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Bobcat 7753 Service Repair
Bobcat 7753 Service Repair
Bobcat 7753 Service Repair
7
Service
Manual
5
3 6720899 (6–91) Printed in U.S.A. © Melroe Company 1991
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
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.
DRIVE
SYSTEM
MAIN
FRAME
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SPECIFICATIONS
A general inspection of the following items must be made after the loader has had service or repair:
3. The seat belt must be correctly 11. Safety treads must in good
installed, functional and in condition.
good condition.
4. The seat bar and pedal 12. Check for correct function of
interlocks must be correctly indicator lamps (Optional on
adjusted, clean and lubricated. some models).
6. Steering levers and foot pedals 14. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.
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.
W–2003–0199
The following publications provide information on the safe use of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealers.
• The EM Manual delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from Bobcat loader dealers for use by mechanics to do shop–type
service and repair work.
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this
symbol follow the safety message to avoid personal injury or death.
• Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.
• Wear safety glasses when maintaining or servicing the loader.
• Exhaust gases can kill, vent engine exhaust outdoors.
• Know where fire extinguisher and first aid kits are located and how to use them.
• Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• 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.
• Clean the loader before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire
extinguisher near the loader when welding.
• Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in this Manual for connecting battery.
• Use the procedure in this Manual for cleaning the spark arrestor muffler after each 100 hours of operation.
7753 Bobcat Loader
i Service Manual
SERIAL NUMBER LOCATIONS
A
Always use the serial number of the loader when
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
CD–06863
DELIVERY REPORT
C
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 [D].
FRONT LIGHTS
SEAT BAR
OPERATOR
GRAB SEAT
HANDLES
STEERING
LEVER
TILT CYLINDER FRONT
AUXILIARY
QUICK
COUPLERS
BUCKET
SAFETY TREAD
BUCKET STEPS
OPERATOR CAB
(ROPS & FOPS)
LIFT ARM LINK
LIFT ARM
REAR GRILL
TAIL LIGHT
LIFT CYLINDER
REAR LIGHT
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 SAE
J1043, ISO 3471 and ISO 3449 LEvel 1. Level 2 kit is available from your Bobcat dealer. The Bobcat loader is
base–equipped with a standard operator cab as shown.
ALTERNATOR BELT
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
BATTERY
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
COOLING SYSTEM
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Cleaning The Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . 1–14
DIAGNOSTIC TOOL
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–31
DRIVE BELT
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Adjusting The Drive Belt With Spring Loaded Drive Idler . . . . . . . . . . . . 1–25
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24
Replacing The Drive Belt With Spring Loaded Drive Idler . . . . . . . . . . . 1–26
FUEL SYSTEM
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Checking The Hydraulic Reservoir Breather Cap . . . . . . . . . . . . . . . . . . 1–18
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
Page
Number
LIFT ARM SUPPORT DEVICE
Installing The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Removing The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
SERVICE CODES
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–33
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
L Check wheel nut torque every 8 hours for the first 24 hours.
• Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ‘‘ON’’.
J Or every 12 months.
* Inspect the new belt after first 50 hours.
Put the floor jack under the rear of the loader [B].
Lift the rear of the loader and install jackstands [B].
P–02852
Put the floor jack under the front of the loader [C]. C
Lift the front of the loader and put jackstands under the
axle tubes [C].
NOTE: Make sure the jackstands do not touch the
tires.
P–02850
The loader can also be lifted with the single point lift which
is available as a kit from your Bobcat loader dealer.
Install the kit and lift as shown [C].
The single point lift, supplied by Melroe Company is
designed to lift and support the Bobcat loader without
affecting roll over and filling object protection features of
the operator cab.
MC–01822
P–03264 P–01644
The seat bar restraint system has a pivoting seat bar with
arm rests and has spring loaded interlocks for the lift and tilt
control pedals. The operator controls the use of the seat bar. B
The seat bar in the down position helps to keep the operator
in the seat. The interlocks require the operator to lower the
seat bar in order to operate the foot pedal controls. When
the seat bar is up, the lift and tilt pedals are locked when
returned to the neutral position.
P–00371
(Optional)
B
It is important to change the air filter element only when
the service codes (on the optional instrument panel)
shows the symbols AF 2 [B].
Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.
B–12914
P–01604
P–01603
CD–08698
P–01601
P–01607
P–01610
Operate the hand pump (priming bulb) until the fuel flows
from the vent with no air bubbles [B].
P–01576
Close the vent (Item 1) on the fuel filter housing [A].
C
Open the vent (Item 1) on the fuel injection pump [C].
Operate the hand pump (priming bulb) until the pump
feels solid [B]. 1
P–01573
P–01586
Put 7.5 qts. (7,1 L) of oil in the engine (See Oil Chart, Page
1–11) [B].
B
Start the engine and let it run for several minutes. Stop the
engine. Check for leaks and check the oil level. Add oil as
needed if it is not at the top mark (Item 1) on the dipstick
[B].
1
Raise the oil cooler and clean the top of the radiator [B]. P–01651
P–01586
P–01654
BATTERY
Removal and Installation
Open the rear door.
Disconnect the negative (–) battery cable [C].
Disconnect the positive (+) battery cable [D]. P–01609
CD–11460
CD–11461
P–01584
P–01635
P–01502 P–01643
Disconnect the hose from the case drain filter and plug the
filter and the case drain hose [B].
B
Remove the case drain filter and drain the fluid into a
container.
Replace the hydraulic/hydrostatic filter element.
Replace both case drain filters (Item 1) on the hydrostatic
motors [C] & [D].
When all the fluid is removed from the reservoir,
reconnect the hose to the case drain filter on the reservoir.
Add the correct fluid to the reservoir until the fluid level is
between the marks on the dipstick. DO NOT fill above the
top mark on the dipstick.
P–01650
P–01645
P–01593
P–01535
Tire Rotation
Check the tires regularly for wear, damage and pressure
B
(See Specification, Section 8 for the correct tire
pressure).
Rear tires usually wear faster than front tires. To keep the
tire wear even, move the front tires to the rear and rear
tires to the front [B].
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 speed and cause excessive wear.
The tread bars of all the tires must face the same
direction.
Recommended tire pressure must be maintained to avoid B–09976
excessive tire wear and loss of stability and handling
capability.
Tire Mounting
Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
Do not inflate tires above specified pressure.
The rim flange must be cleaned and free of rust. The tire Failure to use correct tire mounting procedure
bead and rim flange must be lubricated with a rubber can cause an explosion which can result in
lubricant before mounting the tire, avoid excessive injury or death.
pressure which can rupture the tire and cause serious W–2078–1285
injury or death. During inflation of the tire, check the tire
pressure frequently to avoid over–inflation.
P–01616
P–01619
FAN GEARBOX
Checking Grease Level
D
See the Service Schedule (Page 1–1) for the correct 1
service interval.
Raise the operator cab (Page 1–5).
Remove the plug (Item 1) to check the lubricant level [D].
If the level is low, add SAE 90W gear lube through the
check plug hole until the lubricant flows from the hole.
Install and tighten the plug.
P–01498
P–01659
Use the correct tools to adjust the idler tensioner and the
drive belt:
C
MEL–1405 – Belt Tensioner Bar
MEL–1406 – Spring Scale
The idler tensioner is located between the flywheel and
pump pulley. Loosen the bolt (Item 1) at the pulley
tensioner [C]. P–01662
P–01618
1
P–00593
Remove the drive belt from the pump pulley and flywheel.
Remove the drive belt from the loader [D].
P–01618
Install the new drive belt. Install the pulley tensioner
assembly.
Adjust the drive belt as shown in adjustment procedure.
D
P–01615
P–08762
PI–11467
PI–11468
CD–11469
CD–11470
CD–11471
CD–11472
PI–11473
10
P–01630
P–01533
PIVOT PINS
C
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and nut [C].
Check that the lock nuts are tightened to 18–20 ft.–lbs.
(24–27 Nm) torque.
PI–11467
Component Value
TEMPERATURE SENDER
70° F. (21° C.) . . . . . . . . . . . . . . . . . . . . . . . . . . 970 ohms
80° F. (27° C.) . . . . . . . . . . . . . . . . . . . . . . . . . 1013 ohms
CD–10399
ENGINE OIL PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ohms Max.
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 7 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . . . . . . 45 ohms
70 PSI (483 kPa) . . . . . . . . . . . . . . . . . . . . . . . . . 59 ohms
TRANSMISSION CHARGE PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–5 ohms
100 PSI (690 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 58 ohms
130 PSI (896 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 75 ohms
150 PSI (1034 kPa) . . . . . . . . . . . . . . . . . . . . . . . 87 ohms
FUEL SENDER
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ohms
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ohms
RPM SENSOR
Continuity Resistance of 250–550 ohms.
Set Clearance as follows from the flywheel:
W/O Plastic Tip . . . . . . . . . . . . . . . . . 0.050” (12,7 mm)
W/Plastic Tip . . . . . . . . . Plastic Tip to Touch Flywheel
Black
Purple/Red
Ground
Negative Com. .5 to 1.5 Volts
Positive Com. 3.5 to 4 Volts
5.0 Volts Regulated Power
During an active Low voltage (5.0) 1. Turn the ignition switch OFF. Re–starting will
WARNING display, triggered reset. return hourmeter reading.
reset occurs and the 2. If re–starting will not return hourmeter reading,
hourmeter becomes check pins B & C as stated in Step 5 below.
all zero’s.
Garbled message, The display is not fault 1. Turn the ignition switch OFF and re–start. A
missing segments, tolerant. Also can be fault is an invalid message that the display tries
etc. an indication of poor to display. Generally a fault occurs if
internal connections. communications of two messages are combined
on the display.
After glow sequence 1. Turn the key OFF and re–start.
or after a WARNING
goes away, the Icon
remains ON.
No Bar Graphs, no Bad display or BOSS 1. Plug in the BOSS tool and start the engine.
Hours. is not communicating. 2. If data is being received by the BOSS tool, the
BOSS unit is not the cause of the problem.
3. If no data is received at the BOSS tool.
disconnect the LCD display.
*4. If messages are now received at the tool, the
display is the problem. If problem still exists go to
* NOTE: The display has caused the Step 5.
problem by locking the 5. Check pins B & C for signal.
communication lines and 6. If there is no signal, install BOSS back–up unit.
stopping communications from 7. If the problem still exists, check the harness for
the BOSS. continuity.
Page
Number
CONTROL PEDALS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18 HYDRAULIC
SYSTEM
HYDRAULIC CONTROL VALVE
Checking the Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Main Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 2–8
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
HYDRAULIC FILTER HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
HYDRAULIC FLUID RESERVOIR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
HYDRAULIC PUMP
Checking the Output of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
HYDRAULIC SYSTEM INFORMATION
Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
O–Ring Face Seal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Straight Thread O–Ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Tubelines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
LIFT CYLINDER(S)
Checking the Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
PEDAL INTERLOCK LINKAGE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
TILT CYLINDER
Checking the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Rod End Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The lift arms or Bob–Tach will move the pedal in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
Tighten to Correct
When repairing hydrostatic and hydraulic Amount from Chart
systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
A–01897
Flare Connections
Use the following procedure to tighten the flare fitting:
B Tube Size Rotate No.
Wrench Size Outside Dia. Thread Size of Hex Flats
Tighten the nut until it makes contact with the seat. Make
a mark across the “flats” of both the male and female parts 5/8” 5/16” 1/2” – 20 2–1/2
of the connection [A]. 11/16” 3/8” 9/16” – 18 2
7/8” 1/2” 3/4” – 16 2
1” 5/8” 7/8” – 14 1–1/2 – 2
Use the chart to find the correct tightness needed [B]. If 1–1/4” 3/4” 1–1/16” – 12 1
the fitting leaks after tightening, disconnect it and inspect
the seat area for damage. 1–3/8” 1” 1–5/16” – 12 3/4 – 1
2” 1–1/4” 1–5/8” – 12 3/4 – 1
2–1/4” 1–1/2” 1–7/8” – 12 1/2 – 3/4
B–07575
CD–11491
CD–11492
Remove the rod end retainer pivot pin bolt and nut [B]. B
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
CD–11493
CD–11496
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
B
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
Disconnect the hose which goes to the base end of the tilt
cylinder [A].
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there CD–11497
is leakage from the open port, remove the tilt cylinder for
repair.
C
Removal and Installation
Remove the retainer bolt from the rod end pivot pin [C]. CD–11498
CD–11499
CD–11501
CD–08713
Use two pieces of shim stock, install the rod end of the tilt
cylinder into the Bob–Tach so there is no damage to the D
seals [D].
CD–08714
1
The hydraulic tester must be in the fully open
position before you start the engine. 2
I–2024–0284
3
B–13443
C
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286
Left Right
Start the engine and run at low idle RPM. Push the mode Steering
switch (Item 1) twice (on the instrument panel) to engage Steering
Lever Lever
the front auxiliary hydraulics ‘‘detent’’, the light (Item 3) will Control
come “ON” [B]. (Optional)
P–02154 P–02152
CD–08717
B
Stop the engine. Move the hydraulic controls to release
the hydraulic pressure. Raise the seat bar.
Lift and block the loader (Page 1–2).
Raise the operator cab (Page 1–5).
Clean the area around the control valve.
Disconnect the wiring harness from the two solenoids on
the control valve [A]. 2
1
Disconnect the hose (Item 1) which goes to the hydraulic
reservoir [B].
P–02451
When this hose is disconnected it will drain the fluid from
the reservoir. Install a plug in the hose or drain the fluid
into a container. C
Disconnect the hose (Item 2) which goes to the
hydrostatic motor [B].
Disconnect the tilt and lift foot pedal linkages from the
valve spools [C].
Disconnect all the hoses and tubelines from the control
valve.
Remove the two mounting bolts.
Installation: Tighten the mounting bolts to 15–16 ft.–lbs.
(21–23 Nm) torque. CD–08720
C
Loosen the hose clamps on the fuel tank fill hose [C].
CD–08730
CD–08731
CD–08732
CD–08727
CD–08733
CD–08734
CD–08735
CD–08736
D
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
P–02287
P–02288
P–02286
B
Disconnect the wires from the sender [A].
CD–08739
CD–08740
CD–08741
CD–08742
P–02451
P–02455
Remove the bolt and plate from the mounting strap [C]. C
Installation: Tighten the bolt to 16–20 ft.–lbs. (21–27 Nm)
torque.
CD–08745
CD–08746
CD–08747
CD–08748
Adjustment C
After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal [C].
The valve spool must travel full stroke without the pedal
hitting the floor panel.
P–01640
Loosen the lock nuts (Item 1) from the interlock bolts [B].
Remove the spring from under the interlock block. B
Remove the lock nut and plastic washers.
Installation: Tighten the interlock nut to 84–96 in.–lbs.
(9,5–10,8 Nm) torque.
Remove the interlock.
Remove the plastic washers between the interlock and 1
the fender. Remove the bolts.
Installation: During installation be sure to keep the
interlock pressed against the loader frame so the
plastic washers on each side of the interlock (top and
bottom) do not fall out. It may be necessary to hold P–01195
the plastic washers with an O–ring pick or small
screw driver.
C
Adjustment
Check the pedal interlock linkage so it is free and locks
both pedals.
Check that the tab on the linkage goes into the slot on the
interlocks and holds the pedal [C].
If not, loosen the bolts and adjust the tab for correct
engagement [C].
Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.
P–01214
Page
Number
DRIVE BELT TENSIONER PULLEY
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Checking Pulley End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
FRONT PANEL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
HYDROSTATIC
HYDROSTATIC MOTOR SYSTEM
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
HYDROSTATIC PUMP
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
OIL COOLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
SPRING LOADED DRIVE BELT IDLER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–35
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–33
STEERING LEVERS
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
STEERING LINKAGE
Centering Plate (S/N 30758 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
Pintle Arm Removal and Installation (S/N 30758 & Below) . . . . . . . . . . 3–13
Pintle Arm Lobe Removal and Installation (S/N 30758 & Below) . . . . . 3–13
Removal and Installation (S/N 30758 & Below) . . . . . . . . . . . . . . . . . . . . 3–11
Removal and Installation (S/N 30759 & Above) . . . . . . . . . . . . . . . . . . . 3–14
Steering Linkage Adjustment (S/N 30758 & Below) . . . . . . . . . . . . . . . . 3–9
Steering Linkage Adjustment (S/N 30759 & Above) . . . . . . . . . . . . . . . . 3–16
Steering Neutral Adjustment (S/N 30759 & Above) . . . . . . . . . . . . . . . . 3–18
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
Service code “HP 2” appears (Warnings, low charge pressure). 8, 11, 12, 13, 14
1
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286
P–02454
Remove the bolts from the rubber boot retainer plate for
the parking brake boot [B].
CD–08755
Remove the bolt from the steering shock (both sides) [C].
C
CD–08756
P–02452
CD–08758
CD–08759
P–02454
CD–08762
CD–08763
CD–08764
CD–08765
CD–08766
Remove the bolts from the steering lever rubber boot for
the stop [B]. B
CD–08767
CD–08768
Use a pry bar to push the centering spring plate all the way
over [C]. C
P–05321
CD–08771
Move the right steering lever until the tires do not turn
(neutral). B
Move the pintle bar against both lobes of the pintle lever.
Tighten the bolts to 28 ft.–lbs. (38 Nm) torque [B].
Move both steering levers backward and forward and let
the transmission return to neutral. If the transmission
does not return to neutral, repeat the above procedure
again.
Stop the engine.
CD–08774
CD–08769
CD–08776
Remove the lock nut from the centering spring bolt [B].
B
Installation: Tighten the centering spring bolts and a
NEW lock nut to 25–28 ft.–lbs. (34–38 Nm) torque.
CD–08777
P–02854
P–02860
CD–08780
CD–08781
CD–08782
CD–08783
P–02861
CD–08790
CD–08791
P–03729
Slide the plate (Item 1) [B] to the right and remove it from
the two guide pins (Item 2) [B].
B
1
12
NOTE: The two (2) guide bushings (Item 3) [B] will be
loose and can fall out of the plate (Item 1) [B]
as soon as it is removed from the guide pins
(Item 2) [B].
3 2
P–03736
2
2 3
P–03735
If the surface of any of the four (4) pintle cams (Item 1) [D] D
is worn, loosen the bolt (Item 2) [D] and rotate the cams
1/4 turn. 1 2
2
1
P–03733
P–03733
P–03734
Move the right hand steering lever to the rear and install P–03724
a 3/8 inch (10 mm) thick spacer (Item 1) [C] between the
pintle arm cam (Item 2) [C] and the centering block (Item
3) [C].
D
Move the right hand steering lever forward and install a
15/16 inch (24 mm) thick spacer (Item 1) [D] between the
center plate (Item 2) [D] and the mounting plate (Item 3)
[D].
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel speed.
2
Remove the 3/8 inch (10 mm) thick spacer (Item 1) [C].
1
3 P–03723
P–03730
Loosen the two (2) bolts and nuts (Item 1) [B] on each
steering linkage bar. B
P–03727
1
P–03723
Loosen the nut (Item 1) [A] about 2 turns, then loosen the
bolt (Item 2) [A]. The bolt (Item 2) [A] is threaded into the
linkage bars (Items 3 & 4) [A]. B
The bolt (Item 2) [A] must be loose enough to allow the 2 1
2
torsion bushing to turn freely between the pintle arm and 1
the linkage bar.
Loosen the four (4) bolts (Item 1) [B] holding the two (2)
centering blocks. Move the right hand centering block to
the right as far as possible.
P–03731
1
P–03757
P–03726
CD–11506
CD–11507
CD–11508
CD–11509
CD–11510
See Page 4–1 to remove the seal carrier and replace the
seal.
SEE THE HYDROSTATIC MOTORS COMPONENT
REPAIR MANUAL FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
Remove the belt shield. Loosen the bolt at the drive belt
tensioner pulley [A].
P–00584
P–00595
P–00592
Hold the hydrostatic pump pulley and loosen the nut [D].
D
Installation: Tighten the nut to 175–200 ft.–lbs.
(237–271 Nm) torque.
Remove the nut and washer.
P–00589
Install a puller and remove the pulley from the pump shaft B
[A].
1
Remove the puller.
CD–08806
P–02288
CD–08809
CD–08810
CD–08811
D
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
CD–08808
CD–12634
CD–12635
CD–12636
Remove the idler pulley and bearing from the shaft using
a press [D]. D
CD–12637
CD–12638
CD–12639
CD–12640
CD–12641
CD–12642
Install the bearing cup using the driver tool (both sides)
[C].
C
NOTE: The seal side of the pulley hub has the larger
I.D. diameter.
CD–12643
Install the taper roller bearing to the pulley (seal side) [D]. D
CD–12644
CD–12645
MC–01648
Press the seal into the pulley hub larger diameter using
a press [C].
C
NOTE: The wear sleeve and the seal must be
replaced as a unit.
DO NOT damage the seal lips with the sharp edge of the
wear sleeve. Install the wear sleeve into the seal.
CD–12646
Use a spacer tube which goes over the shaft and pushes
on the inside diameter of the taper bearing, install the D
pulley, seal and wear sleeve onto the shaft [D].
CD–12647
CD–12648
CD–12649
CD–12650
CD–12651
CD–12652
0.50” (12,7)
MC–01648
Add the oil slowly, at one location of the bearing which will
allow the trapped air to escape from the other side [C].
C OIL LEVEL
MC–01648
CD–12653
P–05320
CD–12655
Move the pulley by hand, back and forth. The correct end
play is 0.005–0.013” (0,13–0,33 mm) [C].
C
If the end play is not correct, there is no adjustment.
Replace the hub, pulley and/or bearings.
CD–12656
P–01617
P–01659
P–08760
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
7. Snap Ring
8. Snap Ring 2
9. Bearing
10. Dust Shield
11. Pulley
12. Bushing
13. Hub 11
14. Washer 3
15. Seal
16. Arrow Indicator Plate
17. Locating Pin 12
18. Spring 4
19. Shaft
20. Bracket
21. Rod
5
NOTE: Drive idler parts are not
available individually. Consult 13
parts catalog for available 6
sub–assemblies.
5 14
15
7
8
16
17
9
18
10
19
21 20
E–02296
P–08858
Remove the bolt (Item 1) [B], the flat washer (Item 2) [B],
the retainer washer (Item 3) [B], the spring washer (Item B
4) [B] and the second retainer washer (Item 3) [B] from
the pulley assembly (Item 5) [B]. 5
2 3
1 4
P–08859
Remove the two pins (Item 1) [C] from the hub assembly
(Item 2) [C] only if they have been damaged. C
Remove the bracket assembly (Item 3) [C] by tapping on
the shaft (Item 4) [C] with a plastic hammer.
3 1
P–08861
P–08862
P–08871
2
3
P–08872
Turn the pulley assembly over and install the two pins
(Item 1) [B] into the hub.
B
P–08873
P–08874
P–08875
P–08876
P–08877
Page
Number
AXLE HUB AND SEAL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
AXLE SPROCKET AND BEARINGS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
CENTER TRANSMISSION COVER
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
CHAINCASE FLUID
Replacing the Chaincase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
DRIVE CHAIN DRIVE
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 SYSTEM
FRONT CHAINCASE COVER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
MOTOR CARRIER (Later Models)
Early Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
PARKING BRAKE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Brake Block and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
REAR CHAINCASE COVER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.
P–02450
P–02294
Loosen the bolt (do not remove the bolt) on the brake
lever [D]. D
P–02088
P–02294
Remove the bolt and nut from lift pedal linkage [C].
C
P–02430
P–02285
P–02299
P–02297
P–02088
P–02087
P–02089
P–01732
CD–08829
CD–08830
P–01725
P–01737
CD–08834
CD–08835
CD–08836
Brake Discs
To remove the brake discs, use the following procedure:
B
Remove the front cover (Page 4–7).
Remove the snap ring [B].
P–02095
REAR
MC–01707
PI–11531
PI–11532
P–02099
P–02103
CD–08841
CD–08842
P–02098
P–02102
P–02096
Early Models
D
Remove the hydrostatic motor (Page 3–13).
Remove the seal carrier from the motor carrier [D].
P–02097
P–02108
P–02094
P–02110
7
8
3 2 5 9
4 6
Lip Faces
OUT
1. Shaft 6. Seal (New)
2. Bearing 7. O–ring
3. Race 8. Seal Adapter (Old)
4. Snap Housing 9. Seal (Old)
5. Spacer
MC–01937
EARLIER MODLES
B
1
2 3
4 Lip Faces
IN
9
10
11
3 2
6 7 Lip Faces
8 OUT
1. Shaft 6. Housing
2. Bearing 7. Snap Ring
3. Race 8. Seal (New)
4. Snap Ring 9. O–ring
5. Spacer 10. Seal Adapter (Old)
11. Seal (Old) MC–01939
CD–11536
CD–11537
CD–11538
CD–11539
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
B
injury.
CD–11540
CD–08860
CD–08861
CD–08862
Installation: Install the new seal on the axle and into the
axle tube [B]. C
Installation: Install the seal driver tool over the axle [C].
CD–08863
CD–08864
Loosen the axle sprocket bolt when the hub bolt is being
removed [A].
P–02092
Installation: Tighten the axle sprocket bolt to 220–245
ft.–lbs. (298–332 Nm) torque.
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket [C].
CD–08867
P–02101
P–02107
P–02105
Install the bearing cup puller tool into the axle tube [C].
C
B–07627
B–07686
B–07687
Using the correct size driver tool, install the outer bearing
cup [B]. B
B–07679
Install the long threaded rod into the axle tube. Install the
correct size bearing cup driver tool. Install the washer and
nut [C].
C
B–07680
B–07681
B–07683
Turn the nut on the outside of the axle tube until the inner
bearing cup is on its seat [B]. B
B–07682
B–07692 B–07691
Remove the front and rear drive chain from the chaincase
[C].
P–02109
B–13504
CD–09373
Remove the plug (Item 1) and drain the oil into a container
[B]. B
PI–09000
P–01551
Page
Number
BOB–TACH
Bob–Tach Lever and Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
LIFT ARMS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
LIFT ARM LINK
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
OPERATOR CAB
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
OPERATOR CAB GAS CYLINDER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 MAIN
FRAME
REAR DOOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
REAR GRILL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
SEAT BAR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.
Connect a chain to the operator cab and lift arm link [B].
CD–11542
CD–11543
CD–11544
CD–11545
Remove the cotter pin from the top pivot pin [B].
B
CD–11546
CD–11547
CD–11548
P–01008
P–01006
OPERATOR CAB C
Removal and Installation
Remove the gas cylinders (Page 5–1).
Disconnect the electrical wiring harness connectors [C].
CD–08880
MC–01526
CD–11549
CD–11550
REAR DOOR
Removal and Installation
C
Connect a chain hoist to the rear door [C].
CD–08883
Remove the pivot bolt and nut (both top and bottom) [D].
Remove the rear door from the loader hinges.
D
CD–08884
CD–11551
Remove the pivot bolt and nut and disconnect the left gas
OLD
cylinder from the rear grill [B]. B
CD–11552
Remove the pivot bolt and nut and disconnect the right
OLD
gas cylinder [C]. C
CD–11553
Remove the cotter pin from the pivot pin (both sides) [D].
OLD
D
CD–11554
CD–11555
OLD
Lift the rear grill from the loader [B]. B
CD–11556
P–02444
Lower the rear grill and remove the cotter pin from the
NEW
pivot pin (both sides) [B]. B
P–02441
P–02440
NEW
Lift the rear grill from the loader [D]. D
P–02449
CD–11497
CD–11498
Use a punch and hammer, remove the tilt cylinder rod end
pivot pin [C]. C
CD–11499
Remove the tilt cylinder rod end. Remove the seals [D]. D
CD–08713
CD–08714
CD–11557
Loosen the bolt at the Bob–Tach pivot pin (both sides) [C].
C
Installation: Tighten the bolt to 130–140 ft.–lbs. (176–190
Nm) torque.
CD–11558
Hit the bolt to start the pivot pin into the Bob–Tach frame
(both sides) [D]. D
Remove the bolt. Use a punch to push the pivot pin all the
way into the Bob–Tach frame.
Installation: A longer bolt may be needed to turn into the
pivot pin. Pull the pivot pin into the lift arms.
Remove the Bob–Tach frame from the lift arms.
CD–11559
CD–08893
CD–08894
Turn the bolt into the pivot pin. Remove the pivot pin from
the Bob–Tach frame [C]. C
Check for wear and damage. Replace the pivot pins as
needed.
CD–08895
CD–08896
CD–08897
CD–08898
Use a punch and hammer, remove the roll pin from the
Bob–Tach wedge and spring bolt clevis assembly [C]. C
CD–08899
CD–08900
CD–08901
CD–08902
CD–11560
Use a drift pin and hammer, remove the lift arm pivot pin
(both sides) [B]. B
CD–11561
Connect a chain and chain hoist on the lift arm link [C].
C
CD–11562
Remove the retainer bolt and nut from the lift arm link
pivot pin (both sides) [D].
D
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
CD–11563
CD–11565
CD–11566
Remove the retainer bolt and nut from the lift arm pivot pin
(both sides) [C]. C
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
CD–11560
Use a drift punch and hammer, remove the lift arm pivot
pin (both sides) [D]. D
CD–11561
Remove the retainer bolt and nut from the stabilizer pivot
pin (both sides) [B]. B
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
Use a drift punch and hammer, remove the stabilizer pivot
pin (Item 1) (both sides) [B].
1
CD–11567
Lift the lift arms with the chain hoist and move them away
from the loader [C]. C
CD–11568
CD–08906
CD–08907
Disconnect the fuel fill hose and vent hose from the fuel
tank [D]. D
CD–08908
CD–08910
Remove the fuel tank inlet screen. Clean and dry the
screen. Check for damage and replace as needed [B]. B
CD–08911
CD–08912
Turn the fuel level sender out of the fuel tank. Remove the
sender from the fuel tank [D].
D
CD–08913
Page
Number
ALTERNATOR
Alternator Output Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
Alternator Regulator Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Checking the Alternator Output (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Checking the Alternator Regulator (Old Style) . . . . . . . . . . . . . . . . . . . . . . . 6–4
Checking the Rectifier (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Checking the Rotor (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Checking the Stator (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Disassembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Disassembly (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Parts Identification (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Rectifier Continuity (Diode) Test (New Style) . . . . . . . . . . . . . . . . . . . . . . 6–12
Rectifier (Diode) Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
Removal and Installation (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Rotor Continuity Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Rotor Ground Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Stator Continuity Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Stator Ground Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
BATTERY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
ELECTRICAL SYSTEM INFORMATION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ELECTRICAL
INSTRUMENT PANEL SYSTEM
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–21
OPERATING SYSTEM UNIT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
STARTER
Checking the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8)
UNLESS OTHERWISE SPECIFIED.
CD–10367
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
CD–06896
B–03710
B–08068
CD–08917
CD–08918
1. Nut 14
2. Pulley
3. Fan
4. Bolt
5. Case Half (Front)
6. Bearing 11. Heat Sink (–)
7. Rotor 12. Case Half (Rear)
8. Slip Ring 13. Condenser Assy.
9. Stator 14. Brush Holder
10. Heat Sink (+) 15. Regulator D–01760
B–09375
Touch one probe to the shaft and one probe to a slip ring,
then touch the other slip ring. There must be maximum C
resistance [C].
B–09376
B–09380
B–09378
B–09377
B–09385
B–09377
B–09385
P–01369
P–01386
P–01365
P–01373
Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [D]. D
Reverse the probes to check the diode in the other
direction.
Touch on Bottom
Heat Sink
P–01370
Touch on Center
Heat Sink
P–01390
P–01808
Bat
If the starter turns, the defect is in the solenoid. S
M
If the starter does not turn, the starter is defective.
Cranking
Motor
A–01991
CD–08919
CD–08920
CD–08921
CD–08922
CD–08923
CD–08924
CD–08925
CD–08926
CD–08927
CD–08928
CD–08929
CD–08930
Armature
Broken or burned insulation
Loose connections at commutator
Open or grounded circuits [C] & [D].
Worn shaft or bearings A–01995
Rough commutator
Brush Holders
Broken springs
D
Broken insulation
Spring Tension
Field Coils
Broken or burned insulation
Electrical continuity
Brush connections
Drive Gears
Worn teeth
Tooth engagement
A–01994
Drive Gear
Worn Teeth
Tooth engagement (drive gear must engage ring gear B–02122
by 1/2 the depth of the ring gear tooth)
To test for ground, use a test light and touch one probe to
the body and the other probe to the field winding end of
B
the brush. The lamp should not light [B].
B–09576
1. Screw
2. Solenoid
3 3. Bolt
4. Lever
2 5. Washer
4 6. Nut
1 7. Plug
8. Washer
9. Housing Drive
10. Washer
11. Bushing
5 12. Ring
6 13. Stop
14. Drive
9 8 7 15. Drive Support
16. Support
17. Drive Shaft
10 18. Washer
19 19. Washer
20. Washer
21. Screw
22. Brush
12 13 23. Frame Assy.
14 16 18 20 24. Gasket
15 17
25. Pin
26. Armature Support
11 27. Bolt
28. Spacer
29. Bearing
21 30. Armature
26 22 31. Bearing
25 24 32. Spring
33. Holder Assy.
34. Brush
35. Screw
36. O–ring
37. Frame
38. Washer
23 39. Screw
27 22 40. Bolt
21
35
35 34
34
28 38
39
40
29 31 32
30 33 36 37
D–02119
CD–08880
CD–08932
CD–08933
CD–08934
CD–08935
CD–08936
Pull the right side instrument panel down and away from
the operator cab [C].
C
Disconnect the wire harness connectors from the
instrument panel display. Replace parts as needed.
CD–10466
CD–10467
CD–10468
Page
Number
AIR CLEANER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
BELT SHIELD
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
BLOWER HOUSING/FAN GEARBOX
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Tension Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
CRANKSHAFT AND BEARINGS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–62
Servicing the Crankshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–63
CRANKSHAFT GEAR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–56
CYLINDER BORE
Checking the Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–67
CYLINDER HEAD
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–43
Servicing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45
ENGINE
Engine Mounts Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7–29
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
ENGINE COMPRESSION ENGINE
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34 SERVICE
ENGINE MUFFLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
FAN GEAR BOX
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Long Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Short Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Long Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Short Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31
FUEL CAMSHAFT
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–55
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–55
Page
Number
FUEL INJECTION PUMP
Adjusting Shut–Off Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37
Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40
Checking the Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40
GLOW PLUGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
IDLER GEAR AND CAMSHAFT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–52
Servicing the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–53
Servicing the Idler Gear and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–54
OIL PUMP
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–57
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–56
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–56
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–57
PISTON AND CONNECTING ROD
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–61
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–58
Servicing the Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . 7–59
RADIATOR ENGINE
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 SERVICE
ROCKER ARM AND SHAFT
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
TENSION PULLEY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
TIMING GEARS
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–54
TIMING GEARCASE COVER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
VALVES, VALVE SEAT AND GUIDE
Checking the Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
Reconditioning the Valve and Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . 7–47
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–48
WATER PUMP
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–68
CD–06892
CD–08943
CD–08944
CD–08945
CD–08946
P–02434
P–02435
CD–08951
CD–09951
CD–08952
CD–08953
PI–09952
.562 .562
AVOID INJURY OR DEATH to to
Wear safety goggles to prevent eye injury .570 .570
when drilling or grinding.
W–2108–1186
C
To insure straight drilling and tapping of the holes, a drill
press is recommended.
Drill the two holes 1.00” (25,4 mm) deep using a 13/64”
(5 mm) bit [C].
Use a 1/4” NC bottom tap to cut maximum threads in the
holes.
P–03007
P–03006
PI–09953
1
PI–09954
PI–08954
Remove the four mounting bolts and the part number tag
[B]. C
Remove the oil from the gear box.
P–02964
P–02963
P–02966
Support the lower flange and press the shaft from the
bearing [C]. C
NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
P–03004
Support the bearing and press the shaft from the bearing
[D]. D
P–03298
P–02997
P–02996
Remove the large snap ring from the flange end of the
housing [C]. C
P–02970
P–02969
P–02978
Remove the snap ring from the cap end of the housing
[B]. B
P–02973
P–02998
Press the bearing from the tapered end of the shaft [D]. D
P–03088
P–03001
P–02972
P–02961
Long Housing
Press a bearing on the short keyed end of the long shaft
[A]. B
P–02960
P–02962
P–02963
P–02964
Install the gear key in the flange end of the shaft [B].
B
P–02965
P–02967
P–02966
P–02968
P–02969
Install the large snap ring in the groove above the shims
[C].
C
P–02970
P–02971
P–02975
P–02976
Install, on the shaft, the same number and size shims that
were removed during disassembly [C]. C
P–02977
P–02974
P–02973
P–02978
P–02987
P–02981
P–02983
Install the long key (Item 1) and the pulley (Item 2) [D].
Install a bolt in the set screw hole to maintain a 1.00” (25.4
D
mm) distance from the shaft center to the bolt head (to be 1.00”
(25,4 mm)
used with a dial indicator).
P–02984
P–02982
P–03089
Install the seal(s) flush with the housing surface [B] & [C].
LONG HOUSING
B
P–02985
SHORT HOUSING
C
P–02986
Add SAE 90 gear oil in the short housing to about 1/2” (12
mm) below the flange surface [D]. D
Clean any oil from the flange surface.
Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 25–28 ft.–lbs. (34–38 Nm)
torque.
P–02989
9
4
12
13 15
14
*16
10
21
11
17
20 12
13
14
18
19
TS–01002
P–00585
Remove the spacers, bolt and washer from the arm [B].
B
P–00582
P–00581
Remove the bolt, spring and arm from the idler pulley [D].
D
Check all parts for damage or wear and replace them as
needed.
P–00583
AIR CLEANER
B
3
Removal And Installation
1
Loosen the hose clamp on the air cleaner intake hose 2
(Item 1) [B].
Loosen the hose clamp on the intake manifold hose (Item 3
2) [B].
Disconnect the hose from the manifold.
Remove the air cleaner housing mounting bolts (Item 3)
[B].
P–02436
Installation: Tighten the bolts to 25–28 ft.–lbs. (34–38
Nm) torque.
Remove the mounting bolts below the air cleaner.
C
Move the air cleaner housing out of the engine
compartment and disconnect the wires from the sender
unit [B].
Remove the air cleaner [C].
P–02437
CD–08964
CD–08965
CD–09980
CD–08718
P–02293
CD–08730
CD–08731
P–02287
CD–08776
CD–08968
P–02303
CD–08970
CD–08880
2 1
CD–08971
CD–08972
P–02469
MC–01771
MC–01765
4’’
2’’
45° 9’’
1’’
4’’
5’’ 1’’
.375’’
.3125’’ (2)
Use Two 3/8’’ x 1–1/4’’ Bolts
for Drilled and Tapped Holes
MC–01799
P–02864
P–00587
P–00586
P–00590
CD–09956
CD–09957
CD–09958
CD–09959
MC–01368
Put the correct size feeler gauge between the rocker arm
and the valve stem. Turn the adjustment bolt until the
clearance is correct [B].
B
Tighten the adjusting bolt lock nut.
B–11621
CD–09964
CD–09965
CD–09966
GLOW PLUGS
D
Checking
Disconnect the glow plug cables and leads.
Touch one probe to the end of the glow plug and the other
probe to the body of glow plug [D].
The reading must be between 1 and 2. If the resistance
is zero ohms the glow plug has a short circuit. If the
resistance is infinite, the coil of the glow plug is broken.
Repeat the procedure for each glow plug.
P–01807
Stop
B–13704
CD–09967
CD–09968
CD–09969
1
1
CD–09971
CD–09972
D
Do not attempt to maintain or adjust unless
you are trained and have the correct 1
equipment.
I–2028–0289
CD–09970
CD–09973
Rotation
MC–01542
CD–09961
B–11493
CD–09967
CD–09974
CD–09975
CD–09976
Remove the fuel return pipe from the fuel injectors [B].
B
CD–09977
CD–09978
CD–09979
2
Do not disassemble or test the fuel injector 3 (1) Nozzle Holder
nozzles unless you have the correct service (2) Adjusting Washer
and testing tools. 4
I–2027–0284 (3) Nozzle Spring
5 (4) Push Rod
6 (5) Distance Piece
The tool listed will be needed to do the following procedure: (6) Nozzle Piece
7 (7) Nozzle Retaining Nut
MEL–10018 – Injector Nozzle Tester
Disassemble and clean the injector nozzle. PI–09981
A–02621
PI–09982
1
Remove the fuel injector nozzles (Page 7–40). B
Remove the glow plugs (Page 7–35).
Remove the belt shield (Page 7–32).
.
Remove the alternator (Page 6–3). .
Remove the rocker arm and shaft assembly (Item 1) [B].
Remove the push rod (Item 2) [B]. 2 2
PI–09983
PI–09984
FRONT
PI–09985
PI–09986
4 3
5
6 2
PI–09987
1 2 3 4 5 6
Cap Collets Retainer Spring Valve Seal
B–04122
B–03643
A–02735
Put the straight edge on the cylinder head’s four sides and
two diagonal as shown in figure [B]. B
The maximum distortion of the head surface is 0.002”
(0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.
PI–09988
Top Clearance
C 2
Install the cylinder head gasket. Put the piston (Item 1)
being checked at T.D.C. [C].
Put 3 pieces of 0.06” (1,5 mm) diameter solder (Item 2)
on the top of the piston [C]. Use grease to hold them in
position.
B–03634
PI–09991
0.295–0.303”
(7,5–7,7 mm)
0.393”
0.2” (10,0 mm) 0.71”
(5,0 mm) (18,0 mm)
PI–09992
PI–09993
PI–09994
PI–09995
A–02759
2
PI–09996
PI–09997
Remove the start spring (Item 1) from the fork lever (Item
2) [C]. C 2
Installation: Be careful, do not drop the spring into the
gearcase.
1
PI–09998
B–03694
PI–09999
B–04095
PI–10000
Installation: Install new O–rings and oil seal into the timing
gearcase cover [D].
D
NOTE: When a new timing gearcase cover is
installed, to establish the “correct position”
of the injection pump fuel rack stop before
removing it from the old timing gearcase
cover, the distance from the machined
surface of the gearcase (gasket surface) to
the end of the stop should be measured. The
stop should then be installed in the new
gearcase and set to the same distance that
was previously measured. Do not try to test Oil Seal
operate the engine to establish if it has O–rings
enough power. The adjustment must be set
by qualified service personnel for the
injection pump. B–03617
B–03655
0.003–0.009”
(0,07–0,22 mm)
PI–10002
B–03620
A–02761
B–05001
A–02760
1.413–1.415”
(35,9–35,95 mm) 1.258–1.259”
(31,96–31,97 mm)
MC–01366
PI–1007
Governor
The governor serves to keep the engine speed constant
C 1 5 4
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load.
3
Disassemble and assemble the governor and fuel 2 9
camshaft as shown in figure [C].
Check all the parts for wear or damage and replace as
needed. 12
6
8 7
10
11
13
1. Start Spring
2. Governor Spring
3. Governor Spring
4. Fork Lever
5. Fork Lever
6. Fork Lever Shaft
7. Fork Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball
PI–10008
OIL PUMP
Removal and Installation
B
Remove the timing gearcase cover (Page 7–50). 1
B–03658
Measure the clearance between the outer rotor and pump B–03616
body [D].
If the clearance exceeds the allowable limit, replace the
oil pump. D
Clearance Between Inner &
Outer Rotor . . . . . . . . . 0.004–0.006” (0,10–0,16 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.008” (0,2 mm)
Clearance Between Outer Rotor
& Body . . . . . . . . . . . . . . 0.004–0.008” (0,10–0,2 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . 0.010” (0,25 mm)
A–02732
Relief Valve
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is a ball
type.
Remove the valve seat (Item 2), ball (Item 3) and spring
(Item 1) [C].
PI–10011
Check the parts for wear or damage and replace as
needed.
PI–10013
A–02903
B–03621
3
PI–10015
PI–10014
A–02733
1.098–1.1004”
1.378” (35 mm) (27,9–27,95 mm) 0.984–0.985”
(25,0–25,011 mm)
MC–01366
PI–10016
Install new piston ring into the lower part of the cylinder.
Measure the ring gap with a feeler gauge [C]. C
Compression Ring Gap 0.012–0.020” (0,38–0,05 mm)
Oil Ring Gap . . . . . . . . . . . 0.010–0.016” (0,25–0,4 mm)
Allowable Limit . . . . . . . . . . . . . . . . . . . . 0.05” (1,25 mm)
B–03622
PI–10017
PI–10019
B–09565
1
PI–10018
PI–10020
B–04092
PI–10021
A–02763
A–02727
A–02716
PI–10022
PI–10023
B–03631
B–03618
REMOVAL TOOL
To remove the front bearing make the driver tool as shown
in figure [C].
C
5.31” (135 mm)
0.8”
(20 mm)
2.0413–2.0433”
2.83” (51,85–51,90 mm)
(72 mm)
To install the front bearing make the driver tool as shown 5.12” (130 mm)
in figure [D]. D 0.8”
(20 mm)
0.35”
(9 mm)
2.2382–2.2402”
(56,85–56,90 mm)
2.83”
(72 mm)
PI–10024
B–04066
A–02717
B–05318
Put the water pump in a vise and remove the nut [B]. B
Remove the pulley using a puller. Remove the key and
snap ring.
B–05324
Drive the shaft out of the impeller side of the water pump
housing [C].
C
B–05325
A–02783
Page
Number
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Crankshaft Re–Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Fuel Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Torque for General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
68.3
(1735)
93° 148.7
(3777) 78.3
(1989)
N/A
115.0
43° (2921)
28.9
(734)
87.5
(2223)
76.1 45°
(1993)
27.9 (709)
85.3
(2167) 62.1
(1577)
25°
26°
7.5
(191) 40.6 48.5
(1031) 6.6
(168) (1232)
101.7
(2583) 66.0
130.1 (1676)
(3305)
MC–1525
This loader was designed without counterweights or ballasts. 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.
Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction & speed controlled by two hand levers.
Loader Function . . . . . . . . . . . . . . . . . . . . Lift, tilt function controlled by separate foot pedals. Auxiliary functions
controlled by electrical push buttons on right steering lever.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever throttle; key–type starter switch.
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Parking Brake . . . . . . . . . . . . . . . . . . . . . . Mechanical disc, foot operated pedal
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V2203–TV–B–MELROE–1
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . 46 HP (34,3 kw)
Maximum Governed RPM . . . . . . . . . . . . 2800 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.5 ft.–lbs. (139 Nm) @ 1600 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . Four
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 3.43/3.64(87,0/92.5)
Displacement . . . . . . . . . . . . . . . . . . . . . . . 134.0 cu.in. (2197 cu. cm.)
Cooling System . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . External
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable cartridge, dual safety element
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel–Compression
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150 RPM
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 2950–3050 RPM
Bore Diameter:
Lift Cylinder (2) .................... 2.25 (57,2)
Tilt Cylinder (1) .................... 3.25 (82,6)
Rod Diameter:
Lift Cylinder (2) .................... 1.50 (38,1)
Tilt Cylinder (1) .................... 1.50 (38,1)
Stroke:
Lift Cylinder (2) .................... 26.00 (660)
Tilt Cylinder (1) .................... 14.50 (368)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . 3–spool, open center, series type W/float on lift & electrical controlled auxiliary
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . SAE standard tubes, hoses & fittings
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328) If fluid is not available, use
10W–30/10W–40 Class SE Motor Oil for temperatures above 0°F. (–18°C)
& 5W–30 Motor Oil for temperatures below 0°F (–18°C).
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Belt drive, 55 amps. Open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, 625 cold crank amps. @ 0°F (–18°C) 160 min. reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
DRIVE SYSTEM
Transmission . . . . . . . . . . . . . . . . . . . . . . . Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydrostatic motors
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . #80 HS roller chain & sprockets in sealed chaincase with oil lubrication
Total Engine to Wheel Reduction . . . . . . 42:09:1
. Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328) If fluid is not available, use
10W–30/10W–40 Class SE Motor Oil for temperatures above 0° F (–18° C)
& 5W–30 Motor Oil for temperatures below 0° F (–18° C).
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . 13 qts. (12,3 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 gals. (53 L)
Engine Oil W/Filter . . . . . . . . . . . . . . . . . . 7.5 qts. (7,1 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 24 qts. (22,7 L)
Hydraulic/Hydrostatic System . . . . . . . . . 8.5 gals. (32,2 L)
Chaincase Reservoir . . . . . . . . . . . . . . . . 9 gals. (34,1 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 10:00–16.5, 6 Ply Rating, Nylon W/Sure Grip Lug
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PSI (345 kPa)
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–15.5–15, 8 Ply Rating, Nylon SCL
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PSI (345 kPa)
Cylinder Head
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64–1.66 (41,7–42,2)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.62 (41,2)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378 (35,0)
Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4 lbs. (117,6 N)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (100,0 N)
Inclination Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Timing
Camshaft
Cylinders
Piston Rings
Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012–0.018 (0,3–0,45)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,25)
Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.016 (0,25–0,4)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,25)
Side Clearance of Ring Groove:
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero Clearance
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0037–0.0047 (0,094–0,12)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.002 (0,02–0,051)
Pistons
Oil Pump
Crankshaft
Crankshaft Alignment
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0031 (0,08)
Oil Clearance Between Journal & Bearing #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0046 (0,04–0,117)
Limit Permitted 0.008 (0,2)
Journal O.D. #1 2.044–2.045 (51,92–51,94)
Bearing I.D. #1 2.046–2.048 (51,97–52,02)
Oil Clearance Between Journal & Bearing #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0041 (0,04–0,104)
Limit Permitted 0.008 (0,2)
Journal O.D. #2 2.044–2.045 (51,92–51,94)
Bearing I.D. #2 2.046–2.048 (51,97–52,02)
Oil Clearance Between Crank Pin & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009–0.0034 (0,023–0,086)
Limit Permitted 0.008 (0,2)
Crank Pin O.D. 1.8488–1.8492 (46,96–46,97)
Crank Pin Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8504–1.8522 (47,0–47,05)
Crankshaft Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059–0.0122 (0,15–0,31)
Limit Permitted 0.020 (0,5)
Timing Gear
Thermostat
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W–30 or 10W–40 SAE Motor Oil (5W–30 for 0° F [–18° C] and
Below).
DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.
Where temperatures below zero degree F. (–18° C) are common, the loader must
be kept in a warm building. Extra warm–up time must be used each time the loader
is started during cold temperature conditions. Cold fluid will not flow easily and it
makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by “TRANS” light “ON”) can cause transmission
damage in less then 60 seconds.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
12 September 1991
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–002
® Revision Number
8 January 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–003
® Revision Number
13 April 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–004
® Revision Number
7 August 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–005
® Revision Number
27 January 1993
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–006
® Revision Number
29 March 1993
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–007
® Revision Number
27 September 1993
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–008
® Revision Number
29 April 1994
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–009
® Revision Number
12 April 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–010
® Revision Number
6 June 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.
7753–011
® Revision Number
5 March 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 7753 SALES MANAGER
Manual No. 6720899 (6–91)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Printed in U.S.A.