-7] before attempting timing.
P-59768
The size of shims (Item 1) [Figure 70-70-9] are identified

by a symbol on the shims.
(1) Two holes means .00079 in (.20 mm) shim.
(2) One hole means .0098 in (.25 mm) shim.
(3) Without hole means .00118 in (.30 mm) shim.
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ENGINE COMPONENTS AND TESTING (CONT’D) Fuel Injector Nozzles Checking
Fuel Injection Pump Timing (Cont’d)
Figure 70-70-10
WARNING
2
W-2072-0496
1
procedure:
P-59780 OEM 1064 - Injector Nozzle Tester

OEM 1065 - Accessory Set
Check the timing marks (Item 1) [Figure 70-70-10] Figure 70-70-11

(located on the flywheel) for proper alignment.

NOTE: The flywheel has two timing marks. One
timing mark has a “T1” below it and the other
timing mark has a “T2” above it. The “T2”
timing mark is used on 463 loaders with S/N
538911001 and above or S/N 539011001 and
above.
When the correct timing mark is aligned with the marker

(Item 2) [Figure 70-70-10], the injection pump timing is
correct.
The correct engine timing for all Kubota D1005-E2B

engines is 17-19° B.T.D.C. Add or subtract shims (Item
A-2513
1) [Figure 70-70-8] to achieve the correct timing.
NOTE: Adding or reducing the shim thickness by 0.05 Connect the injector nozzle to the tester with the nozzle
mm retards or advances the injection timing in the down position [Figure 70-70-11].
by approximately 0.5°.
Slowly operate the hand lever of the test pump until the
injector nozzle valve opens. The pressure must be 1991-
2134 PSI (137,3-147 Bar).
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Fuel Injector Nozzles Checking (Cont’d) Spring
Figure 70-70-12 CORRECT WRONG

Pressure
Pin
Holder
Nozzle
Body
Needle
Valve
3
A-2621
2
1
Check the spray pattern of the nozzle for the following
B-4103 conditions [Figure 70-70-13]:
Does not come out of the nozzle.

NOTE: You can adjust the release pressure of the
injector nozzle by adding or removing Does not have drops coming out of the nozzle.

spacers (Item 1) [Figure 70-70-12] from the top
of the nozzle spring (Item 2) [Figure 70-70-12]. Does not have a flow (solid stream) coming from the
Each spacer will change the release pressure nozzle.
about 34 PSI (2,3 Bar). The release pressure
must be 1991-2134 PSI (137,3-147 Bar). Any of the above conditions show a defect or a dirty
injector nozzle. Clean the nozzle that does not operate
If the pressure is not correct, disassemble the injector correctly and check again.
nozzle and add or remove spacers (Item 1) [Figure 70-
70-12].
NOTE: When assembling the injector nozzle, tighten

the retainer nut (Item 3) [Figure 70-70-12] to
43-58 ft.-lb. (59-79 N•m) torque. Any higher
torque will cause slow action of the valve.
Check for inside leakage. Operate the hand lever until

the pressure is almost enough to open the injector valve.
Make a record of the pressure. Release the hand lever.
Check the pressure decrease to 10 seconds. The nozzle
has damage if the pressure decrease is more than 740
PSI (51 Bar) in 10 seconds.
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Fuel Injector Nozzles Removal
WARNING
W-2072-0496 B-5970
The tool listed will be needed to do the following Loosen the fuel injector with a special socket [Figure 70-
procedure: 70-15].
MEL 1485 - Socket Figure 70-70-16
To remove the injector nozzles, use the following

procedure:
Figure 70-70-14
1
B-5971
2
Remove the fuel injector nozzle from the engine [Figure

70-70-16].
P-39272
Remove the injector tubelines (Item 1) [Figure 70-70-14]

from the injector pump and the injector nozzles.
IMPORTANT
Remove the fuel return hoses (Item 2) [Figure 70-70-14] Do not disassemble or test the fuel injector nozzles
from the banjo fittings. unless you have the correct service and testing
tools.
Remove the banjo fittings from the fuel injector nozzles. I-2027-0284
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ENGINE COMPONENTS AND TESTING (CONT’D) Glow Plugs Checking
Fuel Injector Nozzles Installation Figure 70-70-17
Install the injector nozzle in the cylinder head and tighten

to 36-50 ft.-lb. (49-68,6 N•m) torque.
Install the banjo fitting on the injector nozzle and tighten. 2
Connect the return fuel line to the banjo fittings.
Install the high pressure tubelines at the injectors and

tighten.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-4.) 1
P-39273
Disconnect the three nuts (Item 1) [Figure 70-70-17] that

hold the glow plug electrical bar to the glow plugs.
Remove the electrical bar (Item 2) [Figure 70-70-17]

from the glow plugs.
Test the glow plugs by touching one probe to the end of

the glow plug and the other probe to the body of the glow
plug.
Reading must be approximately 0.9 ohms. If the

resistance is zero ohms the glow plug has a short circuit.
If the resistance is infinite the coil of the glow plug is

broken.
Figure 70-70-18
P-39274
Replace the glow plug as needed [Figure 70-70-18].
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ENGINE COMPONENTS AND TESTING (CONT’D) Fuel Lift Pump Removal And Installation
Engine Compression Test Procedure Figure 70-70-20
The tool listed will be needed to do the following

procedure:
1
MEL10630B- Engine Compression Test Kit
Figure 70-70-19
P-39277
Remove the fuel lines (Item 1) [Figure 70-70-20] from

the fuel lift pump.
Figure 70-70-21

P-39275
Remove one of the glow plugs from the engine, install the
compression adapter in the glow plug hole, and connect
the compression gauge on the adapter [Figure 70-70-
19].
Disconnect the fuel solenoid and crank the engine with

the starter at 200 to 300 RPM. Run the test for each
cylinder two times at 5 to 10 seconds each time and take
the average reading.
1
The correct compression for the engine is 412-469 PSI
(28,4-32,3 Bar) with no more than 10% difference P-39278
between the cylinders.

21] from the lift pump and remove the pump from the
engine.
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ENGINE Figure 70-80-1

4 1
WARNING
2
support device. Failure to use an approved lift arm 6
support device can allow the lift arms or attachment 7
to fall and cause injury or death. 3
W-2059-0598
5
P-37636
IMPORTANT Disconnect the speed control linkage (Item 1) [Figure

70-80-1] from the bellcrank. Remove the bellcrank
mounting bracket from the mainframe by removing the
Always keep hydraulic and hydrostatic parts clean. two mounting bolts (Item 2) [Figure 70-80-1]. Secure the
Clean outside of all assemblies before beginning linkage rod and bellcrank to the engine to keep it out of
repairs. Use plugs and caps to cover open ports. the way.

Dirt can quickly damage the system.
I-2173-0598
Disconnect the outlet hose (Item 3) [Figure 70-80-1]
from the hydraulic pump. Install caps and plugs on the
NOTE: The engine and hydrostatic pumps are fittings and hoses.
removed from the loader as an assembly.
Remove the nuts (Item 4) [Figure 70-80-1] from the
Lift and block the loader. (See Procedure on Page 10- steering lever linkage. Remove the linkage from the
10-1.) hydrostatic pumps.
Raise the lift arms and install the lift arm support device. Disconnect the charge pressure hose (Item 5) [Figure
(See Engaging The Lift Arm Support Device on Page 10- 70-80-1] from the hydrostatic pump. Install caps and
20-1.) plugs in the fittings and hoses.
Open the rear door. Disconnect the drain hose (Item 6) [Figure 70-80-1].
Drain the hydraulic/hydrostatic fluid. (See Replacing The Disconnect the high pressure hoses (Item 7) [Figure 70-
Hydraulic/Hydrostatic Fluid on Page 10-120-2.) 80-1] from the hydrostatic pump. Install caps and plugs
in the fittings and hoses.
Remove the battery. (See Removal And Installation on
Page 60-20-1.)

on Page 10-30-1.)
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ENGINE (CONT’D) Figure 70-80-3

1
Figure 70-80-2
4 7
P-59748
1
6 Disconnect the fuel solenoid connector (Item 1) [Figure

2
P-37672 70-80-3].
Figure 70-80-4
Disconnect the hydraulic oil temperature wire (Item 1)
[Figure 70-80-2]. 1

Disconnect the hydraulic oil pressure connector (Item 2)
[Figure 70-80-2].
Disconnect the brake solenoid connector (Item 3)

[Figure 70-80-2].
Disconnect the lift lock valve connector (Item 4) [Figure

70-80-2].
Disconnect the optional flasher connector (Item 5)

[Figure 70-80-2], if loader is so equipped.
P-37642
Disconnect the optional horn connector (Item 6) [Figure
70-80-2], if the loader is so equipped.
Remove the hydrostatic motor cover (Item 1) [Figure 70-
Disconnect the back up alarm connector (Item 7) [Figure 80-4]. (Both sides.)
70-80-2], if the loader is so equipped.
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Figure 70-80-5
P-37656
Figure 70-80-8
P-37644
Remove both high pressure hoses (Item 1) [Figure 70-

80-5] from the right hydrostatic drive motor. Install caps

and plugs in the fittings and hoses.
Figure 70-80-6
P-37655
1 Remove the nuts, bolts, and spacers (Item 1) [Figure

70-80-8] & [Figure 70-80-7] from the hydrostatic pump
mounts.
Removing the rear tires will make this step easier.

P-37643
Replace the engine mounts if they are damaged.
Remove the lower high pressure hose (Item 1) [Figure Installation: Torque mounting bolts to 65 - 70 ft-lbs (88-
70-80-6] from the left hydrostatic drive motor. Install caps 95 N•m).
and plugs in the fittings and hoses.
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1
Figure 70-80-9
P-37646
Remove and plug the fuel inlet hose (Item 1) [Figure 70-
P-37645 80-11] going to the fuel filter.
Figure 70-80-12
Open the coolant valve (Item 1) [Figure 70-80-9] to drain
the coolant. (See Replacing The Coolant on Page 10-90-

2.)
Figure 70-80-10
P-37648
1
Remove the engine mounting bolts (Item 1) [Figure 70-

80-12].
P-34926
Replace the engine mounts if they are damaged.
Open the radiator cap (Item 1) [Figure 70-80-10]. Installation: Torque mounting bolts to 65 - 70 ft-lbs (88-
95 N•m).
Remove the radiator and radiator mounting bracket.
(See Removal And Installation on Page 70-50-1.)
Close the shutoff valve. (See FUEL SYSTEM on Page

10-100-1.)
Drain the fuel system. (See FUEL SYSTEM on Page 10-

100-1.)
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Figure 70-80-13
1
1
P-37650
Remove the wire (Item 1) [Figure 70-80-15] from the oil

P-34970 pressure sender.
Figure 70-80-16
Remove the mounting bolts (Item 1) [Figure 70-80-13]
from the fuse panel bracket.

Figure 70-80-14
1 2
2
3 1
P-37651
Remove the positive (+) wires (Item 1) [Figure 70-80-16]

P-37649 from the alternator.

Remove the nut (Item 1) [Figure 70-80-14] from the 80-16] from the alternator.
starter mounting bolt and remove the battery and engine
negative (-) cables and wires.
Remove the starter solenoid wire (Item 2) [Figure 70-80-

14].
Remove the battery and engine positive (+) cables and

wires (Item 3) [Figure 70-80-14] from the starter.
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Figure 70-80-17
P-34974
1
Remove the engine air intake hose (Item 1) [Figure 70-

P-37653 80-19].

80-17] for the water temperature sender.

Figure 70-80-18
P-37652
Remove the wire (Item 1) [Figure 70-80-18] from the

glow plugs.
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3
Figure 70-80-20
2
1
P-37685
1
Install a chain with a hook on each end, to the lift eye

P-37657 (Item 1)[Figure 70-80-21] on the engine, and the
provided slot in the engine mounting bracket (Item 2)
[Figure 70-80-21].
Remove the hydraulic inlet line (Item 1) [Figure 70-80-
20] from the hydrostatic pump. Install a plug in the fitting Use a chain lift device (Item 3) [Figure 70-80-21] and

and the hose. chain hoist to remove the engine and hydrostatic pump.
Lift the engine with the chain hoist until the engine
mounts clear the rear lip of the loader frame.
Continue to remove the engine and hydrostatic pump

assembly from the loader.
Reverse the removal procedure to install the engine and

hydrostatic pump in the loader.
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FLYWHEEL Figure 70-90-2

10-1.)
WARNING 1

P-37747
W-2059-0598
Remove the six mounting bolts (Item 1) [Figure 70-90-2]

Raise the lift arms and install the lift arm support device. from the flywheel.
20-1.) Installation: Apply liquid adhesive (LOCTITE #242) to
the mounting bolts and tighten to 40-45 ft.-lb. (54-61
Raise the operator cab. (See Raising The Operator Cab N•m) torque.

on Page 10-30-1.)
Remove the engine and hydrostatic pump assembly from

the loader. (See Removal And Installation on Page 70-
80-1.)
Figure 70-90-1
P-37751
Remove the hydrostatic pump drive belt (Item 1) [Figure

70-90-1]. (See Removal And Installation on Page 30-70-
1.)
Remove the hydrostatic pump pulley and the idler pulley

from the hydrostatic pump shaft. (See Removal And
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ENGINE MOUNTING BRACKET
Figure 70-100-1
1 1
3
P-37746
Remove the flywheel.

end plate.

torque.

hydrostatic pump. (See Removal And Installation on
Page 30-60-2.)
Remove the tension spring (Item 3) [Figure 70-100-1].

(See Tension Pulley And Spring Removal And Installation
on Page 30-70-1.)
Remove the end plate.
Reverse the removal procedure to install the end plate.
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RECONDITIONING THE ENGINE Water Pump Removal And Installation
Thermostat Removal And Installation Figure 70-110-3
Figure 70-110-1 1
1
1 1
1
P13013
P-62027
Remove the loader alternator. (See Removal And
thermostat housing. Remove the four mounting bolts (Item 1) [Figure 70-110-

3] from the belt pulley (Item 2) [Figure 70-110-3] and
Installation: Tighten the bolts to 87-100 in.-lb. (9,8-11,3 remove the pulley from the water pump.
N•m) torque.
NOTE: The bolts may vary in length. Keep the bolts in
Figure 70-110-2 their original location.
1 Figure 70-110-4
2
1 1
P13267A 1 1
P13265
Remove thermostat (Item 1) [Figure 70-110-2] and
replace if necessary.
Remove the seven mounting bolts (Item 1) [Figure 70-
Always replace the thermostat gasket (Item 2) [Figure 110-4] from the water pump.
70-110-2].
Installation: Tighten the mounting bolts to 87-100 in.-lb.
(9,8-11,3 N•m) torque.
Remove the water pump from the engine.
Check the water pump for wear and replace if needed.

Thoroughly clean the area between the water pump and
the block flange. Install a new water pump gasket and
install the water pump.
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RECONDITIONING THE ENGINE (CONT’D) Figure 70-110-7
Timing Gear Case Cover Removal And Installation 1

1
Figure 70-110-5
1 1
1
1
1
1 1
1
1
1 P13270
NOTE: The bolts may vary in length. Keep the bolts in

P13266 their original location.

Remove crankshaft pulley bolt (Item 1) [Figure 70-110- from the timing case cover, and remove the cover.
5].

Installation: Tighten the mounting bolts to 7.2-8.3 in-lb.
Installation: Tighten crankshaft pulley bolt to 101-116 ft.- (9,8-11,3 N•m) torque.
Clean the surface of timing cover.
Figure 70-110-6
Figure 70-110-8
1
P13268
P13271
Remove the crankshaft pulley (Item 1) [Figure 70-110-6]

from the crankshaft. Remove the timing cover gasket (Item 1) [Figure 70-110-
8].
Installation: When installing the crankshaft pulley on the
crankshaft, align the timing marks (Item 2) [Figure 70-
110-6].
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Timing Gear Case Cover Removal And Installation

(Cont’d) 1
Figure 70-110-9
P13279
1
1 1 Installation: Install the timing case cover, then install the
crankshaft collar with the tapered side (Item 1) [Figure
P13272 70-110-11] toward the O-ring.
Figure 70-110-12
Remove the O-rings (Item 1) [Figure 70-110-9] from the

timing case cover.
1
Figure 70-110-10
P13276
1
NOTE: The idle adjustment spring (Item 1) [Figure 70-

P13345 110-12] is located inside the timing case
cover. Be careful not to damage.
Remove the crankshaft collar (Item 1) [Figure 70-110-

10] from the crankshaft.
NOTE: The collar may stay in the gearcase cover,

when the cover is removed.

crankshaft and replace with a new O-ring.
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Oil Pump Removal And Installation
Figure 70-110-13
1
1 1
2
1
P13275
1
1 Replace the front crankshaft seal (Item 1) [Figure 70-
P13272 110-15].
Figure 70-110-16
Remove timing gear case cover. (See Page 70-110-2.)

from the back of the oil pump.

(7,9-12,8 N•m) torque.
Remove the rear cover (Item 2) [Figure 70-110-13].
Figure 70-110-14
P13317
Measure the clearance between the lobes of the inner

rotor and the outer rotor with a feeler gauge [Figure 70-
110-16].
1
The clearance between inner rotor and outer rotor should
be 0.0024-0.0071 inch (0,06-0,18 mm).
P13273
Remove the oil pump rotor assembly (Item 1) [Figure 70-

110-14] and check for wear.
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Oil Pump Removal And Installation (Cont’d)
Figure 70-110-17
P13272
Install the oil pump cover (Item 1) [Figure 70-110-19]

P13316 and tighten the cover bolts to 70-113 in.-lb. (7,9-12,8
N•m) torque.
Measure the clearance between the outer rotor and the Figure 70-110-20
pump body with a feeler gauge [Figure 70-110-17].

The clearance between outer rotor and the pump body is 1
0.0039-0.0071 inch (0,100-0,180 mm).
Figure 70-110-18
P13273
Remove the cover and measure the width of the pressed

plastic gauge (Item 1) [Figure 70-110-20].
P13273 The end clearance between the inner rotor and the oil
pump cover should be 0.0010-0.0030 inch. (0,025-0,075
mm).
Put a strip of plastic gauge (Item 1) [Figure 70-110-18]
onto the rotor face.
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Crankshaft Front Seal Removal And Installation
Figure 70-110-21
1
P-13278
Remove the crankshaft collar (Item 1) [Figure 70-110-

P13266 23].
Figure 70-110-24
Remove the crankshaft pulley bolt (Item 1) [Figure 70-
110-21] and remove the crankshaft pulley.

Installation: Tighten crankshaft pulley bolt to 101-116 ft.-
2
Figure 70-110-22
1
P13277

1 crankshaft.
Remove the front seal (Item 2) [Figure 70-110-24] from

P13268 the timing gear case cover.
Replace the seal.

When installing the crankshaft pulley on the crankshaft,
be sure the timing marks are aligned (Item 1) [Figure 70- Replace the O-ring.
110-22].
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Crankshaft Front Seal Removal And Installation

(Cont’d)
Figure 70-110-25 1
1 2
P13281
Remove the speed control plate from the mounting bolts

and unhook the governor spring (Item 1) [Figure 70-110-
P13279 27] from the governor compensation lever (Item 2)
[Figure 70-110-27].
Install the crankshaft collar with the tapered side (Item 1) Check the return spring (Item 3) [Figure 70-110-27] and

[Figure 70-110-25] toward the O-ring. internal parts for wear and replace if needed.
Engine Speed Control Plate Removal And Installation Governor Spring Removal
Figure 70-110-26 Figure 70-110-28
1 1
P13280 P13284
Remove the mounting bolts and nuts (Item 1) [Figure 70- Remove the engine speed control plate.
110-26] from the engine speed control plate.
Remove the governor spring (Item 1) [Figure 70-110-28].
Installation: Tighten mounting bolts and nuts to 87-100
in.-lb. (9,8-11,3 N•m) torque. Check for wear and replace if needed.
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RECONDITIONING THE ENGINE (CONT’D) Exhaust Manifold Removal And Installation
Start Spring Removal Figure 70-110-31
Figure 70-110-29
1 1 1
1
1 1 1
P13282
P13285
Remove the mounting nuts (Item 1) [Figure 70-110-31]
from the exhaust manifold.
Remove engine speed control plate.
Figure 70-110-32

Remove the governor spring.
Remove start spring (Item 1) [Figure 70-110-29]. 1
Check for wear and replace if needed.
Idle Limit And Fuel Limit Adjustment
Figure 70-110-30
2 P13286
1
Remove the exhaust manifold from the engine and

remove the exhaust manifold gasket (Item 1) [Figure 70-
110-32] from the engine.
Installation: Replace the exhaust manifold gasket.

Tighten the mounting nuts to 12-14 ft.-lb. (16-19 N•m)
P13283 torque.
The idle limit adjustment (Item 1) and fuel limit

adjustment (Item 2) [Figure 70-110-30] have sealed
caps.
NOTE: See your authorized Kubota dealer for proper

adjustment before removing the caps.
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RECONDITIONING THE ENGINE (CONT’D)
Valve Cover Removal And Installation
Figure 70-110-33
1
2
2
P-62026
Remove the engine from the loader. (See Removal And


Remove the breather hose and clamp (Item 1) [Figure
70-110-33] from the valve cover.
Remove the nuts (Item 2) [Figure 70-110-33] from the

valve cover.
Installation: Tighten valve cover nuts to 5.1-6.5 ft.-lb.

(6,9-8,8 N•m) torque.
Remove the valve cover.
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Rocker Arm Removal And Installation
Figure 70-110-34
1 1 1
2
P13312
Remove the rocker arm shaft washers (Item 1) [Figure

P13288 70-110-36].
Remove the rocker arm assembly (Item 2) [Figure 70-

Remove the engine from the loader.(See Removal And 110-36] from the rocker arm shaft.

Figure 70-110-37
Remove the valve cover. (See Page 70-110-9.)
Remove the three mounting nuts from the rocker arms

bracket (Item 1) [Figure 70-110-34], and remove the
rocker arms from the head.
Figure 70-110-35
P13308
1
Measure the outside diameter of the rocker arm shaft
[Figure 70-110-37].
The measurement should be 0.4714-0.4718 inch

P13311 (11,973-11,984 mm) in diameter.
Remove the snap ring (Item 1) [Figure 70-110-35] from

the rocker arm shaft.
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Rocker Arm Removal And Installation (Cont’d)
Figure 70-110-38
1
1 1
2
P13289
Installation: Tighten the three rocker arm mounting nuts

P13314 (Item 1) [Figure 70-110-39] to 16-19.5 ft.-lb. (22-26,5
N•m) torque.
Measure the inside diameter of the rocker arm [Figure Adjust the valve clearance using a feeler gauge (Item 2)
70-110-38]. [Figure 70-110-39].

The measurement should be 0.4724-0.4731 inch Make sure the piston is on top dead center when making
(12,000-12,018 mm) in diameter. the adjustment and adjust the clearance to 0.005-0.007
inch (0,12-0,18 mm).
The clearance between the rocker arm shaft and the
rocker arm should be 0.0006-0.0018 inch (0,016-0,045 NOTE: The engine cylinder sequence and firing order
mm) with an allowable limit 0.0039 inch (0,10 mm). is 1,2,3. Number 1 is at the gear case end of
the engine.
If the measurement exceeds the allowable limit replace
the rocker arm or rocker arm shaft. Push Rod Removal And Installation
Figure 70-110-40
1 1 1
P13291
NOTE: Mark the push rods to prevent interchanging

when installing.
Remove the six push rods (Item 1) [Figure 70-110-40].
Check for wear and replace if needed.

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RECONDITIONING THE ENGINE (CONT’D) Water Flange Removal And Installation
Tappet Removal And Installation Figure 70-110-42
Figure 70-110-41
1 1 1 1
1
1
P13296
P13294
Remove the four mounting bolts (Item 1) [Figure 70-110-
42] from the engine head
Remove the six tappets (Item 1) [Figure 70-110-41] from
the crankcase. Remove water flange from the head.

NOTE: Mark the tappets to prevent interchanging Installation: Replace the water flange gasket as needed.
when installing. Tighten the mounting bolts to 87-100 in-lb. (9,8-11,3 N•m)
torque.
Check the tappets for wear. The inside diameter of the
tappet guide is 0.7874-0.7882 inch (20,000-20,021 mm).
The outside diameter of the tappet is 0.7858-0.7866
(19,959-19,980 mm).
The clearance between the tappet and the guide is

0.0008-0.0024 inch (0,020-0,062 mm) with an allowable
limit 0.0028 inch (0,07 mm).
If wear exceeds the allowable limit, replace the tappets.
NOTE: If the tappets have to be changed because of

excess wear, check the camshaft for wear and
replace if needed. (See Page 70-110-21.)
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RECONDITIONING THE ENGINE (CONT’D) Cylinder Head Installation
Cylinder Head Removal Figure 70-110-44
Figure 70-110-43
1 2
1
1 1
1
1 1
1 1 P13403
P13290
Clean the head and the block.
Remove the fourteen mounting bolts (Item 1) [Figure 70- Replace the head gasket (Item 1) [Figure 70-110-44]
110-43] and remove the head. and O-ring (Item 2) [Figure 70-110-44].

Figure 70-110-45
A-2773
Put oil on the cylinder head bolts and tighten to 47-51 ft.-
lb. (64-69 N•m) torque. Use the tightening sequence as
shown in [Figure 70-110-45]. Allow the head to set for at
least a 1/2 hour. Then check the torque of the head bolts
again using the sequence shown in [Figure 70-110-45].
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Checking Piston Top Clearance 1 1

Figure 70-110-46
2 2
1
1
1
P13300
2
2
Figure 70-110-48
P13297
Remove the cylinder head. (See Page 70-110-13.)

Bring the piston (Item 1) [Figure 70-110-46] to top dead
center.
Fasten a 0.06 inch (1,5 mm) diameter by 0.20-0.28 inch

(5,1-7,1 mm) piece of solder (Item 2) [Figure 70-110-46]
to four spots on the piston with grease.
Put the piston to bottom dead center.
Install the cylinder head and tighten the cylinder head P13299
bolts to specification. (See Page 70-110-13.)
Turn the crankshaft until the piston goes over top dead Remove the cylinder head and measure the squeezed
center. solder wire (Item 1) [Figure 70-110-47] & [Figure 70-
110-48].
The top clearance between the piston and the head

should be 0.0217-0.0276 inch (0,55-0,70 mm).
If the measurement is not within specified amount, check

the oil clearance of the crankpin journal and the piston
pin. (See Page 70-110-36.) Also check the oil clearance
between the crankshaft journals and the crankshaft
bearings. (See Page 70-110-33.)
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RECONDITIONING THE ENGINE (CONT’D) Cylinder Head Assembly
Cylinder Head Disassembly Install the valves.
Figure 70-110-49 Put oil on the valve seal and install the valve seal on the
valve.
1
Install the valve spring and the retainer.
Install the spring collet and the valve cap.
P13302
Figure 70-110-50

Spring
Collets
Cap
Valve
Seal
Retainer
P13303
Using a valve compression tool (Item 1) [Figure 70-110-

49], remove the valve cap and the valve spring collet
[Figure 70-110-50].
Remove the valve spring.
Remove the seal on the valve and remove the valve from
the cylinder head.
Repeat this procedure for all the valves.
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Servicing The Cylinder Head
Figure 70-110-51
P13306
Measure the width of the valve seat [Figure 70-110-52].

P13298
The correct width of the valve seat for both intake and
exhaust, is 0.083 inch (2,1 mm). The seat angle is 45° for
Clean the surface of the cylinder head. the exhaust valve and 60° for the intake valve.

Put a straight edge on the cylinder head [Figure 70-110- Figure 70-110-53
51].
C Valve Contacting
A D Width
Put a feeler gauge (Item 1) [Figure 70-110-51] between 0.083” (2,1 mm)
the straight edge and the surface of the cylinder head. B
The maximum distortion of the cylinder head surface is +

0.0020 inch (+ 0.05 mm).
D
If the measurement is more than the specification, Uncorrected
Corrected
remove the combustion chambers (See Page 70-110- Surface of Surface of
18.), then grind the cylinder head. Grind the same Valve Seat Valve Seat
amount of material from the bottom of the combustion
chambers as was removed from the head. A - 45° cutter
B - 15° cutter
C - 65° or 70° cutter
Clean the surface of the valve seat area. D - 45° valve surface MC-2185
Use the following steps to grind the valve seats [Figure

70-110-53].
Item A - Use a 45° cutter to grind the surface of the valve

seat.
Item B - Use a 15° cutter to grind the front surface of the

valve seat.
Item C - Use A 65° or 70° cutter to grind the rear surface

of the valve seat to finish the seat of a 0.0835 inch (2,12
mm) width.
Item D - Grind the valve surface to a 45° angle.
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Servicing The Cylinder Head (Cont’d)
Figure 70-110-54
1
P13310
Clean the valve guide.

P13305
Install the valve in the cylinder head.
Install the valve in the seat and check the depth [Figure Install a dial indicator gauge (Item 1) [Figure 70-110-55].
70-110-54].

Measure the clearance of the valve guide and the valve.
The specification for the depth of the valve is 0.0020-
0.0098 (-0,05-0,25 mm). Allowable Limit 0.016 inch (0,4 The measurement must be 0.0014-0.0025 inch (0,035-
mm). 0,065 mm). Replace the valve guide and valves as
needed.
NOTE: If the measurement is more than the
specifications add the correct thickness Figure 70-110-56
washer under the valve spring to keep the
correct tension on the spring.
P13301
Measure the valve spring [Figure 70-110-56]. The length

of the spring must be 1.457-1.476 inch (37,0-37,5 mm).
Replace the valve spring if it does not meet the
specification.
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RECONDITIONING THE ENGINE (CONT’D) Combustion Chamber Removal And Installation
Servicing The Cylinder Head (Cont’d) Figure 70-110-59
Figure 70-110-57
P13305
P13304
Locate the combustion chamber (Item 1) [Figure 70-110-
59] in the head.
Check the valve spring with a square to make sure it is
straight [Figure 70-110-57]. Replace the spring if it is not NOTE: Mark the combustion chambers so they do

straight. not get interchanged between cylinders.
Figure 70-110-58 Figure 70-110-60
2
1
4
P-13467
3
A-2759 B-15124
Put the valve spring in a tester [Figure 70-110-58]. Locate the notch on the combustion chamber edge (Item
1) [Figure 70-110-60] (inset). Scribe a line (Item 2)
Push down on the spring 1.22 inches (31 mm). The [Figure 70-110-60] at that point on the cylinder head for
compression load must be 26.4 lb. (11,97 kg). Replace locating purposes.
the valve spring if it does not meet these specifications.
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RECONDITIONING THE ENGINE (CONT’D) Idler Gear Removal And Installation
Combustion Chamber Removal And Installation Figure 70-110-63

(Cont’d)
Figure 70-110-61
2
1 1 1
1
P13345
P13290 Remove the timing gear case cover. (See Page 70-110-
2.)
Remove the combustion chamber by using a blunt punch Remove the crankshaft collar (Item 1) [Figure 70-110-

through the injector ports (Item 1) [Figure 70-110-61]. 63] and O-ring (Item 2) [Figure 70-110-63].
Tap the punch with a hammer and remove the
combustion chamber. NOTE: The crankshaft collar may come off with the
timing case cover, if so remove the O-ring.
Figure 70-110-62
Figure 70-110-64
1
2
2
P13467
P13343
Grind the cylinder head.

Remove the snap ring (Item 1) [Figure 70-110-64] from
Grind the same amount of material from the combustion the idler gear shaft.
chamber at points (Item 1 & 2) [Figure 70-110-62].
Remove the flat washer.
Installation: Install two 9 mm dowels in the head bolt
holes (Item 3) [Figure 70-110-60]. Place a straight edge Remove the idler gear (Item 2) [Figure 70-110-64].
against the dowels and scribe a line (Item 4) [Figure 70-
110-60].
Align the notch on the combustion chamber (Item 1)

[Figure 70-110-60] with the scribe line on the head (Item
4) [Figure 70-110-60], and install the chamber.
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Idler Gear Removal And Installation (Cont’d)

1
Figure 70-110-65 2
P13365
Check the inside diameter of the idler gear bushing (Item

P13346 1) [Figure 70-110-67]. The measurement should be
1.0236-1.0244 inch (26,000-26,021 mm), with an
allowable limit of 0.0039 inch (0,10 mm).
from the idler shaft. If the clearance exceeds the allowable limit, replace the

bushing.
Remove the shaft.
Align the oil hole in bushing (Item 2) [Figure 70-110-67]
Installation: Tighten the bolts to 7.2-8.3 ft.-lb. (9,8-11,3 with oil hole in sprocket, when installing the new bushing.
N•m) torque.
Figure 70-110-66
P13368
With a micrometer measure the outside diameter of the

idler gear shaft (Item 1) [Figure 70-110-66].

(25,967-25,980 mm).
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RECONDITIONING THE ENGINE (CONT’D) Check the key (Item 2) [Figure 70-110-69] and the key
way in the gear and the camshaft for wear and replace if
Camshaft Removal And Installation needed.
Figure 70-110-68 Figure 70-110-70
P13344 P13363
Remove the tappets from the block. (See Page 70-110- Support the camshaft with V-blocks [Figure 70-110-70].
12.)

Measure the height of the intake and exhaust cams at
Align the holes (Item 1) [Figure 70-110-68] in the gear on their highest point with a micrometer.
the camshaft with the mounting plate bolts.
The measurement should be:
Remove the mounting bolts from the camshaft mounting
plate. Intake 1.1339 inch (28,80 mm)
Allowable Limit 1.1319 inch (28,75 mm)
(9,8-11,3 N•m) torque. Exhaust 1.1417 inch (29,00 mm)
Allowable Limit 1.1398 inch (28,95 mm)
Remove the camshaft.
Figure 70-110-69 If the measurement is less than the allowable limit

replace the camshaft.
Figure 70-110-71
1
P13367
Remove the camshaft gear (Item 1) [Figure 70-110-69] P13351

from the camshaft.
Measure the camshaft journal outside diameter (Item 1)
[Figure 70-110-71] with a micrometer. The measurement
should be 1.4147-1.4153 inch (35,934-35,950 mm).
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Camshaft Removal And Installation (Cont’d)
Figure 70-110-72
P13364
Check the camshaft alignment by supporting the

P13347 camshaft in V-blocks. Set a dial indicator with its tip on
the center journal at a right angle [Figure 70-110-74].
Figure 70-110-73 Rotate the camshaft on the V-blocks and get the
misalignment, which is half of the measurement.

The measurement should be 0.0004 inch (0,01 mm).
If the misalignment exceeds the allowable limit, replace

the camshaft.
P13348
Measure the cylinder block bore inside diameter for the

camshaft with an inside micrometer [Figure 70-110-72] &
[Figure 70-110-73].

(36,000-36,025 mm).
The oil clearance of the camshaft is 0.0020-0.0036 inch

(0,050-0,091 mm) with an allowable limit of 0.0059 inch
(0,15 mm).
If the clearance exceeds the allowable limit, replace the

camshaft.
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Injection Pump Shaft Removal And Installation
Figure 70-110-75
1 4
2 1
3 P13369
Remove the fuel cam (Item 1) [Figure 70-110-77] and

P13349 the cam washer (Item 2) [Figure 70-110-77] from the
injection pump shaft gear.
Remove the two mounting bolts (Item 1) [Figure 70-110- Installation: When installing the injection pump shaft
75] and remove the injection pump shaft stop (Item 2) and washer to the injection pump shaft gear align the

[Figure 70-110-75]. timing marks (Item 3) [Figure 70-110-77] on the injection
pump shaft with the timing marks (Item 4) [Figure 70-
Installation: Tighten the mounting bolts to 89-100 in.-lb. 110-77] on the injection pump shaft gear.
(9,8-11,3 N•m) torque.
Figure 70-110-78
Remove the injection pump shaft from the block.
Figure 70-110-76
1
2
P13370
2
P13366 Remove the nut (Item 1) [Figure 70-110-78] from the

injection pump shaft.
Remove the three mounting bolts (Item 1) [Figure 70- Installation: Tighten the nut to 43-51 ft.-lb. (58,3-69,2
110-76] from the injection pump gear (Item 2) [Figure 70- N•m) torque.
110-76].
Remove the injection pump gear (Item 2) [Figure 70-
Installation: Tighten the mounting bolts to 89-100 in.-lb. 110-78] from the injection pump shaft.
(9,8-11,3 mm) torque.
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Injection Pump Shaft Removal And Installation

(Cont’d)
1
Figure 70-110-79
P13313
1
Remove the mounting bolt (Item 1) and remove the oil
pickup tube (Item 2) [Figure 70-110-81].
P13373
Installation: Tighten the oil pickup tube mount bolt to 17-
20 ft.-lb. (23,1-27,1 N•m) torque.
Check the key (Item 1) [Figure 70-110-79] and the

keyways in the gear and on the shaft for wear and Figure 70-110-82
replace if needed.
Check the bearings (Item 2) [Figure 70-110-79] for wear 2

and replace as needed.
Oil Pan Removal And Installation
Figure 70-110-80
1
P13318
1 1 1 Clean the oil pickup tube screen (Item 1) [Figure 70-110-

1 82].
Check the O-ring (Item 2) [Figure 70-110-82] and

replace if worn.
P13309
Use care not to damage O-ring when installing the oil
pickup tube.
Remove the oil pan mounting bolts (Item 1) [Figure 70-
110-80], and remove the oil pan. NOTE: Clean the surface of the oil pan and the block
thoroughly. And apply a new liquid gasket to
Installation: Tighten pan mounting bolts to 87-100 in.-lb. the oil pan before installing.
(9,8-11,3 N•m) torque, in a diagonal order from the
center.
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Governor Shaft Removal And Installation

1
Figure 70-110-83
P13352
Remove the governor shaft assembly (Item 1) [Figure

P13357 70-110-85] from the front of the block.
Figure 70-110-86
Remove the fuel camshaft plug (Item 1) [Figure 70-110-
83] from the block.

Figure 70-110-84
2
P13362
NOTE: The set screw (Item 1) [Figure 70-110-86] must

P13358 be removed to remove the rear governor shaft
bearing.
Remove the snap ring (Item 1) [Figure 70-110-84] from Check the governor gear bushing (Item 2) [Figure 70-
the governor shaft. 110-86] and replace if needed.
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Governor Shaft Removal And Installation (Cont’d)
Figure 70-110-87
P13379
Check the parts from the governor shaft for wear and
P13360 replace if needed [Figure 70-110-89].
Figure 70-110-90
Remove the set screw (Item 1) [Figure 70-110-87] from
the block.

Figure 70-110-88 1
1
P13371
Remove the governor gear holder and governor gear

P13359 (Item 1) [Figure 70-110-90] from the governor shaft.
Remove the rear bearing (Item 1) [Figure 70-110-88].
NOTE: The bearing must be driven out toward the

front of the block.
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Governor Shaft Removal And Installation (Cont’d)
Figure 70-110-91
3
2 2
1
P13377
Remove the governor weight holder (Item 1) [Figure 70-

P13378 110-93] from governor shaft.
Remove the governor sleeve (Item 2) and thrust washer

Remove the governor gear (Item 1) from the gear holder (Item 3) from governor shaft [Figure 70-110-93].
(Item 2) [Figure 70-110-91].

Check all parts and replace if needed.
Figure 70-110-92
1
2
2
3
3
P13374
Remove the governor weight shafts (Item 1) from the

governor weights (Item 2) [Figure 70-110-92].
Remove the governor weights.
Remove the rollers (Item 3) [Figure 70-110-92] from the

governor weights.
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Governor Fork Lever Removal And Installation
Figure 70-110-94
1
1 2
P13356
Remove the fork lever cover and gasket from the block.
P13285
Remove the governor fork lever collar (Item 1) [Figure
70-110-96] from the block.
Remove the speed control plate. (See Removal And
Installation on Page 70-20-1.) Figure 70-110-97

Remove the fuel injection pump. (See Fuel Injection
Pump Removal And Installation on Page 70-70-1.) 2
Remove the start spring (Item 1) from the fork 1

compensation lever (Item 2) [Figure 70-110-94].
Figure 70-110-95
2 P13353
Remove the governor fork lever shaft (Item 1) and outer

bearing (Item 2), using a metric tap (Item 3) screwed into
the threads of the fork lever shaft for leverage [Figure
70-110-97].
1
P13354 Remove the fork compensating lever and fork lever from
the block.
Remove the two mounting bolts (Item 1) from fork lever

shaft cover (Item 2) [Figure 70-110-95].
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RECONDITIONING THE ENGINE (CONT’D) Piston Removal And Installation
Governor Fork Lever Removal And Installation Figure 70-110-100

(Cont’d)
Figure 70-110-98
1
1
2
2
1 2
1
P13381
P13355 Remove the engine from the loader. (See Removal And
Remove the inside governor fork lever bearing (Item 1) Remove the cylinder head from the engine. (See Page

[Figure 70-110-98]. 70-110-13.)
Figure 70-110-99 Remove the oil pan and oil pickup tube. (See Page 70-
110-24.)
NOTE: Mark the connecting rod caps (Item 1) [Figure

70-110-100] Replace the cap on the matching
connecting rod as the piston is removed.
Replace the piston back in the same cylinder
hole when installing.
2
1 Remove the connecting rod bolts (Item 2) [Figure 70-
110-100].
Installation: Tighten bolts to 30-34 ft.-lb. (41-46 N•m)

3 torque.
P13372
Check the parts for wear and replace as needed [Figure

70-110-99].
NOTE: The washer (Item 1) goes between the fork

lever (Item 2) and the fork compensating lever
(Item 3) when being installed [Figure 70-110-
99].
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Piston Removal And Installation (Cont’d)
Figure 70-110-101
2
1
4
1
P13401
3
Measure the piston pin (Item 1) [Figure 70-110-103] with
P13400 a micrometer and the connecting rod bushing (Item 2)
[Figure 70-110-103] with an inside micrometer.
Remove the piston rings (Item 1) [Figure 70-110-101] The specifications for the outside diameter of the piston
from the piston. pin are 0.8662-0.8666 inch (22,002-22,011 mm).

Remove the piston (Item 2) from the connecting rod (Item The specification for the inside diameter of the
3) by removing the piston pin (Item 4) [Figure 70-110- connecting rod bushing are 0.8671-0.8677 inch (22,025-
101]. 22,040 mm).
NOTE: Mark the piston and the connecting rod so The clearance between the piston pin and the connecting
they are assembled correctly. rod bushing is 0.0006-0.0015 inch (0,014-0,038 mm) with
an allowable limit of 0.0059 (0,15 mm).
Checking The Piston And Connecting Rod
Figure 70-110-102
P13398
Measure the piston pin hole with an inside micrometer

[Figure 70-110-102].
The specifications are 0.8661-0.8667 inch (22,000-

22,013 mm). The allowable wear limit is 0.8673 inch
(22,03 mm).
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RECONDITIONING THE ENGINE (CONT’D) Piston Ring Gap
Connecting Rod Alignment Figure 70-110-105
Figure 70-110-104
P13402
B-4067
Put the piston ring in the engine cylinder [Figure 70-110-
105]. Use a piston to push the ring to the lower part of the
NOTE: Check the I.D. of the connecting rod small end cylinder liner.
bushing, because it is used for this check,

make sure it is not worn. (See Page 70-110- Measure the ring gap with a feeler gauge (Item 1)
30.) [Figure 70-110-105].
Install the piston pin into the connecting rod. The specifications are as listed below:
Install the connecting rod on the connecting rod Top Ring 0.0117-0.0177 inch (0,30-0,45 mm)
alignment tool [Figure 70-110-104].
Second Ring 0.0117-0.0177 inch (0,30-0,45 mm)
Put a gauge over the piston pin and move it against the Oil Ring 0.0098-0.0157 inch (0,25-0,040 mm)
face plate.
The allowable wear limit for all the rings is 0.0492 inch
If the gauge does not fit squarely against the face plate, (1,25 mm).
measure the space between the pin of the gauge and the
face plate. If the ring gap exceeds the allowable limit, replace the
ring.
The allowable wear limit is 0.0020 inch (0,05 mm).
If measurement exceeds the allowable limit, replace the

connecting rod.
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RECONDITIONING THE ENGINE (CONT’D) Connecting Rod Installation
Piston Ring Installation Figure 70-110-107
Figure 70-110-106
2
1
B-03614A
P13393
P13393
Figure 70-110-108
Remove the carbon from the ring grooves in the piston.

Install the rings on the piston [Figure 70-110-106].
Position the top ring so the gap is not lined up with the
piston pin. Position the other rings so there is a gap every
90°. 1
NOTE: The top ring (Item 1) [Figure 70-110-106]

(inset) is a 1/2 flat key stone type ring and
must be installed with the flat side toward the
bottom of the piston as shown.
The second ring (Item 2) [Figure 70-110-106]

(inset) must be installed with the notch down P13396
as shown.
The oil ring (Item 3) [Figure 70-110-106] (inset) Install the connecting rod to the piston.
must be installed as shown.
NOTE: The arrow (Item 1) [Figure 70-110-107] on the
Measure the clearance between the ring and piston must point in the direction of the
the ring groove in the piston, with a feeler numbers (Item 1) [Figure 70-110-108] on the
gauge. connecting rod and the connecting rod cap.
The clearance between compression ring (Item 2) The alignment arrow and numbers must be
[Figure 70-110-106] and the ring groove is 0.0033- installed pointing opposite of the camshaft
0.0044 inch (0,085-0,112 mm) with an allowable limit of and in the same cylinder it was removed from.
0.0079 inch (0,20 mm).
The clearance between the oil ring (Item 3) [Figure 70-

110-106] and the ring groove is 0.0008-0.0021 inch
(0,15 mm).

ring.
If the clearance still exceeds the allowable limit after

replacing the ring, replace the piston.
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RECONDITIONING THE ENGINE (CONT’D) Crankshaft Removal And Installation
Checking Engine Cylinder Bore Figure 70-110-111
Figure 70-110-109
1 1
P13381
P13384
Remove the engine from the loader. (See Removal And
Figure 70-110-110
Remove engine starter. (See Removal And Installation

on Page 60-40-1.)
Remove engine flywheel. (See Removal And Installation

on Page 70-90-1.)
Remove the engine cylinder head.(See Page 70-110-13.)
Remove the engine oil pan. (See Page 70-110-24.)
Remove the pistons. (See Page 70-110-30.)
Remove the two main bearing mounting bolts (Item 1)

[Figure 70-110-111].
P13382
Installation: Tighten the mounting bolts to 36.2-39.8 ft.-
lb. (49-53,9 N•m) torque.
Use a micrometer to measure the inside diameter of the
cylinders [Figure 70-110-109] & [Figure 70-110-110].
To find the maximum wear, measure the inside diameter

of the cylinder in three different locations. The inside
diameter specification is 2.9921-2.9929 inches (76,000-
76,019 mm). The allowable wear limit is 0.0059 inch
(+0,15 mm).
NOTE: When the cylinder has more wear than the

specifications the block can be bored and
honed one time. The oversize cylinder inside
diameter is +0.0197 inch (+0,5 mm). Be sure to
use the correct oversize piston and rings to
match the cylinder.
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Crankshaft Removal And Installation (Cont’d) 1

1
Figure 70-110-112
1 1
1
1
1 1
2
1 1
1
1
1
1 P13386
1 1
Remove the eight mounting bolts (Item 1) [Figure 70-
1
P13380 110-114] from the crankshaft bearing case cover and
remove the cover.
Remove the nine mounting bolts (Item 1) from the Installation: Tighten the mounting bolts to 87-100 in.-lb.
crankshaft bearing case cover (Item 2) [Figure 70-110- (9,8-11 N•m) torque.

112].
Figure 70-110-115
(9,8-11 N•m) torque.
Figure 70-110-113
1
1
P13388
Replace the crankshaft bearing case cover gasket (Item

P13375 1) [Figure 70-110-115].
Replace the oil seal (Item 2) [Figure 70-110-115].

Remove the crankshaft from the rear of the engine
[Figure 70-110-113].
Check the gasket (Item 1) [Figure 70-110-113] and

replace.
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Crankshaft Removal And Installation (Cont’d) 1
Figure 70-110-116
1
1
1
2 1
1
2
1
2 P13397
Check the thrust bearings (Item 1) [Figure 70-100-117],

P13387 located on the rear main bearing only, and replace if worn
NOTE: When replacing the thrust bearings be sure to

Mark the main bearing caps (Item 1) [Figure 70-110- install the oil groove facing outward.
116].

Remove the main bearing cap bolts (Item 2) [Figure 70-
110-116].
Installation: Tighten the main bearing cap bolts to 22-25

ft.-lb. (29,4-34 N•m) torque.
NOTE: Since diameters of main bearings vary, install

the caps back on the bearings as they are
removed. Install them in the order they were
marked from the gear case side. When
installing the main bearing cap assemblies
face the mark (FLYWHEEL) on the
assemblies, toward the flywheel end of the
crankshaft.
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Checking Crankshaft Journal And Block Bearing
Figure 70-110-118
1
1
P13391
The outside diameter of the crankshaft number one

P13385 journal (Item 1) [Figure 70-110-120] is 1.8872-1.8878
inch (47,934-47,950 mm).
Measure the inside diameter of the front crankshaft The oil clearance between the crankshaft and the
bearing (Item 1) [Figure 70-110-118]. crankshaft bearing is 0.0013-0.0045 inch (0,034-0,114

mm) with an allowable limit of 0.0079 inch (0,2 mm).
Figure 70-110-119
P13383
The crankshaft bearing inside diameter is 1.8891-1.8917

inch (47,984-48,048 mm) [Figure 70-110-119].
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Checking The Crankshaft Journal And Main Bearing
Figure 70-110-121
P13394
Remove the bolts and remove the main bearing cap and
P13395 measure with the plastic gauge scale [Figure 70-110-
123], to get oil clearance.
Clean the crankshaft journal and crankshaft bearing. The oil clearance between crankshaft and crankshaft
number one bearing is 0.0013-0.0045 inch (0,034-0,114

Put a strip of plastic gauge (Item 1) [Figure 70-110-121] mm) with an allowable limit of 0.0079 inch (0,2 mm).
on the main bearing.
The oil clearance between the crankshaft and crankshaft
Figure 70-110-122 number two and three bearing is 0.0013-0.0037 inch
(0,2 mm).
1
The oil clearance between the crankshaft and crankshaft
number four bearing is 0.0013-0.0039 inch (0,034-0,098
mm) with an allowable limit of 0.0079 inch (0,2 mm).

crankshaft bearing.
P13392
Install the main bearing cap (Item 1) [Figure 70-110-122]

and tighten to 22-25 ft.-lb. (29,4-34 N•m) torque.
NOTE: Make sure to use the correct size bearing

during installation. Oversize bearings are
generally marked.
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Checking The Crankshaft Journal And Main Bearing

(Cont'd)
Figure 70-110-124
3 2 1
P13383
Measure the connecting rod bearings [Figure 70-110-

125] & [Figure 70-110-126]. the measurement should be
P13391 1.5750-1.5768 inches (40,004-40,050 mm).
NOTE: Make sure to use the correct size bearing

The measurement for the outside diameter of crankshaft during installation. Oversize bearings are

number two journal (Item 1) [Figure 70-110-124] and generally marked.
crankshaft number three journal (Item 2) [Figure 70-110-
124] is 1.8872-1.8878 inch (47,934-47,950 mm). Figure 70-110-127
The crankshaft bearing inside diameter for number two

and three journals are 1.8891-1.8909 inch (47,984-
48.029 mm).
The measurement for the outside diameter of the

crankshaft number four journal (Item 3) [Figure 70-110-
124] is 2.0041-2.0449 inch (51,921-51,940 mm).
The crankshaft bearing inside diameter for number four

journal is 2.0462-2.0480 inches (51,974-52,019 mm).
Connecting Rod Journal
Figure 70-110-125 P13390
Measure the connecting rod journals [Figure 70-110-

127].
The measurement should be 1.5732-1.5738 inches

(39,959-39,975 mm).
The oil clearance between the crankpin and the crankpin

bearing is 0.0011-0.0036 (0,029-0,091 mm) with an
allowable limit of 0.0079 inch (0,2 mm).
P13399
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RECONDITIONING THE ENGINE (CONT’D) Crankshaft Alignment
Checking The End Play Of The Crankshaft Figure 70-110-129
Figure 70-110-128
P13389
P13376
Support the crankshaft with V-blocks and set a dial
indicator on one of the center journals at a right angle
Move the crankshaft toward the crankshaft pulley end. [Figure 70-110-129].

Set a dial indicator (Item 1) [Figure 70-110-128] to the Rotate the crankshaft on the V-blocks and get the
crankshaft. misalignment (half of the measurement).
Measure the end play by pushing the crankshaft toward The measurement should be 0.0008 inch (0,02 mm).
flywheel end.
If the misalignment exceeds the allowable limit, replace
The end play should be between 0.0059-0.0122 inch the crankshaft.
(0,15-0,31 mm) with an allowable limit of 0.0197 inch (0,5
mm).
If the measurement exceeds the allowable limit replace

the thrust bearings. (See Page 70-110-34.)
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RECONDITIONING THE ENGINE (CONT’D) Idler Gear And Crankshaft
Engine Timing Installation Figure 70-110-132
Figure 70-110-130
1
2
3
2
4
1
P13271
P13346
Set a dial indicator (lever type) with its tip on a gear tooth
of the idler gear (Item 1) [Figure 70-110-132].
Install the crankshaft (Item 1) [Figure 70-110-130]. (See
Page 70-110-34.) Hold the crankshaft gear (Item 2) [Figure 70-110-132]

and move the idler gear.
Install the camshaft (Item 2) [Figure 70-110-130]. (See
Page 70-110-21.) Check the amount of movement on the dial indicator.
Install the governor shaft (Item 3) [Figure 70-110-130]. The measurement should be 0.0013-0.0045 inch (0,032-
(See Page 70-110-25.) 0,115 mm) with an allowable limit of 0.0059 inch (0,15
mm).
Install the fuel campshaft (Item 4) [Figure 70-110-130].
(See Page 70-110-23.) If the backlash exceeds the allowable limit, check the oil
clearance between idler gear shaft and the idler gear
Figure 70-110-131 bushing. (See Page 70-110-16.)
If the clearance is within the allowable limit, replace the

idler gear.
P13269
Install the idler gear (Item 1) [Figure 70-110-131] on the

idler shaft. (See Page 70-110-19.)
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RECONDITIONING THE ENGINE (CONT’D) Idler Gear And Injection Pump Shaft Gear
Idler Gear And Camshaft Gear Set a dial indicator (lever type) with its tip on a gear tooth
of the injection pump shaft gear (Item 1) [Figure 70-110-
Figure 70-110-133 133].
Hold the idler gear (Item 3) [Figure 70-110-133] and

move the camshaft gear.
1
3 Check the amount of movement on the dial indicator.
The measurement should be 0.0013-0.0046 inch (0,034-

2 0,116 mm) with an allowable limit of 0.0059 inch (0,15
4 mm).
If backlash exceeds allowable limit replace the camshaft

gear.
If after replacing the camshaft gear the backlash exceeds

P13271 the allowable limit check the camshaft bearing. (See
Page 70-110-21.)
Set a dial indicator (lever type) with its tip on a gear tooth Injection Pump Shaft And Governor Shaft Gear
of the camshaft gear (Item 1) [Figure 70-110-133].

Set a dial indicator (lever type) with its tip on a gear tooth
Hold the idler gear (Item 2) [Figure 70-110-133] and of the governor shaft gear (Item 4) [Figure 70-110-133].
move the camshaft gear.
Hold the injection pump shaft gear (Item 3) [Figure 70-
Check the amount of movement on the dial indicator. 110-133] and move the governor gear.
The measurement should be 0.0014-0.0045 inch (0,036- Check the amount of movement on the dial indicator.
0,114 mm) with an allowable limit of 0.0059 inch (0,15
mm). The measurement should be 0.0012-0.0046 inch (0,030-
0,117 mm) with an allowable limit of 0.0059 inch (0,15
If the backlash exceeds the allowable limit replace the mm).
camshaft gear.
If backlash exceeds the allowable limit replace the
If after replacing the camshaft gear the backlash exceeds governor shaft gear.
the allowable limit check the camshaft bearing. (See
Page 70-110-16.) If after replacing the governor shaft gear the backlash
exceeds the allowable limit check the governor shaft
bearings. (See Page 70-110-25.)
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SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-60-2 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 DRIVE
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 SYSTEM
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-40-1 ELECTRICAL
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2 SYSTEM &
O-Ring Face Seal Connection . . . . . . . . . . . . . . . . . . . SPEC-40-1 ANALYSIS
O-Ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-4
Straight Thread O-Ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-40-1
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1 ENGINE
SERVICE
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-50-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 SPECIFICATIONS
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Floor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-30-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-30-1
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-30-1

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LOADER SPECIFICATIONS
Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.

B-20824A
Changes of structure or weight distribution of the loader can cause changes in control and steering response and
can cause failure of the loader parts.
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LOADER SPECIFICATIONS (CONT’D)
Performance
463
Rated Operating Capacity (SAE) 700 lb. (318 kg)
Tipping Load (SAE Rating) 1405 lb. (637 kg)
Operating Weight 2708 lb. (1229 kg)
SAE Breakout Force - Lift 1450 lbf (6450 N)
Tilt 2025 lbf. (9008 N)
Torque Ripple 196 ft.-lbf @2950 PSI (266 N•m @ 203 Bar)
Travel Speed 0-6.5 MPH (10,5 km/hr.)
Controls
Vehicle Steering Direction and speed controlled by two hand levers

Loader Hydraulics:
Lift And Tilt Controlled by separate foot pedals.
Front Auxiliary (optional) Controlled by lateral movement of RH steering lever.
Engine Hand lever throttle; Key Type starter switch and shutdown
Starting Aid Switch activated glow plugs.

Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers.
Secondary Brake One of the hydrostatic transmissions
Parking Brake Mechanical Disc, Instrument panel switch operated
Engine
Make/Model KUBOTA/D1005-E2B
Fuel/Cooling Diesel/Liquid
Horsepower (SAE Net) 22.5 HP (16,8 kW)
Maximum Governed RPM (High Idle) 3150 RPM (3125-3220 RPM)
Torque (SAE Net) 43 ft.–lb. (58,3 N•m) @ 2200 RPM
Number of Cylinders Three
Displacement 61.08 cu. in. (1,0 L)
Bore/Stroke 2.99/2.90 (75,95/73,66)
Lubrication Gear Pump Pressure System W/Filter
Crankcase Ventilation Closed Breather
Air Cleaner Dry replaceable paper cartridge
Ignition Compression Diesel
RPM (Low Idle) 1125-1175 RPM
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Hydraulic System
463
Pump Engine driven, Gear type
Pump Capacity 9.8 GPM (37,1 L/min.) @3000 RPM
System Relief at Quick 3000 PSI (206,9 Bar)
Couplers
Filter 10 micron replaceable cartridge in the hydrostatic pump charge line.
Hydraulic Cylinders Double-acting
Bore Diameter: Lift Cylinder (2) 2.00 (50,8)
Tilt Cylinder (1) 3.00 (76,2)
Rod Diameter: Lift Cylinder (2) 1.25 (31,8)
Tilt Cylinder (1) 1.25 (31,8)
Stroke: Lift Cylinder (2) 21.88 (555,8)
Tilt Cylinder (1) 10.56 (268,2)
Control Valve 3-Spool series type, open center w/float detent on lift and detent in auxiliary.
Fluid Lines SAE standard tubes, hoses and fittings

Fluid Type Bobcat Fluid (P/N 6903117).
Hydraulic Function Time:
Raise Lift Arms 3.6 Seconds
Lower Lift Arms 2.5 Seconds
Bucket Dump 2.3 Seconds
Bucket Rollback 2.1 Seconds
Electrical
Alternator 65 amp ventilated

Battery 12 volt; 600 cold cranking amps @ 0°F (-18°C); 115 minute reserve capacity at 25 Amps
Starter 12 volt Gear Type; 3.62 HP (2,7 kW)
Instrumentation (Standard) Gauges: Hourmeter, Voltmeter , Eng. Temp. & Fuel (on tank)
Warning lights: Engine Oil Pressure & Temperature, Hyd. Oil Temp. & Pressure.
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Drive System
463
Main Drive Hydrostatic 4 wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final Drive #60HS endless roller chain & sprockets in sealed chaincase with oil lubrication
Total Engine to Wheel 31.25:1
Reduction
Axle Size 1.5 (38,1)
Wheel Bolts (5) 7/16”
Capacities
Cooling System 6.0 qts. (5,7 L)

Fuel 6.5 gals. (24,6 L)
Engine Oil W/Filter 5.0 qts. (4,7 L)
Hydraulic/Hydrostatic Reservoir 5.3 qts. (5,0 L)
Hydraulic/Hydrostatic System 4.0 gals. (15,1 L)

Chaincase Reservoir 3.0 gals. (11,4 L)
Tires
Standard 23 x 5.7-12, 4 ply rating

Flotation 23 x 8.5-12, 6 ply rating
Turf 23 x 8.5-12, 8 ply rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix
brands of tires used on the same loader
Floor Pressure
Front Rear Front Rear

Std. Tires - Rated Load 68 PSI (469 kPa) 61 PSI (420 kPa) 68 PSI (469 kPa) 64 PSI (441 kPa)
Unloaded 49 PSI (338 kPa) 67 PSI (462 kPa) 49 PSI (338 kPa) 69 PSI (476 kPa)
Flot. Tires - Rated Load 25 PSI (172 kPa) 21 PSI (145 kPa) 25 PSI (172 kPa) 23 PSI (159 kPa)
Unloaded 14 PSI (97 kPa) 25 PSI (172 kPa) 14 PSI (97 kPa) 27 PSI (186 kPa)
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ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Engine
Compression (At Operating Temperature) 412-469 PSI (28,4-32,3 Bar)
Limit Permitted 327 PSI (22,5 Bar)
Fuel Injector Nozzles
Opening Pressure 1991-2134 PSI (137,3-147 Bar)

Fuel Tightness Nozzle Seat 1849 PSI (127,5 Bar)
Fuel Injection Pump
Fuel Tightness of Plunger Limit Permitted 2133 PSI (147 Bar)

Fuel Tightness of Delivery Valve 10 Sec: Initial Pressure Drop From 1991-1849 PSI (137,3-127,5 Bar)
Limit Permitted 5 Sec: Initial Pressure Drop From 1991-1849 PSI (137,3-127,5 Bar)
Injection Timing 17-19° B.T.D.C.
Cylinder Head

Flatness Limit Permitted 0.0020 (0,05)
Top Clearance 0.0217-0.0276 (0,55-0,70)
Valves
Valve Seat Angle 60° intake 45° exhaust

Valve Seat Width 0.0835 (2,12)
O.D. of Valve Stem 0.2741-0.2746 (6,960-6,975)
I.D. of Valve Guide 0.2760-0.2765 (7,010-7,025)
Clearance between Valve Stem & Guide 0.0014-0.0025 (0,035-0,065)
Limit Permitted 0.0039 (0,1)
Depth of Valve *negative value *0.0020-0.0098 *(0,05-0,25)
Valve Clearance (Cold) (Intake & Exhaust) 0.0057-0.0073 (0,145-0,185)
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ENGINE SPECIFICATIONS (CONT’D)
parentheses.
Valve Springs
Free Length 1.457-1.476 (37,0-37,5)
Fitted Length 1.22 (31,0)
Load To Compress To Fitted Length 26.4 ft. lbs (117,4 N)
Limit Permitted 22.5 ft. lbs (100 N)
Limit Permitted for Spring Tilt 0.039 (1,0)
Rocker Arms
O.D. of Rocker Arm Shaft 0.4714-0.4718 (11,973-11,984)

I.D. of Rocker Arm 0.4724-0.4731 (12,000-12,018)
Clearance Between Rocker Arm Shaft & Rocker 0.0006-0.0018 (0,016-0,045)
Arm
Limit Permitted 0.0039-(0,10)
Camshaft

O.D. of Camshaft Bearing Journal 1.4147-1.4153 (35,934-35,950)
I.D. of Camshaft Bearing 1.4173-1.4183 (36,000-36,025)
Clearance Between Camshaft Bearing & Journal 0.002-0.0036 (0,050-0,091)
Alignment of the Camshaft 0.0004 (0,01)
Intake Lobe Height 1.1339 (28,80)
Exhaust Lobe Height 1.1417 (29,00)
Gear Backlash 0.0014-0.0045 (0,036-0,114)
Cylinders
I.D. of Cylinder Liner 2.9921-2.9929 (76,000-76,019)

Limit Permitted +0.0059 (+0,15)
Rebore Size for Over size Piston +0.0197 (+0,5)
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parentheses.
Piston Rings
Top & 2nd Ring Gap 0.0118-0.0177 (0,30-0,45)
Oil Ring Gap 0.0098-0.0157 (0,25-0,40)
Limit Permitted (Top, 2nd & Oil Ring) 0.0492 (1,25)
Side Clearance Of Ring Groove:
Top Ring Because of our top ring design, measurement does not apply
2nd Ring 0.0033-0.0044 (0,085-0,112)
Oil Ring 0,0008-0,0021 (0.020-0.055)
Oversize of Piston & Ring +0.0197 +(0,5)
Pistons
I.D. of Piston Bore 0.8661-0.8667 (22,000-22,013)


O.D. of Piston Pin 0.8662-0.8666 (22,002-22,011)
I.D. of Connecting Rod Bushing (Small End, Fitted) 0.8671-0.8677 (22,025-22,040)
Oil Clearance Between Piston Pin & Bushing Limit Permitted 0.0059 (0,15)
Connecting Rod Alignment Limit Permitted 0.002 (0,05)
Crankshaft
Crankshaft Alignment Limit Permitted 0.0008 (0,02)

O.D. of Crankshaft Journal No. 1 1.8872-1.8878 (47,934-47,950)
I.D. of Crankshaft Bearing No. 1 1.8891-1.8917 (47,984-48,048)
Oil Clearance Between No.1 Crankshaft Journal and Bearing 0.0013-0.0045 (0,034-0,114)
O.D. of Crankshaft Journal No. 2 & No. 3 1.8872-1.8878 (47,934-47,950)
I.D. of Crankshaft Bearing No. 2 & No. 3 1.8891-1.8909 (47,984-48,029)
Oil Clearance Between No. 2 & No. 3 Crankshaft Journals & Bearings 0.0013-0.0037 (0,034-0,095)
O.D. of Crankshaft Journal No. 4 2.0441-2.0449 (51,921-51,940)
I.D. of Crankshaft Bearing No. 4 2.0462-2.0480 (51,974-52,019)
Oil Clearance Between No. 4 Crankshaft Journal and Bearing 0.0013-0.0039 (0,034-0,098)
O.D. of Connecting Rod Journals 1.5732-1.5738 (39,959-39,975)
I.D. of Connecting Rod Bearings 1.5750-1.5768 (40,004-40,050)
Oil Clearance Between Connecting Rod Journals and Bearings 0.0011-0.0036 (0,029-0,091)
Crankshaft End Play 0.0059-0.0122 (0,15-0,31)
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parentheses.
Oil Pump
Oil Pressure @ Rated RPM 28-64 PSI (1,9- 4,4 Bar)

Limit Permitted @ Rated RPM 21 PSI (1,4 Bar)
Oil Pressure @ Idle Speed 7 PSI (0,5 Bar)
Rotor Lobe Clearance Limit Permitted 0.0118 (0.3)
Clearance Between Outer Rotor & Pump Body 0.0039-0.0071 (0,100-0,180)
End Clearance Between Inner Rotor & Cover 0.0010-0.0030 (0,025-0,075)
Clearance Between Inner Rotor & Outer Rotor 0.0024-0.0071 (0,06-0,18)
Thermostat
Opening Temperature
Starting 157-163°F (70-73°C)
Fully Open 185°F (85°C)
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PUNCHED NUMBER BOLT MATERIAL GRADE

None or 4 Standard Bolts SS41,S20C
7 Special Bolts S43C, S48C (Refined)
9 Special Bolts SCM3, SCR3 (Refined)
Bolt Torques
MATERIAL GRADE STANDARD BOLT SPECIAL BOLT SPECIAL BOLT

NOMINAL DIAMETER SS42, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined)
M6 6 to 7 ft.-lb. 7 to 8 ft.-lb. 9 to 11 ft.-lb.
(8 to 9 N•m) (10 to 11 N•m) (12 to 15 N•m)
(18 to 20 N•m) (23 to 28 N•m) 30 to 34 N•m)
(39 to 45 N•m) (48 to 56 N•m) (61 to 71 N•m)
(62 to 73 N•m) (78 to 90 N•m) ( 103 to 118 N•m)
M14 80 to 93 ft.-lb. 91 to 109 ft.-lb. 123 to 145 ft.-lbs
(108 to 126 N•m) (123 to 148 N•m) (167 to 197 N•m)
(167 to 191 N•m) (197 to 225 N•m) (260 to 304 N•m)

(245 to 285 N•m) (275 to 319 N•m) (343 to 403 N•m)
(334 to 392 N•m) (367 to 431 N•m) (491 to 578 N•m)
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TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter “H” following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

.250 80-90 110-120
INCH (9-10) (13-14)
LBS. .3125 180-200 215-240
(N•m) (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
(300-330) (410-450)
LBS. .875 330-360 475-525

(450-490) (645-710)
(N•m) 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)
Torque For General Metric Bolts
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3-4 ft.-lb.
(4-5 N•m)
M 6 x 1.0 6-7 ft.-lb. 6-9 ft.-lbs
(8-9 N•m) (8-12 N•m)
M 8 x 1.25 6-9 ft.-lb. 11-16 ft.-lb. 18-25 ft.-lb.
(8-12 N•m) (15-22 N•m) (24-34 N•m)
M 10 x 1.25 13-18 ft.-lb. 22-30 ft.-lb. 36-50 ft.-lb.
(18-24 N•m) (30-41 N•m) (49-68 N•m)
M 12 x 1.25 22-30 ft.-lb. 40-54 ft.-lb. 69-87 ft.-lb.
(30-41 N•m) (54-73 N•m) (94-118 N•m)
M 14 x 1.5 36-50 ft.-lb. 58-80 ft.-lb. 116-137 ft.-lb.
(49-68 N•m) (79-108 N•m) (157-186 N•m)
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HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-Ring Fitting
Figure SPEC-40- 2
IMPORTANT
clean the work area before disassembly and keep all Nut Nut
tube lines and ports to keep dirt out. Dirt can quickly Washer
damage the system. Washer
I-2003-0888 O-Ring
O-Ring
O-Ring Face Seal Connection
Figure SPEC-40-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
2].

Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-7575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].
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HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it makes contact with the seat. Make
(CONTD) a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40- 3].
Flare Fitting
Use the chart below to find the correct tightness needed
Use the following procedure to tighten the flare fitting: (Item 2) [Figure SPEC-40- 3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
Figure SPEC-40- 3 damage.
TS-1619

Flare Fitting Tightening Torque
Tubeline TORQUE NEW RE-ASSEMBLY
Outside Ft.-lb. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (N•m) of Hex Flats of Hex Flats
5/8” 5/16” 1/2”-20 17 (23) 2-1/2 1
11/16” 3/8” 9/16”-18 22 (30) 2 1
7/8” 1/2” 3/4”-16 40 (54) 2 1
1” 5/8” 7/8”-14 60 (81) 1-1/2 1
1-1/4” 3/4” 1-1/16”-12 84 (114) 1 3/4
1-3/8” 1” 1-5/16”-12 118 (160) 3/4 3/4
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HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT’D) fitting.
O-Ring Flare Fitting Figure SPEC-40- 5
Figure SPEC-40- 4 Hex Flat Tightening Method

O-Ring Flare
Primary
Seal
1
TS-1619
Secondary
Seal P-13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts of
The flare is the primary seal, the O-ring is the secondary the connection (Item 1) [Figure SPEC-40- 5].
seal and helps absorb vibration and pressure pulses at

the connection [Figure SPEC-40- 4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-40- 5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.
O-RING FLARE FITTING TIGHTENING TORQUE

* ** ***
Tubeline TORQUE NEW RE-ASSEMBLY
Outside Ft.-lb. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (N•m) of Hex Flats of Hex Flats
5/8” 5/16” 1/2”-20 17 (23) 2-1/2 1
11/16” 3/8” 9/16”-18 22 (30) 2 1
7/8” 1/2” 3/4”-16 40 (54) 2 1
1” 5/8” 7/8”-14 60 (81) 1-1/2 1
1-1/4” 3/4” 1-1/16”-12 84 (114) 1 3/4
1-3/8” 1” 1-5/16”-12 118 (160) 3/4 3/4
*If a torque wrench is used to tighten a new fitting to a **If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
*If a torque wrench is used to tighten a used fitting to a **If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a new hose/tubeline.
*If a torque wrench is used to tighten a new fitting to a ***If using the hex flat tightening method to tighten a used
new hose/tubeline. fitting to a new hose/tubeline.
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HYDRAULIC CONNECTION SPECIFICATIONS Port Seal Fitting
(Cont'd)
Figure SPEC-40- 7
O-ring Flare Fitting (Cont’d)
NOTE: O-ring flare fittings are not recommended in

all applications. Use the standard flare fittings
in these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Figure SPEC-40- 6
Nut Seals
To Fitting
Copper Bonnet Orifice
Nut Seals
To Port

1
Secondary O-Ring Seal

P-13008
P-13572
The nut is the primary seal, the O-ring is the secondary

Use a standard flare fitting (Item 1) [Figure SPEC-40- 6] seal and helps absorb vibration and pressure pulses at
as shown. the connection [Figure SPEC-40- 7].
When a O-ring flare fitting is used as a straight thread The hex portion of the nut does not contact the surface of
port adapter the O-ring flare face is not used to seal. The the component when the nut is tight.
O-ring may come off the fitting and enter the system.
Use the following procedure to tighten the port seal
fitting:
Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
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HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)
Port Seal Fitting (Cont’d)
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
Fitting TORQUE
Nut Ft.-lb.
Wrench Size Thread Size (N•m)
11/16” 9/16”-18 22 (30)
15/16” 3/4”-16 40 (54)

1-1/8” 7/8”-14 60 (81)
1-1/4” 1-1/16”-12 84 (114)
1-1/2” 1-5/16”-12 118 (160)
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HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the loader must be kept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat hydraulic fluid (P/N 6903117 - 2, 2-1/2 Gal.), not flow easily and it makes action on the hydraulic
(P/N 6903118 - 5 Gal.), (P/N 6903119 - 55 Gal.). function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can
DO NOT use automatic transmission fluids in the loader cause transmission damage in less than 60 seconds.
or permanent damage to the transmission will result.
WARNING WARNING
During cold weather (32°F [0°C] and below), do not
Diesel fuel or hydraulic fluid under pressure can operate machine until the engine has run for at least
penetrate skin or eyes, causing serious injury or five minutes at less than half throttle. This warm-up
death. Fluid leaks under pressure may not be visible. period is necessary for foot pedal operation and safe
Use a piece of cardboard or wood to find leaks. Do stopping. Do not operate controls during warm-up
not use your bare hand. Wear safety goggles. If fluid period.
from a physician familiar with this injury. When temperatures are below -20°F (-30°C), the
W-2072-0496 hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low

temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
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CONVERSIONS
Decimal And Millimeter Equivalents
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CONVERSIONS (CONT’D)
U.S. To Metric Conversion
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ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 463-1

Date: 23 March 2006
Product: Bobcat Loader
Model: 463
Manual No: 6903711 (12-04)
463 Service Manual (P/N 6903711) Dated (2-06) contains updated service information which replaces the previous
463 Service Manual (P/N 6902680) Dated (12-04).
Printed in U.S.A.
369 of 372
370 of 372
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 463-2

Date: 3 August 2007
Product: Bobcat Loader
Model: 463
Manual No: 6903711 (8-07)
The following Sections are a revision to the above Service Manual.
COVER

10-170
50-40
Printed in U.S.A.
371 of 372
372 of 372

463 6903711 SM 8-07 PDF

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Service

Dealer Copy -- Not for Resale

6903711 (8-07) Printed in U.S.A. © Bobcat Company 2007

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Dealer Copy -- Not for Resale

B-6590 B-6580 B-6589

AIR CLEANER ........................................................ 70-01 INSTRUMENT PANEL.............................................60-01

BOB-TACH ............................................... 10-01, 50-01

DRIVE BELT ........................................................... 30-01 RADIATOR ..............................................................70-01

Dealer Copy -- Not for Resale

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

Dealer Copy -- Not for Resale

463 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

6. Machine signs must be 14. Check hydraulic fluid level,

7. Steering levers and foot 15. Inspect for fuel, oil or

8. Check for correct funtion of 16. Lubricate the loader.

463 Bobcat Loader

Dealer Copy -- Not for Resale

21. Inspect for loose or broken

463 Bobcat Loader

463 Bobcat Loader

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

463 Bobcat Loader

The dealer and owner/operator review the recommended

Dealer Copy -- Not for Resale

463 Bobcat Loader

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

Dealer Copy -- Not for Resale

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

463 Bobcat Loader

463 Bobcat Loader

Always use the serial number of the loader when Figure 3

Bobcat Loader Serial Number

The engine serial number is located on the engine fuel

Dealer Copy -- Not for Resale

The loader serial number plate is located on the inside of

Explanation of loader Serial Number:

The Delivery Report must be filled out by the dealer and

 FACTORY OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

463 Bobcat Loader

†BUCKET TILT CYLINDER

Dealer Copy -- Not for Resale

LIFT ARM SUPPORT

463 Bobcat Loader

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1

FACTORY OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)