Service Manual: S/N 52001100 & Above S/N 519911001 & Above

Service
Manual
Dealer Copy -- Not for Resale

S/N 52001100 & Above
S/N 519911001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6901177 (3-06) Printed in U.S.A. © Bobcat Company 2006

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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 LIFTING AND BLOCKING THE LOADER...............10-01

AIR CLEANER SERVICE ....................................... 10-01 LIGHTS....................................................................60-01
ALTERNATOR ....................................................... 60-01 LUBRICATING THE LOADER.................................10-01
AUXILIARY CONTROL LOCKBOLT....................... 10-01
MAIN RELIEF VALVE ..............................................20-01
BATTERY................................................................ 60-01 MUFFLER................................................................70-01
BICS™ (With Press To Operate Button) ................ 60-01
BICS™ BLOCK VALVE .......................................... 20-01 OPERATOR CAB .........................................10-01, 50-01
BICS™ SYSTEM CONTROLLER........................... 60-01 OPERATOR SEAT...................................................20-01
BOB-TACH................................................... 10-01, 50-01
PARKING BRAKE....................................................40-01
CHARGE PRESSURE ............................................ 30-01 PIVOT PINS ............................................................10-01
CHAINCASE .......................................................... 40-01
CONTROLS ........................................................... 20-01 RADIATOR ..............................................................70-01
CONTROL PANEL ................................................. 30-01 REAR DOOR...........................................................50-01
CONVERSIONS ...............................................SPEC-01 REAR WINDOW .....................................................50-01
CYLINDER ............................................................. 20-01 REMOTE START SWITCH .....................................10-01
RECONDITIONING THE ENGINE..........................70-01
DRIVE BELT ........................................................... 30-01
DRIVE COMPONENTS .......................................... 40-01 SEAT BAR ..............................................................50-01
SEAT BAR RESTRAINT SYSSTEM........................40-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 SEAT BAR SENSOR ...............................................60-01

ENGINE .................................................................. 70-01 SERVICE SCHEDULE ............................................10-01
ENGINE COMPONENTS AND TESTING .............. 70-01 SPARK ARRESTOR MUFFLER..............................10-01
ENGINE COOLING SYSTEM ................................. 10-01 STARTER ................................................................60-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 STEERING ..............................................................30-01
ENGINE MOUNTING BRACKET ........................... 70-01
ENGINE SPECIFICATIONS.............................. SPEC-01 TIRE MAINTENANCE .............................................10-01
ENGINE SPEED CONTROL .................................. 70-01 TOWING THE LOADER .........................................10-01
THERMOSTAT ........................................................70-01
FAN ......................................................................... 70-01 TORQUE SPECIFICATIONS FOR BOLTS ...... SPEC-01
FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01 TRACTION LOCK ...................................................60-01
FLYWHEEL ............................................................ 70-01 TRANSPORTING THE LOADER ............................10-01
FUEL LIFT PUMP ................................................... 70-01 TROUBLESHOOTING ............................................70-01
FUEL SYSTEM ....................................................... 10-01
FUEL TANK............................................................. 50-01
GLOWPLUGS ........................................................ 70-01
HYDRAULIC CONNECTION SPEC ..................SPEC-01

HYDRAULIC CONTROL VALVE ............................ 20-01
HYDRAULIC FILTER .............................................. 20-01
HYDRAULIC/HYDROSTATIC
FLUID SPECIFICATIONS .................................SPEC-01
HYDRAULIC/HYDROSTATIC SYSTEM ................ 10-01
HYDRAULIC PUMP ................................................ 20-01
HYDRAULIC RESERVOIR ..................................... 20-01
HYDRAULIC SYSTEM INFORMATION.................. 20-01
HYDROSTATIC MOTOR ........................................30-01
HYDROSTATIC PUMP .......................................... 30-01
HYDROSTATIC SYSTEM INFORMATION ............. 30-01
INSTRUMENT PANEL ........................................... 60-01
LIFT ARM SUPPORT DEVICE................................10-01

LIFT ARMS ............................................................. 50-01
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CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY AND
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V MAINTENANCE
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

HYDRAULIC
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX SYSTEM
BOBCAT SKID STEER LOADER IDENTIFICATION . . . . . . . . . . . . X HYDROSTATIC

SYSTEM
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 DRIVE

SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
MAIN
s
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 FRAME
A
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
SYSTEM AND
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 ENGINE

SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
SPECIFICATIONS
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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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 Operation & Maintenance Manual for operating
instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that 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 Recommend to the owner that all
battery and cables. necessary corrections be made
before the machine is returned to
service.
18. Inspect the air cleaner for

damage or leaks. Check the
condition of the element.
19. Check the electrical charging

system.
20. Check tires for wear and

pressure.

21. Inspect for loose or broken
parts or connections.
22. Operate the loader and check

all functions.
23. Check for any field

modification not completed.
24. Check for correct function of

the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

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

IMPORTANT available through your local dealer or at
www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
This notice identifies procedures which must be of correct operation of the Skid-Steer Loader. The
followed to avoid damage to the machine. course is available in English and Spanish versions.
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-9791
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
Module 2. - Production
Sequence (Series) B-16315
Module 1. - Model/Engine
Combination 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].
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BOBCAT SKID STEER LOADER IDENTIFICATION
OPERATOR
◆OPERATING LIGHTS HANDBOOK
SEAT BAR
GRAB OPERATOR
HANDLES SEAT
STEERING
LEVER
SAFETY TREAD
STEPS

TILT CYLINDER
†BUCKET
B-15914
•OPERATOR CAB
◆OPERATING LIGHT (ROPS/FOPS)
UPRIGHTS
REAR
DOOR LIFT ARM SUPPORT
DEVICE
LIFT ARMS
LIFT CYLINDER
TIRES*
◆ FACTORY OPTION 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.
• ROPS, FOPS - Roll-Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and ISO
3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level 1. The Bobcat loader is
B-15915
base-equipped with a standard operator cab as shown. Extra insulated cab is available as an option
(Reduced noise level).
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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
REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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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-7288
W-2003-0199
Figure 10-10-1 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-7023
Procedure
Always park the loader on a level surface.

P7289
WARNING Put the floor jack under the front of the loader [Figure 10-
10-3].
Put jackstands under the front axles and rear corners Lift the front of the loader and put jackstands under the
of the frame before running the engine for service. loader frame.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death. NOTE: Make sure the jackstands do not touch the
W-2017-0286
tires.
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LIFT ARM SUPPORT DEVICE Figure 10-20-2
WARNING
Never work on a machine with the lift arms up unless P-19460
the lift arms are secured by an approved lift arm

support device. Failure to use an approved lift arm
Lower the lift arm support device on top of the lift
support device can allow the lift arms or attachment
cylinder. Fasten the free end of the spring (Item 1)
to fall and cause injury or death.
[Figure 10-20-2] to the lift arm support device so there
W-2059-0598
will be no interference with the support device
engagement.
Engaging The Lift Arm Support Device

With the operator in the seat, seat belt fastened and seat
Figure 10-20-1 bar lowered, start the engine. Press the green PRESS
TO OPERATE Button.
Figure 10-20-3
P-9773 P-19458
Put jackstands under the rear corners of the loader

P-9800
(Inset) [Figure 10-20-1].
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 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)
Figure 10-20-4
P-9807
1
Connect the spring from the lift arm support device to the
P-9808 tubeline bracket (Item 1) [Figure 10-20-6] on the lift
arms.
Install the retaining pin (Item 1) [Figure 10-20-4] into the With the operator in the seat, seat belt fastened and seat
rear of the lift arm support device below the cylinder rod. bar lowered, start the engine. Press the green PRESS

TO OPERATE Button.
Raise the lift arms a small amount and the spring will lift
WARNING the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine.
Service lift arm support device if damaged or if parts
Raise the seat bar and move pedals until both pedals
are missing. Using a damaged lift arm support or
lock.
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Disconnect the spring from the bracket.
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

The Bobcat loader has an operator cab (ROPS and the front (both sides) of the operator cab.
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer Figure 10-30-2
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
highway maintenance, landscaping, and other
construction site services.
Check with your dealer if the operator cab has been

changed.
P-19462
Figure 10-30-1
Stand on the ground. Lift slowly until operator cab is all

the way up [Figure 10-30-2].
The operator cab will lock in the raised position
WARNING
1
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
P-19461
and falling objects, and result in injury or death.
W-2069-1299
The operator cab fastening nuts (Item 1) [Figure 10-30-
1] must be tightened to 40-50 ft.-lbs. (54-68 Nm) torque.
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OPERATOR CAB (CONT’D) Figure 10-30-4
Lowering The Operator Cab
WARNING
The cab must be held to prevent falling while hand is
in access hole.
W-2205-0695
Figure 10-30-3
P-19499
1
Hold the operator cab. Release the locking mechanism
by pushing the lever (Item 1) [Figure 10-30-3] inward
2 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.
REMOVE YOUR HAND FROM THE HOLE BEFORE

LOWERING THE OPERATOR CAB
P19498
Stand on the ground and pull down on the operator cab.
Avoid slippery surfaces when lowering the cab.
NOTE: Guide the operator cab over the fastening

bolts to prevent thread damage.
Figure 10-30-5
P-19461
Install the cab washers and nuts. Tighten the nuts (Item
1) [Figure 10-30-5] (both sides) to 40-50 ft.-lbs. (54-68
Nm) torque.
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Emergency Exit
Figure 10-30-6
P-19463
Exit throught the rear of the cab [Figure 10-30-7].

P-9829
The front opening on the operator cab and rear window

provide exits.

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-9924
Fasten the rear of the loader as shown with a loop of

chain through the tie down provided [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
Be sure the transport and towing vehicles are of

adequate size and capacity. P-21493
P-21495
To prevent damage to the loaders hydrostatic system, a

tow valve is available for towing the loader short distances Install the tow valves in the fitting holes [Figure 10-50-2].
at slow speeds. (Example: Moving the loader onto a
transport vehicle.) Figure 10-50-3
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.

1
Figure 10-50-1
P-21497
Tighten the jam nut (Item 1) [Figure 10-50-3] to 20-25 ft.-

lbs. (27-34 Nm) torque while the tow valve flats are in the
1
horizontal position.
P-21492
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 Machine 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 SWITCH Figure 10-60-1
Procedure
The tool listed will be needed to do the following

procedure:
MEL1429-B- Remote Start Switch Kit
Kit Includes:
MEL1429-1 Adapter 1
MEL1429- 2 Start Switch
MEL1429-3 Adapter
The Remote Start Switch is required when the operator

cab is in the raised position for service and the service
technician needs to start the engine. The operator cab
wire harness connectors must be separated from the
engine wiring harness connector under the cab.
The remote start switch is required when the service

technician is adjusting the steering linkage and checking
the hydraulic/hydrostatic system.

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service. P-7523
fall or move and cause injury or death.
W-2017-0286 Connect the remote start switch to the connectors (Item
1) [Figure 10-60-1].
Replace the inner filter every third time the outer filter is
WARNING replaced or as indicated by the Service Schedule.
Never work on a machine with the lift arms up unless

W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10-
20-1.)

on Page 10-30-1.)
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REMOTE START SWITCH (CONT’D) Figure 10-60-4
Figure 10-60-2
P-4714
1 Move the traction lock override switch (Item 1) [Figure

P-7101 10-60-4] to the OFF position so the traction function is
unlocked. The wheels are now able to turn.
NOTE: On late model loaders, the connector on the

BICS™ harness is a round 7-pin connector,

NOT a rectangular 8-pin connector. Use the
adapter (Item 1) [Figure 10-60-2] if your loader
has a round 7-pin BICS harness connector.
Figure 10-60-3
P-4713
Put the traction lock override switch (Item 1) [Figure 10-

60-3] in the ON position so the traction function is locked.
The wheels are not able to turn.
Turn the key to the right and start the engine.
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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 Sys- Clean debris from oil cooler, radiator and grill. Check coolant level in
tem 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 correct operation. Clean dirt and debris from moving parts.
Safety Signs (Decals) Check for damaged sign (decals) and safety treads. Replace any signs or
and Safety Tread safety treads that are damaged or worn.
Lift Arms and Bob- Lubricate with multi-purpose lithium based grease.
Tach 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
and Tubelines or replace as needed.
Bobcat Interlock Con- Check BICS™ System Controller functions. Clean dirt, debris or objects
trol System (BICS™) from under or behind seat as required.
Battery Check cables, connections and electrolyte level. Add distilled water as
needed.
Control Pedals & Check for correct operation. Repair or adjust as needed.
Steering
Bob-Tach Check locking levers & wedges for condition & operation.
Wheel Nuts ❑Check for loose wheel nuts & tighten to 40-45 ft.-lbs. (54-61 Nm) 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 Ele- Replace Filter Element.
ment
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 Replace the fluid.
(Chaincase)
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
(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.
Figure 10-80-1 1
3 P-19450
Figure 10-80-3
2
1

P-19452 P-19453
NOTE: Before replacing the filter element, push the

button on the condition indicator (Item 1)
[Figure 10-80-1]. Start the engine, then stop
the engine. If the red ring does not show, do
not replace the filter element. 1
Replace the outer filter element only when the red ring
shows in the window of the condition indicator (Item 2)
P-19451
[Figure 10-80-1].
Replace the inner filter every third time the outer filter is Remove the outer filter element (Item 1) [Figure 10-80-2]
replaced or when the red ring still shows in the indicator and if required, remove the inner filter element (Item 1)
window after the outer filter has been replaced. [Figure 10-80-3].
Release the two fasteners (Item 3) [Figure 10-80-1] to Clean the inside of the filter housing.
remove the cover. Clean any debris or dust from the
cover. Install the inner element, if required.
Install the outer element.
Install the cover and engage the two fasteners.
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ENGINE COOLING SYSTEM Cleaning The Cooling System
Check the cooling system every day to prevent

overheating, loss of performance or engine damage.
Checking The Coolant Level

WARNING
Figure 10-10-1 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

special debris screens.
P-9816

Open the rear door.
The coolant recover tank (Item 1) [Figure 10-10-1] is

located between the radiator and the right upright.
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
P-9806
Open the drain valve (Item 1) [Figure 10-90-4]. Located

P-9881 on the front engine by the fuel lift pump. Turn the valve
counterclockwise to open.
Open the rear door.

Place the drain hose (Item 1) [Figure 10-90-2] into a
clean container.

on Page 10-30-1.)
Figure 10-90-3
P-19402
Remove the radiator cap (Item 1) [Figure 10-90-3].
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FUEL SYSTEM Filling The Fuel Tank
Fuel Specification
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
WARNING
The following is a suggested blending guideline which Stop and cool the engine before adding fuel. NO
should prevent fuel gelling problems: SMOKING! Failure to obey warnings can cause an
explosion or fire.
Temp. F°/ C° No. 2 No.1 W-2063-0887
+15° (-9° ) 100% 0%
Down to -20° / (-29° ) 50% 50% Figure 10-100-2
Below -20° / (-29° ) 0% 100%
We recommend an operator contact their fuel supplier for

local recommendations.
Figure 10-100-1

2
1
P-9830
Remove the fuel fill cap (Item 1) [Figure 10-100-2].
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
P-9831
SMOKING .[Figure 10-100-2]
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
Always clean up spilled fuel or oil. Keep heat, flames,
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Drain Water: 1

service interval when to remove the water from the fuel
P-9880
filter.
Figure 10-100-4 Loosen the drain (Item 1) [Figure 10-100-5] at the

bottom of the filter element to drain water from the filter.
Close the drain.

OFF Open the shut-off valve (Item 1) [Figure 10-100-4] to turn
on the fuel supply.
Replace Fuel Filter:

1
service interval when to replace the fuel filter.
ON Clean the area around the fuel filter.
Close the shut-off valve (Item 1) [Figure 10-100-4].
Remove the fuel filter [Figure 10-100-5].
P-9831 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) Figure 10-100-7
Removing Air From The Fuel System
Figure 10-100-6
P-19025
Open the valve (Item 1) [Figure 10-100-7] on the injector

P-9880 pump and squeeze the hand pump several times until
fuel flows from the valve.

After replacing the fuel filter element or when the fuel Close the valve (Item 1) [Figure 10-100-7].
tank has run out of fuel, air must be removed from the
fuel system before starting the engine. Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
Open the rear door. The engine must be cool.
Start the engine.
Open the vent plug (Item 1) [Figure 10-100-6].
Operate the hand pump (priming bulb) (Item 2) [Figure

10-100-6] until fuel flows from the vent plug with no air
bubbles.
WARNING
Close the vent plug. Always clean up spilled fuel or oil. Keep heat, flames,
With the operator in the seat, seat belt fastened, seat bar Failure to use care around combustibles can cause
lowered, and parking brake engaged, start the engine. explosion or fire which can result in injury or death.
W-2103-1285
NOTE: If engine fails to start, remove air from the fuel
injection pump as follows:
Put jackstands under the rear of the frame. (See LIFTING

AND BLOCKING THE LOADER on Page 10-10-1.)

on Page 10-30-1.)
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ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil Figure 10-110-2
Figure 10-110-1
2
1
P-9882
P-9892
service interval for replacing the engine oil filter.
Check the oil every day.
Run the engine until it its at operating temperature. Stop

Stop the engine and remove the dipstick (Item 1) [Figure the engine.
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.) Remove the filter (Item 2) [Figure 10-110-1].
Oil Chart Clean the filter housing surface. Put clean oil on the
gasket of the new filter. Install the filter and hand tighten.
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
C° Install and tighten the cap on the drain hose.
F° TEMPERATURE RANGE ANTICIPATED

BEFORE NEXT OIL CHANGE (DIESEL ENGINES
MUST USE API CLASSIFICATION CD, CF4, CG4)
*Can be used ONLY when available with appropriate
diesel rating.
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ENGINE LUBRICATION SYSTEM (CONT’D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
P-9874
Turn the oil fill cap (Item 1) [Figure 10-110-3] 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 10-110-3].
NOTE: DO NOT overfill the crankcase.
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HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-1
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or 1
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-19414
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system. Open the rear door. Remove the dipstick (Item 1)
(See HYDRAULIC/HYDROSTATIC FLUID [Figure 10-120-1].
SPECIFICATIONS on Page SPEC-50-1.)
The fluid level is correct if the fluid is between the marks
Stop the loader on a level surface. Lower the lift arms on the dipstick.
and tilt the Bob-Tach fully back.

NOTE: The dipstick may indicate an incorrect level of
Stop the engine. 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

service interval to replace the fluid. The fluid must also
IMPORTANT be replaced if it becomes contaminated and after any
major repairs.
Fluid such as engine oil, hydraulic fluid, coolants, Stop the engine. Open the rear door.
grease, etc. must be deposed of in an
environmentally safe manner. Some regulations Remove the fill cap/dipstick.
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state Figure 10-120-3
and federal regulations for the correct disposal.
I-2067-0499
Hydraulic/Hydrostatic Filter Replacement

correct service interval.
Stop the engine. Open the rear door. Raise the operator
cab. (See Raising The Operator Cab on Page 10-30-1.)
Clean the area around the filter housing.
1

Figure 10-120-2
P-9863
Loosen the nut (Item 1) [Figure 10-120-3] which fastens

1 the fill tube to the loader frame.
Loosen the clamp at the fill tube, turn the fill tube down to
drain the fluid from the reservoir [Figure 10-120-3].
After the fluid is removed, put the fill tube in the correct
position, tighten the hose clamp and tighten the bolt.
Replace the hydraulic filter element.

P-7527
Add Hydraulic/Hydrostatic fluid to the reservoir. (See
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Remove the filter element (Item 1) [Figure 10-120-2]. on Page SPEC-50-1.)
Clean the surface of the filter housing where the filter Do Not over fill the reservoir.
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/
HYDROSTATIC FLUID SPECIFICATIONS on Page
SPEC-50-1.)
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-19415
The Auxiliary control has a lockbolt (Item 1) [Figure 10-

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

hydraulics.

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
Lubricate the loader as specified in the SERVICE

SCHEDULE Contents, Page 10-01 for the best
performance of the loader.
1
Record the operating hours each time you lubricate the
Bobcat loader.
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: P-19456
Figure 10-160-1
Lift Arm Pivot Pin (Item 1-Both sides) [Figure 10-160-3].
Figure 10-160-4

1
1
P-7548
Base End Lift Cylinder (Item 1-Both sides) [Figure 10- P-19466
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
Figure 10-160-5
1
P-19035
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]. Lever Disassembly And Assembly on Page
30-30-3.) to disassemble and lubricate the

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

sides).
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TIRE MAINTENANCE Tire Inflation
Wheel Nuts

service interval to check the wheel nuts. The correct
WARNING
torque is 40-50 ft.-lbs. (54-61 Nm) 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.
Figure 10-170-1 W-2078-1285
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
B-9976 mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
Check the tires regularly for wear, damage and pressure. bead and rim flange must be lubricated with a rubber
(See Tires on Page SPEC-10-4.) lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
Rear tires usually wear faster than front tires. To keep injury or death. During inflation of the tire, check the tire
tire wear even, move the front tires to the rear and rear pressure frequently to avoid over inflation.
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.
If this machine is operated on flammable forest,

1
brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
P-9764 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
Figure 10-190-1
P-19288
Figure 10-190-2

1
P-19291
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.-lbs. (11-

13 Nm) 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 (See SERVICE SCHEDULE on Page 10-70-1.) and on
arm rests and has spring loaded interlocks for the loft and the loader for correct service interval.
tilt control pedals. The operator controls the use of the
seat bar. The seat bar in the down position helps to keep Figure 10-200-1
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
Button. Operate each foot pedal to check both the lift and
tilt functions. raise the lift arms until the bucket is about 2
feet (600 mm) off the ground. P-9790
Raise the seat bar, try to move each pedal. The pedals
Figure 10-200-2
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
and operate the foot pedals to be sure that the pedals are
firmly locked in the neutral position. Unbuckle the seat
belt.
P-4400
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.-lbs. (34-38 Nm).
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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-7528
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
BICS™ BLOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-50-2 SAFETY &
MAINTENANCE
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Control Pedals Removal And Installation. . . . . . . . . . . . . . 20-90-2
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2 HYDRAULIC
Pedal Interlock Linkage Removal And Installation. . . . . . . 20-90-1 SYSTEM
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

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

Checking The Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-21-4

ELECTRICAL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SYSTEM &
ANALYSIS
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Auxiliary Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-40-3 ENGINE
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3 SERVICE
Lift Spool Detent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Load Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Port Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 SPECIFICATIONS
Port Relief/Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . 20-40-5
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
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
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Checking The Main Relief Valve Without Auxiliaries . . . . . 20-30-1
Checking The Main Relief Valve With Auxiliaries. . . . . . . . 20-30-2
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . 20-30-3
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463 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 520011001 AND ABOVE
(PRINTED APRIL 2001)
V-0050legend
LEGEND
1 RESERVOIR: 17 RELIEF/ANTICAVITATION VALVE -
Capacity . . . . . . . . . 5.3 Qts. (5,0 L) PORT . . . . . . . . 1700 PSI (11720 kPa)
at Full Speed
2 FILTER - HYDRAULIC/HYDROSTATIC
(CANISTER) 18 FILTER - BICS CONTROL VALVE
3 CHARGE PRESSURE SWITCH:
17-21 PSI (118-144 kPa) 19 CHECK VALVE - BICS CONTROL VALVE
4 TEMPERATURE SWITCH
20 SOLENOID ACTIVATED DIRECTIONAL
225-232 degrees F.
(108-111 degrees C.) CONTROL VALVE - BICS CONTROL
5 RELIEF VALVE - CHARGE: 21 PULL BUTTON ACTIVATED
85 PSI (586 kPa) DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS
6 BY PASS VALVE - COOLER:
22 CHECK VALVE - BICS CONTROL VALVE
625 PSI (4308 kPa)

7 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDRAULIC/ 23 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
HYDROSTATIC MOTOR
8 VARIABLE CAPACITY DISPLACEMENT
24 PILOTED ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDRAULIC/
CONTROL VALVE - TILT CONTROL
HYDROSTATIC PUMP
9 HYDRAULIC PUMP: 25 SOLENOID ACTIVATED DIRECTIONAL
Gear Type . . . 10.0 GPM (37,85 L/min.) CONTROL VALVE - BUCKET POSITION
at 3100 RPM VALVE (ON/OFF)
10 RELIEF VALVE - HIGH PRESSURE:
3000 PSI (20682 kPa) 26 FLOW DIVIDER ADJUSTMENT VALVE
11 REPLENISHING VALVE
12 RELIEF VALVE - MAIN: CONTROL VALVE - FLOW CONTROL
SPOOL
2450 PSI (16890 kPa)
at Front Quick Couplers 28 CHECK VALVE - BUCKET POSITION
13 LOAD CHECK VALVE VALVE

14 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - UNLOADING
PORT . . . . . . . . . 1700 PSI (11720 kPa) SPOOL
at Full Speed
15 RELIEF VALVE - PORT:
1700 PSI (11720 kPa)
NOTE: Unless otherwise specified
at Full Speed
springs have NO significant
16 RELIEF VALVE - PORT: pressure value.
1700 PSI (11720 kPa)
at Full Speed
Printed in U.S.A. V-0050legend (3-26-01)
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463 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 520011001 AND ABOVE BUCKET POSITION VALVE (OPTIONAL)
(PRINTED APRIL 2001) D
V-0050 28
DRIVE MOTOR
2 MALE
HYDRAULIC
FILTER
(FRONT AUXILIARY
QUICK COUPLERS)
26
7
3
FEMALE
4
OIL COOLER
A
Dealer Copy -- Not for Resal
25 C
5
27
HYDROSTATIC PUMPS 6 29
8 B
HYDRAULIC CONTROL VAVLE
11
10 TILT CYLINDER
AUXILIARY
SPOOL
17
INLET 13
11
10
BICS CONTROL VALVE
8
16
P2 B1
24
9 TILT
INLET OUTLET CYLINDER
SPOOL
15
13
23 LIFT CYLINDERS
P1 L1
DRIVE MOTOR
7
22
LIFT
14 CYLINDER
SPOOL
13
21
12
PP
20
18 19
PT
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
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Printed in U.S.A. 1 V-0050 (3-26-01)
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 operating. 1, 3
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 position. 4
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 HYDRAULIC/HYDROSTATIC FLUID
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-19328
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.
P-19326
Use a hammer to remove the pivot pin (left side shown)

[Figure 20-20-2].
Pull the cylinder forward. Mark the hoses for correct

reassembly.
Check only one cylinder at a time.
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CYLINDER (LIFT) (CONT’D) Figure 20-20-6
Removal And Installation
Fully lower the lift arms.
Stop the engine. Pull up on the lift arm by-pass control 1

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

cover and pivot pin from the right lift cylinder.
1
Remove the cover and pivot pin [Figure 20-20-6].
Figure 20-20-7

P-19288
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.
Remove the retainer and the rod end pin [Figure 20-20-
4]. P-19324
Figure 20-20-5
Lower the right lift cylinder onto the fender [Figure 20-20-
7].
P-19325
Lower the left cylinder into the fender [Figure 20-20-5].
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Removal And Installation (Cont’d)
Open the rear door.

1
Figure 20-20-8
P-19328
Pull the cylinder forward to remove the hose (Item 1)

[Figure 20-20-10] from the base end and the hose (Item
2) [Figure 20-20-10] from the rod end. Mark the hoses
P-19327 for correct reassembly.
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).
Figure 20-20-9
P-19326
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
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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CYLINDER (LIFT) (CONT’D) Put the rod end in a vise.
Disassembly And Assembly Remove the nut (Item 1) [Figure 20-20-12], piston (Item
2) [Figure 20-20-12], spacer (Item 3) [Figure 20-20-12]
Use the following tools to disassemble and assemble the and head (Item 4) [Figure 20-20-12].
cylinder:
Installation: Lift: tighten the nut to 105 ft.-lbs. (142 Nm)
MEL 1074 - O-ring Seal Hook torque.
MEL 1396 - Seal Installtion Tool
MEL 1033 - Rod Seal Installation Tool Figure 20-20-13
Piston Ring Compressor
Spanner Wrench 3
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. 2
Put the base end of the cylinder in a vise. 1
Figure 20-20-11

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].
P-7429
Use a spanner wrench to loosen the head [Figure 20-20-

11].
Figure 20-20-12
4
2 3
P-7428
Remove the head and the rod assembly from the cylinder
[Figure 20-20-12].
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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 Figure 20-21-2
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received 1
immediately.
W-2145-0290
2
Figure 20-21-1 P-19274
Tilt the Bob-Tach fully forward until it rests on the floor.
Stop the engine and raise the seat bar.

Engage the parking brake.
Remove the bolt (Item 1) [Figure 20-21-2] and the

retainer (Item 2) [Figure 20-21-2] from the Bob-Tach and
1 tilt cylinder rod end pivot pin.
Remove the pivot pin from the Bob-Tach.
P-19273 Figure 20-21-3
Stop the engine. Raise the seat bar.
Disconnect the hose (Item 1) [Figure 20-21-1] from the 1

base end of the tilt cylinder.
Install a plug in the hose and tighten the plug.
Lower the seat bar, engage the parking brake and start
the engine.
1
Push the bottom (heel) if the tilt pedal until system relief
pressure is reached.
P-19273
There should be no leaks from the base end of the port.
If there is leakage from the open port of the tilt cylinder, Remove the hoses (Item 1) [Figure 20-21-3] from the tilt
remove the cylinder for repairs. 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.
Remove the bolt (Item 1) [Figure 20-21-4] and the

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 13 14
4. Piston
5. Seal 11
6. O-Ring 11
7. Bolt
8. Clamp
9. Nut
10. O-Ring
11. Seal 12
12. Head
13. Rod 11
14. Seal 10

8
7
9
1 6
2
5
4
3
C-1808
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CYLINDER (TILT) (CONT’D) Put the rod end in a vise.
Disassembly And Assembly Remove the nut (Item 1) [Figure 20-21-7], piston (Item 2)
[Figure 20-21-7], spacer (Item 3) [Figure 20-21-7] and
Use the following tools to disassemble and assemble the head (Item 4) [Figure 20-21-7]
cylinder:
Installation:Lift: Tighten the nut to 300 ft.-lbs. (407 Nm)
MEL 1074 - O-ring Seal Hook torque.
MEL 1396 - Seal Installation Tool
MEL 1033 - Rod Seal Installation Tool Figure 20-21-8
Piston Ring Compressor
Spanner Wrench 3
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. 2
Put the base end of the cylinder in a vise. 1
Figure 20-21-6

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].
P-7429
Use a spanner wrench to loosen the head [Figure 20-21-

6].
Figure 20-21-7
4
2 3
P-7428
Remove the head and the rod assembly from the cylinder
(Item 1) [Figure 20-21-7].
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CYLINDER (TILT) (CONT’D) Figure 20-21-11
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
Checking The Main Relief Valve Without Auxiliaries
IMPORTANT
WARNING The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

of the frame before running the engine for service. Check the hose routing, from the tester, for clearance
Failure to use jackstands can allow the machine to while doing this procedure.
Sit in the operator seat, lower the seat bar and fasten the
W-2017-0286 seat belt.
Figure 20-30-1 Start the engine and run at low RPM. Push the bottom
(heel) of the right foot pedal to retract the tilt cylinder.
Check for hydraulic leaks. Be sure the tester is showing

flow.
1
Increase the engine speed to full RPM.
Push the bottom (heel) of the right foot pedal until the

system relief pressure is reached.
The correct pressure for the main relief valve is 2500 PSI
(17235 kPa).
If the relief valve pressure is not correct, stop the engine.

P-19273 Adjust or replace the main relief valve. (See Main Relief
Valve Adjustment on Page 20-30-3.)
NOTE: The following procedure is for checking the When the test is complete return the foot pedal to neutral
main relief valve only. Use this procedure position, reduce the engine RPM to idle.
when it is known that the hydraulic pump is in
good working condition. If the hydraulic Stop the engine.
pump is not working correctly, refer to
checking the output of the hydraulic pump.
(See Checking The Output Of The Pump on
Page 20-60-1.)
The tools listed will be needed to do the following

procedure:
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
Lift and block the loader. (See LIFTING AND

BLOCKING THE LOADER on Page 10-10-1.)
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.)
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MAIN RELIEF VALVE (CONT’D) The tools listed will be needed to do the following
procedure:
Checking The Main Relief Valve With Auxiliaries
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
WARNING Lift and block the loader. (See LIFTING AND

Put jackstands under the front axles and rear corners Connect the IN port of the hydraulic tester to the bottom
of the frame before running the engine for service. (female) quick coupler (Item 1) [Figure 20-30-2] on the
Failure to use jackstands can allow the machine to loader.
Connect OUT port of the hydraulic tester to the top
W-2017-0286
(male) quick coupler (Item 2) [Figure 20-30-2] on the
loader.
Open the restrictor (Item 3) [Figure 20-30-2] fully
WARNING (counterclockwise) before testing the relief valve.
Remove the auxiliary hydraulics lock bolt. (See
When the engine is running during service, the AUXILIARY CONTROL LOCKBOLT on Page 10-140-1.)
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or Figure 20-30-3
death.
W-2006-0284

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Figure 20-30-2
P-10750
Start the engine and run at low idle RPM. Push the right
steering lever all the way to the right to engage the front
auxiliary hydraulics detent [Figure 20-30-3].
3
2 Increase the engine sped to full RPM. Watch the flow
meter on the hydraulic tester to make sure the flow is
correct.
There should be 6.3 GPM (23,8 L/min.) free flow.
Slowly turn the restrictor control knob (Item 3) [Figure
1 20-30-2], on the tester, until the main relief valve opens.
P-5933 Record the pressure reading.
The correct pressure for the main relief valve is 2500 PSI
NOTE: The following procedure is for checking the
main relief valve only. Use this procedure (17235 kPa).
when it is known that the hydraulic pump is in If the relief valve pressure is not correct, stop the engine.
good working condition. If the hydraulic
pump is not working correctly, refer to Adjust or replace the main relief valve. (See Main Relief
checking the output of the hydraulic pump. Valve Adjustment on Page 20-30-3.. When the test is
(See Checking The Output Of The Pump on complete, move the steering lever back to center to
Page 20-60-1.) disengage the front auxiliary hydraulics.
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MAIN RELIEF VALVE (CONT’D) Main Relief Valve Adjustment
Removal And Installation Figure 20-30-5
IMPORTANT O-Ring
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 1
damage the system.
I-2003-0888
Backup
Figure 20-30-4
B-6764
1 Connect the hydraulic tester. (See Checking The Main

Relief Valve Without Auxiliaries on Page 20-30-1.)
An adjustment screw is located on the end of the main

relief valve (Item 1) [Figure 20-30-4].
Remove the end cap (Item 1) [Figure 20-30-5] from the

main relief valve.
Turn the adjusting screw in (increase pressure) or out

(decrease pressure) until the correct main relief pressure
P-19208 2500 PSI (17235 kPa) is obtained.
If the correct pressure can not be obtained, remove the

Raise the operator cab. (See Raising The Operator Cab main relief valve from the main control valve. (See
on Page 10-30-1.) procedure above.)
Clean the area around the control valve. Loosen and Remove the O-rings and back-up washers from the main
remove the main relief valve (Item 1) [Figure 20-30-4]. relief valve [Figure 20-30-5].
Installation: Tighten the main relief valve to 35-40 ft.-lbs. Clean the main relief valve in clean solvent. Use air
(47-54 Nm) torque. pressure to dry the valve.
NOTE: The engine has been removed for clarity only. Install new O-rings and back-up washers. Install the
It does not need to be removed to remove the main relief valve (Item 1) [Figure 20-30-4] and tighten.
main relief valve. Readjust the main relief valve to the correct setting.
NOTE: If the correct pressure can not be obtained

after cleaning and readjusting the main relief
valve, replace the relief valve. Always check
the pressure of a new relief valve.
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HYDRAULIC CONTROL VALVE Figure 20-40-1
3
2
WARNING P-7312
Never work on a machine with the lift arms up unless Remove the hair pin (Item 1) [Figure 20-40-1], the
the lift arms are secured by an approved lift arm fastener link (Item 2) [Figure 20-40-1] and the foot pedal
support device. Failure to use an approved lift arm linkage from the control valve spool (lift and tilt).
to fall and cause injury or death. Remove the hair pin fastener (Item 3) [Figure 20-40-1]
W-2059-0598 from the auxiliary spool.

Raise the lift arms and install the lift arm support device. Remove the retaining pins from the spool and pivot
(See Engaging The Lift Arm Support Device on Page 10- [Figure 20-40-1].
20-1.)
Figure 20-40-2
Stop the engine. Pull out on the lift arm by-pass knob
and move the lift pedal to release the hydraulic pressure.
Raise the seat bar.
Install jackstands under the rear corners of the loader.

(See LIFTING AND BLOCKING THE LOADER on Page
10-10-1.)

on Page 10-30-1.)
Remove the center control shield and the steering lever

covers. (See Control Shield And Steering Lever Panels 1
Removal And Installation on Page 30-20-1.)
P-7307
Remove the steering levers. (See Lever Removal And
Installation on Page 30-30-1.)
Remove the two screws (Item 1) [Figure 20-40-2] to
Remove the BICS™ block valve. (See Block Removal remove the auxiliary bracket from the control valve.
Thoroughly clean the control valve area.
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HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-5
Figure 20-40-3
1
3
P-7314
1
2 Remove the hoses from the control valve [Figure 20-40-
P-7311 5].
Remove the mounting bolts (Item 1) [Figure 20-40-5]

Remove the tublines (Item 1, 2, & 3) [Figure 20-40-3] and remove the control valve.
from the control valve and filter block.

Figure 20-40-4
P-7309
Remove the lift and tilt tubelines (Item 1) [Figure 20-40-

4] and the auxiliary tubelines (Item 2) [Figure 20-40-4]
from the control valve.
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HYDRAULIC CONTROL VALVE (CONT’D) Disassembly And Assembly
Identification Chart (See Identification Chart on Page 20-40-3.) for the control
Item 463 Series valve parts assembly.
A1 Lift Cylinder Base End
A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulics
B1
B2
Lift Cylinder Rod End
Tilt Cylinder Rod End
IMPORTANT
B3 Auxiliary Hydraulics When repairing hydrostatic and hydraulic systems,
C1 Load Check Valve/Lift Function clean the work area before disassembly and keep all
C2 Load Check Valve/Tilt Function parts clean. Always use caps and plugs on hoses,
C3 Load Check Valve/Auxiliary Function tubelines and ports to keep dirt out. Dirt can quickly
D1 Lift Spool Detent damage the system.
D2 Centering Spring Tilt Spool I-2003-0888
D3 Auxiliary Spool Detent
E1 Port Relief/Anti-Cavitation Valve
E2 Port Relief/Anti-Cavitation Valve Mark each valve section and spool so that the parts will
F1 Port Relief be returned to their original bore during assembly.
F2 Port Relief
G1 Lift Spool Use bolts to fasten the control valve to a work bench for
G2 Tilt Spool easier disassembly and assembly.
G3 Auxiliary Spool
MR Main Relief Valve

D1 D3
MR D2
F2 F1
B1 B2 B3
INLET
A1 A2 A3
OUTLET
E1 E2
G3
G1 G2 AUXILIARY
LIFT TILT
PE-1122
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HYDRAULIC CONTROL VALVE (CONT’D) Main Relief Valve
Load Check Valves Figure 20-40-8
Figure 20-40-6
1
P-16967
P-16965
Remove the main relief valve (Item 1) [Figure 20-40-8]
from the control valve.
Loosen the load check plug (Item 1) [Figure 20-40-6].
Assembly: Always use new O-rings and back-up

Assembly: Always use new O-rings. Tighten the plug to washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
35-40 ft.-lbs. (47-54 Nm) torque.
Figure 20-40-9
Figure 20-40-7
2
1
2
P-7359
P-16966
Remove the O-rings (Item 1) [Figure 20-40-9], and back-

Remove the load check plug (Item 1) [Figure 20-40-7], up washers (Item 2) [Figure 20-40-9] from the main relief
spring (Item 2) [Figure 20-40-7], and load check valve valve.
(Item 3) [Figure 20-40-7].
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HYDRAULIC CONTROL VALVE (CONT’D) Port Relief Valves
Port Relief/Anti-Cavitation Valve Figure 20-40-12
Figure 20-40-10
P-16968
P-16973
Loosen and remove the Port Relief valves (Item 1)
[Figure 20-40-12].
Loosen the Anti Cavitation valve (Item 1) [Figure 20-40-
10]. Assembly: Always use new O-rings and back-up

washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Assembly: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque. Figure 20-40-13
Figure 20-40-11
1 2
1 2
P-16969
P-16974
Remove the O-rings (Item 1) [Figure 20-40-13], and
back-up washers (Item 2) [Figure 20-40-13] from the
Remove the O-rings (Item 1) [Figure 20-40-11], and Port Relief valve.
back-up washer (Item 2) [Figure 20-40-11] from the Port
Relief/Anti-Cavitation valve.
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HYDRAULIC CONTROL VALVE (CONT’D) Lift Spool Detent
Rubber Boot Figure 20-40-16
Figure 20-40-14
1 1 2
P-16975
P-16973
The tool listed will be needed to do the following
procedure:
Remove the two screws (Item 1) [Figure 20-40-14] from
the rubber boot retainer. MEL 1278 - Detent Tool

Assembly: Tighten the screws to 90-100 ft.-lbs. (10,2- The lift spool detent (Item 1) [Figure 20-40-16] is located
11,3 Nm) torque. next to the main relief valve (Item 2) [Figure 20-40-16].
Figure 20-40-15 Figure 20-40-17
3
2
1
2
1
3 1
P-16971 P-16976
Remove the rubber boot (Item 1) [Figure 20-40-15] and Remove the two screws (Item 1) [Figure 20-40-17] from
boot retainer (Item 2) [Figure 20-40-15]. the detent cap (Item 2) [Figure 20-40-17].
Remove the O-ring retainer plate (Item 3) [Figure 20-40- Remove the snap ring (Item 3) [Figure 20-40-17] and
15] and O-ring (Item 4) [Figure 20-40-15]. washer (Item 4) [Figure 20-40-17].
Assembly: Use a new O-ring (Item 4) [Figure 20-40-15]

during assembly.
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Lift Spool Detent (Cont’d)
IMPORTANT 2
The detent assembly has small springs and balls. Do 3

not lose these parts during disassembly and 1
assembly.
I-2012-0284
Figure 20-40-18
2
P-16978
Remove the detent sleeve (Item 1) [Figure 20-40-19],

two detent balls (Item 2) [Figure 20-40-19], and detent
spring (Item 3) [Figure 20-40-19].
Remove the rubber boot assembly from the control valve

(linkage side). (See Rubber Boot on Page 20-40-6 for

correct procedure.)
2
Figure 20-40-20
1
P-16977
Remove the dent cap (Item 1) [Figure 20-40-18].
Wrap a clean rag around the detent sleeve (Item 2)

[Figure 20-40-18] to prevent losing the two detent balls. 3
NOTE: The detent sleeve for the lift spool (Item 2) 2

[Figure 20-40-18] is longer than the detent 1
sleeve located in the auxiliary spool. DO NOT
switch the sleeves from one spool to the
other. P-16979
Remove the spool assembly (Item 1) [Figure 20-40-20],

back-up washer (Item 2) [Figure 20-40-20], and spool
seal (Item 3) [Figure 20-40-20] from the control valve.
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Figure 20-40-21
3
2
P-7278
Lift Spool Only: Remove the stud from the end of the
1
P-7306 spool [Figure 20-40-23].
Removal of plastic plug.

Put the linkage end of the spool assembly (Item 1)
[Figure 20-40-21] in a vise. • Make a center point in the plug using a 3/16 inch drill.

Install MEL 1285 Spring Compressor Tool (Item 2)
• Drill a hole all the way through the plug using a 7/64
[Figure 20-40-21] on the spring assembly.
inch tap drill.
Use an allen wrench to remove the detent adapter (Item
3) [Figure 20-40-21]. • Turn a 6-62 tap into the plug. Pull the tap and plug out
of the spool. BE CAREFUL, do not break the tap.
Put a rag around the detent assembly to prevent losing
the two detent balls when the detent adapter is removed. • Clean all the debris from the inside of the spool bore.
Figure 20-40-22 Figure 20-40-24
1
1
6 2
3 5
4
P-7280 N-18920 P-7443
Remove the detent adapter (Item 1) [Figure 20-40-22] Assembly: Install the new plastic plug (Item 1) [Figure
from the adapter retainer (Item 2) [Figure 20-40-22]. 20-40-24] and O-ring (Item 2) [Figure 20-40-24].
Remove the detent spring (Item 3) [Figure 20-40-22] and

detent balls (Item 4) [Figure 20-40-22].
Remove the centering spring (Item 5) [Figure 20-40-22]

and end cap (Item 6) [Figure 20-40-22] from the spool.
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Figure 20-40-25
1
P-7282
0.600”
(15,2 mm)
Apply grease on all the detent surfaces before assembly.
B-9973
Install the detent balls and spring into the detent adapter
(Item 1) [Figure 20-40-26]. Hold the detent balls in
position with the tool and install the detent adapter into
Install the stud and leave 0.600 inch (15,2 mm) past the the end cap (Item 2) [Figure 20-40-26].
end of the spool [Figure 20-40-25].
NOTE: The detent cap (Item 2) [Figure 20-40-26]

shown, is used for support during assembly.
NOTE: DO NOT US LOCTITE ON THE STUD
THREADS. DO NOT EXCEED 70 in.-lbs. (8 Install the spool seal and back-up washer on the spool,
(See Spool Seal Installation on Page 20-40-12 for correct
Nm) torque during stud installation. Excess procedure.)
torque may cause spool distortion resulting in
sticky spool operation. Use MEL 1285 Compression Spring Tool and install the
centering spring, and detent adapter/end cap assembly
on the spool.
NOTE: Put grease on all detent component surfaces
before assembly. Figure 20-40-27
N-19005
Install the spring assembly to the lift spool hand tight

(Item 1) [Figure 20-40-27].
Remove the spring tool. Check the alignment of the

detent adapter and the washer.
Tighten the detent adapter (Item 1) [Figure 20-40-27] to

90-100 in.-lbs. (10,2-11,3 Nm) torque.
NOTE: The adapter must fit in the center of the washer

(Item 2) [Figure 20-40-27].
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Figure 20-40-28
1 P-16982
Install the detent sleeve over the balls and into position
P-7274 [Figure 20-40-30].
Figure 20-40-31
Install the spool assembly (Item 1) [Figure 20-40-28] in
the control valve.

Figure 20-40-29
1
P-7355
Install the detent cap (Item 1) [Figure 20-40-31].

P-16981
Install the washer and snap ring [Figure 20-40-31].
Hold the detent balls and spring in position with the tool Install the mounting bolts [Figure 20-40-31]
[Figure 20-40-29].
Tighten the mounting bolts to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
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HYDRAULIC CONTROL VALVE (CONT’D) Auxiliary Spool Detent
Tilt Centering Spring Figure 20-40-33
Figure 20-40-32
2 2
1 1
1
3 4
1 P-7287
P-16983
Remove the two mounting screws (Item 1) [Figure 20-
40-33] from the detent cap (Item 2) [Figure 20-40-33].
Remove the end cap mounting screws (Item 1) [Figure
20-40-32]. Remove the snap ring (Item 3) [Figure 20-40-33] and

washer (Item 4) [Figure 20-40-33].
Assembly: Tighten the mounting screws to 90-100 in.-
lbs. (10,2-11,3 Nm) torque. Remove the detent cap (Item 2) [Figure 20-40-33].
Remove the spool end cap (Item 2) [Figure 20-40-32]. See Lift Spool Detent on Page 20-40-6 for correct
procedure.) for the correct removal and disassembly
Remove the spool and centering spring assembly from procedures. These procedures are the same for the
the control valve [Figure 20-40-32]. Auxiliary Spool Detent.
Assembly: If the centering spring bolt is removed, NOTE: The detent sleeve for the auxiliary spool (Item
tighten it to 90-100 in.-lbs. (10,2-11,3 Nm) torque. 5) [Figure 20-40-33] is shorter than the detent
sleeve on the lift spool. DO NOT switch the
Put grease on all the center spring component parts. sleeves from one spool to the other.
Always use a new spool seal.
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Spool Seal Installation
To install new spool seals when the centering spring (tilt

spool) or other detent assembly (lift spool) are not
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 20-40-34
P-16980
Slide the linkage end spool seal (Item 1) [Figure 20-40-

35] over the rubber boot groove.
Be careful not to damage to spool seal.
Figure 20-40-36

1 2
3
4
CD-15080
1
Put plastic material on the valve spool [Figure 20-40-34].
Put clean oil on the spool seal. Install the spool seal
(Item 1) [Figure 20-40-34] on the spool being careful not
to damage the seal on the sharp edges.
Remove the plastic material. P-16971
Install the spool into the control valve.

Install the O-ring (Item 1) [Figure 20-40-36] and O-ring
retainer plate (Item 2) [Figure 20-40-36].
Install the rubber boot retainer (Item 3) [Figure 20-40-36]

and rubber boot (Item 4) [Figure 20-40-36].
Install the two mounting screws and tighten to 90-100 in.-

lbs. (10,2-11,4 Nm) torque.
Continue assembling the control valve.
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BICS™ BLOCK VALVE Figure 20-50-1
Description
Put jackstands under the rear corners of the loader.
P-19032
WARNING Remove the return hose (Item 1) [Figure 20-50-1].
Never work on a machine with the lift arms up unless Figure 20-50-2

W-2059-0598
1 2
WARNING
Before the cab or the lift arms are raised for service, 3
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. P-19033
W-2014-0895
Raise the lift arms and install the lift arm support device. Disconnect the electric solenoid (Item 1) [Figure 20-50-
(See Engaging The Lift Arm Support Device on Page 10- 2] from the loader harness.
20-1.)
Remove the bolts (Items 2 & 3) [Figure 20-50-2] from the
Raise the operator cab. (See Raising The Operator Cab mounting bracket.
on Page 10-30-1.)
Remove the block.
Remove the control shield and steering lever panels.
(See Control Shield And Steering Lever Panels Removal
Install caps and plugs on hoses, tubelines and fittings.

IMPORTANT
Remove the tubeline and hose from the BICS™ block
valve.
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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BICS™ BLOCK VALVE (CONT’D) Figure 20-50-5
Disassembly And Assembly
Figure 20-50-3 1
3 2
3 2
3
1 3
P-7456
Replace the O-ring (Item 1) [Figure 20-50-5], if

P-7451 damaged.
Replace the O-rings (Item 2) [Figure 20-50-5] and back-

Remove the nut (Item 1) [Figure 20-50-3], the solenoid up washer (Item 3) [Figure 20-50-5].
(Item 2) [Figure 20-50-3] and the O-rings (Item 3)

[Figure 20-50-3] from the electric solenoid spool. Figure 20-50-6
Figure 20-50-4
P-7454
P-7453
Remove the by-pass valve (Item 1) [Figure 20-50-6] from
the block.
Remove the spool [Figure 20-50-4].
Replace the by-pass valve if damaged.
Replace the spool if damaged.
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2
Figure 20-50-7 2 2
2
2
2
2
1 1
1 1
P-7458
1 1
1 Remove the O-rings (Item 1) [Figure 20-50-9] and back-
P-7457 up washers (Item 2) [Figure 20-50-9] if damaged.
Remove the O-rings (Item 1) [Figure 20-50-7] and back-

up washers (Item 2) [Figure 20-50-7] if damaged.

Figure 20-50-8
P-7455
Remove the check valves (Item 1) [Figure 20-50-8] from

the block.
Replace check valves if damaged.
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1
Figure 20-50-10
2
N-18049
3 Remove the O-ring (Item 1) [Figure 20-50-12] and back-

1 N-18047 up washer (Item 2) [Figure 20-50-12]from the check
valve if damaged.
Figure 20-50-11

3
2
1
N-18048
Remove the plugs (Item 1) [Figure 20-50-10] & [Figure

20-50-11] from the block.
Remove the O-ring (Item 2) [Figure 20-50-10] & [Figure

20-50-11] from the plugs if damaged.
Remove the check valves (Item 3) [Figure 20-50-10] &

[Figure 20-50-11] from the block.
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HYDRAULIC PUMP Figure 20-60-1
Checking The Output Of The Pump

procedure:
MEL1429 - Remote Start Switch 3

MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
NOTE: The relief pressure must be per specification

before the output test is performed. 1
2
P-7517
WARNING
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
Put jackstands under the front axles and rear corners from the hydraulic pump. Connect the OUTLET hose
of the frame before running the engine for service. from the tester to the hose (Item 1) [Figure 20-60-1].
fall or move and cause injury or death. Connect the INLET hose (Item 2) [Figure 20-60-1] from
W-2017-0286 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.
IMPORTANT Figure 20-60-2
Example: Tester
The hydraulic tester must be in the fully open Connection
position before you start the engine. Reservoir
I-2024-0284

(See Engaging The Lift Arm Support Device on Page 10- Hydraulic Pump
20-1.)
Hydraulic Control
Valve
on Page 10-30-1.)
3
Connect the remote start switch. (See Procedure on B-16917
Page 10-60-1.)
A sample tester connection is shown in picture [Figure
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 hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the hydraulic fluid to 140° F (60° C) by turning the

restrictor control (Item 1) [Figure 20-60-1] & [Figure 20-
60-2] on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
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HYDRAULIC PUMP (CONT’D) NOTE: The engine and hydrostatic pump assembly
Checking The Output Of The Pump (Cont’d) must be moved to the right to remove the
hydraulic pump.
Remove the auxiliary hydraulics lock bolt and push the
right steering lever all the way to the right (detent) Remove the hydraulic reservoir. (See Removal And
[Figure 20-60-2] to engage the auxiliary hydraulics Installation on Page 20-80-1.)
(attachment must be disconnected from the front
auxiliary couplers). The fluid pressure will go over main Figure 20-60-3
relief. If the pressure is not to specifications, first adjust
the main relief valve. (See Main Relief Valve Adjustment
on Page 20-30-3.) 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
pressure, RPM, and Hydraulic pump capacity (GPM). 1
2
P-19023

IMPORTANT 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].
clean the work area before disassembly and keep all Figure 20-60-4
damage the system.
I-2003-0888
1
WARNING
support device can allow the lift arms or attachment P-19024
W-2059-0598
Loosen the clamp (Item 1) [Figure 20-60-4] to remove
the suction hose from the hydraulic oil reservoir fill tube.
(See Engaging The Lift Arm Support Device on Page 10- NOTE: Removing the battery will make gear pump
20-1.) removal and installation easier. (See Removal
Stop the engine and raise the seat bar. And Installation on Page 60-20-1.)

on Page 10-30-1.)
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HYDRAULIC PUMP (CONT’D) Figure 20-60-7
Figure 20-60-5
2 1
P-19029
1
Remove the bolt (Item 1) [Figure 20-60-7] and washer
P-19025 from the hydrostatic pump pulley.
Figure 20-60-8
Remove the bolts (Item 1) [Figure 20-60-5] from the
steering lever linkage. Remove the linkage from the

hydrostatic pumps.
Disconnect the hair pin fastener (Item 2) [Figure 20-60-

5] from the speed control linkage.
Remove the two bolts (Item 3) [Figure 20-60-5] from the

fan housing stabilizer.
Figure 20-60-6
1
P-19028
Remove the nut (Item 1) [Figure 20-60-8] from the right

side hydrostatic pump mounting bolt.
Remove the rubber mount and install the bolt, Tighten

the bolt to pull the hydrostatic pump assembly to the right
1 to allow clearance for hydraulic pump removal.
P-19123
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
2
1
P-19030
Remove the outlet hose (Item 1) [Figure 20-60-9] from

the top of the hydraulic pump and the inlet hose from the

bottom of the pump.
Remove the two hydraulic pump mounting bolts (Item 2)

[Figure 20-60-9] (top and bottom).
Remove the hydraulic pump and the coupler.
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HYDRAULIC PUMP (CONT’D)
1
7
4
5 6 13

8
9 11 10
12
B-13927A
MODEL: 463
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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Disassembly And Assembly

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.-lbs. (33-38 Nm)

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.

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 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 1

of the frame before running the engine for service.
W-2017-0286
P-19128
WARNING Remove the drain hose (Item 1) [Figure 20-70-2] from

the front hydrostatic pump housing.
Figure 20-70-3

W-2059-0598 2
Put jackstands under the front and rear of the loader.

10-10-1.) 1

on Page 10-30-1.)
Raise the lift arms and install lift arm support device.
20-1.) P-19130
Figure 20-70-1
Disconnect the electrical connectors from the charge
pressure switch (Item 1) [Figure 20-70-3] and the
temperature sender (Item 2) [Figure 20-70-3].
2
1
P-19415
Remove the tubelines (Item 1) [Figure 20-70-1] and

hoses (Item 2) [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
3
2
1
1
P-19887
Remove the fitting (Item 1) [Figure 20-70-6], the by-pass

P-19412 spring (Item 2) [Figure 20-70-6] and the poppet (Item 3)
[Figure 20-70-6].
Remove the two mounting bolts (Item 1) [Figure 20-70-4] Clean and inspect the parts. Replace as needed.
from the outside of the fender.

Install a new O-ring on the plug.
Remove the hydraulic filter block.
Figure 20-70-7
Block Disassembly And Assembly
Figure 20-70-5
2
1
P-19888
P-19886 Remove the temperature sender (Item 1) [Figure 20-70-

7] from the filter block.
Remove the plug (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 FILTER (CONT’D)
Block Disassembly And Assembly (Cont’d)
Figure 20-70-8
P-19889
Remove the charge pressure switch (Item 1) [Figure 20-

70-8] from the filter block fitting.
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HYDRAULIC RESERVOIR Figure 20-80-2
Install jackstands under the rear corner of the loader.

10-10-1.)
Remove the hydraulic fluid from the reservoir. (See 2

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

on Page 10-30-1.) 1
Remove the center shield and steering lever panels. P-19039

Remove the return hose (Item 1)[Figure 20-80-2] from
Remove the steering levers. (See Lever Removal And the reservoir.
Remove the nut (Item 2) [Figure 20-80-2] and bolt from
Figure 20-80-1 the 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 reservoir.
P-19038
Remove the filter return hose (Item 1) [Figure 20-80-1]

from the fitting located on the right side of the 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
Remove the nut (Item 1) [Figure 20-90-2] from the

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.-lbs. (9- Figure 20-90-3
10 Nm) 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 (Item 1) [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 the
Remove the bottom nut, washers and bolt from the fender.
interlock and pedal [Figure 20-90-2].
Figure 20-90-4
P-7202

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
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

ELECTRICAL
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-60-5 SYSTEM &
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 ANALYSIS
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1 ENGINE

Replentishing The Valve Function . . . . . . . . . . . . . . . . . . . 30-10-2 SERVICE
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Lever Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 30-30-3 SPECIFICATIONS
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, 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 replentishing 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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HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Replentishing The Valve Function

IMPORTANT
Figure 30-10-1
damage the system.
I-2003-0888
The functions of the replentishing valves are:
1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
Function 1 Valve Moves For flow to the oil cooler for cooling; Function 1 [Figure
Charge Oil
30-10-1].
Replacement
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2
B-2804
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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-19209
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
to fall and cause injury or death. 1
W-2059-0598
Open the rear door.

1
20-1.)

on Page 10-30-1.) P-7216

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

1
WARNING
1
W-2017-0286
2
2
P-19033
WARNING Remove the bolts (Item 1) [Figure 30-30-2] and the

support bracket from the BICS™ block valve.
parking brake solenoid.

W-2059-0598
20-1.)

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

Figure 30-30-1
1
1
P-19032
Remove the nuts and bolts (Item 1) [Figure 30-30-1]

from the steering linkage.
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STEERING (CONT’D) Figure 30-30-5
Lever Removal And Installation (Cont’d)
Figure 30-30-3 1
P-19036
Remove the nuts (Item 1) [Figure 30-30-5] from the pivot

P-19034 bearings (both sides). Hold the bolts from outside the
fender.
Remove the parking brake solenoid. Remove the steering lever assembly from the loader.

Disconnect the electrical connector from the by-pass
solenoid (Item 1) [Figure 30-30-3].
Figure 30-30-4
P-19035

auxiliary hydraulics cable bolt (if equipped). Remove the
cable.
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STEERING (CONT’D) Linkage Adjustment
Lever Disassembly And Assembly
Figure 30-30-6
WARNING
2 2 Put jackstands under the front axles and rear corners
3 of the frame before running the engine for service.
3 Failure to use jackstands can allow the machine to
W-2017-0286
1 1


5 on Page 10-30-1.)
4
P-19037 Install the Remote Start Switch. (See Procedure on Page
10-60-1.) Start the engine and run at a slow RPM.
Remove the bearings (Item 1) [Figure 30-30-6] from the Figure 30-30-7
shaft.

Remove the steering levers (Item 2) [Figure 30-30-6]
from the shaft.
Check the plastic bushings (Item 3) [Figure 30-30-6] and

the washers (Item 4) [Figure 30-30-6] for damage or 2
wear and replace as necessary.
Remove the spacer (Item 5) [Figure 30-30-6] from the 1

shaft.
Assembly: Lightly lubricate the steering shaft during

assembly.
P-19168
Hold the nuts (Item 1) [Figure 30-30-7] and turn the bolts
so the centering springs just touch the pin (Item 2)
[Figure 30-30-7] and the adjustment bolt heads.
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.
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,
repeat the adjustment.
Repeat steps for the other side.
Lower the operator cab. (See Lowering The Operator
Remove the jackstands from the loader frame.
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Pintle Arm Removal And Installation
2
WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-7475
Put jackstands under the rear of the frame. (See LIFTING
AND BLOCKING THE LOADER on Page 10-10-1.)
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 30-30-9]. Remove the spring.
20-1.) Loosen the pintle arm clamping bolt (Item 2) [Figure 30-
30-9].

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 30-30-8 off, it will cause damage to the seal retainer.
2 2
1 P-7476
Remove the adjustment nuts and bolts (Item 1) [Figure

30-30-8] from the centering spring.
Remove the spring retainer brackets (Item 2) [Figure 30-

30-8].
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Pintle Arm Disassembly And Assembly
Figure 30-30-10
P-7481
Put the pintle arm in a vise and use a hammer to drive

P-7479 the bushing (Item 1) [Figure 30-30-11] 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 30-30-10] 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

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) Installation: Lift the drive sprocket to align it with the
motor splines. Be sure the O-ring is installed on the
Removal And Installation (Cont’d) motor flange during installation. Tighten the bolts to 90-
100 ft.-lbs. (123-135 Nm) torque.
NOTE: Mark the hoses for installation purposes.
Remove the motor from the chaincase.
Remove the parking brake cover from the chaincase.
(See Chaincase Cover Assembly And Disassembly on Figure 30-40-2
Page 40-30-2.)
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
P-7493

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.-lbs. (50 Nm)

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- Check the geroler for wear or scratches [Figure 30-40-
18]. 19].

Remove the shaft seal from inside the housing [Figure Figure 30-40-20
30-40-18].
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
NOTE: Always use a NEW seal kit when assembling

the hydrostatic motor. B-6386
Figure 30-40-25
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
B-6385
1 2 1. Shaft
2. Shaft Seal Use a press to install the bearing and shaft assembly in
3. Wear Plate the housing [Figure 30-40-28],
4. Seal
3 5. Shaft & Bearing Lubricate and install the 3 inch diameter O-ring on the
6. Shaft Seal bearing housing.
5 7. Bearing Housing
4 8. Dust Seal NOTE: You can use alignment studs for easier
7
9. Back-Up Washer assembly of the motor.
9
8
6 B-9931
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)
IMPORTANT
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 30-40-34 B-6401
Balance Install the pins and springs in the valve housing [Figure
Outer Ring Outer 30-40-36].
Seal Seal
Lubricate the 3-inch diameter O-ring and install on the
valve housing.

Align the pin grooves in the balance ring with the pins in
the valve housing. Install the balance ring assembly in
Inner the housing.
Seal
Figure 30-40-37
B-9930
Lubricate the inner and outer seals and install the seals
on the balance ring [Figure 30-40-34].
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
The tools listed are needed to complete the following P-19232

procedure:
MEL1173 - Test Kit Connect the pressure gauge into the sender port of the
filter port block (Item 1) [Figure 30-50-2].
THE LOADER on Page 10-10-1.) Start the engine and run at full RPM. The pressure must
be 75-85 PSI (241-586 kPa) minimum with no hydraulic
Raise the operator cab. (See Raising The Operator Cab action.

on Page 10-30-1.)
Stop the engine.
Figure 30-50-1
Figure 30-50-3
3 2
3
1
P-19129
P-19886
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 plug (Item 3) [Figure
block. 30-50-3] & [Figure 30-50-1].
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
29
25
27 24 25
28
27
23 24
26
26
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 31 16 15 7
8
14
13 14 4
11 1213
11
9 5 5 9 4 6
10 12 6 4 10 5 4
30 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 Check Valve
11 Seal 26 Relief Valve
12 Crush Ring 27 Coupler
13 Race, Bearing 28 O-Ring
14 O-Ring 29 Bolt
15 Housing 30 Spacer
31 Shaft
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HYDROSTATIC PUMP (CONT’D) Figure 30-60-1
1
2
WARNING P-19023
Never work on a machine with the lift arms up unless Loosen the left engine mounting bolt (Item 1) [Figure 30-
the lift arms are secured by an approved lift arm 60-1], and remove the right engine mounting bolt (Item 2)
support device. Failure to use an approved lift arm [Figure 30-60-1].
to fall and cause injury or death. Drain the hydraulic reservoir.
W-2059-0598

Figure 30-60-2
Put jackstand under the frame. (See LIFTING AND
20-1.)
Raise the operator cab. (See Raising The Operator Cab 1

on Page 10-30-1.)
NOTE: The engine and hydrostatic pump assembly

must be moved to the right to remove the
hydrostatic pumps.
Use the following procedure to remove the hydrostatic P-19024

pumps:
Loosen the clamp (Item 1) [Figure 30-60-2] to remove
the suction hose from the hydraulic oil reservoir fill tube.
Remove the steering levers. (See Lever Removal And

Remove the battery. (See Removal And Installation on

Page 60-20-1.)
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Figure 30-60-3
3
2
4
1
P-19123
1
Remove the nut (Item 1) [Figure 30-60-4] from the left
P-19025 side hydrostatic pump mounting bolt. Remove the
mounting bolt.
Remove the nuts (Item 1) [Figure 30-60-3] from the Figure 30-60-5
steering lever linkages. Remove the linkages from the

hydrostatic pumps.
Disconnect the clip (Item 2) [Figure 30-60-3] from the

speed control linkage. Remove the linkage. 1

alternator belt shield.
2
Remove the outlet hose (Item 4) [Figure 30-60-3] from
the hydraulic gear pump.
Remove the hydraulic reservoir. (See Removal And

P-19029
Remove the control valve. (See Removal And Installation
on Page 20-40-1.)
Remove the drive belt (Item 1) [Figure 30-60-5]. (See
Remove the high pressure hoses from the drive motors. Removal And Installation on Page 30-70-1.)
(See Removal And Installation on Page 30-40-1.)
Remove the bolt (Item 2) [Figure 30-60-5] and washer
from the hydrostatic pump pulley.
Remove the pulley.
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Figure 30-60-6
P-19128
Remove the drain hose (Item 1) [Figure 30-60-8] from

P-19028 the front of the hydrostatic pump housing.
Figure 30-60-9
Remove the nut (Item 1) [Figure 30-60-6] and bolt from
the right side hydrostatic pump mounting bolt.

Remove the rubber mount and install the bolt. Tighten
the bolt to pull the hydrostatic pump assembly to the right
to allow clearance for hydrostatic pump removal. 1
Figure 30-60-7
P-19126
Remove the charge pressure hose (Item 1) [Figure 30-

60-9] from the fitting on the rear hydrostatic pump.
1
P-19127

hydrostatic pump mounting bracket.
Installation: Tighten the bolts to 27-31 ft.-lbs. (37-42

Nm) torque.
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HYDROSTATIC PUMP (CONT’D) Disassembly And Assembly
Figure 30-60-10
IMPORTANT
damage the system.
I-2003-0888
1
Figure 30-60-11
1
P-1925
Remove the bolts (Item 1) [Figure 30-60-10] from the left

mounting bracket.

The bottom bolt can be reached from the engine area.
Remove the hydrostatic pump assembly. 1
P-19776
Remove the two mounting bolts (Item 1) [Figure 30-60-

11] to remove the hydraulic gear pump and coupler.
Installation: Tighten the mounting bolts to 25-28 ft.-lbs.

(34-38 Nm) torque.
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Figure 30-60-12
2
1
1
2
P-19784
Remove the replenishing check valves (Item 1 & 2)

P-19777 [Figure 30-60-14] located on the bottom side of the
hydrostatic pumps.
Remove the high pressure relief valves (Item 1 & 2) NOTE: Mark the locations for correct installation.
[Figure 30-60-12] located on the top side of the

hydrostatic pumps. Figure 30-60-15
NOTE: Mark the locations for correct installation.
NOTE: Always use new O-rings, gaskets, and seals

during assembly.
Figure 30-60-13
P-19785
Check the condition of the replenishing check valves

2 (Item 1 & 2) [Figure 30-60-15].
1
Remove the charge tubeline from the pumps.
P-19781
Check the condition of the high pressure relief valves

(Item 1 & 2) [Figure 30-60-13].
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Figure 30-60-16
1
1
1
P-19788

1
P-19778 rear pump end cover.

Remove the bolts (Item 1) [Figure 30-60-16] connecting Nm) torque.
the hydrostatic pumps.

Figure 30-60-19
Nm) 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. 2
Separate the pumps. 1
Figure 30-60-17
P-19789
2
Remove the end cover from the rear pump [Figure 30-
60-19].
1
Remove and discard the gasket (Item 1) [Figure 30-60-
19]. Remove the valve plate (Item 2) [Figure 30-60-19].
P-19779
Remove the coupler (Item 1) [Figure 30-60-17], remove

and discard the O-ring (Item 2) [Figure 30-60-17].
NOTE: The internal parts for the pumps are basically

the same. Any differences will be clarified
during the procedure.
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Figure 30-60-20
P-19791
1
Remove the rotating group carefully from the housing so

P-19790 as to retain the piston in the piston block [Figure 30-60-
22].
The valve plate metering slots (Item 1) [Figure 30-60-20] Figure 30-60-23
identify the direction of the rotation group.

Check that the surface (Item 2) [Figure 30-60-20] is
smooth and free of grooves. If grooves can be felt with a
fingernail, replace the valve plate. 2
Figure 30-60-21
Dowel
Numbered
End
1
3
.075” .110”
(2,79 mm) P-19801
(1,91 mm) ‘
Before removing the piston assembly (Item 1) [Figure

30-60-23] mark one piston in the piston block.
Remove the piston assembly, remove the piston (Item 2)

B-15893 [Figure 30-60-23], and install it in the piston block in the
marked location.
If the needle bearing is replaced in the end plate, the This procedure assures pistons will be relocated in their
numbered end of the bearing must face the valve plate original locations.
side of the end plate, [Figure 30-60-21].
Check the piston assemblies, the spiders, the spider pivot
Install the bearing to the dimensions shown [Figure 30- (Item 3) [Figure 30-60-23], and the piston block for
60-21]. excess wear.
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Figure 30-60-24
1
Shoe Piston
Shoe Must Swivel P-19802

Smoothly On Ball
Before assembling the rotation group position the

A-01850 retaining ring (Item 1) [Figure 30-60-26] to hold the pins.
Figure 30-60-27
Check that the shoe swivels freely in each piston
assembly [Figure 30-60-24].

Figure 30-60-25 Drain
Hole
1
1
P-19816
Remove the retaining ring (Item 1) [Figure 30-60-27]

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

Check the face (Item 1) [Figure 30-60-25] of the piston pump.
block for excessive wear or scratches.
NOTE: DO NOT lap the face of the piston block.
NOTE: The piston block usually requires no further

disassembly unless the pins or the block
spring are damaged.
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HYDROSTATIC PUMP (CONT’D) If needed use screwdrivers in the notches to pry the
cover loose.
Remove and discard the O-ring.
Figure 30-60-28
Figure 30-60-30
2 1
3
4 2
1
P-19804
P-19809
The rear pump drive shaft will have a spacer (Item 2)

[Figure 30-60-28] under the snap ring (Item 1) [Figure The bearing cup (Item 1) [Figure 30-60-30] may come

30-60-28]. off with the cover plate.
Remove the bearing snap ring (Item 3) [Figure 30-60-28] The crush ring (Item 2) [Figure 30-60-30] needs removal
and remove the bearing and thrust washers (Item 4) only when the cover, the swash plate assembly, or the
[Figure 30-60-28]. housing assembly is replaced.
Check the bearing, thrust washers, and drive shaft for A shim kit is then required to replace the crush ring. See
wear. your Parts book for the kit number.
Figure 30-60-29 Figure 30-60-31
1 1
1
P-19805 P-19808
To remove the swash plate from the housing, remove the Use a small press (Item 1) [Figure 30-60-31] to remove
screws (Item 1) [Figure 30-60-29] from the control shaft the seal from the cover plate.
cover plate.
Installation: Tighten the bolts to 29 ft.-lbs. (39.9 Nm)

torque.
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2
Figure 30-60-32
1 1
P-19811
Remove the cover plate [Figure 30-60-34].

P-19807
The bearing cup (Item 1) [Figure 30-60-34] in the cover
plate is a press fit and not removable.
Use a small press (Item 1) [Figure 30-60-32] 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 34].
shaft.
NOTE: The swash plate control shaft will fit out either
Figure 30-60-33 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 30-60-35
1
1
P-19810
1
Remove the bolts (Item 1) [Figure 30-60-33] to remove
the cover plate from the opposite side of the housing.
P-19812
Installation: Tighten the bolts to 29 ft.-lbs. (39.3 Nm)

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 30-60-35] toward

the control shaft side and lift it from the pump housing.
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HYDROSTATIC PUMP (CONT’D) NOTE: the swash plate must have no or very little side
clearance and must be able to be pivoted with
Disassembly And Assembly (Cont’d) the force of 45 in.-lbs. (5,1 Nm) or less.
Figure 30-60-36 Figure 30-60-38
2
2 1
1
P-19813 P-19814
Remove the thrust plate (Item 1) [Figure 30-60-36] from Remove the bolts (Item 1) [Figure 30-60-38] from the
the swash plate. front pump end cover.

The thrust plate is reversible and either side may face the Installation: Tighten the bolts to 17-21 ft.-lbs. (23-28
swash plate. Nm) torque.
Check the thrust plate for wear. It must be replaced if the Remove the internal parts and check for wear as done for
rotating group is replaced. the rear pump.
Remove and replace the bearings (Item 2 [Figure 30-60- Figure 30-60-39
36] if needed.
Install the swash plate in the reverse order.
Figure 30-60-37
Numbered End Flange End Of Housing

Of Bearing 1
.07”
(1,78 mm)
P-19815
Remove the retaining ring (Item 1) [Figure 30-60-39]

from the front pump housing.
B-15692A
Use a small press to remove the drive shaft.
If the needle bearing is replaced in the housing, the The seal is located only in the front pump housing and
numbered end of the bearing must face away from the will come out with the shaft removal.
housing and be pressed to the dimension shown [Figure
30-60-37].
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Figure 30-60-40 2 1
2
1
P-19818
Remove the retaining ring (Item 1) [Figure 30-60-41], the

P-19817 bearing and thrust washers (Item 2) [Figure 30-60-41].
Check the bearing, thrust washers, and drive shaft for

Remove the seal (Item 1) [Figure 30-60-40] and washer wear.
(Item 2) [Figure 30-60-40] 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.
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DRIVE BELT Tension Pulley And Spring Removal And Installation
Removal And Installation NOTE: Remove the engine and pump assembly from
the loader. (See Removal And Installation on
Figure 30-70-1 Page 70-80-1.)
Figure 30-70-2
P-19124
P-9794
Put jackstands under the rear of the loader. (See
LIFTING AND BLOCKING THE LOADER on Page 10-

10-1.) Use a wrench to lift the tension pulley (Item 1) [Figure
30-70-2]. Remove the drive belt.
on Page 10-30-1.) Figure 30-70-3
Use a pry bar to lift the tension pulley. 1 3
Remove the belt (Item 1) [Figure 30-70-1] from the

pulley. Lower the pulley slowly onto a wooden block.
P-9795
Use the wrench to turn the tension pulley clockwise to

install a wooden block (Item 1) [Figure 30-70-3]
between the flywheel and the tension pulley arm. Rest
the pulley against the wooden block.
Remove the bolt (Item 2) [Figure 30-70-3] and washer.
Install two 5/16 inch x 2.5 inch bolts in the holes (Item 3)
[Figure 30-70-3]. Attach flanged 5/16 inch nuts to the
volts on the backside of the pulley.
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DRIVE BELT (CONT’D) Figure 30-70-6
Tension Pulley And Spring Removal And Installation

(Cont’d)
Figure 30-70-4
1 2
1
P-7389
Pull the shaft (Item 1) [Figure 30-70-6] from the spring

and mounting brackets.
P-9799
Installation: Align the spring with the slot in the shaft
(Item 2) [Figure 30-70-6].
Install a small wheel puller (Item 1) [Figure 30-70-4] and

remove pulley from shaft. Figure 30-70-7
Figure 30-70-5
P-7390
P-7391
Remove the spring and tube from the mounting bracket
[Figure 30-70-7].
Hold the tension pulley arm tightly and remove the wood
block. Rotate the arm (Item 1) [Figure 30-70-5] Installation: Install the spring hook in the mounting
counterclockwise to release the spring tension. bracket.
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DRIVE BELT (CONT’D)
Tension Pulley And Spring Removal And Installation

(Cont’d)
Figure 30-70-8
P-7393
Remove the bearing mounting bolts (Item 1) [Figure 30-

70-8].
Check the parts for damage and replace as needed.
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DRIVE SYSTEM
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Chaincase Cover Assembly And Disassembly . . . . . . . . . 40-30-2
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 . . . . . . . . . . . . . . . . . . . . . . 40-10-3 SYSTEM
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . . 40-10-2
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-1

ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
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PARKING BRAKE Figure 40-10-2
WARNING
1
W-2059-0598
Pedal Removal And Installation

P-19210
Raise the loader lift arms and install the lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) Disconnect the electrical connector (Item 1) [Figure 40-
10-2].
Put jackstands under the rear of the loader. (See
LIFTING AND BLOCKING THE LOADER on Page 10- Remove the parking brake assembly from the loader.
10-1.)
Reverse the removal procedure to install the parking

Raise the operator cab. (See Raising The Operator Cab brake assembly in the loader.
on Page 10-30-1.)
Remove the control shield. (See Control Shield And

Steering Lever Panels Removal And Installation on Page
30-20-1.)
Figure 40-10-1
2
1
P-7209

parking brake mounting bracket.
Installation: Tighten the mounting bolts to 25-28 ft.-lbs.

(34-38 Nm) torque.
Remove the bolt (Item 2) [Figure 40-10-1] from the

wiring tube clamp.
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PARKING BRAKE (CONT’D) Figure 40-10-4
Pedal Disassembly And Assembly
Figure 40-10-3
1
P-4156
1
3
2 Photo [Figure 40-10-4] shows the parking brake
P-4189 disassembled to identify the existing parts of the brake
assembly.
Loosen and remove the mounting bolt (Item 1) [Figure

40-10-3] and nut from the spring mounting bracket (Item

2) [Figure 40-10-3].
Remove the brake pedal spring (Item 3) [Figure 40-10-3]

from the spring mounting bracket (Item 2) [Figure 40-10-
3]. and from the brake pedal mounting bracket (Item 4)
[Figure 40-10-3].
Remove the two mounting bolts, washers, and nuts (Item

5) [Figure 40-10-3] from the brake pedal sensor.
Remove the harness mounting clamp (Item 1) [Figure

40-10-4] from the pedal mounting bracket (Item 4)
[Figure 40-10-3].
Remove the sensor harness form the pedal mounting

bracket.
Remove the pedal mounting bolt (Item 6) [Figure 40-10-

3], plastic spacers, and bushing nut from the brake pedal.
Remove the pedal from the pedal mounting bracket.
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PARKING BRAKE (CONT’D) Figure 40-10-6
Disc Removal And Installation 1
Figure 40-10-5
P-7226
Remove the brake disc (Item 1) [Figure 40-10-6].

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 40-10-5] 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 hub
NOTE: If the axle and bearings are being replaced, 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.-lbs. (240-255 Nm) torque.

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

ft.-lbs. (54-61 Nm) 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.
Remove the axle seal. If installed correctly, the axle seal will be slightly recessed
in the axle tube after installation.
Installation: Use MEL 1525 - seal driver to install the Reverse the removal procedure to install the axle hub
seal in the axle housing. and wheel on the loader.
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DRIVE COMPONENTS (CONT’D) Figure 40-20-6
Removing The Axle
The tools listed are needed for the following procedure:
MEL 1202A - Axle Bearing Service Tool

Slide Hammer
NOTE: The procedure is the same for the front and 1

rear axle. The front axle procedure will be
shown.
WARNING P-7522
Never work on a machine with the lift arms up unless NOTE: A box end wrench should be used to loosen
the lift arms are secured by an approved lift arm the bolt (Item 1) [Figure 40-20-6]. The wrench
support device. Failure to use an approved lift arm must be ground to fit between the two axle
support device can allow the lift arms or attachment bolts.
W-2059-0598 Remove the axle hub. (See Axle Hub Removal And

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


on Page 10-30-1.)


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.-lbs. (238-257 Nm) 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.-lbs. (238-257 Nm) 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
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
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 Figure 40-30-2
Removing Oil From The Chaincase
Figure 40-30-1
2
P-19033
P-7490 Disconnect the electrical harness (Item 1) [Figure 40-

30-2] for the parking brake.
Remove the plug located in front of the chaincase (Item
1) [Figure 40-30-1]. Remove the mounting bracket bolts (Item 2) [Figure 40-
30-2] from the BICS™ block valve.
Use a transfer pump [Figure 40-30-1] to remove the oil

from the chaincase into a clean container. Remove the traction lock assembly. (See Removal And
Installation: Add oil to the chaincase through the check Installation on Page 60-100-2.)
plug hole. (See Capacities on Page SPEC-10-4.)
Figure 40-30-3
NOTE: Oil can also be removed or added through the
chaincase cover.
Chaincase Cover Removal And Installation
WARNING 1
1

W-2059-0598 P-7223
Raise the loader arms and install the lift arm support Remove the mounting bolts (Item 1) [Figure 40-30-3]
device. (See Engaging The Lift Arm Support Device on from the chaincase cover.
Page 10-20-1.)
Put jackstands under the rear of the loader. (See Remove the chaincase cover.
10-1.)
on Page 10-30-1.)
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CHAINCASE (CONT’D) Figure 40-30-5
Chaincase Cover Assembly And Disassembly 1
Figure 40-30-4
2
1
1
1
P-7228
Remove the four mounting bolts (Item 1) [Figure 40-30-

P-7227 5] from the disc guides.
Figure 40-30-6
Remove the four bolts (Item 1) [Figure 40-30-4] from the
brake disc guide block.

REAR OF LOADER
Assembly: Put liquid adhesive (LOCTITE #242) on the
bolt threads for the disc guide block. Tighten the bolts to
65-70 ft.-lbs. (88-95 Nm) torque.
1
2 3
MC-2327
Assembly: The guide blocks (Item 1) [Figure 40-30-6]

have angled slots (Item 2) [Figure 40-30-6] which must
be parallel to each other when installed in the disc guide
(Item 3) [Figure 40-30-6]. When installed in the
chaincas cover correctly the top of both slots must be
toward the rear of the loader. Put liquid adhesive
(LOCTITE #242) on the bolt threads for the disc guide.
Tighten the bolts to 25-28 ft.-lbs. (34-38 Nm) torque.
Installation: Install a new gasket (Item 2) [Figure 40-30-

5] 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
Exhaust Pipe Removal And Installation . . . . . . . . . . . . . . . 50-70-1
REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 ENGINE

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4 SPECIFICATIONS
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
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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
3 P-9554
Remove the mounting bolt and nut (Item 1) [Figure 50-

10-7] and remove the mounting bracket (Item 2) [Figure
P-9548
50-10-7] (both sides).
Disconnect the wiring harness connector (Item 1) Installation: Tighten the mounting bolt and nut (Item 1)
[Figure 50-10-5] (left side). [Figure 50-10-7] to 180-200 in.-lbs. (21-23 Nm) 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
holding it at the pivot holes with the 3/16 inch
P-9547
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-
10-11] and duct tape (Item 2) [Figure 50-10-11] to
P-9930
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
pivot end of the seat bar between the cab and the grab
P-9931
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
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
bar pivot assembly [Figure 50-10-14].
P-3284
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.-lbs. (21-23 Nm)
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
Figure 50-20-1 1
1
P-19401
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-19329
Put jackstands under the rear corners of the loader. (See

10-1.)

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 P-19402
Disconnect the ground wire (Item 1) [Figure 50-20-3]

from the operator cab.

Remove the nuts (Item 2) [Figure 50-20-3] from the U-
bolts (both sides).
P-19403
Install a lift strap through the fuel fill access hole (Item 1)
[Figure 50-20-4] in the operator cab.
Use a chain connected to the two lift straps (Item 1 & 2)

[Figure 50-20-4] and remove the operator cab.
Reverse the procedure to install the operator cab.
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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

Turn the clip (Item 1) [Figure 50-20-6] to remove it from
the hole in the base end of the cylinder.
Figure 50-20-7
W-2059-0598

10-1.)
Raise the lift arm and install the arm support device. 1
20-1.)

on Page 10-30-1.)
Figure 50-20-5 P-19400
Rotate the cylinder to remove it from the ball (Item 1)

[Figure 50-20-7]
P-19398
Pull the clip (Item 1) [Figure 50-20-5] enough to clear the

base end ball of the cylinder.
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OPERATOR CAB (CONT’D)
Gas Cylinder Removal And Installation (Cont’d)
Figure 50-20-8
P-19330
Hold the nut under the fender and remove the bolt (Item
1) [Figure 50-20-8] 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

10-1.)

on Page 10-30-1.)
Figure 50-30-1
1
P-19247
1
Lower the operator cab and remove the two mounting
bolts (Item 1) [Figure 50-30-2] from the seat mount.
Remove the operator seat.

P-19446
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
Figure 50-40-1
P-19448
1 Remove the pivot pin (Item 1) [Figure 50-40-3] from the

P-19447 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
1 P-19279
2
Remove the grease fitting (Item 1) [Figure 50-40-4] and
slightly loosen the bolt (Item 2) [Figure 50-40-4].
P-19274
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) [Figure 50-40-2] 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.-lbs. Remove the Bob-Tach.
(24-27 Nm) torque.
NOTE: Use the tapered ream MEL1233 to clean the
tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
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BOB-TACH (CONT’D) Figure 50-40-7
Installation
Figure 50-40-5
2
1
2
P-19274
Install the pin retainer (Item 1) [Figure 50-40-7] and the

P-19279 retainer bolt (Item 2) [Figure 50-40-7].
Tighten the bolt (Item 2) [Figure 50-40-7] to 18-20 ft.-lbs.

Push the pivot pin into the Bob-Tach fully and install the (24-27 Nm) 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 175-190 ft.-lbs. (240-255 Nm) torque.
Figure 50-40-6
P-19448
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) [Figure
50-40-10], washer (Item 2) [Figure 50-40-10], spring Figure 50-40-13
(Item 3) [Figure 50-40-10], and lever (Item 4) [Figure 50-
40-10].
Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm) 4

torque.
Figure 50-40-11 3
1
P-19287
If the bolt (Item 1) [Figure 50-40-13], handle pivot (Item

2) [Figure 50-40-13], spring (Item 3) [Figure 50-40-13],
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 Use caps and plugs in the fittings during the procedure.
Figure 50-50-3
Figure 50-50-1
1 1
P-19292
P-19288
Remove the auxiliary tubelines (Item 1) [Figure 50-50-3]

Put jackstands under the front and rear corner of the from the auxiliary coupler bulkhead fittings.
loader. (See LIFTING AND BLOCKING THE LOADER
on Page 10-10-1.) Figure 50-50-4

Remove the Bob-Tach. (See Removal on Page 50-40-1.)
Install a sling (Item 1) [Figure 50-50-1] around the lift
arm crossmember and use a chain hoist to raise the lift
arms. 1
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

2
end pivot pin retainer on the left lift cylinder. Remove the
retainer and the pivot pin.
Lower the cylinder to the fender.
Figure 50-50-2 P-19290
Remove the rod end pivot pin bolt (Item 1) [Figure 50-50-
1 4] from the right lift cylinder. Remove the pivot pin.
Lower the cylinder to the fender.
Remove the bolt (Item 2) [Figure 50-50-4] from the tilt

cylinder tubeline cover.
1 Remove the tubeline clamps from the right lift arm.
P-19293
Remove the auxiliary tubeline clamps (Item 1) [Figure

50-50-2] (if equipped).
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LIFT ARMS (CONT’D) Figure 50-50-7
Figure 50-50-5
P-19321
Use a slide hammer to remove the pivot pin from the

P-19323 upright (both sides) [Figure 50-50-7].
Figure 50-50-8
Wrap the lifting strap around the lift arm as shown
[Figure 50-50-5] (both sides) and attach it to the chain

hoist.
Figure 50-50-6
1
2
P-19291

upright pivot pin retainer (both sides).
Remove the retainer (Item 2) [Figure 50-50-6].
P-19322
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
P-19418
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 the 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 the plastic stick (Item 1) [Figure 50-60-7] to position

P-19420 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
P-19421
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 Removal And Installation
Exhaust Pipe Removal And Installation Figure 50-70-2
Open the rear door.
Figure 50-70-1
1
P-19405

Remove the mounting bolts (Item 1) [Figure 50-70-1] to
remove the exhaust pipe.
2
P-19404
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
Figure 50-80-1
1 1
1
2 P-19207

P-9937 fuel tank mounting strap.
Remove the fuel tank from the loader.


10-1.)

on Page 10-30-1.)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4 MAINTENANCE
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Alternator Regulator Test Using Voltmeter. . . . . . . . . . . . . . . . . . 60-30-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Full Field Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
DRIVE
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 SYSTEM
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . 60-20-4
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

ELECTRICAL
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . 60-80-1 SYSTEM &
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . 60-80-1 ANALYSIS
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 ELECTRICAL

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2 SYSTEM &
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2 SPECIFICATIONS
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-13
Checking The Starter In The Loader . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-12
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
463 Bobcat Loader

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WIRES CONNECT BY
463 WIRING SCHEMATIC RED = RED

BATTERY FEED 1000-1999 RED, RED/WHT, RNG
LETTER ACROSS GROUND 2000-2999 BLK RNG = ORANGE
CONNECTORS BLK = BLACK
A B MONITORING 3000-3999 LBL
LBL = LIGHT BLUE
B A HYDRAULIC 4000-4999 LGN
DBL = DARK BLUE
S/N 520011001 - 520011710 ATTACHMENT CONTROLS 5000-5999 YEL LGN = LIGHT GREEN
LIGHTS 6000-6999 PNK DGN = DARK GREEN
S/N 519911001 - 519911424 SOME CONNECTOR
ACCESSORIES 7000-7999 WHT
YEL = YELLOW
PNK = PINK
(PRINTED JANUARY 2004) BODIES NOT SHOWN
FOR DRAWING CLARITY
ENGINE 8000-8999 TAN
WHT = WHITE
COMMUNICATION 9000-9999 PUR BRN = BROWN
V-0051 TAN = TAN
PUR = PURPLE
GRY = GRAY
TO OPTIONS ENGINE HARNESS - 6714018 BLK HORN

CAB HARNESS - 6707498
C109
STARTER
B RNG/DBL X X RNG/DBL (If Equipped)
A RNG
BUCKET LEVEL SWITCH
BLK WHT WHT M M WHT (If Equipped) GLOW PLUG
86 85
BUCKET POSITION VALVE OFF
WHT/LGN RED
87 30 (If Equipped) 1 2 RUN

STAR
87 BLK RNG V V RNG T
A 3
DIODE
4 5
GLOW PLUG 6
SO
GLOW PLUG SWITCH
BLK LBL/BLK J J LBL/BLK WHT

86 85 1 2 B ST
RED/WHT
HR LBL/RNG RED
87 30 3 RED/WHT
GLOW PLUG
87 5
4 WHT/BLK
A
6 RNG
I
RED/WHT G G RED/WHT IGNITION SWITCH
RNG L L RNG
ENGINE WARNING LIGHT
RNG C C RNG RNG

LGN/WHT
RNG
HYDROSTATIC OIL ENGINE OIL
C201
TEMPERATURE PRESSURE SWITCH YEL/DGN F F YEL/DGN YEL/DGN
C114
SWITCH A YEL/DBL YEL/DBL
C C YEL YEL/DBL A
C110
DIODE CHARGE RNG
PRESSURE B B BLK
YEL/BRN RNG
SWITCH A A YEL/BRN YEL/BRN K K
TRANSMISSION WARNING LIGHT
LGN/WHT
t
LGN
ENGINE COOLANT
SENDER PUR/WHT P P PUR/WHT
3 2 1
C162 COOLANT
3 2 1
ACCESSORY FUSE
BLK - AUXILIARY
TEMPERATURE HOURMETER
POWER
RED RED/WHT B B RED/WHT GAUGE H RNG
+
25A
SOCKET S VOLTMETER
LIGHT FUSE I RNG I
C206
C207
RED RED/WHT E E RED/WHT T G BLK G
25A V
LIGHT BRN LIGHT
RNG
BAT
GRY BLK
ALTERNATOR DBL BLK

GAUGE
FUSE RIGHT FRONT
25A HEADLIGHT
C208 (Domestic) or
C216 (European)
RED
A PNK R R PNK
D BRN/YEL BRN/YEL T T BRN/YEL
C101
BRN/ BRN/
E BRN/DGN U U REAR
DGN DGN
TAIL
RED
C DBL BLK
LAMP
F BLK D D BLK LIGHT SWITCH LEFT FRONT
B BLK BRN H H BRN (IF EQUIPPED) HEADLIGHT
TO OPTIONS RED/WHT 1
TO OPTIONS 2
BLK
C105
A RNG L X BLK
(European)
SWITCHED B 3
C216
BLK
POWER FLASHER BRN/DGN
4 5
(Domestic)
B 87 PNK
(If Equipped)
C208
TO
C108
ENGINE FUSE A C BRN/YEL
OPTIONS PNK
RED B BRN/DGN 6
C164
30 87 ACCESSORY FUSE BLK DBL/WHT
S 15A RED RED RED RNG A
TIMER
FUEL SOLENOID FUSE 25A REAR WORK LAMP
4 3 85 86 TO OPTIONS HAZARD SWITCH
RED WHT/BLK RNG RNG BLK
STARTER (If Equipped)
25A BL
WHT/BLK
K
DIODE
1 2 2 1 BRN/
BRN BRN
DGN
FUEL SOLENOID 3
BRN/YEL
4 BEACON SWITCH
BRN
RED
5 (If Equipped)
6 BLK
BICS 6
BLK
FUSE 5
4
10A
RED
3
RED/WHT
RIGHT TURN SIGNAL 1 2
BATTERY LIGHT INDICATOR
RED/WHT
- + BLK BRN/DGN
BLK
LEFT TURN SIGNAL
LIGHT INDICATOR
B A
BRN BLK
C209
B A
BLK
RE
D
TO OPTIONS
B BRN/DGN
A BRN/YEL
C215
DOME LIGHT
C DBL WITH SWITCH
E BRN/RED
(If Equipped)
D PNK
F BLK BICS CONTROLLER 2
HARNESS - 6717581 7
BRAKE SOLENOID 21
BICS BRAKE 14
MAINFRAME CONTROLLER HARNESS - 6710423
ENGINE
87
15A
10A
SEAT BAR 9
A
19
BICS CONTROLLER
SENSOR
GAUGE
BRAKE FUSE 30 87 RED A A LBL/RED 15
C305
10A
RED RED/WHT WHT

25A
25A BLK B B LBL/BLK 10
FUEL SOL 85 86
PNK/WHT BLK DGN C C LBL/DGN 20
17
WHT
RED
BLK
LIGHT 6
BRAKE
TRACTION
25A
25A 4
LOCK
ACCESSORY
B C A OVERRIDE 18
C308 SWITCH 11
25A
C307
25A MANUAL
B C A A A DBL/WHT 12
ACCESSORY HYDRAULIC BRAKE
SWITCH B B GRY 22
LOCK SOLENOID
BLK
DBL F F DBL 13
WHT G G WHT 23
C301
FUSE BLOCK BLK DGN C C DGN 1
WHT C C WHT BLK B B BLK 16
C115
BLK B B BLK RED D D RED 3
209 of 361 PNK/WHT

RNG
D
A
D
A
PNK/WHT
RNG
PNK/WHT
RNG
E
A
E
A
PNK/WHT
RNG
5
8
Printed in U.S.A. V-0051 (1-6-04)

WIRES CONNECT BY
463 WIRING SCHEMATIC RED = RED

BATTERY FEED 1000-1999 RED, RED/WHT, RNG
LETTER ACROSS GROUND 2000-2999 BLK RNG = ORANGE
CONNECTORS BLK = BLACK
A B MONITORING 3000-3999 LBL
LBL = LIGHT BLUE
B A HYDRAULIC 4000-4999 LGN
DBL = DARK BLUE
S/N 520011711 AND ABOVE ATTACHMENT CONTROLS 5000-5999 YEL LGN = LIGHT GREEN
LIGHTS 6000-6999 PNK DGN = DARK GREEN
S/N 519911425 AND ABOVE SOME CONNECTOR
YEL = YELLOW
PNK = PINK
(PRINTED JANUARY 2004) BODIES NOT SHOWN
FOR DRAWING CLARITY
ENGINE 8000-8999 TAN
WHT = WHITE
COMMUNICATION 9000-9999 PUR BRN = BROWN
V-0475 TAN = TAN
PUR = PURPLE
GRY = GRAY
ENGINE HARNESS - 6729790

STARTER
8210 L L 8210 CAB HARNESS - 6729788
TO OPTIONS
8210 2060
C109
86 85 B 7200 7200 S S 7200
HORN
8200 1030 A 1900 2730
87 30 2620
OFF
87 RUN
A STAR
DIODE
M T

OPEN M OPEN
GLOW PLUG SWITCH OFF

RUN
8500 H H 8500 8210
1 2 B ST
1200
GLOW PLUG
1100
3
4 5
2030 1420
8500
86 85 1700
6
HR 8510 1060
I
87 30 1100 G G 1100 IGNITION SWITCH
GLOW PLUGS
87
A
1750 K K 1700
ENGINE WARNING LIGHT
6810
6820
HYDROSTATIC OIL ENGINE OIL
1810
C201
TEMPERATURE PRESSURE SWITCH 3500 F F 3500 3500
C114
341 SWITCH C 3400 3400
C C 3400 C
C110
DIODE CHARGE 0 6820
PRESSURE B B 3010
SWITCH A A 3420 3420 J

HOURMETER
TRANSMISSION WARNING LIGHT
H
1800
J 3420 3420 - + 1840
1830
1020
1600 D D 1800
3 2 1
t
ENGINE COOLANT
C162 SENDER 3200 N N 3200
3 2 1 ACCESSORY FUSE 2790 - AUXILIARY

POWER COOLANT
1070 1190 1190 A A 1190 1840
+
25A
SOCKET TEMPERATURE S 3200 VOLTMETER
LIGHT FUSE GAUGE
I 1850 I
1040 1210 1210 E E 1210 T G 2780 G
25A V
1050 LIGHT 6850 LIGHT
2000 B B 2000
1600
BAT
ALTERNATOR
GAUGE 6840 2700
OPEN R R OPEN
FUSE
25A 6120 2760
RIGHT FRONT
1045
A 6330 P P 6330 HEADLIGHT

D 6440
C101
E 6540 REAR
1000
C TAIL 6110 2750

LAMP
F LEFT FRONT
B LIGHT SWITCH
2600 HEADLIGHT
1210
TO OPTIONS 1150
1
TO OPTIONS RIGHT TURN SIGNAL 2
LIGHT INDICATOR 2610 OPEN
C105
A 1720 6650 2650 2650

SWITCHED B 2050
3
6680 2640
1060 POWER 5
B 263
6200
4 6340
87 TO 0
C108
ENGINE FUSE A C 6430 TO OPTIONS
OPTIONS LEFT TURN SIGNAL 6610
6530
REAR WORK LAMP 6350
8200 1010 1100 B 6
C164
30 87 105
ACCESSORY FUSE LIGHT INDICATOR
S 15A 1130 E 6650
TIMER 1050 1025 1710 1730 A
5
FUEL SOLENOID FUSE 25A D 6640 6640 2640
C215
4 3 85 86 TO OPTIONS
1065 8810 1610 2070 8000 OPEN
STARTER F 6670 2790
25A
8800 2500 A 1150
1 2
B 1420
FUEL SOLENOID C 1180
1035
1 6420
BICS 6520
2 1180
FUSE E
C110
3 2010 BUCKET POSITION VALVE
B 6680
C216
10A (If Equipped)
RED
4 1130
A 6670
5 4420 A A 6610
C
1140
6 1740 2420 B B
BATTERY D 6360
- + TO OPTIONS F 2620
TO OPTIONS
BICS CONTROLLER
HARNESS - 6729863
TRAVEL CONTROL
LOCKOUT SWITCH
(EUROPE ONLY)
BRAKE SWITCH
3 6 2 3
MAINFRAME CONTROLLER HARNESS - 6729862 2700 1170
2 5 1
4500 4700 4
5 6 7
2110 21
BRAKE SOLENOID 1 4 4
BICS BRAKE 14
ENGINE
87
15A
1930
1150
10A 9
A
19
BICS CONTROLLER
GAUGE
BRAKE FUSE 30 87
17
10A
25A
1080 1360 1360 4100 SEAT BAR
25A 85 SENSOR 6
FUEL SOL 86
2040 1700 A A 3910
RED 15
C305
BLK B B 3920 10
WHT
RED
BLK
LIGHT DGN C C 3900 20
BRAKE
25A
25A 2
ACCESSORY
B C A TRACTION LOCK 18
OVERRIDE SWITCH
C308 11
25A
C307
25A
B C A A A 1160 12
ACCESSORY HYDRAULIC
LOCK SOLENOID B B 4600 22
2200
OPEN F F OPEN 1930 23
OPEN G G OPEN 4500 13
A B
B A
2200
C301
FUSE BLOCK 4410 4410 C C 4410 4410 1
4100 C C 4100 2700 B B 2700 2100 16
C115
2730 B B 2730 4200 D D 4200 4200 3

1700 D D 1700 1700 E E 1700 1700 5
1140 A A 1140 1140 A A 1140 1130 8
210 of 361
Printed in U.S.A. V-0475 (1-6-04)
463 WIRING SCHEMATIC
OPTIONS
(PRINTED SEPTEMBER 2005)
V-0056
EUROPEAN ONLY
HORN
RIGHT LEFT
(Optional)
C105
TO ENGINE
REAR REAR
2710 B
C109
RNG/DBL B TAILLIGHT TAILLIGHT 1710 A
LICENSE A OPEN
RNG A
E A C B D F PLATE E F C B D A B 2710
HORN HARNESS - LIGHT C 4200 4800 B
C457
C702 C701
D 4100 4700 C
6708506 or 6709526 E A C B D F E F C B D A
E 4300 1710 A
F 4400
BOOM
OPEN
CONNECTOR G
C441
LBL/WHT
4300 A
PNK
PNK
BLK
BLK
H OPEN
TO ATTACHMENT HORN 4400 B
SKI CONTROL J OPEN
C441
TO ENGINE
B DBL RNG/WHT A C109 K OPEN
RNG/
A WHT
DBL
B BRN/YEL D L OPEN
BLK B
M ATTACHMENT
OPEN
C454
PNK A
C YEL/LGN
REAR AUX. TURN SIGNAL
DGN B F
N OPEN
OPEN
CONTROL HARNESS
P
C457
C453
B YEL/RED BRN A C 6727870

A RNG YEL C BRN/DGN E
TO ATTACHMENT
LEFT HANDLE TAILGATE HARNESS - 6707509
(If Equipped)
TO CAB
B
Power B 2320 2300 Ground
A Supply
C215
TO OPTIONS
DOME LIGHT For Kit A 1610
C
BACKUP ALARM SWITCH 25 A
D
1620
2310
C608
SWITCHES A RED BEACON Fuse
C609
A A BRN/RED E
BLK B BLK OR
TO ENGINE STROBE B B BLK F
-
C105
BLK BLK BLK

RNG
B
A
DOME LIGHT 87A 87 86
+ RNG
BEACON/STROBE HARNESS - 6708318
BACKUP ADDITIONAL POWER
ALARM CONNECTOR
30 85
C717
RNG B
BLK A
1740 1
1600
1730
BACKUP ALARM HARNESS - 6708739 EUROPEAN ONLY
LEFT RIGHT
ACCESSORY 1
BEACON
CLEARANCE CLEARANCE OR HARNESS
BLK
(WORK LIGHT) (WORK LIGHT) BLK STROBE

To Starter
BEACON LEFT
LAMP LAMP 6736214 B Terminal
TURN RIGHT
OR TURN
B A STROBE LAMP
LAMP
BLK
BLK
C607 B A
PNK
LEFT B A C608
TURN RIGHT TO CAB
TURN B A
LAMP TO CAB
BLK
LAMP
BRN/RED E
F FRONT WIPER
BLK BRN/RED E
C215
WATER BOTTLE PUMP HAZARD SWITCH

C BLK F
C215
M BEACON SWITCH 1140
DGN B C FRONT WIPER
1190
D DGN B 2
SWITCH
5 1760
YEL A PNK D 5 2
3
YEL A 1
JV FLASHER LIGHT HARNESS - 6710905 TO OPTIONS
6 4 3 1
6 4 5
2
4-WAY FLASHER HARNESS - 6709530 C608
B A 6 4 3 1
6000
FRONT WIPER
6700
2745
2755
6420
6640
MOTOR
2745
7310
2710
1110
2750
2765
1780
V
7310
7210
TO MAINFRAME DIODE M
EUROPEAN ONLY HARNESS
3 2000
WIRES CONNECT BY LETTER
1 6420
ACROSS CONNECTORS
LEFT RIGHT
C452
BEACON 2 6520 6520 C B
A B CLEARANCE CLEARANCE OR B C
BLK
BLK
BLK
BLK
4 1130 2755
B A (WORK LIGHT) (WORK LIGHT) STROBE
LAMP LAMP 6 1720 7160 A A
LEFT
TURN RIGHT 5 4420 BUCKET
LEFT RIGHT
6650
TURN POSITION
SOME CONNECTOR LAMP HEADLIGHT HEADLIGHT SWITCH
LAMP
BODIES NOT SHOWN 6
DBL
B A
PNK
FOR DRAWING CLARITY 5
1140
4
RED = RED C716
RNG = ORANGE B A 3
1130
BLK = BLACK 1 2
TO CAB
BATTERY FEED 1000-1999 RED, RED/WHT, RNG LBL = LIGHT BLUE L
B 1420
GROUND 2000-2999 BLK
DBL = DARK BLUE BRN/RED E X
A 1150 1180
LGN = LIGHT GREEN F
C216
MONITORING 3000-3999 LBL BLK

F
C215
DGN = DARK GREEN OPEN FLASHER

HYDRAULIC 4000-4999 LGN
DBL C
YEL = YELLOW C 6700
ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK
WHT = WHITE
DGN
PNK
B
D
E 6650 ACCESSORY HARNESS
LIGHTS 6000-6999 PNK E 6640
BRN = BROWN
TAN = TAN
YEL A
TO CAB
6729789
ENGINE 8000-8999 TAN PUR = PURPLE HARNESS
COMMUNICATION 9000-9999 PUR GRY = GRAY
HEADLIGHT HARNESS - 6707672
211 of 361
V-0056 (8-31-05)
Printed in U.S.A.
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 Location
Description Figure 60-10-2
IMPORTANT 2
Do Not use silicone base sprays and/or sealants on

harness connectors or components.
I-2123-0397
1
Figure 60-10-1
P-19212
Figure 60-10-3

P-9895
The loader has a 12 volt, negative ground alternator

charging system [Figure 60-10-1].
P-19211
The electrical system is protected by 6 fuses located in

the engine compartment [Figure 60-10-2].
Remove the clips (Item 1) [Figure 60-10-2] and remove

the fuse covers to access the fuses [Figure 60-10-3].
The decal (Item 2) [Figure 60-10-2] located by the fuse

holders specifies the fuse sizes used in the various
electrical circuits.
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ELECTRICAL SYSTEM INFORMATION (CONT’D)
Relay Switches Location
Figure 60-10-4
P-9769
The loader engine harness relay switches (Item 1)

[Figure 60-10-4] are located on the lower right side of

the engine compartment.
There are five relay switches for the circuitry on the

loader.
The relay switches are for the starter, switch power, glow
plugs, brake, and fuel shut down solenoid.
Replace the relay switch if the switch is malfunctioning.

Refer to the engine electrical wiring diagram at the
beginning of this section for correct wiring connections.
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BATTERY

WARNING
Keep arcs, sparks flames and lighted tobacco away
WARNING from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Batteries contain acid which burns eyes and skin on Do not jump start or charge a frozen or damaged
contact. Wear goggles, protective clothing and battery. Warm battery to 60° F (16° C) before
rubber gloves to keep acid off body. connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
In case of acid contact, wash immediately with water. lean over battery while boosting, testing or charging.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15 Battery gas can explode and cause serious injury.
minutes. W-2066-1296
If electrolyte is taken internally drink large quantities

Figure 60-20-2
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
Figure 60-20-1
1

1
2
P-19407
Remove the nuts (Item 1) [Figure 60-20-2] from the

battery holddown clamp.
P-19406
Loosen the nut (Item 2) [Figure 60-20-2] which fastens
the hydraulic fill tube to the frame, and move out of the
Open the rear door. way.
Disconnect the negative (-) cable (Item 1) [Figure 60-20- Remove the battery from the loader and set on floor.
1] from the battery.
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BATTERY (CONT’D) Figure 60-20-4
Figure 60-20-3
P-9589
Figure 60-20-5
P-19408
Remove the positive (+) cable from the battery [Figure

60-20-3].

Use the reverse procedure to install the battery.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
P-9590
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water. Always clean the terminals and cable ends when
In case of eye contact get prompt medical attention installing a new battery[Figure 60-20-4] and [Figure 60-
and wash eye with clean, cool water for at least 15 20-5].
minutes.
When installing the battery in the loader, do not touch any
If electrolyte is taken internally drink large quantities metal parts with the battery terminal posts.
prompt medical attention. Connect and tighten the battery cables. Connect the
W-2065-1296
negative (-) cable last to prevent sparks.
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BATTERY (CONT’D)
Servicing
Figure 60-20-6
P-9588
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 60-20-6].
Clean the terminals and cable ends as shown in [Figure

60-20-4] and [Figure 60-20-5] .
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.
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BATTERY (CONT’D) Figure 60-20-7
Using A Booster Battery (Jump Starting)
WARNING 1
Batteries contain acid which burns eyes and skin on 2
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
P-19409
minutes.
If electrolyte is taken internally drink large quantities Figure 60-20-8

prompt medical attention. 1
W-2065-1296

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-19410
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-
7] 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 60-20-8] 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 20-7] 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 60-20-8] 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 60-20-8] first.
Remove the cable from the starter.
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ALTERNATOR Figure 60-30-2
IMPORTANT 1
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
both cables from the battery.)
• Extra battery cables (booster cables) are
P-9792
connected wrong.
I-2023-1285
Disconnect the red wires (Item 1) [Figure 60-30-2] from
Figure 60-30-1 the alternator.
Figure 60-30-3

1
1
P-9817
1
P-9895
Open the rear door. Disconnect the negative (-) battery
cable.
Loosen the alternator adjustment bolts (Item 1) [Figure
Remove the battery from loader. (See Removal And 60-30-3]. Remove the mounting bolts and remove the
Installation on Page 60-20-1.) alternator.
Disconnect the wiring harness connector (Item 1) Reverse the procedure to install the alternator.
[Figure 60-30-1] from the alternator.
Move the protective cover (Item 2) [Figure 60-30-1] from

the alternator.
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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.
Stop the engine and open the rear door.
Remove the battery from the loader. (See Removal And
Figure 60-30-4 Installation on Page 60-20-1.)
Put jackstands under the rear corner of the loader. (See

10-1.)

on Page 10-30-1.)
Figure 60-30-5
1
P-9770

Loosen the adjustment bolts (Item 1) [Figure 60-30-3]
and move the alternator so there is 1/4 inch (6 mm)
movement between the pulleys with 15 pounds (67 N) of
force [Figure 60-30-4].
Tighten the adjustment bolts. 1

P-9895
Loosen the alternator adjustment bolts (Item 1) [Figure

60-30-5].
Move the alternator ahead to loosen and remove the

alternator belt from the pulley.
Figure 60-30-6
P-9817
Remove the bolt (Item 1) [Figure 60-30-6] from the belt

shield.
463 Bobcat Loader
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ALTERNATOR (CONT’D) Figure 60-30-9
Alternator Belt Removal And Installation (Cont’d)
Figure 60-30-7
1
P-9787
P-9802
Through the end of the fan housing [Figure 60-30-9]

P-9814 loosen and remove the four bolts (Item 1) [Figure 60-30-
9] holding the fan to the water pump.
Remove the bolt (Item 1) [Figure 60-30-7] from the rear Installation: Apply liquid adhesive (LOCTITE #242) to
fuel filter mount. the mounting bolts and tighten to 85-92 in.-lbs. (9.5-10.5

Nm) torque.
Figure 60-30-8
Remove the aluminum bushing (Item 1) [Figure 60-30-
8].
Remove the alternator belt.
Reverse the removal procedure to install the alternator

belt.
P-9812
Move the alternator belt shield and fan housing cover

[Figure 60-30-8].
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ALTERNATOR (CONT’D) Alternator Output Test
Description
Figure 60-30-10
WARNING
1
3 2 air must be added to avoid concentration of exhaust
4
W-2050-1285

Check the battery and battery connections. (See

Servicing on Page 60-20-3.)
P-10018
5 P-10023
Disconnect the fuel stop solenoid connector.
The output terminal (Item 1) [Figure 60-30-10]. Turn the lights on (if equipped) and crank the engine for
30 seconds to discharge the battery.

The battery or power sensing terminal (Item 2) [Figure
60-30-10]. Connect the solenoid connector.
The ignition terminal (Item 3) [Figure 60-30-10]. Figure 60-30-11
Open terminal not used in the loader harness (Item 4)

[Figure 60-30-10].
Access hole for full field test (Item 5) [Figure 60-30-10] 1
Tests
Perform the following alternator tests in this order:
Alternator Output Test: Tests the alternator and regulator

output.
Full Field Test: Tests the maximum amperage output to

the alternator.
P-21112
Alternator Regulator Test: Tests the regulator voltage

output. Use an induction meter and loop it around the positive
wires (Item 1) [Figure 60-30-11] at the alternator.
Start the engine and run at full RPM.
The ammeter reading should be between 35 and 40

amps.
If the ammeter reading is less than 35 amps do the full

field test.
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ALTERNATOR (CONT’D) Alternator Regulator Test
Full Field Test Disconnect the fuel stop solenoid connector.
Turn the lights on (if equipped) and crank the engine for
30 seconds to discharge the battery.
WARNING Connect the fuel stop solenoid connector.
air must be added to avoid concentration of exhaust
The ammeter reading should be around 35 amps and
slowly decrease with alternator output.
W-2050-1285
If ammeter reading is low or does not decrease with time,
replace the alternator’s regulator.
Figure 60-30-12
Disconnect the negative (-) cable from the battery.
Reconnect the alternator wires.
Reconnect the negative (-) cable from the battery.

1

P-10021
Place a small screwdriver in the test port (Item 1) [Figure

60-30-12] to provide a ground to the alternator case.
This will give maximum amperage output from the
alternator.
NOTE: The full field test should only last long enough
to get ammeter reading to prevent damage to
the alternator.
The ammeter reading should be above 35 amps.
If the ammeter reading is low, repair or replace the

alternator.
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ALTERNATOR (CONT’D)
Alternator Regulator Test Using Voltmeter
Figure 60-30-13

P-10019
Connect the positive (+) voltmeter lead to the positive (+)

battery terminal (Item 1) [Figure 60-30-13].
Connect the negative (-) voltmeter lead to the negative (-)

battery terminal (Item 2) [Figure 60-30-13].
The voltmeter should read between 13.9 and 14.7 volts.
If the voltmeters reading is not within this range, replace

the alternators’s regulator.
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STARTER Figure 60-40-2

2
Stop the engine and open the rear door.
4
Disconnect the negative (-) cable from the battery.
Installation: Make note of the wiring connections on the

starter to ensure correct installation.
Figure 60-40-1 1 3
P-9878
Remove the positive (+) wires (Item 1) [Figure 60-40-2]

1 from the starter.
Remove the solenoid wire (Item 2) [Figure 60-40-2].

2
Remove the starter mounting bolt (Item 3) [Figure 60-40-

2] and negative (-) cables.
P-9896 Remove the starter mounting bolt (item 4) [Figure 60-40-

2].
Remove the rubber covers from the solenoid terminal Remove the starter.
(Item 1) [Figure 60-40-1] and positive (+) starter terminal
(Item 2) [Figure 60-40-1]. Installation: Tighten the starter mounting bolts to 25-28
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STARTER (CONT’D) Figure 60-40-4
Checking The Starter In The Loader
NOTE: The starter is removed from the loader for

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. 2
Figure 60-40-3 1
P-9976
Connect a jumper wire between the battery terminal

(Item 1) [Figure 60-40-4] and the motor terminal (Item 2)
2
[Figure 60-40-4].
If the starter turns, the defect is in the solenoid.

If the starter does not turn, the starter is defective.
P-9975
Connect a jumper wire between battery terminal (Item 1)

[Figure 60-40-3] and the solenoid terminal (Item 2)
[Figure 60-40-3].
If the starter turns but does not turn the engine, the
starter drive has a defect.
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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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Disassembly
Figure 60-40-5
1
1
N-15021
Remove the frame (Item 1) [Figure 60-40-7] from the

N-15019 magnetic switch.
Figure 60-40-8
Remove the cable (Item 1) [Figure 60-40-5] from the
magnetic switch.

Mark the frame and magnetic switch (Item 2) [Figure 60-
40-5] for ease of assembly.
2
Figure 60-40-6
N-15022
1 Remove the screws (Item 1) [Figure 60-40-8] from the

brush cover (Item 2) [Figure 60-40-8].
1
Remove the cover (Item 2) [Figure 60-40-8].
N-15020
Remove the bolts (Item 1) [Figure 60-40-6].
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Figure 60-40-9
1
1
1 N-15025
3 Remove the bearings (Item 1) [Figure 60-40-11] from

N-15023 both ends of the armature.
Figure 60-40-12
Using a needle nose pliers, pull the brush springs (Item
1) [Figure 60-40-9] back and remove the brushes (Item

2) [Figure 60-40-9].
NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder 1
(for the negative brushes) and yolk (for the
positive brushes). 1
Remove the brush holder (Item 3) [Figure 60-40-9] from

the end of the armature.
Figure 60-40-10
N-15026
1 Remove the bolts (Item 1) [Figure 60-40-12] from the

starter housing.
N-15024
Remove the armature (Item 1) [Figure 60-40-10] from

the frame.
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Figure 60-40-13
N-15029
Remove the idler gear (Item 1) [Figure 60-40-15], rollers

1
N-15027 (Item 2) [Figure 60-40-15] and retainer (Item 3) [Figure
60-40-15].
Remove the starter housing (Item 1) [Figure 60-40-13] Figure 60-40-16

from the magnetic switch housing.

Figure 60-40-14
N-15042
1
N-15028 In order to remove the snap ring from the pinion shaft, a
tube 0.605 inches (15,4 mm) in diameter by 2.0 inches
(50,8 mm) in length is needed [Figure 60-40-16].
Remove the ball (Item 1) [Figure 60-40-14] from the
pinion shaft.
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Figure 60-40-17
N-15047
1 Remove the snap ring (Item 1) [Figure 60-40-19].

N-15045
Figure 60-40-20
Install the tube (Item 1) [Figure 60-40-17] in the over

running clutch.

Figure 60-40-18 2
3 1
4
1 N-15053
2
Remove the collar (Item 1) [Figure 60-40-20], pinion
(Item 2) [Figure 60-40-20], spring (Item 3) [Figure 60-
N-15046 40-20], and spring seat (Item 4) [Figure 60-40-20].
Press down on the carrier (Item 1) [Figure 60-40-18] to

extend the pinion shaft. Press down in the pinion (Item 2)
[Figure 60-40-18].
Press the collar (Item 3) [Figure 60-40-18] down to gain

access to the snap ring.
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Figure 60-40-21
1 2
N-15035

N-15033 starter housing.
Figure 60-40-24
Remove the pinion shaft (Item 1) [Figure 60-40-21] and
spring (Item 2) [Figure 60-40-21] from the starter drive.

Figure 60-40-22
1 1
N-15030
Remove the spring (Item 1) [Figure 60-40-24] from the

N-15034 magnetic switch.
Remove the over running clutch (Item 1) [Figure 60-40-

22].
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STARTER (CONT’D) Inspection And Repair
Disassembly (Cont’d) Figure 60-40-27
Figure 60-40-25
B-14455
N-15031
Inspect the brush cover for discoloration, indicating the
starter has been overheated.
magnetic switch cover. Inspect the pinion teeth for wear and damage.

Figure 60-40-26 Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-27]. A 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 60-40-28
N-15032
Remove the cover (Item 1) [Figure 60-40-26], gasket

(Item 2) [Figure 60-40-26] and switch (Item 3) [Figure
60-40-26].
N-15036
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-28]. 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 60-40-29
1
B-14460
Measure the segment mica depth (Item 1) [Figure 60-40-

N-15037 31].
Service Limit - 0.008 inch (0,2 mm)

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

60-40-29]. 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 60-40-30
Figure 60-40-32
B-14458
N-15039
Commutator Run-Out Test: Check the commutator run-

out as shown in [Figure 60-40-30]. Check the field windings for wear and damage.
Service Limit - 0.020 inch (0,4 mm) Check all the connections for clean and tight solder joints.
If the comutator exceeds the service limit, repair as Field Winding Ground Test: Use a circuit tester, touch
needed. one probe to the field winding end of the brush and the
other probe to the surface of the frame [Figure 60-40-
32]. There should be no continuity. If there is continuity,
the field windings are grounded.
Replace the field windings.
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Inspection And Repair (Cont’d)
Figure 60-40-33 1
N-15043
Inspect the over running clutch (Item 1) [Figure 60-40-

N-15040 35], 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 60-40-33]. 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 60-40-34
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 60-40-34]. 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) Figure 60-40-38
Figure 60-40-36
50
50 C
C
M.T.
M.T.
B-14469
B-14471
The following test should be done after reassembling the
starter:
Pull-In Test: Connect the wires as shown in [Figure 60-
40-36]. When connecting Terminal C and M.T. are Return Test: With the same conditions as in the hold-in

closed, the pinion should engage. test, open the connecting terminal 50 [Figure 60-40-38].
the pinion should return immediately.
Figure 60-40-37
Figure 60-40-39
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 60-40-37]. 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 60-40-39]. 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
Clean all parts and apply high temperature grease to the

armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
Figure 60-40-40
1 3
2 N-15030
Install the spring (Item 1) [Figure 60-40-42] on the

magnetic switch.
Figure 60-40-43
N-15032

Install the switch plunger (Item 1) [Figure 60-40-40],
gasket (Item 2) [Figure 60-40-40] and cover (Item 3)
[Figure 60-40-40] on the switch housing.
1
Figure 60-40-41
1 N-15035
Install the O-ring (Item 1) [Figure 60-40-43] in the starter

housing.
1
N-15031
Install the bolts (Item 1) [Figure 60-40-41].
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Assembly (Cont’d)
Figure 60-40-44
1
N-15042
In order to install the pinion and snap ring on the pinion

N-15034 shaft, a tube (Item 1) [Figure 60-40-46] 0.605 inch (15,4
mm) in diameter by 2.0 inches (50,8 mm) in length is
needed.
Install the over running clutch (Item 1) [Figure 60-40-44]
in the starter housing. Figure 60-40-47

Figure 60-40-45
1 2
1
N-15044
N-15033
Install the tube (Item 1) [Figure 60-40-47] in the over
running clutch.
Install the spring (Item 1) [Figure 60-40-45] and pinion
shaft (Item 2) [Figure 60-40-45] in the over running
clutch.
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Assembly (Cont’d)
Figure 60-40-48
1
N-15056
Install the pinion (Item 1) [Figure 60-40-50].

N-15054
Figure 60-40-51
Place the starter drive on the bench, and press down on

the starter drive housing. 1

Install the spring seat (Item 1) [Figure 60-40-48] on the
pinion shaft.
Figure 60-40-49
N-15057
Install the collar (Item 1) [Figure 60-40-51].
N-15055
Install the spring (Item 1) [Figure 60-40-49].
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Assembly (Cont’d)
Figure 60-40-52
1
1
N-15041
Install the rollers (Item 1) [Figure 60-40-54] in the

N-15047 retainer.
Figure 60-40-55
Install the snap ring (Item 1) [Figure 60-40-52]. Pull the
collar (Item 2) [Figure 60-40-52] over the snap ring.
1

Figure 60-40-53
N-15029
1
Install the roller/retainer assembly (Item 1) [Figure 60-
N-15058 40-55] on the starter housing.
Install the idler gear (Item 2) [Figure 60-40-55] over the

With the pinion shaft extended, extend and release the roller/retainer assembly.
pinion (Item 1) [Figure 60-40-53]. The pinion must
return to the fully retracted position.
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Assembly (Cont’d)
Figure 60-40-56
1
1
N-15026
1 Install the two bolts (Item 1) [Figure 60-40-58]. Tighten

N-15028 the bolts to 60-104 in.-lbs. (7-12 Nm) torque.
Figure 60-40-59
Install the ball (Item 1) [Figure 60-40-56] in the pinion
shaft.

Figure 60-40-57
1 2
N-15025
1 Install the bearings (Items 1 & 2) [Figure 60-40-59] on

N-15027 both ends of the armature.
Install the starter drive (Item 1) [Figure 60-40-57] on the

magnetic switch.
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Assembly (Cont’d)
Figure 60-40-60
1 2
N-15049
Install the frame (Item 1) [Figure 60-40-62] over the

N-15048 armature.
NOTE: Make sure the tab (Item 2) [Figure 60-40-62] on

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

Figure 60-40-61 Figure 60-40-63
1 3
1
N-15050 N-15051A
Install the new O-rings (Item 1) [Figure 60-40-61] on Install the brush holder (Item 1) [Figure 60-40-63] on the
both ends of the frame. armature.
Using a needle nose pliers, pull the spring (Item 2)

[Figure 60-40-63] back and install the brushes (Item 3)
[Figure 60-40-63].
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Assembly (Cont’d)
Figure 60-40-64
1 N-15019
Install the cable (Item 1) [Figure 60-40-66] on the

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

40-64].

Figure 60-40-65
N-15020
Install the thru bolts (Item 1) [Figure 60-40-65]. Tighten

the bolts to 60-104 in.-lbs. (7-12 Nm) 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-19246
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: Be careful to 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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BICS™ SYSTEM CONTROLLER
Trouble Shooting 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 10
Activated, Valve And 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. Remove
controller and 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.
Figure 60-70-1
1
2
P-7186A

on Page 10-30-1.)
P-7191
The controller mounting bolts are located on the back of
the operator cab [Figure 60-70-1].
NOTE: The operator seat is removed in photo [Figure
Remove the top mounting bolt (Item 1) [Figure 60-70-1] 60-70-2] for clarity purposes only. The seat
from the controller. does not need to be removed to remove the
controller.
Loosen the two lower mounting bolts (Item 2) [Figure 60-
70-1]. Slide the controller (Item 1) [Figure 60-70-2], up and
remove it from the back of the operator cab.
Disconnect the electrical harness from the controller and
remove the controller from the loader.
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BICS™ SYSTEM CONTROLLER (CONT’D)
IMPORTANT
Be sure the connector to the BICS system controller
are correctly engaged in the controller when
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
be removed it has been correctly installed [Figure 60-
70-3].
I-2087-1095
Figure 60-70-3

2
P-4707
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.-lbs. (9-10 Nm) torque.
Reverse the procedure to install the controller.
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BICS™ SYSTEM (WITH PRESS TO OPERATE Inspecting The Traction Lock (Engine RUNNING)
BUTTON)
6. Fasten the seat belt, disengage the parking brake
Inspecting The BICS™ Controller (Engine STOPPED - pedal, press the green PRESS TO OPERATE Button
Key ON) and raise the Seat Bar fully. MOve the steering levers
slowly forward and backward. The Traction lock
Figure 60-80-1 should be engaged. Lower the Seat Bar. Press the
green PRESS TO OPERATE Button.
7. Engage the parking brake pedal and move the

2 1
steering levers slowly forward and backward. The
Traction Lock should be engaged.
3
Inspecting The Lift Arm By-Pass Control
4
5 8. Raise the lift arms 6 feet (2 meters) off the ground.
Stop the engine.
Pull and hold the by-pass control knob. Push the toe of
the left foot pedal until the lift arms slowly lower.
P-4242
WARNING

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 AVOID INJURY OR DEATH
controller lights should be ON (Items 1, 2, 3 ,4 & 5) The Bobcat Interlock Control System (BICS™) must
[Figure 60-80-1]. deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
2. Engage the parking brake pedal and raise the seat modify the system.
bar fully. System Activated (Item 1), Seat Bar (Item W-2151-0394
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.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in the operator’s seat. Lower the seat bar.

Engage the parking brake pedal. Fasten seat belt.
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
should stop. Repeat using the tilt function.
NOTE: The auxiliary hydraulic functions are not

affected by the Bobcat Interlock Control
System (BICS™).
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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.
If one of the lights stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions
in Preventive Maintenance section.
(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
Troubleshooting Guide
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 (MEL 1428) for the following

procedure:
Disconnect the short adapter test leads if connected.
Figure 60-90-1 2
1 P-4698
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-4702 Figure 60-90-4
Disconnect the seat bar sensor connector (Item 1)

[Figure 60-90-1].
Figure 60-90-2 1
P-4699
P-4701
Lower the seat bar. The Sensor Test light (Item 1)

[Figure 60-90-4] should illuminate.
P-4700 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] inline If the above tests fail, there is a problem with the seat bar
as shown to the seat bar sensor connectors. See inset sensor.
[Figure 60-90-2].
Disconnect the Sensor Tester.
Turn the key to the ON position. DO NOT START THE
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
1
P-4702

[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.-lbs.

(34-38 Nm) torque.
Remove the sensor mounting bolt (Item 2) [Figure 60-

90-6] and nut.
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SEAT BAR SENSOR (CONT’D)
Figure 60-90-8
3 6 2 1
Left Side
5 of Seat Bar
4
P-3284
Pull the seat back and remove the assembly as follows:

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.-lbs. (21-23 Nm) 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) Power light illuminated, move the toggle switch (Item 2)
[Figure 60-90-10] on the sensor tester (Item 1) [Figure
BICS™ Controller Seat Bar Sensor Circuit Test 60-90-10] to the Present position.
Use Sensor Tester (MEL 1428) For the following NOTE: The sensor test light (Item 3) [Figure 60-90-10]
procedure: is activated by the seat bar. It will be off with
the seat bar up or on with the seat bar down.
Disconnected the short adapter test leads if connected.
Figure 60-90-11
Figure 60-90-9
1
1
P-4701
P-4704

P-4702
The seat bar light (Item 1) [Figure 60-90-11] on the BICS

Figure 60-90-10 controller should illuminate.
Figure 60-90-12
1
1
P-4703
P-4699
[Figure 60-90-9].
Move the toggle switch (Item 1) [Figure 60-90-12] on the
Connect Sensor Tester (Item 1) [Figure 60-90-10] inline sensor tester to the Absent position.
as shown to the seat bar sensor connectors. See inset
[Figure 60-90-9]. The seat bar light (Item 1) [Figure 60-90-11] should go
off.
Turn the key in the ON position. DO NOT START THE
ENGINE. If the tests above fail, there is a problem with the BICS™
system controller or the wiring harness
No power light on the sensor tester check the testor or
wiring harness.
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TRACTION LOCK
Troubleshooting Guide
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, 8
Intermittent activation of traction lock. 9, 10, 11
1. Check that controller power indicator light is ON.
2. Make sure brake pedal is not engaged.
3. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it

can retract.
4. If all lights indicate the brake should be released, but it doesn’t, check the brake 25 amp. fuse.
5. When checking fuse, also check other fuses. Check the fuse block for correct orientation and
location of fuses. (See Fuse Location on Page 60-10-2.)
6. To test the solenoid, the pull coil should be .4 to .5 ohms and the hold coil 10.5 to 11.0 ohms.
7. Check the brake solenoid adn cover mounting hardware for the correct torque.
8. Remove the brake cover and check wedges for binding in the wedge guides.
9. Check wire connections for loose connector body.
10. Check for loose or bent pins in connectors.
11. Check for loose spade connectors in fuse holder.
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TRACTION LOCK (CONT’D) Figure 60-100-2

1
2
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
function of the parking brake. Service work on the
traction lock system should only be performed by a
3
qualified technician. Use only genuine Bobcat 4
P-7225
Company parts if repair is necessary.
W-2165-0100
Remove the electric solenoid/mounting bracket assembly

Figure 60-100-1 (Item 1) [Figure 60-100-2] from the chaincase cover.
Remove and inspect the compression spring (Item 2)

1 [Figure 60-100-2] for wear and damage. Replace if
necessary. The spring may also stay with the shaft when

the electric solenoid and bracket are removed from the
chaincase.
Installation: Install the compression spring (Item 2)

P-4712 [Figure 60-100-2] on the collar located on the electric
solenoid.
Remove the traction lock assembly (Item 3) [Figure 60-

2 100-2] from the chaincase.
2
P-19423 Check the gasket (Item 4) [Figure 60-100-2] condition
and replace as needed.
Put jackstands under the rear of the loader.
Raise the loader operator cab. (See Raising The

Operator Cab on Page 10-30-1.)
Remove the center shield. (See Control Shield And

Steering Lever Panels Removal And Installation on Page
30-20-1.)
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.-lbs.

(34-38 Nm) 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 solenoid toward the rear of the loader when installed
correctly. (See inset photo [Figure 60-100-1].)
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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

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
SAFETY &
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 MAINTENANCE
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-70-1

Engine Compression Test Procedure . . . . . . . . . . . . . . . . 70-70-9
Fuel Injection Pump Check . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-3 DRIVE
Fuel Injector Nozzles Checking . . . . . . . . . . . . . . . . . . . . . 70-70-6 SYSTEM
Fuel Injector Nozzles Installation . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Injector Nozzles Removal . . . . . . . . . . . . . . . . . . . . . 70-70-7
Glow Plugs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
ENGINE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . 70-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

ELECTRICAL
SYSTEM &
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 ANALYSIS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 ENGINE

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 SERVICE
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Mounting Bracket Removal And Installation . . . . . . . . . . . 70-50-1
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ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Checking Timing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-21
Crankshaft Bearings Removal And Installation . . . . . . . . . . . 70-110-22
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . 70-110-14
Cylinder Bore Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-26
Cylinder Head Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . 70-110-1
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-3
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . 70-110-13
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-14
Hydraulic Oil Cooler And Shrouding Removal And Installation70-110-26
Idler Gear And Camshaft Removal And Installation. . . . . . . . 70-110-10
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . 70-110-24
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-110-15
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Piston And Connecting Rod Removal And Installation . . . . . 70-110-17
Piston And Connecting Rod Servicing . . . . . . . . . . . . . . . . . . 70-110-19

Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . . . . 70-110-7
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . . . . . . 70-110-3
Servicing The Idler Gear And Shaft . . . . . . . . . . . . . . . . . . . . 70-110-12
Testing The Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . 70-110-27
Timing Gearcase Cover Removal And Installation . . . . . . . . . 70-110-8
Valve Guide Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Valve Spring Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . 70-110-28
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . 70-110-28
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 24, 30, 32, 33, 44, 53
pressure.
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 back and forth at a comfortable
tension.
W-2059-0598
Remove the speed control rod (Item 3) [Figure 70-20-1]
from the lever.
Install jackstands under the rear of the loader. (See Figure 70-20-2
10-1.)
20-1.)

on Page 10-30-1.)
1
Remove the center shield and left steering lever panel.
(See Contents Page 30-01.)
Figure 70-20-1
P-9911
Remove the clip (Item 2) [Figure 70-20-2] from the

speed control lever. Remove the speed control rod from
the lever.
1 2
P-7212
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
1
2
P-21115

muffler mounting bracket.
P-21113 Remove the muffler.
Use a new gasket (Item 2) [Figure 70-30-3] between the

Remove the nuts (Item 1) [Figure 70-30-1] from the intake manifold and the muffler flange.
exhaust pipe clamp.
Remove the clamp and the exhaust pipe from the muffler.
Figure 70-30-2
1 1
P-21114
Remove the four bolts (Item 2) [Figure 70-30-2] from the

muffler flange and exhaust manifold.
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AIR CLEANER Figure 70-40-3
Housing Removal And Installation
Figure 70-40-1
1
P-21124
Remove the condition indicator (Item 1) [Figure 70-40-3]

P-21127 from the fitting.
Remove the air cleaner housing from the loader.

Remove the air cleaner cover and filter elements. (See
AIR CLEANER SERVICE on Page 10-80-1.)

Loosen the two bolts (Item 1) [Figure 70-40-1] located in
the air cleaner housing mounting bracket.
The bolt heads will pass through the air cleaner housing
bracket.
Figure 70-40-2
P-21125
Loosen the clamp (Item 1) [Figure 70-40-2] from the

intake manifold hose.
Remove the hose from the intake manifold.
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RADIATOR Mounting Bracket Removal And Installation
Removal And Installation Figure 70-50-2
Figure 70-50-1
1 1
2 1
1 2
P-9820
P-9820
Remove the radiator (See Removal And Installation on
Page 70-50-1.).
Open the rear door.

Drain the coolant from the engine. (See Replacing The 2].
Coolant on Page 10-90-2.)
Figure 70-50-3
Remove the oil cooler and shroud. (See Hydraulic Oil
Cooler And Shrouding Removal And Installation on Page
70-110-26.)
Remove the two hose clamps (Item 1) [Figure 70-50-1] 1

and hoses from the radiator.
Remove the two mounting bolts (Item 2) [Figure 70-50-1] 2

and remove the radiator.
Reverse the procedure to install the radiator.
P-9816
Remove the mounting bolt and bracket (Item 1) [Figure

70-50-3] from the engine coolant tank.
Loosen the right side mounting bolt (Item 2) [Figure 70-

50-3].
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RADIATOR (CONT’D)
Mounting Bracket Removal And Installation (Cont’d)
Figure 70-50-4
P-9818
Loosen the left side mounting bolt (Item 1) [Figure 70-

50-4].

Remove the radiator and the radiator mounting bracket.
Reverse the procedure to install the radiator and

mounting bracket.
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FAN Figure 70-60-2
WARNING
the lift arms are secured by an approved lift arm 1
to fall and cause injury or death. 2
W-2059-0598
P-9802
20-1.) Remove the radiator hose mounting bolts (Item 1)
[Figure 70-60-2].
Install jackstands under the rear of the loader. (See
LIFTING AND BLOCKING THE LOADER on Page 10- Remove the nut (Item 2) [Figure 70-60-2] and remove
10-1.) the radiator hose guide clamp and the hose.

Raise the operator cab. (See Raising The Operator Cab Figure 70-60-3
on Page 10-30-1.)
Remove the engine and hydrostatic pump assembly from

the loader. (See Removal And Installation on Page 70-
80-1.)
Loosen the alternator adjustment bolts. (See Removal 1

Figure 70-60-1
1
P-9791

and remove the fan shroud.
P-9797

from the fan. Remove the fan and water pump pulley.
Installation: Apply liquid adhesive (LOCTITE #242) to

the mounting bolts and tighten to 85-92 in.-lbs. (9,5-10,5
Nm) torque.
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FAN (CONT’D)
Figure 70-60-4
P-9907
Remove the bolts (Item 1) [Figure 70-60-4] to remove

the water pump shield.

Reverse the removal procedure to install the fan.
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ENGINE COMPONENTS AND TESTING Figure 70-70-3
Valve Clearance Adjustment 0.0057-0.0073 in.

(0,145-0,185 mm)
Figure 70-70-1
3 A-2730
Make sure the piston is at TDC when adjusting the

B-5893 clearance at the valves. The correct clearance is 0.0057-
0.0073 inch (0,145-0,185 mm) cold clearance [Figure
70-70-3].
Adjust the valve clearance as follows:

Loosen the lock nut (Item 1) [Figure 70-70-1].
Turn the adjustment screw (Item 2) [Figure 70-70-1] until

the correct clearance is obtained.
NOTE: The clearance is measured between the rocker

arm and valve stem tip (Item 3) [Figure 70-70-
1].
Figure 70-70-2
B-15284
With No. 1 piston at TDC (Compression) both the intake

and exhaust valves are up. Set valves 1, 2, 4, & 5
[Figure 70-70-2].
Rotate the flywheel 360°, No. 1 piston on exhaust stroke

(overlap position) intake valve open, exhaust valve
closed. Set valves 3 & 6 [Figure 70-70-2].
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ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-5
Fuel Injection Pump Check

procedure:
MEL 1237 - Adapter Fuel Line 3

MEL1173-1 - Pressure Gauge
Figure 70-70-4 2
B-8235
Connect a pressure gauge (Item 1) [Figure 70-70-5] to

the long leg of the test tubeline (Item 2) [Figure 70-70-5]
and tighten.
1
Connect the short leg of the tubeline to the fitting at the
fuel injection pump (Item 3) [Figure 70-70-5].

P-9912 With the starter, rotate the engine to increase the
pressure to 2133 PSI (14707 kPa). Align the plunger with
TDC.
To check the initial discharge pressure, remove a high
pressure tubeline (Item 1) [Figure 70-70-4] from the fuel The pressure should hold at 2133 PSI (14707 kPa), for 5
injection pump. seconds or more.
Loosen the other end of the tubeline at the injector, so If the time is less than the allowable limit, replace the
that the tubeline can be turned away from the fitting. injection pump.
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ENGINE COMPONENTS AND TESTING (CONT’D) Fuel Injection Pump Removal And Installation
Fuel Lift Pump Removal And Installation
Figure 70-70-6
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
IMPORTANT
Never steam clean or put cold water on an injection
pump while the engine is running or while it is hot. If
1 you do it will cause serious damage to the injection
P-24985 pump.
I-2135-0997
Remove the fuel line (Item 1) [Figure 70-70-6] from the

Clean the injection pump and area around it with a
fuel lift pump.
cleaning solvent or steam cleaning.

Figure 70-70-7
Use these tools for the following procedure:
MEL 1270 - Fuel Line Removal Tool

MEL1271 - Delivery Valve Removal Tool
Figure 70-70-8
1 1
P-24984
1
Remove the two mounting bolts (Item 1) [Figure 70-70-7]
from the lift pump and remove the pump from the engine.
P-9791
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Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 70-70-9
1
B-14423
Lift the injection pump while moving it to align the pin

(Item 1) [Figure 70-70-11] in the control rack with the slot
P-9918 in the engine block to remove the pump.
Installation: When the injection pump is installed, make

Remove the injector nozzle tubelines (Item 1) [Figure 70- sure the pin (item 1) [Figure 70-70-11] on the control

70-8] & [Figure 70-70-9] from the injection pump and the rack is correctly installed in the fork lever. If the slot is not
injectors. installed correctly, the engine will run over a maximum
speed and serious damage can result.
Installation: Tighten the tubelines to 11-19 ft.-lbs. (15-26
Nm) torque. NOTE: Make sure the same number shims are
installed under the injection pump. The shims
Figure 70-70-10 are used for engine timing.
Fuel Injection Pump Timing
3 Figure 70-70-12
3
1
P-9912
1
Disconnect the fuel inlet hose (Item 1) [Figure 70-70-10]

and the fuel return hose (Item 2) [Figure 70-70-10].
P-9912
Remove the four bolts (Item 3) [Figure 70-70-10] from

the injection pump. Remove the high pressure tubelines (Item 1) [Figure 70-
70-12] from the injection pump and the injectors.
Installation: Tighten the four nuts to 70-20 ft.-lbs. (23-27
Nm) torque.
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Fuel Injection Pump Timing (Cont’d)
Figure 70-70-13
2
P-10030
At this point look at the timing mark (Item 1) [Figure 70-

P-13132 70-15] (located on the flywheel) for proper alignment.
When the timing mark is aligned with the marker (Item 2)
[Figure 70-70-15], the injection pump timing is correct.
Install a short plastic tube (Item 1) [Figure 70-70-13] in
the fitting of the number 1 cylinder port. Point the tube The correct engine timing for all Kubota D722-BE

up. engines is 20-22° B.T.D.C. Add or subtract shims (Item
1) [Figure 70-70-14] to achieve the correct timing.
Figure 70-70-14
NOTE: Adding or reducing the shim thickness by 0.05
mm retards or advances the injection timing
by approximately 0.5°.
B-10007
Timing the fuel injection pump is done by changing the

number of shims between the injection pump and the
injection pump mounting surface (Item 1) [Figure 70-70-
14].
Addition or reduction of shim .0059 inches (.15 mm) will

delay or advance the injection timing by approximately
1.5°. The timing of the pump will be later when a shim is
added, and earlier when a shim is removed.
NOTE: The fuel must be in the tube (Item 1) [Figure

70-70-13] before attempting timing.
Move the fuel lever on the injection pump to full fuel

position (or full throttle).
Turn the flywheel clockwise slowly until the fuel starts to

rise in the plastic tube (Item 1) [Figure 70-70-14].
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Fuel Injector Nozzles Checking
WARNING
penetrate skin or eyes, causing serious injury or 3
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do 2
not use your bare hand. Wear safety goggles. If fluid 1
from a physician familiar with this injury.
W-2072-0496 B-4103
The tools listed will be needed to do the following NOTE: You can adjust the release pressure of the
procedure: injector nozzle by adding or removing
spacers (Item 1) [Figure 70-70-17] from the top
OEM 1064 - Injector Nozzle Tester of the nozzle spring (Item 2) [Figure 70-70-17].
OEM 1065 - Accessory Set Each spacer will change the release pressure
about 142 PSI (980 kPa). The release pressure

Figure 70-70-16 must be 1990-2133 PSI (13721-14707 kPa).
If the pressure is not correct, disassemble the injector

nozzle and add or remove spacers (Item 1) [Figure 70-
70-17].
NOTE: When assembling the injector nozzle, tighten

the retainer nut (Item 3) [Figure 70-70-17] to
43-58 ft.-lbs. (59-79 Nm) 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 he injector valve.
Make a record of the pressure. Release the hand lever.
Check the pressure decrease to 10 seconds. The nozzle
A-2513 has damage if the pressure decrease is more than 740
PSI (5162 kPa) in 10 seconds.
Connect the injector nozzle to the tester with the nozzle

in the down position [Figure 70-70-16].
Slowly operate the hand lever of the test pump until the
injector nozzle valve opens. The pressure must be 1990-
2133 PSI (13721-14707 kPa).
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ENGINE COMPONENTS AND TESTING (CONT’D) Fuel Injector Nozzles Removal
Fuel Injector Nozzles Checking (Cont’)
Figure 70-70-18
WARNING
Spring
CORRECT WRONG penetrate skin or eyes, causing serious injury or
Pressure death. Fluid leaks under pressure may not be visible.
Pin Use a piece of cardboard or wood to find leaks. Do
Holder not use your bare hand. Wear safety goggles. If fluid
Nozzle from a physician familiar with this injury.
Body W-2072-0496
Needle
Valve The tool listed will be needed to do the following
procedure:
A-2621 MEL 1485 - Socket
To remove the injector nozzles, use the following

Check the spray pattern of the nozzle for the following procedure:
conditions [Figure 70-70-18]:

Figure 70-70-19
Does not come out of the nozzle.
Does not have drops coming out of the nozzle.
Does not have a flow (solid stream) coming from the

nozzle.
Any of the above conditions show a defect or a dirty

injector nozzle. Clean the nozzle that does not operate
correctly and check again.
P-9791
Remove the injector tubelines (Item 1) [Figure 70-70-19]

from the injector pump.
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Fuel Injector Nozzles Removal (Cont’d)
Figure 70-70-20
1
1
2
3 B-5971
Remove the fuel injector nozzle from the engine [Figure

P-9918 70-70-22].
Remove the injector tubelines (Item 1) [Figure 70-70-20]

from the injectors.
IMPORTANT

Remove the fuel return hoses (Item 2) [Figure 70-70-20]
from the banjo fittings. Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
Remove the banjo fittings (Item 3) [Figure 70-70-20] tools.
from the fuel injector nozzles. I-2027-0284
Figure 70-70-21 Fuel Injector Nozzles Installation
Install the injector nozzle in the cylinder head and tighten

to 21-36 ft.-lbs. (29-49 Nm) torque.
Install the banjo fitting on the injector nozzle and tighten.
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.)
B-5970
Loosen the fuel injector with a special socket [Figure 70-

70-21].
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ENGINE COMPONENTS AND TESTING (CONT’D) Engine Compression Test Procedure
Glow Plugs Checking The tool listed will be needed to do the following
procedure:
Figure 70-70-23
MEL10630 - Engine Compression Test Kit
MEL1546 - Engine Compression Test Adapter
Warm the engine.

2
2
Remove the fuel injector nozzles from the engine. (See
Fuel Injector Nozzles Removal on Page 70-70-7.)
Install the compression adapter in the cylinder head.
Figure 70-70-25
P-9918
Disconnect the three nuts (Item 1) [Figure 70-70-23] that

hold the glow plug electrical bar to the glow plugs.

Remove the electrical bar (Item 2) [Figure 70-70-23]
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.
P-7537
Threading must be approximately 1.5. If the resistance is

zero ohms the glow plug has a short circuit. Connect the compression gauge to the adapter [Figure
70-70-25].
If the resistance is infinite the coil of the glow plug is
broken. Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 seconds
Figure 70-70-24 each time and take the average reading.
The correct compression for the engine is 337-448 PSI

(2324-3089 kPa) with no more than 10% difference
between the cylinders.
P-3420
Replace the glow plug as needed [Figure 70-70-24].
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ENGINE Remove the nuts (Item 3) [Figure 70-80-1] from the
Removal And Installation steering lever linkage. Remove the linkage from the
hydrostatic pumps.
Remove the high pressure hoses (Item 4) [Figure 70-80-

WARNING 1] from the hydrostatic pumps. Install caps and plugs on
the fittings, tubelines and hoses.
Never work on a machine with the lift arms up unless Figure 70-80-2
W-2059-0598
1
NOTE: The engine and hydrostatic pumps are
removed from the loader as an assembly.
Lift and block the loader. (See LIFTING AND
20-1.)
P-9914

Open the rear door.
Drain the hydraulic/hydrostatic fluid. (See Replacing The Disconnect the charge pressure hose (Item 1) [Figure
Hydraulic/Hydrostatic Fluid on Page 10-120-2.) 70-80-2] from the hydrostatic pump. Install caps and
Remove the battery. (See Removal And Installation on plugs in the fittings, tubelines and hoses.
Page 60-20-1.)
on Page 10-30-1.)
Figure 70-80-1
3 3
4 4
1
P-9877
Disconnect the speed control linkage (Item 1) [Figure

70-80-1] from the injector pump. (See Removal And
Disconnect the outlet hose (Item 2) [Figure 70-80-1]
from the hydraulic pump. Install caps and plugs on the
fittings, tubelines and hoses.
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ENGINE (CONT’D) Figure 70-80-5
Figure 70-80-3
3
1
P-9900
2
1
4 Disconnect the lift lock valve wiring harness (Item 1)
P-9915 [Figure 70-80-5].
Figure 70-80-6
Disconnect the hydraulic oil temperature wire (Item 1)
[Figure 70-80-3]. 1

Disconnect the hydraulic oil pressure wires (Item 2)
[Figure 70-80-3].
Disconnect the optional horn wire (Item 3) [Figure 70-80-

3], if the loader is so equipped.
Disconnect the optional flasher wire (Item 4) [Figure 70-

80-3], if loader is so equipped.
Figure 70-80-4
P-9903
2
Remove the hydrostatic motor cover (Item 1) [Figure 70-
80-6]. (Both sides.)
1
P-9916
Disconnect the brake solenoid wiring harness (Item 1)

[Figure 70-80-4].
Disconnect the brake switch wiring harness (Item 2)

[Figure 70-80-4].
Installation: Install a new Do Not Modify sta-strap (P/N

6665527) in the brake switch and solenoid harness
connectors.
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Figure 70-80-7
P-9806
Open the coolant valve (Item 1) [Figure 70-80-9] to drain

P-9902 the coolant. (See Replacing The Coolant on Page 10-90-
2.)
Remove the high pressure hoses (Item 1) [Figure 70-80- Figure 70-80-10
7] from the right hydrostatic drive motor. Install caps and

plugs in the fitting, tubelines and hose.
Figure 70-80-8
P-7531
Open the radiator cap [Figure 70-80-10].

P-9904
Remove the hydraulic cooler and shroud. (See Hydraulic
Oil Cooler And Shrouding Removal And Installation on
Remove the high pressure hoses (Item 1) [Figure 70-80- Page 70-110-26.)
8] from the left hydrostatic drive motor. Install caps and
plugs in the fittings, tubelines and hose. Remove the radiator and radiator mounting bracket and
engine coolant tank. (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 70-80-11
1
1
1
P-10029
2

P-9814 from the relay switch bracket.
Figure 70-80-14
Remove and plug the fuel lines (Item 1) [Figure 70-80-
11].

Remove the fuel filter assembly by removing the two
mounting bolts (Item 2) [Figure 70-80-11].
2
Figure 70-80-12
3 1
P-9896

starter mounting bolt and remove the battery and engine
negative (-) cables.
1
P-9875 Remove the starter solenoid wire (Item 2) [Figure 70-80-
14].
Remove the engine mounting bolts (Item 1) [Figure 70- Remove the positive (+) wires (Item 3) [Figure 70-80-14]
80-12]. from the starter.
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Figure 70-80-15
P-9894
1
Remove the wire (Item 1) [Figure 70-80-17] from the
P-9891 water temperature sender.
Figure 70-80-18
Remove the wire (Item 1) [Figure 70-80-15] from the oil
pressure sender.

Figure 70-80-16
P-9918
1
Remove the wire (Item 1) [Figure 70-80-18] from the

2 P-9817 glow plug.
Disconnect the electrical harness (Item 2) [Figure 70-80-

Remove the positive (+) wires (Item 1) [Figure 70-80-16] 18] from the fuel shutoff solenoid.
from the alternator.

80-16] from the alternator.
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Removal And Installation (Cont’d) 2
Figure 70-80-19
1
1
1
P-9920
Install a chain with a hook on each end, to each lift eye

P-9876 (Item 1) [Figure 70-80-21] on the engine.
Use a chain lift device (Item 2) [Figure 70-80-21] and

Remove the engine air intake hose (Item 1) [Figure 70- chain hoist to remove the engine and hydrostatic pump.
80-19].

Raise the chain hoist slowly until the hoist supports the
Disconnect the hydraulic hose (Item 2) [Figure 70-80-19] engine.
from the oil cooler tubeline.
Figure 70-80-20
P-9764
Remove the muffler exhaust extension (Item 1) [Figure

70-80-20].
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Figure 70-80-22
P-9884
Remove the hydraulic inlet line (Item 1) [Figure 70-80-

P-9914 24] from the hydrostatic pump. Install caps and plugs in
the fittings, tubelines and hoses.
Figure 70-80-23 Continue to remove the engine and hydrostatic pump

assembly from the loader.

Replace the engine mounts if they are damaged.
Reverse the removal procedure to install the engine and

hydrostatic pump in the loader.
P-9899
Remove the nuts, bolts and spacers (Item 1) [Figure 70-

80-22] & [Figure 70-80-23]from the hydrostatic pump
mounts.
Lower the operator cab. (See Lowering The Operator

Lift the engine with the chain hoist until the engine
mounts clear the rear lip of the loader frame.
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FLYWHEEL Figure 70-90-2
WARNING
support device can allow the lift arms or attachment 1
W-2059-0598
P-9796
Remove the five 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.-lbs. (54-61
Raise the operator cab. (See Raising The Operator Cab Nm) 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-9805
Remove the hydrostatic pump drive belt (Item 1) [Figure

70-90-1]. (See Removal And Installation on Page 30-60-
2.)
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 2
3
1
1 P-9801
Remove the flywheel.

end plate.

Nm) 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 muffler mounts (Item 4) [Figure 70-100-1].
Remove the end plate.
Reverse the removal procedure to install the end plate.
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RECONDITIONING THE ENGINE Figure 70-110-3
Cylinder Head Removal And Installation
Figure 70-110-1
B-14417
Remove the water return hose [Figure 70-110-3].

B-14415
Figure 70-110-4

valve cover and remove the valve cover and gasket.

Remove the fuel injector nozzles. (See Fuel Injector
Nozzles Removal on Page 70-70-7.)
Remove the glow plugs. (See Glow Plugs Checking on

Page 70-70-9.)
Remove the alternator. (See Removal And Installation

on Page 60-30-1.)
Figure 70-110-2
B-14490
1
Remove the cylinder head bolts in order of #14 to #1
[Figure 70-110-4].
Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence to 29-33 ft.-lbs. (39-44 Nm)
torque.
NOTE: Re-tighten the cylinder head bolts in the

correct sequence after the engine has been
run for 30 minutes.
B-14416
Remove the rocker arm and shaft assembly (Item 1)

[Figure 70-110-2].
Installation: Tighten the nuts to 7-8 in.-lbs. (9,8-11,3

mm) torque.
Remove the intake and exhaust manifolds.
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RECONDITIONING THE ENGINE (CONT’D) Figure 70-110-7
Cylinder Head Removal And Installation (Cont’d)
Remove the cylinder head from the engine block.
Figure 70-110-5
PI-9988
Put the straight edge on the cylinder head’s four sides

1 and two diagonal as shown in figure [Figure 70-110-7].
B-14334 The maximum distortion of the head surface ± 0.002 in.

(± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

Installation: Always use a new head gasket and new O-
ring. Make sure the O-ring (Item 1) [Figure 70-110-5] is
seated over the dowel.
Cylinder Head Inspection
Clean the surface of the cylinder head.
Figure 70-110-6
A-2735
Put a straight edge (Item 1) [Figure 70-110-6] on the

cylinder head.
NOTE: Do not put the straight edge across

combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-110-6] between

the straight edge and the surface of the cylinder head.
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RECONDITIONING THE ENGINE (CONT’D) Rocker Arm And Shaft Checking
Cylinder Head Top Clearance Figure 70-110-9
Figure 70-110-8
2
2
1
1
3
B-3697
PI-9989
Measure the rocker arm I.D. (Item 1) [Figure 70-110-9]
with an inside micrometer.
Install the cylinder head gasket. Put the piston (Item 1)
[Figure 70-110-8] being checked at T.D.C. Measure the rocker shaft O.D. (Item 2) [Figure 70-110-9]

with an outside micrometer.
Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)
[Figure 70-110-8] on the top piston. Use grease to hold If the clearance exceeds the allowable limit, replace the
them in position. bushing.
NOTE: Put the solder in position so they do not touch If the clearance still exceeds the allowable limit after the
the valves. bushing is replaced, replace the rocker arm shaft.
Turn the piston to bottom dead center.

Oil Clearance Between 0.0006-0.00018 inch
Rocker Arm & Shaft (0,016-0,045 mm)
Install the cylinder head and tighten to the correct torque
in the correct sequence. (See Cylinder Head Removal Allowable Limit 0.0059 inch (0,15 mm)
And Installation on Page 70-110-1.) Rocker Arm 0.4123-0.4128 inch
Shaft O.D. 10,47-10,48 mm)
Turn the crankshaft until the piston exceeds T.D.C. Rocker Arm I.D. 0.04134-0.4141 inch
Remove the cylinder head. (10,5-10,52 mm)
Remove the solder wire (Item 3) [Figure 70-110-8] and

measure it.
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.0197-0.0256 in. (0,50-0,65 mm)
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RECONDITIONING THE ENGINE (CONT’D) Valve Spring Checking
Valve Removal Figure 70-110-12
Figure 70-110-10
3
2
5 B-3680
4 B-14418
Measure the length of the valve spring. If the
measurement is less than the allowable limit, replace the
Figure 70-110-11 spring [Figure 70-110-12].

Free Length 1.244 inch (31,6 mm)
Allowable Limit 1.118 inch (28,4 mm)
4
2 3 Put the spring on a flat surface, place a square on the
1 6
side of the spring [Figure 70-110-12].
Rotate the spring and measure the maximum tilt. If the

measurement is in excess if the allowable limit, replace
the spring.
5 Tilt 0.047 inch (1,2 mm)

B-4122
Use a valve spring compressor to compress the valve

spring (Item 1) [Figure 70-110-10].
Remove the valve cap (Item 1) [Figure 70-110-11] and

valve spring collet (Item 2) [Figure 70-110-10] & [Figure
70-110-11].
Remove the valve spring retainer (Item 3) [Figure 70-

110-10] & [Figure 70-110-11] and the spring [Figure 70-
110-10] & [Figure 70-110-11].
Remove the valve (Item 5) [Figure 70-110-10] & [Figure

70-110-11].
Remove the seal (Item 6) [Figure 70-110-11].
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RECONDITIONING THE ENGINE (CONT’D) Valve Guide Checking
Valve Removal (Cont’d) Figure 70-110-14
Figure 70-110-13
B-3634
A-2759
Remove the valve and spring from the cylinder head.
(See Valve Removal on Page 70-110-4.)
Put the spring on a tester and compress to specified
length [Figure 70-110-13]. Clean the valve seat and combustion chamber.

Read the compressed load on the gauge. If the Install the valve into the guide. Measure the valve
measurement exceeds allowable limit, replace the spring. recessing with a depth gauge [Figure 70-110-14].
Setting Length 1.063 inch (27 mm) Figure 70-110-15

Setting Load 14.6 lbs (64.1 N)
Allowable Limit 12.3 lbs. (54.9 N) 2
(setting load)
1
1
1. Cylinder Head
Surface
2. Recessing
PI-9990
If the measurement exceeds allowable limit, replace the

valve or cylinder head [Figure 70-110-15].
Recessing 0.004 inch (0,10 mm)

(Recessing)
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7.87” (200 mm)
Valve Guide Checking (Cont’d)
1.57”
0.79” 3.15” (80 mm) (40 mm)
0.3921-0.3929”
Remove carbon from the valve guide. (20 mm)
(9,96-9,98 mm)
Figure 70-110-16
0.2165-0.2244”
(5,5-5,7 mm)
0.2” 0.276” 0.71”

(5,0 mm) (7 mm) (18,0 mm)
0.236-0.240” 0.59” 0.417-0.421”

(6,0-6,1 mm) (15,0 mm) (10,6-10,7 mm) MC-1364
To remove and replace the valve guide, make the driver

tools as shown in [Figure 70-110-17].
B-14335 Figure 70-110-18

Measure the valve stem O.D. [Figure 70-110-16].
Measure the valve guide I.D. [Figure 70-110-16].
Calculate the clearance. If the clearance exceeds the

allowable limit, replace the valve and/or valve guide. 1
Valve Guide I.D. 0.2366-0.2372 inch 2

(6,01-6,025 mm)
Valve Stem O.D. 0.2350-0.2354 inch
(5,9168-5,980 mm)
Clearance 0.0016-0.0018 inch
PI-9992
Between Valve (0,04-0,07 mm)
Stem and guide
Allowable Limit 0.0039 inch (0,1 mm) Press the used valve guide out of the cylinder head using
the special driver tool [Figure 70-110-18]. (See [Figure
70-110-17] for tool dimensions.)
Put oil on the outside diameter of the new valve guide.

Press the new valve guide into the cylinder head for the
top side. Use the special driver tools (Item 1 & 2) [Figure
70-110-18], press the new guide until the tools contact
the cylinder head.
Ream the valve guide to the correct specifications.
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Reconditioning The Valve And Valve Seat 1 2
Figure 70-110-19
0.0835” (2,12 mm) PI-9995
Check the seat surface and valve face (Item 1) [Figure

PI-9993 70-110-21].
If the seat surface is too wide, use a 15 degree cutter

Grind the valve face to the correct angle using a valve re- (Item 2) [Figure 70-110-21] to get the correct width (Item
facer [Figure 70-110-19]. 3) [Figure 70-110-21].

Figure 70-110-20 Valve Seat Width
Intake 0.0835 inch (2,12 mm)
Exhaust 0.0835 inch (2,12 mm)
Valve Seat & Face Angle
Intake 45°
Exhaust 45°
PI-9994
Grind the valve surface in the cylinder head to the correct

angle [Figure 70-110-20].
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Timing Gearcase Cover Removal And Installation
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 70-70-3.)
Remove the cylinder head, rocker arms and push rods. 1

(See Cylinder Head Removal And Installation on Page
70-110-1.)
Figure 70-110-22
1 2
B-14870
2 Remove the bolt (Item 1) [Figure 70-110-24] and

disconnect the shaft spring (Item 2) [Figure 70-110-24].
Figure 70-110-25

B-14868
Remove the screws (Item 1) [Figure 70-110-22] from the

speed control plate (Item 2) [Figure 70-110-22].
Figure 70-110-23
B-14871
1
Remove the crankshaft pulley bolt.
Installation: Tighten the bolt 72-80 ft.-lbs. (98-108 Nm)

torque.
Use a puller and remove the crankshaft pulley [Figure

70-110-25].
B-14869
Separate the speed control plate from the engine and

remove the spring (Item 1) [Figure 70-110-23].
Remove the speed control plate.
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Timing Gearcase Cover Removal And Installation

(Cont’d)
Figure 70-110-26
Oil Seal O-rings
B-3617
Installation: Install three new O-rings and the oil seal

into the timing gear case cover [Figure 70-110-28].
B-14872
When installing the crank shaft pulley, make sure to align

the marks [Figure 70-110-26].
Figure 70-110-27
B-14873
Remove the timing gear case bolts.
Installation: Tighten the bolts 7-8 ft.-lbs. (10-11 Nm)

torque.
Remove the timing gear case [Figure 70-110-27].
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Idler Gear And Camshaft Removal And Installation
Figure 70-110-29
1
2 B-14874
3
Installation: Make sure the timing marks are aligned

B-14341 when installing the timing gears [Figure 70-110-31].
Align the holes on the camshaft gear with the camshaft

Remove the snap ring (Item 1) [Figure 70-110-29] and retainer plate bolts.
collar (Item 2) [Figure 70-110-29] from the idler gear

shaft (Item 3) [Figure 70-110-29]. Remove the bolts.
Figure 70-110-30 Installation: Tighten the camshaft retainer bolts to 14-15

Figure 70-110-32
1
B-3699
Remove the idler gear (Item 1) [Figure 70-110-30].

B-3655
Remove the camshaft from the engine block [Figure 70-

110-32].
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Idler Gear And Camshaft Removal And Installation

(Cont’d)
Figure 70-110-33
B-5001
Measure the camlobes at their highest point [Figure 70-

110-35].
B-3620
If the measurement is less than the allowable limit,
replace the camshaft.
Measure the camshaft bearing in the engine block

[Figure 70-110-33]. Cam Lobe Height 1.058 inch (26,88 mm)
Figure 70-110-34
Figure 70-110-36
A-2761
Measure the camshaft journal [Figure 70-110-34]. A-2760
Calculate the oil clearance. If the clearance exceeds the

Put the camshaft in V-blocks. Install a dial indicator
allowable limit, replace the camshaft.
[Figure 70-110-36].
Bearing I.D. 1.299-1.300 inch Turn the camshaft at a slow rate. If the misalignment
(33,0-33,03 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.2966-1.2973 inch
(32,93-32,95 mm) Camshaft Alignment 0.0004 inch (0,01 mm)
Clearance of 0.002-0.004 inch Allowable Limit
Camshaft Journal (0,05-0,09 mm)
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Servicing The Idler Gear And Shaft 0.79” (20 mm)
Figure 70-110-37 5.91” (150 mm)
1.18”
0.98”
(30 mm)
(25mm)
0.862-0.864”
(21,9-21,95 mm) 0.784-0.785”
(19,9-19,95 mm)
MC-1366
To replace the idler gear bushing, make a driver tool as

PI-10003 shown in [Figure 70-110-38].
Figure 70-110-39
Measure the O.D. of the idler gear shaft [Figure 70-110-
37].

Measure the I.D. if the idler gear bushing [Figure 70-110-
37].
If the clearance exceeds the allowable limit, replace the

bushing.
Idler Gear Shaft O.D. .786-.787 inch

(19.97-19.98 mm)
Idler Gear Shaft I.D. 0.787-0.789 inch
(20,00-29,05 mm)
Oil Clearance between 0.0008-0.0033 inch
idler shaft & Gear Bushing (0,020-0,089 mm) PI-10004

Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 70-110-39].
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RECONDITIONING THE ENGINE (CONT’D) Fuel Camshaft Removal And Installation
Checking Timing Gear Backlash Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Figure 70-110-40 110-8.)
Remove the idler gear. (See Idler Gear And Camshaft

Figure 70-110-41
PI-10005
1
When the gears are installed, check the backlash as
follows:

B-14342
Install a dial indicator [Figure 70-110-40].
Hold one gear while turning the other gear [Figure 70- Remove the bolt (Item 1) [Figure 70-110-41] from the
110-40]. retainer plate (Item 2) [Figure 70-110-41].
If the backlash exceeds the allowable limit, check the oil Installation: Tighten the bolt to 6-7.2 in-lbs. (6,8-8,1 Nm)
clearance of the shaft and gear. If the oil clearance is torque.
correct, replace the gear.
Remove the fuel camshaft retainer plate (Item 2) [Figure
Crank Gear & Idler Gear 0.002-0.005 inch 70-110-41].
(0,043-0,0124 mm)
Allowable Limit 0.006 inch (0,15 mm) Remove the fuel camshaft and fork lever assembly at the
Cam Gear & Idler Gear 0.002-0.005 inch same time.
(0,047-0,12 mm)
Injection Pump Gear & 0.002-0.005 inch
Idler Gear (0,046-0,124 mm)
Oil Pump Gear & 0.002-0.005 inch
Crankshaft Cover (0,041-0,123 mm)
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RECONDITIONING THE ENGINE (CONT’D) Crankshaft Gear Removal And Installation
Governor Remove the timing gearcase cover. (See Timing

The governor serves to keep the engine speed constant 110-8.)
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. Remove the idler gear. (See Idler Gear And Camshaft
Figure 70-110-42
Figure 70-110-43
2
1 4
3
11
10
6
9

B-3686
1. Start Spring 8
7
2. Governor Spring
3. Fork Lever Remove the crankshaft gear with a puller [Figure 70-
4. Fork Lever 110-43].
5. Fork Lever Shaft
6. Governor Sleeve Remove the crankshaft key.
7. Retainer Plate
8. Bearing
9. Fuel Camshaft
10. Bearing
11. Snap Ring
B-14875
Disassemble and assemble the governor and fuel

camshaft as shown in [Figure 70-110-42].
Check all parts for wear or damage and replace as

needed.
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RECONDITIONING THE ENGINE (CONT’D) Oil Pump Service
Oil Pump Removal And Installation Figure 70-110-45
Remove the timing gearcase cover. (See Timing

110-8.)
Remove the crankshaft gear.
Figure 70-110-44
B-3616
Measure the clearance between the lobes of the inner

rotor and outer rotor [Figure 70-110-45].
2
Figure 70-110-46

B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-110-44].
Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 70-110-44].
Installation: Tighten the oil pump mounting bolts to 60-

72 in.-lbs. (6,9-8,1 Nm) torque.
A-2732
Measure the clearance between the outer rotor and

pump body [Figure 70-110-46].
If the clearance exceeds the factory limit, replace the oil

pump.
Clearance Between Inner 0.002-0.006 inch

& Outer Rotor (0,03-0,14 mm)
Clearance Between 0.003-0.006 inch
Outer Rotor & Body (0,07-0,15 mm)
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RECONDITIONING THE ENGINE (CONT’D) Install a pressure gauge [Figure 70-110-48].
Oil Pump Service (Cont’d) Start the engine and run until it is at operating
temperature.
Figure 70-110-47
If the oil pressure is less than the allowable limit, check
the following items:
• Engine Oil Level Low

• Oil Pump Defective
• Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Clearance at the Rod & Main Bearings
• Relief Valve Stuck
At Idle Speed Allowable 14 PSI (98 kPa)

Limit
At Rated Speed 28-64 PSI (196-441 kPa)
Allowable Limit 14 PSI (98 kPa)
PI-10009
Relief Valve
Put a piece of press gauge on the rotor face [Figure 70-
110-47]. Figure 70-110-49

Install the cover and tighten the bolts.
Remove the cover carefully. Measure the width of the

press gauge [Figure 70-110-47].
If the clearance exceeds the factory limit replace the oil

pump. 3
2
End Clearance 0.003-0.005 inch
(0,75-0,14 mm) 1
Checking Engine Oil Pressure
Remove the oil pressure sensor. C-3438
Figure 70-110-48
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is ball
type.
Remove the valve seat (Item 1) [Figure 70-110-49], ball

(Item 2) [Figure 70-110-49] and spring (Item 3) [Figure
70-110-49].
Check the parts for wear or damage and replace as

needed.
B-14876
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Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan.
Figure 70-110-50
PI-10013A PI-10013
Remove the rod cap and bearing [Figure 70-110-51].
Use a hammer handle and push the piston connecting

1 rod assembly out of the cylinder bore [Figure 70-110-
51].

NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore.
Figure 70-110-52
B-14344
Remove the oil pump strainer (Item 1) [Figure 70-110-

50].
Turn the flywheel and put a pair of connecting rods at

bottom dead center.
Remove the connecting rod bolts. 1
Installation: Tight the connecting rod bolts to 20-23 ft.-

lbs. (27-30 Nm) torque.
A-2903
Installation: Make sure the marks (Item 1) [Figure 70-

110-52] on the connecting rod and bearing are aligned
when installing the bearing cap [Figure 70-110-52].
Repeat the procedure to remove the other piton/

connecting rod assemblies from the engine block.
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Piston And Connecting Rod Removal And

Installation (Cont’d) 2
Figure 70-110-53
6
1 180°
4
1
5
2
3
4
PI-10015A PI-10015
7 3
Installation: When installing new rings, assemble the
ring so the mark (Item 1) [Figure 70-110-54] near the
B-3621 gap faces the top of the piston. When installing the oil
ring, place the expander joint gap (Item 2) [Figure 70-
110-54] 180° from the oil ring gap (Item 3) [Figure 70-
Remove the first compression ring (Item 1) [Figure 70- 110-54].

110-53].
Figure 70-110-55
Remove the second compression ring (Item 2) [Figure
70-110-53]. 3 4
Remove the oil ring (Item 3) [Figure 70-110-53].
Remove the snap ring (Item 4) [Figure 70-110-53] and

piston pin (Item 5) [Figure 70-110-53].
1
2
Separate the piston (Item 6) [Figure 70-110-53] from the
connecting rod (Item 7) [Figure 70-110-53].
NOTE: Make sure the piston and rod assembly is 5

marked so as not to change the piston rod
assembly with another piston or connecting
rod. PI-10014A
Installation: When reassembling, align the marks (Item

1) [Figure 70-110-55] on the connecting rod and piston
(Item 2) [Figure 70-110-55]. Heat the piston in oil to
176° F (80° C) for 10 to 15 minutes and tap the piston pin
into position. Place the piston ring gaps every 120° (Item
3, 4 & 5) [Figure 70-110-55] with no gap facing the
piston pin in the cylinder.
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Piston And Connecting Rod Servicing
Figure 70-110-56
1
B-3633
Measure the O.D. of the piston pin (Item 1) [Figure 70-

A-2733 110-57].
Measure the I.D. of the connecting rod small end (Item 2)

Measure the I.D. of the piston pin bore in both horizontal [Figure 70-110-57].
and vertical direction [Figure 70-110-56].

Calculate the oil clearance. If the clearance exceeds the
If the measurement exceeds the allowable limit, replace allowable limit, replace the bushing. If it still exceeds the
the piston. specifications, replace the piston pin.
Piston Pin Bore I.D. 0.7874-0.7879 inch Piston Pin O.D. 0.7875-0.7878 inch
(20,0-20,13 mm) (20,002-20,011 mm)
Allowable Limit 0.789 inch (20,05 mm) Bushing I.D. 0.7884-0.7890 inch
(20,025-20,04 mm)
Oil Clearance between 0.0006-0.0015 inch
Piston Pin & Bushing (0,014-0,0398 mm)
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Piston And Connecting Rod Servicing (Cont’d)
Figure 70-110-58
0.79” (20 mm)
5.7” (145 mm)
0.98”
0.98”
(25 mm)
(25mm)
0.8622-0.8642” B-3622
(21,9-21,96 mm) 0.78350.7854”
(19,9-19,95 mm)
Install a new piston ring into the lower part of the cylinder
MC-1366 bore. Measure the ring gap with a feeler gauge [Figure
70-110-60].
To replace the connecting rod small end bushing, make a If the gap exceeds the allowable limit, replace the ring.
driver tool as shown in [Figure 70-110-58]

Top Compression Ring & 0.006-0.012 inch
Figure 70-110-59 Oil Ring (0,15-0,30 mm)
Second Compression 0.012-0.018 inch
Ring (0,030-0,450mm)
Removal Installation
PI-10016
Use a press and special driver tool to remove the small

end bushing [Figure 70-110-59].
Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until
it is flush [Figure 70-110-59].
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RECONDITIONING THE ENGINE (CONT’D) Connecting Rod Alignment
Piston And Connecting Rod Servicing (Cont’d) NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-110-61 doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-110-62
B-14475
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler

gauge [Figure 70-110-61].

piston.
Second ring 0.0035-0.0043 inch B-4067
(0,09-0,12 mm)
Oil Ring 0.0016-0.0031 inch If the gauge does not fit squarely against the face plate,
(0,04-0,08 mm) measure the space between the gauge and face plate
Allowable limit second 0.0059 inch (0,2 mm) [Figure 70-110-62].
ring
Allowable limit oil ring 0.0059 inch (0,2 mm) If the measurement exceeds the allowable limit, replace
the connecting rod.
Rod Alignment Allowable 0.002 inch (0,05 mm)

Limit
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Crankshaft Bearings Removal And Installation
Remove the piston and connecting rod assemblies. (See

Piston And Connecting Rod Removal And Installation on
Page 70-110-17.)
Remove the engine flywheel. (See Removal And

Remove the bolts which fasten the bearing case cover to

the block.
Installation: Tighten the bearing case cover bolts to 7-8

ft.-lbs. (10-11 Nm) torque. B-9565
Figure 70-110-63
Before removing the crankshaft/main bearings, check the
end play. Install a dial indicator. Measure the end play by
moving the crankshaft back and forth [Figure 70-110-
65].
If the measurement exceeds the allowable limit, replace

the thrust washers.
End Play 0.006-0.012 inch
(0,15-0,31 mm)
Figure 70-110-66
B-3648
2
Install two bolts into the bearing case cover and pull the
cover out [Figure 70-110-63].
Figure 70-110-64
B-14346
1
Remove the main bearing case bolt (Item 1) [Figure 70-
110-66].
Installation: Align the bearing case hole (Item 2)

[Figure 70-110-66] with the hole in the block. Put oil on
B-14877
the bolt threads and tighten to 20-22 ft.-lbs. (27-30 Nm)
torque.
Installation: When installing the cover (Item 1) [Figure
70-110-64], make sure the casting mark (Item 2) [Figure
70-110-64] is in the up position.
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Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 70-110-67
PI-10021
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
B-14878 side of the engine block [Figure 70-110-69]. Be sure the
thrust washer with its oil grooves face outward.
Remove the crankshaft/main bearing assembly from the

engine block [Figure 70-110-67].
Mark the bearing case halves for correct installation.
Figure 70-110-68
B-4092
Remove the two bearing case bolts [Figure 70-110-68].
Remove the bearing case and bearing.
Installation: Tighten the bearing case bolts to 9-12 ft.-

lbs. (13-16 Nm) torque.
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Inspection Of Crankshaft And Bearings
Figure 70-110-70
A-2716
Measure the crankpin O.D. [Figure 70-110-72].

A-2763
Calculate the oil clearance.
Put the crankshaft in V-blocks. Install a dial indicator on Crankpin Bearing I.D. 1.338-1.340 inch
the center journal [Figure 70-110-70]. (33,99-34,04 mm)

Crankpin O.D. 1.337-1.338 inch
Turn the crankshaft at a slow rate. (33,96-33,98 mm)
Oil Clearance 0.0008-0.0032 inch
If the misalignment exceeds the allowable limit, replace (0,019-0,081 mm)
the crankshaft. Allowable limit 0.0059 inch (0,15 mm)
Alignment 0.0031 inch (0,02 mm)
Figure 70-110-71
120°
A-2727
Tighten the connecting rod cap bolts 20-22 ft.-lbs. (27-30

Nm) torque.
Measure the crankpin bearing I.D. [Figure 70-110-71].
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Inspection Of Crankshaft And Bearings (Cont’d)
Figure 70-110-73
PI-10025
1
Measure the flattened press gauge [Figure 70-110-75].
PI-10024
crankshaft bearing.
Figure 70-110-74
Crankshaft Journal O.D. 1.7297-1.7303 inch
(Flywheel side) (43,93-43,95 mm)

5.12”
(130 MM)
Bearing I.D. 1.7317-1.7333 inch
(43,90-44,03 mm)
(Middle) (39,93-39,95 mm)
Bearing I.D. 1.5742-1.5758 inch
0.79” 1.5790-1.5728”
(39,90-39,95 MM)
(39,98-40,04 mm)
(20 MM)
(Front) (33,98-30,03 mm)
Bearing I.D. .5742-1.5728 inch
1.7283-1.7303” (33,98-40,04 mm)
(43.90-43.95 MM) 0.87”
(22 MM) Oil Clearance 0.001-0.004 inch
0.39” (0,4-0,10 mm)
(10 MM) B-14879
Remove the bearing (Item 1) [Figure 70-110-73] from

the front of the engine block with the removal tool shown
in [Figure 70-110-74].
Installation: Clean the new bearing and bore and apply

oil to them. Install the new bearing with the installation
driver tool [Figure 70-110-73].
Clean the crankshaft journal and bearing. Put a strip of

press gauge on the center journal.
Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
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RECONDITIONING THE ENGINE (CONT’D) Hydraulic Oil Cooler And Shrouding Removal And
Installation
Cylinder Bore Inspection
Open the rear door.
Figure 70-110-76
Figure 70-110-78
B-10073 1
P-9815
Check the inside diameter of the cylinder line [Figure 70-

110-76]. Remove the fuse holder (Item 1) [Figure 70-110-78].

Figure 70-110-77 Figure 70-110-79
A-2717 P-9905
To find the maximum wear check the inside diameter in Remove the oil cooler hose (Item 1) [Figure 70-110-79]
six different locations [Figure 70-110-77]. and drain the hydraulic oil into a clean container.
When the cylinder bore is not within specifications, bore

the cylinder for an oversize piston.
Cylinder Bore I.D. 2.638-2.639 inch
(67,0-67,02 mm)
Allowable Limit 0.006inch (0,15 mm)
NOTE: Make sure you use the correct oversize

pistons and rings.
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RECONDITIONING THE ENGINE (CONT’D) Thermostat Removal And Installation
Hydraulic Oil Cooler And Shrouding Removal And Drain the engine coolant until it is below the thermostat
Installation (Cont’d) level.
Figure 70-110-80 Figure 70-110-82
P-9813 P-9918
Remove the hydraulic tubeline (Item 1) [Figure 70-110- Remove the bolts (Item 1) [Figure 70-110-82] and the

80]. thermostat housing.
Figure 70-110-81 Installation: Make sure all gasket surfaces are clean.
Replace the gasket before installing the thermostat
housing.
Figure 70-110-83
1
1
P-9819
Remove the two bolts (Item 1) [Figure 70-110-81] from 2

the oil cooler shrouding.
B-3643
Slide the oil cooler and shrouding to the rear and remove.
Remove the housing and thermostat (Item 1) [Figure 70-
The oil cooler will lift out of the shroud. 110-83].
Reverse the procedure to install the oil cooler and Remove the four mounting bolts at the coolant housing
shroud. (Item 2) [Figure 70-110-83].
Remove the coolant housing from the engine block.
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RECONDITIONING THE ENGINE (CONT’D) Water Pump Disassembly And Assembly
Testing The Thermostat Put the water pump in a vise.
Hang the thermostats in a suitable container filled with Remove the pulley.
coolant.
Press the shaft (Item 3) [Figure 70-110-84] out of the
Heat the coolant gradually. Use a thermometer to check pulley side of the water pump.
the temperature when it starts to open and when it’s fully
open. Remove the seal (Item 4) [Figure 70-110-84] and
impeller (Item 5) [Figure 70-110-84].
If the thermostats do not operate correctly they must be
replaced. Install a new seal when assembling the water pump.
NOTE: Identify thermostat temperature by the

stamping on the by-pass valve.
Water Pump Removal And Installation
Drain the cooling system.
Remove the radiator. (See Removal And Installation on

Page 70-50-1.)

Remove the alternator belt.
Remove the fan.
Figure 70-110-84
B-14859
Remove the water pump bolts (Item 1) [Figure 70-110-

84].
Remove the water pump.
Installation: Always use a new gasket (Item 2) [Figure

70-110-84] when installing the water pump.
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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-30-1
Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-5
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1 DRIVE
Engine Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-5 SYSTEM
Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-4
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
Re-Grinding The Crankshaft . . . . . . . . . . . . . . . . . . . . SPEC-30-6
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2

ELECTRICAL
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-4 SYSTEM &
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2 ANALYSIS
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-40-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2 ENGINE
O-Ring Face Seal Connection . . . . . . . . . . . . . . . . . . . SPEC-40-1 SERVICE
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
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
SPECIFICATIONS
LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Floor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
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
Machine Specifications
• 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.
36
(914)
97°
34°
18
(458)
74.3
(1886)
24°

30
(762) 33.4
MS-1096A MS1096
35.4 (848)
(900)
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.
Specifications
Performance
463
Rated Operating Capacity (SAE) 700 lbs. (318 kg)
Tipping Load (SAE Rating) 1421 lbs. (645 kg)
Operating Weight 2708 lbs. (1229 kg)
SAE Breakout Force - Lift 1840 lbs. (835 kg)
Tilt 1440 lbs. (654 kg)
Axle Torque 1775 ft.-lbs. (2407 Nm)
Travel Speed 0-6.2 MPH (9,9 km/hr.)
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LOADER SPECIFICATIONS (CONT’D)
Specifications (Cont’d)
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 Key activated glow plugs.
Service Brake Two independent hydrostatic systems controlled by tow hand operate steering levers.
Secondary Brake One of the hydrostatic transmissions
Parking Brake Mechanical Disc, foot operated pedal
Engine
Make/Model KUBOTA/D722-E
Fuel/Cooling Diesel/Liquid

Horsepower (SAE Net) 15.7 HP (11,7 kW)
Maximum Governed RPM 3100 RPM
Torque 31 ft.–lbs. (42 Nm) @ 2200 RPM
Number of Cylinders Three
Displacement 44.01 cu. in. (719 cm³)
Bore/Stroke 2.64/2.68 (67,0/68,0)
Lubrication Pressure System W/Filter
Crankcase Ventilation External
Air Cleaner Dry replaceable paper cartridge
Ignition Compression Diesel
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Hydraulic System
463
Pump Engine driven, Gear type
Pump Capacity 10.0 GPM (37,8 L/min.) @3100 RPM
System Relief at Quick Couplers 2500 PSI (17235 kPa)
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 6563328) if fluid is not available use 10W-30/10W40 Class SE
motor oil for temperature above 0°F (-18°C) 5W-30 Motor Oil for temperatures
below 0°F (-18°C).
Hydraulic Function Time:
Raise Lift Arms 3.5 Seconds
Lower Lift Arms 2.3 Seconds
Bucket Dump 2.0 Seconds
Bucket Rollback 1.8 Seconds
Electrical
Alternator 40 amp open

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 #60 endless roller chain & sprockets in sealed chaincase with oil lubrication
Total Engine to Wheel Reduction 2.61:1
Axle Size 1.5 (38,1)
Wheel Bolts (5) 7/16”
Capacities
Cooling System 7 qts. (6,6 L)

Fuel 6.5 gals. (24,6 L)
Engine Oil W/Filter 3.4 qts. (3,2 L)

Hydraulic. Reservoir 5.3qts. (5,0 L)
Hydraulic/Hydrostatic System 4.0 gals. (15,1 L)
Chaincase Reservoir 3.0 gals. (11,4 L)
Tires
Standard 5.70-12, 4ply rating

Flotation 23 x 8.5-12, 4 or 6 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 (2839-3231 kPa)

Limit Permitted 327 PSI (2253 kPa)
Fuel Injector Nozzles
Opening Pressure 1991-2133 PSI (13726-14705 kPa)

Fuel Tightness Nozzle Seat 1849 PSI (12,747 kPa)
Fuel Injection Pump
Fuel Tightness of Plunger Limit Permitted 8 Sec. Initial Pressure Drop From 2133 PSI (14696 kPa)
Fuel Tightness of Delivery Valve Limit Permitted 5 Sec. Initial Pressure Drop From 2133-1990 PSi (14708-13721 kPa)
Injection Timing 20-22° B.T.D.C.
Cylinder Head

Cylinder Distortion Limit 0.002 (0,05) in 3.9 (100) of the length for the cylinder head
Thickness of Gasket Free 0.0415-0.0512 (1,15-1,30)
Thickness of Gasket Tightened 0.0413-0.0453 (1,05-1,15
Top Clearance 0.020-0.030 (0,51-0,8)
Valves
Valve Seat Angle 45°

Valve Seat Width 0.08 (2,1)
O.D. of Valve Stem 0.235-0.2354
I.D. of Valve Guide 0.2366-0.2372 (6,01-6,025)
Clearance between Valve Stem & Guide 0.0012-0.0022 (0,03-0,057)
Limit Permitted 0.004 (0,1)
Depth of Valve -0.004-0.004 (-0,10-0,10)
Valve Clearance (Cold) (Intake & Exhaust) 0.006-0.007 (0,145-0,185)
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ENGINE SPECIFICATIONS (CONT’D)
parentheses.
Valve Springs
Free Length 1.24 (31,6)

Fitted Length 1.063 (27)
Load To Compress To Fitted Length 14.6 lbs. (6,6 kg)
Limit Permitted 12.3 lbs. (5,6 kg)
Limit Permitted for Spring Tilt 0.047 (1,2)
Rocker Arms
O.D. of Rocker Arm Shaft 0.4123-0.4128 (10,47-10,48)

I.D. of Rocker Arm Bushing 0.4134-0.4141 (10,5-10,52)
Clearance Between Rocker Arm Shaft & Bushing 0.0006-0.0018 (0,016-0,045)
Limit Permitted 0.0059-(0,15)

Camshaft
O.D. of Camshaft Bearing Journal 1.2966-1.2972 (32,93-32,95)

I.D. of Camshaft Bearing 1.2992-1.3002 (32,99-32,95)
Clearance Between Camshaft Bearing & Journal 0.002-0.004 (0,05-0,91)
Alignment of the Camshaft 0.0004 (0,01)
Cam Lobe Height 1.0583 (26,88)
Gear Backlash 0.002-0.005 (0,047-0,123)
Cylinders
I.D. of Cylinder Liner 2.6378-2.6385 (67,0-67,019)

Rebore Size for Over size Piston 2.6476-2.6483 (67,249-67,267)
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ENGINE SPECIFICATIONS (CONT’D
parentheses.
Piston Rings
Ring Gap, Top & Oil 0.0059-0.0118 (0,15-0,30)

Ring Gap 2nd 0.00118-0.0177 (0,30-0,45)
Side Clearance Of Ring Groove:
Top Ring Because of our top ring design, measurement does not apply
2nd Ring 0.0035-0.0045 (0,09-0,12)
Oil Ring 0.0016-0.0031 (0,04-0,08)
Oversize of Piston & Ring 0.0098 (0,25)
Pistons
I.D. of Piston Bosses 0.787-0.788 (19,98-20,02)

O.D. of Piston Pin 0.787-0.788 (19,98-20,04)
I.D. of Connecting Rod Bushing (Small End, Fitted) 0.788-0.790 (20,02-20,07)
Clearance Between Piston Pin & Bushing Limit Permitted 0.004 (0,10)
Connecting Rod Alignment Limit Permitted 0.002 (0,05)
Crankshaft
Crankshaft Alignment Limit Permitted 0.003 (0,02)

O.D. of Crankshaft Journal No. 1 & No. 3 1.5722-1.5728 (39,93-39,95)
O.D. of Crankshaft Journal No. 2 1.7297-1.7303 (43,93-43,95)
I.D. of Crankshaft Bearing No. 1 1.5742-1.5763 (39,98-40,04)
Clearance Between No.1 Crankshaft Journal and Bearing 0.0013-0.0042 (0,03-0,11)
Clearance Between No. 2 Crankshaft Journal and Bearing 0.0013-0.0036 (0,03-0,09)
Clearance Between No. 3 Crankshaft Journal and Bearing 0.0013-0.0036 (0,03-0,09)
O.D. of Connecting Rod Journals 1.3370-1.3376 (33,96-33,98)
I.D. of Connecting Rod Bearings 1.3386-1.3402 (33,99-34,04)
Clearance Between Connecting Rod Journals and Bearings 0.0008-0.0032 (0,02-0,08)
Crankshaft End Play 0.006-0.012 (0,15-0,30)
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ENGINE SPECIFICATIONS (CONT’D
parentheses.
Oil Pump
Oil Pressure @ Rated RPM 28-64 PSI (193-441 kPa)

Limit Permitted 14 PSI (98 kPa)
Oil Pressure @ Idle Speed 14 PSI (98 kPa)
Rotor Lobe Clearance Limit Permitted 0.008 (0,2)
Clearance Between Outer Rotor & Pump Body 0.003-0.0006 (0,08-0,15)
End Clearance Between Inner Rotor & Cover 0.003-0.005 (0,08-0,13)
Clearance Between Inner Rotor & Outer Rotor 0.012-0.006 (0,30-0,14)
Thermostat
Opening Temperature
Starting 157-163°F (70-73°C)

Fully Open 185°F (85°C)
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ENGINE SPECIFICATIONS (CONT’D)
Engine Bolt Torque
ft. lbs. Nm
*Cylinder Head Bolts & Nuts 29-33 39-44
*Main Bearing Bolts 20-22 27-30
*Main Bearing Case Bolts 9-12 13-16
*Flywheel Bolts 40-43 54-59
*Connecting Rod Bolts 20-22 27-30
*Rocker Arm Bracket Nuts 7-8 10-11
*Idler Gear Shaft Bolts 7-8 9-11
Glow Plugs 6-11 8-15
Nozzle Holder 36-50 49-69
Oil Pressure Sending Unit 11-15 15-20
Fuel Injection Tubeline Fittings 18-25 25-34
Crankshaft Bolt 72-80 91-108
Injection Pump Mounting Bolt and Nuts 7-8 10-11
*Lightly Oiled Threads
PUNCHED NUMBER BOLT MATERIAL GRADE

None Standard Bolts SS41,S20C
7 Special Bolts S43C, 248C (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.-lbs. 7 to 8 ft.-lbs. 9 to 11 ft.-lbs.
(8 to 9 Nm) (9 to 11 Nm) (12 to 15 Nm)
(18 to 20 Nm) (23 to 27 Nm) 30 to 34 Nm)
(39 to 45 Nm) (47 to 56 Nm) (61 to 71 Nm)
(62 to 73 Nm) (77 to 91 Nm) ( 103 to 118 Nm)
M14 80 to 93 ft.-lbs. 91 to 109 ft.-lbs. 123 to 145 ft.-lbs
(108 to 126 Nm) (123 to 148 Nm) (167 to 197 Nm)
(167 to 191 Nm) (197 to 225 Nm) (260 to 304 Nm)
(245 to 285 Nm) (275 to 319 Nm) (343 to 403 Nm)
(334 to 392 Nm) (367 to 431 Nm) (491 to 578 Nm)
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ENGINE SPECIFICATIONS (CONT’D) Grind the crank pin and journal with a wheel which has
specified round corner and width without shoulder
Re-Grinding The Crankshaft [Figure SPEC-20-1].
If the standard size bearing cannot be used due to 1. 0.071-0.087 (1,8-2,2 mm)
excessive wear of the crank pin and crank journal use
undersize or oversize bearings. 2. 0.091-0.106'' (2,3-2,7 mm)
For undersize or oversize bearing use, follow the 3. Be sure to chamfer the oil hole circumference to 0.04-
precautions noted below. 0.06'' (1,0-1,5 mm) radius with and oil stone.
Figure SPEC-20-1 4. The crank pin must be fine finished to higher than
(0,4-S).
B 1 1 5. The crank journal must be fine-finished to higher than

6
3 (0,4-S).
6. The crank journal side surface must be fine-finished

to higher than (1,6-S).
A
C
2

1 5 D
4
B-5928
SIZE CODE NO. NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM.
-0.008” Crankshaft Bearing 1
(0,2 mm) 15861-23911 0.008” minus (0,2 minus) 020 US 1.5643-1.5650”
-0.008” Crankshaft Bearing 2 (39,734-39,750 mm)
(0,2 mm) 15694-2931 0.008” minus (0,2 minus) 020 US
-0.08” Crankshaft Bearing 3 1.7218-1.7224 in.
(0,2 mm) 15861-23861 0.08” minus (0,2 minus) 020 US (43,734-43,750 mm)
-0.0016” Crankshaft Bearing 1
(0,4 mm) 15861-23921 0.016” minus (0,4 minus) 040 US A 1.5565-1.5571”
-0.0016” Crankshaft Bearing 2 (39,534-39,550 mm)
(0,4 mm) 15699-23941 0.0016” minus (0,4 minus) 040 US
-0.016” Crankshaft Bearing 3 1.7139-1.7146”
(0,4 mm) 15861-23871 0.016” minus (0,4 minus) 040 US (43,534-43,550 mm)
-0.008” Crank Pin Bearing 1.3291-1.3297”
(-0,2 mm) 15861-22971 0.008” minus (0,2 minus) 020 US (33,759-33,775 mm)
-0.016 Crank Pin Bearing B 1.3212-1.3219”
(-0,4 mm) 15861-22981 0.016” minus (0,4 minus) 040 US (33,559-33,575 mm)
Thrust Bearing 1
+0.008” 15261-23951 0.008” plus (0,2 plus) 020 OS 1.815-1.823”
(+0,2 mm) Thrust Bearing 2 (46,1-46,3 mm)
15261-23971 0.008” plus (0,2 plus) C
Thrust Bearing 1
+0.016” 15261-23961 0.016” plus (0,4 plus) 040 OS 1.823-1.831”
(+0,4 mm) Thrust Bearing 2 (46,3-46,5 mm)
15261-23981 0.016” plus (0,4 plus)
0.008” 1.815-1.823”
(0,2 mm) Crankshaft oversize D (46,1-46,3 mm)
0.016” Dimension 1.823-1.831”
(o,4 mm) (46,3-46,5 mm)
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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
Melroe 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
(Nm) (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)

(Nm) 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.-lbs.
(4-5 Nm)
M 6 x 1.0 6-7 ft.-lbs. 6-9 ft.-lbs
(8-9 Nm) (8-12 Nm)
M 8 x 1.25 6-9 ft.-lbs. 11-16 ft.-lbs. 18-25 ft.-lbs.
(8-12 Nm) (15-22 Nm) (24-34 Nm)
(18-24 Nm) (30-41 Nm) (49-68 Nm)
(30-41 Nm) (54-73 Nm) (94-118 Nm)
(49-68 Nm) (79-108 Nm) (157-186 Nm)
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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.-lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) 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
The flare is the primary seal, the O-ring is the secondary of 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.-lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) 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.-lbs.
Wrench Size Thread Size (Nm)
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/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Bobcat hydraulic transmission fluid (P/N 6563328). If this fluid is not available, use 10W-30 or 10W-40 SAE Motor Oil
(5W-30 for 0°F [-18°C] and Below).
DO NOT use automatic transmission fluids in the loader or permanent damage to the transmission will result.
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
WARNING 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
When temperatures below zero°F (-18°C) are common, the excavator must be kept in a warm building. Extra warm-up
time must be used each time the excavator is started during cold temperature conditions. Cold fluid will not flow easily and
it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by
TRANS light ON) can cause transmission damage in less than 60 seconds.

During cold weather 32°F (0°C) and below, do not operate machine until the
engine has run for at least five (5) minutes at less than half throttle. This
warm-up period is necessary for foot pedal operation and safe stopping.
Do not operate controls during warm-up period. When temperatures are
WARNING below -20°F (30°C), 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 Above Listed Manual For Future Reference.
Revision No: 463-1

Date: 6 April 2001
Product: Bobcat Loader
Model: 463
Manual No: 6901177 (11-00)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN REVISION DECRIPTION
Alpha Index Alpha Index Text revised
HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC Legend Revised

463 (S/N 520011001 & Above) 463 (S/N 520011001 & Above)
(S/N 519911001 & Above) (S/N 519911001 & Above)
(PRINTED DECEMBER 2000) (PRINTED DECEMBER 2000)
V-0050legend V-0050legend
HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC Schematic Revised

463 (S/N 520011001 & Above) 463 (S/N 520011001 & Above)
(S/N 519911001 & Above) (S/N 519911001 & Above)
V-0050 V-0050
10-30-1, 10-30-2 10-30-1, 10-30-2 Text revised

20-30-3, 20-30-4 20-30-3, 20-30-4 Text revised
20-40-1, 20-40-2 20-40-1, 20-40-2 Text revised
463 WIRING SCHEMATIC 463 WIRING SCHEMATIC Schematic Revised

OPTIONS OPTIONS
S/N 520011001 AND ABOVE 520011001 AND ABOVE
S/N 519911001 AND ABOVE S/N 519911001 AND ABOVE Revised text and photo
V-0056 V-0056
463 WIRING SCHEMATIC 463 WIRING SCHEMATIC Schematic Revised

S/N 520011001 AND ABOVE S/N 520011001 AND ABOVE Text revised
S/N 519911001 AND ABOVE S/N 519911001 AND ABOVE
V-0051 V-0051
Printed in U.S.A.
354 of 361
TAKE OUT PUT IN REVISION DESCRIPTION
70-01, 70-02 70-01, 70-02 Text revised
70-70-1, 70-70-2 70-70-1, 70-70-2 Added Fuel Lift Pump
SPEC-10-1, SPEC-10-2 SPEC-10-1, SPEC-10-2 Text revised
2
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ROUTE TO
ATTENTION
PARTS MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 463-2

Date: 7 January 2004
Model: 463
Manual No: 6901177 (11-00)

463 WIRING SCHEMATIC 463 WIRING SCHEMATIC Revised Serial Number Break Information
S/N 520011001 AND ABOVE S/N 520011001 - 520011710
S/N 5199911001 AND ABOVE S/N 5199911001 - 519911424
(PRINTED APRIL 2001) (PRINTED JANUARY 2004)
V-0051 V-0051
463 WIRING SCHEMATIC Added New Schematic

(PRINTED JANUARY 2004)
V-0475
Printed in U.S.A.
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2
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: 463-3

Date: 6 September 2005
Model: 463
Manual No: 6901177 (11-00)

463 WIRING SCHEMATIC 463 WIRING SCHEMATIC Added Information
OPTIONS OPTIONS
S/N 520011001 AND ABOVE S/N 520011001 - 520011710
S/N 5199911001 AND ABOVE S/N 5199911001 - 519911424
(PRINTED APRIL 2001) (PRINTED SEPTEMBER 2005)
V-0056 V-0056
Printed in U.S.A.
358 of 361
359 of 361
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ATTENTION
PARTS MANAGER
Revision No: 463-4

Date: 23 March 2006
Model: 463
Manual No: 6901177 (11-00)
463 Service Manual (P/N 6901177) Dated (3-06) contains updated service information which replaces the previous
463 Service Manual (P/N 6901177) Dated (11-00).
Printed in U.S.A.
360 of 361
361 of 361

Service Manual: S/N 52001100 & Above S/N 519911001 & Above

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Service

Dealer Copy -- Not for Resale

6901177 (3-06) Printed in U.S.A. © Bobcat Company 2006

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Dealer Copy -- Not for Resale

B-6590 B-6580 B-6589

AIR CLEANER ........................................................ 70-01 LIFTING AND BLOCKING THE LOADER...............10-01

Dealer Copy -- Not for Resale

GLOWPLUGS ........................................................ 70-01

HYDRAULIC CONNECTION SPEC ..................SPEC-01

INSTRUMENT PANEL ........................................... 60-01

LIFT ARM SUPPORT DEVICE................................10-01

463 Bobcat Loader

463 Bobcat Loader

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

BOBCAT SKID STEER LOADER IDENTIFICATION . . . . . . . . . . . . X HYDROSTATIC

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 DRIVE

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

Dealer Copy -- Not for Resale

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 ENGINE

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

18. Inspect the air cleaner for

19. Check the electrical charging

20. Check tires for wear and

Dealer Copy -- Not for Resale

22. Operate the loader and check

23. Check for any field

24. Check for correct function of

463 Bobcat Loader

463 Bobcat Loader

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

• Service Safety Training Courses are available from

• 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