Bobcat CT335 Compact Tractor Service Manual

Service Manual
CT335 Compact Tractor
HST - S/N ABH811001 & Above

SST - S/N AK9G11001 & Above
6987078 (12-09) Printed in U.S.A. © Bobcat Company 2009
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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-2003-0807
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
P-90216 B-23NEW B-23552
Never service the machine Before exiting machine, engage Cleaning and maintenance are
without instructions. parking brake. Chock wheels required daily.
before servicing
WRONG WRONG WRONG
B-23556 B-23525 B-23590
Have good ventilation when Disconnecting or loosening any Never start the machine if not
welding or grinding painted parts. hydraulic tubeline, hose, fitting, properly seated in the operator’s
Wear dust mask when grinding component or a part failure can seat.
painted parts. Toxic dust and gas cause loader arms to drop. Never work on the machine with
can be produced. Lower loader arms, attachments, loader arms raised.
Avoid exhaust fume leaks which and implements (if equipped) Never modify equipment or add
can kill without warning. Exhaust before servicing. attachments not approved by
system must be tightly sealed. DO NOT service the compact Bobcat Company.
tractor or implement with the
PTO system engaged.
WRONG WRONG WRONG
B-235517 B-23564 B-6589
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust machine exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If 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 engine cover and side attention.
running, while smoking or when access panels closed except for
near open flame. service.
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.
MSW32-0409
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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 70-01 ENGINE SPEED CONTROL PEDAL

AIR CLEANER SERVICE ....................................... 10-01 (SST MODELS) .......................................................70-01
AIR CONDITIONING BELT..................................... 10-01 EVAPORATOR ........................................................80-01
AIR CONDITIONING SERVICE.............................. 80-01 EVAPORATOR / HEATER UNIT..............................80-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 EVAPORATOR / HEATER UNIT COVER................80-01
ALTERNATOR ....................................................... 60-01 EXPANSION VALVE ................................................80-01
ALTERNATOR BELT .............................................. 10-01
AUXILIARY CONTROL VALVE .............................. 20-01 FAN..........................................................................70-01
AXLE AND DIFFERENTIAL ................................... 40-01 FENDER (WITH CAB) .............................................50-01
AXLE AND DIFFERENTIAL (SST MODELS) ......... 40-01 FENDER (WITHOUT CAB) .....................................50-01
AXLE CASE ........................................................... 40-01 FENDER ASSEMBLY (WITHOUT CAB)
AXLE TOE IN (HST MODELS) .............................. 10-01 (HST MODELS) ......................................................50-01
AXLE TOE IN (SST MODELS) ............................... 10-01 FENDER ASSEMBLY (WITHOUT CAB)
(SST MODELS) ..................................................... 50-01
BATTERY................................................................ 60-01 FIREWALL (WITH CAB) (HST MODELS) ...............50-01
BLOWER FAN ........................................................ 80-01 FIREWALL (WITHOUT CAB) (HST MODELS) .......50-01
BOB-TACH HAND LEVER...................................... 10-01 FIREWALL (SST MODELS) ................................... 50-01
BRAKE CASE ......................................................... 40-01 FLOORMAT (HST MODELS) ..................................50-01
BRAKE PEDAL ASSEMBLY ................................... 40-01 FLOORMAT (SST MODELS) ..................................50-01
BRAKE/CLUTCH PEDAL ASSEMBLY FLOOR PLATE ........................................................50-01
(SST MODELS) ..................................................... 40-01 FLYWHEEL AND HOUSING (HST MODELS) ........70-01
BRAKE SYSTEM ................................................... 10-01 FLYWHEEL AND HOUSING (SST MODELS)........ 70-01
F-N-R LEVER (SST ONLY) .................................... 60-01
CAB (HST MODELS) .............................................. 50-01 FRESH AIR FILTERS (WITH CAB) .........................10-01
CAB COVER ........................................................... 50-01 FRONT AIR DUCT ..................................................80-01
CAB POST COVER ............................................... 50-01 FRONT AXLE ...............................................10-01, 40-01
CAMSHAFT AND TIMING GEARS......................... 70-01 FRONT AXLE (SST MODELS) ................... 10-01, 40-01
CLUTCH PEDAL AND HOUSING (SST ONLY) ..... 10-01 FRONT LIGHTS (WITH CAB) .................................60-01
CLUTCH PEDAL (SST ONLY)................................ 10-01 FRONT WORK LIGHT (WITH CAB) .......................60-01
CLUTCH ASSEMBLY (SST MODELS)................... 70-01 FRONT WORK LIGHT MOUNT (WITH CAB) .........50-01
CLUTCH LEVER (SST MODELS) ......................... 70-01 FRONT WHEEL DRIVE ..........................................20-01
COMPACT TRACTOR STORAGE AND RETURN FUEL, COOLAND AND LUBRICANTS
TO SERVICE ...................................................... 10-01 (ALL MODELS) .......................................... SPEC-01
COMPONENTS ...................................................... 80-01 FUEL LEVEL SENDER ...........................................60-01
COMPRESSOR ...................................................... 80-01 FUEL SYSTEM.............................................10-01, 70-01
CONDENSOR......................................................... 80-01 FUEL TANK .............................................................50-01
CONSOLE COVER (WITH CAB)............................ 50-01
CONSOLE COVER (WITHOUT CAB) .................... 50-01 GENERAL AIR CONDITIONING SERVICE
CONVERSIONS ................................................SPEC-01 GUIDELINES .......................................................80-01
CRANKSHAFT AND PISTONS ............................. 70-01 GRILL ......................................................................50-01
CRUISE CONTROL (HST ONLY)........................... 60-01
CYLINDER HEAD ................................................... 70-01 HEADLINER ............................................................50-01
HEATER COIL .........................................................80-01
DIFFERENTIAL LOCK............................................ 10-01 HEATER VALVE ......................................................80-01
DRAW BAR............................................................. 50-01 HOOD LIGHTS ........................................................60-01
DRAW BAR ASSEMBLY ........................................ 50-01 HORN .....................................................................60-01
DRIVE SHAFT (EARLY MODELS) ......................... 40-01 HVAC CONTROL PANEL........................................80-01
DRIVE SHAFT (LATER MODELS) ......................... 40-01 HYDRAULIC PUMP ................................................20-01
HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
ENGINE COOLING SYSTEM ...................... 10-01, 70-01 HYDRAULIC /HYDROSTATIC/
ENGINE COVER ......................................... 10-01, 50-01 TRANSMISSION SYSTEM ..................................10-01
ENGINE INFORMATION ........................................ 70-01 HYDROSTATIC PUMP (HST MODELS) .................30-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
ENGINE SIDE COVER ........................................... 50-01
ENGINE SPEED CONTROL .................................. 70-01
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ALPHABETICAL INDEX (CONT’D)
HYDROSTATIC PUMP TESTING STEERING CYLINDER........................................... 20-01

(HST MODELS) ..................................................... 30-01 STEERING CYLINDER (SST MODELS) ............... 20-01
HYDROSTATIC SYSTEM INFORMATION STEERING COLUMN COVER................................ 60-01
(HST MODELS) ..................................................... 30-01 STEERING VALVE .................................................. 20-01
STEERING VALVE TESTING ................................. 20-01
INNER FENDER ACCESS COVER (WITH CAB) ...50-01 SUPPORTING THE COMPACT TRACTOR
INSTRUMENT PANEL.............................................60-01 ON JACKSTANDS ............................................... 10-01
SYSTEM CHARGING AND RECLAMATION .......... 80-01
LUBRICATING THE COMPACT TRACTOR............10-01 SYSTEM TROUBLESHOOTING CHART ............... 80-01
LUBRICATION SYSTEM .........................................70-01
TEMPERATURE / PRESSURE............................... 80-01
MAIN RELIEF VALVE ..............................................20-01 THERMOSTAT ........................................................ 80-01
MID MOUNT PTO SWITCH.....................................60-01 THREE POINT CYLINDER ..................................... 20-01
MID PTO CONTROL ...............................................50-01 THREE POINT CYLINDER CONTROL .................. 20-01
MLS VALVE ............................................................ 20-01 THREE POINT HITCH HOUSING .......................... 20-01
MODULATOR VALVE ..............................................20-01 THREE POINT HITCH LOWER LINKS................... 50-01
TIRE MAINTENANCE ............................................. 10-01
OIL COOLER (HST MODELS) ................................20-01 TORQUE SPECIFICATIONS FOR BOLTS ....... SPEC-01
OPERATOR SEAT...................................................50-01 TOWING THE COMPACT TRACTOR .................... 10-01
TRANSMISSION (HST MODELS) .......................... 40-01
PARKING BRAKE SYSTEM ....................................10-01 TRANSMISSION (SST MODELS) ......................... 40-01
PIVOT PINS.............................................................10-01 TRANSMISSION CASE (HST MODELS) ...............50-01
PRESSURE SWITCH..............................................80-01 TRANSMIAAION CASE (SST MODELS)............... 50-01
PTO LEVER (MID) (IF EQUIPPED)........................ 60-01 TRANSPORTING THE COMPACT TRACTOR ON A
PTO SAFETY SHIELD.............................................50-01 TRAILER.............................................................. 10-01
PTO SWITCH (REAR) .............................................60-01 TROUBLESHOOTING ............................................ 70-01
TRAVEL CONTROL PEDAL (HST ONLY) .............. 10-01
REAR LIGHTS.........................................................60-01 TRAVEL CONTROL PEDAL LINKAGE
REAR PTO ..............................................................20-01 (HST MODELS)..................................................... 30-01
REAR WORKLIGHT (WITH CAB) ...........................60-01 TRAVEL CONTROL PEDAL PIVOT ARMS
RECEIVER / DRIER ...............................................80-01 (HST MODELS)...................................................... 30-01
REGULAR MAINTENANCE ....................................80-01 TRAVEL CONTROL PEDALS (HST MODELS) ...... 30-01
RESISTOR ..............................................................80-01
RIGHT JOYSTICK (WITH CAB) ..............................20-01
RIGHT JOYSTICK (WITHOUT CAB) ......................20-01
RIGHT JOYSTICK VALVE (IF EQUIPPED).............20-01
ROPS ......................................................................50-01
ROCK SHAFT..........................................................20-01
SAFETY...................................................................80-01
SAFETY INTERLOCK SYSTEM -
NEUTRAL START ................................................10-01
SAFETY INTERLOCK SYSTEM -
OPERATING .........................................................10-01
SEAT BELT ..............................................................10-01
SEAT SENSOR .......................................................60-01
SEPERATING THE TRACTOR (HST MODELS).....40-01
SEPERATING THE TRACTOR (SST MODELS).... 40-01
SERVICE BRAKE ...................................................40-01
SERVICE SCHEDULE ............................................10-01
SIDE AIR DUCT ......................................................80-01
SPARK ARRESTOR MUFFLER ...................10-01, 70-01
SPEED RANGE LEVER (HST MODELS) ....10-01, 60-01
SPLASH BOARD.................................................... 50-01
STARTER ................................................................60-01
STEERING AXLE ADJUSTMENT (HST MODELS) 40-01
STEERING AXLE ADJUSTMENT (SST MODELS)40-01
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CONTENTS
SAFETY AND
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II MAINTENANCE
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V
HYDRAULIC
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X HYDROSTATIC

HYDROSTATIC
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI SYSTEM
COMPACT TRACTOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . .XII
COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL LOADER DRIVE SYSTEM

AND REAR BALLAST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII
COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL THREE-

POINT IMPLEMENT AND FRONT BALLAST) . . . . . . . . . . . . . . . . . . XIV MAINFRAME
COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL CAB). . XV
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 ELECTRICAL

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

ENGINE SERVICE
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
HVAC
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

SPECIFICATIONS
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
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FOREWORD
This manual is for the Bobcat compact tractor mechanic. It provides necessary servicing and
adjustment procedures for the Bobcat compact tractor 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 compact tractor has had service or repair:
1. Check that the ROPS is in 8. Enclosure door latches must
good condition and is not open and close freely.
modified.
2. Check that ROPS mounting 9. Attachment locking pins must

hardware is tightened and is function correctly and be in
Bobcat approved. good condition. Bob-Tach
wedges and linkages (if
equipped) must function
correctly and be in good
condition.
3. The seat belt must be 10. Safety treads must be in good
correctly installed, functional condition.
and in good condition.
4. Machine signs (decals) must 11. Check for correct function of

be legible and in the correct indicator lamps.
location.
5. Travel control pedal(s) and 12. Check hydraulic fluid level,

loader joystick control lever engine oil level and fuel
must return to neutral. supply.
6. Check for correct function of 13. Inspect for fuel, oil or

the work lights. hydraulic fluid leaks.
7. The parking brake must 14. Lubricate the compact tractor.

function correctly.
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15. Check the condition of the 20. Check for any field
battery and cables. modification not completed.
16. Inspect the air cleaner for 21. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.
17. Check the electrical charging 22. Check Safety Interlock

system. System (Neutral Start and
Operating) for correct
function before the machine
is returned to the customer.
18. Check tires for wear and 23. Check function or condition of
pressure. Use only approved all equipped options and
tires. accessories (examples: back-
up alarm, front-end loader,
etc.).
19. Inspect for loose or broken 24. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
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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 / implement contains
operating information as well as routine maintenance
and service procedures. It is a part of the machine
WARNING and can 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 /
Handbook and signs (decals) on machine. Follow implement. The signs and their locations are shown in
warnings and instructions in the manuals when the Operation & Maintenance Manual. Replacement
making repairs, adjustments or servicing. Check for signs are available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened below the
can cause injury or death. instrument panel. It’s brief instructions are convenient
W-2003-0903 to the 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.
IMPORTANT • The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
DANGER
The signal word DANGER on the machine and in the
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
D-1002-1107
WARNING
The signal word WARNING on the machine and in the
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
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SAFETY INSTRUCTIONS (CONT’D)
Use Safety Rules
• Read and follow instructions in the machine and the

attachment’s / implement’s Operation & Maintenance
Manual before operating.
• Check for underground lines before operating

attachment / implement (if applicable).
• In addition to the design and configuration of

equipment, hazard control and accident prevention
are dependent upon the awareness, concern,
prudence and proper training of personnel involved in
the operation, transport, maintenance and storage of
equipment.
Call Before You Dig
Dial 811 (USA Only)
• Check that the attachment mounting pins and
hardware are installed correctly and securely 1-888-258-0808 (USA & Canada)
fastened (if equipped).
When you call, you will be directed to a location in your
• Check that the loader is securely installed to the state / province, or city for information about buried lines
compact tractor using the correct pins and hardware. (telephone, cable TV, water, sewer, gas, etc.).
• Check that the Bob-Tach levers are in the locked
position and the wedges are fully engaged into the
mounting holes of the attachment (if applicable).
• Check that the implement is securely fastened to the

machine.
• Depress brake pedals (or make sure parking brake is

engaged) and make sure all the machine controls are
in the NEUTRAL position before starting the machine.
• Always start the machine from the operator’s seat.
• Operate the attachment / implement according to the

Cutting or drilling concrete containing sand or rock
Operation & Maintenance Manual.
containing quartz may result in exposure to silica dust.
• When learning to operate the attachment / implement, Do not exceed Permissible Exposure Limits (PEL) to
do it at a slow rate in an area clear of bystanders. silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
• DO NOT permit personnel to be in the work area means to control dust. Silica dust can cause lung disease
when operating the machine and attachment / and is known to the state of California to cause cancer.
implement.
• The attachment / implement must be used ONLY on

approved machines. See your Bobcat dealer for
updated list of approved attachments / implements for
each machine model.
• DO NOT modify equipment or add attachments /
implements that exceed manufacturer’s
specifications.
• DO NOT make any adjustments or repairs on the

machine or attachment / implement while the engine
is running.
• Keep shields and guards in place. Replace if

damaged.
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SAFETY INSTRUCTIONS (CONT’D) • Make certain that the Slow Moving Vehicle (SMV)
emblem is installed so that it is visible and legible.
Safety Rules For Power Take-Off (PTO) Driven When transporting the equipment, use the compact
Implements tractor flashing warning lights and follow all local
regulations.
• Keep PTO shields and all guards in place. Replace
damaged or missing shields and guards before • Operate this equipment with a compact tractor
operating. equipped with an approved Roll-Over Protective
Structure (ROPS). Always wear seat belt when the
• Follow warnings and instructions on machine signs ROPS is up. Serious injury or death could result from
(decals). Replace damaged or missing decals. falling off the compact tractor.
• Do not wear loose or bulky clothing around the PTO • Before leaving the compact tractor operator’s seat:
or other moving parts.
1. Park on flat level ground.
• Keep bystanders away from PTO driven equipment, 2. Fully lower the loader arms and put the
and never allow children near machines. attachment flat on the ground (if equipped).
3. Fully lower the three-point hitch or mid-mount
• Read and understand the manuals for the PTO driven implements (if equipped).
equipment and be aware of safe operating 4. Lock brake pedals together and engage the
procedures and hazards that may not be readily parking brake.
apparent. 5. Place all controls in neutral.
6. Stop engine, unfasten seat belt and remove the
• Always walk around equipment to avoid coming near
key.
a turning PTO driveline. Stepping over, leaning
across or crawling under a turning PTO driveline can
cause entanglement.
• Never allow riders on the compact tractor or
implement. Falling off can result in serious injury or
• Position the machine and implement hitch correctly to
death.
prevent driveline stress and separation.
• Start the compact tractor only when properly seated in
• Use caution when turning. Turning too sharp can
the operator’s seat. Starting a compact tractor in gear
cause driveline damage.
can result in serious injury or death.
• Use caution when raising PTO driven implement.
• Operate the compact tractor and attachments /
Excessive driveline angle can cause driveline
implements from the operator's position only.
damage. Use stops if needed.
• Add the correct front ballast for rear three-point hitch
Compact Tractor Requirements and Capabilities
implements and pull type implements. Add the correct
rear ballast when using the loader and attachments.
• Fasten seat belt securely when Roll-Over Protective
Front and rear ballast can be purchased from your
Structure (ROPS) is up and locked. DO NOT wear
compact tractor dealer.
seat belt if ROPS is down.
• Do not handle large objects (such as round bales or
• Compact tractor must be equipped with sway bars or
posts) unless the loader is equipped with the proper
chains.
attachment and the load is secured.
• Stop the compact tractor and engage the parking
• The parking brake must be engaged before leaving
brakes. Install blocks in front of and behind the rear
the compact tractor operator’s seat. Rollaway can
tires of the compact tractor. Install blocks underneath
occur because the transmission may not prevent
and support the implement securely before working
machine movement. Lock the brake pedals together
under raised implements.
before activating the parking brake.
• Keep bystanders clear of moving parts and the work
area. Keep children away.
• Use increased caution on slopes and near banks and

ditches to prevent overturn.
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FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments / implements have solvents.
components that are at high temperatures under normal
operating conditions. The primary source of high Fueling
temperatures is the engine and exhaust system. The
electrical system, if damaged or incorrectly maintained,
can be a source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine Stop the engine and let it cool before adding fuel. No
compartment is a potential fire hazard. smoking! Do not refuel a machine near open flames or
sparks. Fill the fuel tank outdoors.
The operator’s area, engine compartment and engine
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Operation
Do not use the machine where exhaust, arcs, sparks or Spark Arrestor Exhaust System
hot components can contact flammable material,
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
Electrical hot.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
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FIRE PREVENTION (CONT’D)
Welding And Grinding

Always clean the machine and attachment / implement,
disconnect the battery, and disconnect the wiring from
the Bobcat 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 dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI CT-1008 SM
IX CT335 Service Manual

15 of 1161
SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the compact tractor Figure 2

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.
Figure 1 1
P-81352
The engine serial number is located on the top of the

injection pump (Item 1) [Figure 2].
P-78999 Loader Serial Number (Optional)
Figure 3
Compact Tractor Serial Number
The compact tractor serial number plate is located on the

right front corner of the frame [Figure 1].
Explanation of machine Serial Number:

XXXX XXXXX
Module 2. - Production
Sequence (Series) 1
Module 1. - Model / Engine

Combination
1. The four digit Model/Engine Combination Module

number identifies the model number and engine P-80999
combination.
The loader serial number is located on the right loader
2. The five digit Production Sequence Number identifies
arm (Item 1) [Figure 3].
the order which the compact tractor is produced.
X CT335 Service Manual

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DELIVERY REPORT
Figure 4
B-16315
The delivery report must be filled out by the dealer and

signed by the owner or operator when the compact
tractor is delivered. An explanation of the form must be
given to the owner. Make sure it is filled out completely
[Figure 4].
XI CT335 Service Manual

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COMPACT TRACTOR IDENTIFICATION
z ROLL-OVER PROTECTIVE
STRUCTURE (ROPS)
STEERING
WHEEL OPERATOR’S SEAT
WITH SEAT BELT
AND SEAT SWITCH
DIRECTIONAL SIGNAL
HEAD LIGHTS / HAZARD / FLASHER
LIGHTS
GRAB HANDLES (2)
BRAKE PEDALS
* TIRES
OPERATION & * REAR (REMOTE)

MAINTENANCE HYDRAULIC COUPLERS
MANUAL
* SLOW MOVING VEHICLE

(SMV) EMBLEM OPERATOR’S
HANDBOOK
THREE-POINT HITCH
ADJUSTABLE TOP LINK
PTO SHIELD
THREE-POINT HITCH
LOWER LINKS (2)
TRAVEL CONTROL
PEDALS
REAR LIGHTS
DRAWBAR
ADJUSTABLE
SWAY BARS (2) LIFT LINK
B-23805
B-23806
† ATTACHMENTS AND IMPLEMENTS - Attachments and implements are available for the compact tractor.
z ROPS - Roll-Over Protective Structure, per ASABE S478 and OSHA 29 CFR PART 1928 Subpart C.
* OPTIONAL OR FIELD ACCESSORIES (Not Standard Equipment).
XII CT335 Service Manual

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COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL LOADER AND REAR BALLAST)
OPERATOR’S SEAT
WITH SEAT BELT
AND SEAT SWITCH
* GRILL GUARD
* TILT CYLINDERS
* LOADER MOUNTS (2)
* LIFT CYLINDERS
* LOADER ARMS
† BUCKET
STRUCTURE(ROPS)
* BALLAST BOX
* JOYSTICK CONTROL
LEVER With LOCK LEVER
* TIRES
B-23865
B-23866
* OPTIONAL OR FIELD ACCESSORIES (Not Standard Equipment) See Specification Page for tires with correct load rating.
XIII CT335 Service Manual

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COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL THREE-POINT IMPLEMENT AND FRONT BALLAST)
OPERATOR’S SEAT
WITH SEAT BELT
AND SEAT SWITCH
* FRONT
BALLAST
STRUCTURE(ROPS)
Implement PTO
Shield
PTO Driveline
with Guards
† AUGER
PTO Shaft B-23867

PTO Shield B-23868
XIV CT335 Service Manual

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COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL CAB)
STRUCTURE(ROPS)
REAR WORK
FRONT WORK FRONT WIPER
LIGHTS
LIGHTS
MIRROR
MIRROR
OPERATOR’S SEAT
DIRECTIONAL SIGNAL / WITH SEAT BELT
HAZARD / FLASHER LIGHTS AND SEAT SWITCH
HEAD LIGHTS
REAR LIGHTS
STEPS (Both Sides)
NA1031A
XV CT335 Service Manual

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XVI CT335 Service Manual
22 of 1161
SAFETY AND MAINTENANCE SAFETY &
MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1
AIR CONDITIONING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-161-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-161-1
Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161-1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
AXLE TOE IN (HST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-1
AXLE TOE IN (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-270-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-270-1
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-230-2
CLUTCH PEDAL AND HOUSING (SST ONLY) . . . . . . . . . . . . . . . . . . . . 10-280-1

Draining Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-280-1
Storage Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-280-1
CLUTCH PEDAL (SST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-251-1

COMPACT TRACTOR STORAGE AND RETURN TO SERVICE. . . . . . 10-150-1

Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-150-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-150-1
CRUISE CONTROL (HST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250-1

DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-290-1

Continued On Next Page
10-01 CT335 Service Manual

23 of 1161
SAFETY AND MAINTENANCE (CONT’D)
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Hoses And Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
F-N-R LEVER (SST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-241-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-241-1
FRESH AIR FILTERS (WITH CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81-1
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Axle Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2
Checking And Adding Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling A Portable Fuel Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
HYDRAULIC / HYDROSTATIC / TRANSMISSION SYSTEM . . . . . . . . . . . . 10-120-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hoses And Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Removing And Replacing Hydraulic / Hydrostatic / Transmission Filters 10-120-2
Removing And Replacing Hydraulic / Transmission Fluid . . . . . . . . . . . . 10-120-3
Transmission / Differential Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
LUBRICATING THE COMPACT TRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

24 of 1161
SAFETY AND MAINTENANCE (CONT’D)
PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

SAFETY INTERLOCK SYSTEM - NEUTRAL START . . . . . . . . . . . . . . . . . 10-200-1

Inspection And Maintenance (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Inspection And Maintenance (SST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
SAFETY INTERLOCK SYSTEM - OPERATING. . . . . . . . . . . . . . . . . . . . . . 10-210-1

Inspection And Maintenance (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Inspection And Maintenance (SST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
SPEED RANGE LEVER (HST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-260-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-260-1
SUPPORTING THE COMPACT TRACTOR ON JACKSTANDS . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Front Wheel Nuts / Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Rear Wheel Nuts / Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Wheel Spacing (AG And Industrial Tires Only) . . . . . . . . . . . . . . . . . . . . 10-180-2
TOWING THE COMPACT TRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE COMPACT TRACTOR ON A TRAILER. . . . . . . . . . . 10-40-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-2
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TRAVEL CONTROL PEDAL (HST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-240-1


25 of 1161
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SUPPORTING THE COMPACT TRACTOR ON
JACKSTANDS
Procedure WARNING
For service work under the compact tractor, or to remove
the rims and tires, always support the compact tractor AVOID INJURY OR DEATH
with jackstands or blocks of adequate capacity for the Instructions are necessary before operating or
weight of compact tractor. (See Performance on Page servicing machine. Read and understand the
SPEC-10-5.) Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
Park the compact tractor on a flat level surface. warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Figure 10-10-1 correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
WARNING
AVOID INJURY OR DEATH
Put jackstands under the front and rear axles of the
frame of the compact tractor before running the
engine for service. Failure to use jackstands can
allow the machine to fall or move.
1 P-84807 W-2677-0907
Figure 10-10-2
2
P-84806
Put jackstands under the front and rear axles (Item 1)

[Figure 10-10-1] and (Item 2) [Figure 10-10-2].
10-10-1 CT335 Service Manual

27 of 1161
28 of 1161
ENGINE COVER Closing
Opening And Closing Figure 10-20-2
Opening
Figure 10-20-1
2 1
P-84848
The engine cover is held open by a gas cylinder (Item 1)

P-86349 [Figure 10-20-2].
To lower the engine cover, push down on the front of the

Then engine cover (Item 1) is opened by pulling down on engine cover until it locks in the closed position [Figure
the knob (Item 2) [Figure 10-20-1] and pushing down on 10-20-1].
the front of the engine cover. (The knob is located on the
lower right side of the frame.) NOTE: If hood rattles during operation, inspect the
rubber moulding (Item 2) [Figure 10-20-2]. The
Raise the front of the engine cover. moulding will need to be replaced if damaged
or if the hood rattles during operation.

29 of 1161
30 of 1161
SEAT BELT Figure 10-30-1
Inspection And Maintenance

1
WARNING 3
Failure to properly inspect and maintain the seat belt

can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
Check the seat belt daily for correct function. 2 4
Inspect the seat belt system thoroughly yearly or more

often if the machine is exposed to severe environmental
conditions or applications.
The seat belt system should be repaired or replaced if it

shows cuts, fraying, extreme or unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,
dusty/dirty conditions, abrasion to the seat belt webbing,
or damage to the buckle, latch plate, retractor (if
equipped), or hardware.
B-22283
The items below are referenced in [Figure 10-30-1].
1. Check the seat belt webbing. If the system is

equipped with a retractor, pull the webbing completely
out and inspect the full length of the webbing. Look for
cuts, wear, fraying, dirt and stiffness.
2. Check the buckle and latch for proper function. Make

sure latch plate is not excessively worn, deformed or
buckle is not damaged.
3. Check the retractor web storage device (if equipped)

by extending the seat belt webbing to determine if it
extends and retracts the webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have weakened.

31 of 1161
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TRANSPORTING THE COMPACT TRACTOR ON A Figure 10-40-1
TRAILER
LOADER & BALLAST BOX
Loading And Unloading
WARNING
AVOID SERIOUS INJURY OR DEATH
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-2058-0807 1
P-84880A
Figure 10-40-2
IMPORTANT COMPACT TRACTOR WITH OR

WITHOUT AN IMPLEMENT
Remove sunshade before transporting compact
tractor at highway speeds. Sunshade damage may
occur if left installed.
I-2258-0607
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of machine. (See
SPECIFICATIONS on Page SPEC-01.)
1
P-86350
A compact tractor with a loader, attachment and rear

ballast must be loaded backward onto the trailer [Figure
10-40-1].
A compact tractor with or without an implement must be

loaded backward [Figure 10-40-2].
The rear of the trailer must be blocked or supported (Item

1) [Figure 10-40-1] and [Figure 10-40-2] when loading
or unloading to prevent the front end of the trailer from
raising up.

33 of 1161
TRANSPORTING THE COMPACT TRACTOR ON A Fasten at the front of the compact tractor using the front
TRAILER (CONT’D) chain loops (Item 1) [Figure 10-40-3] and to the transport
Fastening vehicle (both sides).
WARNING WARNING
Before you leave the operator’s seat:
The parking brake must be engaged before leaving
• Fully lower the loader arms, put the attachment the operator’s seat. Rollaway can occur because the
flat on the ground (if equipped). transmission may not prevent machine movement.
• Fully lower the implement(s) to the ground (if Lock the brake pedals together before activating the
equipped). parking brake.
• Lock brake pedals together and engage the W-2656-0807
parking brake.
• Place F-N-R lever in neutral (SST models only).
• Place all controls in neutral.
• Stop the engine, unfasten the seat belt and
remove the key.
W-2569-0909
Use the following procedure to fasten the compact tractor

to the transport vehicle to prevent it from moving during
turns, sudden stops or when going up and down slopes.
Fully lower the loader arms and put the attachment flat
on the tow vehicle.
Fully lower the mid-mount implement (if equipped). Figure 10-40-4
Fully lower the three-point hitch implement (if equipped).
Lock brake pedals together and engage the parking
brake.
Place all controls in neutral.
Stop the engine and exit the compact tractor.
1
Figure 10-40-3
1
P-80920A
Fasten the rear of compact tractor using the drawbar

mounting frame (Item 1) [Figure 10-40-4] and to the
transport vehicle (both sides).
When using chains, use chain binders to tighten the

chains and then secure the chain binder levers to prevent
P-80919B
loosening.

34 of 1161
TOWING THE COMPACT TRACTOR Towing compact tractor with loader installed;
Procedure If possible, slightly raise the attachment off of the ground.

The compact tractor will need to be towed backwards (if
possible), to avoid the bucket (or attachment) from
digging into the ground while towing.
IMPORTANT Use the towing procedure described but install the tow
chain to the rear of the compact tractor and tow
Never tow the compact tractor faster than 10 mph (16 backwards.
km/h). Always have someone seated to steer and
brake the towed compact tractor. Towing compact tractor with implement installed;
Tow the compact tractor for short distances only. If the engine can be started, slightly raise the implement
I-2263-1007 off of the ground. The type of implement will determine
which direction to tow the compact tractor.
NOTE: When the engine is not running, turning the
Implements that dig into the ground will be difficult to tow
steering wheel will require more effort. Power
and may require the implement to be disconnected from
steering assist is not available when the
the compact tractor before towing. (Example; plow or
engine is OFF.
cultivator.) If the implement must be removed before
towing, use the procedure described previously and tow
Install a tow chain (or cable) to the front (for towing in the
forward to get the compact tractor away from the
forward direction) or to the drawbar (for towing in the
implement.
rearward direction).
NOTE: Do not connect the tow chain (or cable) to the
The tow chain (or cable) must be rated at 1.5 times the
loader, attachment or the implement. Connect
weight of the compact tractor and implement /
to the compact tractor only as shown. The
attachment. (See SPECIFICATIONS on Page SPEC-01.)
rated strength of the tow chain or cable must
be rated at 1-1/2 times the weight of the engine
Enter the compact tractor and fasten the seat belt. Move
towed load (compact tractor plus the
both the rear and the mid-PTO levers to the disengaged
attachment or implement installed). Add the
(OFF) position.
weight of the compact tractor, the loader, the
attachment and/or the implement together for
Disengage the front wheel assist.
the total machine weight to calculate the
strength of the tow chain or cable needed.
Move the speed range lever to neutral. Place all controls
in neutral.
Disengage the parking brake (but leave the brake pedals

locked together for slowing or stopping the compact
tractor).
Always have an operator seated in the operator’s seat to

operate the steering and brakes while towing the
compact tractor. Use ROPS and fasten seat belt. Engage
the parking brake and stop the engine before leaving the
machine.
If the compact tractor is equipped with a loader or has an

implement attached and the engine can not be started,
tow the compact tractor using one of the following
procedures.

35 of 1161
36 of 1161
AXLE TOE IN (HST MODELS) Measure the rear centerline of the front tires (Item 2)
[Figure 10-60-2] and write this dimension down.
The front dimension (Item 1) [Figure 10-60-1] & [Figure
Park the tractor on a flat level surface. 10-60-2] should be 0.08 - 0.31 in. (2 - 8 mm) less than
the rear dimension (Item 2) [Figure 10-60-2].
on the ground (if equipped). Fully lower the implement to Figure 10-60-3
the ground (if equipped).
Engage the parking brake.
Place all controls in the neutral position. 1

2
Stop the engine and exit the compact tractor.
Figure 10-60-1
P-84814
If the dimension is not correct, loosen the tie rod lock nut
(Item 1) (both sides) and install a wrench on the flat area
(Item 2) [Figure 10-60-3] on the tie rod. Turn the tie rod
to adjust the toe in until the correct measurement is
1
obtained.
P-84815 Measure the toe in dimension again after the tie rod has
been adjusted. Readjust as necessary.
Figure 10-60-2 Tighten the lock nut (Item 1) [Figure 10-60-3] (both
sides.)
1
P-77895
The front axle toe in will need to be measured at the

centerline of the front tires, both on the front side (Item 1)
and rear side (Item 2) [Figure 10-60-2] of the front axle.
Measure the front centerline of the front tires (Item 1)

[Figure 10-60-1] & [Figure 10-60-2] and write this
dimension down.

37 of 1161
38 of 1161
AXLE TOE IN (SST MODELS) Figure 10-61-3
Adjustment
The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.
Figure 10-61-1
NA5006
Measure the distance between the ends of the two bars

[Figure 10-61-3]. The measurement must be equal.
Figure 10-61-4
P-86041
Raise the front of the tractor and install jack stands

[Figure 10-61-1] 1
3
Turn the steering wheel until the steering cylinder rod is 2
positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 10-61-2
NA5007
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 10-61-4] of both tie rods until the measurement
is the same.
1 Tighten the nut (Item 3) [Figure 10-61-4] (to 221 ft.-lb.

(300 N•m) torque.
NA5005
Install two identical, straight bars (Item 1) [Figure 10-61-

2] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

ground.

39 of 1161
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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 product.
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
WARNING 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
SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED 8-10 50 100 200 400 800 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Hydraulic (Trans / Diff) Fluid Check level and add as needed.
Engine Air Filter and Air System Check condition indicator (if equipped). Check for leaks and damaged
components. Do not use compressed air to clean elements.
Engine Cooling System Clean debris from oil cooler, radiator, screen and grills. Check coolant level
cold, add premixed coolant as needed.
Safety Interlock System (Neutral Check for proper function.
Start and Operating)
Seat Belt Check the condition of seat belt and mounting hardware. Repair or replace as
needed.
Tires Check for wear, damaged tires and ensure for proper sized tires and correct
air pressure.
Parking Brake Check operation and have dealer adjust if required.
Clean Pedals Clean brake pedals, travel control pedals, and footrest area.
General Items Check for loose or broken parts, damaged operator cab, instrument
operation, loose wheel nuts / bolts, oil leaks and damaged or missing signs
(decals). Replace floormat if damaged or missing.
PTO Inspect the splines. Replaced damaged or missing shields and guards.
Three-Point Linkage Check operation and condition of pins, links and sway bars.
Loader (If Equipped) Check mounting hardware for loose or broken parts.
Wheel Nuts and / or Bolts Check for loose wheel nuts / bolts and tighten to correct torque. See TIRE
MAINTENANCE in this Manual. *
Front Differential Check fluid level and add as needed.
Grease Fittings Grease all machinery pivot points with multipurpose lithium based grease.
Engine Oil and Filter Replace oil and filter. Use CF / CG4 or better grade oil and Bobcat filter. ■
Spark Arrestor Muffler Empty Spark Chamber (if equipped).
Battery Check for damage, hold downs, cables, connections and electrolyte level.
Add distilled water as needed.
Fan / Alternator Belt Check for damage and correct tension. Adjust or replace as needed. ■
Engine Air Filter Check primary filter element and clean as needed. Replace every year.
Brakes Check free travel of pedals and adjust as necessary ■
Clutch (If equipped) Check free travel of pedal and adjust as necessary
Fuel Lines Check hose condition and clamp tension. Replace and adjust as necessary. ■
Fuel Filter Replace filter element.
Hydraulic Oil Filter Replace the filter element. ■
Hydrostatic Oil Filter Replace the filter element. ■
Hydraulic, Hydrostatic and Power Check for damage and leaks. Repair or replace as needed.
Steering Hoses and Tubelines
Radiator Hoses and Clamps Check hose condition and clamp tension. Replace and/or adjust tension as
needed.
Toe In Check front axle toe in. Adjust if necessary.
Hydraulic (Trans / Diff) Fluid Replace the fluid and filter. ■
Differential Oil - Front Replace the front differential oil. ■
Clutch Housing (If equipped) Drain water from clutch housing.
Engine Valves Check and adjust
Engine Coolant Flush the cooling system. Replace the coolant. (or every 2 years)
* Check every 8 hours for the first 24 hours.
■ Service at first 50 hours and thereafter as scheduled.

41 of 1161
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AIR CLEANER SERVICE Pull the filter element (Item 1) [Figure 10-80-2] from the
air cleaner housing.
Replacing Filter Element
Clean the inside of the filter housing and seal. Do not use
See the Service Schedule for the correct service interval. compressed air.
(See Chart on Page 10-70-1.)
Check the housing for damage.
Open the engine cover. (See Opening And Closing on
Page 10-20-1.) Install the new filter element.
Check the air intake hose and the air cleaner housing for Install the dust cup (Item 2) and engage the fasteners
damage. (Item 1) [Figure 10-80-1].
Check to make sure all connections are tight.
Outer Filter
Figure 10-80-1
2
1
P-84846
Release the three fasteners (Item 1) [Figure 10-80-1].
Remove and clean the dust cup (Item 2) [Figure 10-80-

1].
Figure 10-80-2
P-84845

43 of 1161
AIR CLEANER SERVICE (CONT’D)
Replacing Filter Element (Cont’d)
Inner Filter
Replace the inner filter every third time the outer filter is
replaced.
Figure 10-80-3
P-84844
Remove the inner filter (Item 1) [Figure 10-80-3].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install a new inner element (Item 1) [Figure 10-80-3].
Install the outer element (Item 1) [Figure 10-80-2 on

Page 10-80-1].
Install the dust cover (Item 2) [Figure 10-80-1 on Page

10-80-1].

44 of 1161
FRESH AIR FILTERS (WITH CAB)
Removal And Installation
The fresh air filters must be cleaned regularly. The four

filters are located on the left and right side of the cab
cover.
Figure 10-81-1
P-87491
Remove the two screws (Item 1) [Figure 10-81-1].
Figure 10-81-2
P-87492
Remove the air filter (Item 1) [Figure 10-81-2] from the

cab cover.
Use low air pressure to clean the filter. Replace the filter
when very dirty.

45 of 1161
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ENGINE COOLING SYSTEM Figure 10-90-2
Checking Level

Page 10-20-1.)
Figure 10-90-1
1
P-84843
1 The coolant level in the recovery tank must be between

the marks on the tank (Item 1) [Figure 10-90-2] when the
engine is cool.
P-84838
NOTE: The cooling system is factory filled with
ethylene glycol coolant (green color). DO NOT
mix ethylene glycol with propylene glycol.
The coolant recovery tank (Item 1) [Figure 10-90-1] is
located on the right side of the engine. Ethylene Glycol
Add premixed coolant; 50% water 50% ethylene glycol to

the recovery tank if the coolant level is low.
WARNING One gallon (3,8 L) ethylene glycol mixed with one gallon
(3,8 L) of water is the correct mixture of coolant to
provide a -34° F (-37° C) freeze protection.
AVOID INJURY
Stop the engine and allow to cool before adding Use a refractometer to check the condition of ethylene
coolant or you can be burned. glycol in your cooling system.
W-2106-0907
WARNING
IMPORTANT AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
AVOID ENGINE DAMAGE of the following conditions exist:
Always use the correct ratio of water to antifreeze. • When fluids are under pressure.
• Flying debris or loose material is present.
Too much antifreeze reduces cooling system • Engine is running.
efficiency and may cause serious premature engine • Tools are being used.
damage. W-2019-0907
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

47 of 1161
ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-4
Cleaning 1
WARNING
2
AVOID INJURY
Use safety goggles when using air or water under
pressure. Do not use cold water to clean a hot
engine.
W-2064-0907
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage. P-84836

Page 10-20-1.) Remove the left (Item 1) and right debris screen (Item 2)
[Figure 10-90-4] by pulling up on the screen.
Figure 10-90-3
Clean the debris screens.
Use low air or water pressure to remove debris in the

area of the radiator and oil cooler.
2
1 1
IMPORTANT
Do not use a pressure washer to clean the radiator
and oil cooler. High pressure can damage the fins.
I-2219-1102
P-84837
Check the cooling system for leaks.
There are two debris screens (Item 1) [Figure 10-90-3] Reinstall the screens.
located in front of the radiator.
Hoses And Clamps
Remove the wing nut bolt and washer (Item 2) [Figure
10-90-3]. Check radiator hoses for bulges or damage. Replace as
needed.
Check hose clamps for tightness or damage. Tighten or

replace as needed.

48 of 1161
Removing And Replacing Coolant
WARNING 1
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907

Page 10-20-1.)
P-86346
Remove the engine side cover. (See Removal And

Installation on Page 50-100-1.) The radiator drain fitting (Item 1) [Figure 10-90-6] is
located on the right side on the bottom of the radiator.
Figure 10-90-5
P-84837
Allow the engine to cool and remove the radiator cap

(Item 1) [Figure 10-90-5] from the radiator.

49 of 1161
ENGINE COOLING SYSTEM (CONT’D) Enter the compact tractor, fasten the seat belt, engage
the parking brake, and start the engine. Let it run until it is
Removing And Replacing Coolant (Cont’d)
at operating temperature.
Figure 10-90-7
Stop the engine and check the coolant level. Add
premixed coolant to the recovery tank as needed.
Close the engine cover.
1 2
P-86345
Pull the drain hose (Item 1) out of the strap (Item 2)

[Figure 10-90-7] to drain the radiator.
Open the drain fitting (Item 1) [Figure 10-90-6] and drain

the coolant into a container.
Re-use or dispose of the used coolant in an

environmentally safe manner.
Tighten the drain plug (Item 1) [Figure 10-90-6].
Install the drain hose (Item 1) back into the tie strap (Item
2) [Figure 10-90-7].
Remove coolant from the recovery tank.
NOTE: The compact tractor is factory filled with

ethylene glycol coolant (green color). DO NOT
mix ethylene glycol with propylene glycol.
Add premixed coolant, 50% water and 50% ethylene

glycol to the radiator. Install the cap.
Add premixed coolant, 50% water and 50% ethylene

glycol to the recovery tank. (See Removing And
Replacing Coolant on Page 10-90-3.) Install the cap.
One gallon (3,8 L) of ethylene glycol mixed with one

gallon (3,8 L) of water is the correct mixture of coolant
to provide a -34° F (-37° C) freeze protection.

50 of 1161
FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
• Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel jelling during cold temperatures:
• Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE F° (C°) NO. 2 NO. 1 corrosion and plugging of fuel system components.
+15° (9°) & Above 100% 0%
• Use of biodiesel blend fuel may result in premature
Down to -20° (-29°) 50% 50% failure of fuel system components, such as plugged
Below -20° (-29°) 0% 100% fuel filters and deteriorated fuel lines.
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel • Shorter maintenance intervals may be required, such
must be used in this machine. as cleaning the fuel system and replacing fuel filters
and fuel lines.
The following fuels may also be used in this machine:
• Using biodiesel blended fuels containing more than
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel. five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
• Biodiesel Blend Fuel - Must contain no more than five pump and seals.
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly Apply the following guidelines if biodiesel blend fuel is
marketed as B5 blended diesel fuel. used:
• Ensure the fuel tank is as full as possible at all times

to prevent moisture from collecting in the fuel tank.
WARNING • Ensure that the fuel tank cap is securely tightened.
AVOID INJURY OR DEATH • Biodiesel blend fuel can damage painted surfaces,
Stop and cool the engine before adding fuel. NO remove all spilled fuel from painted surfaces
SMOKING! Failure to obey warnings can cause an immediately.
explosion or fire.
W-2063-0807 • Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended

oil change intervals can cause engine damage.
WARNING • Before vehicle storage: drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer and
AVOID INJURY OR DEATH run the engine for at least 30 minutes.
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. NOTE: Biodiesel blend fuel does not have long term
Failure to use care around combustibles can cause stability and should not be stored for more
explosion or fire. than three months.
W-2103-0508

51 of 1161
FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an 1
explosion or fire.
W-2063-0807
The fuel tank is located under the engine cover. P-81614
Figure 10-100-1 Remove the fill cap (Item 1) [Figure 10-100-2].
Use a clean, approved safety container to add fuel of the

correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING
1 Install and tighten the fuel cap (Item 1) [Figure 10-100-

2].
Close the cover (Item 1) [Figure 10-100-1].
P-78820
WARNING
Open the fuel fill access cover (Item 1) [Figure 10-100- Always clean up spilled fuel or oil. Keep heat, flames,
1]. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

52 of 1161
FUEL SYSTEM (CONT’D) Remove the locking collar (Item 2) [Figure 10-100-4] at
the filter element and remove the fuel bowl and filter.
Fuel Filter
Remove the filter and drain the fuel, water and any
Remove water from or replace the fuel filter at the correct sediment into the drain pan. Dispose of the used fuel in
interval. (See Chart on Page 10-70-1.) an environmentally safe manor.
Figure 10-100-3 Reinstall the filter and bowl. Turn the lever to the ON
position [Figure 10-100-5].
4
Replacing Filter:
5 Clean the area around the filter housing.
Move the fuel shut off lever to the OFF position (Item 1)
6
[Figure 10-100-4].
3
Place a drain pan under the fuel filter.

2
Remove the locking collar (Item 2) [Figure 10-100-4] at
1 the filter element and remove the fuel bowl and filter.
Remove the filter and drain the fuel, water and any
B-26786
sediment into the drain pan. Dispose of the used fuel and
filter in an environmentally safe manner.
The fuel filter assembly consists of the following: Locking Put clean oil on the O-Rings.
Collar (Item1), Bowl (Item 2), O-Ring (Item 3), O-Ring
Install the new fuel filter, bowl and locking collar.
(Item 4), Filter (Item 5), and Spring (Item 6) [Figure 10-
100-3].
Figure 10-100-5
Removing Water:
Figure 10-100-4 ON
OFF 1
2 P-84843
Return the shutoff lever to the ON position (Item 1)

P-84843A [Figure 10-100-5].
Remove air from the fuel system. (See Removing Air

The fuel filter is located under the engine cover on the From The Fuel System on Page 10-100-4.)
right side of the engine [Figure 10-100-4].
.
Clean the area around the filter housing.
Move the fuel shut off lever 90° to the OFF position (Item
1) [Figure 10-100-4].
Place a drain pan under the fuel filter.

53 of 1161
FUEL SYSTEM (CONT’D) Start the engine and let it run for about 30 seconds and
then stop the engine.
Removing Air From The Fuel System
Exit the compact tractor.
Figure 10-100-7
WARNING
ON
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
WARNING
P-84843
Do not attempt to start the engine by shorting across
the starter terminals. Rotate the shut off lever (Item 1) [Figure 10-100-7] to the
ON position (as shown).
Always start the machine from the operator’s
position only.
W-2438-0807
After replacing the fuel filter or when the fuel tank has run
WARNING
out of fuel, air must be removed from the fuel system
before starting the engine. AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
Be sure the engine is cool. penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Figure 10-100-6 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-2072-0807
AIR Filling A Portable Fuel Container
Static electric spark can explosively ignite gasoline

vapors when filling ungrounded portable containers (e.g.
plastic).
Always put the container ON THE GROUND before

1 filling.
P-84842 Keep the nozzle in contact with container while filling.
Rotate the shutoff lever (Item 1) [Figure 10-100-6] to the

AIR position.
Enter the compact tractor and fasten the seat belt.

Perform the Pre-Starting procedure.

54 of 1161
ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil
Check the engine oil level every day.

If the engine has been running, wait about five minutes
before checking oil level.
Figure 10-110-1
B-16320
Use good quality engine oil that meets API Service

Classification of CD or better.
P-86347
The engine oil dipstick (Item 1) [Figure 10-110-1] can be

accessed from below the right engine side cover.
Remove the dipstick (Item 1) [Figure 10-110-1] to check

the oil level.
Keep the oil level between the marks on the dipstick.

55 of 1161
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-3
Removing And Replacing Oil And Filter
Follow the service interval for replacing the engine oil and
filter. (See Chart on Page 10-70-1.)
Run the engine until it is at operating temperature.
Stop the engine.
Figure 10-110-2
1
P-86348
Remove the oil filter (Item 1) [Figure 10-110-3] and clean

the filter housing surface.
1 Use genuine Bobcat filters only.

1
Put clean oil on the new filter gasket, install the filter and
hand tighten.
P-84840
Remove the two drain plugs (Item 1) [Figure 10-110-2].

Drain the oil into a container and recycle or dispose of
used oil in an environmentally safe manner.
Reinstall the two drain plugs.

Page 10-20-1.)
Remove the right side engine cover. (See Removal And

Installation on Page 50-100-1.)

56 of 1161
ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter (Cont’d)
Figure 10-110-4
P-86348
Remove the fill cap (Item 1) [Figure 10-110-4].
Put the correct quantity of oil in the engine. (See Chart on

Page SPEC-50-1.)
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 2) [Figure 10-110-4] and

check the oil level [Figure 10-110-1 on Page 10-110-1].
Install the dipstick.
Add oil as needed if it is not at the top mark on the

dipstick.
Install the right side engine cover. (See Removal And

Close the engine cover. (See Opening And Closing on

Page 10-20-1.)
WARNING
explosion or fire.
W-2103-0508

57 of 1161
58 of 1161
HYDRAULIC / HYDROSTATIC / TRANSMISSION Transmission / Differential Fluid Chart
SYSTEM
Checking And Adding Fluid
Use only recommended fluid in the hydraulic / hydrostatic

/ transmission system. (See Chart on Page SPEC-50-1.)
Put the compact tractor on a flat level surface, lower the

loader arms (if equipped) and lower implement (if
equipped).
Lock brake pedals together and engage the parking

brake.
Place all controls in the neutral position.
P-64023D
Stop the engine.
Figure 10-120-1
Figure 10-120-2
1 1
P-84805
P-84808
Check the fluid level at the dipstick (Item 1) [Figure 10-120- If needed, remove the fill cap (Item 1) [Figure 10-120-2]
1]. and add fluid. (See chart above.)
Keep the oil level between the marks on the dipstick. NOTE: When installing the fill cap (Item 1), position it
as shown. The fill cap has a breather hole
(Item 2) [Figure 10-120-2] that needs to be in
the up position.

59 of 1161
HYDRAULIC / HYDROSTATIC / TRANSMISSION Figure 10-120-4
SYSTEM (CONT’D)
Removing And Replacing Hydraulic / Hydrostatic /

Transmission Filters
Replace the filters at the correct interval (See Chart on

Page 10-70-1.)
WARNING 1

Diesel fuel or hydraulic fluid under pressure can P-84829
penetrate skin or eyes, causing serious injury or
Use a piece of cardboard or wood to find leaks. Do Remove the hydraulic / hydrostatic / transmission filter
not use your bare hand. Wear safety goggles. If fluid (Item 1) [Figure 10-120-4] (below the operator’s area on
enters skin or eyes, get immediate medical attention the left side of the frame).
W-2072-0807 Clean the surface of the filter housings where the filter
seal contacts the housing.
Figure 10-120-3 Put clean oil on the seal of the new filters. Install and
hand tighten.
Start the engine and operate all the hydraulic controls.
Stop the engine and check for leaks at the filters.
Check fluid level and add as needed.
WARNING
1 Failure to use care around combustibles can cause
P-84830 explosion or fire.
W-2103-0508
Remove the filter (Item 1) [Figure 10-120-3] (near the

right rear wheel).

60 of 1161
HYDRAULIC / HYDROSTATIC / TRANSMISSION Hoses And Clamps
SYSTEM (CONT’D)
Inspect hydraulic, cooler and power steering hoses and
Removing And Replacing Hydraulic / Transmission tubelines. Replace as necessary.
Fluid
Inspect hose clamps for damage and tightness. Tighten
Replace hydraulic / hydrostatic / transmission fluid at the or replace as necessary.
correct service interval (See Chart on Page 10-70-1.)
Fluid should also be replaced if it becomes contaminated

or after major repair.
Always replace the filters whenever the hydraulic /

hydrostatic / transmission fluid is replaced. (See Figure
10-120-2 on Page 10-120-1.)
Figure 10-120-5
1
11 1
P-84827
Remove the three plugs (Item 1) [Figure 10-120-5] from

the bottom of the transmission case.
If equipped with mid-PTO, remove the plug (Item 2)

[Figure 10-120-5] from the side of the mid-PTO housing.
Drain the fluid into a container.
Recycle and dispose of the used fluid in an

environmentally safe manner.
Install the drain plugs and add hydraulic fluid [Figure 10-
120-1 on Page 10-120-1].
WARNING
explosion or fire.
W-2103-0508

61 of 1161
62 of 1161
FRONT AXLE Figure 10-130-2
Checking And Adding Lubricant 1

Stop the compact tractor on a flat level surface.
on the ground (if equipped).
Fully lower the implement(s) (if equipped).
Lock the brake pedals together and engage the parking

brake.
Put all controls in the neutral.
Stop the engine and exit the compact tractor. P-84825
Figure 10-130-1
If the fluid level is low, clean the area around the fill plug
and add lubricant through the fill plug hole (Item 1)
1 [Figure 10-130-2] until oil level is at the center of the
sight gauge (Item 1) [Figure 10-130-1].
NOTE: When adding axle housing lubricant. See

Drive System for correct fluid type. (See Chart
on Page SPEC-50-1.)
Install and tighten the plug.
Drive the compact tractor for five minutes and recheck

the lubricant level. Add additional lubricant if needed.
P-84826A
An oil level sight gauge (Item 1) [Figure 10-130-1] is

located on the left side of the front axle.
The correct oil level is at the center of the sight gauge.

63 of 1161
FRONT AXLE (CONT’D) Axle Pivot
Removing And Replacing Lubricant Adjust the front axle pivot every 600 hours of operation.
Figure 10-130-3 If the front axle pivot pin adjustment is incorrect, front
wheel vibration can occur causing vibration in the
steering wheel.
Figure 10-130-4
2 2
1
P-84824
Remove the drain plugs (Item 1) (both sides) at the

bottom on the front axle by the rims and from the center
P-84824
section (Item 2) [Figure 10-130-3].
Remove the fill plug (Item 1) [Figure 10-130-2] so that Loosen the lock nut (Item 1) and turn the bolt (Item 2)
the oil will drain faster. [Figure 10-130-4] in until resistance is felt.
Drain the lubricant into a container and recycle or Turn the bolt (Item 2) out 1/6 turn and then tighten the
dispose of it in an environmentally safe manner. lock nut (Item 1) [Figure 10-130-4] to 72 - 109 ft.-lb. (98 -
147 N•m) torque.
Install and tighten drain plugs (Item 1) (both sides) and
(Item 2) [Figure 10-130-3].
Add lubricant through the fill plug hole (Item 1) [Figure

10-130-2 on Page 10-120-1] until oil is at the center of
the sight gauge (Item 1) [Figure 10-130-1 on Page 10-
120-1].
Install and tighten the plugs.
Drive the compact tractor for five minutes and recheck

the lubricant level. Add additional lubricant if needed.
NOTE: When adding axle housing lubricant. See

Drive System for correct fluid type. (See Chart
on Page SPEC-50-1.)

64 of 1161
SPARK ARRESTOR MUFFLER Figure 10-140-1
Cleaning Procedure
Clean the spark arrestor muffler at the correct service

interval. (See Chart on Page 10-70-1.)
Do not operate the compact tractor with a defective

exhaust system.
1
WARNING
Stop engine and allow the muffler to cool before P-78979
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285 Remove the plug (Item 1) [Figure 10-140-1] from the
clean out hole in the muffler.
Start the engine and run for about ten seconds while a
second person, wearing safety glasses, holds a block of
WARNING wood over the outlet of the muffler.
This will force contaminants out through the clean out

AVOID INJURY OR DEATH hole (Item 1) [Figure 10-140-1].
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust Stop the engine and install the plug.
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
IMPORTANT
Stop the engine and allow it to cool.
This compact tractor is facory equipped with a spark
Open the engine cover. (See Opening And Closing on arrestor muffler. It is necessary to do maintenance
Page 10-20-1.) on this spark arrestor muffler to keep it in working
condition. The spark arrestor muffler must be
Remove the left side engine cover. (See Removal And serviced by dumping the spark chamber every 100
Installation on Page 50-100-1.) hours of operation.
If this machine is operated on flammable forest,

brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442
PRC.
Consult local laws and regulations for spark arrestor

requirements
I-2269-0907

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COMPACT TRACTOR STORAGE AND RETURN TO Return To Service
SERVICE
After the compact tractor has been in storage, it is
Storage necessary to complete this list of items to return the
compact tractor to service.
• Check the engine and hydraulic oil levels; check

WARNING coolant level.
• Install a fully charged battery.
• Remove grease from exposed cylinder rods.
air must be added to avoid concentration of exhaust • Check belt tension.
fumes. If the engine is stationary, vent the exhaust • Be sure all shields and guards are in place.
• Lubricate the compact tractor as shown. (See
W-2050-0807
Lubrication Locations on Page 10-170-1.)
• Check tire inflation and remove blocks from under
Sometimes it may be necessary to store your compact frame.
tractor for an extended period of time. Below is a list of • Remove cover from exhaust pipe opening.
items to perform before storage. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Thoroughly clean the compact tractor including the correct operation.
engine compartment.
• Operate compact tractor, check for correct function.
• Lubricate the compact tractor as shown in the
• Check brake and parking brake function.
Operation & Maintenance Manual.
• Replace worn or damaged parts. • Stop the engine and check for leaks. Repair as
needed.
• Park the compact tractor in a dry protected shelter.
• Lower the loader arms and implement (if equipped)
and put the attachment and implement flat on the
ground.
• Put grease on any exposed cylinder rods.
• Put fuel stabilizer in the fuel tank and run the engine
a few minutes to circulate the stabilizer to the pump
and fuel injectors.
• Drain and flush the cooling system. Refill with
premixed coolant.
• Replace all fluids and filters (engine, hyd. / hydros /
trans.).
• Replace air cleaner filter.
• Put blocks under the frame to remove weight from the
tires.
• Put all controls in neutral.
• Remove the battery. Be sure the electrolyte level is
correct then charge the battery. Store it in a cool, dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the compact tractor to indicate that it is in storage
condition.
• Lock brake pedals together and engage the parking

brake.

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ALTERNATOR BELT Figure 10-160-2
Belt Adjustment
Stop the engine and engage the parking brake.

Page 10-20-1.)
Remove the right side engine panel. (See Removal And

Figure 10-160-1
2 1
P-84822A
The tension is correct with 5/16 in. (8 mm) belt movement

at mid span (Item 1) [Figure 10-160-2] when 15 lb. (67
N) force is applied to the belt.
Tighten the mounting bolt (Item 1) and adjustment bolt

(Item 2) [Figure 10-160-1].
1 Belt Replacement
P-78985 Loosen the mounting bolt (Item 1) and adjustment bolt

(Item 2) [Figure 10-160-1]. and move the alternator all
the way in. Remove the belt.
Loosen the mounting bolt (Item 1) and adjustment bolt
(Item 2) [Figure 10-160-1]. Install the new belt and adjust as shown above.
Move the top of the alternator outward [Figure 10-160-1]

to tighten the belt.

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AIR CONDITIONING BELT Figure 10-161-2
Belt Adjustment

Page 10-20-1.)
Remove the left side engine panel. (See Removal And

Figure 10-161-1 1
P-87870
2
Turn the inner nut (Item 1) [Figure 10-161-2] clockwise
to tighten the belt or counterclockwise to loosen the belt.
Figure 10-161-3
P-87868
Loosen the jam nut (Item 1) on the belt tensioner and the
nut (Item 2) [Figure 10-161-1] on the pulley.
P-89325

at mid span (Item 1) [Figure 10-161-3] when 15 lb. (67
N) force is applied to the belt.
After adjustment is made, tighten the jam nut (Item 1)

and the nut (Item 2) [Figure 10-161-1] on the pulley.
Belt Replacement
Loosen the jam nut (Item 1) on the belt tensioner and the
nut (Item 2) [Figure 10-161-1] on the pulley.
Loosen the adjusting nut (Item 1) [Figure 10-161-2]

completely.
Remove the belt.

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LUBRICATING THE COMPACT TRACTOR Figure 10-170-2
Lubrication Locations
WARNING
If equipped with a loader or implement, always have
the attachment or implement fully lowered on the
ground. Stop the engine and engage the parking 2
brake before doing any maintenance to the compact
tractor. Do Not work under raised loader arms or
raised implement.
P-84804
W-2599-0607
Lubricate as specified for the best performance of the 2. Left Brake Pedal Pivot (1) [Figure 10-170-2] (below
(See Chart on Page 10-70-1.) left floor plate).
Record the operating hours each time you lubricate the Figure 10-170-3
compact tractor.
Always use a good quality lithium based multi-purpose

grease. Apply lubricant until extra grease shows.
Lubricate the following:
Figure 10-170-1
1
4 P-84824
3. Axle Pivot (1) [Figure 10-170-3] (on front side of front

axle).
4. (HST MODELS ONLY) Base End Steering Cylinder

(2) [Figure 10-170-3] (under compact tractor).
P-84821
1. Right Brake Pedal Pivot (1) [Figure 10-170-1] (below

right floor plate)

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LUBRICATING THE COMPACT TRACTOR (CONT’D) Figure 10-170-6
Lubrication Locations (Cont’d)
Figure 10-170-4
6
5
8
P-84802
8. Three-Point Hitch Position Lever (1) [Figure 10-170-

P-84820 6] (above right side of rear axle).
Figure 10-170-7
5. (HST MODELS ONLY) Rod End Steering Cylinder (2)
[Figure 10-170-4] (both sides).
6. Axle Pivot (2) [Figure 10-170-4] (both sides).
Figure 10-170-5
P-84803
9. Three-Point Hitch Lifting Link (Both Sides) (2) [Figure

7 10-170-7]
P-78853
7. Axle Pivot (1) [Figure 10-170-5] (on rear side of front

axle).

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LUBRICATING THE COMPACT TRACTOR (CONT’D) Figure 10-170-10
Lubrication Locations (Cont’d)
Figure 10-170-8
10
11 14 15
P-84818
14. Base End Lift Cylinder (both Sides) (2) [Figure 10-
170-10] (if equipped).
P-77986A
15. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-
10. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-
170-8] (if equipped). Figure 10-170-11
11. Bucket Pins (Both Sides) (2) [Figure 10-170-8] (if

equipped).
Figure 10-170-9
13 16
P-84817
16. Bob-Tach Wedge (Both Sides) (2) [Figure 10-170-

12 11] (if equipped).
P-84819A
12. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-
13. Loader Arm Pin (Both Sides) (2) [Figure 10-170-9] (if
equipped).

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TIRE MAINTENANCE Mounting
Check the tires regularly for wear, damage and pressure.
IMPORTANT
Foam filled tires are NOT approved for use on the
WARNING
Compact Tractor. Axle damage may occur with foam
filled tires. Warranty will be voided if foam filled tires
• Do Not attempt to mount a tire on the rim. This
are used on this machine.
I-2277-0608
must be done by qualified personnel with the
proper equipment.
• Always maintain the correct tire pressure. Do not
Front Wheel Nuts / Bolts inflate the tires above the recommended
pressures shown in the Operation & Maintenance
Check the wheel nut / bolt torque at the correct service Manual or on the side of the tire.
interval. (See Chart on Page 10-70-1.) • Use tires with the correct load rating for proper
loader operation.
Front Wheels: The correct bolt torque is 166 ft.-lb. (225 W-2598-0907
N•m).
Tires are to be repaired only by an authorized person
Front Wheels: The correct nut torque is 166 ft.-lb. (225
using the proper procedures and safe equipment.
N•m).
Tires and rims must always be checked for correct size
Rear Wheel Nuts / Bolts
before mounting. Check rim and tire bead for damage.
Check the wheel nut / bolt torque at the correct service
The rim flange must be cleaned and free of rust.
interval. (See Chart on Page 10-70-1.)
The tire bead and rim flange must be lubricated with a
Rear Wheels: The correct bolt torque is 166 ft.-lb. (225
rubber lubricant before mounting the tire.
N•m).
Avoid excessive pressure which can rupture the tire and
Rear Wheels: The correct nut torque is 166 ft.-lb. (225
cause serious injury or death.
N•m).
During inflation of the tire, check the tire pressure
Check the tires regularly for wear, damage and pressure.
frequently to avoid over inflation.
Use tires with the correct load rating for proper loader
operation. (See Dimensions (Standard Machine) on Page
SPEC-10-3.)
WARNING
IMPORTANT Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
Inflate tires to the MAXIMUM pressure shown on the W-2078-1007
sidewall of the tire. DO NOT mix brands of tires used
on the same compact tractor.
I-2270-0907

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TIRE MAINTENANCE (CONT’D) Figure 10-180-3
Wheel Spacing (AG And Industrial Tires Only)
The rear wheel spacing on Ag and Industrial tires is

adjustable. To provide the best stability, operate the
compact tractor in the widest wheel spacing position
whenever possible. 1
1
Raise the rear wheels and support the rear axle on
jackstands. (See Procedure on Page 10-10-1.)
Figure 10-180-1
1
P-80899B
1
Remove the four nuts (Item 1) [Figure 10-180-3] and
bolts that retain the wheel center section to the rim.
Figure 10-180-4
P-81899A
2
The rim can be mounted on the wheel center section with
the bracket (Item 1) [Figure 10-180-1] to the inside or the
outside of the wheel center section. (To the inside 1
provides a narrower spacing, to the outside provides a
wider spacing.) P-80898
Figure 10-180-2
Position the wheel center section (Item 1) to the desired
position and install the bolt (Item 2) [Figure 10-180-4]
2 and nut.
1
Tighten the nuts to 166 ft.-lb. (225 N•m) torque.
Reinstall the wheel assembly and tighten the wheel nuts

and bolts. (See Rear Wheel Nuts / Bolts on Page 10-180-
1.)
1
2
IMPORTANT
P-78841
Foam filled tires are NOT approved for use on the
Compact Tractor. Axle damage may occur with foam
Remove the four bolts (Item 1) and the two nuts (Item 2) filled tires. Warranty will be voided if foam filled tires
[Figure 10-180-2] and remove the wheel assembly from are used on this machine.
I-2277-0608
the compact tractor.

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PIVOT PINS
Figure 10-190-1
1
P-78909
Some pivot pins (Item 1) [Figure 10-190-1] are held in

position with a bolt.
Check that the bolts are tightened to 25 - 28 ft.-lb. (34 -

37 N•m) torque.
Figure 10-190-2
1
P-77986
Some pivot pins (Item 1) are held in position with a bolt

and lock nut (Item 2) [Figure 10-190-2].
Check that the lock nuts are tightened to 25 - 28 ft.-lb. (34

- 37 N•m) torque.

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SAFETY INTERLOCK SYSTEM - NEUTRAL START Figure 10-200-1
Inspection And Maintenance (HST)
WARNING
The Safety Interlock System must not allow the
compact tractor's engine to be started unless: the 1
operator is in the operator's seat, one brake pedal is
depressed, the PTO switch is off, and the speed
range lever is in neutral. Contact your dealer for
service if the Safety Interlock System does not
function properly. DO NOT MODIFY THE SYSTEM.
P-78025
W-2802-0709
The Safety Interlock System - Neutral Start: The seat switch (Item 1) [Figure 10-200-1] is installed in
the bottom of the seat. Replace the seat switch and
The engine will not start unless all the following components if damaged or missing. See your Bobcat
conditions are present: dealer for parts.
1. The operator is seated in the operator’s seat.
2. One or both brake pedals are depressed.
3. The PTO switch is disengaged (OFF).
4. The speed range lever is in the neutral position. WARNING
If the engine starts without all of the above conditions AVOID INJURY OR DEATH
present, the compact tractor must be serviced by your • Check that seat switch is properly installed and
Bobcat dealer. functions correctly.
Inspecting Procedure: • Replace switch and components if damaged or
missing.
Perform this procedure on flat level ground and make W-2676-0907
sure the area is clear of bystanders.
a. Sit in the operator’s seat - Engage the parking brake
- Place all controls in neutral - Raise off of the seat -
Turn the key to start; THE ENGINE MUST NOT
START
b. Sit in the operator’s seat and fasten the seat belt -
Engage the parking brake - Place all controls in
neutral - Release the Parking Brake - Turn the key to
start; THE ENGINE MUST NOT START
c. Sit in the operator’s seat and fasten the seat belt -
neutral - Move the PTO switch to the ON position -
START
d. Sit in the operator’s seat and fasten the seat belt -
neutral - Move the speed range lever to LOW (L)
speed range - Turn the key to start; THE ENGINE
MUST NOT START. Repeat this step for MEDIUM
(M) and HIGH (H) speed ranges.
If the engine starts after performing any of the above
procedures, further troubleshooting must be done.

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SAFETY INTERLOCK SYSTEM - NEUTRAL START Figure 10-200-2
(CONT’D)
Inspection And Maintenance (SST)
WARNING
1
The Safety Interlock System must not allow the
compact tractor's engine to be started unless: the
operator is in the operator's seat, the brake pedals
are depressed, the PTO switch is off, and the F-N-R
lever is in neutral. Contact your dealer for service if
the Safety Interlock System does not function P-78025
properly. DO NOT MODIFY THE SYSTEM.
W-2803-0709
The seat switch (Item 1) [Figure 10-200-2] is installed in
The Safety Interlock System - Neutral Start: the bottom of the seat. Replace the seat switch and
components if damaged or missing. See your Bobcat
The engine will not start unless all the following dealer for parts.
conditions are present:
1. The operator is seated in the operator’s seat.
2. The right brake pedal is depressed.
3. The PTO switch is disengaged (OFF). WARNING
4. The F-N-R lever is in the neutral (N) position.
If the engine starts without all of the above conditions • Check that seat switch is properly installed and
present, the compact tractor must be serviced by your functions correctly.
Bobcat dealer. • Replace switch and components if damaged or
Inspecting Procedure: missing.
W-2676-0907
Perform this procedure on flat level ground and make
a. Sit in the operator’s seat - Engage the parking brake
- Place all controls in neutral - Raise off of the seat -
START
neutral - Release the Parking Brake - Turn the key to
start; THE ENGINE MUST NOT START
neutral - Move the PTO switch to the ON position -
START
d. Sit in the operator’s seat and fasten the seat belt -
neutral - Move the F-N-R lever to Forward (F) - Turn
the key to start; THE ENGINE MUST NOT START.
Repeat this step with the F-N-R lever in Reverse (R).
If the engine starts after performing any of the above
procedures, further troubleshooting must be done.

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SAFETY INTERLOCK SYSTEM - OPERATING Figure 10-210-1
Inspection And Maintenance (HST)
WARNING
The Safety Interlock System must shut off the engine
if the operator leaves the operator’s seat unless: the 1
parking brake is engaged, the mid-PTO lever is
disengaged, and the speed range lever is in neutral.
Contact your dealer for service if the Safety Interlock
System does not function properly. DO NOT MODIFY
THE SYSTEM. P-78025
W-2749-0708
The Safety Interlock System - Operating: The seat switch (Item 1) [Figure 10-210-1] is installed in
the bottom of the seat. Replace the seat switch and
The engine must shut off if the operator leaves the components if damaged or missing. See your Bobcat
operator’s seat, unless all the following conditions are dealer for parts.
present:
1. The parking brake is engaged.
2. The mid-PTO lever (if equipped) is in the disengaged
(OFF) position.
WARNING
3. The speed range lever is in the neutral position. AVOID INJURY OR DEATH
If the engine does not shut off when the operator leaves • Check that seat switch is properly installed and
the operator’s seat without all of the above conditions functions correctly.
present, the compact tractor must be serviced by your • Replace switch and components if damaged or
Bobcat dealer. missing.
Inspecting Procedure: W-2676-0907

a. Sit in the operator’s seat and fasten the seat belt -
neutral - Move engine speed control lever to low
engine speed - Start the engine - Release the Parking
Brake - Unfasten the seat belt and raise off the
operator’s seat; THE ENGINE MUST STOP.
engine speed - Start the engine - Move the mid-PTO
lever to the ON position (if equipped) - Unfasten the
seat belt and raise off the operator’s seat; THE
ENGINE MUST STOP.
engine speed - Start the engine - Move the speed
range lever to LOW (L) speed range - Unfasten the
ENGINE MUST STOP. Repeat this step for MEDIUM
(M) and HIGH (H) speed ranges.
If the engine does not shut off after performing any
of the above procedures, further troubleshooting
must be done.

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SAFETY INTERLOCK SYSTEM - OPERATING Figure 10-210-2
(CONT’D)
Inspection And Maintenance (SST)
WARNING
The Safety Interlock System must shut off the engine 1
if the operator leaves the operator’s seat unless: the
parking brake is engaged, the mid-PTO lever is
disengaged, and the F-N-R lever is in neutral.
Contact your dealer for service if the Safety Interlock
System does not function properly. DO NOT MODIFY P-78025
THE SYSTEM.
W-2804-0709
The seat switch (Item 1) [Figure 10-210-2] is installed in

The Safety Interlock System - Operating: the bottom of the seat. Replace the seat switch and
components if damaged or missing. See your Bobcat
The engine must shut off if the operator leaves the dealer for parts.
operator’s seat, unless all the following conditions are
present:
1. The parking brake is engaged.
2. The mid-PTO lever (if equipped) is in the disengaged
WARNING
(OFF) position.
3. The F-N-R lever is in the neutral (N) position. • Check that seat switch is properly installed and
If the engine does not shut off when the operator leaves functions correctly.
the operator’s seat without all of the above conditions • Replace switch and components if damaged or
present, the compact tractor must be serviced by your missing.
Bobcat dealer.
W-2676-0907
Inspecting Procedure:
a. Sit in the operator’s seat and fasten the seat belt -
engine speed - Start the engine - Release the Parking
Brake - Unfasten the seat belt and raise off the
operator’s seat; THE ENGINE MUST STOP.
engine speed - Start the engine - Move the mid-PTO
lever to the ON position (if equipped) - Unfasten the
ENGINE MUST STOP.
engine speed - Start the engine - Move the F-N-R
lever to Forward (F) - Turn the key to start; THE
ENGINE MUST NOT START. Repeat this step with
the F-N-R lever in Reverse (R).
If the engine does not shut off after performing any of
the above procedures, further troubleshooting must
be done.

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PARKING BRAKE SYSTEM Figure 10-220-1
Inspection And Maintenance UNLOCKED LOCKED
NOTE: The brakes must be adjusted if the brake 2

pedals can be pressed down more than the
allowable limit. (See Adjusting on Page 10-
230-2.)
WARNING
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
W-2050-0807
1
HST Model P-84900
Figure 10-220-2
WARNING UNLOCKED LOCKED
The parking brake must be engaged before leaving 2
the operator’s seat. Rollaway can occur because the
transmission may not prevent machine movement.
Lock the brake pedals together before activating the
parking brake.
W-2656-0807
SST Model 1 P-92929A
The brake pedals (Item 1) [Figure 10-220-1] or [Figure

10-220-2] must be locked together for parking brake
application.
Rotate the brake pedal lock lever (Item 2) [Figure 10-

220-1] or [Figure 10-220-2] to the locked position.

85 of 1161
PARKING BRAKE SYSTEM (CONT’D) Figure 10-220-5
Inspection And Maintenance (Cont’d) LOCKED
SST Model
Figure 10-220-3
1
P-92930
With the brake pedals locked together, press down fully

P-78874
on the brake pedals (Item 1) [Figure 10-220-4] or
[Figure 10-220-5]. Press down and hold the parking
Position the compact tractor on a 15° slope [Figure 10- brake lever (Item 2) [Figure 10-220-4] or [Figure 10-
220-3] so that both the front and rear tires are on the 220-5] and remove foot from the brake pedals (Item 1)
slope with the heavy end uphill. [Figure 10-220-4] or [Figure 10-220-5]. The brake
pedals (Item 1) [Figure 10-220-4] or [Figure 10-220-5]
NOTE: If equipped with a loader, raise the loader arms
18.00 in. (457 mm) above the ground. must remain in the engaged position.
Figure 10-220-4 Make sure no bystanders are in the area.
HST Model LOCKED Stop the engine.
For HST models: Move the speed range lever to neutral.
For SST models: Press the clutch pedal fully and move
the Forward-Neutral-Reverse (F-N-R) lever to Neutral,
the gear shift lever to neutral, and the range lever to the
neutral position.
The engaged parking brake must hold the compact

1 tractor from moving. If movement is detected, the brakes
must be adjusted. (See Adjusting on Page 10-230-2.)
P-84902
P-84901

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BRAKE SYSTEM The brake pedals (Item 1) [Figure 10-230-1] must be
unlocked for brake inspection and maintenance.
When the brakes are used to slow the compact tractor, Rotate the lock lever (Item 2) [Figure 10-230-1] to the
there should be no noticeable pulling to the left or the unlocked position.
right. If brakes need adjusting, use the following
procedure.
Figure 10-230-2
The brakes are inspected by measuring pedal free travel.
For HST models: One or both brake pedals must be HST Model
depressed before the engine can be started.
For SST models: Both brake pedals must be depressed
before the engine can be started. 1
WARNING
Stop engine and chock both rear tires before
inspecting or adjusting brakes.
W-2590-0607
MEASURE PEDAL FREE TRAVEL
P-84847A
Figure 10-230-1
UNLOCKED 2 LOCKED SST Model
2
MEASURE PEDAL FREE TRAVEL P-92924
HST Model 1 P-84900 Press down lightly on the left brake pedal (Item 1)
[Figure 10-230-2] until resistance is felt.
UNLOCKED LOCKED
2 Measure the distance that the pedal traveled.
2
Repeat the procedure for the other brake pedal.
The correct brake pedal free travel for both the left and
right brake pedal is:
Brake pedal free travel 0.78 - 1.18 in. (20 - 30 mm)

2 Adjust until the free travel is equal for both the left and
right brake pedals.
After brake pedal inspection or adjustment is completed,

lock the brake pedals together. Rotate the pedal lock
(Item 2) to the locked position [Figure 10-230-1].

87 of 1161
BRAKE SYSTEM (CONT’D)
Adjusting
Figure 10-230-4
WARNING
Brake pedals must be locked together before 1
activating the parking brake or for road travel. Only
unlock the brake pedals when brake adjustment is
needed or when using the brake pedals for slow
speed turning in work applications. Using unlocked 2
brake pedals to stop the machine at high speeds may
cause accidental turning or tipping. Slow down
before making a turn. Inspect and adjust the brakes
1
as needed. P-92910A
W-2750-0708
Left Brake Pedal Adjustment
Figure 10-230-3 The adjustment linkage for the left brake pedal is located
on the left side of the instrument panel.
To adjust the left brake pedal free travel, loosen the two
lock nuts (Item 1) [Figure 10-230-4].
1 Turn the turn buckle (Item 2) [Figure 10-230-4] to
change pedal travel.
When both the left and right pedals have been set to the
same free travel, tighten the two lock nuts (Item 1)
2 [Figure 10-230-4].
After the brake pedals have been adjusted, the compact

tractor should stop in a straight line when using the brake
1 pedals. If compact tractor pulls to one side, readjust the
P-92911
brakes as needed.

NOTE: This procedure and the photos are shown lock the brake pedals together. Rotate the lock lever
(Item 2) to the locked position [Figure 10-230-1 on Page
using a HST model, the procedure for the SST
10-230-1].
model is the same.
Check the parking brake. (See BRAKE SYSTEM on
Right Brake Pedal Adjustment Page 10-220-1.)
The adjustment linkage for the right brake pedal is
located on the right side of the instrument panel.
To adjust the right brake pedal free travel, loosen the two
Turn the turn buckle (Item 2) [Figure 10-230-3] to

change pedal travel.
[Figure 10-230-3].
10-230-2 CT335 Service Manaul

88 of 1161
TRAVEL CONTROL PEDAL (HST ONLY)
Figure 10-240-1
1
2
P-84194
When on flat, level ground, if any movement of the

compact tractor is detected when the travel control
pedals (Item 1 & 2) [Figure 10-240-1] are in neutral and
the speed range lever in gear, further troubleshooting
and testing must be done.
WARNING
When on flat level ground, the compact tractor must
not move with the travel control pedal(s) in the
neutral position and the speed range lever in gear. If
any movement is detected, discontinue operation
and contact your Bobcat dealer for service.
W-2591-0907

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F-N-R LEVER (SST ONLY)

Figure 10-241-1
P-92921
When on flat level ground, if any movement of the

compact tractor is detected when the F-N-R lever (Item
1) [Figure 10-241-1] is in neutral (N), the speed range
lever is in gear, the gear shift lever is in gear and the
clutch pedal is released, further trouble shooting and
testing must be done.

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CRUISE CONTROL (HST ONLY) Figure 10-250-3
Inspection And Maintenance 3
Figure 10-250-1 2
P-84852
P-84914
The cruise control is controlled by a magnet (Item 1) that
holds the forward travel pedal (Item 2) [Figure 10-250-3]
in the selected forward travel speed position.
If the cruise control switch (Item 1) [Figure 10-250-1]
If adjustment is needed, loosen the bolts (Item 3) [Figure
does not maintain the selected speed, the cruise control
10-250-3] and position the magnet so there is 0.039 -
will need to be adjusted.
0.059 in. (1,0 - 1,5 mm) clearance between the side of
the forward travel pedal and the face of the magnet.
Figure 10-250-2
Tighten the bolts after adjustment is made.
Figure 10-250-4
2
3
1
P-84851 1
P-84850
NOTE: The brake pedals (Item 1) must be in the locked
position with the lock lever (Item 2) and the
brake switch (Item 3) [Figure 10-250-2]
The controller (Item 1) [Figure 10-250-4] located below
engaged to activate the cruise control. If the
the operator’s seat, also controls the cruise control
brake pedals are not locked together, the
magnet. If the cruise control will still not maintain the
switch will not allow power to the cruise
selected speed, the controller may be defective.
control switch. Make sure the switch is
activated before proceeding with any
The cruise control must disengage when both brake
additional adjustment procedures.
pedals are pressed or the cruise control switch is moved
to the OFF position. If the system does not function
properly, further troubleshooting and testing must be
done.

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CLUTCH PEDAL (SST ONLY)
Figure 10-251-1
P-92923
When on flat level ground, if any movement of the

compact tractor is detected when the clutch pedal (Item
1) [Figure 10-251-1] is fully depressed, the speed range
lever is in gear, gear shift lever is in a gear and the F-N-R
lever is in F or R, clutch pedal adjustment or clutch
replacement may be needed.
Press down lightly on the clutch pedal (Item 1) [Figure

10-251-1] until resistance is felt.
Measure the distance that the clutch pedal traveled.
The correct clutch pedal free travel is:
Clutch pedal free travel 0.78 - 1.18 in. (20 - 30 mm)

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SPEED RANGE LEVER (HST ONLY) Figure 10-260-3
Calibration 4
1
Figure 10-260-1
3
1
2
P-86146
The speed range lever will need to be calibrated when LOW N MED N HIGH
the cruise unit (Item 1) or range sensor (Item 2) [Figure
10-260-1] has been replaced.
P-86344
Turn the key switch to the ON position. Do not start the

engine. The H lamp (Item 1) [Figure 10-260-3] will begin to blink,
indicating the unit is ready for calibration.
Figure 10-260-2
2 Move the speed range lever (Item 2) to the neutral

position between high and medium range. The H lamp
(Item 3) [Figure 10-260-3] will blink, indicating 3 ± 0.3
volts.
Engage and quickly disengage the cruise control switch.

The H lamp and N lamp will stop blinking for one second,
then resume blinking.
Move the speed range lever (Item 2) to the medium

position. The H lamp (Item 1) and M lamp (Item 4)
[Figure 10-260-3] will blink, indicating 2.5 ± 0.3 volts.
1
P-84899
Press the brake pedals (Item 1) and within three

seconds, engage and disengage the cruise control switch
(Item 2) [Figure 10-260-2].

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SPEED RANGE LEVER (HST ONLY) (CONT’D)
Calibration (Cont’d)
Engage and quickly disengage the cruise control switch,

the H lamp (Item 1) and M lamp (Item 4) [Figure 10-260-
3 on Page 10-260-1] will stop blinking for one second,
then continue blinking.
Move the speed range lever (Item 2) to the neutral

position between the medium and low range. The H lamp
(Item 1) and N lamp (Item 3) [Figure 10-260-3 on Page
10-260-1] will blink indicating 1.8 ± 0.3 volts.

The H lamp (Item 1) and N lamp (Item 3) [Figure 10-260-
If the lamps do not blink correctly in each step, engage

the cruise switch to correct or adjust the mounting
location of the sensor.
Turn the key switch to the off position then back to the on
position to save the calibration.
Figure 10-260-4
P-886147
If calibration can not be obtained, repeat the calibration

procedure and check the voltage at the white (middle)
wire (Item 1) [Figure 10-260-4].

98 of 1161
BOB-TACH (HAND LEVER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
Inspection And Maintenance 270-2] mounting frame.
Figure 10-270-1 If the wedge does not contact the lower edge of the hole
[Figure 10-270-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-270-3
P-84816
Move the Bob-Tach levers down to engage the wedges

[Figure 10-270-1].
The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208
Figure 10-270-2
2
B-17460
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-270-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
P-79780
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
The wedges (Item 1) [Figure 10-270-2] must extend Lubricate the wedges. (See SERVICE SCHEDULE on
through the holes in the attachment mounting frame. Page 10-70-1.) (See LUBRICATING THE COMPACT
TRACTOR on Page 10-170-1.)

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CLUTCH PEDAL AND HOUSING (SST ONLY) Figure 10-280-2
Draining Water
1
Water can be trapped in the clutch housing after washing
the machine, heavy rains, melting snow or driving
through water.
The clutch housing should be drained after any of these

events and/or should be checked and drained on a
periodic bases.
If water is trapped in the clutch housing and not drained

and the tractor is not used for an extended period of time,
the clutch can rust and make clutch disengagement
P-92908
difficult.
Figure 10-280-1 Fully press the clutch (Item 1) and rotate the retainer
(Item 2) [Figure 10-280-2] to hold the clutch in the
disengaged position.
P-92912
Remove the plug (Item 1) [Figure 10-280-1] from the

bottom of the clutch housing and allow all water to drain.
Reinstall the plug and tighten.
Storage Position
If the machine is going to be stored or not used for an
extended period of time, the clutch pedal should be put in
the storage position so that the clutch can not rust and
lock in the engaged position.

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DIFFERENTIAL LOCK
Figure 10-290-1
HST Model
P-84823A
SST Model
1 P92922A
The differential lock (Item 1) [Figure 10-290-1], when

activated will cause both rear wheels to turn at the same
speed.
Adjustment
There are no external adjustments for the differential

lock. If the differential lock is not functioning properly, the
transmission will need to be serviced.

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HYDRAULIC SYSTEM
AUXILIARY CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Detent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
End Cap Section Disassembly And Assembly. . . . . . . . . . . . . . . . 20-100-1 HYDRAULIC
Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . 20-100-4 SYSTEM
Valve Section Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
FRONT WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Engagement Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols For Compact Tractors20-10-1
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Joystick Valve Circuit . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Power Lift Circuit . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Steering Circuit. . . . . . . . . . . . . . . . . . . . . . . . 20-10-7
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1

Testing And Adjusting The Main Relief Valve . . . . . . . . . . . . . . . . . .20-20-1
Testing Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1
MLS VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Adjustment (HST Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-12
Adjustment (SST Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-14
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
MODULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3
OIL COOLER (HST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

REAR PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Engagement Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

105 of 1161
HYDRAULIC SYSTEM (CONT’D)
ROCK SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

RIGHT JOYSTICK (WITHOUT CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
RIGHT JOYSTICK (WITH CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
RIGHT JOYSTICK VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . 20-62-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-9
STEERING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

STEERING CYLINDER (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . 20-51-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-4
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
STEERING VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1

Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-2

106 of 1161
HYDRAULIC SYSTEM (CONT’D)
THREE POINT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-130-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4
THREE POINT CYLINDER CONTROL . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Adjusting The Position Control Lever (HST Models) . . . . . . . . . . . 20-140-7
Adjusting The Position Control Lever (SST Models) . . . . . . . . . . . 20-140-9
THREE POINT HITCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1


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HYDRAULIC SCHEMATIC
CT335 (S/N ABH811001 AND ABOVE)
(PRINTED DECEMBER 2009)

V-1305legend
LEGEND
1 HYDRAULIC RESERVOIR: 17 PILOT VALVE
Reservoir Capacity . . . 44,0 Qts. (42 L)
18 CONTROL SPOOL
2 FILTER - SUCTION (150 Micron)
19 DISCHARGE VALVE
3 HYDRAULIC PUMP - STEERING . . . Gear Type
6.6 GPM (25 L/min.) at High Engine Idle
20 RELIEF VALVE – THREE-POINT HITCH
2845 PSI (196 bar)
4 HYDRAULIC PUMP - HYDRAULIC . . Gear Type
7.9 GPM (39,9 L/min.) at High Engine Idle 21 CHECK VALVE
5 CHECK VALVE 22 ORIFICE
23 ORIFICE ............... 0.108 in. (2,75 mm)

6 RELIEF VALVE - STEERING
1991 PSI (137 bar) 24 CYLINDER – THREE-POINT HITCH
7 CHECK VALVE ROCKSHAFT
25 RELIEF VALVE – Hydraulic:

8 FILTER – HYDRAULIC / HYDROSTATIC 2560 PSI (177 bar)
(100 Micron) at High Engine Idle
140 degrees F. (60 degrees C.) Fluid
9 VARIABLE CAPACITY DISPLACEMENT 26 SEQUENCE VALVE:
BIDIRECTIONAL HYDROSTATIC PUMP 255 PSI (17,6 bar) minimum
10 FORWARD / REVERSE VALVE 27 PRESSURE REDUCING VALVE

270 - 290 PSI (18,6 - 20 bar)
11 RELIEF VALVE – CHARGE PRESSURE: 28 SOLENOID ACTIVATED DIRECTIONAL
256 PSI (17,7 bar) CONTROL VALVE - PTO
at High Engine Idle
140 degrees F. (60 degrees C.) Fluid 29 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – 4WD
12 NEUTRAL VALVE (2) 30 SHUTTLE VALVE
13 RELIEF / REPLENISHING VALVE - HIGH 31 PILOT ACTIVATED DIRECTIONAL

PRESSURE: 4978 PSI (343 bar)
CONTROL VALVE
14 FIXED DISPLACEMENT BIDIRECTIONAL
HYDROSTATIC MOTOR
15 THREE-POINT HITCH LOWERING

SPEED / LOCK VALVE
16 REGULATOR PISTON
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1305legend (12-1-09)
109 of 1161
4WD CLUTCH
PACK
ENCLOSURE
HYDRAULIC/HYDROSTATIC WORKING CIRCUITS PTO CLUTCH

PACK 31
SCHEMATIC PILOT PRESSURE
28 STEERING
SYSTEM RETURN LINES 29 CONTROL UNIT
CT335 (S/N ABH811001 AND ABOVE) 30
DIRECT TANK RETURN
Printable Version Click Here
STEERING CIRCUIT
V-1305
27
1 5 7
HYDROSTATIC PUMP
L L
MODULATOR
26 VALVE R
R
3
14 9
6
11 10
2 HYDRAULIC
12 13
MANIFOLD FRONT AXLE
4 25 (ONLY USED
WITHOUT
JOYSTICK)
R F
JOYSTICK CONTROL
VALVE (IF EQUIPPED)
OIL
8 COOLER
T
THREE POINT HITCH CONTROL VALVE
P
REAR AUXILIARY (REMOTE)
HYDRAULIC VALVE (IF EQUIPPED) 25
16
17
19 18
B2 B1
C
2 2
A2 A1
1 1
21
15
24
22
23 TILT LIFT
D C B A B2 B1
20
A2 A1
V-1305 (12-1-09)
110 of 1161
HYDRAULIC SCHEMATIC
CT335 (S/N AK9G11001 AND ABOVE)

V-1375legend
LEGEND
1 HYDRAULIC RESERVOIR: 17 CYLINDER – THREE-POINT HITCH
Reservoir Capacity . . . 44,0 Qts. (42 L) ROCKSHAFT
2 FILTER - SUCTION (150 Micron) 18 RELIEF VALVE – Hydraulic:

2560 PSI (177 bar)
3 HYDRAULIC PUMP - STEERING . . . Gear Type at High Engine Idle
6.6 GPM (25 L/min.) at High Engine Idle 140 degrees F. (60 degrees C.) Fluid
4 HYDRAULIC PUMP - HYDRAULIC . . Gear Type 19 SEQUENCE VALVE:

7.9 GPM (39,9 L/min.) at High Engine Idle 255 PSI (17,6 bar) minimum
5 CHECK VALVE 20 PRESSURE REDUCING VALVE

270 - 290 PSI (18,6 - 20 bar)
6 RELIEF VALVE - STEERING

21 SOLENOID ACTIVATED DIRECTIONAL
1991 PSI (137 bar)
CONTROL VALVE - PTO
7 CHECK VALVE
22 SOLENOID ACTIVATED DIRECTIONAL
8 CONTROL VALVE – 4WD
THREE-POINT HITCH LOWERING
SPEED / LOCK VALVE
23 SHUTTLE VALVE
9 REGULATOR PISTON
24 PILOT ACTIVATED DIRECTIONAL
10 PILOT VALVE CONTROL VALVE
11 CONTROL SPOOL
12 DISCHARGE VALVE
13 RELIEF VALVE – THREE-POINT HITCH

2845 PSI (196 bar)
14 CHECK VALVE
15 ORIFICE
16 ORIFICE ............... 0.108 in. (2,75 mm)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1375legend (12-1-09)
111 of 1161
4WD CLUTCH
PACK
ENCLOSURE
WORKING CIRCUITS PTO CLUTCH

HYDRAULIC SCHEMATIC PILOT PRESSURE
PACK 24
21 STEERING
CT335 (S/N AK9G11001 AND ABOVE) SYSTEM RETURN LINES 22 CONTROL UNIT
23
Printable Version Click Here DIRECT TANK RETURN
STEERING CIRCUIT
V-1375
20
1 5 7
L L
MODULATOR
19 VALVE R
R
3
2 HYDRAULIC
MANIFOLD FRONT AXLE
4 18 (ONLY USED
WITHOUT
JOYSTICK)
THREE POINT HITCH CONTROL VALVE
9 JOYSTICK CONTROL
10 VALVE (IF EQUIPPED)
P
REAR AUXILIARY (REMOTE)
HYDRAULIC VALVE (IF EQUIPPED) 18
12 11
14
B2 B1
8 C
17
2 2
15 A2 A1
16
1 1
13
TILT LIFT
112 of 1161 D C B A B2 B1
A2 A1
V-1375 (12-1-09)
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols For Compact Tractors

113 of 1161
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols For Compact Tractors (Cont’d)
MS-1892-2

114 of 1161
Glossary Of Hydraulic / Hydrostatic Symbols For Compact Tractors (Cont’d)
MS-1892-3

115 of 1161
Glossary Of Hydraulic / Hydrostatic Symbols for Compact Tractors (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
LOCK VALVE - hydraulic pressure is

applied to open the valve to allow the
hydraulic cylinder to move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR VALVE

(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.
TOW VALVE - Normally in closed

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

116 of 1161
Troubleshooting The Hydraulic Circuit
PROBLEM CAUSE CORRECTION

No hydraulic operation at one or Hydraulic oil level low Refill with correct oil
more circuits Hydraulic pump drive coupling damaged Replace
Hydraulic pump defective Repair or replace
Main relief valve defective Readjust or replace
Hydraulic power insufficient to one Main relief valve pressure setting incorrect Readjust or replace
or more circuits
All hydraulic speed too slow Hydraulic oil level or viscosity incorrect Fill to correct level and use
correct viscosity oil
Engine RPM reduced Readjust or replace
Control valve linkage defective Check, repair or replace
Hydraulic pump volume low Check, repair or replace
Oil temperature too high Oil cooler or radiator fins plugged Clean oil cooler external
surface
Hydraulic oil level low Fill to correct level
Non recommended hydraulic oil Replace
Relief valve excessively activated Use proper operating
procedures
One or more relief valves not set correctly Readjust or replace
Extreme operating conditions. High ambient
temperature (i.e.: Enclosed structure)
Engine accessory drive belt loose Tighten belt
Troubleshooting The Joystick Valve Circuit

External leakage control kit or Worn spool seal due to mechanical actuation or Locate the leakage and
opposite side high back pressure replace the seal.
Check back pressure level.
Excessive internal leakage on A Increase clearance between spools and body due Replace the direction control
and B ports to high wear valve and check the oil
contamination level
Dropping load during transition High leakage of the load check valve Remove the load check valve
while raising and clean the seat
Inability to build pressure on A and Main pressure relief valve blocked open Remove and clean or replace
B ports the main relief valve
Low pump pressure and flow Check the pump and circuit

117 of 1161
HYDRAULIC SYSTEM TROUBLESHOOTING (CONT’D)
Troubleshooting The Power Lift Circuit

The rockshaft jerks while being Insufficient oil level in the tank Check the oil level
raised Pump inlet filter clogged Clean or replace the filter
Infiltration of air into the pump inlet pipe Check the inlet pipe and any
coupling and gasket
Rockshaft does not operate Adjusting piston or pilot valve stuck Remove the control valve and
unblock the pilot valve and
adjusting piston
The rockshaft does not descend Sensibility adjusted incorrectly Adjust sensitivity of control
over its entire travel valve
Faulty adjustment of the control lever Adjust control position lever
The rockshaft does not descend Hydraulic block switched on Unscrew the manual lever
Outlet valve spring damaged Change the spring
Piston blocked Check piston and cylinder
Lifting capacity does not meet Safety and main relief valves out of calibration Correct the calibration of the
specifications two valves
Poor pump efficiency Replace the pump
Poor control valve efficiency Overhaul the control valve
Deterioration of the control valve seal rings Remove the control valve and
replace the external seal rings
The rockshaft supports loads with Piston gasket worn Replace the gasket
difficulty; there is arhythmic Oil leakage from cylinder Overhaul the cylinder
oscillation when the engine is Oil leakage from one of the following control Remove the control valve and
running; the load descends when valves: non-return valve, outlet valve, and safety overhaul the following valves:
the engine is off valve that protects the cylinder In case of leakage over-haul
the control valve
When the arms are in a the upper Faulty adjustment of the maximum upper position Adjust the control lever,
position, the safety valve (relief of rockshaft lift arms limiting the maximum upper
valve) place on the body of the position travel
rockshaft starts operating

118 of 1161
HYDRAULIC SYSTEM TROUBLESHOOTING (CONT’D)
Troubleshooting The Steering Circuit

Excessive steering wheel play Steering linkage worn Replace
Centering spring weaken or broken Replace
Tractor pulls to right or left Tire pressure uneven Adjust
Steering wheel play too small Adjust
Improper toe-in adjustment Adjust
Front wheel hub ball bearing worn or damaged Replace
Brake pedal play unevenly adjusted Adjust
Front wheels vibration Steering linkage worn Replace
Improper toe-in adjustment Adjust
Knuckle shaft bushing worn Replace
Clearance between center pin and bushing Replace
Hard steering Transmission fluid improper or insufficient Change
Oil leak from pipe fittings Retighten
Hydraulic pump malfunctioning Replace
Relief valve malfunctioning Adjust or replace
Seals in the steering gear box damaged Replace
Backlash between sector gear shaft and ball nut Adjust
too small
Air in the hydraulic pipes Air vent
Low operating pressure Refer to next item
Low operating pressure Hydraulic pump malfunctioning Replace
Improper relief valve adjustment Adjust
Control valve malfunctioning Replace
Seals in the steering gear box damaged Replace
Ball nut malfunctioning Replace ball nut assembly
Oil leak from pipe or pipe broken Replace
Steering wheel does not return to Control valve malfunctioning Replace
neutral position Valve spool and valve housing jammed Repair or replace
Valve housing oil seal damaged Replace
Centering spring weaken or broken Replace
Steering force fluctuates Insufficient oil Replenish
Insufficient bleeding Bleed
Control valve malfunctioning Replace
Noise Insufficient oil Replenish
Air sucked in pump from suction circuit Repair
Pipe deformed Replace

119 of 1161
120 of 1161
MAIN RELIEF VALVE Testing And Adjusting The Main Relief Valve
Testing Information For machines without joystick and without rear auxiliary
hydraulics
There are four different procedures to test and adjust the
main relief valve depending on which of four options the Figure 20-20-1
machine is equipped with.
For machines without a joystick and without rear auxiliary

hydraulics. (See For machines without joystick and
without rear auxiliary hydraulics on Page 20-20-1.)
For machines without a joystick and equipped with rear

auxiliary hydraulics. (See For machines without joystick
and equipped with rear auxiliary hydraulics on Page 20-
20-3.)
For machines equipped with joystick and without rear

auxiliary hydraulics. (See For machines equipped with
1
joystick and without rear auxiliary hydraulics on Page 20-
20-4.) P-81337
For machines equipped with both joystick and rear

auxiliary hydraulics. (See For machines equipped with Remove the plug (Item 1) [Figure 20-20-1] from the
both joystick and rear auxiliary hydraulics on Page 20-20- “OUT” port on the hydraulic block.
6.)
All testing is done with the hydraulic oil at operating

temperature.
The following tools will be needed for the testing of the

IMPORTANT
main relief valve:
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
MEL1654 - Compact Tractor Hydraulic Test Kit
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

121 of 1161
MAIN RELIEF VALVE (CONT’D) Figure 20-20-4
Testing And Adjusting The Main Relief Valve (Cont’d)
For machines without joystick and without rear auxiliary

hydraulics (Cont’d)
Figure 20-20-2
P-84628
1
Figure 20-20-5
P-84628
Connect the adaptor / 5000 PSI (345 bar) gauge

assembly (Item 1) [Figure 20-20-2] into the “OUT” port.
Figure 20-20-3
P-84632
1 Remove the cap (Item 1) [Figure 20-20-4] and add

shims (Item 1) [Figure 20-20-5] to increase pressure.
Reduce the number of shims to decrease pressure.
Retest the main relief valve after adjustment.
P-84629
Engage the parking brake, start the engine and run at low
RPM. Rotate the selector (Item 1) [Figure 20-20-3] to the
horizontal position.
Increase the engine speed to full RPM. The main relief

valve pressure shown on the gauge should be 2560 PSI
(177 bar).
If adjustment is needed, rotate the selector (Item 1)

[Figure 20-20-3] to the vertical position. Decrease
engine speed to low RPM and stop the engine.

122 of 1161
For machines without joystick and equipped with rear

auxiliary hydraulics
Figure 20-20-6
P-81337
Figure 20-20-8
P-78770
Install the coupler / gauge assembly (Item 1) [Figure 20-

20-6] onto one of the rear auxiliary couplers.
Engage the parking brake, and start the engine. Increase

the engine speed to full RPM.
Engage the control lever for the rear auxiliary coupler. 1
The main relief valve pressure shown on the gauge P-84632

should be 2560 PSI (177 bar).
If adjustment is needed, disengage the control lever for Remove the cap (Item 1) [Figure 20-20-7] and add
the rear auxiliary coupler, decrease engine speed to low shims (Item 1) [Figure 20-20-8] to increase pressure.
RPM and stop the engine. Reduce the number of shims to decrease pressure.
IMPORTANT
damage the system.
I-2003-0888

123 of 1161

NOTE: If the machine is equipped with the loader

[Figure 20-20-9] and [Figure 20-20-10] are not
performed. Disconnect the hydraulic hoses
from the loader to the valve.
Figure 20-20-9 1
P-84559
Install the loader female quick coupler (Item 1) [Figure

20-20-10] in the port.
Figure 20-20-11
P-84558

boom down port.
IMPORTANT P-84560

Install the loader male quick coupler on the test gauge /
hose assemble. Connect the gauge / hose assemble
(Item 1) [Figure 20-20-11] to the valve.
damage the system.
I-2003-0888
Engage the parking brake and start the engine. Increase
Move the joystick lever to the boom down position

(forward as viewed from the operators seat). Do NOT
engage the float position.
The main relief valve pressure shown on the gauge

If adjustment is needed, move the joystick lever to the

neutral position, decrease engine speed to low RPM and
stop the engine.

124 of 1161
MAIN RELIEF VALVE (CONT’D)

auxiliary hydraulics (Cont’d)
Figure 20-20-12
P-84561
Loosen the nut (Item 1) and turn the adjustment screw

(Item 2) [Figure 20-20-12] clockwise to increase
pressure, counter clockwise to decrease pressure.

125 of 1161
For machines equipped with both joystick and rear

Figure 20-20-13
1 1
P-84561
Loosen the nut (Item 1) and turn the adjustment screw

(Item 2) [Figure 20-20-14] clockwise to increase
pressure, counter clockwise to decrease pressure.
P-78770 Retest the main relief valve after adjustment.
Install the coupler / gauge assembly (Item 1) [Figure 20-

20-13] into one of the rear auxiliary couplers.
Engage the parking brake and start the engine.
Increase the engine speed to full RPM.
Engage the correct control lever for the rear auxiliary

coupler.
The main relief valve pressure shown on the gauge

If adjustment is needed, disengage the control lever for

the rear auxiliary coupler, decrease engine speed to low
RPM and stop the engine.

126 of 1161
HYDRAULIC PUMP Figure 20-30-2
IMPORTANT 1
damage the system.
I-2003-0888
P-84699
Open the engine cover.

Loosen the hose clamp (Item 1) [Figure 20-30-2] on the
Disconnect the battery. (See Removing And Installing suction line.
Battery on Page 60-20-1.)
Figure 20-30-3
Remove the right side engine cover. (See Removal And
Figure 20-30-1
1
P-84698
1 1
Remove the two bolts (Item 1) and suction tube line (Item
P-86157 2) [Figure 20-30-3].
Remove the four bolts (Item 1) [Figure 20-30-1] from the

high pressure lines.

127 of 1161
HYDRAULIC PUMP (CONT'D)
Removal And Installation (Cont'd)
Figure 20-30-4
P-84701
Remove the two bolts (Item 1) [Figure 20-30-4] and

remove the pump.

128 of 1161
Parts Identification
1. Seal
2. Washer
3. Snap Ring
4. Ring
5. Quad Ring
6. Backup Ring
7. Seal
8. Bushing 5
9. Drive Gear #1 12
10. Drive Gear #2
11. Pin 11
12. Housing 7
13. Mounting Flange 8
14. Coupler Shaft
15. Center Plate 9
16. Drive Gear
17. Washer 8
18. Bolt 7
6 6
19. Cover 5 11
13
4
10
1
3
2 18
1
17
19
11
5
11
7
8
16
8 11
6
5
15 6 11
11
16
14
11
MS-2503S

129 of 1161
HYDRAULIC PUMP (CONT'D) Figure 20-30-6
Disassembly
IMPORTANT 1

damage the system.
I-2003-0888
P-78142
Clean the outside of the pump before disassembly.

Mark the outside of the pump for correct assembly
Figure 20-30-5 [Figure 20-30-6].
Remove the O-ring (Item 1) [Figure 20-30-6] from the

mounting flange.
Figure 20-30-7
1 1 1
1 1
P-84702

block.
P-78143
Remove the four bolts (Item 1) [Figure 20-30-7].

130 of 1161
Disassembly (Cont’d)
Figure 20-30-8 1
P-78146
Remove the quad ring (Item 1) [Figure 20-30-10] (both

P-78144 sides).
Figure 20-30-11
Remove the cover (Item 1) [Figure 20-30-8].
Figure 20-30-9
1
P-78147
P-78145 Remove the bearings / gear assembly (Item 1) [Figure

20-30-11].
Remove the housing [Figure 20-30-9].

131 of 1161
Figure 20-30-12
3 4 3
1 2 2 1
P-78151
4
Remove the housing [Figure 20-30-14].
P-78148
Figure 20-30-15
Remove the seals (Item 1), backup rings (Item 2) and

bearings (Item 3) from the gears (Item 4) [Figure 20-30-
1
12].
Figure 20-30-13
P-78152
Remove the quad ring (Item 1) [Figure 20-30-15] (both

sides).
P-78150
Remove the center plate [Figure 20-30-13].

132 of 1161
Figure 20-30-16 3
1
1
2
P-78154
Remove the ring (Item 1), snap ring (Item 2) and seals
P-78153 (Item 3) [Figure 20-30-18] from the mounting flange.
Remove the bearings / gear assembly (Item 1) [Figure

20-30-16].
Figure 20-30-17
4
3 3
1 1 2
2
P-78155
Remove the seals (Item 1), backup rings (Item 2) and

bearings (Item 3) from the gears (Item 4) [Figure 20-30-
17].

133 of 1161
Assembly
Inspect all parts for wear or damage. Replace any worn 1

or damaged parts.
Always install new seals and O-rings. Lubricate all seals 2

and O-rings with clean hydraulic fluid before installation.
Clean all parts in solvent and dry with compressed air.
Figure 20-30-19
P-78153
3
1 Assemble the bearings / gears (Item 1) and install onto

the mounting flange (Item 2) [Figure 20-30-21] in the
position shown.
2
Figure 20-30-22
P-78154
Install the seals (Item 1), snap ring (Item 2) and ring (Item
3) [Figure 20-30-19] into the mounting flange.
Figure 20-30-20
P-78152
3
Install the quad ring (Item 1) [Figure 20-30-22] into the
housing (both sides).
2
1
P-78149
Install the backup ring (Item 1), and seal (Item 2) into the
bearing (Item 3) [Figure 20-30-20].

134 of 1161
Assembly (Cont’d)
Figure 20-30-23
2
1
2
1 3
P-78149
Install the backup ring (Item 1) and seal (Item 2) into the
P-78151 bearing (Item 3) [Figure 20-30-25].
Figure 20-30-26
Install the housing over the bearing / gears [Figure 20-
30-23].
NOTE: The grooves (Item 1) in the bearing must face 1

the port (Item 2) [Figure 20-30-23] in the
housing.
2
Figure 20-30-24
P-78147
Assemble the bearings / gears (Item 1) and install onto

the center plate (Item 2) [Figure 20-30-26] in the position
shown.
P-78150
Install the center plate [Figure 20-30-24].

135 of 1161
Assembly (Cont’d)
Figure 20-30-27
1
P-78144
Install the cover (Item 1) [Figure 20-30-29].

P-78146
Figure 20-30-30
Install the quad ring (Item 1) [Figure 20-30-27] into the

housing (both sides). 1
1
Figure 20-30-28
1
1 1
2
P-78143
Install the four bolts (Item 1) [Figure 20-30-30] and

tighten to 33 ft.-lb. (45 N•m) torque.
P-78145
Install the housing over the bearing / gears [Figure 20-

30-28].
NOTE: The grooves (Item 1) in the housing must face

the port (Item 2) [Figure 20-30-28] in the
housing.

136 of 1161
Assembly (Cont’d)
Figure 20-30-31
P-78142
Install the O-ring (Item 1) [Figure 20-30-31] on the

mounting flange.

137 of 1161
138 of 1161
STEERING VALVE Figure 20-40-3
NOTE: The following procedure is performed on a

compact tractor equipped with HST. Although
the photos may appear different the 1
procedure is the same for compact tractors
equipped with SST.
Remove the instrument panel. (See Removal And

Figure 20-40-1
P-84741
Figure 20-40-4
1 1
P-84739
1
Remove the two hoses (Item 1) [Figure 20-40-1] from
the steering valve.
P-84742
NOTE: Mark hoses for correct installation.
Figure 20-40-2 Remove the four mounting bolts (Item 1) [Figure 20-40-
3] and [Figure 20-40-4].
Installation: Tighten the bolts to 25 - 33 ft.-lb. (34 - 44

N•m) torque.
IMPORTANT
1 1
P-84740
damage the system.
I-2003-0888

the steering valve.
Installation: Tighten the hoses to 18 - 22 ft.-lb. (25 - 29

N•m) torque.

139 of 1161
STEERING VALVE (CONT'D)
1. Bolt
2. End Cap 1
3. Spacer 2
4. O-Ring
5. Spacer Gear
6. Geroler® Assembly 4
7. Driveshaft 4 5
8. Valve Plate
6
9. Spool
10. Springs
11. Sleeve
3
12. Pin 4 7
13. Bolt
14. Check Ball 8
15. Housing 4
16. Poppet
17. Spring
18. Piston
9
19. Plug
20. Thrust Washer
21. Thrust Bearing
22. Quad Ring 10
23. Seal Housing
24. Retainer Ring
25. Seal
16 15
17 11
18
4
19
12
13
20
21
20
14
22
4
23
24
25
MS-2504S

140 of 1161
STEERING VALVE (CONT'D) Figure 20-40-7
Disassembly
Figure 20-40-5
P-78361
Remove the end cap (Item 1) [Figure 20-40-7].

P-78359
Figure 20-40-8
Remove the four fittings (Item 1) [Figure 20-40-5] from

the steering valve.
1
Figure 20-40-6
P-78362

end cap.
P-78360
Remove the seven end cap bolts (Item 1) [Figure 20-40-

6].

141 of 1161
Disassembly (Cont'd)
Figure 20-40-9
1
P-78365
Remove the O-ring (Item 1) [Figure 20-40-11].

P-78363
Figure 20-40-12
Remove the spacer (Item 1) [Figure 20-40-9].

1
Figure 20-40-10
2
1
P-78366
Remove the valve plate (Item 1) and driveshaft (Item 2)

P-78364 [Figure 20-40-12].
Remove the Geroler® assembly (Item 1) [Figure 20-40-

10].

142 of 1161
Figure 20-40-13
1
P-78372
Remove the seal housing (Item 1) [Figure 20-40-15] by

P-78369 prying upwards.
Figure 20-40-16
Remove the check ball (Item 1) from the deepest bolt
hole and the O-ring (Item 2) [Figure 20-40-13] from the
housing.
1
Figure 20-40-14
P-27173
Remove and discard the seal (Item 1) [Figure 20-40-16].
P-78371
Remove the seal retaining ring (Item 1) [Figure 20-40-

14].

143 of 1161
Figure 20-40-17
1
2
P-27176
Remove the two thrust washers (Item 1) and thrust

P-27174 bearing (Item 2) [Figure 20-40-19] from the spool.
Figure 20-40-20
Remove and discard the quad ring seal (Item 1) [Figure
20-40-17].
2
Figure 20-40-18
1
P-78376
Remove the control spool sleeve assembly (Item 1) from

P-78374 the metering end of the housing (Item 2) [Figure 20-40-
20].
Remove and discard the O-ring (Item 1) [Figure 20-40- NOTE: When removing the spool, keep the drive pin
18] from the housing. (Item 1) [Figure 20-40-21 on Page 20-40-7]
horizontal. If the pin becomes vertical, it may
drop from the spool and get caught in an oil
passage inside the housing.

144 of 1161
Figure 20-40-21
P-78378
Remove the springs (Item 1) [Figure 20-40-23] from the

P-78377 spool.
NOTE: There are six springs positioned three per side

Remove the drive pin (Item 1) [Figure 20-40-21]. and back to back.
Figure 20-40-22 Figure 20-40-24
1 2
2
1
P-78379 P-78382
Remove the spool (Item 1) from the sleeve (Item 2) Remove the check valve plug (Item 1), piston (Item 2),
[Figure 20-40-22]. spring (Item 3) and poppet (Item 4) [Figure 20-40-24]
from the housing.
NOTE: If the spool and sleeve will not slide or rotate
within each other freely or in the housing,
they must replaced.

145 of 1161
STEERING VALVE (CONT'D) Assembly
Inspection Figure 20-40-27
Figure 20-40-25
1
2 P-78385
P-78384
Install a new O-ring (Item 1) [Figure 20-40-27] on the
check valve plug.
Inspect the spool (Item 1) and sleeve (Item 2) [Figure
20-40-25] for any damage or wear. Replace as needed. Figure 20-40-28
Figure 20-40-26
4
1
P-78382
P-78383
Install the poppet (Item 1), spring (Item 2), piston (Item 3)
and plug (Item 4) [Figure 20-40-28] into the housing.
Inspect the driveshaft (Item 1) [Figure 20-40-26] for
damage or wear.

146 of 1161
Assembly (Cont'd)
Figure 20-40-29
1
P-78377
Install the drive pin (Item 1) [Figure 20-40-31].

P-27178
Figure 20-40-32
Install the springs (Item 1) [Figure 20-40-29] into the

spool.
2
NOTE: There are six springs and should be
positioned three per side and back to back.
Figure 20-40-30
1
1 P-78376
Install the control spool / sleeve assembly (Item 1) into

the metering end of the housing (Item 2) [Figure 20-40-
32].
NOTE: When installing the spool assembly keep the

P-27181 drive pin (Item 3) [Figure 20-40-32] horizontal.
If the pin becomes vertical it may drop from
the spool and get caught in an oil passage
Install the spool (Item 1) into the sleeve (Item 2) [Figure inside the housing.
20-40-30].
NOTE: The spool should turn freely inside the sleeve.

147 of 1161
Assembly (Cont'd)
Figure 20-40-33 1
P-27174
2 Install a new quad ring seal (Item 1) [Figure 20-40-35].

P-27176
Figure 20-40-36
Install the two thrust washers (Item 1) and thrust bearing

(Item 2) [Figure 20-40-33] on the spool.
1
Figure 20-40-34
P-27173
Install a new seal (Item 1) [Figure 20-40-36].
P-78374
Install a new O-ring (Item 1) [Figure 20-40-34] into the

housing.

148 of 1161
Assembly (Cont'd)
Figure 20-40-37
P-78369
Install the check ball (Item 1) [Figure 20-40-39] into the

P-78372 deepest retainer bolt hole.
Figure 20-40-40
Install the seal housing (Item 1) [Figure 20-40-37].
Figure 20-40-38
P-78368
P-78371 Install a new O-ring (Item 1) [Figure 20-40-40] into the

housing.
Install the seal retaining ring (Item 1) [Figure 20-40-38].

149 of 1161
Assembly (Cont'd)
Figure 20-40-41
1
P-78391
To assure proper Geroler® alignment, mark the top of the

P-78367 driveshaft (Item 1) [Figure 20-40-43] (as shown) parallel
to the port face.
Align and install the valve plate (Item 1) [Figure 20-40- Figure 20-40-44
41] on the housing.
Figure 20-40-42
1
P-78392
P-78366 Install a new O-ring (Item 1) [Figure 20-40-44] into the

Geroler® star.
Align the groove in the driveshaft with the drive pin and
install the driveshaft (Item 1) [Figure 20-40-42]. Be sure
the driveshaft is engaged with the pin.
NOTE: The pin must be parallel with the port face of

the housing.

150 of 1161
Assembly (Cont'd)
Figure 20-40-45
2
1
3
1
P-78394
Install the outer gear (Item 1) onto the star (Item 2)

P-78393 [Figure 20-40-47] and align the bolt holes without
disengaging the driveshaft.
Install the Geroler® star (Item 1) [Figure 20-40-45] onto NOTE: The Geroler® lobe (Item 3) must be aligned
the valve plate and driveshaft. with the hole in the Geroler® ring (Item 4)
[Figure 20-40-47] located at the fitting side of
Figure 20-40-46 the pump as shown for proper assembly.
Figure 20-40-48
P-78365
P-78363
Install a new O-ring (Item 1) [Figure 20-40-46] into the
outer gear.
Install the spacer (Item 1) [Figure 20-40-48].

151 of 1161
Assembly (Cont'd)
Figure 20-40-49
1
1
P-78359
Install the fittings (Item 1) [Figure 20-40-51] as shown.

P-78362
Install a new O-ring (Item 1) [Figure 20-40-49] on the

end cap.
Figure 20-40-50
2
1
P-78396
Install the end cap (Item 1) [Figure 20-40-50].
Install the bolt with the pin (Item 2) [Figure 20-40-50] into
the deepest bolt hole that contains the check ball.
Tighten the bolts to 8 - 13 ft.-lb. (11 - 18 N•m) torque in a

criss cross pattern.

152 of 1161
STEERING VALVE TESTING Figure 20-41-2
Relief Pressure

procedure is the same for a compact tractor 1
equipped with SST.
Figure 20-41-1
P-84569
Install a 5000 PSI (344,8 bar) gauge assembly (Item 1) to

the steering cylinder hose (Item 2) [Figure 20-41-2].
Install a cap (Item 3) [Figure 20-41-2] on the cylinder

1 fitting. Engage the parking brake, start the engine and
increase the engine speed to full RPM.
P-84568 Turn the steering wheel in the direction of the removed

hose and record the pressure shown on the gauge.
Remove the hose (Item 1) [Figure 20-41-1] from the right The relief pressure should be 1988 PSI (137,1 bar).
side of the steering cylinder.
Decrease engine speed to low RPM and stop the engine.
Figure 20-41-3
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-78371
To increase pressure, turn the plug (Item 1) [Figure 20-

41-3] clockwise, to reduce pressure turn the plug counter
clockwise. Turn the plug in no more than 90° increments
and retest.

153 of 1161
STEERING VALVE TESTING (CONT'D) Figure 20-41-5
Working Pressure
Figure 20-41-4
1 P-84570
Install a 5000 PSI (344,8 bar) hose, tee fitting and gauge
P-84568 (Item 1) [Figure 20-41-5] between the steering cylinder
and cylinder hose.
Remove the hose (Item 1) [Figure 20-41-4] from either Engage the parking brake, start the engine and increase
the left or right side of the steering cylinder. the engine speed to full RPM.
NOTE: The right steering cylinder is shown. Turn the steering wheel to the right if the gauge assembly
is installed on the right steering cylinder, turn the steering
wheel to the left if the gauge assembly is installed on the
left steering cylinder.
Working pressure should be slightly less than relief

pressure of 1988 PSI (137,1 bar).

154 of 1161
STEERING CYLINDER Figure 20-50-3

3
Figure 20-50-1
1 P-86150
Remove the cotter pin (Item 1) and nut (Item 2) [Figure

P-86148 20-50-3].
Installation: Tighten the nut to 36 - 41 ft.-lb. (48 - 56

Remove the steering cylinder hose (Item 1) [Figure 20- N•m) torque.
50-1] from the cylinder.
Using a soft faced hammer, remove the rod end of the
Installation: Tighten the hose to 18 - 22 ft.-lb. (25 - 29 cylinder (Item 3) from the axle case (Item 4) [Figure 20-
N•m) torque. 50-3].
Figure 20-50-2 Figure 20-50-4
1
2
1
P-86149 P-86151
Remove the two bolts (Item 1) and cylinder cover (Item 2) Remove the bolt (Item 1) and cylinder pin (Item 2)
[Figure 20-50-2]. [Figure 20-50-4] from the base end of the cylinder.

155 of 1161
STEERING CYLINDER (CONT’D)
Removal And Installation (Cont’d)
Figure 20-50-5
P-86152
Remove the spacer (Item 1) and cylinder (Item 2) [Figure

20-50-5] from the axle.

156 of 1161
STEERING CYLINDER (CONT’D)
1. Bearing
2. Rod
3. Dust Seal
4. Bushing
5. Seal
6. Housing
4
5
MS2512S

157 of 1161
STEERING CYLINDER (CONT’D) Figure 20-50-8
Disassembly And Assembly
Drain the oil from the steering cylinder.
Figure 20-50-6
2
1
P-78576
Remove the bushing (Item 1) and seal (Item 2) [Figure

20-50-8].
P-78573 Assembly: Lubricate the bushing and seal before

installation.
Pull the cylinder rod (Item 1) from the housing (Item 2) Figure 20-50-9
[Figure 20-50-6].
Figure 20-50-7
1
2
P-78577
P-78574 Remove the snap ring (Item 1) and bearing (Item 2)

[Figure 20-50-9] from the cylinder rod.
Remove the dust seal (Item 1) [Figure 20-50-7] from the

housing.

158 of 1161
STEERING CYLINDER (SST MODELS) Installation: Tighten the hose to 18 - 22 ft.-lb. (25 - 29
N•m) torque.
Figure 20-51-3
Figure 20-51-1
P-98205
P-98203
Remove the steering cylinder hose (Item 1) [Figure 20-

Raise the front of the machine and install jack stands 51-3] from the left side.
under the tractor frame [Figure 20-51-1].
Installation: Tighten the hose to 18 - 22 ft.-lb. (25 - 29
N•m) torque.
Figure 20-51-4
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
I-2003-0888
Figure 20-51-2
2
P-98210
Remove the two bolts (Item 1) and cylinder cover (Item 2)

P-98204
Remove the steering cylinder hose (Item 1) [Figure 20-

51-2] from the right side.

159 of 1161
STEERING CYLINDER (SST MODELS) (CONT’D) Figure 20-51-7
Figure 20-51-5
3 1
1
4
2
1
1
P-98209
Remove the six lug nuts (Item 1) [Figure 20-51-7] from

P-98211 the right front wheel. Remove the tire.
Installation: Tighten the lug nuts to 166 ft.-lb. (226 N•m)

Remove the cotter pin (Item 1) and nut (Item 2) [Figure torque.
20-51-5] (both sides).
Figure 20-51-8
N•m) torque.
Using a soft faced hammer, remove the rod end of the

cylinder (Item 3) from the axle case (Item 4) [Figure 20-
51-5] (both sides).
Figure 20-51-6
1
P-98213
1 Remove the steering cylinder (Item 1) through the axle

housing (Item 2) [Figure 20-51-8].
2
P-98212
Remove the two bolts (Item 1) from the cylinder (Item 2)


160 of 1161
STEERING CYLINDER (SST MODELS) CONT’D)
1. Tie Rod End

2. Swivel End
3. Wiper
4. Seal
5. Fitting 1
6. Housing
7. Bushing 2
8. Set Screw
5
9. Rod 3
10. Expander O-ring
11. Wear Seal
12. O-ring
13. Head Gland
6
4
7
10
11
5
12
7
13
4
3
NA5008

161 of 1161
STEERING CYLINDER (SST MODELS) CONT'D Figure 20-51-11
Disassembly
Figure 20-51-9
1
P-98323
Remove the set screw (Item 1) [Figure 20-51-11].

P-98311
Figure 20-51-12
Put the cylinder in a vise and remove the tie rod swivel
end (Item 1) [Figure 20-51-9] from the cylinder (both 2
ends).
1
Figure 20-51-10
1
P-98313
Remove the rod assembly (Item 1) from the housing

(Item 2) [Figure 20-51-12].
P-98312
Place a drain pan under the cylinder. Remove the fitting

(Item 1) [Figure 20-51-10] from the cylinder (both sides).
Drain the oil from the cylinder.

162 of 1161
2
Figure 20-51-13 1
1 2
P-98325
Remove the wiper seal (Item 1), seal (Item 2) and

P-98324 bushing (Item 3) [Figure 20-51-15] from the head.
Figure 20-51-16
Remove the head assembly (Item 1) from the rod (Item
2) [Figure 20-51-13].
Figure 20-51-14
2
1
1
P-98318
Remove the wiper seal (Item 1), seal (Item 2) and

P-98314 bushing (Item 3) [Figure 20-51-16] from the housing.

head.

163 of 1161
STEERING CYLINDER (SST MODELS) CONT'D Assembly
Disassembly (Cont’d) Use the following tools to assemble the cylinder.
Figure 20-51-17 MEL1396 - Seal Installation Tool

MEL 1033 - Rod Seal Installation Tool
1 Wash the cylinder ports in solvent and dry with

compressed air.
Figure 20-51-18
P-98315
Remove the wear ring and the expander O-ring (Item 1)

[Figure 20-51-17] from the piston.
P-98327
Figure 20-51-19
P-98336
Inspect cylinder parts for nicks, scratches or other

damage.
Replace any damaged parts [Figure 20-51-18] and

[Figure 20-51-19].
Lubricate all O-rings and seals with hydraulic oil during

installation.
Always use new O-rings and seals.

164 of 1161
Assembly (Cont’d)
Figure 20-51-20
P-98318
Install the bushing (Item 1) and wiper seal (Item 2)

P-22594 [Figure 20-51-22] in the housing.
Figure 20-51-23
Install the rod seal on the rod seal installation tool
[Figure 20-51-20].
NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

51-20].
Figure 20-51-21
P-98328
Install the rod seal in the head[Figure 20-51-23].
P-98317
Install the rod seal in the housing [Figure 20-51-21].

165 of 1161
Assembly (Cont’d)
Figure 20-51-24
1
P-98329
Install the expander O-ring onto the piston followed by

P-98325 the wear ring (Item 1) [Figure 20-51-26].
Figure 20-51-27
Install the bushing (Item 1) and wiper seal (Item 2)
[Figure 20-51-24] in the head.
Figure 20-51-25
P-98314
Install the O-ring (Item 1) [Figure 20-51-27] onto the

P-7424 head.
Install a new wear ring on the tool and slowly stretch it

until it fits the piston [Figure 20-51-25].
Allow the wear ring to stretch for 30 seconds before

installing it on the piston.

166 of 1161
Assembly (Cont’d)
1
Figure 20-51-28
2 P-98320
Install the set screw (Item 1) [Figure 20-51-30].

P-98324
Figure 20-51-31
Install the head (Item 1) onto the machined end (Item 2)

[Figure 20-51-28] of the cylinder rod.
Figure 20-51-29 1
2 1
P-98331
Install the fitting (Item 1) [Figure 20-51-31] (both sides).
P-98330
Lubricate the piston, wear ring and O-ring and install into
the housing. Align the hole (Item 1) in the housing, with
the hole (Item 2) [Figure 20-51-29] in the head.

167 of 1161
STEERING CYLINDER (SST MODELS) CONT'D
Assembly (Cont’d)
Figure 20-51-32
P-98311
Install the tie rod swivel end (Item 1) [Figure 20-51-32]

onto the cylinder rod. Tighten to 300 ft.-lb. (406 N•m)
torque (both sides).

168 of 1161
RIGHT JOYSTICK (WITHOUT CAB) Figure 20-60-2
Remove the right side console cover. (See Removal And

2
Remove the right fender. (See Removal And Installation
on Page 50-120-1.)
Figure 20-60-1
3
1
P-86185
Loosen the nut (Item 1) and remove the two screws (Item
2). Unthread the flange (Item 3) [Figure 20-60-2] from
the cable.
Installation: Tighten the screws (Item 2) [Figure 20-60-

2] to 7 ft.-lb. (6,6 N•m) torque.
P-86184 Figure 20-60-3
Measure and record the cable dimension as shown

[Figure 20-60-1].
NOTE: The factory measurement is approximately

2.75 in. (70 mm).
P-86186
Remove the pin (Item 1) [Figure 20-60-3].

169 of 1161
RIGHT JOYSTICK (WITHOUT CAB) (CONT’D) Figure 20-60-6
Figure 20-60-4
3
2
P-86191
1
NOTE: When installing the cable flange on the valve,
P-86187 install the O-ring (Item 1) [Figure 20-60-6] in
the O-ring bore of the flange.
Loosen the nut (Item 1) and remove the two screws (Item Figure 20-60-7
the cable.

Figure 20-60-5
1 2 3
P-81342
1 Remove the bolts (Item 1), lock washers (Item 2) and flat
washers (Item 3) [Figure 20-60-7].
Installation: Tighten the bolts to 20 ft.-lb. (27 N•m)

P-86188 torque.
Remove the joystick and cable assembly from the frame.


170 of 1161
RIGHT JOYSTICK (WITHOUT CAB) (CONT’D)
1. Lever
2. Dust Boot
3. Nut
4. Selector
5. Pin
6. Body
7. Ring
8. Washer
9. Screw
10. Cable
1
8
7
9
10 10
B-23905

171 of 1161
Disassembly And Assembly 3

Figure 20-60-8
1 2
P-86193
1
Tilt the handle (Item 1) away from the body, and remove
P-86189 the pin (Item 2) from the body and selector (Item 3)
[Figure 20-60-10].
Loosen the nuts (Item 1) and remove the dust boot (item Figure 20-60-11
2) [Figure 20-60-8] from the joystick body.
Figure 20-60-9
1
2 1
1
P-86197
2
P-86192 Installation: Install the pin with the flat sides (Item 1)
[Figure 20-60-11] aligned with the flat sides in the
joystick body bore.
Remove the screw (Item 1) and washer from the joystick
body. Thread both cables (Item 2) [Figure 20-60-9] into
the body.

172 of 1161
Disassembly And Assembly (Cont'd)
Figure 20-60-12
2
2
P-86196
1
2 Loosen the nut (Item 1) and remove the pin (Item 2)
P-86194 [Figure 20-60-14] from both cables.
Remove the selector (Item 1) from the pins (Item 2)

[Figure 20-60-12].
Figure 20-60-13
P-86195
Unthread the cables (Item 1) [Figure 20-60-13] from the

joystick body.

173 of 1161
Adjustment
Cable adjustment must be done on the valve before

adjusting the cable on the joystick body.
2
Figure 20-60-15
1
1
P-86198
2 Thread the cables (Item 1) in or out of the body as

needed until the lever lock (Item 2) [Figure 20-60-17] will
engage the two pins that are on the cable ends.
1
P-86185 Figure 20-60-18
Loosen the nut (Item 1) and two screws (Item 2) [Figure

20-60-15].
1
Figure 20-60-16 1
P-86199
2
Tighten the nuts (Item 1) [Figure 20-60-18] & [Figure 20-
60-15] and screws (Item 2) [Figure 20-60-15] after
1
adjustment is complete.
P-86184
Turn the flange (Item 1) until the dimension of 2.75 in. (70
mm) is obtained (Item 2) [Figure 20-60-16].

174 of 1161
RIGHT JOYSTICK (WITHOUT CAB) (CONT’D)
Adjustment (Cont'd)
Figure 20-60-19
P-86200
Install the dust boot (Item 1) [Figure 20-60-19].

175 of 1161
176 of 1161
RIGHT JOYSTICK (WITH CAB) Figure 20-61-2
Remove the right side console cover. (See Right Side

Removal And Installation on Page 50-21-2.)
NOTE: The fender is removed for photo clarity.
Figure 20-61-1
2
3
1 P-86185
the cable.

P-86184
Figure 20-61-3

[Figure 20-61-1].

2.75 in. (70 mm).
P-86186

177 of 1161
RIGHT JOYSTICK (WITH CAB) (CONT’D) Figure 20-61-6
Figure 20-61-4
3
2
P-86191
1
the cable.

4] to 7 ft.-lb. (6,6 N•m) torque. 3
Figure 20-61-5 2
1
1
P-87753
Remove the plastic cover (Item 1) remove the bolts, lock

washers and flat washers (Item 2) [Figure 20-61-7].

P-86188 torque.
Remove the joystick and cable assembly from the frame.


178 of 1161
RIGHT JOYSTICK (WITH CAB) (CONT’D)
1. Lever
2. Dust Boot
3. Nut
4. Selector
5. Pin
6. Body
7. Ring
8. Washer
9. Screw
10. Cable
1
8
7
9
10 10
B-23905

179 of 1161
Disassembly And Assembly 3

Figure 20-61-8
1 2
P-86193
1
Tilt the handle (Item 1) away from the body, and remove
P-86189 the pin (Item 2) from the body and selector (Item 3)
[Figure 20-61-10].
Loosen the nuts (Item 1) and remove the dust boot (item Figure 20-61-11
2) [Figure 20-61-8] from the joystick body.
Figure 20-61-9
1
2 1
1
P-86197
2
P-86192 Installation: Install the pin with the flat sides (Item 1)
[Figure 20-61-11] aligned with the flat sides in the
joystick body bore.
Remove the screw (Item 1) and washer from the joystick
body. Thread both cables (Item 2) [Figure 20-61-9] into
the body.

180 of 1161
Figure 20-61-12
2
2
P-86196
1
2 Loosen the nut (Item 1) and remove the pin (Item 2)
P-86194 [Figure 20-61-14] from both cables.
Remove the selector (Item 1) from the pins (Item 2)

[Figure 20-61-12].
Figure 20-61-13
P-86195
Unthread the cables (Item 1) [Figure 20-61-13] from the

joystick body.

181 of 1161
Adjustment
Remove the inner fender access cover. (See Removal

And Installation on Page 50-220-1.)
Cable adjustment must be done on the valve before 2

adjusting the cable on the joystick body.
2
1 1
Figure 20-61-15
P-87785
Thread the cables (Item 1) [Figure 20-61-17] in or out of

the body as needed until the lever lock (Item 3) [Figure
20-61-7 on Page 2] will engage.
Tighten the nuts (Item 2) [Figure 20-61-17] after

2 adjustment is complete.
1
P-86185
Loosen the nut (Item 1) and two screws (Item 2) [Figure

20-61-15].
Figure 20-61-16
1
P-86184
Turn the flange (Item 1) until the dimension of 2.75 in. (70
mm) is obtained (Item 2) [Figure 20-61-16].

182 of 1161
RIGHT JOYSTICK VALVE (IF EQUIPPED) Figure 20-62-3
Remove the operators seat. (See Removal And

Figure 20-62-1
P-86186
Figure 20-62-4
P-86184
3

[Figure 20-62-1].

2.75 in. (70 mm).
2
Figure 20-62-2
1
P-86187
2 Loosen the nut (Item 1) and remove the two screws (Item
the cable.
Installation: Tighten the screws (Item 2) to 7 ft.-lb. (6,6

N•m) torque.
3
1
P-86185
the cable.

2] to 7 ft.-lb. (9 N•m) torque.

183 of 1161
RIGHT JOYSTICK VALVE (IF EQUIPPED) (CONT’D) Figure 20-62-7
Figure 20-62-5
1 P-84450
Remove the joint bolt (Item 1) [Figure 20-62-7].

P-86188
Figure 20-62-8
Figure 20-62-6
P-84448
1
P-86191
Installation: Tighten the joint bolts to 22 - 25 ft.-lb. (29 -
34 N•m) torque.
install the O-ring (Item 1) [Figure 20-62-6] in

184 of 1161
RIGHT JOYSTICK VALVE (IF EQUIPPED) (CONT’D)
Figure 20-62-9
P-80100
Installation: Tighten the joint bolt to 22 - 25 ft.-lb. (29 -

34 N•m) torque.
Figure 20-62-10
1
P-81343
Support the valve (Item 1) and remove the three bolts

and washers (Item 2) [Figure 20-62-10].
Remove the valve.

185 of 1161
RIGHT JOYSTICK VALVE (IF EQUIPPED) (CONT’D)
1. Spool Cap
2. Spool Positioner
3. Spacer
4. O-Ring
5. Load Check Valve
6. Plug
1 7. Valve Body
8. Spool
9. Relief Valve
2 10. Pin
3 6 11. Clevis
1
12. Cover
4 4 13. Screw
14. Cable
2 15. Backup Ring
3
4 6
4
5 4
4
6
10 4 8
15 4
11 9 8
12
4
3
14
13
MS-2516S

186 of 1161
Disassembly
Figure 20-62-11
1
1
P-80002
Remove the cap (Item 1) [Figure 20-62-13].

P-80000
Figure 20-62-14
Remove and discard the two O-rings (Item 1) [Figure 20-

62-11].
Figure 20-62-12
P-80003
1
Gently slide the spool (Item 1) [Figure 20-62-14] from

the valve body.
P-80001
NOTE: The two spools are not interchangeable and
must be installed into the same bore they
Remove the two screws (Item 1) [Figure 20-62-12]. were removed from.

187 of 1161
Figure 20-62-15
P-80006
Remove the cap (Item 1) [Figure 20-62-17].

P-80004
Figure 20-62-18

spool.
Discard the O-ring.
Figure 20-62-16
1
P-80007
Gently slide the spool (Item 1) [Figure 20-62-18] from

the valve body.
1
P-80005

188 of 1161
Figure 20-62-19 1
P-80010
Remove the O-ring (Item 1) [Figure 20-62-21] from both

P-80008 check valves.
Discard the O-rings.

spool. Figure 20-62-22
Figure 20-62-20
P-80011
P-80009
Remove the relief valve (Item 1) [Figure 20-62-22].
Remove the two load check valves (Item 1) [Figure 20-

62-20].

189 of 1161
Figure 20-62-23
1
1
1
P-80014
2 Remove the O-ring (Item 1) [Figure 20-62-25] from the

P-80012 plug.
Discard the O-ring.

Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-62-23] from the relief valve.
Discard the O-rings and back-up ring.
Figure 20-62-24
P-80013
Remove the plug (Item 1) [Figure 20-62-24].

190 of 1161
Inspection
Inspect the spools and the spool bores for pitting,

1
scratching, or excess wear. If they are found defective,
replace the joystick valve assembly.
Check that the spool moves freely in the spool bore.
Inspect the load check valve poppets for pitting or

scratches.
Inspect all springs for distortion. Replace those found to

be defective.
P-80013
Replace all O-rings and seals during reassembly and
lightly lubricate with petroleum jelly.
Install the plug (Item 1) [Figure 20-62-27] into the valve
Assembly body.
Figure 20-62-26 Figure 20-62-28
1
1
2
P-80014 P-80012
Install the O-ring (Item 1) [Figure 20-62-26] on the plug. Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-62-28] onto the relief valve.

191 of 1161
Assembly (Cont'd)
1
Figure 20-62-29
1 P-80009
Install the load check valves (Item 1) [Figure 20-62-31]

P-80011 into the valve body.
Figure 20-62-32
Install the relief valve (Item 1) [Figure 20-62-29] into the
valve body.
Tighten the relief valve to 31 ft.-lb. (42 N•m) torque.
Figure 20-62-30 1
P-80008

spool.
P-80010
Install the O-ring (Item 1) [Figure 20-62-30] onto the load

check valves.

192 of 1161
Assembly (Cont'd)
Figure 20-62-33
1
1
1
P-80005
Install the two screws (Item 1) [Figure 20-62-35].

P-80007
Tighten the screws to 7 ft.-lb. (6,6 N•m) torque.
Install the spool (Item 1) [Figure 20-62-33] into the valve Figure 20-62-36
body.
NOTE: The spools are not interchangeable and must

be installed into the same bore they were
removed from. 1
Figure 20-62-34
P-80004
1
Install the O-ring (Item 1) [Figure 20-62-36] onto the float
spool.
P-80006
Install the spool cap (Item 1) [Figure 20-62-34].

193 of 1161
Assembly (Cont'd)
Figure 20-62-37
1
1
1
P-80001
Install the two screws (Item 1) [Figure 20-62-39].

P-80003
Tighten the screws to 7 ft.-lb. (6,6 N•m) torque.
Install the float spool (Item 1) [Figure 20-62-37] into the

valve body.
Figure 20-62-38
P-80002
Install the spool cap (Item 1) [Figure 20-62-38].

194 of 1161
REAR PTO The gauge should not read less than 255 PSI (17,7 bar)
(charge pressure). The rear PTO engagement pressure
Engagement Testing is not adjustable.
The following tools will be needed for testing the rear Decrease engine speed to low RPM and stop the engine.
PTO engagement:
Remove the gauge hose and fitting.
MEL-1654 Compact Tractor Hydraulic Test Kit
Reinstall the plug.
The testing for the PTO engagement is done on the
modulator valve located under the right side of the
machine.
Figure 20-70-1
1
P-84639
Figure 20-70-2
P-84641
Install the fitting, hose and 400 PSI (27 - 28 bar) gauge
(Item 1) [Figure 20-70-2] on the modulator valve.
RPM. Engage the rear PTO switch. Increase engine
speed to high RPM.

195 of 1161
196 of 1161
OIL COOLER (HST MODELS) Figure 20-80-3

1
Open the engine cover. (See Opening And Closing on 1
Page 10-20-1.)
Remove the air cleaner. (See Removal And Installation

on Page 70-40-1.)
Figure 20-80-1
1
P-84661
2
Remove the two joint bolts (Item 1) [Figure 20-80-3] and

2 remove the cooler lines.
Figure 20-80-4
P-84659
1
1
Remove the thumb screw (Item 1) and both debris 2
screens (Item 2) [Figure 20-80-1].
Figure 20-80-2
2 1
1
P-84662
Remove the four bolts (Item 1) and the oil cooler (Item 2)
[Figure 20-80-4].
1
P-84660
Remove the bolt (Item 1) (both sides) and cover (Item 2)

[Figure 20-80-2].

197 of 1161
198 of 1161
THREE POINT HITCH HOUSING Figure 20-90-2
Drain the transmission oil. (See Checking And Adding 1

Fluid on Page 10-120-1.)
Remove the fender assembly. (See Removal And

Installation on Page 50-110-1.) 2
Remove the ROPS. (See Removal And Installation on

Page 50-140-1.)
Remove the top link assembly. (See Top Link Assembly 3

P-98117
NOTE: The following procedure is done on a
compact tractor equipped with rear auxiliary
hydraulics. Remove the two cable ties (Item 1) open the clamps
(Item 2) and reposition the wire harness (Item 3) [Figure
Figure 20-90-1 20-90-2].
Figure 20-90-3
3 2
2
1 2
P-98115
P-98118
Remove the retaining clip (Item 1) and pin (Item 2)
[Figure 20-90-1].
Remove the four joint bolts (Item 1) and tube lines (Item
Remove the lift rod (Item 3) [Figure 20-90-1] (both 2) [Figure 20-90-3].
sides).

199 of 1161
THREE POINT HITCH HOUSING (CONT'D) Figure 20-90-6
Figure 20-90-4 1
2
3
1
P-98121
2
Remove the snap ring (Item 1), pivot pin (Item 2) and the
P-98119 three point center bracket (Item 3) [Figure 20-90-6].
Figure 20-90-7
Remove the two bolts (Item 1) and remove the tube line
mounting bracket (Item 2) [Figure 20-90-4].
Figure 20-90-5
1 1
1
1 P-98122
Remove the two bolts (Item 1) and fill tube [Figure 20-
P-98120 90-7].
Installation: Apply gasket eliminator and tighten the

Remove the three bolts (Item 1) [Figure 20-90-5] from bolts to 22 ft.-lb. (30 N•m) torque.
the three point center bracket.

200 of 1161
THREE POINT HITCH HOUSING (CONT'D)
Figure 20-90-8
1
2 1
2
1
1
P-98123
Remove the five mounting bolts (Item 1) and three nuts

(Item 2) [Figure 20-90-8] from the cover.
NOTE: The lengths of the mounting bolts are

different. Record the correct location.

N•m) torque.
Figure 20-90-9
P-98124
Using a hoist and lifting straps in the arrangement shown,

remove the three point hitch cover [Figure 20-90-9].

201 of 1161
202 of 1161
AUXILIARY CONTROL VALVE Figure 20-100-2
End Cap Section Disassembly And Assembly
The following procedure is shown with the three point 1

hitch housing removed.
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly P-81846
damage the system.

I-2003-0888
Remove the two nuts (Item 1) [Figure 20-100-2].
Figure 20-100-1 Assembly: Tighten the nuts to 22 - 25 ft.-lb. (29 - 34

N•m) torque.
2
Figure 20-100-3
1
2
P-95441 1
Remove the four set screws (Item 1) and linkage

P-81847
assemblies (Item 2) [Figure 20-100-1].
Remove the end cap (Item 1) [Figure 20-100-3].

203 of 1161
AUXILIARY CONTROL VALVE (CONT’D)
End Cap Section Disassembly And Assembly

(Cont’d)
Figure 20-100-4
P-81848
Remove the three O-rings (Item 1) [Figure 20-100-4]

from the end cap.

204 of 1161
AUXILIARY CONTROL VALVE (CONT’D)
Valve Section Parts Identification
1. Cap
2. Detent Sleeve 6
3. Fitting 4
4. Ball
5. Spring
6. Spool
4 4
7. Actuator 3
8. Boot 5
9. Cover 2
10. Screw
1
11. Pin
12. Seal
13. O-ring
14. Body
15. Spring Assembly
16. Washer
17. Cover 14
13
18. Washer
7
13
8 13
12
13
9 11
10
10
18
17
10
16
15
12
MS-2680S

205 of 1161
AUXILIARY CONTROL VALVE (CONT’D) Figure 20-100-7
Valve Section Disassembly And Assembly
Figure 20-100-5
1
P-95411
1 Remove the cover (Item 1) [Figure 20-100-7].

P-95442
Figure 20-100-8
Remove the valve section (Item 1) [Figure 20-100-5].
Figure 20-100-6
P-95413
1
If the valve is equipped with a detent, wrap a rag around
P-95410 the spool end to contain the detent balls and spring when
removing the fitting [Figure 20-100-8].
Remove the four O-rings (Item 1) [Figure 20-100-6].

206 of 1161
Valve Section Disassembly And Assembly (Cont’d)
Figure 20-100-9
5
3
2
P-95415
1
4
Remove the boot (Item 1)[Figure 20-100-11].
P-95414
Figure 20-100-12
Remove the sleeve (Item 1), fitting (Item 2), large ball
(Item 3), three small balls (Item 4) and the spring (Item 5)
[Figure 20-100-9]. 2
NOTE: See “Detent Assembly” on page 20-100-8
Figure 20-100-10
P-95416
Remove the pin (Item 1) and the actuator (Item 2)

[Figure 20-100-12].
1
P-95412
If the valve is not equipped with a detent, remove the

fitting (Item 1) [Figure 20-100-10].

207 of 1161
Figure 20-100-13
P-95420
1
Remove the two bolts / washers (Item 1) [Figure 20-100-
P-95418 15] from the opposite end.
Figure 20-100-16
Remove the two bolts / washers (Item 1) [Figure 20-100-
13] from the cover.
Figure 20-100-14
2
1
P-95421
1 Remove the cover (Item 1) [Figure 20-100-16].

P-95419
Remove the cover (Item 1) and the seal (Item 2) [Figure

20-100-14].

208 of 1161
Figure 20-100-17
1
P-95424
2
Push the spool in and remove the O-ring (Item 1) [Figure
P-95422 20-100-19].
Figure 20-100-20
Using a punch (Item 1) to hold the valve spool, remove
the bolt (Item 2) [Figure 20-100-17] and washer with a
hex wrench.
Installation: Apply (Loctite® 242) to the bolt threads and

tighten the bolt to 6 ft.-lb. (8 N•m) torque.
2
Figure 20-100-18
1
P-95425
Remove the spool (Item 1) from the opposite end and

remove the O-ring (Item 2) [Figure 20-100-20].
2
1
P-95423
Remove the spring assembly (Item 1) and the seal (Item

2) [Figure 20-100-18].

209 of 1161
Detent Assembly
IMPORTANT
Always move rear auxiliary hydraulic lever(s) out of
detent position before stopping the machine.
• Lever(s) left in detent will make starting the
machine difficult.
• Lever(s) left in detent with no implement
connected will cause the hydraulic fluid to
overheat and may damage the system. P-95427
I-2279-0808
Apply grease on the detent spring (Item 1) [Figure 20-

Figure 20-100-21 100-22] and install into the end of the spool.
Figure 20-100-23
1
1
P-95426
P-95428
Clamp the valve in a vise with padded jaws as shown
[Figure 20-100-21].
Apply grease on the three smaller balls (Item 1) [Figure
20-100-23] and install into the holes in the spool.

210 of 1161
Detent Assembly (Cont’d)
Figure 20-100-24
P-95431
Install the sleeve (Item 1) [Figure 20-100-26].

P-95429
Figure 20-100-27
Install the fitting (Item 1) [Figure 20-100-24].
Figure 20-100-25
P-95432
While holding the sleeve, push in on the large ball until

P-95430 the three smaller balls move into the spool while sliding
the sleeve into the fitting [Figure 20-100-27].
Apply grease on the large ball (Item 1) [Figure 20-100- NOTE: The diameter of the tool used must be small
25] and into the spool. enough to push the large ball (Item 1) [Figure
20-100-25] down below the three smaller balls
(Item 1) [Figure 20-100-23] and allow the three
balls to move inward.

211 of 1161
Detent Assembly (Cont’d)
Figure 20-100-28
P-95435
To test the detent function, push the punch (Item 1)

P-95433 [Figure 20-100-30] forward to move the spool in the
detent position.
Install the cover (Item 1) [Figure 20-100-28]. Figure 20-100-31
Figure 20-100-29
P-95436
P-95434
Pull the punch (Item 1) [Figure 20-100-31] backwards to
move the spool into the opposite detent position. The
Insert a punch in the actuator as shown [Figure 20-100- distance the actuator moves to put the spool in detent
29]. should be approximately the same for both positions.
The actuator and spool should move freely and lock in

the forward and back positions.

212 of 1161
ROCK SHAFT Figure 20-110-3
Remove the three point hitch housing. (Removal And

Mark the location of both lift arms for correct assembly.
Figure 20-110-1
1
3
P-77071
Remove the allen head bolt (Item 1) [Figure 20-110-3]

from the front of the housing.
1
Installation: Apply Loctite® 577 or equivalent to the bolt
threads and tighten to 46 - 54 ft.-lb. (63 - 73 N•m) torque.
2
P-81853 Figure 20-110-4
Remove the snap ring (Item 1), lift arm (Item 2) and
washer (Item 3) [Figure 20-110-1] (both sides).
Figure 20-110-2 1
P-77080
Mark the arm / shaft assembly (Item 1) [Figure 20-110-4]

for correct alignment during installation.
P-81854 Remove the set screw (Item 2) [Figure 20-110-4].
Remove the allen head bolt (Item 1) [Figure 20-110-2]

from the top of the housing.
Installation: Apply Loctite® 577 or equivalent to the bolt

threads and tighten to 46 - 54 ft.-lb. (63 - 73 N•m) torque.
Turn the housing over.

213 of 1161
ROCK SHAFT (CONT’D) Figure 20-110-7
Figure 20-110-5
P-77101
2
1
Remove the seal (Item 1) [Figure 20-110-7] from the
P-81855 housing.
Installation: Install seal until it is fully seated. See the

Using a soft faced hammer, remove the rock shaft (Item following procedure for bushing replacement guidelines.
1) [Figure 20-110-5] from the housing.
NOTE: The seal (Item 2) [Figure 20-110-5] will be

removed when the shaft is removed.
Figure 20-110-6
P-77082

shaft.

214 of 1161
MLS VALVE Figure 20-120-3
Drain the transmission. (See Checking And Adding Fluid

on Page 10-120-1.)
Remove the operator seat. (See Removal And

Figure 20-120-1
1
1 P-84400
Remove the MLS valve assembly (Item 1) [Figure 20-

120-3].
P-84398
Remove the cotter pin (Item 1) and lower the shaft (Item
2) [Figure 20-120-1].
Figure 20-120-2
1
P-84399
Mark the MLS valve assembly for correct installation and

remove the two bolts (Item 1) [Figure 20-120-2].
Installation: Tighten the two bolts evenly to 17 - 20 ft.-lb.

(24 - 27 N•m) torque.

215 of 1161
MLS VALVE (CONT’D)
1. Bolt
2. Nut
3. Screw
1
4. Rubber Boot 2
5. Cover 4
6. Plug
3
7. O-Ring
8. Spring 5
9. Lever Assembly
10. Pin
11. Valve 6
12. Valve Seat
13. Valve
7 9
14. Spool 13
15. Housing 8
16. Ball 16
10
17. Spacer
7 8 17
18. Plate 13 11
7 7
7 12 8
7
6
17
14 8
1 11
17
18
3
15
3 2
3
8
7
14
7
11
12
MS-2498S

216 of 1161
MLS VALVE (CONT’D) Figure 20-120-5
IMPORTANT
damage the system.
I-2003-0888 1
P-77143
Clean all parts in solvent and dry with compressed air.

Remove the rubber boot (Item 1) [Figure 20-120-5].
Inspect all parts for wear or damage. Replace any worn
or damaged parts. Figure 20-120-6
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
1
Figure 20-120-4
1
1
P-77144
Remove the three bolts (Item 1) and remove the cover

(Item 2) [Figure 20-120-6].
P-77140
Remove the three O-rings (Item 1) [Figure 20-120-4]

from the valve assembly and replace.

217 of 1161
Disassembly And Assembly (Cont’d)
Figure 20-120-7
P-77149
Assembly: The orientation of the balancing passage

P-77146 (Item 1) [Figure 20-120-9] must be assembled in the
position shown.
Remove the spool (Item 1) [Figure 20-120-7] from the Figure 20-120-10
valve by pulling outward.
Figure 20-120-8
1
1
1
P-77148
P-77147 Remove the three O-rings (Item 1) [Figure 20-120-10]

from the spool and replace.
Remove the spring / poppet assembly (Item 1) [Figure

20-120-8] from the spool.

218 of 1161
Figure 20-120-11 6
5
4
3
2
1 1
P-77153
Remove the speed control valve (Item 1), pin (Item 2),
P-77150 valve (Item 3), valve seat (Item 4), spring (Item 5) and
valve (Item 6) [Figure 20-120-13] from the valve body.
Remove the plug (Item 1) [Figure 20-120-11]. Figure 20-120-14
Figure 20-120-12
1
1
P-77154
P-77151
speed control valve and replace.
Remove and replace the O-ring (Item 1) [Figure 20-120-
12].

219 of 1161
Figure 20-120-15
1
P-77158
Temporarily install the cover bolt (Item 1) [Figure 20-120-

P-77155 17] removed in [Figure 20-120-6 on Page 20-20-3]
Assembly: Tighten the screw to 6 ft.-lb. (8 N•m) torque.

valve seat and replace. Figure 20-120-18
Figure 20-120-16 1
1
2 1
P-77159
P-77157
With the valve assembly in the position shown, loosen
the three bolts (Item 1) [Figure 20-120-18] evenly until
Remove the center bolt (Item 1) [Figure 20-120-16]. the two outer bolts disengage from the threads in the
valve body. The spring tension will now be released.
NOTE: The following procedures must be followed as
the end plate (Item 2) [Figure 20-120-16] is
under spring pressure.

220 of 1161
Figure 20-120-19
P-77164
Compress the spring (Item 1) until it is free from the

P-77160 spring pocket (Item 2) [Figure 20-120-21] and remove
from the spool.
Remove the center bolt (Item 1) [Figure 20-120-19]. Figure 20-120-22
Figure 20-120-20
P-77165
P-77161
Remove the spring (Item 1) from the spool (Item 2)
[Figure 20-120-22].
Remove the end plate, spring and valve spool assembly
[Figure 20-120-20] from the valve body.

221 of 1161
Figure 20-120-23
1
P-777170
Remove the spring seat (Item 1) and spring (Item 2)

P-77169 [Figure 20-120-25].
Figure 20-120-26
NOTE: Do not adjust the lock nut and adjusting bolt
(Item 1) [Figure 20-120-23] as this will change
the internal relief pressure.
Figure 20-120-24 1
1
2
1
P-77171
Remove the spring seat (Item 1) and check ball (Item 2)

[Figure 20-120-26].
P-77162
Record the location of the spacers (Item 1) [Figure 20-

120-24] and remove.

222 of 1161
Figure 20-120-27
P-77174
Remove the pilot valve (Item 1) [Figure 20-120-29].

P-77172
Figure 20-120-30
Remove the valve seat (Item 1) [Figure 20-120-27].
Figure 20-120-28
P-77175
Remove the spring (Item 1) [Figure 20-120-30].

P-77173
Remove the O-ring (Item 1) [Figure 20-120-28] and

replace.

223 of 1161
Figure 20-120-31 1
P-77178

P-77176
Figure 20-120-34
Remove the piston (Item 1) [Figure 20-120-31].
Figure 20-120-32 1
P-77179
Remove the spool (Item 1) [Figure 20-120-34].

P-77177
Remove the O-ring (Item 1) [Figure 20-120-32] and

replace.

224 of 1161
Figure 20-120-35
P-77180
Remove the orifice (Item 1) [Figure 20-120-35] from the

valve body.

225 of 1161
Adjustment (HST Models)
Lift and block the compact tractor. (See Procedure on

Page 10-10-1.)
1
Temporarily install an attachment on the tractors three

point hitch. 3
Figure 20-120-36 2
P-84889
Put the Speed Range Lever (Item 1) [Figure 20-120-37]

in the neutral position.
Make sure the mid PTO lever (Item 2) (if equipped) and
the rear PTO button (Item 3) [Figure 20-120-37] are in
the disengaged (OFF) position.
1
Figure 20-120-38
P-84019
Order a seat switch from Bobcat parts and plug into the
connector (Item 1) [Figure 20-120-36] to use to start the
compact tractor for adjusting the three point hitch lower
MLS valve.
P-84435
The travel control pedals (Item 1) [Figure 20-120-38]

must be in the neutral position.

226 of 1161
Adjustment (HST Models) (Cont’d)
Figure 20-120-39
P-84020
Start the engine and raise the three point hitch lower links
and attachment approximately half way. The drop / lock
valve will now be in the neutral position [Figure 20-120-
39].
Figure 20-120-40
P-84434
With the engine running, loosen the jam nut (Item 1) and
turn the set screw (Item 2) clockwise until the three point
hitch lower links begin to bounce, at this time turn the set
screw (Item 2) [Figure 20-120-40] counterclockwise 1/2 -
3/4 turn.
Tighten the jam nut (Item 1) [Figure 20-120-40].

227 of 1161
Adjustment (SST Models)

Page 10-10-1.)


point hitch.
Figure 20-120-41
3
2
P-92925
1
Put the Forward-Neutral-Reverse Lever (Item 1) [Figure
20-120-43] (F-N-R) in the neutral position.
P-84019 the rear PTO button (Item 3) [Figure 20-120-43] are in
the disengaged (OFF) position.
Order a seat switch from Bobcat parts and plug into the Figure 20-120-44
compact tractor for adjusting the three point hitch lower
MLS valve.
Figure 20-120-42
1 2
P-84020
Start the engine and raise the three point hitch lower links
and attachment approximately half way. The MLS valve
P-92934 will now be in the neutral position [Figure 20-120-44].
Put the Speed Range Lever (Item 1) and gear shift lever
(Item 2) [Figure 20-120-42] in the neutral position.

228 of 1161
Adjustment (SST Models) (Cont’d)
Figure 20-120-45
P-84434
With the engine running, loosen the jam nut (Item 1) and
turn the set screw (Item 2) clockwise until the three point
hitch lower links begin to bounce, at this time turn the set
screw (Item 2) [Figure 20-120-45] counterclockwise 1/2 -
3/4 turn.
Tighten the jam nut (Item 1) [Figure 20-120-45].

229 of 1161
230 of 1161
THREE POINT CYLINDER Figure 20-130-3
Remove the three point hitch housing. (See Removal

1
Figure 20-130-1
P-77075
Remove the piston (Item 1) [Figure 20-130-3].
Assembly: Apply clean hydraulic oil onto the piston

(Item 1) [Figure 20-130-3] before assembly.
P-77073
Figure 20-130-4

cylinder.
Figure 20-130-2
3
1
P-77138
Assembly: After the piston (Item 1) has been installed

into the cylinder (Item 2) apply grease (Item 3) [Figure
P-77074 20-130-4] into the piston.
Using a brass drift, push the piston from the cylinder

[Figure 20-130-2].

231 of 1161
THREE POINT CYLINDER (CONT’D) Figure 20-130-7
Figure 20-130-5 3
2
1
P-77083
Remove the linkage (Item 1) from the pin (Item 2)

P-77077 [Figure 20-130-7].
Remove the arm assembly (Item 3) [Figure 20-130-7].

piston. Figure 20-130-8
Figure 20-130-6
1
1
P-77084
P-77078
Remove the linkage pin (Item 1) [Figure 20-130-8] from
the arm.
Remove the backup ring (Item 1) [Figure 20-130-6] from
the piston.

232 of 1161
THREE POINT CYLINDER (CONT’D)
Figure 20-130-9
2
1
3
P-77085
Remove the roll pin (Item 1) and remove the rod (Item 2)
from the arm (Item 3) [Figure 20-130-9].

233 of 1161
THREE POINT CYLINDER (CONT’D) Figure 20-130-12
Inspection
Figure 20-130-10
P-77086
Inspect the internal splines (Item 1) [Figure 20-130-12]

P-77076 on the arm for wear or damage.
Figure 20-130-13
Check the inside surface of the cylinder for scratches or
damage [Figure 20-130-10].
Figure 20-130-11
1
P-77088
1
Inspect the roll pin holes (Item 1) and rod running surface
B-23581 (Item 2) [Figure 20-130-13] for wear or damage.
Measure the inside diameter of the cylinder (Item 1)

[Figure 20-130-11].
If the measured value exceeds the allowable limits

replace the hydraulic cylinder.
Cylinder I.D. Reference 3.54330 - 3.54527 in.

dimension (90,000 - 90,050 mm)
Allowable 3.54921 in.
limit (90,150 mm)

234 of 1161
THREE POINT CYLINDER (CONT’D)
Inspection (Cont’d)
Figure 20-130-14
P-77079
Inspect the piston running surface (Item 1) [Figure 20-

130-14] for wear or damage.

235 of 1161
236 of 1161
THREE POINT CYLINDER CONTROL Figure 20-140-3
Remove the three point cylinder. (See Disassembly And

Assembly on Page 20-130-1.)
Figure 20-140-1 1
2
1
P-77102
Remove the set screw (Item 1) [Figure 20-140-3].
1 Figure 20-140-4
P-77097 1
Remove the two “C” clips (Item 1) and safety rod (Item 2)
[Figure 20-140-1].
Figure 20-140-2
1 2
1
P-77103
Lift up on the arm (Item 1) and slide the linkage assembly

2 (Item 2) [Figure 20-140-4] from the shaft.
P-77098
Remove the two snap rings (Item 1) and short linkage

(Item 2) [Figure 20-140-2].

237 of 1161
THREE POINT CYLINDER CONTROL (CONT’D) Figure 20-140-7
Figure 20-140-5
P-77106
Remove the bushing (Item 1) [Figure 20-140-7].

P-77104
Figure 20-140-8
Remove the lever assemblies from the pivot shafts

[Figure 20-140-5].
3
Figure 20-140-6
1 P-77107
2
Remove the “C” clip (Item 1) and spring assembly (Item

2) from the linkage (Item 3) [Figure 20-140-8].
P-77105
Remove the “C” clip (Item 1) and remove the arm

assembly (Item 2) [Figure 20-140-6] from the spring.

238 of 1161
Figure 20-140-9
P-77111
Measure and record the bolt adjustment for correct

P-77110 assembly [Figure 20-140-11].
Figure 20-140-12
Measure and record the spring adjustment for correct
assembly [Figure 20-140-9].
Figure 20-140-10
4 3 2 1
5
2
1
P-77112
Loosen the jam nut (Item 1) and remove the adjustment

P-77109 bolt (Item 2) [Figure 20-140-12].
Remove the jam nut (Item 1), linkage pin (Item 2),
washer (Item 3) and spring (Item 4) from the shaft (Item
5) [Figure 20-140-10].

239 of 1161

1
Figure 20-140-13
P-77115
1
Remove the washer (Item 1) [Figure 20-140-15] from

P-77113 both shaft assemblies.
Figure 20-140-16
Remove the washer (Item 1) and snap ring (Item 2)
[Figure 20-140-13].
Figure 20-140-14 1
1
1
P-77117
Remove the two bolts (Item 1) [Figure 20-140-16] from

P-77114 the hydraulic control.
Remove the two shaft / shoulder assemblies (Item 1)

[Figure 20-140-14].

240 of 1161
Figure 20-140-17 2
P-77127
Remove the snap ring (Item 1) from the end of the shaft
P-77118 and remove the bolt (Item 2) [Figure 20-140-19].
Figure 20-140-20
Remove the hydraulic control assembly (Item 1) [Figure
20-140-17] from the housing.
Figure 20-140-18
2
1 1
P-77128
Mark the end of the shaft as shown (Item 1). Remove the
P-77119 linkage assembly (Item 2) [Figure 20-140-20] from the
shaft.

hydraulic control assembly shaft.

241 of 1161
Figure 20-140-21
P-77135
Remove the shaft assembly from the housing (Item 1)

P-77129 [Figure 20-140-23].
Figure 20-140-24
Measure and record the spring adjustment for correct
assembly [Figure 20-140-21].
Figure 20-140-22
P-77133

P-77130 shaft.
NOTE: See the position control lever. (See Adjusting

Remove the two bolts (Item 1) and remove the clutch The Position Control Lever (HST Models) on
assembly (Item 2) [Figure 20-140-22]. Page 20-140-7.)

242 of 1161
Adjusting The Position Control Lever (HST Models)

Page 10-10-1.)


point hitch.
1
Figure 20-140-25
P-84435
The travel control pedals (Item 1) [Figure 20-140-27]

must be in the neutral position.
Start the engine and run at low idle.
P-84019
Order a seat switch from Bobcat parts and plug into the
compact tractor for adjusting the position control lever.
Figure 20-140-26
P-84889
Put the speed range lever (Item 1) [Figure 20-140-26] in

the neutral position.
rear PTO button (Item 3) [Figure 20-140-26] are in the
disengaged (off) position.

243 of 1161
THREE POINT CYLINDER CONTROL (CONT’D)
Adjusting The Position Control Lever (HST Models)

(Cont’d)
Figure 20-140-28
.079 -.394”
(2 - 10 mm)
2
4
1 3
NA1253
Loosen the bolt (Item 1) that fixes the position control

lever (Item 2) to the shaft (Item 3) [Figure 20-140-28].
Move the position control lever (Item 2) until it contacts

the stop (Item 4) [Figure 20-140-28].
Turn the position control shaft (Item 3) counter clockwise

to lift the lifting arms (Item 5) to the highest position. Then
turn the control shaft (Item 3) clockwise until the height of
the lifting arms (Item 5) [Figure 20-140-28] is lowered
by.079 -.394 in. (2 - 10 mm).
Make sure the position control lever (Item 2) touches the

stop (Item 4) and tighten the bolt (Item 1) [Figure 20-
140-28].
Lift and lower the position control lever 2-3 times to check
that the lift arms are operating correctly and its highest
position is consistent and not bottoming out.

244 of 1161
Adjusting The Position Control Lever (SST Models)

Page 10-10-1.)


point hitch.
Figure 20-140-29
3
2
P-92925
1
Put the Forward-Neutral-Reverse Lever (Item 1) [Figure
20-140-31] (F-N-R) in the neutral position.
P-84019 rear PTO button (Item 3) [Figure 20-140-31] are in the
disengaged (off) position.
Order a seat switch from Bobcat parts and plug into the Start the engine and run at low idle.
compact tractor for adjusting the position control lever.
Figure 20-140-30
2
1
P-92934
Put the speed range lever (Item 1) and gear shift lever
(Item 2) [Figure 20-140-30] in the neutral position.

245 of 1161
THREE POINT CYLINDER CONTROL (CONT’D)
Adjusting The Position Control Lever (SST Models)

(Cont’d)
Figure 20-140-32
.079 -.394”
(2 - 10 mm)
2
4
1 3
NA1253
Loosen the bolt (Item 1) that fixes the position control

lever (Item 2) to the shaft (Item 3) [Figure 20-140-32].
Move the position control lever (Item 2) until it contacts

the stop (Item 4) [Figure 20-140-32].
Turn the position control shaft (Item 3) counter clockwise

to lift the lifting arms (Item 5) to the highest position, then
turn the control shaft (Item 3) clockwise until the height of
the lifting arms (Item 5) [Figure 20-140-32] is lowered
by.079 -.394 in. (2 - 10 mm).
Make sure the position control lever (Item 2) touches the

stop (Item 4) and tighten the bolt (Item 1) [Figure 20-
140-32].
Lift and lower the position control lever 2-3 times to check
that the lift arms are operating correctly and its highest
position is consistent and not bottoming out.

246 of 1161
MODULATOR VALVE Figure 20-150-3

1
the photos may appear different the
procedure is the same for a compact tractor
equipped with SST.
Figure 20-150-1
P-86006
Loosen the hose clamps (Item 1) and remove the supply

line (Item 2) [Figure 20-150-3].
1
Figure 20-150-4
P-84787
Loosen the hose clamps (Item 1) [Figure 20-150-1] on

the supply line.
Figure 20-150-2 1
1
P-86005
Disconnect the wire harness (Item 1) [Figure 20-150-4].
P-84788
Remove the bolt (Item 1) [Figure 20-150-2].
Installation: Tighten the bolt to 18 ft.-lb. (24,5 N•m)

torque.

247 of 1161
MODULATOR VALVE (CONT’D) Figure 20-150-7
Figure 20-150-5
1
1 P-86002
2 Slide the valve (Item 1) [Figure 20-150-7] away from the

P-86004 hydrostatic transmission case and remove the valve.
Remove the hose (Item 1) and tubelines (Item 2) [Figure

20-150-5].
Figure 20-150-6
1
1
P-86003
Remove the three bolts (Item 1) [Figure 20-150-6].
Installation: Tighten the bolts to 18 ft.-lb. (24,4 N•m)

torque.

248 of 1161
MODULATOR VALVE (CONT’D)
2
3 1
4
1
3
10
5
2
8
9
7
1
6
5
6 5
11
5
8 5
12
7
8
5
6
5
6 MS-2747S

249 of 1161
Figure 20-150-8
P-84791
Remove the O-rings (Item 1) [Figure 20-150-10] from

P-84789 the valve.
Figure 20-150-11
Remove the tube (Item 1) [Figure 20-150-8] from the
back side of the valve.
Figure 20-150-9
1
1
2 2
P-84792
1 1
Turn the valve over and remove the nuts and washers
P-84790 (Item 1) and coils (Item 2) [Figure 20-150-11].
Installation: Install the concave side of the washer

Remove the O-rings (Item 1) [Figure 20-150-9] from the against the coil.
tube.

250 of 1161
Disassembly and Assembly (Cont’d)
Figure 20-150-12
1 1
1
P-84795
Remove the pilot valve plug (Item 1) [Figure 20-150-14].

P-84793
Figure 20-150-15
Remove the solenoid stem (Item 1) [Figure 20-150-12]

from both ends of the valve.
Figure 20-150-13
2
1
1
P-77117
1
Remove the spring (Item 1) and poppet (Item 2). Remove
the O-ring (Item 3) [Figure 20-150-15] from the plug.
P-84794
Remove the O-rings (Item 1) [Figure 20-150-13] from

both solenoid stems.

251 of 1161
Figure 20-150-16 2
P-84799
1
1
Measure the adjustment screw depth of the reducing
P-84797 valve (Item 1). Loosen the nut (Item 2) [Figure 20-150-
18].
Remove the sequence valve plug (Item 1) [Figure 20- Figure 20-150-19
150-16] from both ends of the valve.
Figure 20-150-17
1 2
2 1 3 P-77128
3
P-77119 Remove the adjustment screw (Item 1) and plug (Item 2)

[Figure 20-150-19].
Remove the spool (Item 1) and spring (Item 2). Remove Installation: Install the adjustment screw to the
the O-rings (Item 3) [Figure 20-150-17] from both plugs. dimensions recorded earlier.

252 of 1161
MODULATOR VALVE (CONT’D)
Figure 20-150-20
3 1 2 3
P-86001
Remove the spring (Item 1) and spool (Item 2). Remove

the O-rings (Item 3) [Figure 20-150-20] from the plug
and adjustment screw.

253 of 1161
254 of 1161
FRONT WHEEL DRIVE The gauge should read 270-290 PSI (18,6-20 bar)
(charge pressure). The front wheel drive engagement
Engagement Testing pressure is not adjustable.
The following tools will be needed for testing the front Decrease engine speed to low RPM and stop the engine.
wheel drive engagement:
Adjustment
MEL-1654 Compact Tractor Hydraulic Test Kit
NOTE: Before adjusting the relief valve, always verify
The testing for the front wheel drive engagement is done the pressure on both the front wheel drive and
on the modulator valve located under the right side of the rear PTO systems. (See Engagement Testing
machine. on Page 20-170-1.)
Figure 20-160-1 Figure 20-160-3
1
1
2
P-84639 P-93927
Disconnect the tubeline (Item 1) and remove the fitting Loosen the nut (Item 1). Turn the adjustment screw (Item
(Item 2) [Figure 20-160-1]. 2) [Figure 20-160-3] clockwise to increase the pressure
or counterclockwise to decrease the pressure.
Figure 20-160-2
Tighten the nut (Item 1) [Figure 20-160-3] and retest.
When the pressure is within specification, remove the

gauge, hose and fitting.
Reinstall the fitting and reconnect the tubeline.

1
P-84640
Install the fitting, hose and 400 PSI (27,6 bar) gauge
(Item 1) [Figure 20-160-2] on the modulator valve.
RPM. Engage the front wheel drive switch. Increase
engine speed to high RPM.

255 of 1161
256 of 1161
HYDROSTATIC SYSTEM
HYDROSTATIC PUMP (HST MODELS) . . . . . . . . . . . . . . . . . . .30-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-29
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-9
Hydrostatic Pump Start-Up . . . . . . . . . . . . . . . . . . . . . . . . .30-20-48
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-26
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-1 HYDROSTATIC
SYSTEM
HYDROSTATIC PUMP TESTING (HST MODELS) . . . . . . . . . .30-30-1
Charge Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-30-1
Hydrostatic Drive Pressure Testing . . . . . . . . . . . . . . . . . . . .30-30-2
Neutral Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-30-4
HYDROSTATIC SYSTEM INFORMATION (HST MODELS). . . .30-10-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
TRAVEL CONTROL PEDAL LINKAGE (HST MODELS) . . . . . .30-50-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-50-1
TRAVEL CONTROL PEDAL PIVOT ARMS (HST MODELS) . . .30-60-1

TRAVEL CONTROL PEDALS (HST MODELS) . . . . . . . . . . . . .30-40-1


257 of 1161
258 of 1161
HYDROSTATIC SYSTEM INFORMATION (HST
MODELS)
Troubleshooting Chart WARNING

The following Troubleshooting Chart is provided for Check for correct function after adjustments, repairs
assistance locating and correcting problems which are or service. Failure to make correct repairs or
most common. Many of the recommended procedures adjustments can cause injury or death.
must be done by authorized Bobcat Service Personnel W-2004-1285
only.
Problem Cause
Excessive noise in the hydrostatic pump. 1, 2, 3, 4, 5, 17
Hydrostatic pump overheating. 1, 4, 6, 7, 13
System not developing pressure. 1, 8, 9
Loss of fluid. 10, 11
No drive in one direction. 5, 8, 9, 17
Loss of hydrostatic power under load. 5, 8, 15, 16, 17
Compact Tractor Loader moves with foot pedal in neutral. 12, 16
Slow or no drive. 5, 8, 9, 13, 14, 15, 16, 17
Key To Correct Cause

1. Low fluid in the reservoir.
2. Air in the system.
3. Incorrect hydraulic fluid.
4. Excessive internal wear.
5. Lack of charge pressure.
6. Oil cooler dirty or cooler fan not working.
7. Engine not being operated at correct RPM.
8. High pressure relief valve not working correctly.
9. Hydrostatic pump replenishing valve not working correctly.
10. Leaking tubelines.
11. Hydrostatic motor seal leaking.
11. Travel pedal not adjusted correctly.
13. Charge relief valve is not working correctly.
14. Hydraulic pump is not working correctly.
15. Hydrostatic motor is damaged.
16. Hydrostatic pump is damaged.
17. Charge pump is damaged.

259 of 1161
260 of 1161
HYDROSTATIC PUMP (HST MODELS) Figure 30-20-2
Remove the transmission case (HST models). (See

Removal And Installation on Page 50-30-1.) 1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly P-81736
damage the system.

I-2003-0888
Remove the snap ring (Item 1) [Figure 30-20-2] from the
shaft.
Figure 30-20-1
Figure 30-20-3
P-81735
P-81737
Remove the coupler (Item 1) [Figure 30-20-1] from the
shaft.
Tap on the end of the shaft with a soft faced hammer and
remove [Figure 30-20-3].

261 of 1161
HYDROSTATIC PUMP (HST MODELS) (CONT’D) Figure 30-20-6
Removal And Installation (Cont’d) 1
Figure 30-20-4
2 P-81739
Remove the return tubeline (Item 1) and couplers (Item

P-81738 2) [Figure 30-20-6].
Figure 30-20-7
Loosen the bolt (Item 1) and remove the lever (2) [Figure
30-20-4] from the shaft.
1
Figure 30-20-5
1 1
P-81742
Remove the two O-rings (Item 1) [Figure 30-20-7] from

P-81740 the return tubeline.
Remove the joint bolt (Item 1) and tubeline (Item 2)

[Figure 30-20-5] from the top of the housing.

262 of 1161
Figure 30-20-8 1
1
1
P-81747
1 1
Remove the shaft / bearing (Item 1) [Figure 30-20-10]
P-81743 from the housing.
Figure 30-20-11
Remove the six bolts (Item 1) and cover (Item 2) [Figure
30-20-8].
Installation: Tighten to 8 ft.-lb. (11 N•m) torque. 1
Figure 30-20-9
P-81749
Remove the two bearings (Item 1) [Figure 30-20-11]

from the shaft.
P-81745

cover.

263 of 1161

1
Figure 30-20-12
1 1
P-81755
Remove the four bolts (Item 1) [Figure 30-20-14] from

P-81750 the housing.
Installation: Tighten to 58 ft.-lb. (78 N•m) torque.

Remove the gear / bearing (Item 1) [Figure 30-20-12].
Figure 30-20-15
Clean the gasket material from the mounting surface.
Figure 30-20-13
1 P-81754
P-81751 Tap on the end of the shaft (Item 1) and collar (Item 2)
[Figure 30-20-15] to remove the pump from the housing.

from the gear.

264 of 1161
Figure 30-20-16
P-81759
Remove the return tube (Item 1) [Figure 30-20-18].

P-81758
Figure 30-20-19
Remove the pump from the housing [Figure 30-20-16].
Figure 30-20-17
1
1
P-81680

P-81757 return tube.
NOTE: The collar [Figure 30-20-17] must be removed

with the pump.

265 of 1161
Figure 30-20-20
2 P-81685
Remove the two O-rings (Item 1) [Figure 30-20-22].

P-81681
Figure 30-20-23
Remove the snap ring (Item 1) and oil seal (Item 2)

[Figure 30-20-20] from the case.
Figure 30-20-21 1
P-81686
1 Remove the oil seal (Item 1) [Figure 30-20-23] from the

collar.
P-81684
Remove the collar (Item 1) [Figure 30-20-21] from the

pump.

266 of 1161
HYDROSTATIC PUMP (HST MODELS) (CONT’D)
1. Bolt
2. Cover
3. Pin
4. Seal
5. Bearing
6. Shaft
7. Gear
8. Housing
9. Joint bolt 1
10. O-ring
11. Tubeline 9
12. Pin
13. Pump
12
11 10
10
10
13
10
10
11
10
11
5
6
5
2 4 8
5
7
3
5
MS2678S

267 of 1161
HYDROSTATIC PUMP (HST MODELS) (CONT’D)
Parts Identification (Cont’d)
1. Bolt
2. Cover 1
3. Gasket 2
4. O-Ring
5. Snap Ring 3
6. End Piece 4
7. Spring 6 5 29
28 12 26
8. Spool 4
9. Power Piston 7 26
10. Ball
11. Plug 8 25
12. Spacer 9
13. Nut
14. Washer 10 24
23
15. Return Spring 4 22 1 27
5 36
16. Backup Ring 6
17. Fulcrum 11 5 26 34
18. Adjusting Arm 13 4 33
14 4 19 3
19. Housing
20. Seal 31 32 5
5 12 30
1 35
2 15 16 4 18 36
21. Collar
12 26
22. Gasket 4 34
23. Bearing 4 19
1 11
24. Pump Shaft 32
25. Swash Plate Holder
31 5
20 30
26. Pin 35
37
27 Bearing 4 1
28 Retainer Block 26 33
29. Swash Plate 21
4 39
30. Piston
31. Retainer Ring
32. Retainer Washer 1
33. Cylinder Block 26 38
34. Spring Retainer
40
35. Spring 23 5
20 1
36. Valve Plate 5 11 4
4 4
37. Thrust Plate
38. Plate 5
12 44
39. Motor Shaft
40. Relief Valve 41 16
26 46 8 35
Assembly 11 11
41. Spring Holder
42. Inlet Body
43. Bearing 1
42 43 4 4
44. Check Valve 45
26
45. Front Cover 43
46. Neutral Valve
Assembly
B-23804

268 of 1161
Disassembly
Figure 30-20-24
1
1
P-81690
2
Record the position of the spring (Item 1) [Figure 30-20-
P-81687 26] before removing.
Figure 30-20-27
Remove the four bolts (Item 1) and cover (Item 2)
[Figure 30-20-24].
Figure 30-20-25
1
1
P-81691
Remove the snap ring (Item 1) and washer (Item 2)

P-81689 [Figure 30-20-27] from the shaft.
Remove the gasket (Item 1) [Figure 30-20-25] from the

cover.

269 of 1161
Figure 30-20-28
2
P-81695
1 Remove the jam nut (Item 1) and washer (Item 2)

P-81692 [Figure 30-20-30].
Figure 30-20-31
Remove the adjustment cam shaft (Item 1) from the
cover (Item 2) [Figure 30-20-28].
Figure 30-20-29
1
1
P-81696
Remove the adjusting bolt (Item 1) [Figure 30-20-31]

P-81694 from the cover.

270 of 1161
Figure 30-20-32
P-81700
1
P-81697 housing.
Figure 30-20-35
adjusting bolt.
Figure 30-20-33
P-81701
1
P-81698 plug.

cover.

271 of 1161
Figure 30-20-36
1 1
1
1 1
P-81705

P-81702 the tube.
Figure 30-20-39
Remove the five bolts (Item 1) and cover (Item 2) [Figure
30-20-36].
Figure 30-20-37
1
1
P-81707
Remove the plug (Item 1) [Figure 30-20-39]. from the

P-81706 housing.
Remove the tube (Item 1) [Figure 30-20-37].

272 of 1161
Figure 30-20-40
1 3
P-81711
Remove the neutral valve cap (Item 1) spring (Item 2)

P-81708 and spool (Item 3) [Figure 30-20-42] from the cover.
Figure 30-20-43
plug.
Figure 30-20-41
1
2
1
1
1
P-81712
1
P-81709 cap.
Remove the eleven bolts (Item 1) [Figure 30-20-41] from

the cover.
NOTE: The cover is under spring pressure.
NOTE: The valve plates may be stuck to the cover. Do

not intermix the valve plates.

273 of 1161
Figure 30-20-44
P-81715
1
Remove the neutral valve cap (Item 1), spring (Item 2)
P-81713 and spool (Item 3) [Figure 30-20-46] from the cover.
Figure 30-20-47
Remove the valve assembly (Item 1) [Figure 30-20-44]
from the cover.
Figure 30-20-45
1
2
1
P-81718

P-81714 cap.
Remove the two O-rings (Item 1) and back-up ring (Item

2) [Figure 30-20-45] from the valve.

274 of 1161
Figure 30-20-48
3
1
B-81720
1
Remove the high pressure relief plug (Item 1), spring
P-81717 (Item 2) and valve (Item 3) [Figure 30-20-50] from the
cover.
Loosen the valve assembly (Item 1) [Figure 30-20-48]. Figure 30-20-51
Figure 30-20-49
P-81721
P-81718
plug.

275 of 1161
Figure 30-20-52
2
1
P-81725
1
Remove the high pressure relief plug (Item 1), spring

P-81722 (Item 2) and valve (Item 3) [Figure 30-20-54] from the
cover.
Remove the high pressure relief valve assembly (Item 1) Figure 30-20-55
[Figure 30-20-52].
Figure 30-20-53
1 1
2
1
P-81726
P-81723 Remove the O-ring (Item 1) [Figure 30-20-55] from the

plug.


276 of 1161
Figure 30-20-56
1
1 P-81729

P-81727 side of the cover.
Figure 30-20-59
Remove the high pressure relief valve assembly (Item 1)
[Figure 30-20-56].
Figure 30-20-57
1
1
P-81730

P-81728


277 of 1161
Figure 30-20-60
2
1
1
P-81733
Remove the relief valve (Item 1) [Figure 30-20-62].

P-81731
Figure 30-20-63
Remove the two bolts (Item 1) and spring holder (Item 2)

[Figure 30-20-60]. 1
Figure 30-20-61
2
1
1
1
P-81734
Remove the two inlet bodies (Item 1) [Figure 30-20-63].
P-81732
Remove the two spacers (Item 1) and spring (Item 2)

[Figure 30-20-61].

278 of 1161
Figure 30-20-64
1
1
P-81762

P-81760 cover.
Repeat above procedure for second seal.

Remove the O-ring (Item 1) and back-up ring (Item 2)
[Figure 30-20-64] from the inlet body (both sides). Figure 30-20-67
Figure 30-20-65
1
1
P-81763
P-81761
Turn the cover over and remove the two bearings (Item
1) [Figure 30-20-67].
Turn the cover over and remove the snap ring (Item 1)
[Figure 30-20-65].

279 of 1161
1
Figure 30-20-68
P-81770
Remove the retainer washer (Item 1) [Figure 30-20-70].

P-81768
Figure 30-20-71
Lay the housing on its side and remove the cylinder block
/ piston assembly from the motor shaft.
1
Figure 30-20-69
1 1
1
2
P-81771
Remove the three pins (Item 1) [Figure 30-20-71] from

the cylinder block.
P-81769
Remove the pistons and retainer plate assembly (Item 1)

from the cylinder block (Item 2) [Figure 30-20-69].

280 of 1161
Figure 30-20-72
1
P-81774
Remove the retainer washer (Item 1) [Figure 30-20-74].

P-81772
Figure 30-20-75
Remove the cylinder block / piston assembly from the 1

pump shaft.
1
NOTE: Do not mix rotating group ports from the pump
shaft with the motor shaft.
Figure 30-20-73
P-81775
2
Remove the three pins (Item 1) [Figure 30-20-75] from
the cylinder block.
P-81773
Remove the pistons and retainer plate assembly (Item 1)

from the cylinder block (Item 2) [Figure 30-20-73].

281 of 1161
Figure 30-20-76
3
2
1
P-81780
1
Remove the retainer (Item 1) and spacer (Item 2) from

P-81776 the swash plate (Item 3) [Figure 30-20-78].
Figure 30-20-79
Remove the thrust plate (Item 1) [Figure 30-20-76].
Figure 30-20-77
1
1
P-81781
P-81778 Remove the two bolts (Item 1) and remove the plate
(Item 2) [Figure 30-20-79] from the motor shaft.
Remove the swash plate [Figure 30-20-77].

282 of 1161
2
Figure 30-20-80
1
1
1
P-81786
2
Remove the snap ring (Item 1) and bearing (Item 2)

P-81783 [Figure 30-20-82] from the shaft.
Figure 30-20-83
Remove the four bolts (Item 1) and remove the swash
plate holder (Item 2) [Figure 30-20-80].
Figure 30-20-81
P-81788
1
Remove the pump shaft / bearing (Item 1) [Figure 30-20-

P-81785 83] from the housing.
Remove the motor shaft / bearing (Item 1) [Figure 30-20-

81] from the housing.

283 of 1161
Figure 30-20-84
1
1
P-81800
Remove the power piston assembly (Item 1) [Figure 30-

P-81789 20-86].
Figure 30-20-87
[Figure 30-20-84] from the shaft. 2
1
Figure 30-20-85
1
1
P-81794
Remove the two O-rings (Item 1) from the power piston

P-81791 (Item 2) [Figure 30-20-87].
Remove the two pins (Item 1) [Figure 30-20-85] from the

housing.

284 of 1161
Figure 30-20-88
1 3 2 1
1 P-81797
Remove the two end caps (Item 1), spring (Item 2) and
P-81795 spool (Item 3) [Figure 30-20-90] from the power piston.
NOTE: Record the orientation of the spool.

Remove the snap ring (Item 1) [Figure 30-20-88] from
the power piston. (both ends) Figure 30-20-91
Figure 30-20-89
P-81798
P-81796
Remove the O-ring (Item 1) [Figure 30-20-91] from both
end caps.
Holding your hand and rag over the end cap (Item 1)
[Figure 30-20-89] carefully pry the spool towards the end
cap.

285 of 1161
Inspection
1
Clean all the parts in solvent and dry with compressed
air. DO NOT use cloth or paper because small pieces of 1
material can get into the system and cause damage.
Always install new O-rings and seals.
Lubricate all O-rings and seals with hydraulic oil during 2

installation.
Figure 30-20-92
P-81835
1
Check the running surface (Item 1) [Figure 30-20-94] of
the swash plate for damage or wear.
Check the shaft (Item 2) [Figure 30-20-94] for wear.
Figure 30-20-95
P-81843
Check the valve plates (Item 1) [Figure 30-20-92]. The

surface must be smooth and free of scratches. If
scratches can be felt with a fingernail, replace the plate.
Figure 30-20-93
P-81836
1
Check the block, it should be flat with no signs of cracks

or wear [Figure 30-20-95].
P-81834
Check the swash plate (Item 1) [Figure 30-20-93], the

surface must be smooth and free of scratches.

286 of 1161
Figure 30-20-96
2
1
2
P-81839
2
Check the retainer ring, it should be flat with no cracks or

2
P-81833 wear [Figure 30-20-98].
Figure 30-20-99
Check the swash plate cradle bearings (Item 1) [Figure
30-20-96] they should be smooth with no signs of cracks.
If replacement is necessary, remove the four pins (Item 1

2) and remove the bearings (Item 1) [Figure 30-20-96].
Figure 30-20-97
P-81840
Inspect the splines (Item 1) [Figure 30-20-99] for wear or

damage.
P-81837
Check the thrust plate, it should be flat with no signs of

cracks or wear [Figure 30-20-97].

287 of 1161
1
Figure 30-20-100
P-81842
Check the end of the cylinder block (Item 1) [Figure 30-

P-81838 20-102] the surface must be smooth and of scratches.
If there is any defect in the rotating group, the complete

Check each piston (Item 1) and shoe (Item 2) [Figure 30- unit must be replaced.
20-100] for wear or scratches.
Figure 30-20-101
P-81841
Check the cylinder block bores (Item 1) [Figure 30-20-

101] for wear and scratches.

288 of 1161
Assembly
Figure 30-20-103
P-81798
Install a new O-ring (Item 1) [Figure 30-20-105]onto the

P-81799 end cap.
Figure 30-20-106
Remove the old gasket (Item 1) [Figure 30-20-103] and
thoroughly clean the mounting surface.
Figure 30-20-104
1
1
2
1
P-81801
Lightly lubricate the end cap (Item 1), install the snap ring
P-81791 (Item 2) [Figure 30-20-106].
NOTE: Only install end cap and snap ring in the

Install the two pins (Item 1) [Figure 30-20-104] into the recessed end of the power piston.
housing.

289 of 1161
Assembly (Cont’d)
1
Figure 30-20-107
1 P-81806
Figure 30-20-110
1
P-81794
3
Install the two O-rings (Item 1) [Figure 30-20-107] onto
1
the power piston.
Figure 30-20-108 2
2
1
3
2 P-81825
After the power piston has been fully installed the narrow
groove (Item 1) [Figure 30-20-109] must face inward,
and the wide groove (Item 1) [Figure 30-20-110] must
face outward.
P-81805
Install the two spacers (Item 2) and gasket (Item 3)
[Figure 30-20-110].
Lightly lubricate the O-rings and power piston (Item 1)
and install into the housing (Item 2) [Figure 30-20-108].
NOTE: Make sure the narrow groove (Item 3) [Figure

30-20-108] faces the housing.

290 of 1161
Assembly (Cont’d)
2
Figure 30-20-111
1
1
3
2
3
P-41786
Install the bearing (Item 1) onto the motor shaft (Item 2)

P-81789 until fully seated and install the snap ring (Item 3) [Figure
30-20-113].
Install the bearing (Item 1) onto the pump shaft (Item 2) Figure 30-20-114
until fully seated and install the snap ring (Item 3) [Figure
30-20-111].
Figure 30-20-112
P-81785
1
Install the motor shaft / bearing assembly (Item 1)

P-81788 [Figure 30-20-114].
Install the pump shaft / bearing assembly (Item 1)

[Figure 30-20-112].

291 of 1161
Assembly (Cont’d)
Figure 30-20-115
1
1
P-81781
Align the pin in the housing with the plate and install the
P-81784 two bolts (Item 1) [Figure 30-20-117] and tighten to 8 ft.-
lb. (10 N•m) torque.
Install the cradle (Item 1) [Figure 30-20-115] into the Figure 30-20-118
housing.
3
NOTE: Make sure the pin (Item 2) is aligned with the
cradle (Item 1) [Figure 30-20-115].
Figure 30-20-116
1
2
1 1
P-81810
Install the spacer (Item 1) and retainer (Item 2) onto the

swash plate (Item 3) [Figure 30-20-118].
P-81783


292 of 1161
Assembly (Cont’d)
2
Figure 30-20-119
3 1
2 1
P-81815
Lightly lubricate the pistons (Item 1) and install into the

P-81811 retainer ring (Item 2) [Figure 30-20-121],
Figure 30-20-122
Lightly lubricate the cradle and install the swash plate
assembly (Item 1). Make sure the hole (Item 2) is
pointing up when installed into the power piston groove
(Item 3) [Figure 30-20-119]. 1
Figure 30-20-120
1
1
1 P-81771
Install the three pins (Item 1) into the block (Item 2)

[Figure 30-20-122].
P-81776 NOTE: Apply light grease to the pins to retain them.
Install the thrust plate (Item 1) [Figure 30-20-120].
NOTE: The beveled edge must face the plate.

293 of 1161
Assembly (Cont’d)
2
Figure 30-20-123
P-81817
Temporarily wrap a rubber band (Item 1) around the

P-81770 pistons to help retain them in the cylinder (Item 2). Install
the cylinder assembly (Item 2) [Figure 30-20-125] onto
the pump shaft. Make sure the splines are aligned.
Install the retainer washer (Item 1) [Figure 30-20-123] on
top of the pins. Remove the rubber band.
Figure 30-20-124 Figure 30-20-126
1
2
P-81816 P-81815
Install the piston assembly (Item 1) into the block (Item 2) Lightly lubricate the pistons (Item 1) and install into the
[Figure 30-20-124]. retainer ring (Item 2) [Figure 30-20-126].

294 of 1161
Assembly (Cont’d)
Figure 30-20-127
1
1
1
1 2
P-81773
Install the piston assembly (Item 1) into the block (Item 2)

P-81775 [Figure 30-20-129].
Figure 30-20-130
Install the three pins (Item 1) into the block (Item 2)
[Figure 30-20-127].
NOTE: Apply light grease to the pins to retain them.
Figure 30-20-128
1 2
81819
Temporarily wrap a rubber band (Item 1) around the

pistons to help retain them in the cylinder (Item 2), install
the cylinder assembly (Item 2) [Figure 30-20-130] onto
P-81774 the motor shaft. Make sure the splines are aligned.
Remove the rubber band.

Install the retainer washer (Item 1) [Figure 30-20-128] on
top of the pins.

295 of 1161
Assembly (Cont’d)
2 1
Figure 30-20-131
P-81760
Install a new O-ring (Item 1) and back-up ring (Item 2)

P-81763 [Figure 30-20-133] onto the inlet body.
Repeat above procedure on second inlet body.

Install the bearings (Item 1) [Figure 30-20-131] into the
cover. Figure 30-20-134
Figure 30-20-132
1
P-81734
P-81761
Install the two inlet bodies (Item 1) [Figure 30-20-134]
into the cover.
Turn the cover over, lubricate and install the seal (Item 1)
and snap ring (Item 2) [Figure 30-20-132].
Repeat above procedure for the other seal.

296 of 1161
Assembly (Cont’d)
Figure 30-20-135
1
1 P-81731
Install the spring holder (Item 1) and bolts (Item 2)

P-81733 [Figure 30-20-137] tighten the bolts to 8 ft.-lb. (11 N•m)
torque.
Install the relief valve (Item 1) [Figure 30-20-135]. Figure 30-20-138
Figure 30-20-136
2 1
P-81730
P-81732
Install an O-ring (Item 1) [Figure 30-20-138] onto the
plug.
Install the spring (Item 1) and spacers (Item 2) [Figure
30-20-136] on the cover.

297 of 1161
Assembly (Cont’d)
Figure 30-20-139
P-81727
1
Install the high pressure relief valve assembly (Item 1)
P-91729 [Figure 30-20-141] into the cover and tighten to 25 ft.-lb.
(34 N•m) torque.
Install the plug (Item 1) [Figure 30-20-139] into the side Install the O-ring (Item 1) [Figure 30-20-142] onto the
of the cover. Tighten to 18 ft.-lb. (24 N•m) torque. plug.
Figure 30-20-140 Figure 30-20-142
2 1
P-81728 P-81726
Install the two O-rings (Item 1) and back-up ring (Item 2)

[Figure 30-20-140] onto the valve.

298 of 1161
Assembly (Cont’d)
Figure 30-20-143
2 P-81722
3
Install the high pressure relief valve assembly (Item 1)
P-81725 [Figure 30-20-145] into the cover and tighten to 25 ft.-lb.
(34 N•m) torque.
Install the valve (Item 1) spring (Item 2) and high Figure 30-20-146
pressure relief plug (Item 3) [Figure 30-20-143] into the
cover.
Figure 30-20-144
1
P-81721

P-81723 plug.


299 of 1161
Assembly (Cont’d)
Figure 30-20-147
3 1 1
P-81717
2
Install the valve assembly (Item 1) [Figure 30-20-149]

P-81720 into the cover. Tighten to 25 ft.-lb. (34 N•m) torque.
Figure 30-20-150
Install the valve (Item 1), spring (Item 2) and high
pressure relief plug (Item 3) [Figure 30-20-147] into the
cover.
Figure 30-20-148
1
2
1
P-81716

cap.
P-81718


300 of 1161
Assembly (Cont’d)
Figure 30-20-151
1
1
P-81713
2
3 Install the valve assembly (Item 1) [Figure 30-20-153]

P-81715 into the cover. Tighten to 25 ft.-lb. (34 N•m) torque.
Figure 30-20-154
Install the spool (Item 1), spring (Item 2) and cap (Item 3)
[Figure 30-20-151].
Figure 30-20-152
1
1
1
1
P-81712

P-81714 cap.


301 of 1161
Assembly (Cont’d)
Figure 30-20-155
2 P-81767
3 Install a new gasket (Item 1) [Figure 30-20-157] into the

P-81711 cover.
Lightly lubricate the oil seals.

Install the spool (Item 1), spring (Item 2) and cap (Item 3)
[Figure 30-20-155] into the cover. Figure 30-20-158
Figure 30-20-156 2
2 2 1
1 2
2
2 2 2
4
4
P-81710
3 P-81764
Install the cover (Item 1) onto the housing using the
eleven bolts (Item 2) [Figure 30-20-158] and tighten to
Lightly lubricate the valve plates and install the valve 33 ft.-lb. (44 N•m) torque.
plate (Item 1) with four notches (Item 2) [Figure 30-20-
156] in the position shown. NOTE: Make sure the valve plates stay in position.
Install the second valve plate (Item 3) with the notches

(Item 4) [Figure 30-20-156] in the position shown.

302 of 1161
Assembly (Cont’d) 1
Figure 30-20-159
P-81705
Install the two O-rings (Item 1) [Figure 30-20-161] onto

P-81708 the tube.
Figure 30-20-162
plug.
Figure 30-20-160
1
1
P-81706
Install the tube (Item 1) [Figure 30-20-162].

P-81707
Install the plug (Item 1) [Figure 30-20-160]] into the

housing and tighten to 18 ft.-lb. (25 N•m) torque.

303 of 1161
Assembly (Cont’d)
Figure 30-20-163
1
P-81696
1
Install the adjusting bolt (Item 1) [Figure 30-20-165] into
P-81698 the cover.
Figure 30-20-166
Install the O-ring (Item 1) [Figure 30-20-163] in the
cover.
Figure 30-20-164
1 P-81695
Install the washer (Item 1) and jam nut (Item 2) [Figure

P-81697 30-20-166].
Install the O-ring (Item 1) [Figure 30-20-164] on the

adjusting bolt.

304 of 1161
Assembly (Cont’d)
Figure 30-20-167
1
P-81693
The pin (Item 1) must enter the spring (Item 2) [Figure

P-81694 30-20-169] (as shown).
Figure 30-20-170
Install the spring (Item 1) [Figure 30-20-167] onto the
cover as shown.
Figure 30-20-168
P-81691
1 2 Install the washer (Item 1) and snap ring (Item 2) onto the
P-81692 shaft (Item 3) [Figure 30-20-170].
Install the adjustment arm (Item 1) into the cover (Item 2)

[Figure 30-20-168].

305 of 1161
Assembly (Cont’d)
Figure 30-20-171
P-81823
The pin groove (Item 1) [Figure 30-20-173] on the end of

P-81821 the spool (Item 2) [Figure 30-20-172] must be centered.
Figure 30-20-174
Figure 30-20-172
2 1
1
2
P-81826
P-81802
Align the pin (Item 1) with the pin groove (Item 2) [Figure
Install the spool (Item 1) [Figure 30-20-171] and [Figure 30-20-174] and install the cover.
30-20-172] into the power piston.
NOTE: The pin groove (Item 2) [Figure 30-20-172] on

the spool must go into the power piston first.

306 of 1161
Assembly (Cont’d)
Figure 30-20-175
1
1 1
1
P-81798

P-81828 end cap.
Figure 30-20-178
Figure 30-20-176
P-81821
Install the end cap (Item 1) [Figure 30-20-178] into the

P-91922 spool.
Install the spring (Item 1) [Figure 30-20-176] into the

spool.

307 of 1161
Assembly (Cont’d)
2
2
Figure 30-20-179
2 1
1
P-81832
Install the cover (Item 1) and five bolts (Item 2) [Figure

P-81830 30-20-181]. Tighten the bolts to 14 ft.-lb. (19 N•m) torque.
Hydrostatic Pump Start-Up

Install the snap ring (Item 1) [Figure 30-20-179].
Disconnect the fuel shut-off solenoid at the fuel injection
Figure 30-20-180 pump.
Crank the engine, with the starter, for 15-20 seconds.
1 Connect the fuel shut-off solenoid.
Start the engine and run at idle speed for 5-7 minutes
before operating the tractor. Do Not run the engine above
idle speed while doing the above procedure.
P-91931
Install a new gasket (Item 1) [Figure 30-20-180].

308 of 1161
HYDROSTATIC PUMP TESTING (HST MODELS) Figure 30-30-2
Charge Pressure Testing
All testing is done with hydraulic oil at operating

temperature.
The following tools will be needed for the testing of the

charge pressure:
MEL1654 - Compact Tractor Hydraulic Pressure Testing

Kit 1
Figure 30-30-1
P-84633
Remove the bottom plug (Item 1) [Figure 30-30-2] from

the hydrostatic pump.
NOTE: Either the top or bottom port can be used for

charge pressure testing.
P-84634
The test port for testing charge pressure is located under

the left side of the machine [Figure 30-30-1].
IMPORTANT
damage the system.
I-2003-0888

309 of 1161
(CONT’D)
1
Charge Pressure Testing (Cont’d)
Figure 30-30-3
P-84635
Charge pressure is provided by the rear gear pump (Item

1) [Figure 30-30-4].
P-84585
Hydrostatic Drive Pressure Testing
Install the adaptor and 400 PSI (27,6 bar) gauge (Item 1) All testing is done with hydraulic oil at operating
[Figure 30-30-3] into the hydrostatic pump. temperature.
NOTE: Do not engage the travel pedal during this test The following tools will be needed for the testing of the
or gauge damage will result. hydrostatic drive pressure:
Engage the parking brake, start the engine and increase MEL1654 - Compact Tractor Hydraulic Pressure Testing
the engine speed to full RPM. Kit
The charge pressure should be 255 PSI (17,7 bar). Support the compact tractor on jackstands. (See
SUPPORTING THE COMPACT TRACTOR ON
Decrease engine speed to low RPM and stop the engine. JACKSTANDS on Page 10-10-1.)
The charge relief valve is not adjustable. Figure 30-30-5
Low charge pressure can be caused by a worn or
damaged charge pump or internal wear in the hydrostatic
pump / motor.
Charge pressure is also used to engage the front wheel

drive. Test the front wheel drive engagement. See
Engagement Testing to determine if the charge pump or
hydrostatic pump / motor is worn. (See Engagement
Testing on Page 20-160-1.)
P-84634
The test port for testing the drive relief is located under
the left side of the machine (Item 1) [Figure 30-30-5].

310 of 1161
(CONT’D)
Hydrostatic Drive Pressure Testing (Cont’d)
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888 P-84585
The top plug is reverse travel, the bottom plug is forward Install the adapter and 10,000 PSI (690 bar) gauge (Item
travel. 1) [Figure 30-30-7] into the hydrostatic pump.
Figure 30-30-6 Engage the parking brake, start the engine and increase
Shift the hydrostatic pump to the high range.
Press the forward travel pedal until the relief pressure is

obtained.
Relief pressure should be 4975 PSI (343 bar) [Figure 30-

30-3].
1 Repeat the procedure for the reverse travel relief valve.
P-84633
Remove the bottom plug (Item 1) [Figure 30-30-6].

311 of 1161
HYDROSTATIC PUMP TESTING (HST MODELS)
(CONT’D)
Neutral Valves
Figure 30-30-8
P-84633
The neutral valves (Item 1) [Figure 30-30-8] provide a

wider neutral band for the hydrostatic pump. The valves
are located in the high pressure drive circuit.
Figure 30-30-9
2 1
4 3
P-84638
The valves are made up of the plug (Item 1), body (Item
2), spring (Item 3) and poppet (Item 4) [Figure 30-30-9].
The neutral valves are not adjustable.

312 of 1161
TRAVEL CONTROL PEDALS (HST MODELS)
Figure 30-40-1
P-81577

N•m) torque.
Figure 30-40-2
P-81573
Remove the travel pedals (Item 1) [Figure 30-40-2].

313 of 1161
314 of 1161
TRAVEL CONTROL PEDAL LINKAGE (HST MODELS) Figure 30-50-3
Remove the travel control pedals. (See Removal And

NOTE: The floor plate is removed for photo clarity.
Figure 30-50-1 1
P-84547
Remove the cotter pin (Item 1) [Figure 30-50-3] from

1 1 both ends of the forward linkage.
Figure 30-50-4
P-84545
1
Remove the snap rings (Item 1) [Figure 30-50-1] from
both ends of the reverse linkage.
Figure 30-50-2
P-84548
Remove the forward linkage (Item 1) [Figure 30-50-4].

1
P-884546
Remove the reverse linkage (Item 1) [Figure 30-50-2].

315 of 1161
316 of 1161
TRAVEL CONTROL PEDAL PIVOT ARMS (HST Figure 30-60-3
MODELS)
Removal And Installation 1

Remove the travel control pedal linkage. (See Removal

Figure 30-60-1
P-84551
2 Remove forward pivot arm (Item 1) [Figure 30-60-3]

from the pivot shaft.
P-84549

[Figure 30-60-1].
Figure 30-60-2
P-884550
Remove the reverse pivot arm (Item 1) [Figure 30-60-2]

from the pivot shaft.

317 of 1161
318 of 1161
DRIVE SYSTEM
AXLE AND DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Axle Shaft Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-39
Axle Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-16
Axle Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-80-17
Axle Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-18
Axle Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-37
Axle Shaft Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . 40-80-15
Bevel Gear Case Group Assembly . . . . . . . . . . . . . . . . . . . . . . . 40-80-41
Bevel Gear Case Group Disassembly . . . . . . . . . . . . . . . . . . . . . 40-80-12
Bevel Gear Case Group Inspection . . . . . . . . . . . . . . . . . . . . . . . 40-80-14
Bevel Gear Case Group Parts Identification . . . . . . . . . . . . . . . . 40-80-11
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-29 DRIVE SYSTEM
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-25
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-28
Differential Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-33
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-24
Differential Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-23
Front Axle Case Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . 40-80-43
Front Axle Case Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . 40-80-8
Front Axle Case Group Parts Identification . . . . . . . . . . . . . . . . . . 40-80-7
Front Axle Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-47
Front Axle Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-3
Front Axle Cover Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-6
Front Axle Cover Parts Identification . . . . . . . . . . . . . . . . . . . . . . . 40-80-2
Pinion Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-34
Pinion Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-22
Pinion Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-22
Pinion Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-35
Pinion Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-21
Pinion Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-20
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

319 of 1161
DRIVE SYSTEM (CONT’D)
AXLE AND DIFFERENTIAL (SST MODELS) . . . . . . . . . . . . . . . . . . .40-81-1

Axle Shaft Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-39
Axle Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-16
Axle Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-17
Axle Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-18
Axle Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-37
Axle Shaft Group Parts Identification . . . . . . . . . . . . . . . . . . . . . .40-81-15
Bevel Gear Case Group Assembly . . . . . . . . . . . . . . . . . . . . . . .40-81-41
Bevel Gear Case Group Disassembly . . . . . . . . . . . . . . . . . . . . .40-81-12
Bevel Gear Case Group Inspection . . . . . . . . . . . . . . . . . . . . . . .40-81-14
Bevel Gear Case Group Parts Identification . . . . . . . . . . . . . . . . 40-81-11
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-29
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-25
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-28
Differential Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-33
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-24
Differential Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-23
Front Axle Case Group Assembly . . . . . . . . . . . . . . . . . . . . . . . .40-81-43
Front Axle Case Group Disassembly. . . . . . . . . . . . . . . . . . . . . . .40-81-8
Front Axle Case Group Parts Identification . . . . . . . . . . . . . . . . . .40-81-7
Front Axle Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-47
Front Axle Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-3
Front Axle Cover Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-6
Front Axle Cover Parts Identification . . . . . . . . . . . . . . . . . . . . . . .40-81-2
Pinion Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-34
Pinion Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-22
Pinion Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-22
Pinion Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-35
Pinion Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-21
Pinion Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-20
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-81-1
AXLE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-1
BRAKE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-3

320 of 1161
BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

BRAKE / CLUTCH PEDAL ASSEMBLY (SST MODELS) . . . . . . . . . . 40-21-1

DRIVESHAFT (EARLY MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-1

DRIVESHAFT (LATER MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . .40-31-1

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

FRONT AXLE (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-71-1

SEPARATING THE TRACTOR (HST MODELS) . . . . . . . . . . . . . . .40-100-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
SEPARATING THE TRACTOR (SST MODELS). . . . . . . . . . . . . . . .40-110-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
Stop Switch Adjustment (HST Models) . . . . . . . . . . . . . . . . . . . . . 40-10-5
Stop Switch Adjustment (SST Models) . . . . . . . . . . . . . . . . . . . . . 40-10-7
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
STEERING AXLE ADJUSTMENT (HST MODELS) . . . . . . . . . . . . . . 40-90-1

Rocking Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-2
Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Toe-In Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
STEERING AXLE ADJUSTMENT (SST MODELS) . . . . . . . . . . . . . . 40-91-1

Rocking Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1
Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-2
Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-3
Toe-In Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-2

321 of 1161
TRANSMISSION (HST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-60-1

Bearing Cover / Shift Links Assembly . . . . . . . . . . . . . . . . . . . . . . 40-60-96
Bearing Cover / Shift Links Disassembly . . . . . . . . . . . . . . . . . . . . 40-60-20
Bearing Cover / Shift Links Inspection . . . . . . . . . . . . . . . . . . . . . . 40-60-24
Bearing Cover / Shift Links Parts Identification . . . . . . . . . . . . . . . 40-60-19
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-68
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-60
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-67
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-59
Front Wheel Drive Shaft Group Assembly . . . . . . . . . . . . . . . . . . . 40-60-78
Front Wheel Drive Shaft Group Disassembly . . . . . . . . . . . . . . . . 40-60-52
Front Wheel Drive Shaft Group Inspection . . . . . . . . . . . . . . . . . . 40-60-54
Front Wheel Drive Shaft Group Parts Identification . . . . . . . . . . . . 40-60-51
Idle Shaft Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-80
Idle Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-46
Idle Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-50
Idle Shaft Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . 40-60-45
Middle Case / Countershaft Group Assembly . . . . . . . . . . . . . . . 40-60-102
Middle Case / Countershaft Group Disassembly . . . . . . . . . . . . . . 40-60-17
Middle Case / Countershaft Group Inspection . . . . . . . . . . . . . . . . 40-60-18
Middle Case / Countershaft Group Parts Identification . . . . . . . . . 40-60-16
Middle Case / PTO Clutch Group Assembly . . . . . . . . . . . . . . . . 40-60-106
Middle Case / PTO Clutch Group Disassembly . . . . . . . . . . . . . . . . 40-60-3
Middle Case / PTO Clutch Group Inspection . . . . . . . . . . . . . . . . . 40-60-10
Middle Case / PTO Clutch Group Parts Identification . . . . . . . . . . . 40-60-2
Middle Case / PTO Countershaft Group Assembly . . . . . . . . . . . 40-60-105
Middle Case / PTO Countershaft Group Disassembly. . . . . . . . . . 40-60-12
Middle Case / PTO Countershaft Group Inspection. . . . . . . . . . . . 40-60-13
Middle Case / PTO Countershaft Group Parts Identification . . . . . 40-60-11
Middle Case / 23 Gear Shaft Group Assembly . . . . . . . . . . . . . . 40-60-104
Middle Case / 23 Gear Shaft Group Disassembly . . . . . . . . . . . . . 40-60-15
Middle Case / 23 Gear Shaft Group Inspection . . . . . . . . . . . . . . . 40-60-15
Middle Case / 23 Gear Shaft Group Parts Identification . . . . . . . . 40-60-14
Pinion Shaft Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-90
Pinion Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-26
Pinion Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-32
Pinion Shaft Group Parts Identification . . . . . . . . . . . . . . . . . . . . . 40-60-25
PTO Shaft Group Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-87
PTO Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-34
PTO Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-37
PTO Shaft Group Parts Identification. . . . . . . . . . . . . . . . . . . . . . . 40-60-33
PTO 15 Gear Shaft Group Assembly. . . . . . . . . . . . . . . . . . . . . . . 40-60-83
PTO 15 Gear Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . 40-60-42
PTO 15 Gear Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . 40-60-44
PTO 15 Gear Shaft Group Parts Identification. . . . . . . . . . . . . . . . 40-60-41

322 of 1161
TRANSMISSION (HST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Range Shifter Shaft Group Assembly . . . . . . . . . . . . . . . . . . . . . . 40-60-86
Range Shifter Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . 40-60-39
Range Shifter Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . 40-60-40
Range Shifter Shaft Group Parts Identification . . . . . . . . . . . . . . . 40-60-38
Rear PTO Shaft Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-76
Rear PTO Shaft Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . 40-60-56
Rear PTO Shaft Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-58
Rear PTO Shaft Group Parts Identification . . . . . . . . . . . . . . . . . . 40-60-55
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
TRANSMISSION (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-1

Bearing Cover / Countershaft Assembly . . . . . . . . . . . . . . . . . . .40-61-160
Bearing Cover / Countershaft Disassembly . . . . . . . . . . . . . . . . . . 40-61-24
Bearing Cover / Countershaft Inspection . . . . . . . . . . . . . . . . . . . . 40-61-31
Bearing Cover / Countershaft Parts Identification . . . . . . . . . . . . . 40-61-23
Bearing Cover / Main Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 40-61-159
Bearing Cover / Main Shaft Disassembly . . . . . . . . . . . . . . . . . . . 40-61-33
Bearing Cover / Main Shaft Inspection . . . . . . . . . . . . . . . . . . . . . 40-61-33
Bearing Cover / Main Shaft Parts Identification . . . . . . . . . . . . . . . 40-61-32
Bearing Cover / PTO Driveshaft Assembly . . . . . . . . . . . . . . . . . 40-61-173
Bearing Cover / PTO Driveshaft Disassembly . . . . . . . . . . . . . . . . 40-61-18
Bearing Cover / PTO Driveshaft Inspection . . . . . . . . . . . . . . . . . . 40-61-18
Bearing Cover / PTO Driveshaft Parts Identification . . . . . . . . . . . 40-61-17
Bearing Cover / PTO Countershaft Assembly . . . . . . . . . . . . . . . 40-61-174
Bearing Cover / PTO Countershaft Disassembly. . . . . . . . . . . . . . 40-61-15
Bearing Cover / PTO Countershaft Inspection. . . . . . . . . . . . . . . . 40-61-16
Bearing Cover / PTO Countershaft Parts Identification . . . . . . . . .40-61-14
Bearing Cover / Shift Links Assembly . . . . . . . . . . . . . . . . . . . . .40-61-168
Bearing Cover / Shift Links Disassembly . . . . . . . . . . . . . . . . . . . . 40-61-20
Bearing Cover / Shift Links Inspection . . . . . . . . . . . . . . . . . . . . . .40-61-22
Bearing Cover / Shift Links Parts Identification . . . . . . . . . . . . . . .40-61-19
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-61-108
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-61-100
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-61-107
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-61-99
Front Wheel Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . .40-61-118
Front Wheel Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . .40-61-92
Front Wheel Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . .40-61-94
Front Wheel Drive Shaft Parts Identification . . . . . . . . . . . . . . . . . 40-61-91
Idle Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-120
Idle Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-86
Idle Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-90
Idle Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-85

323 of 1161

Middle Case / Bearing Cover Installation . . . . . . . . . . . . . . . . . . . 40-61-158
Middle Case / Bearing Cover Removal . . . . . . . . . . . . . . . . . . . . . 40-61-35
Middle Case Bearing Cover / Shift Links Assembly . . . . . . . . . . . 40-61-136
Middle Case Bearing Cover / Shift Links Disassembly . . . . . . . . . 40-61-60
Middle Case Bearing Cover / Shift Links Inspection . . . . . . . . . . . 40-61-64
Middle Case Bearing Cover / Shift Links Parts Identification . . . . . 40-61-59
Middle Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-158
Middle Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-34
Middle Case / PTO Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . 40-61-142
Middle Case / PTO Clutch Disassembly . . . . . . . . . . . . . . . . . . . . 40-61-54
Middle Case / PTO Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . 40-61-58
Middle Case / PTO Clutch Parts Identification . . . . . . . . . . . . . . . . 40-61-53
Middle Case / Shift Link Assembly. . . . . . . . . . . . . . . . . . . . . . . . 40-61-155
Middle Case / Shift Link Disassembly . . . . . . . . . . . . . . . . . . . . . . 40-61-37
Middle Case / Shift Link Inspection . . . . . . . . . . . . . . . . . . . . . . . . 40-61-39
Middle Case / Shift Link Parts Identification. . . . . . . . . . . . . . . . . . 40-61-36
Middle Case / Shuttle Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 40-61-147
Middle Case / Shuttle Shaft Disassembly . . . . . . . . . . . . . . . . . . . 40-61-43
Middle Case / Shuttle Shaft Inspection . . . . . . . . . . . . . . . . . . . . . 40-61-50
Middle Case / Shuttle Shaft Parts Identification . . . . . . . . . . . . . . . 40-61-42
Middle Case / 19 Gear Shaft Assembly . . . . . . . . . . . . . . . . . . . . 40-61-154
Middle Case / 19 Gear Shift Disassembly . . . . . . . . . . . . . . . . . . . 40-61-41
Middle Case / 19 Gear Shaft Inspection . . . . . . . . . . . . . . . . . . . . 40-61-41
Middle Case / 19 Gear Shaft Parts Identification . . . . . . . . . . . . . . 40-61-40
Middle Case / 23-20 Gear Shaft Assembly . . . . . . . . . . . . . . . . . 40-61-146
Middle Case / 23-20 Gear Shaft Disassembly . . . . . . . . . . . . . . . . 40-61-52
Middle Case / 23-30 Gear Shaft Inspection . . . . . . . . . . . . . . . . . . 40-61-52
Middle Case / 23-20 Gear Shaft Parts Identification . . . . . . . . . . . 40-61-51
Pinion Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-130
Pinion Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-66
Pinion Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-72
Pinion Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-65
PTO Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-127
PTO Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-74
PTO Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-77
PTO Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-73
PTO 15 Gear Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-123
PTO 15 Gear Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-82
PTO 15 Gear Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-84

324 of 1161

PTO 15 Gear Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . 40-61-81
Range Shifter Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-126
Range Shifter Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-79
Range Shifter Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-80
Range Shifter Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . 40-61-78
Rear PTO Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-116
Rear PTO Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-96
Rear PTO Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-98
Rear PTO Shaft Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-61-95
Transmission Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-175
Transmission Case Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-7
Transmission Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-183
Transmission Case Parts Identification . . . . . . . . . . . . . . . . . . . . . . 40-61-6
Transmission Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-1

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SERVICE BRAKE
Troubleshooting Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Braking power is not constant 1, 2, 3
Braking power is trailed 4, 5, 6, 7
Braking Power is weakened 2, 3, 8, 9, 10
KEY TO CORRECT THE CAUSE

1. Brake pedal clearance is not constant
2. Brake disc is worn
3. Cam plate is bent
4. Brake pedal clearance is too small
5. Cam plate balls are worn unequally
6. Brake pedal return spring is worn or broken
7. Brake cam is corroded
8. Brake pedal clearance is excessive
9. Brake cam or lever is worn
10. Improper lubrication oil
Description
The left and right brakes are operated by separate foot

pedals, they are the primary brakes used during machine
operation.

327 of 1161
SERVICE BRAKE (CONT’D) Figure 40-10-1
Inspection And Maintenance UNLOCKED 2 LOCKED

When the brakes are used to slow the compact tractor, 2
there should be no noticeable pulling to the left or the
right. If brakes need adjusting, use the following
procedure.
The brakes are inspected by measuring pedal free travel.
For HST models: One or both brake pedals must be
depressed before the engine can be started.
For SST models: Both brake pedals must be depressed
before the engine can be started. 2
WARNING
AVOID INJURY OR DEATH HST Model 1 P-84900
Stop engine and chock both rear tires before

inspecting or adjusting brakes. UNLOCKED LOCKED
W-2590-0607
2
2
The brake pedals (Item 1) [Figure 40-10-1] must be

unlocked for brake inspection and maintenance.
Rotate the lock lever (Item 2) [Figure 40-10-1] to the

unlocked position.

328 of 1161
SERVICE BRAKE (CONT’D)
Inspection And Maintenance (Cont’d)
Figure 40-10-2
HST Model
MEASURE PEDAL FREE TRAVEL

P-84847A
SST Model
MEASURE PEDAL FREE TRAVEL P-92924
Press down lightly on the left brake pedal (Item 1)

[Figure 40-10-2] until resistance is felt.
Measure the distance that the pedal traveled.
Repeat the procedure for the other brake pedal.
The correct brake pedal free travel for both the left and
right brake pedal is:
Brake pedal free travel 0.78 - 1.18 in. (20 - 30 mm)

Adjust until the free travel is equal for both the left and
right brake pedals.

lock the brake pedals together. Rotate the pedal lock

329 of 1161
SERVICE BRAKE (CONT’D)
Adjusting
Figure 40-10-4
WARNING
Brake pedals must be locked together before 1
activating the parking brake or for road travel. Only
unlock the brake pedals when brake adjustment is
needed or when using the brake pedals for slow 2
speed turning in work applications. Using unlocked
brake pedals to stop the machine at high speeds may 1
cause accidental turning or tipping. Slow down
before making a turn. Inspect and adjust the brakes P-92910A
as needed.
W-2750-0708
Left Brake Pedal Adjustment
The adjustment linkage for the left brake pedal is located

Figure 40-10-3 on the left side of the instrument panel.
To adjust the left brake pedal free travel, loosen the two
Turn the turn buckle (Item 2) [Figure 40-10-4] to change

1 pedal travel.
[Figure 40-10-4].
2
After the brake pedals have been adjusted, the compact
tractor should stop in a straight line when using the brake
pedals. If compact tractor pulls to one side, readjust the
1 brakes as needed.
P-92911 After brake pedal inspection or adjustment is completed,
lock the brake pedals together. Rotate the lock lever
NOTE: This procedure and the photos are shown
using a HST model, the procedure for the SST Check the parking brake. (See PARKING BRAKE
model is the same. SYSTEM on Page 10-220-1.)
Right Brake Pedal Adjustment
The adjustment linkage for the right brake pedal is

located on the right side of the instrument panel.
To adjust the right brake pedal free travel, loosen the two
Turn the turn buckle (Item 2) [Figure 40-10-3] to change

pedal travel.
[Figure 40-10-3].

330 of 1161
Stop Switch Adjustment (HST Models)
Right Switch Adjustment

Figure 40-10-5
P-84733
1
Depress the brake pedal. There must be continuity

shown on the multimeter (Item 1) [Figure 40-10-7].
Figure 40-10-8
P-84731
1
Figure 40-10-6
1 P-84734
Loosen the nuts (Item 1) [Figure 40-10-8] and adjust the

switch until there is continuity when the brake pedal is
depressed and no continuity when the brake pedal is
released.
P-84732
Connect a multimeter to the switch wire connector. There

must be no continuity shown on the multimeter (Item 1)
[Figure 40-10-6].

331 of 1161
Stop Switch Adjustment (HST Models) (Cont’d)
Left Switch Adjustment 1

Figure 40-10-9
P-84737

1 shown on the multimeter (Item 1) [Figure 40-10-11].
Figure 40-10-12
P-84735
Figure 40-10-10
1 1
1
P-84738
Loosen the nuts (Item 1) [Figure 40-10-12] and adjust

the switch until there is continuity when the brake pedal is
released.
P-84736

[Figure 40-10-10].

332 of 1161
Stop Switch Adjustment (SST Models)

1
Figure 40-10-13
P-98248

shown on the multimeter (Item 1) [Figure 40-10-15].
Figure 40-10-16
P-98246
Figure 40-10-14
1 1
P-98249
Loosen the nuts (Item 1) [Figure 40-10-16] and adjust

the switch until there is continuity when the brake pedal is
P-98247
released.

[Figure 40-10-14].

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BRAKE PEDAL ASSEMBLY Figure 40-20-3

Figure 40-20-1 2
2
3
1
1
P-84750
Remove the snap ring (Item 1), four bolts (Item 2) and
bracket (Item 3) [Figure 40-20-3] from the left side of the
firewall.
P-84749 Figure 40-20-4
Remove the cotter pin, washer and clevis pin (Item 1)

[Figure 40-20-1] from the right brake linkage.
Figure 40-20-2
1
P-84751

[Figure 40-20-4].
P-84756

335 of 1161
BRAKE PEDAL ASSEMBLY (CONT'D) Figure 40-20-7
Figure 40-20-5
1
P-84754
Cut and remove the cable tie (Item 1). Disconnect the
P-84752 wire harness (Item 2) [Figure 40-20-7].
Figure 40-20-8
Remove spring (Item 1) [Figure 40-20-5].
Figure 40-20-6
1
1
P-84755
P-84753 Remove the roll pin (Item 1) [Figure 40-20-8].
Remove the left brake pedal (Item 1) [Figure 40-20-6].

336 of 1161
BRAKE PEDAL ASSEMBLY (CONT'D) Figure 40-20-11
Figure 40-20-9
1
P-84759
Figure 40-20-12
P-84757
Remove the right brake pedal (Item 1) [Figure 40-20-9].
Figure 40-20-10
P-84760
1
Remove the bearings (Item 1) [Figure 40-20-11] &
[Figure 40-20-12] from both sides of the brake pedal rod
housing.
P-84758
Installation: Apply a light coat of grease to the bearings
before installing the bearings in the housing.
Slide the brake pedal rod (Item 1) [Figure 40-20-10] out
the right side of the machine.

337 of 1161
338 of 1161
BRAKE / CLUTCH PEDAL ASSEMBLY Figure 40-21-3
(SST MODELS)
Remove the instrument panel. (See Brake System

Removal And Installation on Page 60-81-1.) 1
Figure 40-21-1
1
P-98264
NOTE: The brake linkage was removed for photo

clarity.
P-98250 Figure 40-21-4

[Figure 40-21-1] from the right brake linkage.
Figure 40-21-2
2 2
1
P-98253
1
Remove the snap ring (Item 1), four bolts (Item 2) and
bracket (Item 3) [Figure 40-21-4] from the right side of
the firewall.
P-98251

339 of 1161
BRAKE / CLUTCH PEDAL ASSEMBLY (SST MODELS) Figure 40-21-7
(CONT'D)
Figure 40-21-5
P-98256
1
Remove the left brake pedal (Item 1) [Figure 40-21-7].
P-98254 Figure 40-21-8
Remove the right brake pedal (Item 1) [Figure 40-21-5].
Figure 40-21-6
P-98252
1

[Figure 40-21-8] from the left brake linkage.
P-98255
Remove the roll pin (Item 1) [Figure 40-21-6].

340 of 1161
BRAKE / CLUTCH PEDAL ASSEMBLY (SST Figure 40-21-11
MODELS) (CONT'D)
Figure 40-21-9
P-98260
1 Remove the spring (Item 1) [Figure 40-21-11].
P-98258 Figure 40-21-12

from the clutch lever (Item 2) [Figure 40-21-9].
Figure 40-21-10
2
1
P-98261
Slide the brake / clutch pedal pivot shaft (Item 1) and

remove the clutch pedal (Item 2) [Figure 40-21-12] from
the left side of the machine.
P-98259

[Figure 40-21-10] from the clutch linkage.

341 of 1161
BRAKE / CLUTCH PEDAL ASSEMBLY (SST
MODELS) (CONT'D)
Figure 40-21-13
P-98262
Figure 40-21-14
P-98263
Remove the bearings (Item 1) [Figure 40-21-13] and

[Figure 40-21-14] from the brake / clutch pedal housing.
Installation: Apply a light coat of grease to the bearings

before installing the bearings in the housing.
For Brake Pedal Adjustment: (See Brake System

Adjusting on Page 10-230-2.)
For Clutch Pedal Adjustment (See CLUTCH ASSEMBLY

(SST MODELS) on Page 70-130-1.).
(See Clutch Pedal Play And Stopper Bolt Adjustment on

Page 70-130-3.)

342 of 1161
DRIVESHAFT (EARLY MODELS) Figure 40-30-3

1
Put blocks in front and behind the rear wheels to keep
machine from rolling.
Figure 40-30-1
P-84610
1
Move the snap ring (Item 1) back and slide the coupler
(Item 2) [Figure 40-30-3] onto the driveshaft.
Figure 40-30-4
P-84608
2
Remove the bolt (Item 1) from the front of the driveshaft
cover and slide the cover (Item 2) [Figure 40-30-1] back. 1
Installation: Tighten the bolt to 17 - 20 ft.-lb. (24 - 27

N•m) torque.
Figure 40-30-2
P-84609
1
Remove the roll pin (Item 1) and slide the coupler
(Item 2) forward [Figure 40-30-4] onto the driveshaft.
Remove the driveshaft.
P-84607
Remove the bolt (Item 1) from the rear of the driveshaft

cover and slide the cover (Item 2) [Figure 40-30-2]
forward.

N•m) torque.

343 of 1161
344 of 1161
DRIVESHAFT (LATER MODELS) Figure 40-31-3

2
Put blocks in front and behind the rear wheels to keep
machine from rolling.
1
Figure 40-31-1
1
P-84607
Remove the bolt (Item 1) from the rear of the driveshaft

cover and slide the cover (Item 2) [Figure 40-31-3]
forward.
P-95533 Installation: Tighten the bolt to 17 - 20 ft.-lb. (24 - 27

N•m) torque.
Remove the bolt (Item 1) from the front of the driveshaft Figure 40-31-4
cover and slide the cover (Item 2) [Figure 40-31-1] back.
Installation: Tighten the bolt to 17 - 20 ft.-lb. (24 - 27 2

N•m) torque.
1
Figure 40-31-2
P-84609
Remove the roll pin (Item 1) and slide the coupler (Item
2) forward [Figure 40-31-4] onto the driveshaft.
P-95534 Remove the driveshaft.
Remove the roll pin (Item 1) and slide the coupler (Item
2) [Figure 40-31-2] back onto the driveshaft.

345 of 1161
346 of 1161
AXLE CASE Figure 40-40-3
Drain the transmission oil. (See Checking And Adding

Fluid on Page 10-120-1.)
Remove the fender. (See Removal And Installation on

Page 50-120-1.) 1 2
Remove the lower lift arm. (See Right Side Removal And
1
Figure 40-40-1
P-86154
Remove the nine bolts (Item 1) and two nuts (Item 2)

[Figure 40-40-3].
Assembly: Tighten the bolts and nuts to 36 ft.-lb. (49

N•m) torque.
Figure 40-40-4
P-77780
Raise the rear of the machine and place a stand (Item 1)

[Figure 40-40-1] under the transmission.
Remove the rear wheel.

1
Figure 40-40-2
P-86155
1 Thread two bolts (removed from the axle case) into the
threaded holes of the axle case. Tighten the bolts (Item
1) [Figure 40-40-4] to push the axle case off of the dowel
pins.
P-86153
Use a hoist and lifting chain (Item 1) [Figure 40-40-2] to

support the axle case.

347 of 1161
AXLE CASE (CONT’D)
Figure 40-40-5
2 1
P-84024
Remove the axle case [Figure 40-40-5].
Installation: Apply gasket eliminator to the mounting

surface of the axle case.
NOTE: The shaft (Item 1) may stay in the brake case

or the axle case (item 2) [Figure 40-40-5].
If the shaft stays in the axle case, use care

during reassembly to make sure the shaft
splines correctly engage the brake disc
splines.

348 of 1161
1. Bearing
2. Nut
3. Gear
4. Spacer Tube
5. Washer
6. Dowel Pin
7. Axle Case
8. Nut
9. Lockwasher
10. Axle Shaft
11. Bolt
12. Axle Cover
13. O-Ring
14. Seal
15. Stud Bolt
1
2 3
4
5 6 7
11
11
1
15
14 9
13 8
12
10
B-23802

349 of 1161
AXLE CASE (CONT’D) Figure 40-40-8
Figure 40-40-6
P-77284
Assembly: After the nut has been tightened, stake the

P-77266 nut into the shaft groove [Figure 40-40-8].
Figure 40-40-9
With the axle case on a work surface, remove the
bearing (Item 1) [Figure 40-40-6].
Figure 40-40-7
1
P-77269
Remove the gear (Item 1) [Figure 40-40-9] from the axle

P-77268 case.
NOTE: Mark the gear for correct assembly.

Remove the nut (Item 1) [Figure 40-40-7] from the shaft.
Assembly: A new nut must be used. Tighten the nut to

145 - 181 ft.-lb. (197 - 245 N•m) torque.

350 of 1161

1
Figure 40-40-10 1
1 1
P-77275
2 Remove the four bolts (Item 1) [Figure 40-40-12].

P-77271
Assembly: Tighten the bolts to 35 ft.-lb. (49 N•m) torque.
Remove the spacer tube (Item 1) and bearing (Item 2) Figure 40-40-13
[Figure 40-40-10]
Figure 40-40-11
P-77276
P-77274 Remove the axle shaft [Figure 40-40-13].
Remove the copper washer (Item 1) [Figure 40-40-11].

351 of 1161
Figure 40-40-14
1
P-77279
1
Remove the axle cover (Item 1) [Figure 40-40-16] from
P-77277 the shaft.
Figure 40-40-17
Clean the gasket mounting surface (Item 1) [Figure 40-
40-14].
Figure 40-40-15
1
P-77280

P-77278 axle cover.
Remove the outer bearing (Item 1) [Figure 40-40-15].

352 of 1161
Figure 40-40-18
P-77281
Remove the seal (Item 1) [Figure 40-40-18].

353 of 1161
354 of 1161
BRAKE CASE Figure 40-50-3
Remove the axle case. (See Removal And Installation on

Page 40-40-1.) 1
Figure 40-50-1
P-84057
1
Remove the bearing (Item 1) [Figure 40-50-3].
Figure 40-50-4
P-84055
Remove the nut and lock washer (Item 1) [Figure 40-50-

1
1].

N•m) torque.
Figure 40-50-2 2
1
P-86156
Remove the four bolts (Item 1) and nut (Item 2) [Figure

40-50-4].
2
Installation: Tighten the bolts and nut to 54 - 69 ft.-lb.
1 (74 - 93 N•m) torque.
P-84056
Remove the brake linkage (Item 1) and spacers (Item 2)

[Figure 40-50-2].

355 of 1161
BRAKE CASE (CONT’D) Figure 40-50-7
Removal And Installation (Cont’d) 1

2
Figure 40-50-5 1
1
2
1
1
1 1 1
P-84061
Remove the six balls (Item 1) from the ball guide plate
P-84059 (Item 2) [Figure 40-50-7].
Installation: Apply a small amount of grease to each ball

Remove the seven bolts (Item 1) and nut (Item 2) [Figure for ease of assembly.
40-50-5].
Figure 40-50-8
Installation: Apply gasket eliminator onto the mounting
surface of the brake case.
1
Installation: Tighten the seven bolts (Item 1) to 54 - 69 1
ft.-lb. (74 - 93 N•m) torque. Tighten the nut (Item 2) to 25 1
- 36 ft.-lb. (35 - 49 N•m) torque.
Figure 40-50-6
1 1
1
1
P-84062
Remove the six ball guide seats (Item 1) [Figure 40-50-

8] from the plate.
P-84060
Remove the brake housing (Item 1) [Figure 40-50-6].

356 of 1161
BRAKE CASE (CONT’D)
1. Bearing
2. Shaft
3. Snap Ring
4. Brake Case
5. Plug
6. Washer
7. Nut
8. Cam Lever
9. Lockwasher
10. Brake Cam
11. Stud Bolt
12. Bolt
1 13. Cam Plate
14. Friction Disk
15. Spacer Disk
16. Ball
2 17. Ball Seat
18. Lever Shaft
19. Dowel Pin
3 20. O-ring
1 19
11 11 4
11
10 9
9
12
11
9 *18
17 7 5 6
16
12
9
15
20
13 9 7
6
14 8
* SST MODELS ONLY
NOTE: Larger machines are equipped with extra friction and spacer disks.
MS-2679S

357 of 1161
Figure 40-50-9 1
P-95444
Remove and replace the O-rings (Item 1) [Figure 40-50-

P-77295 11] from the brake case.
Figure 40-50-12
With the brake case on a work surface, remove the brake
cam lever (Item 1) [Figure 40-50-9].
2
Figure 40-50-10
1
P-77298
Remove the cam plate (Item 1) [Figure 40-50-12].

P-77296
Assembly: The four holes (Item 2) [Figure 40-50-12] in
all plates must be aligned.
Assembly: The pin (Item 1) on the brake cam lever must
be installed into the groove (Item 2) [Figure 40-50-10] in NOTE: On later model machines the cam plate (Item
the cam plate. 1) [Figure 40-50-12] may appear different, but
the procedure is the same.

358 of 1161
Figure 40-50-13
1
P-77301
Remove the friction plate (Item 1) [Figure 40-50-15].

P-77299
Figure 40-50-16
Figure 40-50-14
P-77305
Remove the snap ring (Item 1) [Figure 40-50-16].

P-77300
Remove the spacer plate (Item 1) [Figure 40-50-14].

359 of 1161
Figure 40-50-17
P-77310
1
Clean the gasket mounting surface [Figure 40-50-19].

P-77306
Remove the shaft / bearing assembly (Item 1) [Figure

40-50-17] from the brake case.
Figure 40-50-18
2 1
P-77310
Remove the bearing (Item 1) from the shaft (Item 2)

[Figure 40-50-18].

360 of 1161
Inspection
Figure 40-50-20
B-23595
Seat the ball into the cam plate and measure the height
B-23596 of the ball from the bottom of the cam plate [Figure 40-
50-22]. If the measured value exceeds the allowable
limit, replace the cam plate and ball.
Measure the thickness of the brake disc [Figure 40-50-
20]. If the measured value exceeds the allowable limit, Sect. Specified Allowable Limit
replace the brake disc.
Height of ball 0.7909 - 0.7913 in. 0.7898 in.
from bottom of (20,09 - 21,1 mm) (20,06 mm)
Sect. Specified Allowable Limit
cam plate
Thickness of 0.181 - 0.189 in. 0.165 in.
brake disc (4,60 - 4,80 mm) (4,2 mm) Figure 40-50-23
Figure 40-50-21
P-77309
B-23597
Inspect the axle shaft teeth for broken or damaged teeth
[Figure 40-50-23]. Replace axle shaft if damaged.
Measure the thickness of the brake plate [Figure 40-50-
21]. If the measured value exceeds the allowable limit,
replace it.
Sect. Specified Allowable Limit

Thickness of 0.1000 - 0.1047 in. 0.0433 in.
brake plate (2,54 - 2,66 mm) (2,10 mm)

361 of 1161
362 of 1161
TRANSMISSION (HST MODELS)
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Excessive or unusual noise at all times 1, 2, 3, 4
Noise while turning 3, 5, 6
Differential lock can not be engaged 7, 8
Differential lock pedal does not return 9
Pinion or ring gear tooth broken 4, 10, 11, 12, 13
Pinion teeth pitted 4, 14
Worn or pitted bearings 4, 10, 11, 12, 13
Oil leakage 4, 15, 16, 17, 18
Pinion teeth fatigue 4, 19
Side gear spline worn 4, 19
Thrust washer surface worn 4
Range shifting lever does not shift into gear 3, 4, 20

1. Improper backlash between pinion shaft and pinion gear
2. Improper backlash between pinion shaft and differential side gear
3. Worn bearings
4. Insufficient, improper, or contaminated transmission oil
5. Differential pinions or side gears worn or damaged
6. Differential lock does not disengage
7. Differential lock shift fork damaged
8. Differential lock arm damaged
9. Differential lock pedal return spring weakened or damaged.
10. Excessive gear load
11. Incorrect gear adjustment (excessive play)
12. Pinion nut loose
13. Incorrect gear adjustment (insufficient play)
14. Excessive use
15. Operation at high temperature
16. Low oil level
17. Normal wear
18. Lip seal damaged
19. Overloaded continuously
20. Start tractor move range shifting lever to “N”, press the travel pedal to forward or reverse and release pedal to
neutral, move range shifting lever to desired range.

363 of 1161
TRANSMISSION (HST MODELS) (CONT’D)
Middle Case / PTO Clutch Group Parts Identification
1. Bearing
2. Shaft
3. 34 Gear
4. Snap Ring
5. Splined Hub
6. Washer
7. Spring 14
8. Plate 13
9. Friction Plate 11
10. Pressure Plate 12
11. O-Ring 11
12. Piston
13. Ring 9, 10
14. Stopper Plate
15. Clutch Housing 8
16. Seal 4
17. Pin 7
18. Bearing Cover 6
4
19. Bolt 1 17 18
5
4
1
3
2
1
19
4
6 17
1
16
16
15
MS-2690S

364 of 1161
TRANSMISSION (HST MODELS) (CONT’D) Figure 40-60-3
Middle Case / PTO Clutch Group Disassembly
Remove the hydrostatic pump. (See Removal And

Remove the modulator valve. (See Removal And

Figure 40-60-1
P-84067
Separate and remove the middle case [Figure 40-60-3].
Figure 40-60-4
P-84063
1
Use a lifting chain and hoist to lift and support the middle
case [Figure 40-60-1].
Figure 40-60-2
1
P-84070
1
Remove the coupler (Item 1) [Figure 40-60-4] from the
shaft.
P-84066
Remove the mounting bolts and nuts (Item 1) [Figure 40-

60-2].

365 of 1161

(Cont’d) 2
Figure 40-60-5
1 1 1
1
P-84073

1 [Figure 40-60-7] from the PTO clutch bearing.
P-84071
Figure 40-60-8

bearing cover.
Figure 40-60-6
P-84075
1
Press the PTO clutch assembly from bearing cover
[Figure 40-60-8].
P-84072
Install two 6 mm bolts (Item 1) [Figure 40-60-6] in the

position shown, tighten the bolts equally to remove the
cover.

366 of 1161

(Cont’d) 1
Figure 40-60-9
P-84079
Remove the bearing (Item 1) [Figure 40-60-11] from the

cover.
P-84077
Figure 40-60-12
Remove the bearing (Item 1) [Figure 40-60-9]. 1

Figure 40-60-10
P-84080
Remove the two seals (Item 1) [Figure 40-60-12] from

P-84078 the clutch assembly.

367 of 1161

(Cont’d)
Figure 40-60-13
1
1
P-84084
P-84105 Repeat the above procedures to remove the remaining

pressure and friction plates.
Remove the snap ring (Item 1) [Figure 40-60-13]. Figure 40-60-16
Figure 40-60-14
P-84086
P-84103
Remove the splined hub (Item 1) [Figure 40-60-16] from
the clutch assembly.
Remove the pressure plate (Item 1) [Figure 40-60-14].

368 of 1161
Middle Case / PTO Clutch Group Disassembly 2

(Cont’d)
1
Figure 40-60-17
P-84371
Install the tool (Item 1) and nut (Item 2) onto the clutch
pack, tighten the nut and remove the snap ring (Item 3)
P-84087 [Figure 40-60-19] from the grove.
Remove the tool from the clutch pack.

Figure 40-60-20
Figure 40-60-18
P-84090
P-84370
Remove the washer (Item 1) and spring (Item 2) [Figure

Install a 3/4 x 5 in. (M 20 x 130 mm) bolt (Item 1) and 40-60-20].
washer (Item 2) [Figure 40-60-18] into the clutch pack as
shown.

369 of 1161

(Cont’d) 1
Figure 40-60-21
1 2
P-84097
Remove the ring (Item 1) and stop plate (Item 2) [Figure

40-60-23] from the clutch housing.
P-84093
Figure 40-60-24
Remove the piston (Item 1) [Figure 40-60-21] from the

clutch housing.
Figure 40-60-22 1
P-84106
1
the PTO countershaft bearing.
P-84094

the piston.

370 of 1161

(Cont’d)
Figure 40-60-25
1
P-84112

housing.
P-84108
Figure 40-60-28
Using a slide hammer arrangement, remove the PTO

countershaft / bearing (Item 1) [Figure 40-60-25].
1
Figure 40-60-26
P-84109
1
Remove the bearing (Item 1) from the shaft (Item 2)
[Figure 40-60-28].
P-84111
Remove the 34 gear (Item 1) [Figure 40-60-26].

371 of 1161
Middle Case / PTO Clutch Group Inspection
Figure 40-60-29
P-84110
1
Inspect the shaft splines for wear or damage [Figure 40-

P-84136 60-31].
Figure 40-60-32
Inspect the pressure plates for wear or cracks, make sure
the dampening rubbers (Item 1) [Figure 40-60-29] are in
good condition.
Figure 40-60-30
P-84095
Inspect the piston for wear or damage [Figure 40-60-32].
P-84137
Inspect the friction plates for wear or damage [Figure 40-

60-30].

372 of 1161
Middle Case / PTO Countershaft Group Parts Identification

1. Roll Pin
2. Coupler
3. Seal
4. Bearing
5. 15 Gear
6. Countershaft
4
6
5
4
3
2
MS-2691S

373 of 1161
Middle Case / PTO Countershaft Group Disassembly
Figure 40-60-33
P-84115
1
P-84113
Figure 40-60-36
Remove the PTO countershaft (Item 1) [Figure 40-60-

33].
1
Figure 40-60-34
P-84119

housing.
P-84118

shaft.

374 of 1161
Middle Case / PTO Countershaft Group Inspection
Figure 40-60-37
P-84117
Inspect the gear (Item 1) [Figure 40-60-37] for worn or

cracked teeth.
If any of the gears are damaged, replace all the gears.

One damaged gear can cause a microscopic fatigue
crack in mating teeth and cause premature failure after
servicing.
Figure 40-60-38
P-84116
Inspect the shaft splines (Item 1) [Figure 40-60-38] for

wear or damage.

375 of 1161
Middle Case / 23 Gear Shaft Group Parts Identification
1. Bearing
2. 23 Gear Shaft
1
1
MS-2692S

376 of 1161
Middle Case / 23 Gear Shaft Group Disassembly
Figure 40-60-39
P-84122

P-84120
Middle Case / 23 Gear Shaft Group Inspection
Remove the 23 gear shaft assembly (Item 1) [Figure 40- Figure 40-60-42
60-39] from the housing.
Figure 40-60-40 1
P-84123
P-84121 Inspect the gear (Item 1) and shaft splines (Item 2)

[Figure 40-60-42] for wear or damage.
Remove the bearing (Item 1) [Figure 40-60-40]. If any of the gears are damaged, replace all the gears.
servicing.

377 of 1161
Middle Case / Countershaft Group Parts Identification

1. Coupler
2. Pin
3. Seal
4. Bearing
5. 22 Gear
6. Countershaft
4
6
5
4
MS-2689S

378 of 1161
Middle Case / Countershaft Group Disassembly
Figure 40-60-43
1
1
P-834127

P-84124
Figure 40-60-46
Remove the countershaft assembly (Item 1) [Figure 40-

Figure 40-60-44 1
P-84128
P-84126

shaft.

379 of 1161
TRANSMISSION (HST MODELS) (CONT’D) Middle Case / Countershaft Group Inspection
Middle Case / Countershaft Group Disassembly Figure 40-60-49

(Cont’d)
Figure 40-60-47
1
P-84129
P-84131 Inspect the gear [Figure 40-60-49] for worn or cracked

teeth.
Remove the seal (Item 1) [Figure 40-60-47] from the Figure 40-60-50
housing.
Figure 40-60-48
P-84130
P-84132 Inspect the shaft splines (Item 1) [Figure 40-60-50] for

wear or damage.
Remove any gasket material from the mounting surface

(Item 1) [Figure 40-60-48] on the housing.

380 of 1161
Bearing Cover / Shift Links Parts Identification
1. Roll Pin
2. Linkage
3. Bolt
4. Retainer Plate
5. O-Ring
6. Shift Arm
7. Ball
8. Spring
9. Shift Fork
10. Shift Rod
11. Bearing Cover
1
2
4
5
5
2
6 6 4
3
7 9 7
1
8 8
10
1
9
10
11
MS-2713S

381 of 1161
Bearing Cover / Shift Links Disassembly
Figure 40-60-51
P-84204
1
Move the mid PTO shift arm (Item 1) [Figure 40-60-53]

P-84201 outward.
Figure 40-60-54
Remove the roll pin (Item 1) and mid PTO shift linkage
(Item 2) [Figure 40-60-51].
2
Figure 40-60-52
1
1
P-84205
Remove the roll pin (Item 1) and range shift linkage (Item
P-84203 2) [Figure 40-60-54].
Remove the bolt (Item 1) and retainer plate (Item 2)

[Figure 40-60-52].

382 of 1161
Bearing Cover / Shift Links Disassembly (Cont’d)
Figure 40-60-55
1 1
2 1
1
P-84209
1
Remove the six bolts (Item 1) [Figure 40-60-57].
P-84207
Figure 40-60-58

[Figure 40-60-55]. 1
Figure 40-60-56
P-84210
Remove the bearing cover assembly (Item 1) [Figure 40-

P-84208
Move the range shift arm (Item 1) [Figure 40-60-56]

outward.

383 of 1161
Figure 40-60-59 1
P-84302
Remove the mid PTO shift arm (Item 1) [Figure 40-60-

P-84212 61] from the housing.
Figure 40-60-62
Remove the mid PTO fork rod assembly from the cover
[Figure 40-60-59].
Figure 40-60-60
P-84303
3
P-84301 shift arm.
Remove the fork (Item 1) from the selector rod (Item 2).
When the selector rod is pulled from the fork it will slide
through each shifting range on the selector rod. When
the fork is removed, cover the hole (Item 3) [Figure 40-
60-60] in the fork to retain the ball and spring.

384 of 1161
Figure 40-60-63 1
1
2
3
P-84304
Remove the fork (Item 1) from the selector rod (Item 2).
P-84213 When the selector rod is pulled from the fork it will slide
through each shifting range on the selector rod. When
the fork is removed, cover the hole (Item 3) [Figure 40-
Remove the roll pin (Item 1) [Figure 40-60-63]. 60-65] in the fork to retain the ball and spring.
Figure 40-60-64 Figure 40-60-66
1 1
P-84214 P-84306
Remove the range shift fork rod assembly (Item 1) Remove the range shift arm (Item 1) [Figure 40-60-66]
[Figure 40-60-64] from the cover. from the housing.

385 of 1161
Figure 40-60-67
1
P-84307
Inspect the shifting arm (Item 1) [Figure 40-60-69] for

P-84307 wear or damage.

shift arm.
Bearing Cover / Shift Links Inspection
Figure 40-60-68
P-84308

wear or damage.

386 of 1161
Pinion Shaft Group Parts Identification
1. Bolt
2. Bearing Cover
3. Nut
4. Bearing Case
5. Shim
6. Bearing Cover
7. Bearing
8. Spacer 13
9. 24 Gear
8
10. Snap Ring 13
11. Thrust Collar 12
12. 30 Gear Shaft
13. Needle Bearing 11
14. 36 Gear 10
15. Shifter Gear 9
16. Spline Boss 8
17. 18 Gear 7
18. Pinion Shaft 8
8
6 7
5
4
3
2 18
1
7
10
11
13
13
17
10
16
10
15
10
14
7
10
7
MS-2716S

387 of 1161
Pinion Shaft Group Disassembly
Figure 40-60-70
1 1
P-84219
Remove the bearing cover (Item 1) [Figure 40-60-72].

P-84215
Figure 40-60-73
Remove the nut (Item 1) [Figure 40-60-70].
Figure 40-60-71
1 1
1
P-84220
Tap on the end of the shaft with a soft faced hammer

P-84218 [Figure 40-60-73].
Remove the three bolts and lock washers (Item 1)

[Figure 40-60-71].

388 of 1161
Pinion Shaft Group Disassembly (Cont’d)
Figure 40-60-74
1 1 2
P-84224
Remove the two bearing races (Item 1) and spacer (Item

P-84221 2) [Figure 40-60-76] from the bearing case.
Figure 40-60-77
Remove the shim [Figure 40-60-74].
Figure 40-60-75
P-84225
P-84223 Using a puller remove the bearing and spacer from the
shaft [Figure 40-60-77].
Remove the pinion shaft assembly [Figure 40-60-75]

from the bearing cover.
NOTE: The bearing case (Item 1) [Figure 40-60-75] will

not be removed at this time.

389 of 1161
Figure 40-60-78
1 P-84231
Remove the gear assembly from the shaft [Figure 40-60-

P-84227 80].
Figure 40-60-81
Remove the spacer (Item 1) and 24 gear (Item 2) [Figure
Figure 40-60-79
2
1
1
P-84233

P-84229
Remove the snap ring (Item 1) and thrust collar (Item 2)

[Figure 40-60-79].

390 of 1161
Figure 40-60-82
2 1
P-84239

P-84234 30 gear shaft.
Figure 40-60-85
Remove the 36 gear (Item 1) from the 30 gear (Item 2)
[Figure 40-60-82].
Figure 40-60-83
1
1
1
2
1
P-84241
Remove the two needle bearings (Item 1) and spacer

P-84235 (Item 2) [Figure 40-60-85] from the shaft.

[Figure 40-60-83].

391 of 1161

1
Figure 40-60-86
P-84247
Remove the spline boss (Item 1) [Figure 40-60-88].

P-84243
Figure 40-60-89
Remove the shifter gear (Item 1) [Figure 40-60-86].
Figure 40-60-87 1
1 P-84249

P-84246

392 of 1161
Figure 40-60-90
P-84253
Remove the thrust collar (Item 1) [Figure 40-60-92].

P-84251
Figure 40-60-93

the shaft.
Figure 40-60-91 1
1 P-84254
P-84252
Remove the two needle bearings (Item 1) [Figure 40-60-

91].

393 of 1161
TRANSMISSION (HST MODELS) (CONT’D) Pinion Shaft Group Inspection
Pinion Shaft Group Disassembly (Cont’d) Figure 40-60-95
Figure 40-60-94
P-84237
P-84255
Inspect the gears for worn or cracked teeth [Figure 40-
60-95].
If any of the gears are damaged, replace all gears. One
damaged gear can cause a microscopic fatigue crack in
mating teeth and cause premature failure after servicing.
Figure 40-60-96
P-84256
Inspect the pinion gear (Item 1) and shaft splines (Item 2)

[Figure 40-60-96] for broken or damaged teeth.

394 of 1161
PTO Shaft Group Parts Identification
1. Snap Ring
2. Washer
3. 28 Gear
4. Bearing Cover
5. Bearing
6. Thrust Collar 6
7. 20/27 Gear
8. Needle Bearing
9. Shaft 1
10. Coupler
4
5
2
1
10
6
8
MS-2712S

395 of 1161
PTO Shaft Group Disassembly
Figure 40-60-97
1
1
P-84261

P-84259
Figure 40-60-100

the PTO shaft.
Figure 40-60-98
1
1
P-84264
Remove the PTO shaft assembly (Item 1) [Figure 40-60-

100] from the backside of the bearing cover.
P-84260
Remove the washer (Item 1) [Figure 40-60-98].

396 of 1161
PTO Shaft Group Disassembly (Cont’d)
Figure 40-60-101
P-84267
1
P-84265
Figure 40-60-104
Remove the coupler (Item 1) [Figure 40-60-101].
Figure 40-60-102 1
P-84268
Remove the second snap ring (Item 1) [Figure 40-60-

P-84266 104] from next to the thrust collar.
Using a puller, remove the two bearings (Item 1) [Figure

40-60-102].

397 of 1161
PTO Shaft Group Disassembly (Cont’d)
Figure 40-60-105 1
P-84272

P-84269 107].
Figure 40-60-108
Figure 40-60-106 1
P-84273
P-84270 Remove the thrust collar (Item 1) [Figure 40-60-108].
Remove the 20 / 27 gear (Item 1) [Figure 40-60-106]

from the shaft.

398 of 1161
TRANSMISSION (HST MODELS) (CONT’D) PTO Shaft Group Inspection
PTO Shaft Group Disassembly (Cont’d) Figure 40-60-110
Figure 40-60-109
1
1
P-84271
P-84274
Inspect the gears for worn or cracked teeth (Item 1)
[Figure 40-60-110].
Figure 40-60-111
P-84275

damage.

399 of 1161
Range Shifter Shaft Group Parts Identification
1. Bearing Cover
2. Roll Pin
3. Coupler
4. Bearing
5. 23 Gear
6. 16 - 34 Gear Shaft
6
3
5
4
MS-2708S

400 of 1161
Range Shifter Shaft Group Disassembly
Figure 40-60-112 1
P-84280
Remove the 23 gear (Item 1) [Figure 40-60-114] from

P-84277 the shaft.
Figure 40-60-115
Remove the shaft assembly (Item 1) [Figure 40-60-112]
Figure 40-60-113
P-84282
Remove the bearing from the end of the shaft [Figure

P-84279 40-60-115].
Using a puller, remove the bearing from the shaft [Figure

40-60-113].

401 of 1161
Range Shifter Shaft Group Inspection
Figure 40-60-116
P-84281

cracked teeth.


402 of 1161
PTO 15 Gear Shaft Group Parts Identification
1. PTO 15 Gear Shaft

2. Bearing
3. Snap Ring
4. Spacer
5. Shift Assembly
6. Spline Boss
7. 28 Gear
8. Thrust Collar
8
7
3
6
5
4
3
MS-2717S

403 of 1161
PTO 15 Gear Shaft Group Disassembly
Figure 40-60-117
1
1
P-84288

P-84287
Figure 40-60-120
Using a puller, remove the bearing (Item 1) [Figure 40-

60-117] from the shaft.
Figure 40-60-118
1 P-84290
Remove the shift assembly (Item 1) [Figure 40-60-120].
P-84300

404 of 1161
PTO 15 Gear Shaft Group Disassembly (Cont’d)
Figure 40-60-121
1
P-84293

P-84291
Figure 40-60-124
Figure 40-60-122
1
P-84294

P-84292

405 of 1161
TRANSMISSION (HST MODELS) (CONT’D) PTO 15 Gear Shaft Group Inspection
PTO 15 Gear Shaft Group Disassembly (Cont’d) Figure 40-60-127
Figure 40-60-125
P-84289
P-84295
60-127].
from the bearing cover. If any of the gears are damaged, replace all gears. One
Figure 40-60-126 mating teeth and cause premature failure after servicing.
Figure 40-60-128
1
1
2
P-84296
P-84297
Inspect the shaft splines (Item 1) and gear (Item 2)

[Figure 40-60-128] for damage or wear.

406 of 1161
Idle Shaft Group Parts Identification
1. Nut
2. Bearing
3. Spacer
4. Snap Ring
5. 26 Gear
6. Spacer Washer
7. Spring
8. 23 Shift Gear
9. O-Ring
10. Shaft
11. Seal Ring
7
6
5
2
4
3
2
1
11
2
9
10
MS-2710S

407 of 1161
Idle Shaft Group Disassembly
Figure 40-60-129
1
1
P-84312

P-84309 60-131].
Figure 40-60-132
Remove the idle shaft assembly (Item 1) [Figure 40-60-
Figure 40-60-130
1
P-84313
Remove the spacer [Figure 40-60-132].

P-84311
Remove the nut (Item 1) [Figure 40-60-130] from the

shaft.

408 of 1161
Idle Shaft Group Disassembly (Cont’d)
Figure 40-60-133
1 2
P-84316
Remove the bearing (Item 1) from the 26 gear (Item 2)

P-84314 [Figure 40-60-135].
Figure 40-60-136
Figure 40-60-134
1 1
P-84318
P-84315 Remove the spacer (Item 1) [Figure 40-60-136].

409 of 1161
Figure 40-60-137 1
P-84321

P-84319
Figure 40-60-140
Figure 40-60-138
1
P-84322

P-84320 the end of the shaft.

the shaft.

410 of 1161
Figure 40-60-141
P-84323

411 of 1161
Idle Shaft Group Inspection
Figure 40-60-142
B-23842
Measure the free length of the spring [Figure 40-60-

P-84324 144]. If it measures less than 2.126 in. (54 mm) it must
be replaced.

wear or damage.
Figure 40-60-143
P-84325

cracked teeth.

412 of 1161
Front Wheel Drive Shaft Group Parts Identification
1. Oil Seal
2. Snap Ring
3. Bearing
4. Coupler
5. Roll Pin
6. Shaft
7. 22 Gear
4
2
3
2
2
1
7
2
MS-2711S

413 of 1161
Front Wheel Drive Shaft Group Disassembly
Figure 40-60-145
1
P-84330
Remove the bearing (Item 1) [Figure 40-60-147] from

P-84328 the shaft.
Figure 40-60-148
Figure 40-60-146
1
1
P-84331
P-84329 Reposition the snap ring (Item 1) [Figure 40-60-148].
Remove the front wheel drive shaft assembly (Item 1)

[Figure 40-60-146] from the housing.

414 of 1161
Front Wheel Drive Shaft Group Disassembly (Cont’d)
Figure 40-60-149
1
P-84334

P-84332 the shaft.
Figure 40-60-150
P-84333
Remove the gear (Item 1) [Figure 40-60-150].

415 of 1161
Front Wheel Drive Shaft Group Inspection
Figure 40-60-152
P-84335

wear or damage.
Figure 40-60-153
P-77615

cracked teeth.

416 of 1161
Rear PTO Shaft Group Parts Identification
1. Snap Ring
2. O-Ring
3. Nut
4. Bearing
5. Oil Seal
6. Collar
7. Bearing Case
8. Bolt
9. Shaft
10. Sleeve
11. Oil Seal
6
5
4
1
3
2
1
11
10
8
7
MS-2709S

417 of 1161
Rear PTO Shaft Group Disassembly
Figure 40-60-154
1
1 1
P-84343

P-84339
Figure 40-60-157

the rear PTO cover.
Figure 40-60-155
P-84344

the cover.
P-84342
Remove the PTO assembly from the housing [Figure 40-

60-155].

418 of 1161
Rear PTO Shaft Group Disassembly (Cont’d)
Figure 40-60-158
P-84349

P-84345 the shaft.
Figure 40-60-161
Remove the cover (Item 1) from the shaft (Item 2)
[Figure 40-60-158].
Figure 40-60-159
P-84351
Unstake and remove the nut (Item 1) [Figure 40-60-161].

P-84348
Remove the two oil seals (Item 1) [Figure 40-60-159]

from the cover.

419 of 1161
TRANSMISSION (HST MODELS) (CONT’D) Rear PTO Shaft Group Inspection
Rear PTO Shaft Group Disassembly (Cont’d) Figure 40-60-163
Figure 40-60-162
1
1
1
P-84353
P-84352
wear or damage.
from the shaft.

420 of 1161
Differential Parts Identification
1. Bearing Case (Right Side)

2. Bearing
3. Shims
4. Bearing Case (Left Side)
5. Differential Lock
6. Differential Carrier
7. Differential Cover
8. Cup Washer
9. Washer
10. Side Gear 18
11. Pinion Gear 19
12. Key
13. Pinion Shaft
14. Pinion Shaft (Short)
15. Ring Gear
16. Bolt
17. Shaft 15
18. Seal
19. Fork
20. Dowel Pin
5
16 8
9 11
11 8
13 12
6
20 10
14
12 9
2 1
3 8
7
14
10 16
11
11
16 8
3
3 4
3
2
18 16
17
MS-2718S

421 of 1161
Differential Disassembly
Figure 40-60-164
1
1
2
P-84356

P-84354
Figure 40-60-167
Remove the spring pin (Item 1) and washer (Item 2)

[Figure 40-60-164]. 1
Figure 40-60-165
P-84357
Remove the shaft assembly (Item 1) [Figure 40-60-167].
P-84355
Remove the pin [Figure 40-60-165].

422 of 1161
Differential Disassembly (Cont’d)
Figure 40-60-168
1 1
1
P-84360
Remove the four bolts (Item 1) [Figure 40-60-170] (both

P-84358 sides).
NOTE: Mark the bearing cases left or right for correct

Remove the seal (Item 1) [Figure 40-60-168] from both assembly.
sides of the housing.
Figure 40-60-171
Figure 40-60-169
1
P-84361
P-84359
Record the number and location of the shims and remove

Remove the differential lock fork (Item 1) [Figure 40-60- [Figure 40-60-171].
169].
Remove the bearing case (Item 1) [Figure 40-60-171]
(both sides).

423 of 1161
Figure 40-60-172
P-77512
Remove the inner bearing (Item 1) [Figure 40-60-174].

P-84362
Figure 40-60-175
Remove the differential assembly [Figure 40-60-172].
Figure 40-60-173
P-77513
Lift and remove the differential lock (Item 1) [Figure 40-

P-77509 60-175].
Support the differential assembly and remove the outer

bearing [Figure 40-60-173].

424 of 1161
Figure 40-60-176
1
P-77517
Remove the eight bolts (Item 1) [Figure 40-60-178] from

P-77510 the cover.
Figure 40-60-179
Turn the differential assembly over and remove the eight
ring gear mounting bolts (Item 1) [Figure 40-60-176].
Figure 40-60-177
1
P-77518

P-77516
Turn the differential assembly over and remove the ring

gear (Item 1) [Figure 40-60-177].

425 of 1161
Figure 40-60-180
P-77522
Using a brass drift, remove the short pinion shaft (Item 1)

P-77519 [Figure 40-60-182].
Figure 40-60-183
Figure 40-60-181 1
P-77525
P-775 Remove the pinion gear (Item 1) [Figure 40-60-183].
Remove the side gear (Item 1) [Figure 40-60-181].

426 of 1161
Figure 40-60-184
1
P-77533
Remove the two pinion gears / cup washers (Item 1)

P-77526 [Figure 40-60-186].
Figure 40-60-187
Remove the cup washer (Item 1) [Figure 40-60-184].
Figure 40-60-185 1
P-77534
P-77532 Remove the side gear (Item 1) [Figure 40-60-187].
Remove the long pinion shaft assembly (Item 1) [Figure

40-60-185].

427 of 1161
Figure 40-60-188
P-77535
Remove the washer (Item 1) [Figure 40-60-188] from the

side gear.

428 of 1161
Differential Inspection
1
Figure 40-60-189
P-77527
Inspect the cup washers (Item 1) [Figure 40-60-191] for

P-77373 wear or damage. Replace as needed.
Inspect the shifting fork wear surfaces (Item 1) [Figure

40-60-189].
Figure 40-60-190
P-77529
Inspect the pinion gear [Figure 40-60-190] for broken or

damaged teeth.
If either gear is damaged, replace both gears.

429 of 1161
Differential Assembly Clearance Factory 0.00197 - 0.00594 in.

between spec. (0.05 - 0.151 mm)
Figure 40-60-192 differential case Allowable 0.0138 in.
bore and limit (0,035 mm)
3 differential side
gear
Clearance Factory 1.59449 - 1.59646 in.

between spec. (40,5000 - 40,550 mm)
differential case Allowable 1.59008 - 1.59252 in.
bore and limit (40,388 - 40,450 mm)
differential side
gear
1 Clearance Factory 0.00197 - 0.00594 in.

2 between spec. (0,05 - 0,151 mm)
MS-2466S
differential case Allowable 0.0138 in.
cover bore and limit (0,035 mm)
Measure and record the inside diameter of the differential differential side
case (Item 1) and cover (Item 2) [Figure 40-60-192]. gear
Measure and record the differential side gear outside

Differential case Factory 1.5945 - 1.5969 in.
diameter (Item 3) [Figure 40-60-192].
cover bore I.D. spec. (40,500 - 40,562 mm)
Differential side Allowable 1.5910 - 1.5925 in.
gear bore O.D. limit (40,411 - 40,450 mm)
If the clearance exceeds the allowable limit, see chart

[Figure 40-60-193].
Figure 40-60-194
P-77534
Install the side gear (Item 1) [Figure 40-60-194] into the

housing.

430 of 1161
Differential Assembly (Cont’d)
Figure 40-60-195
2
1 1
P-77533
2
Install the two cup washers (Item 1) and pinion gears
MS-2467S (Item 2) [Figure 40-60-197] into the housing.
NOTE: Apply a small amount of assembly lube on the

Measure and record the outside diameter of the cup washers to help hold them in position.
differential pinion shaft (Item 1) [Figure 40-60-195].
Figure 40-60-198
Measure and record the inside diameter of the differential
pinion gear (Item 2) [Figure 40-60-195].
Figure 40-60-196
Clearance between Factory 0.0032 - 0.0040 in. 1

differential pinion spec. (0,081 - 0,102 mm)
shaft and Allowable 0.0098 in.
differential pinion limit (0,25 mm)
Differential pinion Factory 0.78579 - 0.78661 in.

shaft O.D. spec. (19,959 - 19,980 mm)
Differential pinion Allowable 0.78898 - 0.78980 in.
I.D. limit (20,040 - 20,061 mm) P-77527
If the clearance exceeds the allowable limit, see chart NOTE: The tang (Item 1) must fit in the notch in the
[Figure 40-60-196]. housing [Figure 40-60-198].
Replace as a set.

431 of 1161
Figure 40-60-199
1
1
P-77523
Make sure the key way (Item 1) [Figure 40-60-201] goes

P-77532 into the housing.
Repeat above procedure to install the final cup washer,

Install the long pinion shaft (Item 1) [Figure 40-60-199], pinion gear and short shaft.
followed by the two cup washers and pinion gears.
Figure 40-60-202
Figure 40-60-200
2 P-77539
P-77530
Position a magnetic base dial gauge on the housing, with

Install the short pinion shaft (Item 1) through the cup the tip of the gauge on the tooth of the differential pinion
washer (Item 2) and pinion gear (Item 3) [Figure 40-60- gear, hold the side gear and move the differential pinion
200]. back and forth to measure the backlash [Figure 40-60-
202].
NOTE: The end of the short pinion shaft must go into
the hole in the long shaft (Item 4) [Figure 40-
60-200] fully.

432 of 1161
If the measurement is not within the allowable limit of:

0.001 - 0.012 in. (0,15 - 0,30 mm) adjust the differential
side gear washer.
Figure 40-60-203 1
P-77519
Install the washer (Item 1) [Figure 40-60-205].
Figure 40-60-206
P-77617
1
Select the correct differential side gear washer [Figure
40-60-203] from the selection below:
Thickness of differential side gear washers:

0.059 in. (1,5 mm)
0.063 in. (1,6 mm)
0.067 in. (1,7 mm)
Figure 40-60-204 P-77618
1 Install the cover (Item 1) [Figure 40-60-206] onto the

housing.
P-77521
Install the side gear (Item 1) [Figure 40-60-204].

433 of 1161
Figure 40-60-207
1
P-77510
Apply Loctite® #270 or equivalent to the eight bolts (Item

P-77517 1) [Figure 40-60-209] and tighten to 51 - 65 ft.-lb. (69 -
88 N•m) torque in a criss cross pattern.
Apply Loctite® #270 or equivalent to the eight bolts (Item Figure 40-60-210
1) [Figure 40-60-207] and tighten to 36 - 41 ft.-lb. (48 -
Figure 40-60-208 1
P-77513
Install the differential lock (Item 1) [Figure 40-60-210].

P-77516
Install the ring gear (Item 1) [Figure 40-60-208] onto the

differential assembly.
Carefully turn the differential assembly / ring gear over.

434 of 1161
Figure 40-60-211
P-84363
Install the differential assembly into the housing [Figure

P-77619 40-60-213].
Figure 40-60-214
Install the bearing (Item 1) [Figure 40-60-211] until it is
fully seated. 1
Figure 40-60-212
2 2
P-84361
Install the bearing cases (Item 1) [Figure 40-60-214] (as

P-77620 marked earlier) to support the differential assembly.
Install the shim pack (Item 2) [Figure 40-60-214]

Install the bearing (Item 1) [Figure 40-60-212] until it is (removed earlier) behind the bearing cases as marked
fully seated. earlier.

435 of 1161
Figure 40-60-215
1
1
1
P-77468
Install a new seal (Item 1) [Figure 40-60-217] on both

P-84360 sides of the housing.
Figure 40-60-218
tighten to 36 - 41 ft.-lb. (48 - 56 N•m) torque (both sides).
Figure 40-60-216
P-84359
Install the differential lock fork (Item 1) [Figure 40-60-

P-84360 218] onto the differential lock assembly (as shown).
Using a light rope make two or three wraps around the

differential shift and connect the other end to a spring
scale [Figure 40-60-216].
Pull up on the scale to measure the rolling force. The

value is 2.9 - 4.7 ft.-lb. (0.4 - 0.65 kgf-m)
If the rolling force is over the specified value, increase the

amount of shims, if it is below the specified value,
decrease the amount of shims (Item 2) [Figure 40-60-
214 on Page 40-60-73].

436 of 1161
Figure 40-60-219
2 1
P-84354
Install the pin (Item 1) and spring pin / washer (Item 2)

P-84357 [Figure 40-60-221].
Install the shaft (Item 1) into the housing and through the
differential lock fork (Item 2) [Figure 40-60-219].
Figure 40-60-220
P-84356
Install the roll pin (Item 1) [Figure 40-60-220].

437 of 1161
Rear PTO Shaft Group Assembly
Figure 40-60-222
1
P-84349

P-84352
Figure 40-60-225
Install the two bearings (Item 1) [Figure 40-60-222] onto

the shaft.
1
Figure 40-60-223
P-84348
Install the two oil seals (Item 1) [Figure 40-60-225] into

the cover.
P-84350
Install the nut (Item 1) [Figure 40-60-223] and tighten to

109 - 145 ft.-lb. (147 - 196 N•m) torque.
After the nut is torqued, stake the nut to the shaft (Item 2)
[Figure 40-60-222].

438 of 1161
Rear PTO Shaft Group Assembly (Cont’d)
Figure 40-60-226
2
1
P-84343

P-84345 cover.
Figure 40-60-229
Lubricate the oil seals (Item 1) [Figure 40-60-225 on
Page 40-60-76] and install the cover (Item 1) onto the
shaft (Item 2) [Figure 40-60-226].
2
2
Figure 40-60-227
1
2
2
P-84339
1 Apply gasket eliminator to the mounting surface and

install the PTO assembly (Item 1) into the housing. Install
P-84344 the four bolts (Item 2) [Figure 40-60-229].

439 of 1161
Front Wheel Drive Shaft Group Assembly
Figure 40-60-230
1
P-84337
Press the bearing (Item 1) [Figure 40-60-232] onto the

P-84367 shaft until it is next to the gear.
Figure 40-60-233
Install the snap ring (Item 1) [Figure 40-60-230] into the
groove.
Figure 40-60-231
1
1
P-84338

P-84366 shaft until fully seated.
Install the gear (Item 1) [Figure 40-60-231] onto the

shaft.

440 of 1161
Front Wheel Drive Shaft Group Assembly (Cont’d)
Figure 40-60-234
P-84329
Install the shaft assembly (Item 1) [Figure 40-60-234]

into the housing.
Figure 40-60-235
P-84328
Install the coupler (Item 1) [Figure 40-60-235].

441 of 1161
Idle Shaft Group Assembly
Figure 40-60-236 1
1 P-84321
Lightly lubricate with oil and install the two O-rings (Item
P-84326 1) [Figure 40-60-238].
Figure 40-60-239
Install the bearing (Item 1) [Figure 40-60-236] onto the
shaft until fully seated.
1
Figure 40-60-237
P-84320
Install the 23 gear (Item 1) [Figure 40-60-239] onto the

P-84322 shaft.
Apply a small amount of assembly lube onto the seals

(Item 1) [Figure 40-60-237] and install.

442 of 1161
Idle Shaft Group Assembly (Cont’d)

2
Figure 40-60-240
3
1 1
P-84315
Install the bearing (Item 1) into the 26 gear (Item 2) and

P-84319 retain with the snap ring (Item 3) [Figure 40-60-242].
Figure 40-60-243
Install the spring (Item 1) [Figure 40-60-240].
Figure 40-60-241
P-84327
2
P-84318 Press the 26 gear (Item 1) [Figure 40-60-243] onto the

shaft and align with the 23 gear.
Install the spacer plate (Item 1) onto the shaft with the
protrusion (Item 2) [Figure 40-60-241] positioned as
shown.

443 of 1161
Idle Shaft Group Assembly (Cont’d)
Figure 40-60-244
1
P-84309
Install the idle shaft assembly (Item 1) [Figure 40-60-

P-84313 246] into the housing.
Figure 40-60-245
P-84311

108 - 145 ft.-lb. (147 - 196 N•m) torque.
After the nut has been tightened, stake the nut into the
shaft groove.

444 of 1161
PTO 15 Gear Shaft Group Assembly
Figure 40-60-247 1
1
P-84294
Install the snap ring (Item 1) [Figure 40-60-249] onto the

P-84298 shaft.
Figure 40-60-250
Figure 40-60-248
1
P-84293
Install the spacer (Item 1) [Figure 40-60-250] onto the

P-84295 shaft.

into the bearing cover.

445 of 1161
PTO 15 Gear Shaft Group Assembly (Cont’d)
Figure 40-60-251
1
1
P-84288
Install the 28 gear (Item 1) [Figure 40-60-253].

P-84291
Figure 40-60-254
Install the spline boss (Item 1) and snap ring (Item 2)

[Figure 40-60-251].
Figure 40-60-252
1
2
P-84300
Install the thrust collar (Item 1) [Figure 40-60-254] with

the grooves facing the gear.
P-84290
Install the shift assembly (Item 1) [Figure 40-60-252]

onto the spline boss.
NOTE: The groove (Item 2) [Figure 40-60-252] must be

positioned as shown.

446 of 1161
PTO 15 Gear Shaft Group Assembly (Cont’d)
Figure 40-60-255
P-84286

shaft until it is fully seated.

447 of 1161
Range Shifter Shaft Group Assembly
Figure 40-60-256
1
1
P-84285

Figure 40-60-259
Figure 40-60-257
1
1
P-84277

P-84280 into the bearing cover.

shaft.

448 of 1161
PTO Shaft Group Assembly
Figure 40-60-260 1
P-84272
Install the two needle bearings (Item 1) [Figure 40-60-

P-84274 262] onto the shaft.
Figure 40-60-263
Figure 40-60-261
1 2
P-84270
2
Install the 20 / 27 gear (Item 1) [Figure 40-60-263] onto
P-84273 the shaft.
Install the thrust collar (Item 1) onto the shaft with the
grooves (Item 2) [Figure 40-60-261] in the position as
shown.

449 of 1161
PTO Shaft Group Assembly (Cont’d)
Figure 40-60-264
P-84267

P-84269 groove.
Figure 40-60-267
Install the thrust collar (Item 1) [Figure 40-60-264].
NOTE: The grooves in the thrust collar must go next

to the gear.
Figure 40-60-265
P-84276
1

the shaft until fully seated next to the snap ring.
P-84268

450 of 1161
PTO Shaft Group Assembly (Cont’d)
Figure 40-60-268 1
1 2
P-84259
Install the washer (Item 1) and snap ring (Item 2) [Figure

P-84264 40-60-270] onto the shaft.
Figure 40-60-271
Install the PTO shaft assembly (Item 1) [Figure 40-60-
268] into the backside of the bearing cover.
Figure 40-60-269
P-84265
1
P-84261

shaft.

451 of 1161
Pinion Shaft Group Assembly
Figure 40-60-272
1
2
P-84253
Install the thrust collar (Item 1) onto the pinion shaft with
P-84255 the grooves (Item 2) [Figure 40-60-274] positioned as
shown.
Install the bearing (Item 1) [Figure 40-60-272] onto the Figure 40-60-275
pinion shaft until fully seated.
Figure 40-60-273
P-84252
P-84254 Install the two needle bearing assemblies (Item 1)

[Figure 40-60-275].

groove in the pinion shaft.

452 of 1161
Pinion Shaft Group Assembly (Cont’d)
Figure 40-60-276 1
P-84247
Install the spline boss (Item 1) [Figure 40-60-278] onto

P-84251 the shaft.
Figure 40-60-279
step on the shaft.
Figure 40-60-277
P-84246

P-84249 groove.

453 of 1161
Figure 40-60-280
1
P-84238

Figure 40-60-283
Install the shifter gear (Item 1) [Figure 40-60-280].
Figure 40-60-281
2
1
1
2 P-84235
P-84241 Install the bearing (Item 1) and snap ring (Item 2) [Figure
40-60-283] onto the 36 gear.
Install the two needle bearings (Item 1) and spacer (Item

2) [Figure 40-60-281] onto the shaft.

454 of 1161
Figure 40-60-284 2
2 1
P-84229
3
Install the thrust collar (Item 1) and snap ring (Item 2)

P-84233 [Figure 40-60-286].
Figure 40-60-287
Install the 36 gear (Item 1) onto the 30 gear (Item 2) and
install the snap ring (Item 3) [Figure 40-60-284].
1
Figure 40-60-285
2
1
2
P-84227
install the 24 gear (Item 1) and spacer (Item 2) [Figure

P-84231 40-60-287].
Install the 36 / 30 gear assembly (Item 1) onto the shaft

(Item 2) [Figure 40-60-285].

455 of 1161
Figure 40-60-288
P-84223
Install the pinion shaft assembly into the housing and

P-84258 install the bearing (Item 1) [Figure 40-60-290].
Figure 40-60-291
shaft until fully seated. 1
Install the spacer.
Figure 40-60-289
1 1
P-84221
Install the shim (Item 1) [Figure 40-60-291] removed

earlier.
P-84224
Install the two bearing races (Item 1) and spacer (Item 2)

[Figure 40-60-289] into the bearing case.

456 of 1161
Figure 40-60-292
2
2
P-84218
Install the bearing cover (Item 1) and three bolts (item 2)

[Figure 40-60-292].
Figure 40-60-293
P-84215

108 - 145 ft.-lb. (147 - 196 N•m) torque.
shaft groove.

457 of 1161
Bearing Cover / Shift Links Assembly
Figure 40-60-294
1
1 2
P-84301
Apply grease into the hole in the fork. Install the spring
P-84307 and ball and slide the fork (Item 1) onto the selector rod
(Item 2) [Figure 40-60-296] in the position shown,
making sure the fork slides over the ball.
Install a new O-ring (Item 1) [Figure 40-60-292] onto the
shift arm. Figure 40-60-297
Figure 40-60-295
1
1
2
P-84214
P-84306
Install the range shift fork rod assembly (Item 1) into the
bearing cover (Item 2) [Figure 40-60-297].
Install the range shift arm (Item 1) [Figure 40-60-295]
into the housing.

458 of 1161
Bearing Cover / Shift Links Assembly (Cont’d)
Figure 40-60-298
P-84302
Install the mid PTO shift arm (Item 1) [Figure 40-60-300].


Figure 40-60-301
Figure 40-60-299
1 2
P-84304
P-84303
Install the O-ring (Item 1) [Figure 40-60-299] onto the and ball and slide the fork (Item 1) onto the selector rod
shift arm. (Item 2) [Figure 40-60-301] in the position shown,

459 of 1161

1 1
Figure 40-60-302
1
1
1
1
P-84209
Install the six bolts (Item 1) [Figure 40-60-304] and

P-84212 tighten.
Figure 40-60-305
Install the mid PTO fork and assembly into the cover
(Item 1) [Figure 40-60-302].
Figure 40-60-303
1
P-84208

P-84210 inward and align with the shifter fork.
Install the bearing cover assembly (Item 1) [Figure 40-

60-303] onto the housing.

460 of 1161
Figure 40-60-306
1
2 P-84204

Figure 40-60-309
Install the retainer plate (Item 1) and bolt (Item 2) [Figure
40-60-306].
Figure 40-60-307
2
1
1
2
P-84203

P-84205 40-60-309].
Install the range shift linkage (Item 1) and roll pin (Item 2)
[Figure 40-60-307].

461 of 1161

5
Figure 40-60-310
2
1
1
4
3
P-84201
Install the mid PTO shift linkage (Item 1) and roll pin (Item
2) [Figure 40-60-310].
Figure 40-60-311
B-23841
If the backlash is below the permissible range, decrease

the number of shims (Item 1) on the left side of the ring
gear, install the shims removed, on the right side of the
ring gear (Item 2) [Figure 40-60-312].
If the backlash is above the permissible range, decrease

the number of shims (Item 2) on the right side of the ring
gear, install the shims removed, on the left side of the
ring gear (item 1) [Figure 40-60-312].
Apply marking compound lightly over the teeth at three

P-84368 positions equally spaced on the pinion (Item 3) [Figure
40-60-312].
the tip of the gauge on the tooth of the ring gear, move Rotate the ring gear (Item 4) [Figure 40-60-312] while
the pinion shaft back and forth to measure the backlash pressing against the outer edge of the ring gear.
[Figure 40-60-311].
Repeat the above procedure on two or more locations on

the ring gear teeth to obtain an average value.
Check that the backlash is within the permissible range of

0.006 - 0.012 in. (0,15 - 0,25 mm).

462 of 1161
Figure 40-60-313
PE-2470S
If excessive contact on tooth toe and base [Figure 40-

MS-2468S 60-315], replace the shim (Item 5) with a thinner shim to
move the pinion shaft forward, to move the pinion gear
right, reduce the side shim (Item 2) and add shim of the
Correct Pattern: If the pinion/ring gear has been properly same thickness to the left side (Item 1) [Figure 40-60-
adjusted, wear pattern (contact) should be as shown 312 on Page 40-60-100].
[Figure 40-60-313].
Figure 40-60-314
MS-2469S
If excessive contact on tooth heal and tip [Figure 40-60-

314], replace the shim (Item 5) with a thicker shim to
move the pinion shaft backward, to move the pinion gear
left, reduce the side shim (Item 1) and add shim of the
same thickness to the right side (Item 2) [Figure 40-60-
312 on Page 40-60-100].

463 of 1161
Middle Case / Countershaft Group Assembly
Figure 40-60-316
1
1
P-84127

P-84131 shaft next to the gear until it is fully seated.
Figure 40-60-319
Install the seal (Item 1) [Figure 40-60-316] into the
housing.
Figure 40-60-317
1 1
P-84126
Install the bearing (Item 1) [Figure 40-60-319].

P-84128

shaft.

464 of 1161
Middle Case / Countershaft Group Assembly (Cont’d)
Figure 40-60-320
P-84124
Install the countershaft assembly (Item 1) [Figure 40-60-

320] into the housing.

465 of 1161
Middle Case / 23 Gear Shaft Group Assembly
Figure 40-60-321
1
P-84120
Install the 23 gear shaft assembly (Item 1) [Figure 40-60-


shaft next to the gear until it is fully seated.
Figure 40-60-322
P-84121
Install the bearing (Item 1) [Figure 40-60-322] until fully

seated.

466 of 1161
TRANSMISSION(HST MODELS) (CONT’D) Figure 40-60-326
Middle Case / PTO Countershaft Group Assembly
Figure 40-60-324 1
P-84118

Figure 40-60-327
Lightly lubricate the seal (Item 1) [Figure 40-60-324] and
install.
Figure 40-60-325
1
1
P-84113
Install the PTO countershaft (Item 1) [Figure 40-60-327]


shaft.
NOTE: The flange (Item 2) [Figure 40-60-325] must be


467 of 1161
Middle Case / PTO Clutch Group Assembly

3
Figure 40-60-328
2
2
1
P-84106
Align the 34 gear (Item 1) and install the shaft / bearing

P-84109 (Item 2) and snap ring (Item 3) [Figure 40-60-330].
Figure 40-60-331
Install the bearing (Item 1) onto the shaft (Item 2) [Figure
40-60-328] until fully seated.
Figure 40-60-329
P-84101
Install the stop plate (Item 1) and ring (Item 2) [Figure

P-84112 40-60-331] into the clutch housing.
Install the bearing (Item 1) [Figure 40-60-329] into the

housing.

468 of 1161
Middle Case / PTO Clutch Group Assembly (Cont’d)

2
Figure 40-60-332
1
1
P-84090
Install the spring (Item 1) and washer (Item 2) [Figure

P-84094 40-60-334].
Place snap ring into position on top of the washer.

Install new O-rings (Item 1) [Figure 40-60-332] into the
piston. Figure 40-60-335
Figure 40-60-333
P-84092
Lightly lubricate the O-rings on the piston and install into

the clutch housing [Figure 40-60-333]. P-84371
Install the tool (Item 1) and tighten the nut (Item 2) to

compress the spring enough to install the snap ring (Item
3) [Figure 40-60-335].

469 of 1161
Figure 40-60-336
1
P-84086
Install the spline hub (Item 1) [Figure 40-60-338] onto

P-84089 the bearing.
Make sure the snap ring (Item 1) [Figure 40-60-336] is

fully seated.
Figure 40-60-337
P-84087

clutch housing.

470 of 1161
Figure 40-60-339 2 2
1
P-84133
The PTO clutch pack consists of the following [Figure

40-60-339]
A. Seven friction plates

B. Four dampening plates (with rubber)
C. Three non-dampening plates (without rubber)
D. One cover plate (thick)
P-84134 &
Figure 40-60-340 P-84135
2 The dampening rubbers (Item 1) should face the same

direction except the last one on top (Item 2) [Figure 40-
60-341].
3
Figure 40-60-342
P-84082
Align and install the disks (Item 1) over the hub (Item 2)
[Figure 40-60-340] in the following order:
C-A-B-A-C-A-B-A-C-A-B-A-B-A [Figure 40-60-339]

P-84105
The cover plate (Item 3) [Figure 40-60-340] must be
installed with the groove facing down.

471 of 1161
Figure 40-60-343
1
1
P-84077

P-84080
NOTE: This bearing must be installed before the
clutch assembly.
Lightly lubricate and install the two seals (Item 1) [Figure
40-60-343] on the clutch shaft. Figure 40-60-346
Figure 40-60-344
P-84140
P-84078
Install the PTO clutch assembly into the bearing cover
until fully seated [Figure 40-60-346].
Install the bearing (Item 1) and snap ring (Item 2) [Figure
40-60-344].

472 of 1161
Figure 40-60-347
1 1
P-84070
Install the coupler (Item 1) [Figure 40-60-349] onto the

P-84073 shaft.
Installation: Apply gasket eliminator onto the mounting

Install the washer (Item 1) and snap ring (Item 2) [Figure surface of the middle case.
40-60-347] onto the PTO clutch shaft.
Figure 40-60-350
Figure 40-60-348
1
2
2 2
P-84067
P-84071
Using a lifting chain and hoist, lift and install the middle
Install the bearing cover (Item 1) using the four bolts case onto the transmission [Figure 40-60-350].
(Item 2) [Figure 40-60-348].
Tighten the bolts to 36 - 41 ft.-lb. (48 - 56 N•m) torque.

473 of 1161
Middle Case / PTO Clutch Assembly (Cont’d)
Figure 40-60-351
P-84066
Install the mounting bolts and nuts (Item 1) [Figure 40-

60-351].
Tighten bolts and nuts to 84 ft.-lb. (114 N•m) torque.

474 of 1161
TRANSMISSION (SST MODELS)
PROBLEM CAUSE
Excessive or unusual noise at all times 1, 2, 3, 4
Noise while turning 3, 5, 6
Differential lock can not be engaged 7, 8
Differential lock pedal does not return 9
Pinion or ring gear tooth broken 4, 10, 11, 12, 13
Worn or pitted bearings 4, 10, 11, 12, 13, 14
Oil leakage 4, 15, 16, 17, 18
Pinion teeth fatigue 4, 19
Thrust washer surface worn 4
Range shifting lever does not shift into gear 3, 4, 20

1. Improper backlash between pinion shaft and pinion gear
2. Improper backlash between pinion shaft and differential side gear
3. Worn bearings
4. Insufficient, improper, or contaminated transmission oil
5. Differential pinions or side gears worn or damaged
6. Differential lock does not disengage
7. Differential lock shift fork damaged
8. Differential lock arm damaged
9. Differential lock pedal return spring weakened or damaged.
12. Pinion nut loose
14. Excessive use
16. Low oil level
17. Normal wear
19. Overloaded continuously
20. Start tractor move range shifting lever to “N”, press the travel pedal to forward or reverse and release pedal to
neutral, move range shifting lever to desired range.

475 of 1161
TRANSMISSION (SST MODELS) (CONT’D) Figure 40-61-3
Transmission Case Removal
Separate the tractor. (See SEPARATING THE

TRACTOR (SST MODELS) on Page 40-110-1.)
Figure 40-61-1
P-95500
Figure 40-61-4
P-95499
Measure and record the joystick cable dimension as

shown [Figure 40-61-1].

2.75 in (70 mm).
Figure 40-61-2 1 3 2
P-95501
2
the cable.
1
3
P-95499
the cable.

476 of 1161
Transmission Case Removal (Cont’d)
Figure 40-61-5
2
P-95552
Support the valve (Item 1) and remove the two bolts

P-95502 (Item 2) [Figure 40-61-7]. Remove the bracket and
valve.
Remove the pin (Item 1) [Figure 40-61-5]. Figure 40-61-8
Figure 40-61-6
P-95553
P-95551
Remove the three bolts (Item 1) and bracket (Item 2)
[Figure 40-61-8] from the right side.
Remove the joint bolt and tube line (Item 1) [Figure 40-
61-6] from the valve.

477 of 1161
Figure 40-61-9
1 2
1
P-95556
Remove the roll pin (Item 1) from the shift linkage (Item
P-95554 2) [Figure 40-61-11].
Figure 40-61-12
Remove the cotter pin, washer and pin (Item 1) and lower
the brake linkage (Item 2) [Figure 40-61-9] (both sides).
Figure 40-61-10
P-95558
Lift the tractor rear housing and place a stand under the
P-95555 middle case [Figure 40-61-12].
Install the lifting bracket (Item 1) [Figure 40-61-12]. (Both

Remove the three bolts (Item 1) and bracket (Item 2) sides).
[Figure 40-61-10] from the left side.

478 of 1161
Figure 40-61-13
P-95563
Separate the transmission case from the middle case

P-95559 and remove.
With a hoist and lifting chains support the transmission

case (as shown) [Figure 40-61-13].
Figure 40-61-14
P-95562
Remove the ten bolts and nuts (Item 1) [Figure 40-61-

14].

479 of 1161
TRANSMISSION (SST MODELS) (CONT’D)
Transmission Case Parts Identification
1. Bolt
2. Cover
3. Dowel 4
4. Seal 5
3
5. Bearing
6. 26 Gear Shaft 6
7. Snap-Ring 5 5
8.Spacer 7
9. Roll Pin 4 8
7
10. O-Ring
11. Retainer 2
12. 27 Gear
13. Lever
14. Shuttle Shift Arm
15. Shaft
16
16. 18 Gear Shaft 13 9
1
7
11
10
14
12
7
15
7
5
7
7
4
NA1945

480 of 1161
Transmission Case Disassembly

1
IMPORTANT
damage the system. 2
I-2003-0888 1
P-95579
Figure 40-61-16
Install two bolts (Item 1) [Figure 40-61-17] into the cover
1 and tighten evenly to break the sealant bond.
Figure 40-61-18
1
1 1
P-95578
Remove the clutch lever assembly (See CLUTCH

LEVER (SST MODELS) on Page 70-140-1)

P-81745

cover.

481 of 1161
Transmission Case Disassembly (Cont’d)
Figure 40-61-19 1
P-95582
Remove the snap ring (Item 1) and gear (Item 2) [Figure

P-95580 40-61-21] from the main shaft.
Figure 40-61-22
Remove the shaft / bearing (Item 1) [Figure 40-61-19]
from the housing.
1
Figure 40-61-20
1 P-95595

P-95581 lower case.
Remove the seal (Item 1) and bearings (Item 2) [Figure


482 of 1161
Figure 40-61-23
2
1
P-95598

P-95596 [Figure 40-61-25] from the housing.
Figure 40-61-26
the shaft.
Figure 40-61-24
2 1
P-95583
Remove the four bolts (Item 1), and gear shift assembly
P-95597 (Item 2) [Figure 40-61-26].
remove the driveshaft [Figure 40-61-24].

483 of 1161
Figure 40-61-27
P-95601
1
Remove the bearing cover / gear assembly from the
P-95559 housing [Figure 40-61-29].
Figure 40-61-30
Figure 40-61-28
1
1
P-95602
1
P-95600 Remove the snap ring (Item1) [Figure 40-61-30] from
the shaft.
Remove the six bolts (Item 1) [Figure 40-61-28] from the

bearing cover.

484 of 1161
Figure 40-61-31
1
1
P-95606

P-95604
Figure 40-61-34
Remove the washer / spacer (Item 1) [Figure 40-61-31].
Figure 40-61-32
P-95607

P-95605 housing.
remove the 18 gear shaft [Figure 40-61-32].

485 of 1161
Figure 40-61-35
P-95611
1
Remove the roll pin (Item 1) and lever (Item 2) [Figure

P-95609 40-61-37].
Figure 40-61-38
Reposition the snap ring (Item 1) [Figure 40-61-35] to
allow access to the roll pin (Item 1) [Figure 40-61-36].
Figure 40-61-36
2 P-95612

P-95610
Remove the universal joint assembly (Item 2) [Figure 40-

61-36].

486 of 1161
Figure 40-61-39
1
1
2
P-95615

P-95613 housing.

[Figure 40-61-39].
Figure 40-61-40
P-95614
Remove the shuttle shift arm (Item 1) [Figure 40-61-40]

from the housing.

487 of 1161
Bearing Cover / PTO Countershaft Parts Identification
1. Bearing
2. PTO Countershaft
3. 30 Gear
1
3
NA1947

488 of 1161
Bearing Cover / PTO Countershaft Disassembly
Figure 40-61-42
1
1 P-95665
2

P-95663
Middle Case / 23 Gear Shaft Group Inspection
Remove the PTO countershaft assembly (Item 1) from Figure 40-61-45

the bearing cover (Item 2) [Figure 40-61-42].
Figure 40-61-43
P-95666
P-95664 Remove the 30 gear (Item 1) [Figure 40-61-45] from the

shaft.

shaft.

489 of 1161
Bearing Cover / PTO Countershaft Inspection
Figure 40-61-46
P-95752

cracked teeth.
If any of the gears are damaged, replace all the gears.

servicing.
Figure 40-61-47
P-84116

wear or damage.

490 of 1161
Bearing Cover / PTO Driveshaft Parts Identification
1. Bearing
2. 27-18 Gear Shaft
NA1946

491 of 1161
Bearing Cover / PTO Driveshaft Disassembly
Figure 40-61-48 1
P-95671
2
1 Remove the bearing (Item 1) [Figure 40-61-50] from the
P-95668 18 gear end of the shaft.
Bearing Cover / PTO Driveshaft Inspection

Remove the PTO driveshaft assembly (Item 1) from the
bearing cover (Item 2) [Figure 40-61-48]. Figure 40-61-51
Figure 40-61-49
1
P-95782
P-95670
Inspect the gears (Item 1) [Figure 40-61-51] for worn or
cracked teeth.
27 gear end of the shaft. If any of the gears are damaged, replace all the gears.
servicing.

492 of 1161
Bearing Cover / Shift Links Parts Identification
1. 1-2 Gear Shifting Fork

2. 3-4 Gear Shifting Fork
3. Shifting Rod
4. Roll Pin
5. Locking Bolt
6. Lock Washer
7. Detent Ball
8. Spring
7
7
8
6
3 5
2
4
4
3 4
1
4
NA1844

493 of 1161
Bearing Cover / Shift Links Disassembly
Figure 40-61-52 1
P-95675
Remove the roll pin (Item 1) [Figure 40-61-54] from the

P-95672 shifting rod.
Figure 40-61-55
Remove the locking bolt and lock washer (Item 1)
[Figure 40-61-52].
Figure 40-61-53
1
1
P-95676
Remove the two roll pins (Item 1) [Figure 40-61-55].

P-95674
Remove the three detent balls (Item 1) [Figure 40-61-53]


494 of 1161
Figure 40-61-56
P-95680
Remove the spring (Item 1) [Figure 40-61-58] from the

P-95677 bearing cover.
Figure 40-61-59
Cover the bearing cover holes with a rag to avoid losing
the detent ball while taping on the end of the shifting rod
with a soft faced hammer [Figure 40-61-56]. 1
Figure 40-61-57
P-95681
Remove the roll pins (Item 1) [Figure 40-61-59] from the

shifting rod.
P-95679
Remove the shifting fork / rod assembly and detent ball

[Figure 40-61-57].

495 of 1161
Figure 40-61-60
P-95685
Remove the shifting fork / rod assembly and detent ball

P-95682 and spring [Figure 40-61-62].
Bearing Cover / Shift Links Inspection

shifting fork. Figure 40-61-63
Figure 40-61-61
P-95773
P-95683
Inspect the shifting fork (Item 1) [Figure 40-61-63] for
wear or damage.
Cover the bearing cover holes with a rag to avoid losing
with a soft faced hammer [Figure 40-61-61].

496 of 1161
Bearing Cover / Countershaft Parts Identification
1. Bearing 12
2. Thrust Collar
3. 26 Gear 11 4
4. Needle Bearing
5
5. Synchronizer Ring
9 7
6. Shifter
7. Spring
8. Snap Ring
9. Synchronizer Key 7 8
6
10. Synchronizer Hub
11. 30 Gear
5
12. Countershaft
13. 34 Gear 3 4
14. 38 Gear 2
15. Coupler 10
1
16. Roll Pin
15
14
5
7
9 16
8 1
2
7
6
4
5
13
4
10
NA1957

497 of 1161
Bearing Cover / Countershaft Disassembly
Figure 40-61-64
1
2
1
P-95690

P-95686
Figure 40-61-67
Remove the countershaft assembly (Item 1) from the

bearing cover (Item 2) [Figure 40-61-64]. 1
Figure 40-61-65
2
P-95691
Remove the 26 gear (Item 1) and inner needle bearing

(Item 2) [Figure 40-61-67].
P-95689
Remove the bearing (Item 1) [Figure 40-61-65] next to

the 26 gear.

498 of 1161
Bearing Cover / Countershaft Disassembly (Cont’d)
Figure 40-61-68
1
P-95708
1
Remove the shifter / synchronizer hub (Item 1) [Figure

P-95692 40-61-70] from the shaft.
Figure 40-61-71
Figure 40-61-69 2
1
P-95709
P-95693 Slide the shifter (Item 1) off the synchronizer hub (Item 2)
[Figure 40-61-71].
Remove the synchronizer ring (Item 1) [Figure 40-61-

69].

499 of 1161
Figure 40-61-72
1
1
1 P-95714
1 Remove the synchronizer ring (Item 1) [Figure 40-61-74]

P-95710 from the 30 gear.
Figure 40-61-75
Remove the three synchronizer keys (Item 1) [Figure 40-
61-72].
Figure 40-61-73
1
P-95715
Remove the 30 gear (Item 1) [Figure 40-61-75] from the

P-95712 shaft.

hub (both sides).

500 of 1161
Bearing Cover / Countershaft Disassembly Cont’d)
Figure 40-61-76
1
P-95720
Remove the thrust collar (Item 1) [Figure 40-61-78] from

P-95716 the shaft.
Figure 40-61-79
Remove the needle bearing (Item 1) [Figure 40-61-76].
Figure 40-61-77
1
P-95721
P-95719 Remove the 38 gear (Item 1) [Figure 40-61-79] from the

shaft.
Remove the bearing (Item 1) [Figure 40-61-77] next to

the 38 gear.

501 of 1161
Figure 40-61-80
1
1
P-95724
Remove the synchronizer ring (Item 1) [Figure 40-61-

P-95722 82].
Figure 40-61-83
Remove the needle bearing (Item 1) [Figure 40-61-80]
from the gear.
Figure 40-61-81
P-95725

P-95723 40-61-83] from the shaft.

502 of 1161
Figure 40-61-84
2 1
1
P-95712

P-95709 hub (both sides).
Figure 40-61-87
Slide the shifter (Item 1) off the synchronizer hub (Item 2)
[Figure 40-61-84].
Figure 40-61-85 1
P-95726
1
1 Remove the synchronizer ring (Item 1) [Figure 40-61-87]

P-95710 from the 34 gear.

61-85].

503 of 1161
Figure 40-61-88
P-95727

shaft.
Figure 40-61-89
P-95728
Remove the needle bearing (Item 1) [Figure 40-61-89]

from the shaft.

504 of 1161
Bearing Cover / Countershaft Inspection
Figure 40-61-90
1
P-95731
Inspect the synchronizer ring (Item 1) [Figure 40-61-92]

P-95729 for wear and damage.

damage or wear.
Figure 40-61-91
P-95730

cracked teeth.

damaged gear can cause microscopic fatigue cracks in

505 of 1161
Bearing Cover / Main Shaft Parts Identification
1. Bearing
2. Main Shaft
NA1956

506 of 1161
Bearing Cover / Main Shaft Disassembly
Figure 40-61-93
1
P-95758

P-95756
Bearing Cover / Main Shaft Inspection
Remove the main shaft (Item 1) [Figure 40-61-93] from Figure 40-61-96
the bearing cover.
Figure 40-61-94 1
1
1
P-95759
P-95757 Inspect the gears (Item 1) [Figure 40-61-96] for wear or

cracked teeth.
Remove the bearing (Item 1) [Figure 40-61-94] from the If any of the gears are damaged, replace all the gears.
main shaft. One damaged gear can cause a microscopic fatigue
crack in the mating teeth and cause premature failure
after servicing.

507 of 1161
Middle Case Removal
Figure 40-61-97
P-95841
Separate and remove the middle case [Figure 40-61-

P-95844 99].
Set the middle case assembly onto a work surface.

Use approved lifting brackets, chains and hoist to lift and
support the middle case [Figure 40-61-97].
Figure 40-61-98
1 1
P-95842
Remove the bolts and nuts (Item 1) [Figure 40-61-98].

508 of 1161
Middle Case / Bearing Cover Removal
Figure 40-61-100
P-95855
1
Remove the bearing cover assembly from the middle
P-95852 case [Figure 40-61-102].
Remove the five bolts (Item 1) [Figure 40-61-100].
Figure 40-61-101
1
P-95854
Install two 6 mm screws (Item 1) [Figure 40-61-101] into

the bearing cover an tighten evenly to push the bearing
cover assembly away from the middle case housing.

509 of 1161
Middle Case / Shift Link Parts Identification
1. Shuttle Shift Lever

2. Shifting Rod
3. Roll Pin
4. Detent Ball
5. Spring
6. Shifting Fork
7. Retainer Plate
8. Bolt
9. Bearing Cover
9
8
2
1
5
4
NA1980

510 of 1161
Middle Case / Shift Link Disassembly
Figure 40-61-103
P-95860

P-95856 shifting rod.
Figure 40-61-106
Bend the retainer plate (Item 1) [Figure 40-61-103] over.
Figure 40-61-104
1
P-95861
P-95859 Cover the bearing cover holes with a rag to avoid losing
with a soft faced hammer [Figure 40-61-106].
[Figure 40-61-104] from the shifting fork.

511 of 1161
Middle Case / Shift Link Disassembly (Cont’d)

1
Figure 40-61-107
P-95864
Remove the detent spring (Item 1) [Figure 40-61-109]

P-95862 from the cover.
Remove shifting rod (Item 1) [Figure 40-61-107].
Capture the detent ball with the rag.
Figure 40-61-108
P-95863
Remove the shifting fork (Item 1) [Figure 40-61-108].

512 of 1161
Middle Case / Shift Link Inspection
Figure 40-61-110
P-95865
Inspect the shifting fork (Item 1) [Figure 40-61-110] for

wear or damage.
Figure 40-61-111
P-95866
Inspect the shifting rod for wear or damage [Figure 40-

61-111].

513 of 1161
Middle Case / 19 Gear Shaft Parts Identification
1. Bearing Cover
2. Bearing
3. 19 Gear Shaft
2
3
NA1969

514 of 1161
Middle Case / 19 Gear Shift Disassembly
Figure 40-61-112
1
P-95870
Remove the bearings (Item 1) [Figure 40-61-114] from

P-95867 the shaft.
Middle Case / 19 Gear Shaft Inspection

Position the bearing cover / gear assembly on blocks as
shown [Figure 40-61-112]. Figure 40-61-115
Figure 40-61-113
2
1
1
2
P-95871
P-95869
Inspect the shaft (Item 1) [Figure 40-61-115] for wear or
damage.
Pry upward slightly on the shuttle shaft assembly (Item 1)
and remove the 19 gear assembly (Item 2) [Figure 40- Inspect the gears (Item 2) [Figure 40-61-115] for worn or
61-113]. cracked teeth. If any of the gears are damaged, replace
all gears. One damaged gear can cause microscopic
fatigue cracks in mating teeth and cause premature
failure after servicing.


515 of 1161
Middle Case / Shuttle Shaft Parts Identification
1. Bearing Cover
2. Snap Ring
3. Washer
4. Bearing
5. Thrust Collar
7. Spacer 15
8. 17 Spur Gear
9. Inner Cone
10. Center Cone
11. Synchronizer Ring
12. Shaft
13. Shifter 2
14. Spring 17
15. Synchronizer Key 14
16. 22 Gear 13
17. Synchronizer Hub
12
11
10
9
16
6
5
4
3
2
2
3
4
7
5
6
8
9
10
11
NA1971

516 of 1161
Middle Case / Shuttle Shaft Disassembly
Figure 40-61-116
P-95874

P-95872
Figure 40-61-119
Remove the shuttle shaft assembly (Item 1) [Figure 40-

61-116] from the bearing cover.
Figure 40-61-117
1
P-95875
P-95873
Position the shaft assembly as shown [Figure 40-61-

117].

517 of 1161
Middle Case / Shuttle Shaft Disassembly (Cont’d)
Figure 40-61-120
P-95878

P-95876
Figure 40-61-123

the shaft.
Figure 40-61-121 1
P-95879
Remove the 17 spur gear (Item 1) [Figure 40-61-123].
P-95877

518 of 1161
Figure 40-61-124
P-95882
Remove the inner cone (Item 1) [Figure 40-61-126].

P-95880
Figure 40-61-127
Remove the needle bearings (Item 1) [Figure 40-61-124]

from the shaft.
Figure 40-61-125
1
1
P-95883
Remove the center cone (Item 1) [Figure 40-61-127]

from the synchronizer ring.
P-95881
Remove the synchronizer ring assembly (Item 1) [Figure

40-61-125].

519 of 1161
Figure 40-61-128 2
P-95888
1
Slide the shifter (Item 1) off the synchronizer hub (Item 2)
P-95885 [Figure 40-61-130].
Figure 40-61-131
the shaft. 1
Figure 40-61-129
1
1
1
P-95889

P-95886 61-131].

40-61-129].

520 of 1161
Figure 40-61-132
P-95882
Remove the inner cone (Item 1) [Figure 40-61-134].

P-95890
Figure 40-61-135

hub (both sides).
Figure 40-61-133
1
1
P-95883
Remove the center cone (Item 1) [Figure 40-61-135]

from the synchronizer ring.
P-95892
Remove the synchronizer ring assembly (Item 1) [Figure

40-61-133] from the 22 gear.

521 of 1161
Figure 40-61-136
P-95897

P-95895
Figure 40-61-139

the shaft.
Figure 40-61-137 1
P-95898
P-95896

522 of 1161
Figure 40-61-140
P-95899
Remove the thrust collar (Item 1) [Figure 40-61-140]

from the shaft.
Figure 40-61-141
P-95900
Remove the needle bearing (Item 1) [Figure 40-61-141].

523 of 1161
Middle Case / Shuttle Shaft Inspection
Figure 40-61-142
P-95901

wear or damage.
Figure 40-61-143
P-98129

cracked teeth.

damaged gear can cause microscopic fatigue cracks in

524 of 1161
Middle Case / 23-20 Gear Shaft Parts Identification
1. Bearing Cover
2. Bearing
3. 23-20 Gear Shaft
4. Coupler
5. Roll Pin
NA1973

525 of 1161
Middle Case / 23-20 Gear Shaft Disassembly
Figure 40-61-144 1
P-95930

P-95928
Middle Case / 23-30 Gear Shaft Inspection
Remove the 23-20 gear shaft assembly (Item 1) [Figure Figure 40-61-147
40-61-144] from the bearing cover.
2
Figure 40-61-145
1 1
P-95931
P-95929 Inspect the shaft splines (Item 1) [Figure 40-61-147] for

wear or damage.
Remove the bearing (Item 1) [Figure 40-61-145] from Inspect the gears (Item 2) [Figure 40-61-147] for worn or
the shaft. cracked teeth. If any of the gears are damaged, replace
all gears. One damaged gear can cause microscopic
fatigue cracks in the mating teeth and cause premature
failure after servicing.

526 of 1161
Middle Case / PTO Clutch Parts Identification
3
1. Splined Hub
2. Bearing
3. Snap Ring
4. Washer
5. Spring
6. Plate
7. Friction Plate
8. Pressure Plate
9. O-Ring
10. Piston
11. Ring 9, 10
12. Stopper Plate
13. Clutch Housing
14. Seal
15. Bearing Cover
6
3
5
4
3
2
1
3 15
4
2
14
13
12
11
9
10
9
NA1972

527 of 1161
Middle Case / PTO Clutch Disassembly
Figure 40-61-148
2
1
P-95934

P-95932
Figure 40-61-151

[Figure 40-61-148] from the PTO clutch bearing.
Figure 40-61-149 1
P-95935

the cover.
P-95933
Press the PTO clutch assembly from bearing cover

[Figure 40-61-149].

528 of 1161
Middle Case / PTO Clutch Disassembly (Cont’d)
Figure 40-61-152
1
1
P-84103
Remove the pressure plate (Item 1) [Figure 40-61-154].

P-84080
Figure 40-61-155

the clutch assembly.
Figure 40-61-153
1
1
P-84084
P-84105 Repeat the above procedures to remove the remaining

pressure and friction plates.

529 of 1161

2
Figure 40-61-156
P-84370
Install a 3/4 x 5 in. (M 20 x 130 mm) bolt (Item 1) and

P-84086 washer (Item 2) [Figure 40-61-158] into the clutch pack
as shown.
Remove the splined hub (Item 1) [Figure 40-61-156] Figure 40-61-159

from the clutch assembly.
2
Figure 40-61-157
1
1 3
P-84371
P-84087 Install the tool (Item 1) and nut (Item 2) onto the clutch
pack, tighten the nut and remove the snap ring (Item 3)
[Figure 40-61-159] from the grove.
Remove the tool from the clutch pack.

530 of 1161
Figure 40-61-160 1
1
2
P-84094
Remove the two O-rings (Item 1) [Figure 40-61-162]

P-84090 from the piston.
Figure 40-61-163
Remove the washer (Item 1) and spring (Item 2) [Figure
40-61-160].
1
Figure 40-61-161
1
2
P-84097
Remove the ring (Item 1) and stop plate (Item 2) [Figure

P-84093 40-61-163] from the clutch housing.
Remove the piston (Item 1) [Figure 40-61-161] from the

clutch housing.

531 of 1161
Middle Case / PTO Clutch Inspection
Figure 40-61-164
P-84095
1
Inspect the piston for wear or damage [Figure 40-61-

P-84136 166].
Inspect the pressure plates for wear or cracks, make sure

the dampening rubbers (Item 1) [Figure 40-61-164] are
in good condition.
Figure 40-61-165
P-84137
Inspect the friction plates for wear or damage [Figure 40-

61-165].

532 of 1161
Middle Case Bearing Cover / Shift Links Parts Identification

1. Roll Pin
1
2. Linkage
3. Bolt
4. Retainer Plate
3
5. O-Ring 12
6. Shift Arm
4
7. Ball
8. Spring 2
9. Shifting Fork 5
10. Shifting Rod
11. Bearing Cover
12. Spacer
4
3
6
6
7
7
8 8
9
10 9
10
11
NA1997

533 of 1161
Middle Case Bearing Cover / Shift Links Disassembly
Figure 40-61-167
2 1
1 P-95959

P-95957 outward.
Figure 40-61-170
Remove the roll pin (Item 1) and mid PTO shift linkage
(Item 2) [Figure 40-61-167].
2
Figure 40-61-168
1 2
1
3
P-95950
Remove the roll pin (Item 1) and range shift linkage (Item
P-95958 2) [Figure 40-61-170].
Remove the bolt (Item 1), Spacer (Item 2) and retainer

plate (Item 3) [Figure 40-61-168].

534 of 1161

(Cont’d) 1
Figure 40-61-171
1
2
1 1 1
P-95953
P-95951 Figure 40-61-174
Remove the bolt (Item 1) and retainer plate (Item 2) 1

[Figure 40-61-171].
Figure 40-61-172
P-95956
Remove the bearing cover assembly (Item 1) [Figure 40-

P-95952

outward.

535 of 1161
TRANSMISSION (SST MODEL) (CONT’D) Figure 40-61-177

(Cont’d)
1
Figure 40-61-175
P-84302
Remove the mid PTO shift arm (Item 1) [Figure 40-61-

P-84212
Figure 40-61-178
Remove the mid PTO fork / shifting rod assembly from

the cover [Figure 40-61-175].
Figure 40-61-176
2
P-84303

shift arm.
P-84301
Remove the fork (Item 1) from the shifting rod (Item 2).
When the shifting rod is pulled from the fork it will slide
through each shifting range on the shifting rod. When the
fork is removed, cover the hole (Item 3) [Figure 40-61-
176] in the fork to retain the ball and spring.

536 of 1161
TRANSMISSION (SST MODEL) (CONT’D) Figure 40-61-181

(Cont’d)
1
Figure 40-61-179
1 2
3
P-84304
Remove the fork (Item 1) from the shifting rod (Item 2).
When the shifting rod is pulled from the fork it will slide
P-84213 through each shifting range on the shifting rod. When the
fork is removed, cover the hole (Item 3) [Figure 40-61-
181] in the fork to retain the ball and spring.
Figure 40-61-182
Figure 40-61-180
1
1
P-84306
P-84214
Remove the range shift arm (Item 1) [Figure 40-61-182]

Remove the range shifting rod / fork assembly (Item 1) from the housing.
[Figure 40-61-180] from the cover.

537 of 1161
TRANSMISSION (SST MODELS) (CONT’D) Middle Case Bearing Cover / Shift Links Inspection
Middle Case Bearing Cover / Shift Links Disassembly Figure 40-61-184

(Cont’d)
Figure 40-61-183
P-84308
P-84307 Inspect the shifting fork (Item 1) [Figure 40-61-184] for

wear or damage.
Remove the O-ring (Item 1) [Figure 40-61-183] from the Figure 40-61-185
shift arm.
P-84307

wear or damage.

538 of 1161
Pinion Shaft Parts Identification
1. Bolt
2. Bearing Cover
3. Nut
4. Bearing Case
5. Shim
6. Bearing Cover
7. Bearing
8. Spacer 13
9. 24 Gear
8
10. Snap Ring 13
11. Thrust Collar 12
12. 30 Gear Shaft
14. 36 Gear 10
15. Shifter Gear 9
16. Spline Boss 8
17. 18 Gear 7
18. Pinion Shaft 8
8
6 7
5
4
3
2 18
1
7
10
11
13
13
17
10
16
10
15
10
14
7
10
7
MS-2716S

539 of 1161
Pinion Shaft Disassembly
Figure 40-61-186
1 1
P-84219
Remove the bearing cover (Item 1) [Figure 40-61-188].

P-84215
Figure 40-61-189
Figure 40-61-187
1 1
1
P-84220
Tap on the end of the shaft with a soft faced hammer

P-84218 [Figure 40-61-189].
Remove the three bolts and lock washers (Item 1)

[Figure 40-61-187].

540 of 1161
Pinion Shaft Disassembly (Cont’d)
Figure 40-61-190
1 1 2
P-84224
Remove the two bearing races (Item 1) and spacer (Item

P-84221 2) [Figure 40-61-192] from the bearing case.
Figure 40-61-193
Remove the shim [Figure 40-61-190].
Figure 40-61-191
P-84225
P-84223 Using a puller remove the bearing and spacer from the
shaft [Figure 40-61-193].
Remove the pinion shaft assembly [Figure 40-61-191]

NOTE: The bearing case (Item 1) [Figure 40-61-191]

will not be removed at this time.

541 of 1161
Figure 40-61-194
1 P-84231
Remove the gear assembly from the shaft [Figure 40-61-

P-84227 196].
Figure 40-61-197
Remove the spacer (Item 1) and 24 gear (Item 2) [Figure
Figure 40-61-195
2
1
1
P-84233

P-84229
Remove the snap ring (Item 1) and thrust collar (Item 2)

[Figure 40-61-195].

542 of 1161
Figure 40-61-198
2 1
P-84239

P-84234 the 30 gear shaft.
Figure 40-61-201
Remove the 36 gear (Item 1) from the 30 gear (Item 2)
[Figure 40-61-198].
Figure 40-61-199
1
1
1
2
2
P-84241
Remove the two needle bearings (Item 1) and spacer

P-84235 (Item 2) [Figure 40-61-201] from the shaft.

[Figure 40-61-199].

543 of 1161

1
Figure 40-61-202
P-84247

P-84243
Figure 40-61-205
Remove the shifter gear (Item 1) [Figure 40-61-202].
Figure 40-61-203 1
1 P-84249

P-84246

544 of 1161
TRANSMISSION (CONT’D) Figure 40-61-208
Figure 40-61-206
P-84253

P-84251
Figure 40-61-209

the shaft.
Figure 40-61-207 1
1 P-84254
P-84252

207].

545 of 1161
TRANSMISSION (CONT’D) Pinion Shaft Inspection
Pinion Shaft Disassembly (Cont’d) Figure 40-61-211
Figure 40-61-210
P-84237
P-84255
61-211].
Figure 40-61-212
P-84256


546 of 1161
PTO Shaft Parts Identification
1. Snap Ring
2. Washer
3. 28 Gear
4. Bearing Cover
5. Bearing
6. Thrust Collar 6
7. 20/27 Gear
8. Needle Bearing
9. Shaft 1
10. Coupler
4
5
2
1
10
6
8
MS-2712S

547 of 1161
PTO Shaft Disassembly
Figure 40-61-213
1
1
P-84261

P-84259
Figure 40-61-216

the PTO shaft.
Figure 40-61-214
1
1
P-84264
Remove the PTO shaft assembly (Item 1) [Figure 40-61-

216] from the backside of the bearing cover.
P-84260

548 of 1161
PTO Shaft Disassembly (Cont’d)
Figure 40-61-217
P-84267
1
P-84265
Figure 40-61-220
Figure 40-61-218 1
P-84268
Remove the second snap ring (Item 1) [Figure 40-61-

P-84266 220] from next to the thrust collar.
Using a puller, remove the two bearings (Item 1) [Figure

40-61-218].

549 of 1161
PTO Shaft Disassembly (Cont’d)
Figure 40-61-221 1
P-84272

P-84269 223].
Figure 40-61-224
Figure 40-61-222 1
P-84273
P-84270 Remove the thrust collar (Item 1) [Figure 40-61-224].
Remove the 20 / 27 gear (Item 1) [Figure 40-61-222]

from the shaft.

550 of 1161
TRANSMISSION (SST MODELS) (CONT’D) PTO Shaft Inspection
PTO Shaft Disassembly (Cont’d) Figure 40-61-226
Figure 40-61-225
1
1
P-84271
P-84274
cracked teeth.
Figure 40-61-227
P-84275

damage.

551 of 1161
Range Shifter Shaft Parts Identification
1. Bearing Cover
2. Bearing
3. 23 Gear
4. 12 - 36 Gear Shaft
3
2
NA1977

552 of 1161
Range Shifter Shaft Disassembly
Figure 40-61-228 1
P-84280

P-84277 the shaft.
Figure 40-61-231
Figure 40-61-229
P-84282
Remove the bearing from the end of the shaft [Figure

P-84279 40-61-231].
Using a puller, remove the bearing from the shaft [Figure

40-61-229].

553 of 1161
Range Shifter Shaft Inspection
Figure 40-61-232
P-84281

cracked teeth.


554 of 1161
PTO 15 Gear Shaft Parts Identification
1. PTO 15 Gear Shaft

2. Bearing
3. Snap Ring
4. Spacer
5. Shift Assembly
6. Spline Boss
7. 28 Gear
8. Thrust Collar
2
8
3 7
6
4 5
3
NA1978

555 of 1161
PTO 15 Gear Shaft Disassembly
Figure 40-61-233
1
1
P-84288

P-84287
Figure 40-61-236

Figure 40-61-234
1 P-84290
Remove the shift assembly (Item 1) [Figure 40-61-236].
P-84300

556 of 1161
TRANSMISSION (CONT’D) Figure 40-61-239
PTO 15 Gear Shaft Disassembly (Cont’d)
Figure 40-61-237
1
P-84293

P-84291
Figure 40-61-240
Figure 40-61-238
1
P-84294

P-84292

557 of 1161
TRANSMISSION (SST MODELS) (CONT’D) PTO 15 Gear Shaft Inspection
PTO 15 Gear Shaft Disassembly (Cont’d) Figure 40-61-243
Figure 40-61-241
P-84289
P-84295
61-243].
from the bearing cover. If any of the gears are damaged, replace all gears. One
Figure 40-61-242 mating teeth and cause premature failure after servicing.
Figure 40-61-244
1
1
2
P-84296
P-84297
Inspect the shaft splines (Item 1) and gear (Item 2)

[Figure 40-61-244] for damage or wear.

558 of 1161
Idle Shaft Parts Identification
1. Nut
2. Bearing
3. Spacer
4. Snap Ring
5. 26 Gear
6. Spacer Washer
7. Spring
8. 23 Shift Gear
9. O-Ring
10. Shaft
11. Seal Ring
7
6
5
2
4
3
2
1
11
2
9
10
MS-2710S

559 of 1161
Idle Shaft Disassembly
Figure 40-61-245
1
1
P-84312

P-84309 61-247].
Figure 40-61-248
Remove the idle shaft assembly (Item 1) [Figure 40-61-
Figure 40-61-246
1
P-84313
Remove the spacer [Figure 40-61-248].

P-84311
Remove the nut (Item 1) [Figure 40-60-246] from the

shaft.

560 of 1161
Idle Shaft Disassembly (Cont’d)
Figure 40-61-249
1 2
P-84316
Remove the bearing (Item 1) from the 26 gear (Item 2)

P-84314 [Figure 40-61-251].
Figure 40-61-252
Figure 40-61-250
1 1
P-84318
P-84315 Remove the spacer (Item 1) [Figure 40-61-252].

561 of 1161
Figure 40-61-253 1
P-84321

P-84319
Figure 40-61-256
Figure 40-61-254
1
P-84322

P-84320 the end of the shaft.

the shaft.

562 of 1161
Figure 40-61-257
P-84323

563 of 1161
Idle Shaft Inspection
Figure 40-61-258
B-23842
Measure the free length of the spring [Figure 40-61-

P-84324 260]. If it measures less than 2.126 in. (54 mm) it must
be replaced.

wear or damage.
Figure 40-61-259
P-84325

cracked teeth.

564 of 1161
Front Wheel Drive Shaft Parts Identification
1. Coupler
2. Roll Pin
3. Bearing
4. Shaft
5. Snap Ring
6. 21 Gear
6
5
1
4
3
2
NA1979

565 of 1161
Front Wheel Drive Shaft Disassembly
Figure 40-61-261
1
P-84330
1
P-95961 the shaft.
Figure 40-61-264
Figure 40-61-262
1
1
P-84331
P-95962 Reposition the snap ring (Item 1) [Figure 40-61-264].
Remove the front wheel drive shaft assembly (Item 1)


566 of 1161
Front Wheel Drive Shaft Disassembly (Cont’d)
Figure 40-61-265
1
P-84334

P-84332 the shaft.
Figure 40-61-266
P-84333
Remove the gear (Item 1) [Figure 40-61-266].

567 of 1161
Front Wheel Drive Shaft Inspection
Figure 40-61-268
P-84335

wear or damage.
Figure 40-61-269
P-77615

cracked teeth.

568 of 1161
Rear PTO Shaft Parts Identification
1. Snap Ring
2. O-Ring
3. Nut
4. Bearing
5. Oil Seal
6. Collar
7. Bearing Case
8. Bolt
9. Shaft
10. Sleeve
11. Oil Seal
6
5
4
1
3
2
1
11
10
8
7
MS-2709S

569 of 1161
Rear PTO Shaft Disassembly
Figure 40-61-270
1
1 1
P-84343

P-84339
Figure 40-61-273

the rear PTO cover.
Figure 40-61-271
P-84344

the cover.
P-84342
Remove the PTO assembly from the housing [Figure 40-

61-271].

570 of 1161
Rear PTO Shaft Disassembly (Cont’d)
Figure 40-61-274
P-84349

P-84345 the shaft.
Figure 40-61-277
Remove the cover (Item 1) from the shaft (Item 2)
[Figure 40-61-274].
Figure 40-61-275
P-84351
Unstake and remove the nut (Item 1) [Figure 40-61-277].

P-84348
Remove the two oil seals (Item 1) [Figure 40-61-275]

from the cover.

571 of 1161
TRANSMISSION (SST MODELS) (CONT’D) Rear PTO Shaft Inspection
Rear PTO Shaft Disassembly (Cont’d) Figure 40-61-279
Figure 40-61-278
1
1
1
P-84353
P-84352
wear or damage.
from the shaft.

572 of 1161
TRANSMISSION (CONT’D)
1. Bearing Case (Right Side)

2. Bearing
3. Shims
4. Bearing Case (Left Side)
5. Differential Lock
6. Differential Carrier
7. Differential Cover
8. Cup Washer
9. Washer 19
10. Side Gear
11. Pinion Gear
12. Key 5
13. Pinion Shaft 15
14. Pinion Shaft (Short)
15. Ring Gear
16. Bolt 6
17. Shaft 16 8
18. Seal
19. Fork 9 13
11
20. Dowel Pin 10 12
21. Roll Pin
20 8
11
12 14
11 9
8 7
14 16
2 10
1 11
8
3
17 16
3
8
3 3
4
21
21 3
18
3
18 16 2
NA1974

573 of 1161
Figure 40-61-280
1
P-98127
2

P-98125
Figure 40-61-283
Remove the spring pin (Item 1) and washer (Item 2)

[Figure 40-61-280].
Figure 40-61-281
1
1
P-98128
Remove the shaft / spring assembly (Item 1) [Figure 40-

61-283].
P-98126
Remove the pin [Figure 40-61-281].

574 of 1161
Figure 40-61-284
1 1
1
P-84360
Remove the four bolts (Item 1) [Figure 40-61-286] (both

P-84358 sides).
NOTE: Mark the bearing cases left or right for correct

Remove the seal (Item 1) [Figure 40-61-284] from both assembly.
sides of the housing.
Figure 40-61-287
Figure 40-61-285
1
P-84361
P-84359
Record the number and location of the shims and remove

Remove the differential lock fork (Item 1) [Figure 40-61- [Figure 40-61-287].
285].
Remove the bearing case (Item 1) [Figure 40-61-287]
(both sides).

575 of 1161
Figure 40-61-288
P-77512
Remove the inner bearing [Figure 40-61-290].

P-84362
Figure 40-61-291
Remove the differential assembly [Figure 40-61-288].
Figure 40-61-289
P-77513
Lift and remove the differential lock (Item 1) [Figure 40-

P-77509 61-291].
Support the differential assembly and remove the outer


576 of 1161
Figure 40-61-292
1
P-77517
Remove the eight bolts (Item 1) [Figure 40-61-294] from

P-77510 the cover.
Figure 40-61-295
Turn the differential assembly over and remove the eight
ring gear mounting bolts (Item 1) [Figure 40-61-292].
Figure 40-61-293
1
P-77518

P-77516
Turn the differential assembly over and remove the ring

gear (Item 1) [Figure 40-61-293].

577 of 1161
Figure 40-61-296
P-77522
Using a brass drift, remove the short pinion shaft (Item 1)

P-77519 [Figure 40-61-298].
Figure 40-61-299
Figure 40-61-297 1
P-77525
P-775 Remove the pinion gear (Item 1) [Figure 40-61-299].

578 of 1161
Figure 40-61-300
1
P-77533
Remove the two pinion gears / cup washers (Item 1)

P-77526 [Figure 40-61-302].
Figure 40-61-303
Remove the cup washer (Item 1) [Figure 40-61-300].
Figure 40-61-301 1
P-77534
P-77532 Remove the side gear (Item 1) [Figure 40-61-303].
Remove the long pinion shaft assembly (Item 1) [Figure

40-61-301].

579 of 1161
Figure 40-61-304
P-77535
Remove the washer (Item 1) [Figure 40-61-304] from the

side gear.

580 of 1161
1
Figure 40-61-305
P-77527
Inspect the cup washers (Item 1) [Figure 40-61-307] for

P-77373 wear or damage. Replace as needed.
Inspect the shifting fork wear surfaces (Item 1) [Figure

40-61-305].
Figure 40-61-306
P-77529
Inspect the pinion gear [Figure 40-61-306] for broken or

damaged teeth.
If either gear is damaged, replace both gears.

581 of 1161
Differential Assembly Clearance Factory 0.00197 - 0.00594 in.

between spec. (0.05 - 0.151 mm)
Figure 40-61-308 differential case Allowable 0.0138 in.
bore and limit (0,035 mm)
3 differential side
gear
Clearance Factory 1.59449 - 1.59646 in.

between spec. (40,5000 - 40,550 mm)
differential case Allowable 1.59008 - 1.59252 in.
bore and limit (40,388 - 40,450 mm)
differential side
gear
1 Clearance Factory 0.00197 - 0.00594 in.

2 between spec. (0,05 - 0,151 mm)
MS-2466S
differential case Allowable 0.0138 in.
cover bore and limit (0,035 mm)
Measure and record the inside diameter of the differential differential side
case (Item 1) and cover (Item 2) [Figure 40-61-308]. gear
Measure and record the differential side gear outside

Differential case Factory 1.5945 - 1.5969 in.
diameter (Item 3) [Figure 40-61-308].
cover bore I.D. spec. (40,500 - 40,562 mm)
Differential side Allowable 1.5910 - 1.5925 in.
gear bore O.D. limit (40,411 - 40,450 mm)

[Figure 40-60-309].
Figure 40-61-310
P-77534

housing.

582 of 1161
Figure 40-61-311
2
1 1
P-77533
2
Install the two cup washers (Item 1) and pinion gears
MS-2467S (Item 2) [Figure 40-61-313] into the housing.
NOTE: Apply a small amount of assembly lube on the

Measure and record the outside diameter of the cup washers to help hold them in position.
differential pinion shaft (Item 1) [Figure 40-61-311].
Figure 40-61-314
Measure and record the inside diameter of the differential
pinion gear (Item 2) [Figure 40-61-311].
Figure 40-61-312
Clearance between Factory 0.0032 - 0.0040 in. 1

differential pinion spec. (0,081 - 0,102 mm)
shaft and Allowable 0.0098 in.
differential pinion limit (0,25 mm)
Differential pinion Factory 0.78579 - 0.78661 in.

shaft O.D. spec. (19,959 - 19,980 mm)
Differential pinion Allowable 0.78898 - 0.78980 in.
I.D. limit (20,040 - 20,061 mm) P-77527
If the clearance exceeds the allowable limit, see chart NOTE: The tang (Item 1) must fit in the notch in the
[Figure 40-61-312]. housing [Figure 40-61-314].
Replace as a set.

583 of 1161
Figure 40-61-315
1
1
P-77523
Make sure the key way (Item 1) [Figure 40-61-317] goes

Repeat above procedure to install the final cup washer,

Install the long pinion shaft (Item 1) [Figure 40-60-315], pinion gear and short shaft.
followed by the two cup washers and pinion gears.
Figure 40-61-318
Figure 40-61-316
2 P-77539
P-77530

Install the short pinion shaft (Item 1) through the cup the tip of the gauge on the tooth of the differential pinion
washer (Item 2) and pinion gear (Item 3) [Figure 40-61- gear, hold the side gear and move the differential pinion
316]. back and forth to measure the backlash [Figure 40-61-
318].
NOTE: The end of the short pinion shaft must go into
the hole in the long shaft (Item 4) [Figure 40-
61-316] fully.

584 of 1161
If the measurement is not within the allowable limit of:

0.001 - 0.012 in. (0,15 - 0,30 mm) adjust the differential
side gear washer.
Figure 40-61-319 1
P-77519
Install the washer (Item 1) [Figure 40-61-321].
Figure 40-61-322
P-77617
1
Select the correct differential side gear washer [Figure
40-60-319] from the selection below:
Thickness of differential side gear washers:

0.059 in. (1,5 mm)
0.063 in. (1,6 mm)
0.067 in. (1,7 mm)
Figure 40-61-320 P-77618
1 Install the cover (Item 1) [Figure 40-61-322] onto the

housing.
P-77521

585 of 1161
Figure 40-61-323
1
P-77510
Apply Loctite® #270 or equivalent to the eight bolts (Item

P-77517 1) [Figure 40-61-325] and tighten to 51 - 65 ft.-lb. (69 -
Apply Loctite® #270 or equivalent to the eight bolts (Item Figure 40-61-326
1) [Figure 40-61-323] and tighten to 36 - 41 ft.-lb. (48 -
Figure 40-61-324
1
P-77513
Install the differential lock (Item 1) [Figure 40-61-326].

P-77516
Install the ring gear (Item 1) [Figure 40-61-324] onto the

differential assembly.
Carefully turn the differential assembly / ring gear over.

586 of 1161
Figure 40-61-327
P-84363
Install the differential assembly into the housing [Figure

P-77619 40-61-329].
Figure 40-61-330
fully seated. 1
Figure 40-61-328
2 2
P-84361
Install the bearing cases (Item 1) [Figure 40-61-330] (as

P-77620 marked earlier) to support the differential assembly.
Install the shim pack (Item 2) [Figure 40-61-330]

Install the bearing (Item 1) [Figure 40-61-328] until it is (removed earlier) behind the bearing cases as marked
fully seated. earlier.

587 of 1161
Figure 40-61-331
1
1
1
P-77468
Install a new seal (Item 1) [Figure 40-60-333] on both

P-84360 sides of the housing.
Figure 40-61-334
tighten to 36 - 41 ft.-lb. (48 - 56 N•m) torque (both sides).
Figure 40-61-332
P-84359
Install the differential lock fork (Item 1) [Figure 40-61-

P-84360 334] onto the differential lock assembly (as shown).
Using a light rope make two or three wraps around the

differential shift and connect the other end to a spring
scale [Figure 40-61-332].
Pull up on the scale to measure the rolling force. The

value is 2.9 - 4.7 ft.-lb. (0.4 - 0.65 kgf-m)
If the rolling force is over the specified value, increase the

amount of shims, if it is below the specified value,
decrease the amount of shims (Item 2) [Figure 40-61-
330 on Page 40-61-113].

588 of 1161
Figure 40-61-335
1
2 1
P-98125
Install the pin (Item 1) and spring pin / washer (Item 2)

P-98128 [Figure 40-61-337].
Install the shaft / spring assembly (Item 1) into the

housing and through the differential lock fork (Item 2)
[Figure 40-61-335].
Figure 40-61-336
P-98127

589 of 1161
Rear PTO Shaft Assembly
Figure 40-61-338
1
P-84349

P-84352
Figure 40-61-341

the shaft.
1
Figure 40-61-339
P-84348
Install the two oil seals (Item 1) [Figure 40-61-341] into

the cover.
P-84350

109 - 145 ft.-lb. (147 - 196 N•m) torque.
After the nut is torqued, stake the nut to the shaft (Item 2)
[Figure 40-61-338].

590 of 1161
Rear PTO Shaft Assembly (Cont’d)
Figure 40-61-342
2
1
P-84343

P-84345 cover.
Figure 40-61-345
Lubricate the oil seals (Item 1) [Figure 40-61-341 on
Page 40-61-116] and install the cover (Item 1) onto the
shaft (Item 2) [Figure 40-61-342].
2
2
Figure 40-61-343
1
2
2
P-84339
1 Apply gasket eliminator to the mounting surface and

install the PTO assembly (Item 1) into the housing. Install
P-84344 the four bolts (Item 2) [Figure 40-61-345].

591 of 1161
Front Wheel Drive Shaft Assembly
Figure 40-61-346
1
P-84337

P-84367 shaft until it is next to the gear.
Figure 40-61-349
groove.
Figure 40-61-347
1
1
P-84338

Install the gear (Item 1) [Figure 40-61-347] onto the

shaft.

592 of 1161
Front Wheel Drive Shaft Assembly (Cont’d)
Figure 40-61-350
P-95962

into the housing.
Figure 40-61-351
P-95961

593 of 1161
Idle Shaft Assembly
Figure 40-61-352 1
1 P-84321
Lightly lubricate with oil and install the two O-rings (Item
P-84326 1) [Figure 40-61-354].
Figure 40-61-355
1
Figure 40-61-353
P-84320

P-84322 shaft.
Apply a small amount of assembly lube onto the seals

(Item 1) [Figure 40-61-353] and install.

594 of 1161
Idle Shaft Assembly (Cont’d)

2
Figure 40-61-356
3
1 1
P-84315
Install the bearing (Item 1) into the 26 gear (Item 2) and

P-84319 retain with the snap ring (Item 3) [Figure 40-61-358].
Figure 40-61-359
Install the spring (Item 1) [Figure 40-61-356].
Figure 40-61-357
P-84327
2
P-84318 Press the 26 gear (Item 1) [Figure 40-61-359] onto the

shaft and align with the 23 gear.
Install the spacer plate (Item 1) onto the shaft with the
protrusion (Item 2) [Figure 40-61-357] positioned as
shown.

595 of 1161
Idle Shaft Assembly (Cont’d)
Figure 40-61-360
1
P-84309
Install the idle shaft assembly (Item 1) [Figure 40-61-

Figure 40-61-361
P-84311

108 - 145 ft.-lb. (147 - 196 N•m) torque.
shaft groove.

596 of 1161
PTO 15 Gear Shaft Assembly
Figure 40-61-363 1
1
P-84294

P-84298 shaft.
Figure 40-61-366
Figure 40-61-364
1
P-84293
Install the spacer (Item 1) [Figure 40-61-366] onto the

P-84295 shaft.

into the bearing cover.

597 of 1161
PTO 15 Gear Shaft Assembly (Cont’d)
Figure 40-61-367
1
1
P-84288

P-84291
Figure 40-61-370
Install the spline boss (Item 1) and snap ring (Item 2)

[Figure 40-61-367].
Figure 40-61-368
1
2
P-84300
Install the thrust collar (Item 1) [Figure 40-61-370] with

the grooves facing the gear.
P-84290
Install the shift assembly (Item 1) [Figure 40-61-368]

onto the spline boss.
NOTE: The groove (Item 2) [Figure 40-61-368] must be


598 of 1161
PTO 15 Gear Shaft Assembly (Cont’d)
Figure 40-61-371
P-84286

shaft until it is fully seated.

599 of 1161
Range Shifter Shaft Assembly
Figure 40-61-372
1
1
P-84285

Figure 40-61-375
Figure 40-61-373
1
1
P-84277

P-84280 into the bearing cover.

shaft.

600 of 1161
PTO Shaft Assembly
Figure 40-61-376 1
P-84272
Install the two needle bearings (Item 1) [Figure 40-61-

P-84274 378] onto the shaft.
Figure 40-61-379
Figure 40-61-377
1 2
P-84270
2
Install the 20 / 27 gear (Item 1) [Figure 40-61-379] onto
P-84273 the shaft.
Install the thrust collar (Item 1) onto the shaft with the
grooves (Item 2) [Figure 40-61-377] in the position as
shown.

601 of 1161
PTO Shaft Assembly (Cont’d)
Figure 40-61-380
P-84267

P-84269 groove.
Figure 40-61-383

to the gear.
Figure 40-61-381
P-84276
1

the shaft until fully seated next to the snap ring.
P-84268

602 of 1161
PTO Shaft Assembly (Cont’d)
Figure 40-61-384 1
1 2
P-84259

P-84264 40-61-386] onto the shaft.
Figure 40-61-387
Install the PTO shaft assembly (Item 1) [Figure 40-61-
384] into the backside of the bearing cover.
Figure 40-61-385
P-84265
1
P-84261

shaft.

603 of 1161
Pinion Shaft Assembly
Figure 40-61-388
1
2
P-84253
Install the thrust collar (Item 1) onto the pinion shaft with
P-84255 the grooves (Item 2) [Figure 40-61-390] positioned as
shown.
Install the bearing (Item 1) [Figure 40-61-388] onto the Figure 40-61-391
pinion shaft until fully seated.
Figure 40-61-389
P-84252
P-84254 Install the two needle bearing assemblies (Item 1)

[Figure 40-61-391].

groove in the pinion shaft.

604 of 1161
Pinion Shaft Assembly (Cont’d)
Figure 40-61-392 1
P-84247
Install the spline boss (Item 1) [Figure 40-61-394] onto

P-84251 the shaft.
Figure 40-61-395
step on the shaft.
Figure 40-61-393
P-84246

P-84249 groove.

605 of 1161
Figure 40-61-396
1
P-84238

Figure 40-61-399
Install the shifter gear (Item 1) [Figure 40-61-396].
Figure 40-61-397
2
1
1
2 P-84235
P-84241 Install the bearing (Item 1) and snap ring (Item 2) [Figure
40-61-399] onto the 36 gear.
Install the two needle bearings (Item 1) and spacer (Item

2) [Figure 40-61-397] onto the shaft.

606 of 1161
Figure 40-61-400 2
2 1
P-84229
3
Install the thrust collar (Item 1) and snap ring (Item 2)

P-84233 [Figure 40-61-402].
Figure 40-61-403
Install the 36 gear (Item 1) onto the 30 gear (Item 2) and
install the snap ring (Item 3) [Figure 40-61-400].
1
Figure 40-61-401
2
1
2
P-84227
install the 24 gear (Item 1) and spacer (Item 2) [Figure

P-84231 40-61-403].
Install the 36 / 30 gear assembly (Item 1) onto the shaft

(Item 2) [Figure 40-61-401].

607 of 1161
Figure 40-61-404
P-84223
Install the pinion shaft assembly into the housing and

P-84258 install the bearing (Item 1) [Figure 40-61-406].
Figure 40-61-407
shaft until fully seated. 1
Install the spacer.
Figure 40-61-405
1 1
P-84221
Install the shim (Item 1) [Figure 40-61-407] removed

earlier.
P-84224
Install the two bearing races (Item 1) and spacer (Item 2)

[Figure 40-61-405] into the bearing case.

608 of 1161
Figure 40-61-408
2
2
P-84218
Install the bearing cover (Item 1) and three bolts (item 2)

[Figure 40-61-408].
Figure 40-61-409
P-84215

108 - 145 ft.-lb. (147 - 196 N•m) torque.
shaft groove.

609 of 1161
Middle Case Bearing Cover / Shift Links Assembly
Figure 40-61-410
1
1 2
P-84301
P-84307 and ball and slide the fork (Item 1) onto the shifting rod
(Item 2) [Figure 40-61-412] in the position shown,
Install a new O-ring (Item 1) [Figure 40-61-410] onto the
shift arm. Figure 40-61-413
Figure 40-61-411
1
1
2
P-84214
P-84306
Install the range shift fork rod assembly (Item 1) into the
Install the range shift arm (Item 1) [Figure 40-61-411]
into the housing.

610 of 1161

(Cont’d)
Figure 40-61-414
1
P-84302
Install the mid PTO shift arm (Item 1) [Figure 40-61-416].

into the housing.
P-84213
Install the roll pin (Item 1) [Figure 40-61-414]. Figure 40-61-417
Figure 40-61-415
2
1
P-84304
P-84303
and ball and slide the fork (Item 1) onto the shifting rod
Install the O-ring (Item 1) [Figure 40-61-415] onto the (Item 2) [Figure 40-61-417] in the position shown,
shift arm. making sure the fork slides over the ball.

611 of 1161

(Cont’d) 1
Figure 40-61-418
1
1
P-95953
Install the six bolts (Item 1) [Figure 40-61-420].
P-84212 Tighten the bolts to 57-66 ft. lb. (77-90 N•m) torque.
Figure 40-61-421
Install the mid PTO fork (Item 1) [Figure 40-61-418] and
assembly into the cover.
Figure 40-61-419
1
1
P-95952

Install the bearing cover assembly (Item 1) [Figure 40-

61-419] onto the housing.

612 of 1161

(Cont’d)
1
Figure 40-61-422
1
2
P-95959

inward and align with the shifter fork.
P-95951
Figure 40-61-425

40-61-422].
2
Figure 40-61-423
1
1
2
P-95958

40-61-425].
P-95950
Install the range shift linkage (Item 1) and roll pin (Item 2)
[Figure 40-61-423].

613 of 1161

(Cont’d)
5
Figure 40-61-426
1
1
4
3
P-95957
Install the mid PTO shift linkage (Item 1) and roll pin (Item
2) [Figure 40-61-426].
Figure 40-61-427
B-23841
If the backlash is below the permissible range, decrease

the number of shims (Item 1) on the left side of the ring
gear, install the shims removed, on the right side of the
ring gear (Item 2) [Figure 40-61-428].
If the backlash is above the permissible range, decrease

the number of shims (Item 2) on the right side of the ring
gear, install the shims removed, on the left side of the
ring gear (item 1) [Figure 40-61-428].
Apply marking compound lightly over the teeth at three

positions equally spaced on the pinion (Item 3) [Figure
P-84368
40-61-428].
Position a magnetic base dial gauge on the housing, with Rotate the ring gear (Item 4) [Figure 40-61-428] while
the tip of the gauge on the tooth of the ring gear, move pressing against the outer edge of the ring gear.
the pinion shaft back and forth to measure the backlash
[Figure 40-61-427].
Repeat the above procedure on two or more locations on

the ring gear teeth to obtain an average value.
Check that the backlash is within the permissible range of

0.006 - 0.012 in. (0,15 - 0,25 mm).

614 of 1161

(Cont’d)
Figure 40-61-429
PE-2470S
If excessive contact on tooth toe and base [Figure 40-

61-431], replace the shim (Item 5) with a thinner shim to
MS-2468S move the pinion shaft forward, to move the pinion gear
right, reduce the side shim (Item 2) and add shim of the
same thickness to the left side (Item 1) [Figure 40-61-
Correct Pattern: If the pinion/ring gear has been properly 428 on Page 40-61-140].
adjusted, wear pattern (contact) should be as shown
[Figure 40-61-429].
Figure 40-61-430
MS-2469S
If excessive contact on tooth heal and tip [Figure 40-61-

430], replace the shim (Item 5) with a thicker shim to
move the pinion shaft backward, to move the pinion gear
left, reduce the side shim (Item 1) and add shim of the
same thickness to the right side (Item 2) [Figure 40-61-
428 on Page 40-61-140].

615 of 1161
Middle Case / PTO Clutch Assembly
Figure 40-61-432
P-84092
2
Lightly lubricate the O-rings on the piston and install into
P-84101 the clutch housing [Figure 40-61-434].
Figure 40-61-435
Install the stop plate (Item 1) and ring (Item 2) [Figure
40-61-432] into the clutch housing.
2
Figure 40-61-433
1
1
P-84090
Install the spring (Item 1) and washer (Item 2) [Figure

P-84094 40-61-435].
Place snap ring into position on top of the washer.

Install new O-rings (Item 1) [Figure 40-61-433] into the
piston.

616 of 1161
Figure 40-61-436
1
2
P-84087

clutch housing.
Figure 40-61-439
P-84371
1
Install the tool (Item 1) and tighten the nut (Item 2) to
compress the spring enough to install the snap ring (Item
3) [Figure 40-61-436].
Figure 40-61-437
P-84086
1 Install the spline hub (Item 1) [Figure 40-61-439] onto

the bearing.
P-84089
Make sure the snap ring (Item 1) [Figure 40-61-437] is

fully seated.

617 of 1161
Figure 40-61-440 2 2
1
P-84133
The PTO clutch pack consists of the following [Figure

40-61-440]
A. Seven friction plates

B. Four dampening plates (with rubber)
C. Three non-dampening plates (without rubber)
D. One cover plate (thick)
P-84134 &
Figure 40-61-441 P-84135
2 The dampening rubbers (Item 1) should face the same

direction except the last one on top (Item 2) [Figure 40-
61-442].
3
Figure 40-61-443
P-84082
Align and install the disks (Item 1) over the hub (Item 2)
[Figure 40-61-441] in the following order:
C-A-B-A-C-A-B-A-C-A-B-A-B-A-D [Figure 40-61-441]

P-84105
The cover plate (Item 3) [Figure 40-61-441] must be
installed with the groove facing down.

618 of 1161
Figure 40-61-444
P-84140
Install the PTO clutch assembly into the bearing cover

P-84080 until fully seated [Figure 40-61-446].
Figure 40-61-447
Lightly lubricate and install the two seals (Item 1) [Figure
40-61-444] on the clutch shaft.
Figure 40-61-445
2
P-95932
Install the washer and snap ring (Item 1) [Figure 40-61-

P-95934 447] onto the PTO clutch shaft.

40-61-445].

619 of 1161
Middle Case / 23-20 Gear Shaft Assembly
Figure 40-61-448
1
P-95928
Install the 23-20 gear shaft assembly (Item 1) [Figure 40-

P-95930 61-450] into the bearing cover.

Figure 40-61-449
P-95929


620 of 1161
Middle Case / Shuttle Shaft Assembly
Figure 40-61-451
1
P-95898

Figure 40-61-454
Install the needle bearing (Item 1) [Figure 40-61-451].
Figure 40-61-452
1
1
P-95905
P-95899 Install the washer (Item 1) [Figure 40-61-454].
Install the thrust collar (Item 1) [Figure 40-61-452] onto

the shaft.
NOTE: The grooves in the thrust collar must face the

needle bearing.

621 of 1161
Middle Case / Shuttle Shaft Assembly (Cont’d)
Figure 40-61-455
1
1
P-95912
Install the inner cone (Item 1) onto the center cone (Item
P-95906 2) [Figure 40-61-457].
Figure 40-61-458
Install the snap ring (Item1) [Figure 40-61-455].
Figure 40-61-456 1
2
3
1
P-95914
P-95907 Install the inner cone / center cone assembly (Item 1)

onto the 22 gear [Figure 40-61-458].
Install the 22 gear (Item 1) [Figure 40-61-456] onto the NOTE: Make sure the four tabs (Item 2) on the center
shaft. cone enter the four holes (Item 3) [Figure 40-
61-458] on the 22 gear.

622 of 1161

1
Figure 40-61-459
1
1
1 P-95711
Install the three synchronizer keys (Item 1) [Figure 40-

P-95915 61-461] into the hub.
Figure 40-61-462
Install the synchronizer ring (Item 1) [Figure 40-61-459]
onto the inner cone / center cone assembly.
NOTE: Make sure the tabs (Item 2) [Figure 40-61-459]

line up and allow the synchronizer ring to
drop into position.
Figure 40-61-460
1
2 P-95713
NOTE: The synchronizer keys must be positioned as

shown [Figure 40-61-462] when installed into
the hub.
2
P-95890
Install the spring (Item 1) [Figure 40-61-460] onto the

hub (both sides).
NOTE: Make sure the spring (Item 1) covers the three

openings (Item 2) [Figure 40-61-460].

623 of 1161

1
Figure 40-61-463
P-95917
1
Rotate the shifter / synchronizer hub (Item 1) until it drops
P-95888 down onto the synchronizer ring (Item 2) [Figure 40-61-
465].
Install the shifter (Item 1) onto the synchronizer hub (Item Figure 40-61-466
2) [Figure 40-61-463].
Figure 40-61-464
2
1
P-95911
P-95887 Install the inner cone (Item 1) into the center cone (Item
2) [Figure 40-61-466].
Install the shifter / synchronizer hub (Item 1) [Figure 40-

61-464] onto the shaft.

624 of 1161
Figure 40-61-467
1 1
P-95920

P-95918
Figure 40-61-470
Install the inner cone / center cone (Item 1) into the

synchronizer ring (Item 2) [Figure 40-61-467].
Figure 40-61-468
1
1
2
P-95921
Install the needle bearings (Item 1) [Figure 40-61-470]

onto the shaft.
P-95919
Install the synchronizer ring assembly (Item 1) into the

shifter hub (Item 2) [Figure 40-61-468].
NOTE: Rotate the synchronizer ring until it drops

down into the shifter hub.

625 of 1161
Figure 40-61-471
P-95924

P-95922
NOTE: The grooves in the thrust collar must be next
to the gear.
shaft. Figure 40-61-474
Figure 40-61-472
1
1
2 3
P-95925
P-95923
Install the thick spacer (Item 1) [Figure 40-61-474].
Rotate the 17 gear (Item 1) until the four holes (Item 2)

drop over the synchronizer ring posts (Item 3) [Figure
40-61-472].

626 of 1161
Figure 40-61-475
1
P-95872
Install the shuttle shaft assembly (Item 1) [Figure 40-61-

P-95926 477] into the bearing cover.

Figure 40-61-476
P-95927

40-61-476].

627 of 1161
Middle Case / 19 Gear Shaft Assembly
Figure 40-61-478
P-95870
Install the bearings (Item 1) [Figure 40-61-478] onto the

Figure 40-61-479
2
1
P-95869
Install the 19 gear shaft assembly (Item 1) [Figure 40-61-

479] into the bearing cover.
NOTE: It may be necessary to raise the shuttle shaft

(Item 2) [Figure 40-61-479] slightly.

628 of 1161
Middle Case / Shift Link Assembly
Figure 40-61-480
1
2
P-95939
Install the shifter rod (Item 1) [Figure 40-61-482] into the

P-95937 bearing cover.
NOTE: Position the holes (Item 2) [Figure 40-61-482]

Install the shifter fork (Item 1) [Figure 40-61-480] onto as shown.
the shuttle shaft shifting hub.
Figure 40-61-483
Figure 40-61-481
1
1
P-95940
P-95938
Install the detent ball (Item 1) [Figure 40-61-483] on top

Install the detent spring (Item 1) [Figure 40-61-481] into of the detent spring.
the bearing cover.

629 of 1161
Middle Case / Shift Link Assembly (Cont’d)
Figure 40-61-484 1 2
P-95946
Install the shifter rod (Item 1) into the fork (Item 2)

P-95944 [Figure 40-61-486].
Figure 40-61-487
Cover the opening using a rag to prevent losing the
detent ball [Figure 40-61-484].
Figure 40-61-485
P-95947
1
Position the end of the shifter rod (Item 1) [Figure 40-61-

P-94945 487] as shown.
Using a punch, press down on the detent ball while

installing the shifter rod (Item 1) [Figure 40-61-485].

630 of 1161
Middle Case / Shift Link Assembly (Cont’d)
Figure 40-61-488
P-95857

40-61-488].
Bend the retainer plate (Item 3) [Figure 40-61-488] up

and around the bolt head.
Figure 40-61-489
P-95948
Install the roll pin (Item 1) [Figure 40-61-489] into the

shifter rod.

631 of 1161
TRANSMISSION (SST MODELS) (CONT’D) Middle Case Installation
Middle Case / Bearing Cover Installation Figure 40-61-492
Figure 40-61-490
P-95841
2
P-95855
Align the coupler and slide the middle case onto the
transmission studs [Figure 40-61-492].
Install the bearing cover assembly (Item 1) into the
middle case (Item 2) [Figure 40-61-490]. Figure 40-61-493
Figure 40-61-491
1
1 1
P-95842
1
P-95852
61-493].
Install the five bolts (Item 1) [Figure 40-61-491] and
tighten to 36-41 ft. lb. (48-56 N•m) torque. Tighten the bolts and nuts to 84 ft. lb. (114 N•m) torque.
Apply gasket eliminator onto the mounting surface of the

middle case.

632 of 1161
Bearing Cover / Main Shaft Assembly
Figure 40-61-494
1
P-95760
Install the main shaft assembly (Item 1) [Figure 40-61-

Figure 40-61-495
P-95758
Install the bearing (Item 1) [Figure 40-61-494] and

[Figure 40-61-495] on the main shaft.

633 of 1161
Bearing Cover / Countershaft Assembly 2
Figure 40-61-497
2
P-95712
Install the spring (Item 1) [Figure 40-61-499] into the hub

P-95733 (both sides).
NOTE: Make sure the spring (Item 1) covers the three

Position the splined end of the shaft as shown. Install the openings (Item 2) [Figure 40-61-499]
needle bearing (Item 1) [Figure 40-61-497] onto the
countershaft.
Figure 40-61-498
P-95734

634 of 1161
Bearing Cover / Countershaft Assembly (Cont’d)

1
Figure 40-61-500
1 2
P-95735
1 Install the shifter (Item 1) onto the synchronizer hub (Item

P-95711 2) [Figure 40-61-502].
Figure 40-61-503
Figure 40-61-501
P-95739
P-95713
Install the synchronizer ring (Item 1) onto the

Install the three synchronizer keys (Item 1) [Figure 40- synchronizer hub / shifter assembly (Item 2) [Figure 40-
61-500] into the hub. 61-503] (both sides).

the hub.

635 of 1161
Figure 40-61-504
1
P-95741
1

1
P-95736 shaft.
Figure 40-61-507
Make sure the three synchronizer keys (Item 1) line up
with the three notches (Item 2) [Figure 40-61-504] so the
synchronizer ring drops into the synchronizer hub.
1
Figure 40-61-505
P-95742
Install the needle bearing (Item 1) [Figure 40-61-507]

into the 38 gear.
P-95740
Install the shifter hub / synchronizer assembly (Item 1)

[Figure 40-61-505] onto the shaft next to the 34 gear.
NOTE: Make sure the synchronizer rings remain in

the synchronizer hub.

636 of 1161
Figure 40-61-508 1
P-95746

Figure 40-61-511
shaft.
Figure 40-61-509
P-95747
Turn the shaft Assembly over [Figure 40-61-511].

P-95745

to the gear.

637 of 1161

2
Figure 40-61-512
2
P-95712
Install the spring (Item 1) [Figure 40-61-514] into the hub

NOTE: Make sure the spring (Item 1) cover the three

Install the needle bearings (Item 1) [Figure 40-61-512] openings (Item 2) [Figure 40-61-514].
onto the countershaft.
Figure 40-61-513
P-95749

638 of 1161
Figure 40-61-515 1
2
1
P-95735
Install the shifter (Item 1) onto the synchronizer hub (Item

1
P-95711 2) [Figure 40-61-517].
Figure 40-61-518
Figure 40-61-516
1
2
P-95739
P-95713
Install the synchronizer ring (Item 1) onto the

Install the three synchronizer keys (Item 1) [Figure 40- synchronizer hub (Item 2) [Figure 40-61-518] (both
61-515] into the hub. sides).

the hub.

639 of 1161
Figure 40-61-519
2
1
1
P-95751
2
2 Install the snap ring (Item 1) [Figure 40-61-521] onto the
P-95736 shaft.
Figure 40-61-522
Make sure the three synchronizer keys (Item 1) line up
with the three notches (Item 2) [Figure 40-61-519] so the
synchronizer ring drops into the synchronizer hub.
1
Figure 40-61-520
P-95752
Install the needle bearing (Item 1) into the 26 gear (Item

2) [Figure 40-61-522].
P-95750
Install the shifter hub / synchronizer assembly (Item 1)

[Figure 40-61-520] onto the shaft next to the 30 gear.
NOTE: Make sure the synchronizer rings remain in

the synchronizer hub.

640 of 1161

1
Figure 40-61-523
P-95755

Figure 40-61-526
shaft.
Figure 40-61-524
1
P-95761
Install the countershaft assembly (Item 1) [Figure 40-61-


to the gear.

641 of 1161
Bearing Cover / Shift Links Assembly 4 5

Figure 40-61-527
1
2
P-95765
Install the shifting fork assembly (Item 1) onto the shifter

P-95762 hub (Item 2) [Figure 40-61-529].
Make sure the notches (Item 3) are positioned as shown

Position the bearing cover assembly in the position and install the shifting rod (Item 4) part way into the
shown [Figure 40-61-527]. bearing cover (Item 5) [Figure 40-61-529].
Figure 40-61-528 Figure 40-61-530
P-95763 P-95766
Install the spring (Item 1) [Figure 40-61-528] into the Place the detent ball (Item 1) [Figure 40-61-530] on top
cover. of the spring.

642 of 1161

1
Figure 40-61-531
P-95770
Install the two roll pins (Item 1) [Figure 40-61-533] into

P-95767 the shifting rod.
Figure 40-61-534
Use a rag and cover the openings in the bearing cover
[Figure 40-61-531]. 2
Using a punch, press down on the detent ball while 1
moving the shifting rod into the bearing cover until it stops 3
in the detent groove [Figure 40-61-531].
Figure 40-61-532
P-95771
Align the shifter fork (Item 1) with the shifting rod (Item 2)
and install the roll pin (Item 3) [Figure 40-61-534].
1
P-95769
Using a punch as shown rotate the shifting rod (Item 1)

until the flat surface (Item 2) [Figure 40-61-532] is
pointed upward.

643 of 1161
Figure 40-61-535
1
P-95775
Place the detent ball (Item 1) [Figure 40-61-537] on top

P-95772 of the spring.
Figure 40-61-538
Install the spring (Item 1) [Figure 40-61-535] into the
cover.
Figure 40-61-536
1 P-95776
3
Use a rag and cover the openings in the bearing cover

P-95774 [Figure 40-61-538].
Using a punch, press down on the detent ball while

Install the shifting fork assembly (Item 1) onto the shifter moving the shifting rod into the bearing cover until it stops
hub (Item 2) [Figure 40-61-536]. in the detent groove [Figure 40-61-538].
Make sure the notches (Item 3) are positioned as shown

and install the shifting rod (Item 4) part way into the

644 of 1161
Bearing Cover / Shift Links Assembly (Cont’d) 2
Figure 40-61-539
1
1
P-95780
Align the shifter fork (Item 1) with the shifting rod (Item 2)
P-95778 and install the roll pin (Item 3) [Figure 40-61-541].
Figure 40-61-542
Using a punch as shown rotate the shifting rod (Item 1)
until the flat surface (Item 2) [Figure 40-61-539] is
pointed upward.
Figure 40-61-540
1 1
1 P-95781
Install the three detent balls (Item 1) [Figure 40-61-542]

into the center hole in the bearing cover.
P-95779
Install the two roll pins (Item 1) [Figure 40-61-540] into

the shifting rod.

645 of 1161
Figure 40-61-543
P-95672
Install the locking bolt / lock washer (Item 1) [Figure 40-

61-543] into the bearing cover.

646 of 1161
Bearing Cover / PTO Driveshaft Assembly
Figure 40-61-544
1 1
P-95824
Install the PTO driveshaft assembly (Item 1) [Figure 40-

P-95671 61-546] into the bearing cover.
Figure 40-61-545
P-95670

[Figure 40-61-545] on the PTO driveshaft.

647 of 1161
Bearing Cover / PTO Countershaft Assembly
Figure 40-61-547
P-95825
Install the PTO countershaft assembly (Item 1) [Figure

P-95664 40-61-549] into the bearing cover.
Figure 40-61-548
P-95665

[Figure 40-61-548] on the PTO countershaft.

648 of 1161
Transmission Case Assembly
Figure 40-61-550
2
1
1
P-95613

P-95615 40-61-552] over the shuttle shift arm.
Figure 40-61-553
Install the o-ring (Item 1) [Figure 40-61-550] into the
housing.
Figure 40-61-551
P-95612

P-95614 shuttle shift arm.
Install the shuttle shift arm (Item 1) [Figure 40-61-551]

into the housing.

649 of 1161
Transmission Case Assembly (Cont’d)
Figure 40-61-554
1
P-95609
2
P-95611 snap ring groove.
Figure 40-61-557
Install the shuttle shift lever (Item 1) and roll pin (Item 2)
[Figure 40-61-554].
Figure 40-61-555
2
P-95660
Clean the gasket material from the housing [Figure 40-

P-95610 61-557].
Install the universal joint assembly (Item 1) using the roll

pin (Item 2) [Figure 40-61-555].

650 of 1161

1
Figure 40-61-558
1
1
P-95821

P-95822 40-61-560] onto the shaft.
Figure 40-61-561
housing.

housing. 1
Figure 40-61-559
2
1
P-95820

40-61-561] into the housing.
P-95658
Install the 18 gear shaft (Item 1) [Figure 40-61-559].

651 of 1161
Figure 40-61-562
1
P-95819
1 Install the snap ring (Item 1) [Figure 40-61-564] onto the

P-95661 shaft.
Figure 40-61-565
Install the snap ring (Item 1) onto the driveshaft (Item 2)
[Figure 40-61-562] in the snap ring groove as shown.
1
Figure 40-61-563
2
P-95818
1
Install the seal (Item 1) [Figure 40-61-565] over the

P-95662 driveshaft and into the housing.
Install the driveshaft (Item 1) [Figure 40-61-563] into the

housing.
NOTE: The longer end of the shaft (Item 2) [Figure 40-

61-563] will be out of the back side of the
housing.

652 of 1161

1 2
Figure 40-61-566
2
1
2
2
P-95829
Install the gear assembly bearing case (Item 1) into the

P-95826 housing and install the six bolts (Item 2) [Figure 40-61-
568].
Figure 40-61-567 Figure 40-61-569
P-95827 P-95830
Align the shifting rods (Item 1) [Figure 40-61-566] with Install the coupler (Item 1) [Figure 40-61-569].
the bushings (Item 1) [Figure 40-61-567] in the housing.

653 of 1161
Figure 40-61-570
P-95838
Apply gasket eliminator to the mounting surface of the

P-95836 gear shift assembly [Figure 40-61-572].
Figure 40-61-573
Clean the gear shift housing [Figure 40-61-570].
Figure 40-61-571
1
1
2
P-95839
P-95837 Install the gear shift rod (Item 1) into the shifting forks
(Item 2) [Figure 40-61-573].
Align the shifting forks (Item 1) and (Item 2) [Figure 40-

61-571] as shown.

654 of 1161
Figure 40-61-574
1
P-95581
Install the two bearings (Item 1) and seal (Item 2) [Figure

P-95840 40-61-576].
Figure 40-61-577
tighten.
Figure 40-61-575
P-95817
1
Install the shaft / bearing assembly (Item 1) [Figure 40-
P-95834 61-577] into the housing.
Install the gear (Item 1) and snap ring (Item 2) [Figure

40-61-575] onto the main shaft.

655 of 1161
Figure 40-61-578
P-81745
Clean the gasket material from the cover.
Install the seal (Item 1) [Figure 40-61-578] into the cover.
Apply gasket eliminator or equivalent to the cover.
Figure 40-61-579
2
2
P-95578
Install the cover (Item 1) and six bolts (Item 2) [Figure

40-61-579]. Tighten the bolts to 8 ft.-lb. (11 N•m) torque.
Install the clutch lever assembly (See CLUTCH LEVER

(SST MODELS) on Page 70-140-1).

656 of 1161
Transmission Case Installation
Figure 40-61-580
1
1
P-95562

P-95563 61-582].
Tighten the bolts and nuts to 84 ft. lb. (114 N•m) torque.
Apply gasket eliminator onto the mounting surface of the
transmission case. Figure 40-61-583
Align the coupler and slide the transmission case onto

the middle case studs [Figure 40-61-580].
2
Figure 40-61-581 1
P-95556
Install the shift linkage (Item 1) and roll pin (Item 2)

[Figure 40-61-583].
P-95564
When installing the transmission case to the middle case.

The shuttle fork shifter rod (Item 1) must engage the shift
arm (Item 2) [Figure 40-61-581].

657 of 1161
Transmission Case Installation (Cont’d)
Figure 40-61-584
1
2
P-95553
Install the bracket (Item 1) and three bolts (Item 2)

P-95555 [Figure 40-61-586] on the right side.
Tighten the bolts and nuts to 84 ft. lb. (114 N•m) torque
Install the bracket (Item 1) and three bolts (Item 2) (both sides).
[Figure 40-61-584] on the left side. Tighten the bolts to
84 ft. lb. (114 N•m) torque. Figure 40-61-587
Figure 40-61-585
2
2
P-95552
P-95554
Using the two bolts (Item 1) install the valve / bracket
assembly (Item 2) [Figure 40-61-587].
Install the brake linkage (Item 1) using the pin, washer
and cotter pin (Item 2) [Figure 40-61-585] (both sides). Installation: Tighten the bolts to 84 ft. lb. (114 N•m)
torque.

658 of 1161
Figure 40-61-588 1
P-95502
2
Install the pin (Item 1) [Figure 40-61-590].

P-95551
Figure 40-61-591
Install the joint bolt and tube line (Item 1) on the valve
(Item 2) [Figure 40-61-588].
Figure 40-61-589
2 1
P-95501
1
Thread the flange (Item 1) on the cable. Install the nut
(Item 2) and the two screws (Item 3) [Figure 40-61-591].
P-86191
Before installing the cable flange on the valve. Install the

o-ring (Item 1) [Figure 40-61-589] in the o-ring bore of
the flange.

659 of 1161
Figure 40-61-592
P-95500
Install the pin (Item 1) [Figure 40-61-592].
Figure 40-61-593
2 1
P-95499
Thread the flange (Item 1) on the cable. Install the nut

(Item 2) and the two screws (Item 3) [Figure 40-61-593].
Tighten the screws to 7 ft. lb. (9,4 N•m) torque.

660 of 1161
FRONT AXLE
Engage the parking brake and stop the engine.

IMPORTANT
Remove the driveshaft. (See Removal And Installation on When repairing hydrostatic and hydraulic systems,
Page 40-30-1.) clean the work area before disassembly and keep all
Figure 40-70-1 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 40-70-3
P-86041 1
Raise the front of the machine and install jack stands

under the tractor frame [Figure 40-70-1]. P-86045
Figure 40-70-2
Remove the hose (Item 1) [Figure 40-70-3] from the left
steering cylinder.
Figure 40-70-4
P-86044
Remove the hose (Item 1) [Figure 40-70-2] from the right

steering cylinder. P-86046
Support the front axle using a jack under the axle [Figure
40-70-4].

661 of 1161
FRONT AXLE (CONT’D) Figure 40-70-7
Figure 40-70-5 1
2
1
P-78595
1 2
Remove the two lug nuts (Item 1) and four bolts (Item 2)
P-86048 [Figure 40-70-7] from both front wheels.

Remove the bolt (Item 1) and nut (Item 2) [Figure 40-70- torque and bolts 57 - 67 ft.-lb. (78 - 90 N•m) torque.
5] (both sides) from the rear axle pivot.
Figure 40-70-8
Installation: Tighten the bolts to 91 - 109 ft.-lb. (124 -
147 N•m) torque.
Figure 40-70-6
1
1
2
1
2
P-86049
Remove the hose (Item 1) [Figure 40-70-8] from the top

P-86047 of the axle.
Remove the two bolts (Item 1) and two nuts (Item 2)

[Figure 40-70-6] from the front axle pivot.

147 N•m) torque.

662 of 1161
FRONT AXLE (CONT’D)
Figure 40-70-9
P-86050
Lower the front axle and roll out from under the machine
[Figure 40-70-9].

663 of 1161
664 of 1161
FRONT AXLE (SST MODELS) Figure 40-71-2
Engage the parking brake and stop the engine.
Remove the driveshaft. (See Removal And Installation on

Page 40-31-1.)
Figure 40-71-1
P-98204
Remove the hose (Item 1) [Figure 40-71-2] from the right


N•m) torque.
P-98203 Figure 40-71-3
Raise the front of the machine and install jack stands

under the tractor frame [Figure 40-71-1].
IMPORTANT
damage the system. P-98205
I-2003-0888
Remove the hose (Item 1) [Figure 40-71-3] from the left


N•m) torque.

665 of 1161
FRONT AXLE (SST MODELS) (CONT’D) Figure 40-71-6
Figure 40-71-4
2 1
P-98212
Remove the bolt (Item 1) and nut (Item 2) [Figure 40-71-

P-98206 6] (both sides) from the front axle pivot.

Support the front axle using a floor jack under the axle 147 N•m) torque.
[Figure 40-71-4].
Figure 40-71-7
Figure 40-71-5
1
1
1
1
P-98209
P-98208
Remove the six lug nuts (Item 1) [Figure 40-71-7] from

Remove the bolt (Item 1) and nut (Item 2) [Figure 40-71- both front wheels.
5] (both sides) from the rear axle pivot.
Installation: Tighten the bolts to 91 - 109 ft.-lb. (124 - torque.
147 N•m) torque.

666 of 1161
FRONT AXLE (SST MODELS) (CONT’D)
Figure 40-71-8
P-98214
Remove the hose (Item 1) [Figure 40-71-8] from the top

of the axle. Remove the wheels.
Figure 40-71-9
P-98216
Lower the front axle and roll out from under the machine
[Figure 40-71-9].

667 of 1161
668 of 1161
AXLE AND DIFFERENTIAL
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Axle housing bent 12, 13
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

3. Pinion nut loose
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent

669 of 1161
AXLE AND DIFFERENTIAL (CONT’D)
Front Axle Cover Parts Identification
1. O-Ring
2. Bearing
3. 40 Gear
4. Lock Ring
5. Cover
6. Bolt
7. Seal
8. Axle
9. Stud
2 3
1
5
1 8
2
6 7
B-23893

670 of 1161
AXLE AND DIFFERENTIAL (CONT’D) Figure 40-80-2
Front Axle Cover Disassembly
IMPORTANT
damage the system.
I-2003-0888
P-86051
Remove the steering cylinders. (See Removal And

Installation on Page 20-50-1.) Remove the drain plug (Item 1) [Figure 40-80-2] and
drain the oil from the axle. Dispose of the oil in an
Remove the tie rod. environmentally safe manner.
1
1
P-86052
1 P-86054
Place the axle assembly on a secure work surface Mark the cover and remove the eight bolts (Item 1)
[Figure 40-80-1]. [Figure 40-80-3].

671 of 1161
Front Axle Cover Disassembly (Cont’d)
Figure 40-80-4
1
P-78430

P-86055 axle shaft.
Figure 40-80-7
Remove the gear case cover from the hub [Figure 40-
80-4].
Figure 40-80-5
1
1
P-86066
1
Remove the two piece lock ring (Item 1) [Figure 40-80-

P-78429 7].

80-5] from the axle shaft.

672 of 1161
Figure 40-80-8
P-86062

1 P-78433 cover.
Remove the axle shaft from the cover [Figure 40-80-8].
Figure 40-80-9
P-86063
Remove the floating seal (Item 1) [Figure 40-80-9].

673 of 1161
AXLE AND DIFFERENTIAL (CONT’D) Front Axle Cover Inspection
Front Axle Cover Disassembly (Cont’d) Figure 40-80-13
Figure 40-80-11
P-78730
P-78437
Inspect the 40 gear (Item 1) [Figure 40-80-13] for worn
or cracked teeth.
Remove the axle floating seal (Item 1) [Figure 40-80-11].
Figure 40-80-14
Figure 40-80-12
P-86059
P-86060
Inspect the axle assembly splines (Item 1) [Figure 40-

Remove the O-ring (Item 1) from the seal ring (Item 2) 80-14] for wear or damage.
[Figure 40-80-12].

674 of 1161
Front Axle Case Group Parts Identification
1. Plug
2. Washer
3. Bushing
4. Bearing
5. Axle Case
6. 10 Gear
7. Shim
8. Snap Ring
9. End Cap
1
2
3
4
7
5
8
9
2
1
8
B-23892

675 of 1161
Front Axle Case Group Disassembly
NOTE: The following procedure can be done with the

axle assembly in the machine.
Figure 40-80-15
P-86070
Remove the axle case from the axle housing [Figure 40-
80-17].
Figure 40-80-18
P-86067
Support the axle case assembly using a hoist and lifting 1

strap [Figure 40-80-15].
Figure 40-80-16
1
1
P-86070
Remove the axle shaft (Item 1) and floating seal (Item 2)

[Figure 40-80-18].
NOTE: Mark the axle shaft for correct assembly.

P-78447
NOTE: Record the quantity and location of the shims.

676 of 1161
Front Axle Case Group Disassembly (Cont’d)
Figure 40-80-19
1
2
1
P-78449
Remove the snap ring (Item 1) and end cap (Item 2)

P-86073 [Figure 40-80-21] from the axle case.
Figure 40-80-22
Remove the two piece bearing (Item 1) [Figure 40-80-
19].
1
Figure 40-80-20
P-86076

P-86074

677 of 1161
Figure 40-80-23
P-86077
Remove the shim (Item 1) [Figure 40-80-23].
Figure 40-80-24
P-86079
Remove the bearing / 10 gear (Item 1) [Figure 40-80-

24].

678 of 1161
Bevel Gear Case Group Parts Identification
1. Support
2. Seal
3. Bearing
4. Snap Ring 1
5. Shim
6. 17 Gear
7. Shaft
8. Case 2
9. O-Ring
10. Seal Ring
11. Plug 3
11 9
10
10
B-23890

679 of 1161
Bevel Gear Case Group Disassembly
Figure 40-80-25
1
P-86086

P-86083
Figure 40-80-28
Remove the axle case support (Item 1) [Figure 40-80-

25] by lifting upward.
Figure 40-80-26
1 P-86087
2
P-86086

680 of 1161
Bevel Gear Case Group Disassembly (Cont’d)
Figure 40-80-29
1
P-86091

P-86088 axle support.
Figure 40-80-32
Remove the shims [Figure 40-80-29].
Figure 40-80-30
1
1
P-86092
P-86090 Remove the floating seal (Item 1) [Figure 40-80-32].

30].

681 of 1161
Bevel Gear Case Group Inspection
Figure 40-80-33
P-78467

cracked teeth.
Figure 40-80-34
1
P-78468
Inspect the axle splines (Item 1) [Figure 40-80-34] for

wear or damage.

682 of 1161
Axle Shaft Group Parts Identification
1. Axle Shaft
2. Snap Ring
3. Shim
4. Spacer
5. Bearing
6. 11 Gear
7. O-Ring
8. Case
9. Lock Washer
10. Nut
11. Bolt
1 6 10
2 3 4 5 7
9
11
B-23895

683 of 1161
Axle Shaft Group Disassembly
Figure 40-80-35
1
P-86094
Remove the axle shaft (Item 1) [Figure 40-80-37].

P-86133
Figure 40-80-38
Remove the mounting bolts, nuts and lock washers (Item

1) [Figure 40-80-35].
Figure 40-80-36
P-86097
P-86093
Remove the case (Item 1) [Figure 40-80-36].

684 of 1161
Axle Shaft Group Disassembly (Cont’d)
Figure 40-80-39
1
P-86101
Remove the 11 gear / bearing (Item 1) [Figure 40-80-41]

P-86099 from the case.
Axle Shaft Group Inspection

Remove the shims [Figure 40-80-39] from the housing.
Figure 40-80-42
NOTE: Record the quantity and location of the shims
removed.
Figure 40-80-40 1
P-78467

P-86100 cracked teeth.

685 of 1161
Axle Support Removal
Figure 40-80-43 2
P-78480
Remove the shim (Item 1) and bushing (Item 2) [Figure

P-78482 40-80-45] from the axle support.
Figure 40-80-46
Remove the axle support (Item 1) [Figure 40-80-43]
(both sides) by sliding off the axle.
1
Figure 40-80-44 1
1
1
P-78485

P-78483
Remove the bushing (Item 1) and shim plate (Item 2)

[Figure 40-80-44] from the axle support.

686 of 1161
Axle Support Removal (Cont’d)
Figure 40-80-47
1
P-78488

P-78486
Remove the axle support housing [Figure 40-80-47].
Figure 40-80-48
P-78487

axle support housing.

687 of 1161
Pinion Shaft Removal
Figure 40-80-50
P-78490
Figure 40-80-51
P-78491
Remove the pinion shaft assembly (Item 1) [Figure 40-

80-51].

688 of 1161
1. Pinion Shaft
2. Collar (Adjusting)
3. Bearing
4. Nut
5. Snap Ring
6. Seal
6
4
5
2
3
2
3
2
B-23888

689 of 1161
Pinion Shaft Disassembly 2
Figure 40-80-52
2 1
1
1
1
P-78510
Remove the two bearings (Item 1) and spacer (Item 2)

P-78507 [Figure 40-80-54].
Pinion Shaft Inspection

Mark each adjusting collar (Item 1) and remove from the
pinion shaft (Item 2) [Figure 40-80-52]. Figure 40-80-55
Figure 40-80-53
2
P-25706
P-78508
Unstake the nut (Item 1) [Figure 40-80-53] and remove.
NOTE: Record the direction and location of the

tapered roller bearings before removal.

690 of 1161
Differential Removal
Figure 40-80-56
1 1
P-86131
Figure 40-80-59
P-86129
Remove the snap ring (Item 1) [Figure 40-80-56] from 1

the left side of the housing.
Figure 40-80-57
P-86132
Using a block of wood (Item 1) [Figure 40-80-58].

Remove the differential assembly (Item 1) [Figure 40-80-
59] from the left side of the housing.
P-86130
Remove the shims (Item 1) [Figure 40-80-57]. Record

the number of shims for correct assembly.

691 of 1161
1. 23-Gear
2. Bearing
3. Differential Case Cover
4. Shim
5. Side Gear
6. Pinion Gear
7. Washer
8. Pin
9. Pinion Shaft
10. Bolt
11. Shim
12. Differential Case
3
7
9
6
5
4 8
12
4
2
5
11
6
8
7
10
MS2507S

692 of 1161
Figure 40-80-60
P-78514
Separate the differential housing [Figure 40-80-62].

2
P-78511
Figure 40-80-63
Remove the differential 23 gear (Item 1) and bearing

(Item 2) [Figure 40-80-60].
Figure 40-80-61
1
P-78515
1
P-78513
Mark the housing and remove the four bolts (Item 1)

[Figure 40-80-61].

693 of 1161
Figure 40-80-64
P-78519
Remove the pinion shaft (Item 1) [Figure 40-80-66].

P-78342
Figure 40-80-67

the location of the shim for correct assembly.
Figure 40-80-65
1 1
P-78336
Remove the pinion gears (Item 1) [Figure 40-80-67].
P-78517
Remove the pinion shaft retainer pin (Item 1) [Figure 40-

80-65].

694 of 1161
Figure 40-80-68
P-78523
Remove the shims (Item 1) [Figure 40-80-70] from the

P-78521 housing.
NOTE: Record the number and location of the shims

Remove the washer (Item 1) [Figure 40-80-68] (both removed for correct assembly.
sides.)
Figure 40-80-69
P-78522

695 of 1161
Figure 40-80-71
1
2
P-78285
1
Measure and record the pinion shaft outside diameter

B-23670 (Item 1) and the inside diameter of the pinion gear (Item
2) [Figure 40-80-72].
Measure and record the outside diameter of the side gear If the clearance exceeds the allowable limit, see chart
(Item 1), the inside diameter of the differential case (Item below, replace parts as needed.
2) and the inside diameter of the differential case cover
(Item 3) [Figure 40-80-71]. Item Factory Spec. Allowable
Limit
below, replace parts as needed. Clearance 0.00063 - 0.00205 in. 0.0098 in.
between pinion (0,016 - 0,052 mm) (0,25 mm)
shaft and
Item Factory Spec. Allowable
differential pinion
Limit
Clearance 0.00197 - 0.00358 in. 0.0138 in.
between (0,050 - 0,091 mm) (0,35 mm) Item Factory Spec. Allowable
differential case Limit
(Differential case Pinion shaft O.D. 0.62858 - 0.62929 in. -
cover) and (15,966 - 15,984 mm)
differential side
Differential pinion 0.62992 - 0.63063 in. -
gear
I.D. (16,000 - 16,018 mm)

Limit
Differential case 1.26083 - 1.26181 in. -
bore I.D. (32,025 - 32,050 mm)
cover bore I.D. (32,025 - 32,036 mm)
Differential side 1.25823 - 1.25886 in. -
gear bore O.D. (31,959 - 31,975 mm)

696 of 1161
Differential Assembly 1
Figure 40-80-73
P-78521
Apply a small amount of grease to the back side of the

P-78284 washer (Item 1) [Figure 40-80-75] and install into the
housing (both sides.)
Install the shims (Item 1) [Figure 40-80-73], removed Figure 40-80-76

earlier, into the housing.
Figure 40-80-74
1
1
1
P-78520
P-78522 Install the pinion gears (Item 1) [Figure 40-80-76] into

the housing.

697 of 1161
Figure 40-80-77
2 1
3
3
P-78516
1 Install the shims (Item 1) [Figure 40-80-79], removed

P-78519 earlier, into the housing.
Figure 40-80-80
Install the pinion shaft (Item 1) into the housing (Item 2)
through the washer / pinion gears (Item 3) [Figure 40-80-
77].
1
Figure 40-80-78
P-78515

housing.
P-78517
Install the pinion shaft retainer pin (Item 1) [Figure 40-

80-78].

698 of 1161
Figure 40-80-81
1
2
1
P-78

P-78514 fully seated.
Figure 40-80-84
Install the housing (Item 1) onto the housing / gear
assembly (Item 2) [Figure 40-80-81]. make sure to align
the reference marks made earlier.
Figure 40-80-82
1
1
1
P-78526
Install the bearing / 21 gear (Item 1) [Figure 40-80-84]

until it is fully seated.
1 P-78513

tighten to 29 - 41 ft.-lb. (40 - 56 N•m) torque.

699 of 1161
Figure 40-80-85
P-77617
Select the correct differential side gear adjusting shim

B-23672 [Figure 40-80-86] from the table below:
0.157 in (0,4 mm)

Position the tip of a magnetic base dial gauge on the
tooth of the differential pinion [Figure 40-80-85]. 0.0236 in. (0,6 mm)
0.0315 in. (0,8 mm)
Hold the differential side gear and move the differential 0.0394 in. (1,0 mm)
pinion back and forth to measure the backlash.
0.0472 in. (1,2 mm)
If the measurement is not within the allowable limit of
0.004 - 0.012 in. (0,1 - 0,3mm) adjust the differential side
gear shims.
NOTE: Equal amounts of shims must be installed on

both sides of each side gear.

700 of 1161
Differential Installation
1
Figure 40-80-87
P-86129

P-86132
Install the differential / bearing assembly (Item 1) [Figure

40-80-87] into the axle housing until it is fully seated next
to the pinion shaft.
Figure 40-80-88
P-86130
Install the shims (Item 1) [Figure 40-80-88] (removed

earlier).

701 of 1161

1
Figure 40-80-90
B-23669
1
Attach one end of a light rope to the pinion splines. Make
P-78510 2 or 3 complete wraps and attach the spring scale
perpendicular to the housing to measure the rolling
torque on the bearings. Tighten (or loosen) the nut (Item
Install the two taper roller bearings (Item 1) and spacer 1) [Figure 40-80-92] until 18 - 22 lb. (8 - 10 Kgf) of
(Item 2) [Figure 40-80-90] onto the pinion shaft. smooth and continuous rolling torque is measured on the
spring scale.
NOTE: Install the bearings as marked during
disassembly. Figure 40-80-93
Figure 40-80-91
P-78508
P-78509
Stake the nut (Item 1) [Figure 40-80-93].
Install the nut (Item 1) [Figure 40-80-91] and hand

tighten.

702 of 1161
Pinion Shaft Installation
Figure 40-80-94
1
P-78537
Install the adjusting collar (Item 1) [Figure 40-80-96]

P-78533 marked and removed earlier, into the axle housing.
Figure 40-80-97
marked and removed earlier, into the axle housing.
Figure 40-80-95
1
P-78490

P-78534
Install the pinion shaft assembly into the axle housing

[Figure 40-80-95].

703 of 1161
Pinion Shaft Installation (Cont’d)
Figure 40-80-98
1
P-78248
Install the new seal (Item 1) [Figure 40-80-100] into the

B-23673 axle housing to a depth of 0.039 in. (0,1 mm).
Position a magnetic base dial gauge on the axle housing,

with the tip of the gauge at a 90 angle, move the pinion
shaft lightly by hand and measure the backlash. Check
that the backlash is within the permissible range of 0.004
- 0.012 in. (0,1 - 0,3 mm) [Figure 40-80-98].
Figure 40-80-99
1 2
B-23674
If the backlash is not within the permissible range,

change the adjusting collar (Item 1) to 0.004 in. (0.1 mm)
smaller, and adjusting collar (Item 2) [Figure 40-80-99].
to 0.004 in. (0,1 mm) larger.

704 of 1161
Axle Support Installation

2
Figure 40-80-101 1
1 3
P-78483
Align the hole in the bushing (Item 1) with the grease

P-78487 fitting (Item 2) [Figure 40-80-103] and press the bushing
into the housing until it is fully seated.
Replace the O-ring (Item 1) [Figure 40-80-101] on the Apply grease to the back of the shim plate (Item 3)
axle support housing. [Figure 40-80-103] and install.
Figure 40-80-102 Figure 40-80-104
2
2
1
P-78485 P-78482
Install the axle support housing (Item 1) and install the six Install the axle pivot (Item 1) [Figure 40-80-104] onto the
bolts (Item 2) [Figure 40-80-102] and tighten. axle support.

705 of 1161
Axle Support Installation (Cont’d)
Figure 40-80-105
1
2
1
P-78478
Install the axle support (Item 1) [Figure 40-80-107] onto

P-78480 the axle.

fitting (Item 2) [Figure 40-80-105] and press the bushing
Install the shim (Item 3) [Figure 40-80-105], removed

earlier, into the axle support.
Figure 40-80-106
P-78479
Install the O-ring (Item 1) [Figure 40-80-106] into the

axle support.

706 of 1161
Axle Shaft Group Assembly
Figure 40-80-108
P-86099
Install the shims (Item 1) [Figure 40-80-110] removed

P-86101 earlier.
Figure 40-80-111
Install the 11 gear / bearing (Item 1) [Figure 40-80-108]
into the case.
Figure 40-80-109
1
1
P-86097

P-86100
Install the spacer (Item 1) [Figure 40-80-109] into the

case.

707 of 1161
Axle Shaft Group Assembly (Cont’d)
Figure 40-80-112
1
1
P-86133
Install the mounting bolts, nuts and lock washers (Item 1)

P-86094 [Figure 40-80-114] (both sides).
Tighten the nuts to 57 - 67 ft.-lb. (78 - 90 N•m) torque.

Install the axle shaft (Item 1) [Figure 40-80-112] (both
sides).
Figure 40-80-113
P-86093
Install the axle case (Item 1) [Figure 40-80-113].

708 of 1161
Bevel Gear Case Group Assembly
Figure 40-80-115
2
1
P-86092
Use firm even pressure to pop the O-ring / seal ring

B-14496 assembly (Item 1) [Figure 40-80-116] into the case.
Figure 40-80-117
Install the O-ring (Item 1) on the seal ring (Item 2)
[Figure 40-80-115].
NOTE: Inspect the seal ring for burrs before installing

the O-ring. Install the seal ring making sure it
is not twisted. To remove any twists, gently
pull a section of the O-ring and let it snap
back. 1
The O-ring, seal ring and axle case must be clean and
free of any dust, oil film or foreign matter.
The seal ring assembly must be lubricated with alcohol,

so the O-ring will slip past the housing retaining ring and
seal uniform in the axle case radius. P-86091
Dip the O-ring and seal ring assembly in a pan of alcohol.

Install a new seal (Item 1) [Figure 40-80-117] onto the
Shake off the excess alcohol. axle support.

709 of 1161
Bevel Gear Case Group Assembly (Cont’d)
Figure 40-80-118
1
P-86087

P-86090
Figure 40-80-121
Install the 17 gear / bearing [Figure 40-80-118].
Figure 40-80-119
1
1
P-86086

P-86088

earlier).

710 of 1161
AXLE AND DIFFERENTIAL (CONT’D) Front Axle Case Group Assembly
Bevel Gear Case Group Assembly (Cont’d) Figure 40-80-124
Figure 40-80-122
1
2
P-86079
P-86084
Install the bearing / 10 gear (Item 1) [Figure 40-80-124].
Install the seal (Item 1) [Figure 40-80-122]. Figure 40-80-125
Install the plug (Item 2) [Figure 40-80-122].

1
Figure 40-80-123
P-86077
Install the shim (Item 1) [Figure 40-80-125] (removed

P-86083 earlier).
Install the axle case support (Item 1) [Figure 40-80-123].

711 of 1161
Front Axle Case Group Assembly (Cont’d)
Figure 40-80-126
1
P-86074
Install the bushing (Item 1) [Figure 40-80-128].

P-86076
Figure 40-80-129
Figure 40-80-127
1
2
P-86073
Install the two piece bearing (Item 1) [Figure 40-80-129].

P-86075
Install the end cap (Item 1) and snap ring (Item 2)

[Figure 40-80-127].

712 of 1161
AXLE AND DIFFERENTIAL (CONT’D) Dip the O-ring will slip past the housing retaining ring and
seal uniform on the gear case radius.
Figure 40-80-130
Shake off the excess alcohol.
Figure 40-80-132
P-86072
Install the axle shaft (Item 1) [Figure 40-80-130].

P-86071
Figure 40-80-131
Use firm, even pressure to pop the O-ring / seal ring
assembly (Item 1) [Figure 40-80-132] into the case.
2 Apply a light film of oil to the seal ring. Do not get any oil
1 on the O-ring.
Figure 40-80-133
B-14496

[Figure 40-80-131].

P-86070
back. Support the axle case assembly using a hoist and lifting
The O-ring, seal ring and gearcase assembly must be
clean and free of any dust, oil film or foreign matter.


713 of 1161

1
Figure 40-80-134
P-86068
Install and tighten the four bolts (Item 1) [Figure 40-80-

P-86069 136] to 57 - 67 ft.-lb. (78 - 90 N•m) torque.
Raise the axle case until it contacts the axle support

[Figure 40-80-134].
Figure 40-80-135
P-86067
Measure the clearance between the axle case (Item 1)

and the axle support (Item 2) [Figure 40-80-135].
If axle cover and bevel case make contact, install a shim

that is 0.008-0.020 (0,2-0,5 mm) THICKER than the
clearance.
Select the correct shim thickness from the selection

below:
0.020 in. (0,5 mm)

0.032 in. (0,8 mm)
0.039 in. (1,0 mm)
0.047 in. (1,2 mm)

714 of 1161
Front Axle Cover Assembly
Figure 40-80-137
1
P-86058
1
P-86060 assembly (Item 1) [Figure 40-80-138] onto the hub.
Figure 40-80-139
[Figure 40-80-137].

back.
The O-ring, seal ring and gearcase assembly must be 2


so the O-ring will slip past the housing retaining ring and 1
seal uniformly on the gear case radius. P-86065

Install the O-ring (Item 1) [Figure 40-80-139].
cover.

715 of 1161
AXLE AND DIFFERENTIAL (CONT’D) Use firm even pressure to pop the O-ring / seal ring
assembly (Item 1) [Figure 40-80-141] into the cover.
Front Axle Cover Assembly (Cont’d)
Figure 40-80-142
Figure 40-80-140
1
P-86064
P-86063
Turn the cover over and install the axle shaft (Item 1)
Install the O-ring (Item 1) onto the seal ring (Item 2) [Figure 40-80-141] into the cover.
[Figure 40-80-140].

back.


seal uniformly on the gear case radius.
Figure 40-80-141
P-86063

716 of 1161
Front Axle Cover Assembly (Cont’d) 2

1
Figure 40-80-143
2
2
P-86054
1
1
Install the gear case cover (Item 1) [Figure 40-80-145]
P-86066 onto the axle case.
Install the eight bolts (Item 2) and tighten to 16 - 20 ft.-lb.

Install the two piece lock ring (Item 1) [Figure 40-80-143] (24 - 28 N•m) torque in a criss cross pattern.
into the groove in the axle shaft.
Figure 40-80-144
P-78443

axle shaft.

717 of 1161
To check upper bevel gear and final drive bevel gear tooth contact. Perform the following procedures.
Figure 40-80-146
7 6
3 4
8
P-86064
Remove the 17 gear (Item 1) and 11 gear (Item 2) Shim selection for (Item 6 & 7) [Figure 40-80-146].
[Figure 40-80-146] and remove any oil from the teeth.
0.157 in. (0,4 mm)
Apply contact grease to the teeth on the 11 gear and
0.0315 in. (0,8 mm)
reassemble.
0.0394 in. (1,0 mm) - Standard
Remove the axle cover (Item 3) and remove any oil from 0.0472 in. (1,2 mm)
the 40 gear teeth (Item 4) and 10 gear teeth (Item 5)
[Figure 40-80-146]. Shim selection for (Item 8) [Figure 40-80-146].
Apply contact grease to the teeth on the 10 gear,

0.0039 in. (0,1 mm)
reassembly the axle cover.
0.0079 in. (0,2 mm)
Rotate the axle by hand, disassemble the gears to check 0.0157 in. (0,4 mm)
the teeth engagement.
0.0315 in. (0,8 mm)
If the contact areas on the gear teeth is abnormal, adjust 0.0394 in. (1,0 mm) - Standard
the shims (Item 6, 7 & 8) [Figure 40-80-146] and 0.0422 in. (1,2 mm)
measure tooth engagement again.

718 of 1161
AXLE AND DIFFERENTIAL (SST MODELS)
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Axle housing bent 12, 13
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

3. Pinion nut loose
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent

719 of 1161
AXLE AND DIFFERENTIAL (SST MODELS) (CONT’D)
Front Axle Cover Parts Identification
1. O-Ring
2. Bearing
3. 40 Gear
4. Lock Ring
5. Cover
6. Bolt
7. Seal
8. Axle
9. Stud
2 3
1
5
1 8
2
6 7
B-23893

720 of 1161
AXLE AND DIFFERENTIAL (SST MODELS) (CONT’D) Figure 40-81-2
Front Axle Cover Disassembly
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
P-98273
Remove the steering cylinders. (See Removal And

Installation on Page 20-51-1.) Remove the drain plug (Item 1) [Figure 40-81-2] and
drain the oil from the axle. Dispose of the oil in an
Remove the tie rod. environmentally safe manner.
1 1
P-86052
1 P-98274
Place the axle assembly on a secure work surface Mark the cover and remove the eight bolts (Item 1)
[Figure 40-81-1]. [Figure 40-81-3].

721 of 1161
Figure 40-81-4
1
P-78430

P-98283 axle shaft.
Figure 40-81-7
Remove the gear case cover from the hub [Figure 40-
81-4].
Figure 40-81-5
1
1
P-86066
1
Remove the two piece lock ring (Item 1) [Figure 40-81-

P-78429 7].

81-5] from the axle shaft.

722 of 1161
Figure 40-81-8
P-86062

1 P-78433 cover.
Remove the axle shaft from the cover [Figure 40-81-8].
Figure 40-81-9
P-86063
Remove the floating seal (Item 1) [Figure 40-81-9].

723 of 1161
AXLE AND DIFFERENTIAL (SST MODELS) (CONT’D) Front Axle Cover Inspection
Front Axle Cover Disassembly (Cont’d) Figure 40-81-13
Figure 40-81-11
P-78730
P-78437
Inspect the 40 gear (Item 1) [Figure 40-81-13] for worn
or cracked teeth.
Remove the axle floating seal (Item 1) [Figure 40-81-11].
Figure 40-81-14
Figure 40-81-12
P-86059
P-86060
Inspect the axle assembly splines (Item 1) [Figure 40-

Remove the O-ring (Item 1) from the seal ring (Item 2) 81-14] for wear or damage.
[Figure 40-81-12].

724 of 1161
Front Axle Case Group Parts Identification
1. Plug 1
2. Washer 2
3. Bushing
4. Bearing
5. Axle Case
6. 10 Gear 3
7. Shim
8. Snap Ring
4
9. End Cap
5 6
4
2
1
7
NA5002

725 of 1161
Front Axle Case Group Disassembly
NOTE: The following procedure can be done with the

axle assembly in the machine.
Figure 40-81-15
P-98277
Remove the axle case from the axle housing [Figure 40-
81-17].
Figure 40-81-18
P-98275
Support the axle case assembly using a hoist and lifting 1

Figure 40-81-16
1
1
P-86070
Remove the axle shaft (Item 1) and floating seal (Item 2)

[Figure 40-81-18].
NOTE: Mark the axle shaft for correct assembly.

P-98276
NOTE: Record the quantity and location of the shims.

726 of 1161
Figure 40-81-19
1
2
1
P-78449
Remove the snap ring (Item 1) and end cap (Item 2)

P-86073 [Figure 40-81-21] from the axle case.
Figure 40-81-22
Remove the two piece bearing (Item 1) [Figure 40-81-
19].
1
Figure 40-81-20
P-86076

P-86074

727 of 1161
Figure 40-81-23
P-86077
Remove the shim (Item 1) [Figure 40-81-23].
Figure 40-81-24
P-86079

24].

728 of 1161
Bevel Gear Case Group Parts Identification
1. Support
2. Seal
3. Bearing
4. Snap Ring
5. Shim 1
6. 17 Gear
7. Shaft
8. Case 2
9. O-Ring
10. Seal Ring
11. Plug 3
11
9
10
10
NA5003

729 of 1161
Bevel Gear Case Group Disassembly
Figure 40-81-25
1
P-86086

P-98280
Figure 40-81-28
Remove the axle case support (Item 1) [Figure 40-81-

25] by lifting upward.
Figure 40-81-26
1 P-86087
2
P-86086

730 of 1161
Bevel Gear Case Group Disassembly (Cont’d)
Figure 40-81-29
1
P-86091

P-86088 axle support.
Figure 40-81-32
Remove the shims [Figure 40-81-29].
Figure 40-81-30
1
1
P-86092
P-86090 Remove the floating seal (Item 1) [Figure 40-81-32].

30].

731 of 1161
Bevel Gear Case Group Inspection
Figure 40-81-33
P-78467

cracked teeth.
Figure 40-81-34
1
P-78468
Inspect the axle splines (Item 1) [Figure 40-81-34] for

wear or damage.

732 of 1161
Axle Shaft Group Parts Identification
1. Axle Shaft
2. Snap Ring
3. Shim
4. Spacer
5. Bearing
6. 11 Gear
7. O-Ring
8. Case
9. Lock Washer
10. Nut
11. Bolt
1 6 10
2 3 4 5 7
9
11
B-23895

733 of 1161
Axle Shaft Group Disassembly
Figure 40-81-35
1
P-86094
Remove the axle shaft (Item 1) [Figure 40-81-37].

P-86133
Figure 40-81-38
Remove the mounting bolts, nuts and lock washers (Item

1) [Figure 40-81-35].
Figure 40-81-36
P-86097
P-86093
Remove the case (Item 1) [Figure 40-81-36].

734 of 1161
Axle Shaft Group Disassembly (Cont’d)
Figure 40-81-39
1
P-86101
Remove the 11 gear / bearing (Item 1) [Figure 40-81-41]

P-86099 from the case.
Axle Shaft Group Inspection

Remove the shims [Figure 40-81-39] from the housing.
Figure 40-81-42
NOTE: Record the quantity and location of the shims
removed.
Figure 40-81-40 1
P-78467

P-86100 cracked teeth.

735 of 1161
Axle Support Removal
Figure 40-81-43 1
1
2
P-78483
Remove the bushing (Item 1) and shim plate (Item 2)

P-98278 [Figure 40-81-45] from the axle support.
Figure 40-81-46
Remove the axle support (Item 1) [Figure 40-81-43] by
sliding off the axle pivot.
Figure 40-81-44 2
P-78480
Remove the shim (Item 1) and bushing (Item 2) [Figure

P-98281 40-81-46] from the axle support.

axle pivot.

736 of 1161
Axle Support Removal (Cont’d)
Figure 40-81-47
1
P-78488

P-98279
Figure 40-81-50
Remove the axle support housing (Item 1) [Figure 40-

81-47] by sliding off the axle pivot. 1
Figure 40-81-48
P-78490
P-98282

axle pivot.

737 of 1161
Pinion Shaft Removal
Figure 40-81-51
P-78491
Remove the pinion shaft assembly (Item 1) [Figure 40-

81-51].

738 of 1161
1. Pinion Shaft
2. Collar (Adjusting)
3. Bearing
4. Nut
5. Snap Ring
6. Seal
6
4
5
2
3
2
3
2
B-23888

739 of 1161
Pinion Shaft Disassembly 2
Figure 40-81-52
2 1
1
1
1
P-78510
Remove the two bearings (Item 1) and spacer (Item 2)

P-78507 [Figure 40-81-54].
Pinion Shaft Inspection

Mark each adjusting collar (Item 1) and remove from the
pinion shaft (Item 2) [Figure 40-81-52]. Figure 40-81-55
Figure 40-81-53
2
P-25706
P-78508
Unstake the nut (Item 1) [Figure 40-81-53] and remove.
NOTE: Record the direction and location of the

tapered roller bearings before removal.

740 of 1161
Differential Removal
Figure 40-81-56
1 1
P-86131
Figure 40-81-59
P-86129
Remove the snap ring (Item 1) [Figure 40-81-56] from 1

the left side of the housing.
Figure 40-81-57
P-86132
Using a block of wood (Item 1) [Figure 40-81-58].

Remove the differential assembly (Item 1) [Figure 40-81-
59] from the left side of the housing.
P-86130

the number of shims for correct assembly.

741 of 1161
1. 23-Gear
2. Bearing
3. Differential Case Cover
4. Shim
5. Side Gear
6. Pinion Gear
7. Washer
8. Pin
9. Pinion Shaft
10. Bolt
11. Shim
12. Differential Case
3
7
9
6
5
4 8
12
4
2
5
11
6
8
7
10
MS2507S

742 of 1161
Figure 40-81-60
P-78514
Separate the differential housing [Figure 40-81-62].

2
P-78511
Figure 40-81-63
Remove the differential 23 gear (Item 1) and bearing

(Item 2) [Figure 40-81-60].
Figure 40-81-61
1
P-78515
1
P-78513
Mark the housing and remove the four bolts (Item 1)

[Figure 40-81-61].

743 of 1161
Figure 40-81-64
P-78519
Remove the pinion shaft (Item 1) [Figure 40-81-66].

P-78342
Figure 40-81-67

the location of the shim for correct assembly.
Figure 40-81-65
1 1
P-78336
Remove the pinion gears (Item 1) [Figure 40-81-67].
P-78517
Remove the pinion shaft retainer pin (Item 1) [Figure 40-

81-65].

744 of 1161
Figure 40-81-68
P-78523
Remove the shims (Item 1) [Figure 40-81-70] from the

P-78521 housing.
NOTE: Record the number and location of the shims

Remove the washer (Item 1) [Figure 40-81-68] (both removed for correct assembly.
sides.)
Figure 40-81-69
P-78522

745 of 1161
Figure 40-81-71
1
2
P-78285
1
Measure and record the pinion shaft outside diameter

B-23670 (Item 1) and the inside diameter of the pinion gear (Item
2) [Figure 40-81-72].
Measure and record the outside diameter of the side gear If the clearance exceeds the allowable limit, see chart
(Item 1), the inside diameter of the differential case (Item below, replace parts as needed.
2) and the inside diameter of the differential case cover
(Item 3) [Figure 40-81-71]. Item Factory Spec. Allowable
Limit
below, replace parts as needed. Clearance 0.00063 - 0.00205 in. 0.0098 in.
between pinion (0,016 - 0,052 mm) (0,25 mm)
shaft and
differential pinion
Limit
Clearance 0.00197 - 0.00358 in. 0.0138 in.
between (0,050 - 0,091 mm) (0,35 mm) Item Factory Spec. Allowable
differential case Limit
(Differential case Pinion shaft O.D. 0.62858 - 0.62929 in. -
cover) and (15,966 - 15,984 mm)
differential side
Differential pinion 0.62992 - 0.63063 in. -
gear
I.D. (16,000 - 16,018 mm)

Limit
bore I.D. (32,025 - 32,050 mm)
cover bore I.D. (32,025 - 32,036 mm)
Differential side 1.25823 - 1.25886 in. -
gear bore O.D. (31,959 - 31,975 mm)

746 of 1161
Differential Assembly 1
Figure 40-81-73
P-78521
Apply a small amount of grease to the back side of the

P-78284 washer (Item 1) [Figure 40-81-75] and install into the
housing (both sides.)
Install the shims (Item 1) [Figure 40-81-73], removed Figure 40-81-76

earlier, into the housing.
Figure 40-81-74
1
1
1
P-78520
P-78522 Install the pinion gears (Item 1) [Figure 40-81-76] into

the housing.

747 of 1161
Figure 40-81-77
2 1
3
3
P-78516
1 Install the shims (Item 1) [Figure 40-81-79], removed

P-78519 earlier, into the housing.
Figure 40-81-80
Install the pinion shaft (Item 1) into the housing (Item 2)
through the washer / pinion gears (Item 3) [Figure 40-81-
77].
1
Figure 40-81-78
P-78515

housing.
P-78517
Install the pinion shaft retainer pin (Item 1) [Figure 40-

81-78].

748 of 1161
Figure 40-81-81
1
2
1
P-78

P-78514 fully seated.
Figure 40-81-84
Install the housing (Item 1) onto the housing / gear
assembly (Item 2) [Figure 40-81-81]. make sure to align
the reference marks made earlier.
Figure 40-81-82
1
1
1
P-78526
Install the bearing / 21 gear (Item 1) [Figure 40-81-84]

until it is fully seated.
1 P-78513

tighten to 29 - 41 ft.-lb. (40 - 56 N•m) torque.

749 of 1161
Figure 40-81-85
P-77617
Select the correct differential side gear adjusting shim

B-23672 [Figure 40-81-86] from the table below:
0.157 in (0,4 mm)

Position the tip of a magnetic base dial gauge on the
tooth of the differential pinion [Figure 40-81-85]. 0.0236 in. (0,6 mm)
0.0315 in. (0,8 mm)
Hold the differential side gear and move the differential 0.0394 in. (1,0 mm)
pinion back and forth to measure the backlash.
0.0472 in. (1,2 mm)
If the measurement is not within the allowable limit of
0.004 - 0.012 in. (0,1 - 0,3mm) adjust the differential side
gear shims.
NOTE: Equal amounts of shims must be installed on

both sides of each side gear.

750 of 1161
Differential Installation
1
Figure 40-81-87
P-86129

P-86132
Install the differential / bearing assembly (Item 1) [Figure

40-81-87] into the axle housing until it is fully seated next
to the pinion shaft.
Figure 40-81-88
P-86130

earlier).

751 of 1161

1
Figure 40-81-90
B-23669
1
Attach one end of a light rope to the pinion splines. Make
P-78510 2 or 3 complete wraps and attach the spring scale
perpendicular to the housing to measure the rolling
torque on the bearings. Tighten (or loosen) the nut (Item
Install the two taper roller bearings (Item 1) and spacer 1) [Figure 40-81-92] until 18 - 22 lb. (8 - 10 Kgf) of
(Item 2) [Figure 40-81-90] onto the pinion shaft. smooth and continuous rolling torque is measured on the
spring scale.
NOTE: Install the bearings as marked during
disassembly. Figure 40-81-93
Figure 40-81-91
P-78508
P-78509
Stake the nut (Item 1) [Figure 40-81-93].
Install the nut (Item 1) [Figure 40-81-91] and hand

tighten.

752 of 1161
Pinion Shaft Installation
Figure 40-81-94
1
P-78537

P-78533 marked and removed earlier, into the axle housing.
Figure 40-81-97
marked and removed earlier, into the axle housing.
Figure 40-81-95
1
P-78490

P-78534
Install the pinion shaft assembly into the axle housing

[Figure 40-81-95].

753 of 1161
Pinion Shaft Installation (Cont’d)
Figure 40-81-98
1
P-78248
Install the new seal (Item 1) [Figure 40-81-100] into the

B-23673 axle housing to a depth of 0.039 in. (0,1 mm).
Position a magnetic base dial gauge on the axle housing,

with the tip of the gauge at a 90 angle, move the pinion
shaft lightly by hand and measure the backlash. Check
that the backlash is within the permissible range of 0.004
- 0.012 in. (0,1 - 0,3 mm) [Figure 40-81-98].
Figure 40-81-99
1 2
B-23674
If the backlash is not within the permissible range,

change the adjusting collar (Item 1) to 0.004 in. (0.1 mm)
smaller, and adjusting collar (Item 2) [Figure 40-81-99].
to 0.004 in. (0,1 mm) larger.

754 of 1161
Axle Support Installation
Figure 40-81-101
1
P-98281

P-98282 axle pivot.
Figure 40-81-104
Replace the O-ring (Item 1) [Figure 40-81-101] on the
axle pivot.
2
Figure 40-81-102 1
1 3
P-78483

P-98279 fitting (Item 2) [Figure 40-81-104] and press the bushing
Install the axle support (Item 1) [Figure 40-81-102] onto Apply grease to the back of the shim plate (Item 3)
the axle pivot. [Figure 40-81-104] and install.

755 of 1161
Axle Support Installation (Cont’d)
Figure 40-81-105
1
2
1
P-98278
Install the axle support (Item 1) [Figure 40-81-107] onto

P-78480 the pivot.

fitting (Item 2) [Figure 40-81-105] and press the bushing
Install the shim (Item 3) [Figure 40-81-105], removed

earlier, into the axle support.
Figure 40-81-106
P-78479
Install the O-ring (Item 1) [Figure 40-81-106] into the

axle support.

756 of 1161
Axle Shaft Group Assembly
Figure 40-81-108
P-86099
Install the shims (Item 1) [Figure 40-81-110] removed

P-86101 earlier.
Figure 40-81-111
Install the 11 gear / bearing (Item 1) [Figure 40-81-108]
into the case.
Figure 40-81-109
1
1
P-86097

P-86100
Install the spacer (Item 1) [Figure 40-81-109] into the

case.

757 of 1161
Axle Shaft Group Assembly (Cont’d)
Figure 40-81-112
1
1
P-86133
Install the mounting bolts, nuts and lock washers (Item 1)

P-86094 [Figure 40-81-114] (both sides).
Tighten the nuts to 57 - 67 ft.-lb. (78 - 90 N•m) torque.

Install the axle shaft (Item 1) [Figure 40-81-112] (both
sides).
Figure 40-81-113
P-86093
Install the axle case (Item 1) [Figure 40-81-113].

758 of 1161
Bevel Gear Case Group Assembly
Figure 40-81-115
2
1
P-86092

B-14496 assembly (Item 1) [Figure 40-81-116] into the case.
Figure 40-81-117
[Figure 40-81-115].

back. 1
The O-ring, seal ring and axle case must be clean and
free of any dust, oil film or foreign matter.

seal uniform in the axle case radius. P-86091

Install a new seal (Item 1) [Figure 40-81-117] onto the
Shake off the excess alcohol. axle support.

759 of 1161
Bevel Gear Case Group Assembly (Cont’d)
Figure 40-81-118
1
P-86087

P-86090
Figure 40-81-121
Install the 17 gear / bearing [Figure 40-81-118].
Figure 40-81-119
1
1
P-86086

P-86088

earlier).

760 of 1161
AXLE AND DIFFERENTIAL (SST MODELS) (CONT’D) Front Axle Case Group Assembly
Bevel Gear Case Group Assembly (Cont’d) Figure 40-81-124
Figure 40-81-122
1
2
P-86079
P-86084
Install the bearing / 10 gear (Item 1) [Figure 40-81-124].
Install the seal (Item 1) [Figure 40-81-122]. Figure 40-81-125
Install the plug (Item 2) [Figure 40-81-122].

1
Figure 40-81-123
P-86077
Install the shim (Item 1) [Figure 40-81-125] (removed

P-98280 earlier).
Install the axle case support (Item 1) [Figure 40-81-123].

761 of 1161
Figure 40-81-126
1
P-86074
Install the bushing (Item 1) [Figure 40-81-128].

P-86076
Figure 40-81-129
Figure 40-81-127
1
2
P-86073
Install the two piece bearing (Item 1) [Figure 40-81-129].

P-86075
Install the end cap (Item 1) and snap ring (Item 2)

[Figure 40-81-127].

762 of 1161
AXLE AND DIFFERENTIAL (SST MODELS) (CONT’D) Dip the O-ring will slip past the housing retaining ring and
Figure 40-81-130
Figure 40-81-132
P-86072
Install the axle shaft (Item 1) [Figure 40-81-130].

P-86071
Figure 40-81-131
Use firm, even pressure to pop the O-ring / seal ring
assembly (Item 1) [Figure 40-81-132] into the case.
2 Apply a light film of oil to the seal ring. Do not get any oil
1 on the O-ring.
Figure 40-81-133
B-14496

[Figure 40-81-131].

P-98277
back. Support the axle case assembly using a hoist and lifting


763 of 1161
Figure 40-81-134 1
P-98276
Install and tighten the four bolts (Item 1) [Figure 40-81-

P-98275 136] to 57 - 67 ft.-lb. (78 - 90 N•m) torque.
Raise the axle case until it contacts the axle support

[Figure 40-81-134].
Figure 40-81-135
P-86067
Measure the clearance between the axle case (Item 1)

and the axle support (Item 2) [Figure 40-81-135].
If axle cover and bevel case make contact, install a shim

that is 0.008-0.020 (0,2-0,5 mm) THICKER than the
clearance.
Select the correct shim thickness from the selection

below:
0.020 in. (0,5 mm)

0.032 in. (0,8 mm)
0.039 in. (1,0 mm)
0.047 in. (1,2 mm)

764 of 1161
Front Axle Cover Assembly
Figure 40-81-137
1
P-86058
1
P-86060 assembly (Item 1) [Figure 40-81-138] onto the hub.
Figure 40-81-139
[Figure 40-81-137].

back.
The O-ring, seal ring and gearcase assembly must be 2


so the O-ring will slip past the housing retaining ring and 1

Install the O-ring (Item 1) [Figure 40-81-139].
cover.

765 of 1161

1
Figure 40-81-140
P-86063
1
P-86063 assembly (Item 1) [Figure 40-81-141] into the cover.
Figure 40-81-142
Install the O-ring (Item 1) onto the seal ring (Item 2)
[Figure 40-81-140].

is not twisted. To remove any twists, gently 1
back.



Turn the cover over and install the axle shaft (Item 1)
Shake off the excess alcohol. [Figure 40-81-141] into the cover.

766 of 1161
Figure 40-81-143 2 2
2
P-98274
1
1
Install the gear case cover (Item 1) [Figure 40-81-145]
P-86066 onto the axle case.
Install the eight bolts (Item 2) and tighten to 16 - 20 ft.-lb.

Install the two piece lock ring (Item 1) [Figure 40-81-143] (24 - 28 N•m) torque in a criss cross pattern.
into the groove in the axle shaft.
Figure 40-81-144
P-78443

axle shaft.

767 of 1161
To check upper bevel gear and final drive bevel gear tooth contact. Perform the following procedures.
Figure 40-81-146
7 6
3 4
8
P-86064
Remove the 17 gear (Item 1) and 11 gear (Item 2) Shim selection for (Item 6 & 7) [Figure 40-81-146].
[Figure 40-81-146] and remove any oil from the teeth.
0.157 in. (0,4 mm)
Apply contact grease to the teeth on the 11 gear and
0.0315 in. (0,8 mm)
reassemble.
0.0394 in. (1,0 mm) - Standard
Remove the axle cover (Item 3) and remove any oil from 0.0472 in. (1,2 mm)
the 40 gear teeth (Item 4) and 10 gear teeth (Item 5)
[Figure 40-81-146]. Shim selection for (Item 8) [Figure 40-81-146].
Apply contact grease to the teeth on the 10 gear,

0.0039 in. (0,1 mm)
reassembly the axle cover.
0.0079 in. (0,2 mm)
Rotate the axle by hand, disassemble the gears to check 0.0157 in. (0,4 mm)
the teeth engagement.
0.0315 in. (0,8 mm)
If the contact areas on the gear teeth is abnormal, adjust 0.0394 in. (1,0 mm) - Standard
the shims (Item 6, 7 & 8) [Figure 40-81-146] and 0.0422 in. (1,2 mm)
measure tooth engagement again.

768 of 1161
STEERING AXLE ADJUSTMENT (HST MODELS) Rocking Force
Toe-In Checking Figure 40-90-3
Make sure the air pressure in both front tires is correct.
Figure 40-90-1
P-86041

B-23663 [Figure 40-90-3].
Remove the front tires.

With the front tires in the straight position, measure the
front width (A) and rear width (B) between the front Figure 40-90-4
wheels to obtain the toe-in [Figure 40-90-1].
If the toe-in measurement exceeds 0.08 - 0.31 in. (2 - 8

mm) the toe-in must be adjusted.
Toe-In Adjustment
Figure 40-90-2
2 1
B-23666
Using a spring scale, measure the axle rocking force

[Figure 40-90-4].
P-84814
Loosen the lock nuts (Item 1) [Figure 40-90-2].
Rotate the tie-rod (Item 2) [Figure 40-90-2] until the toe-

in measurement is 0.08 - 0.31 in. (2 - 8 mm).
Tighten the lock nuts (Item 1) [Figure 40-90-2] to 58 - 87

ft.-lb. (79 - 118 N•m) torque.

769 of 1161
STEERING AXLE ADJUSTMENT (HST MODELS) Steering Angle Adjustment
(CONT’D)
Make sure the air pressure in both tires is correct.
Rocking Force (Cont’d)
Figure 40-90-6
Figure 40-90-5
2
2
1
1
B-23668
P-86047
Loosen the lock nut (Item 1) and turn in the adjusting bolt
If the measurement is not within 11 - 27 lb. (5.0 - 12.0 (Item 2) [Figure 40-90-6] fully on the right side of the
Kg). Loosen the lock nut (Item 1) and adjust the bolt (Item front axle.
2) [Figure 40-90-5].
Turn the wheels to the right fully.
Tighten the lock nut (Item 1) [Figure 40-90-5] to 72 - 109
ft.-lb. (98 - 147 N•m) torque. Turn in the adjusting bolt (Item 2) out until it contacts the
axle case (Item 3) [Figure 40-90-6].
Return the steering wheel so the tires are straight, turn

the adjusting bolt (Item 2) [Figure 40-90-6]
approximately an additional half turn until the adjusting
bolt length is 1.259 in. (32 mm) for a steering angle of 55°
(95 rad).
Tighten the lock nut (Item 1) [Figure 40-90-6].
Repeat above procedure for the other side.

770 of 1161
STEERING AXLE ADJUSTMENT (SST MODELS) Figure 40-91-3
Rocking Force
Figure 40-91-1
P-86047
If the measurement is not within 11 - 27 lb. (5.0 - 12.0

P-86041 Kg). Loosen the lock nut (Item 1) and adjust the bolt (Item
2) [Figure 40-91-3].
Raise the front of the tractor and install jack stands Tighten the lock nut (Item 1) [Figure 40-91-3] to 72 - 109
[Figure 40-91-1]. ft.-lb. (98 - 147 N•m) torque.
Figure 40-91-2
B-23666
Using a spring scale, measure the axle rocking force

[Figure 40-91-2].

771 of 1161
STEERING AXLE ADJUSTMENT (SST MODELS) Toe-In Checking
(CONT’D)
Make sure the air pressure in both front tires is correct.
Steering Angle Adjustment
Figure 40-91-5
Make sure the air pressure in both tires is correct.
Figure 40-91-4
3
1
2
B-23663
P-98335 With the front tires in the straight position, measure the
front width (A) and rear width (B) between the front
wheels to obtain the toe-in [Figure 40-91-5].
Loosen the lock nut (Item 1) and turn in the adjusting bolt
(Item 2) [Figure 40-91-4] fully on the right side of the If the toe-in measurement exceeds 0.08 - 0.31 in. (2 - 8
front axle. mm) the toe-in must be adjusted.
Turn the wheels to the right fully.
Turn in the adjusting bolt (Item 2) out until it contacts the

axle case (Item 3) [Figure 40-91-4].
Return the steering wheel so the tires are straight, turn

the adjusting bolt (Item 2) [Figure 40-91-4]
approximately an additional half turn until the adjusting
bolt length is 1.259 in. (32 mm) for a steering angle of 55°
(95 rad).
Tighten the lock nut (Item 1) [Figure 40-91-4].
Repeat above procedure for the other side.

772 of 1161
STEERING AXLE ADJUSTMENT (SST MODELS) ground.
(CONT’D)
Figure 40-91-8
Toe-In Adjustment
The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.
Turn the steering wheel until the steering cylinder rod is

positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-91-6
NA5006
Measure the distance between the ends of the two bars

[Figure 40-91-8]. The measurement must be equal.
Figure 40-91-9
1
P-86041
3
2
[Figure 40-91-6].
Figure 40-91-7
NA5007
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-91-9] of both tie rods until the measurement
is the same.
Tighten the nut (Item 3) [Figure 40-91-9] (to 221 ft.-lb.

1 (300 N•m) torque.
NA5005
Install two identical, straight bars (Item 1) [Figure 40-91-

7] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

773 of 1161
774 of 1161
SEPARATING THE TRACTOR (HST MODELS)
Procedure
Build the service stand to support the tractor. Use the dimensions shown [Figure 40-100-1] to build the service stand or
use MEL1662 separating stands.
Figure 40-100-1
Bolt M14 X 1.50 X 30 mm (Qty 6)

Washer 16 mm ID X 28 mm O.D. X 2.8 mm thick (Qty 6)
MS-2731S

775 of 1161
SEPARATING THE TRACTOR (HST MODELS) Figure 40-100-2
(CONT’D)
Procedure (Cont'd)
Disconnect the battery. (See Removing And Installing 3

Battery on Page 60-20-1.) 1
Drain the transmission. (See HYDRAULIC /

2
HYDROSTATIC / TRANSMISSION SYSTEM on Page
10-120-1.)
Remove the firewall (without cab) HST Models. (See

Remove the firewall (with cab) HST Models. (See

P-84699
Remove the driveshaft. (See Removal And Installation on Loosen the hose clamp (Item 1) and remove the hose
Page 40-30-1.) (Item 2) from the tubeline (Item 3) [Figure 40-100-2].
Remove the engine side covers. (See Removal And Figure 40-100-3

Remove the floor plate. (See Removal And Installation

on Page 50-80-1.)
IMPORTANT 1

clean the work area before disassembly and keep all P-84587

Remove the joint bolt (Item 1) [Figure 40-100-3] from the
damage the system.
tubeline.
I-2003-0888

776 of 1161
(CONT’D)
Procedure (Cont'd)
Figure 40-100-4
1
2
2
1
P-84590

[Figure 40-100-6].
P-84588
Figure 40-100-7
Remove the retainer bolt (Item 1) and tubeline (Item 2)
[Figure 40-100-4].
Figure 40-100-5
P-84591
1
the tubeline.
P-86157

the tubeline.

777 of 1161
(CONT’D)
Procedure (Cont'd)
Figure 40-100-8
P-84598
1 Install the support stand (Item 1) onto the right side of the
housing using the three bolts (M14 x 1.50 X 30 mm) and
P-84593 washers (16 mm X 28 mm O.D. X 2.8 mm thick) (Item 2)
[Figure 40-100-10].
Remove the tubeline (Item 1) [Figure 40-100-8] from the Figure 40-100-11
modulator valve.
Remove the tubeline.
Figure 40-100-9
2
2
P-84599
1
Install the support stand (Item 1) onto the left side of the
housing using the three bolts (M14 X 1.50 X 30 mm) and
P-84596 washers (16 mm I.D. X 28 mm O.D. X 2.8 mm thick)
(Item 2) [Figure 40-100-11].

[Figure 40-100-9] from the filter.

778 of 1161
(CONT’D)
Procedure (Cont'd)
Figure 40-100-12
P-84604
Remove the ten case bolts and nuts (Item 1) [Figure 40-
100-14].
P-84602
Installation: Tighten the bolts and nuts to 84 ft.-lb. (114
N•m) torque.
Use a hoist and lifting chains to lift and support the rear of
the machine [Figure 40-100-12]. Figure 40-100-15
Figure 40-100-13
P-84613
1 P-84600
Separate the tractor by rolling apart. Lower the jack until
the machine is resting on the support stand [Figure 40-
Position a floor jack (Item 1) [Figure 40-100-13] under 100-15].
the oil pan on a flat surface to lift and support the front of
the machine. Apply light pressure.

779 of 1161
SEPARATING THE TRACTOR (HST MODELS)
(CONT’D)
Procedure (Cont'd)
Figure 40-100-16
P-84614
Place a stand under the housing assembly and lower the

hoist [Figure 40-100-16].

780 of 1161
SEPARATING THE TRACTOR (SST MODELS)
Procedure
Build the service stand to support the tractor. Use the dimensions shown [Figure 40-110-1] to build the service stand or
use MEL1662 separating stands.
Figure 40-110-1
NOTE: Depending upon tire size stand support

stand height dimensions may be different.
Bolt M14 X 1.50 X 30 mm (Qty 6)
Washer 16 mm ID X 28 mm O.D. X 2.8 mm thick (Qty 6)
NA1945S

781 of 1161
SEPARATING THE TRACTOR (SST MODELS) Figure 40-110-2
(CONT’D)
Procedure (Cont'd)
Disconnect the battery. (See Removing And Installing 3

Battery on Page 60-20-1.) 1
Drain the transmission. (See HYDRAULIC /

2
HYDROSTATIC / TRANSMISSION SYSTEM on Page
10-120-1.)
Remove the firewall (SST models). (See Removal And

Remove the driveshaft. (See Removal And Installation on

P-84699
Page 40-30-1.)
Remove the engine side covers. (See Removal And Loosen the hose clamp (Item 1) and remove the hose
Installation on Page 50-100-1.) (Item 2) from the tubeline (Item 3) [Figure 40-110-2].
Remove the operator seat. (See Removal And Figure 40-110-3

Remove the floor plate. (See FLOOR PLATE on Page

50-80-1.)
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system. P-95536
I-2003-0888
Remove the joint bolt (Item 1) [Figure 40-110-3] from the

tubeline.

782 of 1161
(CONT’D)
Procedure (Cont'd)
Figure 40-110-4
1
2
2
1
P-84590

[Figure 40-110-6].
P-84588
Figure 40-110-7
Remove the retainer bolt (Item 1) and tubeline (Item 2)
[Figure 40-110-4].
Figure 40-110-5
P-84591
1
the tubeline.
P-86157

the tubeline.

783 of 1161
(CONT’D)
Procedure (Cont'd)
Figure 40-110-8
P-95539
1 Install the support stand (Item 1) onto the left side of the
housing using the three bolts (M14 X 1.50 X 30 mm) and
P-84593 washers (16 mm I.D. X 28 mm O.D. X 2.8 mm thick)
(Item 2) [Figure 40-110-10].
Remove the tubeline (Item 1) [Figure 40-110-8] from the Figure 40-110-11
modulator valve.
Remove the tubeline.
Figure 40-110-9
P-95540
1 Use a hoist and lifting chains to lift and support the rear of
the machine [Figure 40-110-11].
P-95537
Install the support stand (Item 1) onto the right side of the
housing using the three bolts (M14 x 1.50 X 30 mm) and
washers (16 mm X 28 mm O.D. X 2.8 mm thick) (Item 2)
[Figure 40-110-9].

784 of 1161
(CONT’D)
Procedure (Cont'd)
Figure 40-110-12
P-95547
Separate the tractor by rolling apart. Lower the jack until

the machine is resting on the support stand [Figure 40-
1 P-95542 110-14].
Figure 40-110-15
Position a floor jack (Item 1) [Figure 40-110-12] under
the oil pan on a flat surface to lift and support the front of
the machine. Apply light pressure.
Figure 40-110-13
P-95549
1
Place a stand under the housing assembly and lower the
hoist [Figure 40-110-15].
P-95544
Remove the ten case bolts and nuts (Item 1) [Figure 40-
110-13].
Installation: Tighten the bolts and nuts to 84 ft.-lb. (114

N•m) torque.

785 of 1161
786 of 1161
MAINFRAME
CAB (HST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-230-1

Door Glass Removal And Installation . . . . . . . . . . . . . . . . . . 50-230-14
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-230-9
Front Lower Window Removal And Installation . . . . . . . . . . . 50-230-12
Rear Window Removal And Installation. . . . . . . . . . . . . . . . . 50-230-13
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-230-1
Side Window Removal And Installation . . . . . . . . . . . . . . . . . 50-230-14
Windshield Removal And Installation. . . . . . . . . . . . . . . . . . . 50-230-10
CAB COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200-1

CAB POST COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-210-1

CONSOLE COVER (WITH CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-21-1

Left Side Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-21-1 MAINFRAME
Right Side Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-21-2
CONSOLE COVER (WITHOUT CAB) . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Left Side Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Right Side Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-20-2
DRAW BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

DRAW BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . 50-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
ENGINE SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1


787 of 1161
MAINFRAME (CONT’D)
FENDER (WITH CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-121-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-121-1
FENDER (WITHOUT CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

FENDER ASSEMBLY (WITHOUT CAB) (HST MODELS) . . . . . . 50-110-1

Fender Mount Removal And Installation . . . . . . . . . . . . . . . . . 50-110-7
FENDER ASSEMBLY (SST MODELS) . . . . . . . . . . . . . . . . . . . . . .50-111-1

Fender Mount Removal And Installation . . . . . . . . . . . . . . . . . .50-111-7
FIREWALL (WITH CAB) (HST MODELS). . . . . . . . . . . . . . . . . . . . 50-132-1

FIREWALL (WITHOUT CAB) (HST MODELS) . . . . . . . . . . . . . . . . 50-130-1

FIREWALL (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

FLOOR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

FLOORMAT (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-71-1

FLOORMAT (HST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-1

FRONT WORK LIGHT MOUNT (WITH CAB) . . . . . . . . . . . . . . . . . .50-190-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-190-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-1

GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

788 of 1161
MAINFRAME (CONT’D)
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-231-1
INNER FENDER ACCESS COVER (WITH CAB). . . . . . . . . . . . . . .50-220-1

MID PTO CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1

Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1

PTO SAFETY SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-150-1

ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-140-1
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-140-2
SPLASH BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

THREE POINT HITCH LOWER LINKS. . . . . . . . . . . . . . . . . . . . . . .50-180-1

Left Side Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .50-180-1
Right Side Removal And Installation . . . . . . . . . . . . . . . . . . . . . .50-180-2
Top Link Assembly Removal And Installation . . . . . . . . . . . . . . .50-180-3
TRANSMISSION CASE (HST MODELS) . . . . . . . . . . . . . . . . . . . . . .50-30-1

TRANSMISSION CASE (SST MODELS) . . . . . . . . . . . . . . . . . . . . . .50-31-1


789 of 1161
790 of 1161
OPERATOR SEAT Figure 50-10-3

compact tractor equipped with a cab. The 2
procedure is the same for non-cab models.
Figure 50-10-1 1
1 P-87332
Disconnect the seat harness (Item 1) from the main

harness (Item 2) [Figure 50-10-3].
Figure 50-10-4
P-78025
Tilt the seat forward and disconnect the sensor connector

(Item 1) [Figure 50-10-1].
Figure 50-10-2
P-87333
1 Remove the two back mounting bolts (Item 1) [Figure

1 50-10-4].

N•m] torque.
P-78026
Remove the four bolts (Item 1) [Figure 50-10-2] and the

seat.

N•m) torque.

791 of 1161
OPERATOR SEAT (CONT’D) See Safety Interlock System (neutral start). (See
Inspection And Maintenance (HST) on Page 10-200-1.)
Removal And Installation (Cont'd) and (See Inspection And Maintenance (SST) on Page
10-200-2.)
Figure 50-10-5
See Safety Interlock System (operating). (See Inspection
And Maintenance (HST) on Page 10-210-1.) and (See
Inspection And Maintenance (SST) on Page 10-210-2.)
P-87334
Remove the side mounting bolts (Item 1) [Figure 50-10-

5] (both sides.)

N•m] torque.
Figure 50-10-6
P-87335
Remove the three front mounting bolts (Item 1) [Figure

50-10-6].

N•m) torque.
Remove the seat suspension box.
NOTE: After installation of the operator seat, the

Safety Interlock System (neutral start) and
Safety Interlock System (operating) must be
tested and operational.

792 of 1161
CONSOLE COVER (WITHOUT CAB) Figure 50-20-3
Left Side Removal And Installation
Figure 50-20-1
HST MODEL 1
1
2
1
P-84425
Remove the two nuts (Item 1) [Figure 50-20-3].

P-84462
Figure 50-20-4
Figure 50-20-2 HST MODEL
SST MODEL
2 2
3
1
1
1
1
1
P-84463
P-95464
Figure 50-20-5
Remove the set screw (Item 1) and knob (Item 2) [Figure SST MODEL
50-20-1] and [Figure 50-20-2] from the shift lever.
2 1
Remove the knob (Item 3) [Figure 50-20-2] from the
speed range lever by pulling upward.
1
1 1
P-95465
Tilt the seat forward and remove the five screws (Item 1)
and remove the console cover (Item 2) [Figure 50-20-4]
and [Figure 50-20-5] from the left side.

793 of 1161
CONSOLE COVER (WITHOUT CAB) (CONT'D) Figure 50-20-8
Right Side Removal And Installation

2
Figure 50-20-6
1
1 1
1
P-84465
Tilt the seat forward and remove the five screws (Item 1)
P-84464 and remove the console cover (Item 2) [Figure 50-20-8]
from the right side
Remove the three point hitch knob (Item 1) [Figure 50-

20-6] from the lever by pulling upward.
Figure 50-20-7
P-84466
Remove the two nuts (Item 1) [Figure 50-20-7] located

under the fender.

794 of 1161
CONSOLE COVER (WITH CAB) Figure 50-21-3
Remove the cab post covers. (See Removal And

Figure 50-21-1
1
1 1
P-87345

1
1 Figure 50-21-4
P-87342
Remove the seven bolts (Item 1) and remove the cover

(Item 2) [Figure 50-21-1].
Figure 50-21-2
1 1 1
P-87346
Remove the three bolts (Item 1) [Figure 50-21-4] from

the lower part of the console cover.
P-87344
Remove the two rubber washers (Item 1) [Figure 50-21-

2].

795 of 1161
CONSOLE COVER (WITH CAB) (CONT’D) Figure 50-21-7
Left Side Removal and Installation (Cont’d)
Figure 50-21-5
P-87349
Reposition the cover and unplug the two connectors

P-87347 (Item 1) [Figure 50-21-7] from the cab harness.

Remove the bolt (Item 1) [Figure 50-21-5] from the
console, next to the fuse box cover. Remove the cab post covers. (See Removal And
Figure 50-21-6
Figure 50-21-8
P-87348
P-87361
Remove the screw (Item 1) and shift knob (Item 2)

[Figure 50-21-6] from the shifter knob. Remove the switch panel from the cover [Figure 50-21-
8]

796 of 1161
Right Side Removal And Installation (Cont’d)
Figure 50-21-9 2
1 1 1
1
P-87364
Remove the seven bolts (Item 1) and remove the cover

P-87362 (Item 2) [Figure 50-21-11].
Figure 50-21-12
Mark the location of the connectors (Item 1) [Figure 50-
21-9] and unplug from the switches.
1
Figure 50-21-10 1
P-87366
Remove the five upper bolts (Item 1) [Figure 50-21-12].

P-87363
Remove the cup holder (Item 1) [Figure 50-21-10] from

the console.

797 of 1161
Right Side Removal And Installation (Cont’d)
Figure 50-21-13
1
P-87368
1 Remove the knob (Item 1) [Figure 50-21-15] from the

P-87367 three point lever by pulling upward.
Figure 50-21-16
Remove the two lower bolts (Item 1) [Figure 50-21-13].
Figure 50-21-14
P-87370
P-87369 Remove the console cover [Figure 50-21-16].
Remove the front bolt (Item 1) [Figure 50-21-14].

798 of 1161
TRANSMISSION CASE (HST MODELS) Figure 50-30-3
Separate the tractor. (See Procedure on Page 40-100-1.)
Remove both travel control pedal linkages. (See

1
Figure 50-30-1
P-84619
Disconnect the spring (Item 1) [Figure 50-30-3].
Figure 50-30-4
2
P-84616 1
Lift the tractor rear housing and place a stand under the
middle case [Figure 50-30-1].
Figure 50-30-2
1 2 1
P-84620
Remove the two bolts (Item 1) and cruise control

P-84617
Remove the two cotter pins / washers (Item 1) [Figure

50-30-2].
Remove the dampener cylinder (Item 2) [Figure 50-30-

2].

799 of 1161
TRANSMISSION CASE (HST MODELS) (CONT’D) Figure 50-30-7
Figure 50-30-5
1
2 2
P-84623
1 3 1
Remove the pivot linkage (Item 1) [Figure 50-30-7].
P-84621
Figure 50-30-8
Remove the two snap rings (Item 1), washers (Item 2)

and linkage (Item 3) [Figure 50-30-5]. 1
1
Figure 50-30-6
2
2
1
1
1
P-84624
Remove the four bolts (Item 1) and bracket (Item 2)

[Figure 50-30-8].
P-84622

[Figure 50-30-6].

800 of 1161
TRANSMISSION CASE (HST MODELS) (CONT’D) Figure 50-30-11
Figure 50-30-9
1
P-84404
With a hoist and lifting chains support the transmission

P-84625 case (as shown) [Figure 50-30-11].
Figure 50-30-12
Remove the cotter pin, washer and pin (Item 1) and lower
the brake linkage (Item 2) [Figure 50-30-9] (both sides). 1
Figure 50-30-10
1
1
2
1
1
P-84403
1
Remove the ten mounting bolts (Item 1) [Figure 50-30-
P-84626 12].

Remove the three bolts (Item 1) and bracket (Item 2) torque.
[Figure 50-30-10] from the left side.

801 of 1161
TRANSMISSION CASE (HST MODELS) (CONT’D)
Figure 50-30-13
P-84402
Separate the transmission case from the middle case

and remove [Figure 50-30-13].
Installation: Align the front wheel drive shaft and

couplers.

802 of 1161
TRANSMISSION CASE (SST MODELS)
For SST models, (See TRANSMISSION (SST

Models) on page 40-61-1) for correct procedure.

803 of 1161
804 of 1161
FUEL TANK Figure 50-40-2
Remove the engine cover. (See Gas Cylinder Removal

1 3
Remove the engine side covers. (See Removal And
2
Remove the firewall (without cab). (See Removal And
4
Remove the firewall (with cab). (See Removal And 5
P-84669
Disconnect the negative cable from the battery.
Drain the fuel tank. Remove the wire harness (Item 1) from the clamp (Item
2) and unplug the relay connector (Item 3), operating
control unit connector (Item 4) and fuel sending unit
connector (Item 5) [Figure 50-40-2].
WARNING Figure 50-40-3

explosion or fire.
W-2103-0508
Figure 50-40-1 1
2
3
4
3 2
P-84670
Unplug the three connectors from the relays (Item 1) and

1
release the harness (Item 2) from the clamp (Item 3)
[Figure 50-40-3].
P-84667
Unplug the fuel sending unit wire harness (Item 1). Cut
the tie strap (Item 2) and release the harness (Item 3)
from the clamp (Item 4) [Figure 50-40-1].

805 of 1161
FUEL TANK (CONT'D) Figure 50-40-6
Figure 50-40-4
P-84746
Remove the two side mounting bolts (Item 1) [Figure 50-

P-84679 40-5] (both sides.)
Figure 50-40-7
Mark the two fuel lines (Item 1) [Figure 50-40-4] and
remove from the fuel tank.
NOTE: Install caps and plugs.
Figure 50-40-5
P-84681
Remove the bolt (Item 1) [Figure 50-40-7].
P-84745
Support the fuel tank with a chain and lifting device

[Figure 50-40-6].

806 of 1161
FUEL TANK (CONT'D)
Figure 50-40-8
P-84682
Remove the fuel tank. [Figure 50-40-8].

807 of 1161
808 of 1161
MID PTO CONTROL Figure 50-50-3
Lever Removal And Installation 2

1
Figure 50-50-1
P-92206
1 Remove the cotter pin (Item 1) and linkage (Item 2)

[Figure 50-50-3] from the lever.
Figure 50-50-4
P-92211
Loosen the jam nut (Item 1) and remove the lever grip
(Item 2) [Figure 50-50-1] from the shift lever. 2
Figure 50-50-2
3
2
P-92203
Remove the bolt (Item 1) from the bushing (Item 2) and

1 remove the lever (Item 3) [Figure 50-50-4].
P-92210
Remove the jam nut (Item 1) and rubber boot (Item 2)

[Figure 50-50-2].
NOTE: Only cab equipped models have a rubber boot.

809 of 1161
810 of 1161
SPLASH BOARD Figure 50-60-3
Figure 50-60-1
2 1
P-84149
Remove the top bracket mounting bolt (Item 1) [Figure

P-84147 50-60-3].
Figure 50-60-4
Remove the three rivets (Item 1) and remove the splash
board (Item 2) [Figure 50-60-1].
Figure 50-60-2
P-81364
1
Fold the floormat back and remove the bracket to floor

P-84148 plate mounting bolt (Item 1) [Figure 50-60-4].
Remove the bracket.

Remove the protective cover (Item 1) [Figure 50-60-2].

811 of 1161
812 of 1161
FLOORMAT (HST MODELS) For machines equipped with a cab
Removal And Installation Figure 50-70-3

For machines without a cab
Figure 50-70-1
1
P-87351
Remove the floor mat (Item 1) [Figure 50-70-3].
1 Figure 50-70-4
P-95483
Remove the two bolts (Item 1) [Figure 50-70-1] (both

sides) from the bottom side of the floor plate.

N•m) torque.
1
Figure 50-70-2
P-87352
Remove the insulation (Item 1) [Figure 50-70-4].
P-84642
Remove the floormat (Item 1) [Figure 50-70-2].

813 of 1161
814 of 1161
FLOORMAT (SST MODELS) Figure 50-71-3
Figure 50-71-1
2 1 1
P-95481

P-95446 sides) from the bottom side of the floor plate.
Figure 50-71-4
Remove the cotter pin (Item 1) and linkage (Item 2) from
the foot pedal (Item 3) [Figure 50-71-1].
Figure 50-71-2
2
1
3
P-95482
Remove the floormat (Item 1) [Figure 50-71-4].

P-95445

the bracket arm (Item 3) [Figure 50-71-2] on the bottom
side of the floor plate.

815 of 1161
816 of 1161
FLOOR PLATE Figure 50-80-3
Remove the floormat. (See Removal And Installation on

Page 50-70-1.) 5
Remove the firewall. (See Removal And Installation on 3

Page 50-130-1.)
4
Figure 50-80-1 2 1
P-84497
Remove the nut (Item 1), lock washer (Item 2), cup (Item
1 1 3), rubber mount (Item 4) and washer (Item 5) [Figure
50-80-3] (both sides).
Figure 50-80-4
1
P-84494
2 1
Remove the five bolts (Item 1) [Figure 50-80-1] from the

floor plate.
Figure 50-80-2
1
P-84498
1
Remove the two bolts (Item 1) and lower the connector
bracket (Item 2) [Figure 50-80-4] holding the four
connectors.
P-84495
Remove the three bolts (Item 1) [Figure 50-80-2] from

inside the fenders (both sides).

817 of 1161
FLOOR PLATE (CONT’D)
Removal and Installation (Cont’d)
Figure 50-80-5
1 1
P-84499
Remove the two bolts (Item 1) and lower the connector

bracket (Item 2) [Figure 50-80-5] holding the three
connectors.
Remove the floor panel.
Figure 50-80-6
P-84500
Installation: Align the pin and rubber mount (Item 1)

[Figure 50-80-6].

818 of 1161
ENGINE COVER Removal And Installation
Gas Cylinder Removal And Installation Remove the gas cylinder. (See Gas Cylinder Removal
Figure 50-90-2
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288

Page 10-20-1.)
Temporarily install a support to prevent the engine cover

from closing when the gas cylinder is removed.
P-84437
Figure 50-90-1
Disconnect the front light wire harness (Item 1) [Figure

50-90-2].
2
1
Figure 50-90-3
1 2 2 1
P-81458
Remove the two retainer clips (Item 1) and pins (Item 2)

[Figure 50-90-3].
2
Remove the engine cover.
1
P-81456
Remove the retainer clips (Item 1), washers and pins

(Item 2) [Figure 50-90-1].
Remove the gas cylinder (Item 3) [Figure 50-90-1].

819 of 1161
820 of 1161
GRILL Figure 50-91-3

Page 10-20-1.)
Figure 50-91-1
P-84442
Align the spring clip (Item 1) [Figure 50-91-3] with the

1 slot in the grill (both sides).
1 Figure 50-91-4
P-84439
1
Figure 50-91-2
P-84441
1
Tilt the top of the grill (Item 1) [Figure 50-91-4] forward
P-84440 and pull up and out of the rubber grommets.
Flip the spring clip (Item 1) [Figure 50-91-1] up (both

sides) as shown in (Item 1) [Figure 50-91-2].

821 of 1161
GRILL (CONT'D)
Figure 50-91-5
1 1
P-84443
Installation: Make sure the pegs on the bottom of the

grill enter both rubber grommets (Item 1) [Figure 50-91-
5] for proper alignment.

822 of 1161
ENGINE SIDE COVER Figure 50-100-3

Page 10-20-1.)
Figure 50-100-1
1
1
P-81617
Lift up on the rear of the side cover to remove the

alignment pin (Item 1) [Figure 50-100-3] from the
bracket.
P-81580 Figure 50-100-4
Rotate the side cover clamps (Item 1) [Figure 50-100-1]

up.
Figure 50-100-2
P-81620
Remove the engine side cover [Figure 50-100-4].

1
P-81615
Tilt the engine side cover out and remove the front of the
side cover from the bracket (Item 1) [Figure 50-100-2] by
pulling upward.

823 of 1161
824 of 1161
FENDER ASSEMBLY (WITHOUT CAB) (HST Figure 50-110-2
MODELS)
Remove the firewall. (See Removal And Installation on

Page 50-130-1.)

Remove the left console. (See Left Side Removal And
Remove the right console. (See Right Side Removal And

P-84502

Page 50-140-1.) Reposition the MLS control shaft (Item 1) [Figure 50-
110-2] (as shown).
If equipped with a joystick valve, the transmission must
be drained. (See Removing And Replacing Hydraulic / Figure 50-110-3
Transmission Fluid on Page 10-120-3.)
Figure 50-110-1
1
1
2 P-84503
P-84501 Remove the pin / washer (Item 1) and linkage (Item 2)

[Figure 50-110-3] from the remote lever linkage.
Remove the cotter pin (Item 1) and linkage (Item 2)

[Figure 50-110-1] from the differential lock linkage.

825 of 1161
MODELS) (CONT’D)
Figure 50-110-4 1
3
2
1
1 P-84426
Disconnect the two wires (Item 1) [Figure 50-110-6] from

the fender light (both sides).
P-84504
Figure 50-110-7
Remove the nut (Item 1) and linkage (Item 2) from the
three point linkage (Item 3) [Figure 50-110-4].
Figure 50-110-5 1
P-81324
Disconnect the light harness (Item 1) [Figure 50-110-7]

(both sides).
P-84505
Push the three point lever (Item 1) [Figure 50-110-5]

forward.

826 of 1161
MODELS) (CONT’D)
Figure 50-110-8
2
1
P-84506
Remove the seat harness (Item 1) [Figure 50-110-10]

from the grommet.
P-81322
Release the main harness from the rear seat frame and
lower.
Remove the two nuts (Item 1) and bracket (Item 2)
[Figure 50-110-8] from the fender (both sides). Figure 50-110-11
Figure 50-110-9
P-95468
P-84467
[Figure 50-110-11] from the mid PTO lever.
Carefully pull the harness (Item 1) [Figure 50-110-9]
through the hole in the fender (both sides). Remove the floor plate. (See Removal And Installation
on Page 50-80-1.)

827 of 1161
MODELS) (CONT’D)
Figure 50-110-12
1
2 1
2
3
P-95499
P-84511 the cable.

If equipped with auxiliary control valves, remove the two 14] to 7 ft.-lb. (9 N•m) torque.
clips (Item 1) and linkages (Item 2) [Figure 50-110-12]
from the valves. Figure 50-110-15
Figure 50-110-13
P-95500
P-95499
Measure and record the joystick cables dimension as


2.75 in. (70 mm).

828 of 1161
MODELS) (CONT’D)
Figure 50-110-16
1
2
1
P-86191

install the O-ring (Item 1) [Figure 50-110-18] in
P-95501 the O-ring bore of the flange.
Figure 50-110-19
the cable.

Figure 50-110-17
P-84459
Support the fender assembly using a hoist and lifting

straps positioned as shown [Figure 50-110-19].
P-95502

829 of 1161
MODELS) (CONT’D)
Figure 50-110-20
P-84519
Remove the bolt and washer (Item 1) [Figure 50-110-22]

1 from the top of the fender mount (both sides).
P-84518
N•m) torque.
Remove the three rubber caps (Item 1) [Figure 50-110-
20] from the bolts (both sides). Figure 50-110-23
NOTE: Depending on the wheel/tire combination used
on the machine, the rear tires may need to be
removed to access the bolts.
Figure 50-110-21
P-84459
1
Carefully lift and remove the fender assembly [Figure
50-110-23].
P-84460
Hold the inner nuts and loosen the two bolts (Item 1)

830 of 1161
MODELS) (CONT’D)
Fender Mount Removal And Installation 1
Remove the fender assembly. (See Removal And

Figure 50-110-24
P-84452
Remove the four top bolts (Item 1) and mount assembly

(Item 2) [Figure 50-110-25].

1 147 N•m) torque.
P-84515
Remove the four bottom bolts (Item 1) [Figure 50-110-

24].

147 N•m) torque.

831 of 1161
832 of 1161
FENDER ASSEMBLY (SST MODELS) Figure 50-111-2

1
Remove the firewall. (See Removal And Installation on
Page 50-131-1.)

Remove the left console. (See Left Side Removal And

Remove the right console. (See Right Side Removal And

P-95467
Page 50-140-1.)
Reposition the MLS control shaft (Item 1) [Figure 50-
If equipped with a joystick valve, the transmission must 111-2] (as shown).
be drained. (See Removing And Replacing Hydraulic /
Transmission Fluid on Page 10-120-3.) Figure 50-111-3
Figure 50-111-1
1
1
P-84503
P-95466
Remove the pin / washer (Item 1) and linkage (Item 2)
[Figure 50-111-3] from the remote lever linkage.
[Figure 50-111-1] from the differential lock linkage.

833 of 1161
FENDER ASSEMBLY (SST MODELS) (CONT’D) Figure 50-111-6
Figure 50-111-4
1
3
2
1
P-84426
Disconnect the two wires (Item 1) [Figure 50-111-6] from

P-84504 the fender light (both sides).
Figure 50-111-7
Remove the nut (Item 1) and linkage (Item 2) from the
three point linkage (Item 3) [Figure 50-111-4].
Figure 50-111-5
1
P-81324

Push the three point lever (Item 1) [Figure 50-111-5]

forward.

834 of 1161
Figure 50-111-8
2
1
1
P-84506
Remove the seat harness (Item 1) [Figure 50-111-10]

P-81322 from the grommet.
Release the main harness from the rear seat frame and
Remove the two nuts (Item 1) and bracket (Item 2) lower.
[Figure 50-111-8] from the fender (both sides).
Figure 50-111-11
Figure 50-111-9
1
1
P-95468
P-84467

Carefully pull the harness (Item 1) [Figure 50-111-9] [Figure 50-111-11] from the mid PTO lever.
through the hole in the fender (both sides).
Remove the floor plate. (See Removal And Installation
on Page 50-80-1.)

835 of 1161
Figure 50-111-12
1
2 1
2
3
P-95499
P-84511 2). Unthread the flange (Item 3) [Figure 50-111-14] from
the cable.
If equipped with auxiliary control valves, remove the two Installation: Tighten the screws (Item 2) [Figure 50-111-
clips (Item 1) and linkages (Item 2) [Figure 50-111-12] 14] to 7 ft.-lb. (9 N•m) torque.
from the valves.
Figure 50-111-15
Figure 50-111-13
P-95500
P-95499

Measure and record the joystick cables dimension as

2.75 in. (70 mm).

836 of 1161
Figure 50-111-16
2 1
1
P-86191

the cable.

Figure 50-111-17
P-95507
Install jackstands as shown as shown [Figure 50-111-

19].
P-95502

837 of 1161
Figure 50-111-20
1
2
2 P-95508
1
Remove the rubber cap (Item 1) [Figure 50-111-22] from

P-95506 the bolt (both sides).
Figure 50-111-23
Remove the two lug nuts (Item 1) and four bolts (Item 2)
[Figure 50-111-20] from both rear wheels and remove
the wheel assemblies
Installation: Tighten the lug nuts and bolts to 166 ft.-lb.

(226 N•m) torque.
Figure 50-111-21
1
P-95509
Remove the bolt and washer (Item 1) [Figure 50-111-23]

from the top of the fender mount (both sides).

N•m) torque.
P-95497
Support the fender assembly using a hoist and lifting

straps positioned as shown [Figure 50-111-21].

838 of 1161
FENDER ASSEMBLY (SST MODELS) (CONT’D) Fender Mount Removal And Installation
Removal and Installation (Cont’d) Remove the fender assembly. (See Removal And
Figure 50-111-24
Figure 50-111-25
P-95510
P-95515
Carefully lift and remove the fender assembly (Item 1)

[Figure 50-111-24]. Remove the two bolts (Item 1) [Figure 50-111-25].

N•m) torque.
Figure 50-111-26
1
1
P-95516
Remove the four rear bolts (Item 1) and mount assembly

(Item 2) [Figure 50-111-26].

147 N•m) torque.

839 of 1161
840 of 1161
FENDER (WITHOUT CAB) Figure 50-120-3
The following procedure shows the right fender being

removed. The procedure for the left fender is the same.
1
Remove the ROPS and ROPS brackets. (See Removal
Remove the right console cover. (See Right Side

Figure 50-120-1
P-84430
1 Remove the two bolts (Item 1) [Figure 50-120-3].
P-84429
Remove the two bolts (Item 1) [Figure 50-120-1].
Figure 50-120-2
P-84428

841 of 1161
FENDER (WITHOUT CAB) (CONT’D) Figure 50-120-6

1
Figure 50-120-4
2
3
3
1
2
P-84433
Disconnect the wire harness (Item 1) and feed the

P-84431 harness through the hole (Item 2) [Figure 50-120-6] in
the fender.
Remove the bottom bolt (Item 1) and loosen the top two Remove the four bolts (Item 3) [Figure 50-120-6] and
bolts (Item 2) [Figure 50-120-4]. washers. Remove the fender.
Figure 50-120-5 Installation: Tighten the bolts to 91 - 108 ft.-lb. (124 -

147 N•m) torque.
P-84432
Support the wire harness retainer (Item 1) [Figure 50-

120-5] and remove the bolts loosened in [Figure 50-120-
4]. Remove the retainer.

842 of 1161
FENDER (WITH CAB) Figure 50-121-3
The following procedure shows the right fender being

removed. The procedure for the left fender is the same.
Raise the rear wheels and support the rear axle on jack
stands. (See Procedure on Page 10-10-1.)
Figure 50-121-1
1 2
P-87782
Remove the A/C drain hose (Item 1) [Figure 50-121-3]

from the clamp.
1
Figure 50-121-4
2
P-80900
Remove the four bolts (Item 1) and four nuts (Item 2)

[Figure 50-121-1] and remove the wheel assembly from
Figure 50-121-2
1 P-87788
Cut the sealant bond between the fender and cab

[Figure 50-121-4].
Installation: Apply sealant after the fender is installed.
P-87781
Disconnect the light connector (Item 1) from the main


843 of 1161
FENDER (WITH CAB) (CONT’D)
Figure 50-121-5
1 1
P-87784
Remove the sixteen fender mounting bolts (Item 1)

[Figure 50-121-5].
Remove the fender.

844 of 1161
FIREWALL (WITHOUT CAB) (HST MODELS) Figure 50-130-3
Remove the splash boards. (See Removal And

1
Remove the instrument panel (See Removal And

Page 50-70-1.)
Figure 50-130-1
P-84481
Unplug the three connectors (Item 1) [Figure 50-130-3]

located under the floor board on the left side.
1
Figure 50-130-4
1
P-84479
Remove the cotter pin, washer and pin (Item 1) [Figure

50-130-1] from the brake linkage on the left side.
Figure 50-130-2
1
1 P-84484
1
1
50-130-4] from the brake linkage on the right side.
P-84480
Unplug the four connectors (Item 1) [Figure 50-130-2]


845 of 1161
FIREWALL (WITHOUT CAB) (HST MODELS)
(CONT'D)
Figure 50-130-5
2
1
P-87505
Remove the cotter pin (Item 1) washer (Item 2) and

throttle cable (Item 3) [Figure 50-130-5] from the linkage.
Figure 50-130-6
3
1
P-87506
Remove the throttle cable (Item 2) from the bracket (Item

3) [Figure 50-130-6].

846 of 1161
FIREWALL (WITHOUT CAB) (HST MODELS) NOTE: Mark the hoses for correct installation.
(CONT’D)
Removal And Installation (Cont’d) Figure 50-130-9
Figure 50-130-7
1
P-84485
P-84510
Remove the two lower hoses (Item 1) [Figure 50-130-9]
from the steering valve.
Unplug the neutral start harness connector (Item 1)
[Figure 50-130-7] from the main harness. Installation: Tighten the hoses to 18 - 22 ft.-lb. (25 - 29
N•m) torque.
Figure 50-130-10
IMPORTANT
damage the system.
I-2003-0888
Figure 50-130-8
P-84487
Using a hoist and lifting strap, support the firewall

assembly as shown [Figure 50-130-10].
P-84483

the steering valve.

847 of 1161
FIREWALL (WITHOUT CAB) (HST MODELS) Open the engine cover.
(CONT’D)
Figure 50-130-13
Figure 50-130-11
1 1
P-84490
1
1 1
P-84488 Remove the two bolts (Item 1) [Figure 50-130-13] (both
sides).
Remove the eight mounting bolts (Item 1) [Figure 50- Figure 50-130-14
130-11].
Figure 50-130-12
P-84489
Remove the mounting bolt (Item 1) [Figure 50-130-12]

(both sides).
P-84491
Lift and remove the firewall assembly [Figure 50-130-14]

848 of 1161
FIREWALL (SST MODELS) Figure 50-131-3
Remove the splash boards. (See Removal And

1
Remove the instrument panel (See Removal And

Page 50-71-1.)
Figure 50-131-1
P-84481

1 Figure 50-131-4
P-95474
1
50-131-1] from the brake linkage on the left side.
Figure 50-131-2
1 1 P-95476
1

50-131-4] from the brake linkage on the right side.
IMPORTANT
P-95473
Unplug the three connectors (Item 1) [Figure 50-131-2] damage the system.
I-2003-0888

849 of 1161
FIREWALL (SST MODELS) (CONT'D) Figure 50-131-7
Figure 50-131-5
P-87505
1
Remove the cotter pin (Item 1), washer (Item 2) and
P-95484 throttle cable (Item 3) [Figure 50-131-7] from the linkage.
Figure 50-131-8
the steering valve.
NOTE: Mark the hoses for correct installation.
Figure 50-131-6
1
3
P-87506
1 Remove the nut (Item 1) [Figure 50-131-8].
Remove the throttle cable (Item 2) from the bracket (Item

P-95485 3) [Figure 50-131-8].

Installation: Tighten the hoses to 18 - 22 ft.-lb. (25 - 29

IMPORTANT
N•m) torque.
damage the system.
I-2003-0888

850 of 1161
FIREWALL (SST MODELS) (CONT'D) Figure 50-131-11
Figure 50-131-9
1 4 3
2
3 2
1
1 P-95452
4
Remove the cotter pin (Item 1), washer (Item 2) and pin
P-95454 (Item 3) from the clutch linkage (Item 4) [Figure 50-131-
11].
Remove the two nuts (Item 1) and bolts (Item 2) from the Figure 50-131-12
coupler (Item 3) [Figure 50-131-9].

N•m) torque.
Remove the coupler (Item 3) from the FNR shaft (Item 4)

[Figure 50-131-9].
Figure 50-131-10
1
P-95492

assembly as shown[Figure 50-131-12].
P-95451
Remove the cotter pin, washer and pin (Item 1) from the
clutch linkage (Item 2) [Figure 50-131-10].

851 of 1161
FIREWALL (SST MODELS) (CONT’D) Open the engine cover.
Removal And Installation (Cont’d) Figure 50-131-15
Figure 50-131-13
P-95487
1 1
P-95486
sides).
Remove the eight mounting bolts (Item 1) [Figure 50-
131-13]. Figure 50-131-16
Figure 50-131-14
P-84489
Remove the mounting bolt (Item 1) [Figure 50-131-14]

(both sides).
P-95488
Lift and remove the firewall assembly [Figure 50-131-16]

852 of 1161
FIREWALL (WITH CAB) (HST MODELS) Figure 50-132-3
Remove the instrument panel (See Removal And 1

2
Page 50-70-1.)
Remove the cab door. (See Removal And Installation on

Page 50-230-1.)
NOTE: The tool box is removed for photo clarity.
Figure 50-132-1 P-87497
Remove the two bolts (Item 1) and lower the rear

1 harness bracket (Item 2) [Figure 50-132-3].
Figure 50-132-4
2
1
P-87494
1
Remove the two bolts (Item 1) and lower the front
harness bracket (Item 2) [Figure 50-132-1].
Figure 50-132-2 P-87498
Unplug the four electrical connectors (Item 1) [Figure 50-

132-4].
1
1
P-87495

132-2].

853 of 1161
FIREWALL (WITH CAB) (HST MODELS) (CONT’D) Figure 50-132-7
Figure 50-132-5
P-87501
Remove the cotter pin, washer, spring washer and pin

P-87499 (Item 1) [Figure 50-132-7] from the brake linkage on the
right side.
Unplug the three connectors (Item 1) [Figure 50-132-5]. Figure 50-132-8
Figure 50-132-6
P-87502
P-87500
Unplug the neutral start harness connector (Item 1)

[Figure 50-132-8] from the main harness.
(Item 1) [Figure 50-132-6] from the brake linkage on the
left side.
IMPORTANT
damage the system.
I-2003-0888

854 of 1161
Figure 50-132-9
2
1
1 1
3
P-87505

P-87503 throttle cable (Item 3) [Figure 50-132-11] from the
linkage.
Remove the two hoses (Item 1) [Figure 50-132-9] from Figure 50-132-12
the steering valve.
Figure 50-132-10
3 1
1 1 2
P-87506
P-87504 Remove the throttle cable (Item 2) from the bracket (Item
3) [Figure 50-132-12].
Remove the lower hoses (Item 1) [Figure 50-132-10]


855 of 1161
Figure 50-132-13
1
1
P-87511
Remove the eight lower mounting bolts (Item 1) [Figure

P-87508 50-132-15].
Figure 50-132-16
assembly as shown [Figure 50-132-13].
Figure 50-132-14
1
P-87513
Carefully separate the firewall from the cab by braking

the sealant bond [Figure 50-132-16].
1
P-87510
Remove the eight upper mounting bolts (Item 1) [Figure

50-132-14].

856 of 1161
FIREWALL (WITH CAB) (HST MODELS) (CONT’D)
Figure 50-132-17
P-87514
Carefully lift and remove the firewall assembly [Figure

50-132-17].

857 of 1161
858 of 1161
ROPS Figure 50-140-3
Figure 50-140-1
1
2
1
P-81316
Remove the snap pin (Item 1) and pin (Item 2) [Figure

P-80506 50-140-3] (both sides).
Figure 50-140-4
Support the ROPS assembly using a hoist and lifting
strap (Item 1) [Figure 50-140-1].
Figure 50-140-2
1
2
P-81317
1
Remove the pivot bolt / nut (Item 1) [Figure 50-140-4]
Installation: Do not over tighten the bolt and deflect the

Loosen the jam nut (Item 1) and knob (Item 2) [Figure mount.
50-140-2] (both sides).
Lift and remove the ROPS.

859 of 1161
ROPS (CONT’D) Figure 50-140-7
Bracket Removal And Installation
Remove the ROPS assembly. (See Removal And

Figure 50-140-5
2
1 1
P-81319
1
Remove the four bolts (Item 1) and bracket (Item 2)
[Figure 50-140-7] from the top of the fender (both sides).

P-84426 N•m) torque.
Disconnect the two wires (Item 1) [Figure 50-140-5].
Figure 50-140-6
1
2
P-84427
Carefully pull the wires (Item 1) through the hole (Item 2)

[Figure 50-140-6] in the top of the fender.

860 of 1161
PTO SAFETY SHIELD
Figure 50-150-1
2
2
P-84743
Lift the PTO shield slightly and remove the two bolts
(Item 1) and two nuts (Item 2) [Figure 50-150-1].
Installation: Tighten the nuts and bolts to 36 - 41 ft.-lb.

(48 - 56 N•m) torque.
Remove the PTO shield.

861 of 1161
862 of 1161
DRAW BAR
Figure 50-160-1
3 1
1
P-84744
Remove the two clips (Item 1), two pins (Item 2) and
drawbar (Item 3) [Figure 50-160-1].

863 of 1161
864 of 1161
DRAW BAR ASSEMBLY
Remove the PTO safety shield. (See Removal And

Figure 50-170-1
P-84412A
Support the draw bar assembly with a floor jack [Figure

50-170-1].
Figure 50-170-2
1
1
P-84411

147 N•m) torque.
Lower the floor jack and remove the draw bar assembly.

865 of 1161
866 of 1161
THREE POINT HITCH LOWER LINKS Figure 50-180-3
Figure 50-180-1
3
P-84710
1 Record the position of the pin (Item 1) [Figure 50-180-3]

P-84708 for installation.
Support the lower link and remove the pin (Item 1)

Remove the clip (Item 1), washer, pin (Item 2) and sway [Figure 50-180-3].
bar assembly (Item 3) [Figure 50-180-1].
Figure 50-180-4
Figure 50-180-2
P-78560
P-84709
Remove the retaining bolt (Item 1) [Figure 50-180-4].

Remove the retaining clip (Item 1) [Figure 50-180-2].

867 of 1161
THREE POINT HITCH LOWER LINKS (CONT’D) Figure 50-180-7
Left Side Removal And Installation (Cont’d)
Figure 50-180-5
P-84712
1
While supporting the lower link, remove the retaining clip
2
P-78557 (Item 1), pin (Item 2) [Figure 50-180-7] and lower the
lower link.
Remove the pin (Item 1), and the lower links (Item 2) Figure 50-180-8
[Figure 50-180-5].
Figure 50-180-6
2
1
3
P-78562
Remove the retaining bolt (Item 1) [Figure 50-180-8].

1
P-84711
Remove the clip (Item 1), washer, pin (Item 2) and sway
bar assembly (Item 3) [Figure 50-180-6].

868 of 1161
THREE POINT HITCH LOWER LINKS (CONT’D) Top Link Assembly Removal And Installation
Right Side Removal And Installation (Cont’d) Figure 50-180-10
Figure 50-180-9
1
2
2
P-84713
P-78563
[Figure 50-180-10].
Remove the pin (Item 1) and the lower link (Item 2)
[Figure 50-180-9]. Remove the top link assembly (Item 3) [Figure 50-180-
10].
Figure 50-180-11
3
4
P-98115

[Figure 50-180-11].
Remove the link (Item 3) from the arm (Item 4) [Figure

50-180-11] (both sides).

869 of 1161
870 of 1161
FRONT WORK LIGHT MOUNT (WITH CAB) Figure 50-190-3

2 2
Figure 50-190-1
1
P-87175
Tilt the light (Item 1) forward and remove the two bolts
(Item 2) [Figure 50-190-3] (both sides).
Figure 50-190-4
P-87173
Remove the bolt (Item 1) [Figure 50-190-1] from both

sides of the light mount.
Figure 50-190-2
1
1
P-87178
Temporarily place the light mount on top of the cab

[Figure 50-190-4].
P-87174

871 of 1161
FRONT WORK LIGHT MOUNT (WITH CAB) (CONT'D)
Figure 50-190-5
P-87177
Unplug the connectors (Item 1) [Figure 50-190-5] from

the front work light (both sides).
Remove the work light mount.

872 of 1161
CAB COVER Figure 50-200-3
Remove the front work light mount. (See Removal And

1
Figure 50-200-1
1
1
P-87181
Remove the nut and washer (Item 1) [Figure 50-200-3]

(both sides).
Installation: Do not overtighten.

P-87179
Figure 50-200-4
Remove the two nuts and washers (Item 1) [Figure 50-

200-1].
Figure 50-200-2
P-87182
Open the cab cover and install a safety support (Item 1)

[Figure 50-200-4].
NOTE: The support must be long enough to allow

P-87180 access, but not too long, opening the cover
too far.
Remove the plastic nut cover (Item 1) [Figure 50-200-2]

(both sides).

873 of 1161
CAB COVER (CONT'D) Figure 50-200-7
Figure 50-200-5 2
P-87185
Drive the pin (Item 1) inward until the hinge (Item 2)

P-87195 [Figure 50-200-7] is free (both sides).
With help from an assistant, lift and remove the cab

Unplug the connectors (Item 1) [Figure 50-200-5] from cover.
the REAR work light (both sides).
Unplug the antenna from the radio (if equipped).
Lower the cab cover.
Figure 50-200-6
P-87184
Remove the clip (Item 1) [Figure 50-200-6] from the

hinge pin (both sides).

874 of 1161
CAB POST COVER Figure 50-210-3
Left center
1
Figure 50-210-1
P-87338
Open the window latch, remove the cover (Item 1)

[Figure 50-210-3].
P-87336 Left rear
Figure 50-210-4
Remove the two plastic covers (Item 1) [Figure 50-210-
1] (Top and bottom).
Figure 50-210-2
1
P-87340

P-87337 4] (Top and bottom).
Remove the two bolts (Item 1) [Figure 50-210-2] (Top

and bottom).

875 of 1161
CAB POST COVER (CONT'D) Figure 50-210-7
Figure 50-210-5 1
P-87354

P-87341 and bottom).
Figure 50-210-8
and bottom).
1
2
Right center
Figure 50-210-6
P-87356
Open the window latch, remove the cover (Item 1) part

way and unplug the connector (Item 2) [Figure 50-210-8]
from the auxiliary power.
P-87353


876 of 1161
CAB POST COVER (CONT'D)
Right rear
Figure 50-210-9
P-87358

Figure 50-210-10
1 2
P-87359

and bottom).

877 of 1161
878 of 1161
INNER FENDER ACCESS COVER (WITH CAB)
Raise the rear wheels and support the rear axle on jack
stands. (See Procedure on Page 10-10-1.)
Figure 50-220-1
1 2
1
2
P-80900
Remove the four bolts (Item 1) and two nuts (Item 2)

[Figure 50-220-1] and remove the wheel assembly from
Figure 50-220-2
1 1
P-87786
Remove the four bolts (Item 1) and access cover (Item 2)

[Figure 50-220-2].

879 of 1161
880 of 1161
CAB (HST MODELS) Figure 50-230-2
Drain the cooling system. (See Removing And Replacing

Coolant on Page 10-90-3.)
Remove the operator seat.(See Removal And Installation

on Page 50-10-1.) 1
Remove the steering column cover. (See Removal And 1

Remove the center cover. (See Removal And Installation

on Page 60-80-1.)
P-87495
Remove the floor mat. (See Removal And Installation on
Page 50-70-1.)
Evacuate the A/C system. (See SYSTEM CHARGING 230-2].
AND RECLAMATION on Page 80-130-1.)
Figure 50-230-3
Remove the cab cover.(See Removal And Installation on
Page 50-200-1.)
NOTE: The tool box is removed for photo clarity. 1
2
Figure 50-230-1
P-87497
Remove the two bolts (Item 1) and lower the rear

P-87494
Remove the two bolts (Item 1) and lower the front


881 of 1161
CAB (HST MODELS) (CONT'D) Figure 50-230-6
Figure 50-230-4
1 P-87500

P-87498 (Item 1) [Figure 50-230-6] from the brake linkage on the
left side.
Unplug the four electrical connectors (Item 1) [Figure 50- Figure 50-230-7
230-4].
Figure 50-230-5
1
P-87552
P-87550 Disconnect the two air conditioning hoses (Item 1)

[Figure 50-230-7].
Route all the connectors (Item 1) above the heater hose Cap and plug the compressor hoses and fittings with the
(Item 2) [Figure 50-230-5] and secure to the bottom of proper A/C caps and plugs.
the cab.

882 of 1161
Figure 50-230-8 2
P-87561
Remove the cotter pin and washer (Item 1) (both ends)

P-87557 and remove the linkage (Item 2) [Figure 50-230-10].
Figure 50-230-11
Reposition the MLS control shaft (Item 1) [Figure 50-
230-8].
Figure 50-230-9
2
1
3 1
P-87570
2 Remove the nut (Item 1) and linkage (Item 2) [Figure 50-

P-87559 230-11].

the differential lock pedal linkage (Item 3) [Figure 50-
230-9].

883 of 1161
Figure 50-230-12
1
1
2
P-87501
1
P-87560 (Item 1) [Figure 50-230-14] from the brake linkage on
the right side.
Unplug the two connectors (Item 1) and remove from the Figure 50-230-15
frame clamps (Item 2) [Figure 50-230-12].
Figure 50-230-13
P-87502
P-87562 Unplug the neutral start harness connector (Item 1)

Unplug the connector (Item 1) [Figure 50-230-13] from

the main harness.
IMPORTANT
damage the system.
I-2003-0888

884 of 1161
Figure 50-230-16
2
1
1 1
P-87505

P-87503 throttle cable (Item 3) [Figure 50-230-18] from the
linkage.
Remove the two hoses (Item 1) [Figure 50-230-16] from Figure 50-230-19
the steering valve.
Figure 50-230-17
3 1
2
1 1
P-87506
Remove the nut (Item 1)[Figure 50-230-19].
P-87504 Remove the throttle cable (Item 2) from the bracket (Item
3) [Figure 50-230-19].


885 of 1161
Figure 50-230-20
P-86186
Figure 50-230-23
P86184
Measure and record the cable dimensions as shown

[Figure 50-230-20].
3 2
2.75 in. (70 mm).
Figure 50-230-21
P-86187
the cable.
2
3 23] to 7 ft.-lb. (6,6 N•m) torque.
1
P-86185
the cable.


886 of 1161
Figure 50-230-24
P-87568
Disconnect the three connectors (Item 1) [Figure 50-

P-86188 230-26] from the main harness.
Figure 50-230-27
Secure the two cables to the bottom of the cab.
Figure 50-230-25 1
2
1
2 2
2
P-87567
Release the heater hose (Item 1) from the two frame

clamps (Item 2) [Figure 50-230-27].
P-87566
Remove the two clamps (Item 1) and heater hoses (Item

2) [Figure 50-230-25] from the heater hoses in the right
side lower cab corner.

887 of 1161
Figure 50-230-28
1 1
P-87565
2 Remove the bolt (Item 1), washer (Item 2) and mounting

P-87563 plate (Item 3) [Figure 50-230-30] (both sides).

Remove the two bolts (Item 1) and cover (Item 2) [Figure N•m) torque.
50-230-28] (both sides).
Figure 50-230-31
Figure 50-230-29
2
P-87569
P-87564
Using a chain hoist of adequate lifting capacity and

Remove the nut (Item 1), washer (Item 2) and mounting height, lift and remove the cab [Figure 50-230-31].
plate (Item 3) [Figure 50-230-29] from each side of the
instrument panel.

N•m) torque.

888 of 1161
Door Removal And Installation
Open the cab door.
WARNING
2
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
P-87623
Figure 50-230-32
Remove the gas cylinder (Item 1) from the mounting post
(Item 2) [Figure 50-230-34] (both ends),
Remove the center cab post cover. (See Removal And

1 Installation on Page 50-210-1.)
Figure 50-230-35
P-87621
1
Slide the lower gas cylinder retainer (Item 1) [Figure 50-
230-32] down.
Figure 50-230-33
P-87620
Remove the snap ring (Item 1) [Figure 50-230-35] (top

and bottom).
P-87622
Slide the upper gas cylinder retainer (Item 1) [Figure 50-

230-33] up.

889 of 1161
CAB (HST MODELS) (CONT'D) Windshield Removal And Installation
Door Removal And Installation (Cont’d) Figure 50-230-37
Figure 50-230-36
P-87624
P-87619
Open the cover (Item 1) on the front wiper and remove
the nut (Item 2) [Figure 50-230-37].
With the help from an assistant supporting the door,
remove the door pin (Item 1) [Figure 50-230-36] (top and Figure 50-230-38
bottom).
Remove the door.

1
P-87625
Remove and reposition the wiper arm (Item 1) [Figure

50-230-38].

890 of 1161
Windshield Removal And Installation (Cont’d)
Figure 50-230-39
1
P-87626
Support the front window and remove the brackets (Item

P-87628 1) [Figure 50-230-41].
Remove the front window.

Remove the plastic nut cap (Item 1) [Figure 50-230-39]
from all four nuts.
Figure 50-230-40
P-87627
Remove the nut and washer (Item 1) [Figure 50-230-40].

891 of 1161
Front Lower Window Removal And Installation
Figure 50-230-42
P-87631
Remove the window [Figure 50-230-44].

P-87629
Remove the plastic nut cap (Item 1) [Figure 50-230-42].
Figure 50-230-43
P-87630
Remove the nut and washer (Item 1)[Figure 50-230-43].
Installation; Do not overtighten.

892 of 1161
Rear Window Removal And Installation
Open the rear window.
Figure 50-230-45
1
P-87636
Remove the plastic nut cap (Item 1) [Figure 50-230-47]

(both sides).
P-87634 Figure 50-230-48
Slide the gas cylinder retainer (Item 1) [Figure 50-230-

45] up (as shown) on (both sides).
Figure 50-230-46
1
P-87637
With the aid of an assistant to support the window,

remove the nut and washer (Item 1) [Figure 50-230-48]
(both sides).
P-87635
Remove the rear window.
Support the window and remove the gas cylinder (Item 1)

from the mounting post (Item 2) [Figure 50-230-46].
Lower the rear window.

893 of 1161
CAB (HST MODELS) (CONT'D) Door Glass Removal And Installation
Side Window Removal And Installation Open the door.
Open the side window. Figure 50-230-51
Figure 50-230-49
1 P-87640
P-87638
Remove the screw and washer (Item 1) [Figure 50-230-
51] from the latch cover.
Remove the bolt and mount (Item 1) [Figure 50-230-49]
from the window latch. Figure 50-230-52
Figure 50-230-50
P-87641
Remove the latch cover [Figure 50-230-52].

P-87639
Support the window and remove the nut (Item 1) [Figure

50-230-50] (top and bottom).

894 of 1161
Door Glass Removal And Installation (Cont’d)
Figure 50-230-53
1
1
2
P-87646
Slide the gas cylinder retainer (Item 1) up and remove

P-87642 the gas cylinder (Item 2) from the post (Item 3) [Figure
50-230-55].
Remove the large nut (Item 1) [Figure 50-230-53] from Figure 50-230-56
the latch.
Figure 50-230-54
1
P-87644
P-87643 Remove the plastic nut cap (Item 1) [Figure 50-230-56].
Remove the nut and washer (Item 1) [Figure 50-230-54].
Remove the latch assembly.

895 of 1161
Door Glass Removal And Installation (Cont’d)
Figure 50-230-57
1
1
P-87648
With the aid from an assistant to support the door,

P-87645 remove the two nuts and washers (Item 1) [Figure 50-
230-59] (top and bottom).
Remove the nut and washer (Item 1) [Figure 50-230-57]. Remove the door.
Figure 50-230-58
1
1
P-87647
Remove the two plastic nut caps (Item 1) [Figure 50-

230-58] (top and bottom).

896 of 1161
HEADLINER Figure 50-231-3
Remove the cab cover. (See Removal And Installation on

Page 50-200-1.)
Remove the HVAC control panel. (See Removal And

If equipped unplug the left and right speaker wires. 1
If equipped unplug the electrical connector and washer

tubeline from the rear wiper.
Remove the cab post covers. (See Removal And P-89328

Figure 50-231-1 Remove the twelve headliner screws (Item 1) [Figure 50-
231-3].
P-89326
Unplug the dome light connector (Item 1) [Figure 50-

231-1] from the harness.
Figure 50-231-2
P-89327
Remove the knob (Item 1) and mirror (Item 2) [Figure

50-231-2]

897 of 1161
898 of 1161
ELECTRICAL SYSTEM
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
CRUISE CONTROL (HST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Controller Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Magnet Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8 ELECTRICAL
Electrical Component Location (Without Cab) (HST Models) . . . . . . . . 60-10-4 SYSTEM
Electrical Component Location (With Cab) (HST Models). . . . . . . . . . . 60-10-5
Electrical Component Location (SST Models) . . . . . . . . . . . . . . . . . . . . 60-10-6
Fuse And Relay Location - Engine Compartment . . . . . . . . . . . . . . . . . 60-10-8
Fuse And Relay Location - Instrument Panel - HST Models . . . . . . . . 60-10-10
Fuse And Relay Location - Cab (If Equipped) . . . . . . . . . . . . . . . . . . . . 60-10-9
Fuse And Relay Location - Instrument Panel - SST Models . . . . . . . . 60-10-11
Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
FORWARD - NEUTRAL - REVERSE (F-N-R) LEVER (SST MODELS) . 60-150-1

F-N-R Lever Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-150-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

FRONT LIGHTS (WITH CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-52-1

Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-52-2

899 of 1161
ELECTRICAL SYSTEM (CON’T)
FRONT WORK LIGHT (WITH CAB) . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
HOOD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

PTO LEVER (MID) (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . 60-91-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-91-3
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-91-1
PTO Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-91-2
PTO SWITCH (REAR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
REAR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-1

Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-2
REAR WORK LIGHT (WITH CAB) . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

SPEED RANGE LEVER (HST ONLY). . . . . . . . . . . . . . . . . . . . . . 60-150-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Controller Removal And Installation. . . . . . . . . . . . . . . . . . . . . 60-150-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING COLUMN COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1


900 of 1161
WIRING SCHEMATIC RED = RED
BLK = BLACK
BLU = BLUE
GRN = GREEN
CT335 (S/N ABH811001 AND ABOVE) YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
(PRINTED DECEMBER 2009) GRY = GRAY
ORG = ORANGE
V-1304
TO CAB RED/
SPEED
(IF EQUIPPED) WHT
SENSOR
RED/
WHT
RED/
RED/
RED/
BLU
BLU
BLU
RED/
BLU
RED
FUSE - 5A
(OCU)
MID-PTO
SEAT
GLOW PLUG SWITCH A B
30
SWITCH
SWITCHED
85
(IF EQUIPPED)
POWER
OFF
RED/
BLU
A B
YEL/
87A
BLU
YEL
RUN
86
87
START
BLK
WHT
BLK
RED/
GRN
RED/
SO BLK ENGINE 19
OCU 8 4 5 1
YEL/ REAR DIODE ENGINE
POWER
PTO START STOP
RED SWITCH SIGNAL
RED/
SIGNAL
BLK
RED/ RANGE
ST GRN YEL/ NEUTRAL
B WHT
RED (+) SIGNAL
OPERATIONAL CONTROL UNIT YEL/
23
BLU
BLK/ BRAKE (+)
RED SIGNAL
22
DIODE
RED/ 3 18 21 25 17 15
I WHT
WHT
BLU/
BLK/
YEL/
RED
BLK
PNK
TO CAB
YEL/
IGNITION SWITCH
RED
RED/
BLK
(IF EQUIPPED)
BLK
RED/
WHT
(INSTRUMENT PANEL)
RED/
WHT
FUSE – 5A
PNK/
BRN/
BRN/
WHT
WHT
BLK/
RED
BLK
RED
WHT
YEL/
BLK/
RED
RED
RED/
BLK
RED
FUSE – 15A
(LIGHTS)
39 37 7 20 19 11 DASH 18 12 33 13 34
FUEL PULL
FUSE - 25A
INSTRUMENT PANEL
YEL/
BLK
HOURMETER
LIGHTS
ALTERNATOR EXCITE
BLK/
RED
RED
LEFT RIGHT
BLK/
RED
YEL
H DIRECTIONAL DIRECTIONAL
PREHEAT RELAY
LIGHT LIGHT
FUSE - 5A
UNLOCKED
PNK
30
BRAKE
85
ENGINE CRUISE PEDAL

PRE-HEAT ENGINE
PNK/
CHARGE
BLK
PARKING OIL
LIGHT PTO COOLANT
87A
SYSTEM BRAKE PRESS. FUEL HIGH

86
87
LIGHT TEMP. COOLANT

LIGHT LIGHT LIGHT LEVEL
GAUGE TEMP.
TACH RPM
x100
N L M H BEAM
GAUGE LIGHT B1
DIODE
RED
BLK
4WD
BRN/
T WHT
YEL
PNK 5 36 17 2 27 28 40 29 9 LOW
RED BEAM
WHT
BLK/
GRN
BLK/
PULL RELAY
GRN/
WHT
BLU/
GRN
BLK/
GRN/
GRN
YEL/
YEL
RED/
WHT
WHT
WHT
RED
GRY
YEL/
RED
YEL/
RED
BLK/
WHT
YEL/
85 86
YEL/
BLK
BLK
BLK
RED/
WHT
BLK
1 YEL
WHT/
BLK
86 85
HR
HR
HR
HR
BLK YEL BRN

30 87
B A B A
RED
87 30 87A
RED
B A HIGH
87A B A
BEAM
RED/
BLK
BLU
(SLOW BLOW)
GLOW PLUGS
GRN
YEL/
FUSE – 60A
(HORN / FLASHERS)
YEL
RED
WHT/ 85 86 BLK
FUSE – 20A
UNLOCKED 2 YEL
OIL PRESSURE
BRAKE YEL WHT
SWITCH LIGHT SWITCH 30 87 HEADLIGHTS
FUEL LEVEL ENGINE COOLANT PEDAL
RED/
BLU
ALTERNATOR SWITCH
SENSOR TEMPERATURE 87A
RED
RED/
SENSOR
YEL/
BLK
BLU
DIODE
BLK
BLK
DIODE DIODE
WHT
BLK
A B FUSE - 10A HORN HORN
BLK
STARTER 4WD
YEL/ SWITCH
86 85 BLU/ GRN BLK BLK
BLK WHT
CRUISE/PREHEAT/PTO
B M S RED
A B DIODE
RED RED FUEL H B1 BLK/
87 30 4WD SOLENOID BLK
FUSE - 20A
SHUTOFF LGN
SOLENOID GRN WHT
BRN/
87A
WHT
BLK
BLU/
RED
STARTER RELAY PULL HOLD 4WD

SWITCH LGR
TO CAB
0.3 ohm
28 ohm
RED RIGHT TURN /

TURN SIGNAL SWITCH FRONT MARKER
(IF EQUIPPED) LIGHT
R GRN/
B2 WHT GRN/
LGR GRN
RED/ WHT
+
L
RED/
WHT
WHT
RED/
BATTERY YEL
WHT
GRN/
WHT
BLU/
LGN
GRN
GRN
BLK/
BLK/
YEL/
LEFT TURN /
BLU
BLU/
HAZARD SWITCH
YEL
RED
FLASHER
BLK
FRONT MARKER
LIGHT
-
ON
Glow Relay
Brake (+) Grd

CRUISE CONTROL / Temp Unlocked Range Lamp Output LGR BLU
Output
BLK/ Switch Brake
BLK
Signal
RED PREHEAT UNIT Input Pedal (-)
BLK
Output
RED/
Input
GRN
Left Brake RED/
GRN/
WHT
WHT
GRN/
Neutral (+)
WHT
WHT
BLK/ DIODE Switch + Input GRN
Signal
RED
Output
Range
RED/ +5V
Right Brake Key Switch Charge Cruise Switch Cruise Switch Cruise Control Sensor
BLK Output
Switch + Input Input Signal Input ON Input OFF Input Magnet Input
FRAME
GROUND
BLU/
RED/
BLU/
WHT
WHT
PNK
RED
YEL/
RED
BLK
BLU/
RED
YEL/
RED
RANGE
SENSOR
ON OFF CRUISE
CRUISE
BRAKE MAGNET
SWITCH
DIODE RELAY
BLK
PTO FUSE - 10A
BLK
RELAY BRAKE LIGHT 87A BRN/

RIGHT BRAKE WHT
YEL/ 87A RED/ YEL/ 30 87
BLK
SWITCH
RED WHT GRN
87 30 RED/ RED/ RED/
BLK ORG GRN BLK
BLU BLK WHT 85 86
BLK GRN LEFT BRAKE DIODE
86 85
BLK
BLK
PTO RIGHT BRAKE / LEFT BRAKE /
SWITCH
SOLENOID TAIL / TURN TAIL / TURN
BLU/ RED/ RED/
PTO BLU LIGHTS LIGHTS
GRN WHT BRN/
SWITCH
Printed in U.S.A. 901 of 1161 DIODE
YEL
RED/
GRN
V-1304 (12-1-09)
WIRING SCHEMATIC RED = RED
BLK = BLACK
BLU = BLUE
GRN = GREEN
CT335 (S/N AK9G11001 AND ABOVE) YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
(PRINTED DECEMBER 2009) GRY = GRAY
ORG = ORANGE
V-1376
SPEED
SENSOR
RED/
WHT
RED/
RED/
RED/
RED/
BLU
BLU
BLU
BLU
RED/
BLU
RED
FUSE - 5A
SHUTTLE
(OCU)
MID-PTO
WHT
YEL/
SEAT SHIFT
GLOW PLUG SWITCH A B
30
SWITCH
SWITCHED
85
(IF EQUIPPED) (F-N-R)
POWER
OFF SWITCH
30
85
RED/
SHUTTLE
BLU
A B
RELAY
RED/
YEL/
WHT
87A
BLU
YEL
RUN
86
87
87A
START
86
87
BLK
WHT
BLK
RED/
GRN
RED/
SO BLK ENGINE 19
OCU 8 4 5 1
BLK
YEL/ REAR DIODE ENGINE
POWER
PTO START STOP
RED SWITCH SIGNAL
RED/
SIGNAL
BLK
RED/
B
ST GRN
RED OPERATIONAL CONTROL UNIT YEL/
23
BLK/ BRAKE (+) BLU
SIGNAL
RED
Charge 22
Signal Input DIODE
RED/ 3 18 21 25 17
I WHT
WHT
BLU/
BLK/
YEL/
RED
BLK
PNK
IGNITION SWITCH
BLK
RED/
WHT
(INSTRUMENT PANEL)
RED/
WHT
FUSE – 5A
PNK/
WHT
BLU/
BRN/
BRN/
WHT
WHT
BLK/
RED
BLK
RED
WHT
YEL/
BLK/
RED
RED
RED/
BLK
RED
FUSE – 15A
(LIGHTS)
39 37 7 20 19 11 DASH 18 12 33 13 34
FUEL PULL
FUSE - 25A
INSTRUMENT PANEL
YEL/
BLK
HOURMETER
LIGHTS
ALTERNATOR EXCITE
BLK/
RED
RED
LEFT RIGHT
BLK/
RED
YEL
H DIRECTIONAL DIRECTIONAL
PREHEAT RELAY
LIGHT LIGHT
FUSE - 5A
UNLOCKED
PNK
30
BRAKE
85
ENGINE CRUISE PEDAL

PRE-HEAT ENGINE
PNK/
CHARGE
BLK
PARKING OIL
LIGHT PTO COOLANT
87A
SYSTEM BRAKE PRESS. FUEL HIGH

86
87
LIGHT TEMP. COOLANT

LIGHT LIGHT LIGHT LEVEL
GAUGE TEMP.
TACH RPM
x100
N L M H BEAM
GAUGE LIGHT B1
DIODE
RED
BLK
4WD
BRN/
T WHT
YEL
5 36 17 2 27 28 40 29 9 LOW
RED BEAM
WHT
BLK/
GRN
BLK/
PULL RELAY
GRN/
RED/
WHT
WHT
WHT
RED
GRY
BLK/
WHT
YEL/
85 86
YEL/
BLK
BLK
BLK
RED/
WHT
BLK
1 YEL
WHT/
BLK
86 85
HR
HR
HR
HR
BLK YEL BRN

30 87
B A B A
RED
87 30 87A
RED
B A HIGH
87A B A
BEAM
RED/
BLK
BLU
(SLOW BLOW)
GLOW PLUGS
GRN
YEL/
FUSE – 60A
(HORN / FLASHERS)
YEL
RED
WHT/ 85 86 BLK
FUSE – 20A
2 YEL
OIL PRESSURE
YEL WHT
SWITCH LIGHT SWITCH 30 87 HEADLIGHTS
FUEL LEVEL ENGINE COOLANT
RED/
BLU
ALTERNATOR
SENSOR TEMPERATURE 87A
RED
RED/
SENSOR
YEL/
BLK
BLU
DIODE
BLK
BLK
DIODE DIODE
WHT
BLU/
RED FUSE - 10A
A B HORN HORN
BLK
STARTER 4WD
YEL/ SWITCH
86 85 BLU/ GRN BLK BLK
BLK WHT
CRUISE/PREHEAT/PTO
B M S RED
A B DIODE
RED RED FUEL H B1 BLK/
87 30 4WD SOLENOID BLK
FUSE - 20A
SHUTOFF LGN
SOLENOID GRN WHT
BRN/
87A
WHT
BLK
STARTER RELAY PULL HOLD 4WD
SWITCH LGR
TO CAB
0.3 ohm
28 ohm
RED RIGHT TURN /

TURN SIGNAL SWITCH FRONT MARKER
(IF EQUIPPED) LIGHT
R GRN/
GRN/
BLU/
B2
RED
WHT GRN
LGR WHT
RED/
+
L
WHT RED/
BATTERY YEL
WHT
ST HAZARD SWITCH FLASHER LEFT TURN /
PNK/ FRONT MARKER
ON
BLU LIGHT
-
PREHEAT UNIT LGR BLU

PNK
BLK
BLK
BLU
RED/
GRN/
WHT
WHT
GRN/
WHT
WHT
BLK OUT
Grd
BLK
BRAKE
FRAME RELAY
GROUND FUSE - 10A
BRAKE LIGHT 87A
BRAKE SWITCH RED/ YEL/ 30 87
WHT GRN
RED/ RED/ RED/
BLK
BLU BLK WHT 85 86
BRN/
YEL
DIODE PTO
RELAY BRN/
BLU WHT
YEL/ 87A
RED
87 30
BLK ORG GRN
BLK GRN
86 85
BLK
BLK
PTO RIGHT BRAKE / LEFT BRAKE /
SOLENOID TAIL / TURN TAIL / TURN
902 of 1161 PTO LIGHTS LIGHTS
SWITCH
Printed in U.S.A. V-1376 (12-2-09)
RED = RED
WIRING SCHEMATIC BLK = BLACK

BLU = BLUE
GRN = GREEN
YEL = YELLOW
CAB OPTION PNK = PINK

WHT = WHITE
BRN = BROWN
GRY = GRAY RED
REAR WORK
LIGHT SWITCH
1
REAR WORK
CT335 (S/N ABH811001 AND ABOVE) ORG = ORANGE
2
3
WHT/
BLK LIGHTS
Printable Version Click Here 85 86 BLK

7 BLK
WHT/
(PRINTED DECEMBER 2009) 30 87 RED
BLK
V-1309 FRONT WORK
87A
LIGHT SWITCH 85 86 BLK BLK

CAB 1
YEL
RED 30 87
RELAY 2 YEL/
RED BLK
FROM TRACTOR 3 87A
RED/
SWITCHED WHT
85 86 BLK 7
FRONT WORK
FUSE - 15A LIGHTS
POWER RELAY 30 87 (WORKING LIGHTS)
RED RED RED/
87A
/BLU /BLU WHT
THERMOSTAT
FROM FUSE - 60A
TRACTOR (CAB)
RED
RED
STARTER “B” /BLU
TERMINAL
/BLU
RED
/BLU
RED
COMPRESSOR
/BLU
RED
RELAY
(12 V POWER PLUG)

/BLU
RED
FUSE - 10A
85 86
(DOME LIGHT)
FUSE - 5A 30 87
COM
FUSE - 25A GND
(A/C)
RED/ RED/ M HIGH
LGN
YEL YEL MED/HIGH

COMPRESSOR
WHT
BLU/
BLK BLOWER MOTOR MED/LOW
RED/
BLK LOW
BLU
RED/ BLK/ BLOWER SWITCH

YEL WHT
HIGH/LOW
AUX PRESSURE
SOCKET FROM TRACTOR SWITCH
BLK
4 1 5 6
BRN/
LIGHT SWITCH WHT
“T” TERMINAL
RED/ BLK RESISTOR
BLK
WASHER MOTOR
RED M BRN FRONT AIR
/BLK WIPER
WASHER A/C ON/OFF
SWITCH
CONDITIONING
WIPER MOTOR SWITCH
WIPER
COM RELAYS 2
M - GRN
1
BLK
V 3
PARK - WHT
- BLK 86 85 GRN 6
FUSE - 15A GRD BLK
/BLK 5
(WIPER MOTOR) - BLK 4
+ 87 30
RED RED RED
87A
/BLU /BLK /BLK
4
RED 86 85 GRN 5
BLK
/BLK /BLK 6
RED BLK
87 30 3
FROM TRACTOR RED /BLK
/BLU + 87A 1
BLK
IGNITION RELAY -
2
GRD
- BLK
REAR
M PARK - WHT WIPER
WASHER
V - GRN SWITCH
COM
WIPER MOTOR
RED M BRN
/BLK
WASHER MOTOR
RED
/BLU
FUSE - 10A
(RADIO) GRN/BLK _ LEFT
+ SPEAKER
RED RED GRN/RED
RADIO
/BLU /BLK BLU/BLK _ RIGHT
+
BLU/RED SPEAKER
BLK
FROM TRACTOR
BRN/
LIGHT SWITCH WHT
“T” TERMINAL
Printed in U.S.A. V-1309 (12-1-09)
903 of 1161
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting two harnesses together or represent an component that is
C107
3520 C C 3520
3510 B B 3510
a harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

904 of 1161
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at

1 SWITCH - Light - Multi position switch a predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6
DIODE - Allows electrical current to

ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

905 of 1161
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown
in the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at
high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A SPEED SENSOR - magnetic pickup -

detects RPM.
B

906 of 1161
Electrical Component Location (Without Cab) (HST Models)
1. Head Lamp
2. Horn
3. Battery 39. Coolant Temperature
Sensor
38. Engine Stop Solenoid

37. RPM Pickup Sensor
4. Alternator
5. Diode 36. Glow Plugs
6. Slow Blow Fuse

7. Starter Motor
8. Oil Pressure Switch 35. Temperature Switch
9. Operating Control Unit 34. Fuel Pull Relay
10. Switched Power 33. Starter Relay
11. Fuel Sender 32. Preheat Relay
12. One-Side Brake Switch

13. Flasher
31. Brake Switch
14. Brake Switch 30. Low Beam Relay
29. Fuse Box
28. Cruise Engage Switch
15. 4WD Switch
27. 4 WD Solenoid
26. PTO Solenoid
16. Instrument Panel 25. High Beam Relay

17. Range Shift 24. PTO Safety Relay
Sensor (HST) 23. Brake Light Relay
22. Cruise/Preheat
Controller
21. PTO Stop Switch
20. Working Lamp
18. Tail Lamp (LH) 19. Tail Lamp (RH)
MS-2728S

907 of 1161
Electrical Component Location (With Cab) (HST Models)
1. Head Lamp
2. Horn
Sensor
4. Alternator
6. Slow Blow Fuse

7. Starter Motor
8. Oil Pressure Switch 46. Temperature Switch
10. Cab Relay
44. Starter Relay
11. Fuel Sender
43. Preheat Relay
12. One-Side Brake Switch 42. Ignition Relay

13. Flasher Unit
14. PTO Relay 41. Low Beam Relay
40. Fuse Box
15. Brake Switch
39. Brake Switch
16.4WD Switch
38.Auxiliary Power
17. HVA Control 37. 4 WD Solenoid
18. Dome Light
36. PTO Solenoid
19. Instrument Panel
35. High Beam Relay
20. Range Shift
Sensor (HST) 34. PTO Safety Relay
21. Preheat Controller 33. Brake Relay
22. Thermostat
23. Fusebox 32. PTO Stop Switch
24. Speaker 31. Speaker

25. 7-Pin Socket 30. Working Lamp
28. HVAC
Blower Motor
27. Blower Unit Relay
NA-1160

908 of 1161
Electrical Component Location (SST Models)
1. Head Lamp
2. Horn
Sensor
4. Alternator
6. Slow Blow Fuse

7. Starter Motor
8. Oil Pressure Switch
10. Switched Power 34. Starter Relay
11. Fuel Sender 33. Preheat Relay
12. F-N-R Neutral Switch

13. Flasher 32. Brake Switch
14. Preheat Controller 31. Low Beam Relay
30. Fuse Brake
15. SST Neutral Switch Relay
29. Park Brake Switch
16. 4wd Switch
28. 4 WD Solenoid
17. Flasher Switch
27. PTO Solenoid
18. Instrument Panel 26. High Beam Relay
19. Wire Harness Ground 25. PTO Relay
24. Brake Light Relay
23. PTO Stop Switch
22. Working Lamp
NA1895

909 of 1161
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
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-2003-0807
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

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

910 of 1161
ELECTRICAL SYSTEM Figure 60-10-3
Description FUSES
The compact tractor has a 12 volt, negative ground 1

alternator charging system. The electrical system is
protected by fuses and relays. The fuses will protect the
electrical system when there is an electrical overload.
2
The reason for the overload must be found before
starting the engine again.
3
Figure 60-10-1
4
11
5
1 6
12
P-84834 8
Fuse And Relay Location - Engine Compartment

9
FUSES
The fuse panel (Item 1) [Figure 60-10-1] is located below 10

the steering wheel on the right side of the instrument 7157858
panel.
Figure 60-10-2 The decal [Figure 60-10-3] on the fuse panel cover
shows location and size of the fuses. Description and
amp ratings are also shown below.
REF DESCRIPTION AMP REF DESCRIPTION AMP

1 Horn / Directional 20 7 Operational 5
Lights / Hazard Control Unit /
Lights Switched Power
Relay
2 Fuel Shut Off 25 8 Head Lights / Tail 15
Solenoid Lights
3 Instrument Panel 10 9 Cruise Control 5
4 Alternator 5 10 Working Lights 20
(For Cab models
P-81470
this is 25A spare)
5 Glow Plugs / PTO / 20 11 SPARE 20
Remove the fuse cover to get access to the fuses Front Wheel Assist
[Figure 60-10-2]. (FWD)
6 Brake Lights 10 12 SPARE 5

911 of 1161
ELECTRICAL SYSTEM (CONT’D) Figure 60-10-6
Fuse And Relay Location - Cab (If Equipped) FUSES
FUSES
13
The cab fuse panel is located on the left rear corner of 7
1
the cab.
Figure 60-10-4
2 8
14
9
3
4 10
1
15
5 11
6
P-87988 12
Figure 60-10-5
7168868
The decal [Figure 60-10-6] on the fuse panel cover

shows location and size of the fuses. Description and
amp ratings are also shown below.
REF DESCRIPTION AMP REF DESCRIPTION AMP
1 Wipers 20 9 Not Used 15

2 Radio (if equipped) 10 10 Power Port 10
3 Dome Light 5 11 HVAC 25
4 Not Used 20 12 Working Lights 15
P-87987
5 Not Used 20 13 SPARE 10
Remove the fuse cover (Item 1) [Figure 60-10-4] and 6 Fuse Removal --- 14 SPARE 15
[Figure 60-10-5] to get access to the fuses. Tool
7 Accessory 1 20 15 SPARE 25
8 Accessory 2 20

912 of 1161
Fuse And Relay Location - Instrument Panel - HST 7

8 6
Models
9
5
RELAYS
There are eight relays used in the electrical circuit.
Four of the relays and the glow plug timer module are
located on the engine firewall (as shown in [Figure 60-
10-7]).
Four of the relays and the flasher are located under the
instrument panel (as shown in [Figure 60-10-8]). (The
instrument panel must be removed to access these P-84833
components.)
Relay (Item 5) [Figure 60-10-8] is for low beam relay.
Figure 60-10-7
Relay (Item 6) [Figure 60-10-8] is for high beam relay.
2 Relay (Item 7) [Figure 60-10-8] is for Brake Light relay.

1 3 5
4 Flasher (Item 8) [Figure 60-10-8] is for the directional
signals / hazard / flashers.
Relay (Item 9) [Figure 60-10-8] is for PTO relay.
Figure 60-10-9
P-81471 10
Relay (Item 1) [Figure 60-10-7] is for the ignition switch.
Relay (Item 2) [Figure 60-10-7] is for the glow plugs.
Relay (Item 3) [Figure 60-10-7] is for the fuel pull

solenoid.
Operating Control Unit (Item 4) [Figure 60-10-7].
P-84812
Relay (Item 5) [Figure 60-10-7] is for the timer.
Cruise Control / Preheat (Item 10) [Figure 60-10-9]
(located under operator’s seat).

913 of 1161
Fuse And Relay Location - Instrument Panel - SST 10 9 8

11
Models 12 7
6
RELAYS
There are eight relays used in the electrical circuit.
Four of the relays and the glow plug timer module are
located on the engine firewall (as shown in [Figure 60-
10-10]).
Four of the relays and the flasher are located under the
instrument panel (as shown in [Figure 60-10-11]). (The
instrument panel must be removed to access these P-92909
components.)
Relay (Item 6) [Figure 60-10-11] is for low beam relay.
Figure 60-10-10
Relay (Item 7) [Figure 60-10-11] is for high beam relay.
2 Relay (Item 8) [Figure 60-10-11] is for PTO relay.

1 3 5
4 Relay (Item 9) [Figure 60-10-11] is for the brake light.
Relay (Item 10) [Figure 60-10-11] is for the Shuttle Shift

neutral switch.
Flasher (Item 11) [Figure 60-10-11] is for the directional

signals / hazard / flashers.
Preheat controller (Item 12) [Figure 60-10-11] is for

controlling glow plug activation time.
P-81471
Relay (Item 1) [Figure 60-10-10] is for the ignition switch.
Relay (Item 2) [Figure 60-10-7] is for the glow plugs.
Relay (Item 3) [Figure 60-10-7] is for the fuel pull

solenoid.
Operating Control Unit (Item 4) [Figure 60-10-7].
Relay (Item 5) [Figure 60-10-7] is for the timer.

914 of 1161
915 of 1161
BATTERY When installing the battery, do not touch any metal parts
with the battery terminals.
Removing And Installing Battery
Connect the negative (-) cable last to prevent sparks.
Connect and tighten the battery cables.

WARNING
Install and tighten the battery hold down.
Batteries contain acid which burns eyes and skin on Close the engine cover.
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 WARNING
and wash eye with clean, cool water for at least 15
minutes. AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
If electrolyte is taken internally drink large quantities from batteries. When jumping from booster battery
of water or milk! DO NOT induce vomiting. Get make final connection (negative) at machine frame.
prompt medical attention.
W-2065-0807 Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
Open the engine cover. (See Opening And Closing on connecting to a charger. Unplug charger before
Page 10-20-1) connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Remove the grill. (See Removal And Installation on Page
50-91-1) Battery gas can explode and cause serious injury.
W-2066-0705
Figure 60-20-1
1 2
3
4
3
P-81452
Disconnect the negative (-) cable (Item 1) [Figure 60-20-

1].
Disconnect the positive (+) cable (Item 2) [Figure 60-20-

1].
Remove the two nuts, washers (Item 3), washers and the
battery hold down (Item 4) [Figure 60-20-1].
Remove the battery.

916 of 1161
BATTERY (CONT’D)
Battery Maintenance
Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on

In case of eye contact get prompt medical attention
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
W-2065-0807
P9589
Figure 60-20-4
Figure 60-20-3
P9588
P9590
The battery cables must be clean and the connections

Installation: Always clean the terminals and cable ends tight. Remove acid or corrosion from the battery and
when installing a new battery as shown in [Figure 60-20- cables with a sodium bicarbonate (baking soda) and
2] & [Figure 60-20-3]. water solution as shown in [Figure 60-20-4].
When installing the battery in the compact tractor, do not Clean the terminals and cable ends as shown in figure
touch any metal parts with the battery terminal posts. [Figure 60-20-2] and [Figure 60-20-3].
Connect and tighten the battery cables. Connect the Check the electrolyte level in the battery. Add distilled
negative (-) cable last to prevent sparks. water as needed.
Put battery saver P/N (6664458) or grease on the battery

terminals and cable ends to prevent corrosion.

917 of 1161
Using A Booster Battery (Jump Starting)

2
1
3
P-84627
Connect the end of the first cable (Item 1) to the positive

(+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-5] to the
positive terminal on the compact tractor battery.
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the Connect the end of the second cable (Item 3) to the
operator’s seat and one person to connect and negative terminal of the booster battery. Connect the
disconnect the battery cables. other end of the same cable (Item 4) [Figure 60-20-5] to
a ground point on the compact tractor.
The key switch must be OFF. The booster battery must
be 12 volt. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) first. Remove the cable from the positive terminal
WARNING (Item 2) [Figure 60-20-5]. Then remove the cables from
the booster battery.

from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
IMPORTANT
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before Damage to the alternator can occur if:
connecting to a charger. Unplug charger before • Engine is operated with battery cables
connecting or disconnecting cables to battery. Never disconnected.
lean over battery while boosting, testing or charging. • Battery cables are connected when using a fast
charger or when welding. (Remove both cables
Battery gas can explode and cause serious injury. from the battery.)
W-2066-0705 • Extra battery cables (booster cables) are
connected wrong.
I-2217-1102

918 of 1161
919 of 1161
ALTERNATOR Figure 60-30-2
Belt Adjustment

Page 10-20-1.)
Remove the left side engine cover. (See Removal And

Figure 60-30-1
2 P-81629

at mid span (Item 1) [Figure 60-30-2] when 15 lb. (67 N)
of force is applied to the belt.
1
Tighten the mounting bolt (Item 1) and adjustment bolt
(Item 2) [Figure 60-30-1].
P-81479 Belt Replacement
Loosen the mounting bolt (Item 1) and adjustment bolt

Loosen the lower alternator mounting bolt (Item 1) and (Item 2) [Figure 60-30-1] and move the alternator all the
adjustment bolt (Item 2) [Figure 60-30-1]. way in. Remove the belt.
Move the top of the alternator outward [Figure 60-30-1] Install the new belt and adjust as shown above.
to tighten the belt.

920 of 1161
ALTERNATOR (CONT’D) Figure 60-30-3
Charging System Inspection
IMPORTANT 1
Damage to the alternator can occur if:

• Engine is operated with battery cables 2
disconnected.
• Battery cables are connected when using a fast
charger or when welding. (Remove both cables
from the battery.)
• Extra battery cables (booster cables) are P-81486
connected wrong.
I-2217-1102
3. Disconnect the alternator B+ terminal (Item 1) and L
& S terminal connector (Item 2) [Figure 60-30-3]. If
If the charging system malfunctions check the following: the test light goes out, the alternator is faulty. If the
test light stays on, find the short in the system and
Check the condition and tension of the engine accessory repair it.
drive belt. (See Belt Adjustment on Page 60-30-1.) If belt
is worn or deteriorated replace the belt.
Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
WARNING
Check the fuse for the alternator in the fuse panel. If the
Batteries contain acid which burns eyes and skin on
fuse is burned, find the cause and repair/replace. If the
fuse is in doubt, remove and check the fuse for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
In case of eye contact get prompt medical attention
batteries.) Verify the charge of the battery. make sure
battery is fully charged.
minutes.
Disconnect the battery cables (negative first, then
If electrolyte is taken internally drink large quantities
positive). Inspect the cable clamps and battery posts for
of water or milk! DO NOT induce vomiting. Get
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put W-2065-0807
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
With the key off, connect a test light between the

negative battery post and the disconnected negative
cable clamp.
1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test.
2. If the test light lights up, there is a short (drain) in the

electrical system of the compact tractor. The short
must be repaired before the charging system can be
checked.

921 of 1161
ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-5
WARNING
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
1
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. P-81482
Battery gas can explode and cause serious injury.

W-2066-0705 Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-5] from the alternator.
Open the engine cover. (See Procedure on Page 10-10-
Turn the key to the ON position.
1.)
Figure 60-30-6
Figure 60-30-4
1
1
P-81546
Check the voltage across the “L” terminal (Item 1)

P-84521 [Figure 60-30-6]. The voltage should be what the battery
voltage is. If not, check the wire harness, relay, and
fuses. If the wire harness, relay, and fuses are ok,
Start the engine and run at low idle. With a voltmeter,
remove the alternator for replacement or repair.
check the voltage between the B+ terminal (Item 1) and
ground at the starter (Item 2) [Figure 60-30-4].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature).
If the voltage is higher than 14.7 volts, proceed to the
high voltage test.
If the voltage is lower than 13.5 volts, run the engine at
high idle and recheck voltage. If voltage is still below 13.5
volts, proceed to the low voltage test.

922 of 1161
High Voltage Testing
Figure 60-30-7
P-81550
Figure 60-30-9
P-81480
Turn the engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-7] from the alternator. 1
P-84522
Check the continuity between the “S” terminal (Item 1)

[Figure 50-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 1) [Figure 60-30-9].
There should be continuity. If there is no continuity,
replace the wire harness.
If the voltage is still above 14.7 volts at 70° F (alternator

temperature), then remove the alternator for replacement
or repair.

923 of 1161

Page 10-20-1.)
Remove the left side engine cover. (See Removal And 1

Disconnect the negative cable from the battery. 1
Figure 60-30-10
P-81553
Disconnect the wire harness (Item 1) [Figure 60-30-12]

from the alternator.
1
Figure 60-30-13
P-81551
Remove the adjustment bolt (Item 1) [Figure 60-30-10]

from the alternator.
1
Figure 60-30-11 2
P-81556
Remove the nut (Item 1), washers and bolt (Item 2)

[Figure 60-30-13] from the alternator.
1
Remove the alternator.
P-81630
Remove the belt (Item 1) [Figure 60-30-11].
Installation: Adjust the engine accessory drive belt after

installation. (See Belt Adjustment on Page 60-30-1.)

924 of 1161
ALTERNATOR (CONT’D)
1. Alternator
2. Nut 1
3. Pulley 6
4. Spacer
5. Bolt 7
6. Case half
7. Bolt
8. Bearing
9. Retainer 3
10. Rotor
11. Bearing
12. Stator
13. Case half
14. Sleeve
15. Regulator 4 7
16. Rectifier 13 14
17. Cover
18. Spacer
19. Nut 2
12 5
11
10
17 19
16
15
18
C-3529

925 of 1161
STARTER Figure 60-40-2
Testing

equipped with SST.
The key switch must be in the OFF position.
The battery must be at full charge.

1
The cable connections on the battery must be clean and
tight. P-84524

Installation on Page 50-100-1.) Connect a jumper wire between the battery terminal
(Item 1) and motor terminal (Item 2) [Figure 60-40-2].
Figure 60-40-1
If the starter turns but does not turn the engine, the
starter drive has a defect.
P-84523
Connect a jumper wire between the battery terminal

(Item 1) and the solenoid terminal (Item 2) [Figure 60-40-
1].
If the starter turns but does not turn the engine, the
starter drive has a defect.

926 of 1161
STARTER (CONT’D) Figure 60-40-5
Disconnect the negative (-) cable from the battery.

1
Figure 60-40-3
1
P-84526
1
Remove the top bolt (Item 1) [Figure 60-40-5].
Remove the starter.

P-81475
Disconnect the wires (Item 1) from the starter. Cut and

remove the cable tie (Item 2) [Figure 60-40-3].
Figure 60-40-4
P-84525
Remove the bottom nut (Item 1) [Figure 60-40-4] and

washer.

927 of 1161
STARTER (CONT’D)
1. Screw
2. Bolt
3. Brush Cover
4. Brush Holder 1
2
5. Bearing
6. Armature
7. Bearing 4
8. O-Ring
9. Frame 5
10. Bolt
11. Cover 6
12. Gasket
13. Switch
3
7 14. Nut
8 15. Nut
16. Housing
9 17. Idler Gear
18. Roller
8 19. Retainer
20. Spring
21. Ball
22. Pinion Shaft
11 10
12
14 13
15
20
17
15 21
19 18 22
16 23
24 23. Spring
24. Clutch
25. O-Ring
29 26. O-Ring
27. Washer
28. Bolt
31 29. Housing
32
25 30. Spring Seat
34 31. Spring
27
32. Pinion Gear
30 33. Collar
34. Snap Ring
26
33
28
D-2396

928 of 1161
929 of 1161
HOOD LIGHTS Bulb Removal And Installation
Removal And Installation Open the engine cover. (See Opening And Closing on
Page 10-20-1.)
Page 10-20-1.) Disconnect the negative cable from the battery.
Disconnect the negative cable from the battery. Figure 60-50-3
Figure 60-50-1
2
1 1
P-81463
2 P-81462
Disconnect the electrical connector (Item 1) [Figure 60-
50-3] from the hood light.
Disconnect the electrical connectors (Item 1) and remove
the two screws (Item 2) [Figure 60-50-1] securing the Figure 60-50-4
wire harness to the hood.
Figure 60-50-2 1
1 1
P-81465
1 Remove the rubber boots (Item 1) [Figure 60-50-4].

P-84529
NOTE: Hood light assembly is removed for photo

Remove the ten screws (Item 1) [Figure 60-50-2]. clarity.
Remove the light assembly.

930 of 1161
HOOD LIGHTS (CONT’D) Figure 60-50-7
Bulb Removal And Installation (Cont'd)

1
Figure 60-50-5
P-78300
Figure 60-50-8
P-78298
1
Release the bulb retaining clamp (Item 1) [Figure 60-50-
5].
Figure 60-50-6
1
1 1
P-78301
Installation: Align the tangs (Item 1) [Figure 60-50-7] on

the bulb with the notches (Item 1) [Figure 60-50-8] in the
lamp. Install the bulb.
P-78299 NOTE: Do not touch the glass part of the bulb, any dirt
or oil will shorten the service life of the bulb.
Remove the bulb (Item 1) [Figure 60-50-6].

931 of 1161
REAR LIGHTS Figure 60-51-3

1
Figure 60-51-1
P-84532
Remove the four screws (Item 1) [Figure 60-51-3].
Figure 60-51-4
P-84432

from the main harness.
Figure 60-51-2
1
3
1
P-84533
Remove the housing (Item 1) [Figure 60-51-4].
2 2 P-84531
Remove the screws (Item 1) and nuts (Item 2) [Figure

60-51-2].

932 of 1161
REAR LIGHTS (CONT’D)
Bulb Removal And Installation
Remove the rear light cover. (See Removal And

Installation on Page 60-51-1)
Figure 60-51-5
P-84534
Remove the bulb socket (Item 1) [Figure 60-51-5] by

rotating 1/4 turn counter-clockwise.
NOTE: The housing is shown removed for photo

clarity.
Figure 60-51-6
P-84535
Gently push in on the bulb (Item 1) [Figure 60-51-6] and

turn counter-clockwise.
Remove the bulb.

933 of 1161
FRONT LIGHTS (WITH CAB) Figure 60-52-3
Figure 60-52-1
1
1 P-89329
Remove the screws (Item 1) [Figure 60-52-3].

P-87568

from the main harness.
Figure 60-52-2
1
P-89329
Remove the two bolts (Item 1) and light assembly (Item

2) from the mounting bracket (Item 3) [Figure 60-52-2].

934 of 1161
FRONT LIGHTS (WITH CAB) (CONT'D) Figure 60-52-6
Bulb Removal And Installation
Figure 60-52-4
1
P-84535
Gently push in on the bulb (Item 1) [Figure 60-52-6] and

P-89333 turn counter-clockwise.
Remove the bulb.

Remove the lens assembly [Figure 60-52-4].
Figure 60-52-7
Figure 60-52-5
1 1
2
P-89332
P-89330
Remove the three screws (Item 1) and lens (Item 2)

Remove the bulb socket (Item 1) [Figure 60-52-5] by [Figure 60-52-7].
rotating 1/4 turn counter-clockwise.

935 of 1161
SEAT SENSOR Figure 60-60-3
Figure 60-60-1
1
2
P-78319
Rotate the sensor (Item 1) [Figure 60-60-3] and remove.
NOTE: After installation of the seat sensor, the safety

P-78025 interlock system (neutral start) and safety
interlock system (operating) must be tested
and operational.
Tilt the seat forward and disconnect the wire harness
(Item 1) from the seat sensor (Item 2) [Figure 60-60-1]. See Safety Interlock System - Neutral Start. (See
SAFETY INTERLOCK SYSTEM - NEUTRAL START on
Figure 60-60-2 Page 10-200-1.)
See Safety Interlock System - Operating. (See SAFETY

INTERLOCK SYSTEM - OPERATING on Page 10-210-
1 1 1.)
1
P-78157
Depress the three tabs (Item 1) [Figure 60-60-2].

936 of 1161
937 of 1161
FUEL LEVEL SENDER

Page 10-20-1)
Figure 60-70-1
P-81467
Disconnect the fuel level sender harness (Item 1) [Figure

60-70-1] from the main harness.
Figure 60-70-2
1 1
1 2
P-84530
Remove the five nuts (Item 1) and the sending unit (Item
2) [Figure 60-70-2].

938 of 1161
939 of 1161
INSTRUMENT PANEL Figure 60-80-3
NOTE: The following procedure is performed on a 1

equipped with SST.
Remove the steering column cover. (See Removal And

Figure 60-80-1 P-84474
Remove the bolt (Item 1) [Figure 60-80-3] (both sides).

1 1
Figure 60-80-4
1 1
P-84473
Remove the four bolts (Item 1) and remove the center

P-84475
Figure 60-80-2
Remove the bolt (Item 1) [Figure 60-80-4] from the left

side of the instrument panel.
P-84714
Remove the PTO switch knob (Item 1) [Figure 60-80-2].
NOTE: The knob is threaded on the switch.

940 of 1161
INSTRUMENT PANEL (CONT’D) Figure 60-80-7
Removal And Installation (Cont'd) 1
Figure 60-80-5 1
2
P-84477
Tilt the top of the instrument panel cover back slightly and
P-84476 disconnect the three electrical connectors (Item 1)
[Figure 60-80-7] from the instrument cluster.
Remove the bolt (Item 1) [Figure 60-80-5] from the right Disconnect the connector (Item 2) [Figure 60-80-7] from
side of the instrument panel. the horn / flasher switch.
HST MODELS ONLY
1
2
1
P-84478 P-84482
Move the instrument panel cover back slightly and Disconnect the connector (Item 1) from the hazard
disconnect the connector (Item 1) [Figure 60-80-6] from switch, and front wheel assist switch (Item 2) [Figure 60-
the cruise control switch. 80-8].
Remove the instrument panel.

941 of 1161
STEERING COLUMN COVER Figure 60-81-3

equipped with SST.
Figure 60-81-1
P-84472
Tilt the steering column down and remove the top cover
(Item 1) [Figure 60-81-3].
1
P-84470
Remove the three bolts (Item 1) and lower the bottom

Figure 60-81-2
P-84471
Disconnect the key switch (Item 1) [Figure 60-81-2].
Remove the bottom cover.

942 of 1161
943 of 1161
PTO SWITCH (REAR) Inspection Procedure
Inspection And Maintenance Perform this procedure on flat level ground and make
1. Install a rear-PTO implement. (See Installing And

Removing The Rear-PTO in the Operation And
IMPORTANT Maintenance Manual).
To avoid start-up overload on the PTO driveline, 2. Enter the compact tractor and perform the Pre-
reduce engine speed to low idle when engaging the starting Procedure. (See Pre-Starting Procedure in
PTO. After PTO driveline is rotating, increase engine the Operation And Maintenance Manual). Fasten the
speed. seat belt and engage the parking brake. Move the
I-2276-0608 Engine Speed Control lever to low engine speed.
Turn the key switch to the ON position and start the
engine.
Figure 60-90-1
3. Engage the rear-PTO. (See Engaging Rear-PTO in
the Operation And Maintenance Manual). The rear-
PTO drive line must start rotating.
1 4. Disengage the rear-PTO. (See Disengaging PTO in

the Operation And Maintenance Manual).
2
Figure 60-90-2
2
P-84914
The rear-PTO switch (Item 1 & 2) [Figure 60-90-1] 1

engages and disengages the compact tractor rear-PTO
shaft.
3
The rear-PTO switch must be in the disengaged (OFF)
position for then engine to be started.
P-84914
Disconnect the wire harness (Item 1), loosen the nut

(Item 2) and remove the switch (Item 3) [Figure 60-90-2].

944 of 1161
945 of 1161
PTO LEVER (MID) (IF EQUIPPED) Inspection Procedure
Inspection And Maintenance Perform this procedure on flat level ground and make
Figure 60-91-1
1. Install a mid-PTO implement. (See Installing And
Removing The Mid-PTO in the Operation And
Maintenance Manual).
2. Enter the compact tractor and perform the Pre-

Engage Starting Procedure. (See Pre-Starting Procedure in
Operation And Maintenance Manual). Fasten the seat
belt and engage the parking brake. Move the Engine
Speed Control lever to low engine speed. Turn the
key switch to the ON position and start the engine.
1
3. Engage the mid-PTO. (See Engaging Rear-PTO in
Disengage Operation And Maintenance Manual). The mid-PTO
drive line must start rotating.
P-84892
4. Disengage the mid-PTO. (See Disengaging PTO in
Operation And Maintenance Manual). The mid-PTO
Figure 60-91-2 drive line must STOP rotating.
P-84914
The mid-PTO lever (Item 1) [Figure 60-91-1] and the

PTO switch (Item 1) [Figure 60-91-2] engages and
disengages the compact tractor mid-PTO shaft.
The mid-PTO lever must be in the disengaged (OFF)

position for the engine to be started.

946 of 1161
PTO LEVER (MID) (IF EQUIPPED) (CONT’D)
PTO Switch Removal And Installation

Figure 60-91-3
P-84704
Figure 60-91-4
P-84705
Loosen the nut (Item 1) and remove the switch (Item 2)

[Figure 60-91-4].

947 of 1161
PTO LEVER (MID) (IF EQUIPPED) (CONT’D) Figure 60-91-7
Adjustment

Figure 60-91-5
P-84707
1 With the engine off, pull up and engage the mid mount
PTO lever (Item 1) [Figure 60-91-7].
The multimeter (Item 2) [Figure 60-91-7] must show

P-84704 continuity.
Figure 60-91-8
Figure 60-91-6
1 2
P-84705
P-84706 If there is no continuity, loosen the nuts (Item 1) and

adjust the switch (Item 2) [Figure 60-91-8] in until
continuity is made.
Connect a multimeter (Item 1) [Figure 60-91-6] to the
switch wire harness. There must be no continuity. Tighten the nuts (Item 1) [Figure 60-91-8].

948 of 1161
949 of 1161
HORN

Page 10-20-1.)

Figure 60-100-1
P-81461
Disconnect the electrical connectors (Item 1) [Figure 60-

100-1] from the horn.
Figure 60-100-2
P-81460
Remove the bolt (Item 1) and the horn (Item 2) [Figure

60-100-2].

950 of 1161
951 of 1161
REAR WORK LIGHT (WITH CAB) Disassembly And Assembly
Removal And Installation NOTE: Work light is removed for photo clarity.
Remove the cab cover. (See Removal And Installation on Figure 60-110-3
Page 50-200-1.)
Figure 60-110-1 2
4
3
2
1
P-87292
P-87188 Loosen the two screws (Item 1) [Figure 60-110-3].
Assembly: The hole (Item 2) [Figure 60-110-3] must be

Figure 60-110-2 positioned as shown.
Figure 60-110-4
1 2
P-87187
P-87289
Remove the nut (Item 1), lock washer (Item 2), flat
washer (Item 3), and rubber washer (Item 4) [Figure 60-
110-1] from the back of the work light (Item 1) [Figure Remove the two screws (Item 1) and cover (Item 2)
60-110-2] from the horn. [Figure 60-110-4].
Remove the work light.

952 of 1161
REAR WORK LIGHT (WITH CAB) (CONT'D)
Figure 60-110-5
4
2
P-87290
Disconnect the blue wire (Item 1) from the red wire (Item
2). Remove the screw (Item 3) and black wire (Item 4)
Figure 60-110-6
P-87291
NOTE: Do not touch the bulb. If the bulb needs to be

cleaned, use a clean lint free cloth. Any dirt or
oil on the bulb will shorten the service life of
the bulb.

953 of 1161
FRONT WORK LIGHT (WITH CAB) Disassembly And Assembly
Removal And Installation NOTE: Work light is removed for photo clarity.
Remove the front work light mount. (See Removal And Figure 60-120-3
Figure 60-120-1 2
1
2 P-87292
1
P-87284 Loosen the two screws (Item 1) [Figure 60-120-3].
Assembly: The hole (Item 2) [Figure 60-120-3] must be

Remove the nut (Item 1), lock washer (Item 2), flat positioned as shown.
washer (Item 3), and rubber washer (Item 4) [Figure 60-
120-1] from the back of the light bracket. Figure 60-120-4
Figure 60-120-2
P-87289
P-87285
Remove the two screws (Item 1) and cover (Item 2)
[Figure 60-120-4].
Remove the light assembly (Item 1) [Figure 60-120-2]
from the mount.

954 of 1161
FRONT WORK LIGHT (WITH CAB) (CONT'D)
Figure 60-120-5
4
2
P-87290
Disconnect the blue wire (Item 1) from the red wire (Item
2). Remove the screw (Item 3) and black wire (Item 4)
Figure 60-120-6
P-87291
NOTE: Do not touch the bulb. If the bulb needs to be

cleaned, use a clean lint free cloth. Any dirt or
oil on the bulb will shorten the service life of
the bulb.

955 of 1161
CRUISE CONTROL (HST ONLY) Figure 60-130-3
Inspection And Maintenance 3
Figure 60-130-1 2
P-84852
P-84914
The cruise control is controlled by a magnet (Item 1) that
holds the forward travel pedal (Item 2) [Figure 60-130-3]
in the selected forward travel speed position.
If the cruise control switch (Item 1) [Figure 60-130-1]
If adjustment is needed, loosen the bolts (Item 3) [Figure
does not maintain the selected speed, the cruise control
60-130-3] and position the magnet so there is 0.039 -
will need to be adjusted.
0.059 in. (1,0 - 1,5 mm) clearance between the side of
the forward travel pedal and the face of the magnet.
Figure 60-130-2
Tighten the bolts after adjustment is made.
Figure 60-130-4
2
3
1
P-84851 1
P-84850
NOTE: The brake pedals (Item 1) must be in the locked
position with the lock lever (Item 2) and the
brake switch (Item 3) [Figure 60-130-2]
The controller (Item 1) [Figure 60-130-4] located below
engaged to activate the cruise control. If the
the operator’s seat, also controls the cruise control
brake pedals are not locked together, the
magnet. If the cruise control will still not maintain the
switch will not allow power to the cruise
selected speed, the controller may be defective.
control switch. Make sure the switch is
activated before proceeding with any
The cruise control must disengage when both brake
additional adjustment procedures.
pedals are pressed or the cruise control switch is moved
to the OFF position. If the system does not function
properly, further troubleshooting and testing must be
done.

956 of 1161
CRUISE CONTROL (HST ONLY) (CONT'D) Controller Removal And Installation
Switch Removal And Installation Remove the operator seat. (See Removal And
Installation on page 50-10-1.)
Figure 60-130-5
Figure 60-130-7
1
3
2
3
P-84914
P-84850
Carefully pry up on the cruise control switch (Item 1)

[Figure 60-130-5]. Disconnect the connector and Disconnect the connector (Item 1) from the controller
remove the switch. (Item 2) [Figure 60-130-7].
Magnet Removal And Installation Remove the two bolts (Item 3) [Figure 60-130-7].
Remove the forward travel pedal. (See TRAVEL Remove the controller (Item 2) [Figure 60-130-7]
CONTROL PEDALS (HST MODELS) on Page 30-40-1.)
Figure 60-130-6
1
3
P-84510
Disconnect the neutral start harness connector (Item 1)

Remove the two bolts (Item 2) and magnet (Item 3)

[Figure 60-130-6].
Installation: Adjust the cruise control magnet. (See

Inspection And Maintenance on Page 60-130-1.)

957 of 1161
SPEED RANGE LEVER (HST ONLY) Figure 60-140-3
Calibration 4
1
Figure 60-140-1
3
1
2
P-86146
The speed range lever will need to be calibrated when LOW N MED N HIGH
the controller unit (Item 1) or range sensor (Item 2)
[Figure 60-140-1] has been replaced.
P-86344
Turn the key switch to the ON position. Do not start the

engine. The H lamp (Item 1) [Figure 60-140-3] will begin to blink,
indicating the unit is ready for calibration.
Figure 60-140-2
2 Move the speed range lever (Item 2) to the neutral

position between high and medium range. The H lamp
(Item 3) [Figure 60-140-3] will blink, indicating 3 ± 0.3
volts.

The H lamp and N lamp will stop blinking for one second,
then resume blinking.
Move the speed range lever (Item 2) to the medium

position. The H lamp (Item 1) and M lamp (Item 4)
[Figure 60-140-3] will blink, indicating 2.5 ± 0.3 volts.
1
P-84899
Press the brake pedals (Item 1) and within three

seconds, engage and disengage the cruise control switch
(Item 2) [Figure 60-140-2].

958 of 1161
SPEED RANGE LEVER (HST ONLY) (CONT’D) Controller Removal And Installation
Calibration (Cont’d) Remove the operator seat. (See Removal And

Engage and quickly disengage the cruise control switch,
the H lamp (Item 1) and M lamp (Item 4) [Figure 60-140- Figure 60-140-5
Move the speed range lever (Item 2) to the neutral

position between the medium and low range. The H lamp 3
(Item 1) and N lamp (Item 3) [Figure 60-140-3 on Page
60-140-1] will blink indicating 1.8 ± 0.3 volts.

The H lamp (Item 1) and N lamp (Item 3) [Figure 60-140-
3 on Page 60-140-1] will stop blinking for one second, 1
2
If the lamps do not blink correctly in each step, engage 3
the cruise switch to correct or adjust the mounting P-84850
location of the sensor.
Turn the key switch to the off position then back to the on Disconnect the connector (Item 1) from the controller
position to save the calibration. (Item 2) [Figure 60-140-5].
Figure 60-140-4 Remove the two bolts (Item 3) [Figure 60-140-5].
Remove the controller (Item 2) [Figure 60-140-5].
P-886147
If calibration can not be obtained, repeat the calibration

procedure and check the voltage at the white (middle)
wire (Item 1) [Figure 60-140-4].
NOTE: The speed range sensor signal out put to the

controller has an error code built in: If reading
is over 4.8V the M lamp will flash. If reading is
below 0.2V the L lamp will flash.

959 of 1161
FORWARD - NEUTRAL - REVERSE (F-N-R) LEVER Figure 60-150-3
(SST MODELS)

1
Installation on Page 60-80-1). 3
Figure 60-150-1 1
1
2
4 P-95456
2
1
Remove the three bolts, washers (Item 1). Remove the
4 spring (Item 2) and the lever assembly (Item 3) [Figure
60-150-3].
3
P-95459
N•m) torque.
Remove the two nuts (Item 1) and bolts (Item 2) from the
coupler (Item 3) [Figure 60-150-1].

N•m) torque.
Remove the coupler (Item 3) from the F-N-R shaft (Item

4) [Figure 60-150-1].
Figure 60-150-2
2
1
P-95455
Disconnect the connector (Item 1) and remove the cable

tie (Item 2) [Figure 60-150-2].

960 of 1161
FORWARD - NEUTRAL - REVERSE (F-N-R) (SST Figure 60-150-6
MODELS) (CONT’D)
F-N-R Lever Disassembly And Assembly

2
Figure 60-150-4
1 1
3
P-95460
4 2
Remove the collar (Item 1) and the joint (Item 2) [Figure
60-150-6].
P-95457
Figure 60-150-7
Remove the bolt (Item 1), nut (Item 2), spring (Item 3)
and the lever (Item 4) [Figure 60-150-4].
Figure 60-150-5
1
2
P-95461
Remove the two screws, nuts (Item 1) and remove the

F-N-R switch (Item 2) [Figure 60-150-7].
P-95458

961 of 1161
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Idler Gear And Shaft Removal And Installation . . . . . . . . . . . 70-100-4
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . 70-100-7
Timing Gearcase Cover Removal And Installation . . . . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . 70-100-3
CLUTCH ASSEMBLY (SST MODELS) . . . . . . . . . . . . . . . . . . . . 70-130-1

Clutch Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3
Clutch Pedal Play And Stopper Bolt Adjustment . . . . . . . . . . 70-130-3
Pressure Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
CLUTCH LEVER (SST MODELS) . . . . . . . . . . . . . . . . . . . . . . . 70-140-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
CRANKSHAFT AND PISTONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Connecting Rod - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5 ENGINE SERVICE
Crankshaft And Bearings Removal And Installation . . . . . . . . 70-90-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . 70-90-8
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Piston And Connecting Rod Removal And Installation . . . . . . 70-90-1
Piston And Connecting Rod - Servicing. . . . . . . . . . . . . . . . . . 70-90-3
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Cylinder Head Disassembly And Assembly. . . . . . . . . . . . . . . 70-80-7
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Glow Plug - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-80-2
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . . . 70-80-10
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . 70-80-12

962 of 1161
ENGINE SERVICE (CONT’D)
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-80-11
Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Radiator Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . .70-50-2
Testing The Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . 70-50-7
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . 70-50-6
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-50-6
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
ENGINE SPEED CONTROL PEDAL (SST MODELS) . . . . . . . . . . . 70-21-1

Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .70-21-1
ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-20
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Engine Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-9
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .70-10-13
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-3
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-10
70-02 CT335 SErvice Manual

963 of 1161
ENGINE SERVICE (CONT’D)
ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1

Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-2
Valve Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-2
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-3
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-120-1
FLYWHEEL AND HOUSING (HST MODELS) . . . . . . . . . . . . . . . . . 70-110-1

Flywheel Housing Removal And Installation . . . . . . . . . . . . . . . . 70-110-2
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
FLYWHEEL AND HOUSING (SST MODELS) . . . . . . . . . . . . . . . . . 70-111-1

Flywheel Housing Removal And Installation . . . . . . . . . . . . . . . . 70-111-2
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-111-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-1

Bleeding The Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-1
Fuel Camshaft Removal And Installation. . . . . . . . . . . . . . . . . . . .70-70-2
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . .70-70-3
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-9
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . .70-70-14
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-70-11
Fuel Shutoff Solenoid Checking. . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-2
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . .70-70-3
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-15
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-15
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-1
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-4
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-4
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .70-60-2
Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-3
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .70-60-2
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1


964 of 1161
70-04 CT335 SErvice Manual
965 of 1161
ENGINE INFORMATION
Description
Figure 70-10-1
704W201A
The 3B183LWH engine is a vertical, water cooled, 4-

cycle, three cylinder diesel engines [Figure 70-10-1].

966 of 1161
ENGINE INFORMATION (CONT’D)
Cylinder Head
Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness 0.002 in. / 3.94 in.
(0,05 mm / 100 mm)
Top Clearance 0.0294 - 0.0354 in. -
(0,7 - 0,9 mm)
Thickness of gasket When tightened -
0.0465 - 0.0504 in.
(1,18 - 1,28 mm)
Compression Pressure 3.24 - 3.73 MPa 2.55 MPa
(When cranking with starting motor) 33 - 38 kgf/cm2 26 kgf/cm2
469 - 540 PSI 370 PSI
* Variance of compression pressure among cylinders should be 10% or less.
Valves

Valve Clearance (Cold) IN. 0.0059 in (0,15 mm) ±0.002 (0,05 mm)
EX. 0.0059 in. (0,15 mm) ±0.002 (0,05 mm)
Valve Seat Angle IN. 0.785 rad. 45° -
EX. 0.785 rad. 45°
Valve Face Angle IN. 0.785 rad. 45° -
EX. 0.785 rad. 45°
Valve Recessing 0.0079 - 0.0197 in. 0.0315 in.
(0,2 - 0,5 mm) (0,8 mm)
Clearance Between Valve Stem and 0.0016 - 0.0028 in. 0.039 in.
Valve Guide (0,040 - 0,070 mm) (0,10 mm)
Valve Stem O.D. 0.31339 - 0.31398 in. -
(7,960 - 7,975 mm)
Valve Stem I.D. 0.3156 - 0.3161 in. -
(8,015 - 8,030 mm)
Valve Timing

Inlet Valve Open 0.36 rad 21° before T.D.C -
Close 0.75 rad 43° after B.D.C
Exhaust valve Open 0.959 rad 55° before B.D.C -
Close 0.19 rad 11° after T.D.C

967 of 1161
Cylinder

Cylinder bore inner diameter 3.425 - 3.426 in. 0.0059 in.
(87,000 - 87,022 mm) (0,15 mm)
Valve Springs

Free length 1.6417 - 1.6614 in. 1.6220 in.
(41,7 - 42,2 mm) (41,2 mm)
Assembling load / assembling length 26.5 lb. / 1.3839 in 22.5 lb. / 1.3839 in.
(12.0 kgf / 35,15 mm) (10.2 kgf / 35,15 mm)
Squareness - 0.039 in.
(1,0 mm)
Rocker Arms

Rocker arm shaft O.D 0.7463 - 0.7472 in. -
(18,955 - 18,980 mm)
Rocker arm bushing I.D 0.7480 - 0.7490 in -
(19,000 - 19,025 mm)
Tappet

Clearance between tappet and guide 0.00079 - 0.00244 in. 0.0028 in.
(0,020 - 0,062 mm) (0,07 mm)
Tappet O.D 0.94327 - 0.94410 in -
(23,959 - 23,980 mm)
Tappet guide I.D 0.94488 - 0.9457 in -
(24,000 - 24,021 mm)

968 of 1161
Camshaft

Camshaft alignment 0.0004 in. 0.0020 in.
(0,01mm) (0,05 mm)
Cam height IN. 1.335 in 1.3205 in.
(33,9 mm) (33,54 mm)
EX. 1.335 in 1.3244in.
(33,9 mm) (33,64 mm)
Clearance between camshaft 0.00197 - 0.00358 in 0.0059 in.
(0,050 - 0,091 mm) (0,15 mm)
Camshaft journal O.D 1.57221 - 1.57284 in 1.5701 in.
(39,934 - 39,950 mm) (39,88 mm)
Camshaft counter bore I.D 1.57480 - 1.57579 in -
(40,000 - 40,025 mm)
Timing Gear

Timing gear backlash 0.0016 - 0.0043 mm 0.0059 in.
(0,04 - 0,11 mm) (0,15 mm)
Idle gear side clearance 0.0079 - 0.0201 in 0.035 in.
(0,20 - 0,51 mm) (0,9 mm)
Clearance between Idle gear shaft and 0.00098 - 0.00250 in 0.0039 in.
idle gear bushing (0,025 - 0,066 mm) (0,1 mm)
Idle gear shaft O.D 1.49445 - 1.49508 in -
(37,9590 - 37,9950 mm)
Idle gear bushing I.D 1.49608 - 1.49705 in -
(38,000 - 38,025 mm)

969 of 1161
Piston Rings

Piston pin-bore I.D 0.98425 - 0.98448 in. 0.9854 in.
(25,00 - 25,006 mm) (25,03 mm)
Clearance between Oil ring and ring 0.00079 - 0.00236 in. 0.0059 in.
groove (0,020 - 0,060 mm) (0,15 mm)
Oil ring groove width 0.19724 - 0.19803 in. -
(5,01 - 5,03 mm)
Oil ring width 0.19567 - 0.19646 in. -
(4,97 - 4,99 mm)
Clearance between 2nd ring and ring 0.00256 - 0.00394 in. 0.0059 in.
groove (0,065 - 0,100 mm) (0,15 mm)
2nd ring groove width 0.08091 - 0.08150 in. -
(2,055 - 2,070 mm)
2nd ring width 0.07756 - 0.07834 in. -
(1,97 - 1,99 mm)
Top ring, oil ring end gap 0.0098 - 0.01570 in. 0.0492 in.
(0,25 - 0,40 mm) 1,25 mm
2nd ring end gap 0.0098 - 0.01570 in. 0.0492 in.
(0,25 - 0,40 mm) (1,25 mm)
Connecting Rods

Connecting rod alignment - 0.0020 in.
(0,05 mm)
Clearance between piston and small 0.00055 - 0.00150 in. 0.0059 in.
end bushing (0,014 - 0,038 mm) (0,15 mm)
Piston pin O.D 0.98433 - 0.98469 in. -
(25,002 - 25,011 mm)
Small end bushing I.D 0.98524 - 0.98583 in. -
(25,025 - 25,040 mm)

970 of 1161
Crankshaft

Crankshaft alignment - 0.0031 in.
(0,08 mm)
Clearance between crankshaft and crankshaft 0.00157 - 0.00465 in. 0.0079 in.
bearing 1 (0,040 - 0,118 mm) (0,20 mm)
Crankshaft O.D 2.04414 - 2.04488 in. -
(51,921 - 51,940 mm)
Crankshaft bearing 1 I.D 2.04646 - 2.04878 in. -
(51,980 - 52,039 mm)
Clearance between Crankshaft and crankshaft 0.00157 - 0.00409 in. 0.0079 in.
bearing 2 (0,040 - 0,104 mm) (0,20 mm)
Crankshaft O.D 2.04414 - 2.04488 in. -
(51,921 - 51,940 mm)
Crankshaft bearing 2 I.D 2.04646 - 2.04823 in. -
(51,980 - 52,025 mm)
Clearance between Crank pin and Crank pin 0.0014 - 0.0037 in. 0.0079 in.
bearing (0,035 - 0,093 mm) (0,20 mm)
Crank pin O.D 1.73067 - 1.73130 in. -
(43,959 - 43,975 mm)
Crank pin bearing I.D 1.73268 - 1.73433 in. -
(44,010 - 44,052 mm)
Crankshaft side clearance 0.0059 - 0.0122 in. 0.020 in.
(0,15 - 0,31 mm) (0,5 mm)

971 of 1161
Oil Pump

Engine oil pressure At idle speed 9.95 PSI -
(oil temp. 85° - 95° C, 0.7 kgf/cm2
185° - 203° F) more than 68.6 kPa
At rated speed 35.5 - 64.0 PSI 42.7 PSI
2.5 - 4.5 kgf/cm2 3.0 kgf/cm2
245 - 441 kPa 294.2 kPa
Clearance between inner rotor and outer rotor 0.0039 - 0.0063 in. 0.0079 in.
(0,10 - 0,16 mm) (0,2 mm)
Radial clearance between outer rotor and pump 0.0043 - 0.0078 in. 0.0098 in.
(0,11 - 0,19 mm) (0,25 mm)
End clearance between inner rotor and cover 0.00413 - 0.00591 in. 0.00787 in.
(0,105 - 0,150 mm) (0,2 mm)
Thermostat
Valve opening temperature at beginning 157.1° - 162.5° F

(69.5° - 72.5° C)
Opened completely (height 0.315 in. (8 mm) 185° F
(85° C)
Radiator
Radiator tightness No leak at 137 kPa, 1.4 kgf/cm2, 20 PSI

10 seconds or more for pressure from 13 - 9 PSI
Radiator cap tightness (0.9 - 0.6 kgf/cm2)
(88 - 59 kPa)
Fan belt tension 0.28 - 0.35 in. (7 - 9 mm)
[deflection at 98 N (10 kgf, 22 lb.) of force]

972 of 1161
Fuel Injection Pump
Injection timing (BTDC) 18°
Fuel Injection Nozzles
Fuel injection pressure 2,134 PSI

150 kgf/cm2
14.709 MPa
Fuel tightness of nozzle valve seat No fuel leak for 10 sec.
at pressure
1,849 PSI
130 kgf/cm2
12.75 MPa
NOTE:
Injection Sequence
Three Cylinders: 1 --> 2 --> 3
(The cylinder number is given in order from the gear case end.)

973 of 1161
Engine Bolt Torque
Item Size x Pitch N•m kgf•m lbf•ft

Cylinder head bolts M11 x 1.25 103,0 - 107,9 10,5 - 11,0 75.9 - 79.6
Head cover bolts M8 x 1.0 8,8 - 11,8 0,9 - 1,2 6.5 - 8.7
*Bearing case bolt 1 M9 x 1.25 46,1 - 51,0 4,7 - 5,2 34.0 - 37.6
*Bearing case bolt 2 M10 x 1.25 68,6 - 73,6 7,0 - 7,5 50.6 - 54.2
*Flywheel bolt M12 x 1.25 98,1 - 107,9 10,0 - 11,0 72.3 - 79.6
*Connecting rod bolts M8 x 1.0 46,1 - 51,0 4,5 - 5,0 34.0 - 37.6
Rocker arm support bolts M10 x 1.25 60,7 - 70,6 6,2 - 7,2 44.8 - 52.1
Drain plug M12 x 1.25 32,4 - 37,3 3,3 - 3,8 23.9 - 37.3
Glow plugs M10 x 1.25 19,6 - 24,5 2,0 - 2,5 14.5 - 18.1
Oil switch PT1/8 14,7 - 19,6 1,5 - 2,0 10.8 - 14.5
Nozzle locating screws M20 x 1.5 49,1 - 68,7 5,0 - 7,0 36.2 - 50.6
Injection pipe nuts M12 x 1.5 24,5 - 34,3 2,5 - 3,5 18.1 - 25.3
Temperature meter switch PT 1/8 13,7 - 15,7 1,4 - 1,6 10.1 - 11.6
D.C. alternator pulley nut M15 x 1.5 39,2 - 53,9 4,1 - 5,5 28.9 - 39.8
NOTE: For *marked screw, bolts and nuts on the

table, apply engine oil to their threads and
seats before tightening.
The letter “M” in Size x Pitch means that the

screw, bolt or nut dimension stands for
metric. The size is the nominal outside
diameter in mm of the threads. The pitch is the
nominal distance in mm between two threads.

974 of 1161
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
ENGINE DOES NOT START
Crankshaft
does not turn Crankshaft and camshaft have seized up
Frictional Piston and cylinder liner have seized up
resistance of Bearings are oil-stuck
moving parts is too
Lubrication system not working properly
much
Starter faulty
Battery capacity is low or terminal loose
Fuel pipe broken

Fuel supply to Air enters fuel pipe through connection
injection pump is Fuel filter clogged
insufficient
Fuel pump faulty
Injection pump Plunger has worn or seized up

No or small fuel
injection sounds does not send on Delivery valve spring broken
fuel Delivery valve not completely oil-tight
Crankshaft
turns Needle valve stuck
Fuel does not inject Needle spring broken
through injection
nozzle Injection pressure maladjusted
Injection pipe mounting nut loose
Injection Injection timing maladjusted

mistimed
Contact between intake/exhaust valve and
seat not tight
Crankshaft
Intake/exhaust valve spring broken
Intake/exhaust valve stuck
Regular fuel Compressed Gasket faulty
injection sounds air leaks Tightness torque of cylinder head not
enough
Piston ring stuck
Piston ring worn
Tightness torque of injection nozzle and
glow plug not enough
Valve timing
improper Valve clearance excessive
V-0915-1

975 of 1161
Troubleshooting (Cont’d)
Engine does not turn normally

Fuel filter clogged
Fuel pipes broken or loose
Revolution is Air in pump

not smooth at Injection
nozzle wrong Pump capacity not constant
high speeds
Tappet roller and pin worn
Delivery valve not completely oil-tight
Injection Fuel leaks from nozzle tip

nozzle faulty Fuel not spraying properly
Governor spring deformed

Valve clearance incorrect
Injection pump or nozzle not functioning

Irregular
normally
revolution
Compression pressure is different among
cylinders
Idling not Governor sleeve not sliding properly

Fuel supply to
smooth injection pump is Fork lever not functioning normally
insufficient Start spring deformed
Control rack not sliding properly
Injection pump Idling regulator maladjusted

does not send on
fuel Accelerator rod maladjusted
Engine output insufficient
Main moving parts have almost seized up

Engine overheated
Injection mistimed
Governor not functioning normally
Slow engine Fuel supply Filter clogged

revolutions insufficient Fuel pipe broken or loose
Injection pump’s capacity not enough
Nozzle needle valve worn
Compression Air leaking

pressure not Air cleaner clogged
enough
V-0915-2

976 of 1161
Troubleshooting (Cont’d)
Color of exhaust fumes not normal Piston ring stuck

Piston ring worn
Revolution is Fuel supply to
not smooth at Excessive gap between cylinder liner and
injection pump is
high speeds piston
insufficient
Too much oil
Injection delayed
Compression pressure insufficient
Fuel supply to Injection too early

injection pump is
Injection delayed
insufficient
Plunger does not return completely

Idling not Fuel supply to
because spring is stuck or broken
smooth injection pump is
insufficient Plunger worn
Needle valve stuck

Injection pump Nozzle spring broken
does not send on Too much carbon sticks to nozzle tip
fuel
Injection pressure too low
Compressed air leaks

Not enough air
Engine output insufficient Excessive gap between piston and liner

Piston ring stuck
Piston ring worn
Excessive gap between intake /exhaust
valve and valve stem
Valve stem seal broken
Oil leaks from defective packings
Engine output insufficient

Fuel mixed Injection mistimed
with oil Governor not functioning normally
Slow engine Water mixed Injection pump’s capacity not enough

revolutions with oil Nozzle needle valve worn
Gear oil mixed

with oil Air cleaner clogged
V-0915-3

977 of 1161
ENGINE INFORMATION (CONT’D) Figure 70-10-3
Engine Removal And Installation
Separate the tractor. (See Procedure on Page 40-100-1.) 2

1
Drain the radiator. (See Radiator Removal And
Remove the air cleaner assembly. (See Removal And

Remove the muffler. (See Removal And Installation on

Page 70-30-1.)
Figure 70-10-2 P-84664
Remove the two bolts (Item 1) and reposition the

3 overflow tank (Item 2) [Figure 70-10-3] to the front of the
radiator.
1
Figure 70-10-4
2 3
P-84663
2
Remove the overflow hose (Item 1) from the radiator
(Item 2) and bracket (Item 3) [Figure 70-10-2].
P-84722
Disconnect the fuel shut off solenoid connector (Item 1)

and fuel pump connector (Item 2) [Figure 70-10-4].
Remove the hose (Item 3) [Figure 70-10-4] from the filter

housing.

978 of 1161
Engine Removal And Installation (Cont’d) 1
Figure 70-10-5 3
2
1
4
5
P-84668
Release the harness (Item 1) from the clamp (Item 2) and

P-84666 unplug the relay connector (Item 3), operating control unit
connector (Item 4) and fuel sending unit connector (Item
5) [Figure 70-10-7].
Disconnect the wire (Item 1) [Figure 70-10-5] from the
thermostat housing. Figure 70-10-8
Figure 70-10-6
4
2
3
1
2
1
3
P-84670
P-84667
Unplug the three connectors from the relays (Item 1) and
release the harness (Item 2) from the clamp (Item 3)
Unplug the fuel sender (Item 1), cut the tie strap (Item 2) [Figure 70-10-8].
and release the harness (Item 3) from the clamp (Item 4)
[Figure 70-10-6]. Remove any tie straps securing the wire harness to the
firewall.

979 of 1161
Engine Removal And Installation (Cont’d)
Figure 70-10-9
1
1
2
2 4
P-84674
3
Loosen the lower radiator hose clamp (Item 1) and
P-84672 remove the hose (Item 2) [Figure 70-10-11] from the
engine.
Remove the connector from the oil sending unit (Item 1) Figure 70-10-12
[Figure 70-10-9].
Remove the two wires (Item 2) and connector (Item 3)

[Figure 70-10-9] from the starter.
Remove the tie strap (Item 4) [Figure 70-10-9].
Figure 70-10-10
1
P-84686
1
Remove the tubeline (Item 1) [Figure 70-10-12] from the
oil cooler.
P-84673
Unplug the connector (Item 1) and remove the wire (Item

2) [Figure 70-10-10] from the alternator.
Remove the engine harness.

980 of 1161
Figure 70-10-13
1
2
P-84676
Remove the fuel line (Item 1) [Figure 70-10-15] from the

P-84685 fuel pump.
Figure 70-10-16
Remove the mounting bolt (Item 1) and remove the
tubeline (Item 2) [Figure 70-10-13].
Figure 70-10-14
P-84677
3
Support the fuel tank assembly [Figure 70-10-16].
P-84675
Loosen the hose clamp (Item 1) and remove the hose

(Item 2) from the thermostat housing (Item 3) [Figure 70-
10-14].

981 of 1161
Figure 70-10-17
1
1
1
P-84681
Remove the bracket mounting bolt (Item 1) [Figure 70-

P-84679 10-19].
Figure 70-10-20
Mark the two fuel lines (Item 1) [Figure 70-10-17] and
remove from the fuel tank.
NOTE: Install caps and plugs.
Figure 70-10-18
P-84682
Lift and remove the fuel tank assembly [Figure 70-10-

20].
1
P-84680
Remove the two mounting bolts (Item 1) [Figure 70-10-

18] (both sides).

982 of 1161
Figure 70-10-21
1
P-84687
Figure 70-10-24
P-84683
Place a stand (Item 1) [Figure 70-10-21] under the front

of the frame.
Figure 70-10-22
P-84687
Raise the engine with the hoist. Remove the support

stands (both sides) from the flywheel housing and install
onto the left side using the two bolts (Item 1) [Figure 70-
10-23] and right side using the two bolts (Item 1) [Figure
P-84684 70-10-24].
Support the engine using a hoist and lifting chain [Figure

70-10-22].

983 of 1161
Figure 70-10-25
P-84687
Remove the frame bolts (Item 1) [Figure 70-10-25] (both

sides).

N•m) torque.
Figure 70-10-26
P-84689
Lift and remove the engine [Figure 70-10-26].
Installation: If a new or remanufactured engine is being

installed, the paint on the engine mounting surface must
be removed.

984 of 1161
Compression - Checking
The tools listed will be needed to do the following

procedure:
MEL10630 - Engine Compression Kit

MEL1352 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Glow Plug Removal And

Figure 70-10-27
704W248A
Install the correct compression adapter into the cylinder

head [Figure 70-10-27].
Connect the compression gauge [Figure 70-10-27].
Make sure the speed control lever is at low engine idle.
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 250 - 350 RPM

for 5 - 10 seconds
Compression Pressure 469 - 540 PSI
(33 - 38 bar)
Allowable Limit 370 PSI
(26 bar)
The compression must be no lower than the allowable

limit, with no more than 10% variance among cylinders.
Connect the fuel stop solenoid.
Install the glow plugs

985 of 1161
ENGINE SPEED CONTROL Figure 70-20-3
Cable Removal And Installation

Page 10-20-1.)
Remove the right engine side cover. (See Removal And


1
Figure 70-20-1
P-84721
Pull the cable (Item 1) [Figure 70-20-3] through the

firewall into the engine compartment.
1
P-84719
Remove the cotter pin (Item 1) [Figure 70-20-1] and

washer.
Figure 70-20-2
P-84720
Loosen the nut (Item 1) and remove the cable (Item 2)

[Figure 70-20-2] from the bracket.

986 of 1161
ENGINE SPEED CONTROL (CONT’D)
Cable Removal And Installation (Cont’d)
Figure 70-20-4
2
1
P-84722
Remove the plug (Item 1) and remove the cable (Item 2)

[Figure 70-20-4] from the speed control lever.
Figure 70-20-5
2 1
P-84723

Remove the cable.

987 of 1161
ENGINE SPEED CONTROL (CONT’D) Figure 70-20-8
Lever Removal And Installation

Figure 70-20-6
1
2
P-84725
Remove the lever (Item 1) and lining (Item 2) [Figure 70-

20-8].
P-84719
Remove the cotter pin (Item 1) [Figure 70-20-6] and

washer.
Figure 70-20-7
P-84724
Remove the two nuts (Item 1) [Figure 70-20-7] and

washers.
Installation: Install the concave sides of the conical

washers against each other.

988 of 1161
989 of 1161
ENGINE SPEED CONTROL PEDAL (SST MODELS) Cable Removal And Installation
Removal And Installation Figure 70-21-3

Page 50-71-1.)

Page 10-20-1.)
Remove the right engine side cover. (See Removal And

3
Figure 70-21-1 2
1
1 P-95449
Remove the cotter pin (Item 1) and washer [Figure 70-

21-3].
Loosen the nut (Item 2) [Figure 70-21-3] and remove the

cable (Item 3) [Figure 70-21-3] from the bracket.
Figure 70-21-4
P-95447
Remove the two bolts (Item 1) [Figure 70-21-1] and

remove the pedal.
Figure 70-21-2
1
P-98265
Pull the cable (Item 1) [Figure 70-21-4] into the engine

compartment.
P-95448
Remove the two bolts (Item 1) [Figure 70-21-2] from the

bracket. Lower and reposition the bracket.

990 of 1161
ENGINE SPEED CONTROL (SST MODELS) (CONT’D)
Cable Removal And Installation (Cont’d)
Figure 70-21-5
2
1
P-98266
Remove the cable (Item 1) [Figure 70-21-5] from the

speed control lever (Item 2).
Figure 70-21-6
1
2
P-98267

Remove the cable.

991 of 1161
SPARK ARRESTOR MUFFLER Figure 70-30-2
Stop the engine.

Page 10-20-1.) 1
Remove the left engine side cover. (See Removal And

Figure 70-30-1
P-81628
Remove the bolt (Item 1) [Figure 70-30-2] and muffler.
1 1
N•m) torque.
P-81627

muffler.

N•m) torque.

992 of 1161
993 of 1161
AIR CLEANER Figure 70-40-3
Stop the engine

Page 10-20-1.)
Remove the left engine side cover. (See Removal And

1
Figure 70-40-1
P-81558
2
Remove the air cleaner (Item 1) [Figure 70-40-3].
P-81451
Loosen the clamp (Item 1) and remove the hose (Item 2)

[Figure 70-40-1].
NOTE: Plug the hose to prevent any contamination

from getting into the engine.
Figure 70-40-2
1
1
P-81450

994 of 1161
995 of 1161
ENGINE COOLING SYSTEM
Description
Figure 70-50-1
1 2
6
5
B-23874
The water pump receives water from the radiator or from

(1) Water Return Pipe the cylinder head and forces it into the cylinder block.
(2) Thermostat The thermostat opens or closes according to the water
(3) Cylinder Head Water Jacket temperature. When the water temperature is high, the
(4) Cylinder Block Water jacket thermostat opens to allow the water to flow from the
(5) Radiator cylinder block to the radiator. When the water
(6) Cooling Fan temperature is low, the thermostat closes and the flow
(7) Water Pump stays within the block. The opening temperature of the
thermostat is approximate 71° C (160° F) [Figure 70-50-
The cooling system consists of a radiator (Item 5), a 1].
centrifugal water pump (Item 7), a cooling fan (Item 6)
and a thermostat (Item 2). The water is cooled as it flows
through the radiator core, and the fan behind the radiator
pulls the cooling air through the radiator core.

996 of 1161
ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-3
Radiator Removal And Installation
Remove the engine cover. (See Removal And Installation

on Page 50-90-1.)
(See Removal And Installation on Page 50-100-

1.)Remove the engine side covers.
If equipped with air conditioning, remove the condenser.

(See Removal And Installation on Page 80-150-1.)
1
Figure 70-50-2
P-86160
2
Figure 70-50-4
1
1
P-86159
Locate and route the drain hose (Item 1) into the drain
pan. Open the plug (Item 2) [Figure 70-50-2] and drain
the coolant from the radiator. P-86161
Recycle or dispose of coolant in an environmentally safe

manner. Loosen the hose clamps (Item 1) [Figure 70-50-3] and
[Figure 70-50-4] from the air cleaner hose.
Remove the air cleaner hose.

997 of 1161
Radiator Removal And Installation (Cont’d)
Figure 70-50-5
1 2
1 P-78227
Loosen the clamp (Item 1) and remove the lower radiator

1
P-84647 hose (Item 2) [Figure 70-50-7] from the radiator.
Figure 70-50-8
Loosen the hose clamps (Item 1) and remove the top
radiator hose (Item 2) [Figure 70-50-5].
Figure 70-50-6
1 1
P-84722
Loosen the clamp (Item 1) and remove the coolant return

P-84648 hose (Item 2) [Figure 70-50-8] from the radiator.
Remove the radiator over flow hose (Item 1) [Figure 70-

50-6] from the radiator and fan shroud.

998 of 1161
Figure 70-50-9 1
1
P-84652
Remove the upper radiator shroud (Item 1) [Figure 70-

50-10].
Figure 70-50-11
1
2
1 1
P-86163
Remove the four fan shroud bolts (Item 1) [Figure 70-50-

9] (both sides).
P-84653
Slide the fan shroud towards the engine.

Remove the thumb screw (Item 1) and two radiator
screens (Item 2) [Figure 70-50-11] by pulling up on the
two tabs.

999 of 1161
Figure 70-50-12 1
1
P-78231
Lift and remove the radiator (Item 1) [Figure 70-50-13].
Remove the fan shroud.
P-86164
Remove the four radiator mount bolts (Item 1) [Figure

70-50-12] (both sides).

1000 of 1161
ENGINE COOLING SYSTEM (CONT’D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-15
Remove the radiator. (See Radiator Removal And

Remove the alternator belt.

1
3
Remove the fan. (See Removal And Installation on Page 4
70-120-1.)
Figure 70-50-14
1
B-14424
1
Remove the flange (Item 1) [Figure 70-50-15].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

1 50-15] out the impeller side of the water pump.
Remove the impeller (Item 3) [Figure 70-50-15] from the

shaft.
P-78236
Remove the water pump bolts (Item 1) [Figure 70-50- Install a new seal (Item 4) [Figure 70-50-15] when
14]. assembling the water pump.
Remove the water pump.
Installation: Always use a new gasket when installing

the water pump.

1001 of 1161
ENGINE COOLING SYSTEM (CONT’D) Testing The Thermostat
Thermostat Housing Removal And Installation Remove the thermostat. (See Thermostat Housing
Figure 70-50-16
Place the thermostat in a pan of water. Heat the water
while monitoring the temperature.
The thermostat should start to open between 160° F (71°

C).
P-84658
Figure 70-50-17
MS-24995
Remove the housing (Item 1) gasket (Item 2) and

thermostat (Item 3) [Figure 70-50-17].
Installation: Always use a new gasket when installing

the thermostat.

1002 of 1161
1003 of 1161
LUBRICATION SYSTEM
Description
Figure 70-60-1
9 10
11
12
13
1 14
2
15
3
6
4
7
8
5
1 Piston 9 Rocker
2 Idler Gear 10 Rocker Arm
3 Oil Pump 11 Push Rod
4 Relief Valve 12 Tappet
5 Strainer 13 Oil Pressure
6 Oil Filter Switch
Element 14 Camshaft
7 Bypass Valve 15 Crankshaft
8 Oil Pan B-23624
The lubricating oil is forced into each journal through the

oil passages of the cylinder block, cylinder head and
shafts. The oil, splashed by the crankshaft or thrown off
from the bearings, lubricates other engine parts such as
the push rods (Item 11), tappets (Item 12), camshaft
(Item 14), and crankshaft (Item 15) [Figure 70-60-1]

1004 of 1161
LUBRICATION SYSTEM (CONT’D) Oil Pump Removal And Installation
Oil Pan Removal And Installation Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Remove the driveshaft. (See Removal And Installation on 100-1.)
Page 40-30-1.)
Remove the crankshaft gear.
Figure 70-60-2
Figure 70-60-4
1
P-66843
B-3658
Remove oil pan bolts securing oil pan (Item 1) [Figure

70-60-2]. Slightly tapping on the oil pan with a soft mallet Remove the nut from the oil pump shaft. Use a puller to
will break loose the oil pan from the engine block. remove the oil pump gear (Item 1) [Figure 70-60-4].
Remove the gasket (Item 2) [Figure 70-60-2]. Remove the oil pump mounting bolts. Remove the oil
pump (Item 2) [Figure 70-60-4].
Installation: Use a liquid gasket adhesive to the oil pan
side of the oil pan gasket. Tighten oil pan bolts to 29 - 33 Installation: Tighten the oil pump mounting bolts to 60 -
ft.-lb. (39 - 75 N•m) torque. 72 in.-lb. (6,9 - 8,1 N•m) torque.
Figure 70-60-3
P-66844
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-3] from the engine block.
Installation: Apply oil to O-ring.

1005 of 1161
LUBRICATION SYSTEM (CONT’D) Measure the clearance between the outer rotor and
pump body [Figure 70-60-6].
Oil Pump Inspection
Clearance Between Outer 0.0043 - 0.0075 in.
Figure 70-60-5 Rotor & Body (0,11 - 0,19 mm)
Allowable Limit 0.0098 in.
(0,25 mm)
If the clearance exceeds the allowable limit, replace the

oil pump.
Figure 70-60-7
B-3616
Measure the clearance between the lobes of the inner

rotor and outer rotor [Figure 70-60-5].

oil pump.
PI-10009
Clearance 0.0039 - 0.0063 in.

Between Inner & (0,10 - 0,16 mm) Put a piece of press gauge on the rotor face [Figure 70-
Outer Rotor 60-7].
(0,20 mm) Install the cover and tighten the bolts.
Figure 70-60-6 Remove the cover carefully. Measure the width of the
press gauge [Figure 70-60-7].
If the clearance exceeds the allowable limit replace the

oil pump.
End Clearance 0.0041 - 0.0059 in.

(0,11 - 0,15 mm)
(0,20 mm)
A-2732

1006 of 1161
LUBRICATION SYSTEM (CONT’D) Oil Filter
Engine Oil Pressure - Testing Figure 70-60-9
Figure 70-60-8
1 Relief Valve Ball

2 Relief Valve Seat 3 1
3 Relief Valve Spring
B-23625
PI-10010
Drain the engine oil and remove the oil filter to check it
[Figure 70-60-9].
Remove the oil pressure switch. Install the adapter and
pressure tester in its place [Figure 70-60-8]. Check the relief valve for dirt, and the seat (Item 2) and
ball (Item 1) [Figure 70-60-9] for wear and damage.
Start the engine and run until it is at operating
temperature. Measure the oil pressure at both idling and Replace worn and damaged parts.
rated speed.
Check the free length of spring (Item 3) [Figure 70-60-9].
If the oil pressure is less than the allowable limit, check
the following items: Spring free Factory spec 1.38 in.
length (35 mm)
* Engine Oil Level Low
* Oil Pump Defective Allowable limit 1.18 in.
* Oil Galley Plugged (30 mm)
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
Engine At idle Factory spec More than

oil speed 10 PSI
pressure (0,69 Bar)
At Factory 36 - 64 PSI
rated spec (2,50 - 4,41 Bar)
speed Allowable 36 PSI
limit (2,45 Bar)
When reinstalling the oil pressure switch, tighten to 11 -

15 ft.-lb. (15 - 20 N•m) torque.

1007 of 1161
FUEL SYSTEM
Description
Figure 70-70-1
6
5
1
4
2
B-23679
The fuel in the fuel tank (Item 1) is drawn to the fuel pump
(Item 2) and then supplied to the fuel injection pump
(Item 3), passing through the fuel filter (Item 4). The fuel
injection pump feeds the fuel to the injection nozzles
(Item 5) which then injects the fuel into the cylinders for
combustion. The excessive fuel from the fuel injection
pump to the injection nozzles is collected in the fuel
overflow pipes (Item 6) [Figure 70-70-1] and returns to
the fuel tank.

1008 of 1161
FUEL SYSTEM (CONT’D) Fuel Shutoff Solenoid Checking
Fuel Camshaft Removal And Installation Open the engine cover. (See Opening And Closing on
Page 10-20-1.)
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70- Remove the engine right side cover. (See Removal And
100-1.) Installation on Page 50-100-1.)
Remove the idler gear. (See Idler Gear And Shaft Figure 70-70-4
Figure 70-70-2
2
1
1 1
P-86168
1
P-47265 Disconnect the connector (Item 1) [Figure 70-70-4] from
the fuel shutoff solenoid.
Remove the three bolts (Item 1) [Figure 70-70-2]. Use an ohmmeter to check the fuel shutoff solenoid.
Remove the two bolts and fuel camshaft retainer plate Figure 70-70-5
(Item 2) [Figure 70-70-2].
Figure 70-70-3
P-78069
P-47266 The reading between electrical connector terminals must

be approximately 18.6 ohms [Figure 70-70-5].
Remove the fuel camshaft and fork lever assembly at the

same time (Item 1) [Figure 70-70-3].

1009 of 1161
FUEL SYSTEM (CONT’D) Fuel Injection Pump Removal And Installation
Fuel Shutoff Solenoid Removal And Installation

Page 10-20-1.) IMPORTANT
Remove the engine right side cover. (See Removal And
Installation on Page 50-100-1.) Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-6
1
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Clean around the injection pump.

P-86168
Figure 70-70-8

from the fuel shutoff solenoid.
Figure 70-70-7 1
2
P-86011
Loosen the clamp (Item 1) and remove the hose (Item 2)

1
[Figure 70-70-8] from the intake manifold.
P-86169
Plug the intake to keep contaminates out.
Remove the nuts (Item 1) [Figure 70-70-7] from the

solenoid mount bracket.
Remove the solenoid.

1010 of 1161
Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 70-70-9
1 2
P-81500
2 Loosen the clamp (Item 1) and remove the fuel line (Item
2) [Figure 70-70-11] from the fuel filter.
P-84663
NOTE: Early model machines are equipped with a
protective wire around the fuel lines.
(Item 2) and bracket (Item 3) [Figure 70-70-9]. Figure 70-70-12
Figure 70-70-10
2
1
1
P-81501
P-84664
Remove the two bolts (Item 1) and washers and
reposition the fuel filter housing (Item 2) [Figure 70-70-
Remove the two bolts (Item 1), and reposition the 12].
overflow tank (Item 2) [Figure 70-70-10] to the front of
the radiator.

1011 of 1161
Fuel Injection Pump Removal And Installation 2

(Cont’d)
Figure 70-70-13
P-86015
1
1
Remove the nut (Item 1) and bolt (Item 2). Reposition the
brace (Item 3) [Figure 70-70-15].
P-86171
Figure 70-70-16
Remove the fuel lines (Item 1) [Figure 70-70-13] from

the injection pump.
Figure 70-70-14
2
1
1 P-86016
Remove the nut (Item 1) [Figure 70-70-16] and bracket

(Item 2) [Figure 70-70-14].
P-86015

1012 of 1161

(Cont’d)
Figure 70-70-17 2
1
1
1
P-86175
Loosen the clamps (Item 1) and remove the hose (Item

2) [Figure 70-70-19].
P-86173
Figure 70-70-20
Disconnect the high pressure fuel lines (Item 1) [Figure

70-70-17] from the fuel injectors and fuel injection pump.
Remove the fuel shutoff solenoid. (See Fuel Shutoff

2
Solenoid Removal And Installation on Page 70-70-3.)
Figure 70-70-18
P-86176
Remove the nut (Item 1) and glow plug wire (Item 2)

1 [Figure 70-70-20].
P-86174
Remove the high idle body (Item 1) [Figure 70-70-18].

1013 of 1161

(Cont’d)
Figure 70-70-21 1 2
1
1 2 1
P-81507
2
Remove the two nuts (Item 1) and two bolts (Item 2)
[Figure 70-70-23].
P-86177
Figure 70-70-24
Remove the nuts (Item 1) from the two remaining glow

plugs. Remove the strap (Item 2) [Figure 70-70-21] from
the glow plugs.
Figure 70-70-22
1 1
B-23680
Installation: Tighten the bolts and nuts to 17 - 20 ft.-lb.

(23 - 27 N•m) torque in the pattern shown [Figure 70-70-
1 1 24].
P-81506
Remove the five bolts (Item 1) and the intake manifold

(Item 2) [Figure 70-70-22].

1014 of 1161
FUEL SYSTEM (CONT’D)

(Cont’d)
Figure 70-70-25
P-78544
Installation: When the injection pump is installed, the

rack pin (Item 1) [Figure 70-70-25] must be aligned with
the slot in the engine block and positioned on the left side
of the fork lever.
If the rack pin is not installed correctly engine damage

can result.
NOTE: Make sure the same number of shims with the

same thickness are installed under the
injection pump. The shims are used for
engine timing.

1015 of 1161
Fuel Injection Pump Timing
Timing the injection pump is done by changing the

number of shims between the injection pump and the 2
injection pump mounting surface.
IMPORTANT 1
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289 P-78566
Remove the fuel shutoff solenoid. (See Fuel Shutoff Turn the engine until the “1 FI” mark (Item 1) on the fly-
Solenoid Removal And Installation on Page 70-70-3.) wheel is aligned with the mark (Item 2) [Figure 70-70-27]
on the flywheel housing. (Install a tool on the crankshaft
Figure 70-70-26 at the front of the engine to turn the engine.)
Turn the crankshaft counter clockwise approximately 30°

(looking at the front of the engine.)
1
Figure 70-70-28
1
2
P-86025
Remove the two bolts (Item 1) and the timing mark

access cover (Item 2) [Figure 70-70-26].
P-86173
Remove the fuel line clamp (Item 1) [Figure 70-70-28].

1016 of 1161
Fuel Injection Pump Timing (Cont’d)
Figure 70-70-29
B-23682
Remove the fuel in the fuel nozzle with a clean cloth

P-78568 leaving only a small amount [Figure 70-70-31].
Turn the crankshaft clockwise until fuel starts to build up

Remove the number one cylinder high pressure line in the nozzle holder (looking at the front of the engine.)
(Item 1) [Figure 70-70-29] from the injection pump.
NOTE: If the fuel does not build up, turn the
crankshaft 360° to get to the compression
cycle and repeat the previous step.
IMPORTANT Figure 70-70-32
Do not bend the high pressure fuel injection tubes

when removing or installing them.
I-2029-0289
Figure 70-70-30
P-78566
Mark the injector timing on the flywheel through the

timing window [Figure 70-70-32].
Measure the distance between the “1 FI” and the mark

B23681 you made.
Loosen the nozzle holder (Item 1) [Figure 70-70-30]

slightly and tighten when it fills with fuel.

1017 of 1161
FUEL SYSTEM (CONT’D) Fuel Injector Removal And Installation
Fuel Injection Pump Timing (Cont’d) Figure 70-70-34
Figure 70-70-33
3
1 2
P-84663
P-78312
(Item 2) and bracket (Item 3) [Figure 70-70-34].
The correct engine timing is 18° BTDC. The engine is
correctly timed when the timing mark on the flywheel is Figure 70-70-35
aligned with the mark (Item 1) [Figure 70-70-33] on the
timing window.
2
NOTE: Adding or reducing the shim thickness by 0.1
mm retards or advances the injection timing
1
by approximately 1°.
P-84664
Remove the two bolts (Item 1) and reposition the

overflow tank (Item 2) [Figure 70-70-35] to the front of
the radiator.

1018 of 1161
Fuel Injector Removal And Installation (Cont’d)
Figure 70-70-36
2
1
2
P-86015
1
P-81500
Figure 70-70-39
Loosen the clamp (Item 1) and remove the fuel line (Item
2) [Figure 70-70-36] from the fuel filter. 2
Figure 70-70-37
1
1
P-86172
2
Remove the nut (Item 1) and bolt (Item 2). Reposition the
brace (Item 3) [Figure 70-70-40].
P-81501
Remove the two bolts (Item 1) and reposition the fuel

filter and bracket (Item 2) [Figure 70-70-37].

1019 of 1161
Fuel Injector Removal And Installation (Cont’d)
Figure 70-70-40 2
4 3
2
3
1 4
2 1
4 P-86178
Remove the supply hose (Item 1) [Figure 70-70-42].

P-86016
Remove the injection pipe nuts (Item 2) and injection
pipes (Item 3) [Figure 70-70-42].
Remove the nut (Item 1) [Figure 70-70-40] and bracket
(Item 2) [Figure 70-70-38 on Page 70-70-12]. Installation: Tighten the injector pipe nuts to 18 - 25 ft.-
lb. (25 - 34 N•m) torque.
Figure 70-70-41
Remove the injector nozzles (Item 4) [Figure 70-70-42].
Installation: Tighten the injector nozzle to 36 - 51 ft.-lb.

2
1 (49 - 69 N•m) torque.
NOTE: Replace the copper washer and nozzle cap

anytime new or reconditioned fuel injectors
are installed.
3 1
2
WARNING
P-86173
Remove the high pressure fuel line clamps (Item 1) penetrate skin or eyes, causing serious injury or
[Figure 70-70-41]. death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
Remove the fuel lines (Item 2) [Figure 70-70-41] from not use your bare hand. Wear safety goggles. If fluid
the injectors and injector pump. enters skin or eyes, get immediate medical attention
W-2072-0807
Remove the fuel return hose (Item 3) [Figure 70-70-41].

1020 of 1161
Fuel Injector Nozzle Pressure - Checking
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284
The tool listed will be needed to do the following

A-2513
procedure:
MEL 10018 - Injector Nozzle Tester Assemble the injector nozzle. Connect the nozzle to the
tester with the nozzle down [Figure 70-70-44].
Figure 70-70-43
Operate the hand lever at a slow rate and record the
opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove the spacer
(Item 2) [Figure 70-70-44].
1. Nozzle Holder NOTE: When assembling the injector nozzle, tighten

1 2. Adjusting Washer the retainer nut (Item 7) [Figure 70-70-43] to
3. Nozzle Spring 23.5 - 28.9 ft.-lb. (25,3 - 28,9 N•m) torque. Any
4. Push Rod higher torque will cause slow action of the
2 5. Distance Piece valve.
6. Nozzle Piece
7. Nozzle Retaining Nut When the injector nozzle is assembled, tighten the
3
nozzle body to 36 - 51 ft.-lb. (49 - 69 N•m) torque.
4
Check for inside leakage. Operate the hand lever until
5
the pressure 1849 PSI (127 bar). Keep the nozzle under
6 this pressure for 10 seconds, check to see if fuel leaks
from the nozzle. If fuel leaks, replace the nozzle.
PI-09981
The nozzle release pressure can be adjusted by adding

or removing washer(s) (Item 2) from the top of the nozzle
spring (Item 3) [Figure 70-70-43].
Each spacer will change the release pressure by about

34 PSI (2,3 bar).
Fuel Injection Pressure 1991 - 2134 PSI

(137 - 147 bar)

1021 of 1161
FUEL SYSTEM (CONT’D) Valve Seat Tightness
Nozzle Spray Condition Figure 70-70-46
WARNING
W-2072-0807 B-23693
Figure 70-70-45 Set the injection nozzle to a nozzle tester (Code No.
07909-31361) [Figure 70-70-46].
Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/
CORRECT WRONG cm², 1849 PSI) for 10 seconds.
If any fuel leak is found, replace the injection nozzle

assembly or repair at Denso Service Shop.
Valve seat Factory No fuel leak at 12.75 MPa

tightness spec. 130 kgf/cm² 1849 PSI
A-2621
Check that the spray pattern is correct [Figure 70-70-

45].
1. Fuel does not come out the side of the nozzle.

2. Drops of fuel are not present at the nozzle.
3. The injector has an even flow coming from the
nozzle.

1022 of 1161
Bleeding The Fuel System
Figure 70-70-47
1 1
2
P-78643
If the engine still does not start, loosen one or two nozzle
P-86034 holders (Item 1) [Figure 70-70-49] and crank the engine
to bleed the air.
Rotate the valve (Item 1) on the filter to air (Item 2) When air is no longer evident in the bleeding fuel, tighten
[Figure 70-70-47]. the nozzles that were loosened.
Crank the engine several times until the filter is 3/4 full.
NOTE: Do not crank the engine for over five seconds.
Rotate the filter valve (Item 1) [Figure 70-70-47] back to

the on position.
Figure 70-70-48
P-86035
Loosen the bleed bolt (Item 1) [Figure 70-70-48]. Crank

the engine to bleed the air. Tighten the bleed bolt.

1023 of 1161
CYLINDER HEAD
Glow Plug - Testing
Disconnect the glow plug wire harness and connecting

straps.
Figure 70-80-1
P-86037
Use an ohmmeter to check the glow plugs [Figure 70-80-

1].
Touch one probe to the end of the glow plug and the
other probe to the body of the glow plug.
The reading should be approximately 0.5 ohm. If the

resistance is infinite, the coil of the glow plug is broken. If
the resistance is 0 the glow plug is short circuited.
Repeat the procedure for each glow plug.

1024 of 1161
CYLINDER HEAD (CONT’D) Figure 70-80-4
Glow Plug Removal And Installation

1
Figure 70-80-2
P-86165
1
Remove the three glow plugs (Item 1) [Figure 70-80-4].

2
Installation: Tighten the glow plugs to 15 - 18 ft.-lb. (20 -
P-86167 25 N•m) torque.
Remove the rubber boot (Item 1), nut (Item 2) and wire
Figure 70-80-3
P-86166
Remove the nuts (Item 1) [Figure 70-80-3] from the two

remaining glow plugs.
Remove the connecting strap (Item 2) [Figure 70-80-3]

from the glow plugs.

1025 of 1161
Valve Clearance Adjustment
Disconnect the negative battery cable.
Remove the valve cover.
Turn the crankshaft until the intake valve of the No. 2

cylinder and the exhaust valve of the No. 3 cylinder move
simultaneously and the rocker arm height of the two
valves are the same.
Figure 70-80-5
B-23904
Turn the crankshaft 360°. Measure and adjust the

clearance of the intake valve of the No. 2 cylinder and the
exhaust valve of the No. 3 cylinder [Figure 70-80-6].
Factory Spec. Intake Valve 0.006 in

(0,15 mm)
Exhaust Valve 0.006 in
(0,15 mm)
B-23903
Measure and adjust the clearance of the intake and

exhaust valves of the No. 1 cylinder, exhaust valve of the
No. 2 cylinder and the intake valve of the No. 3 cylinder
[Figure 70-80-5].

1026 of 1161
Valve Timing - Checking

1
Stop the engine and open the engine cover.
Remove the timing gearcase cover. (See Timing 2

Gearcase Cover Removal And Installation on Page 70-
100-1.)
Figure 70-80-7
P-47242
Loosen the bolts on the clamps (Item 1) and remove the

injection tubes (Item 2) [Figure 70-80-9].
Remove the overflow tube assembly.
Figure 70-80-10
704W266A
Make sure the timing marks are in the correct alignment

[Figure 70-80-7]. 1
Cylinder Head Removal And Installation

2
Figure 70-80-8
2 4
3 P-47243
Remove the glow plugs (Item 1) and fuel injector holder

1 assemblies (Item 2) [Figure 70-80-10].
Installation: Tighten the glow plugs to 15 - 18 ft.-lb. (20 -

25 N•m) torque.
Tighten the injector holders to 19 - 22 ft.-lb. (26 - 29 N•m)

P-47241 torque.
Remove the glow plug lead (Item 1), breather hose (Item
2), and valve cover bolts (Item 3) [Figure 70-80-8].
Remove the valve cover (Item 4) [Figure 70-80-8] and

gasket.
Installation: Tighten the valve cover bolts to 7 - 9 ft.-lb.

(9 - 12 N•m)

1027 of 1161
Cylinder Head Removal And Installation (Cont'd)
Figure 70-80-11
1
P-47245
Installation: The push rod (Item 1) must be seated in the

P-47244 tappet (Item 2) [Figure 70-80-13] correctly or the push
rods will be damaged.
Remove the rocker arm bolts and remove the rocker arm After installing the rocker arm assembly and push rods,
assembly [Figure 70-80-11]. the valve lash must be adjusted. (See Valve Clearance
Adjustment on Page 70-80-3.)
Figure 70-80-12
Figure 70-80-14
704W250A
P-47246
Installation: Tighten the bolts in the correct sequence in

order of #1 to #3 [Figure 70-80-12] to the specified Remove the clamps (Item 1) and remove the hose (Item
torque listed below. 2) [Figure 70-80-14].
NOTE: (A) is the gearcase side

(B) is the flywheel side [Figure 70-80-12]
Tightening Torque 60.8 - 73.5 N•m

6.2 - 7.2 kgf•m
44.8 - 54.2 lbf-ft.
Remove the pushrods.

1028 of 1161
Cylinder Head Removal And Installation (Cont'd)
Figure 70-80-15
2
B A
A
P-47248
Remove the cylinder head (Item 1) and gasket (Item 2)

704W256A [Figure 70-80-16].
Figure 70-80-17
Remove the cylinder head bolts in order of #14 to #1
[Figure 70-80-15].
Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence in order of #1-#14 to the
specified torque listed below.
Tightening Torque 103,0 - 107,9 N•m

10,5 - 11,0 kgf•m
75.9 - 79.6 lbf-ft.
P-47249
Replace the head gasket with a new one and place on

the cylinder block, be careful of its direction and side
[Figure 70-80-17].
When using the head gasket shim, install the shim on the
cylinder head prior to the gasket.

1029 of 1161
CYLINDER HEAD (CONT’D) Cylinder Head Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-18 Figure 70-80-20
3 2
2
5
4 1
PI-9987A A-2735
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-20] on the
springs [Figure 70-80-18]. cylinder head.
Figure 70-80-19 NOTE: Do not put the straight edge across

combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-20] between

the straight edge and the surface of the cylinder head.
Figure 70-80-21
5
3 Valve
2
4 Spring
1 Retainer
Seal
Collets
B-4122C
Remove the valve spring collet (Item 1) [Figure 70-80-

18] & [Figure 70-80-19].
Remove the valve spring retainer (Item 2) and the spring

PI-9988
(Item 3) [Figure 70-80-18] & [Figure 70-80-19].
Remove the seal (Item 4) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-18] & [Figure 70-80-19]. and two diagonal as shown in figure [Figure 70-80-21].
NOTE: Do not interchange valve and valve parts. The maximum distortion of the head surface is ± 0.0019
in. (± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

1030 of 1161
CYLINDER HEAD (CONT'D) Valve Guide - Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly And Assembly on Page
Figure 70-80-22 70-80-7.)
Clean the valve seat and combustion chamber.

2
Figure 70-80-23
1
3
PI-9989
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-22] being checked at T.D.C.
B-3634
Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)

[Figure 70-80-22] on the top of the piston. Use grease to Install the valve into the guide. Measure the valve
hold them in position. recessing with a depth gauge [Figure 70-80-23].
NOTE: Put the solder in position so they do not touch If the measurement exceeds the allowable limit, replace
the valves. the valve and check the valve seating.
Turn the piston to bottom dead center. Valve Factory 0.0078 - 0.0197 in.
Recessing spec. (0,2 - 0,5 mm)
Install the cylinder head and tighten to the correct torque
in the correct sequence. (See Cylinder Head Removal
Limit (0,8 mm)
Remove the carbon from the valve guide.
Turn the crankshaft until the piston exceeds T.D.C.
Remove the cylinder head.
Remove the solder wire (Item 3) [Figure 70-80-22] and

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

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.02946 - 0.0354 in.

(0,7 - 0,9 mm)

1031 of 1161
Valve Guide - Checking (Cont’d)
Figure 70-80-24
PI-9992
Press the used valve guide out of the cylinder head using
B-14335 the special driver tool [Figure 70-80-25].
Put oil on the outside diameter of the new valve guide.

Measure the valve stem O.D. [Figure 70-80-24]. Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 & 2)
Measure the valve guide I.D. [Figure 70-80-24]. [Figure 70-80-25], press the new guide until the tool
contacts the cylinder head.
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide. Ream the valve guide to the correct specifications.
Valve Stem Factory Spec. 0.0016 - 0.0028 in.

Clearance (0,040 - 0,070 mm)
Allowable 0.004 in.
Limit (0,1 mm)
Valve Factory Spec. 0.31555 - 0.31614 in.
Guide I.D. (8,015 - 8,030 mm)
Valve Stem Factory Spec. 0.31339 - 0.31398 in.
O.D. (7,960 - 7,975 mm)

1032 of 1161
CYLINDER HEAD (CONT'D) Valve Seat Width
Reconditioning The Valve And Valve Seat Intake 0.785 in.

(2,12 mm)
Figure 70-80-26 Exhaust 0.785 in.
(2,12 mm)
Valve Seat & Face Angle
Intake 45°
Exhaust 45°
PI-9993
Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-26].
Figure 70-80-27
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-27].

1033 of 1161
CYLINDER HEAD (CONT'D) Figure 70-80-29
Valve Spring
Figure 70-80-28
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-29].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds the allowable limit, replace the
measurement is less than the allowable limit, replace the spring.
spring [Figure 70-80-28].
Tension Factory 17,7 N / 35,15 mm
Free Length 1.642 - 1.661 in. Spec. 12,0 kgf / 35,15 mm
(41,7 - 42,2 mm) 26.5 lb. / 1.3839 in.
Allowable Limit 1.622 in. Allowable 100 N / 35,15 mm
(41,2 mm) Limit 10,2 kgf / 35,15 mm
22.5 lb. / 1.3839 in.
Put the spring on a flat surface, place a square on the Free Length Factory 1.6417 - 1.6614 in.
side of the spring [Figure 70-80-28]. Spec. (41,7 - 42,2 mm)
Allowable 1.622 in.
Rotate the spring and measure the maximum tilt. If the
Limit (41,2 mm)
measurement exceeds the allowable limit, replace the
spring.
Tilt 0.039 in.

(1,0 mm)

1034 of 1161
CYLINDER HEAD (CONT'D) Rocker Arm And Shaft - Checking
Valve Tappets Figure 70-80-32
Figure 70-80-30
1
2
B-3697
P-47267
Measure the rocker arm I.D. (Item 1) [Figure 70-80-32]
with an inside micrometer.
Remove the valve tappets (Item 1) [Figure 70-80-30].
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-
Figure 70-80-31 80-32] with an outside micrometer.

bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Clearance Factory Spec. 0.00079 - 0.00276 in.

(0,020 - 0,070 mm)
(0,15 mm)
Rocker Factory Spec. 0.74626 - 0.74724 in.
Arm Shaft (18,955 - 18,980 mm)
O.D.
P-47268 0.74803 - 0.74902 in.
Rocker Factory Spec.
Arm I.D. (19,000 - 19,025 mm)
Measure the O.D. of the tappet [Figure 70-80-31].
Measure the ID of the tappet bore [Figure 70-80-31].

tappets.
Tappet OD 0.9433 - 0.9441 in.

(23,96 - 23,98 mm)
Tappet Bore ID 0.9449 - 0.9457 in.
(24 - 24,02 mm)
Clearance Between 0.0008 - 0.0024 in.
Tappet and Tappet Bore (0,02 - 0,06 mm)
(0,07 mm)

1035 of 1161
CRANKSHAFT AND PISTONS Figure 70-90-2
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 70-90-1
PI-10013
1
Remove the rod cap and bearing [Figure 70-90-2].
Use a hammer handle and push the piston/connecting

2 rod assembly out of the cylinder bore [Figure 70-90-2].
NOTE: Make sure the pistons are marked so they will

be returned to the same cylinder bore.
Figure 70-90-3
P-47269
Remove the oil pump strainer (Item 1) and O-ring (Item

2) [Figure 70-90-1] by tapping the edge of the strainer
with a soft faced hammer.
Turn the flywheel and put a pair of connecting rods at 1

bottom dead center.
Remove the connecting rod bolts.
Installation: Tighten the connecting rod bolts to 34 - 38

ft.-lb. (46 - 51 N•m) torque. B-23883
Installation: Make sure the marks on the connecting rod

and bearing are aligned when installing the bearing cap
(Item 1) [Figure 70-90-3].
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

1036 of 1161
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-6
Piston And Connecting Rod Removal And

Installation (Cont’d)
Figure 70-90-4
4
1 3
2
1
B-23881
Installation: When reassembling, align the marks on the

connecting rod and piston. Heat the piston in clean
P-47270 engine oil to 176° F. (80° C.) and tap the piston pin into
position. Place the piston rings so that there are gaps
every 120° [Figure 70-90-6] with no gap facing the
Remove the piston rings [Figure 70-90-4]. piston pin in the cylinder.
Remove the snap ring (Item 1) and piston pin (Item 2) Figure 70-90-7
[Figure 70-90-4].
Separate the piston (Item 3) from the connecting rod

(Item 4) [Figure 70-90-4].
Figure 70-90-5
1
B-23882
1 Installation: Make sure the undercut (Item 1) [Figure

70-90-6] of the second ring faces down.
3
PI-10015D
Installation: When installing new rings, assemble the

ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 70-90-5].

1037 of 1161
CRANKSHAFT AND PISTONS (CONT'D) Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
Piston And Connecting Rod - Servicing specifications, replace the piston pin.
Figure 70-90-8 Piston pin Factory Spec. 0.00055 - 0.00150 in.

and bushing (0,014 - 0,038 mm)
clearance Allowable Limit 0.0059 in.
(0,15 mm)
Piston pin Factory Spec. 0.98433 - 0.98469 in.
O.D. (25,002 - 25,011 mm)
Bushing I.D. Factory Spec. 0.98524 - 0.98583 in.
(25,025 - 25,040 mm)
P-47272
Measure the I.D. of the piston pin bore in both horizontal

and vertical directions [Figure 70-90-8].
If the measurement exceeds the allowable limit, replace

the piston.
Piston pin Piston Bore 0.9843 - 0.9845 in.

bore I.D. I.D. (25,000 - 25,006 mm)
Allowable limit 0.9854 in.
(25,03 mm)
Figure 70-90-9
P-47273
Measure the O.D. of the piston pin (Item 1) [Figure 70-

90-9].
Measure the I.D. of the connecting rod small end (Item 2)

[Figure 70-90-9].

1038 of 1161
CRANKSHAFT AND PISTONS (CONT'D) If the gap exceeds the allowable limit, replace the ring.
Piston And Connecting Rod - Servicing (Cont'd) Piston 2nd Factory Spec. 0.0217 - 0.0276 in.
ring end ring (0,55 - 0,70 mm)
Figure 70-90-10 gap Allowable limit 0.0492 in.
(1,25 mm)
Top Factory Spec. 0.0098 - 0.0157 in.
ring, (0,25 - 0,40 mm)
oil Allowable limit 0.0492 in.
ring (1,25 mm)
Figure 70-90-12
PI-10016
Use a press and special driver tool to remove the small

end bushing [Figure 70-90-10].
Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until
PI-10017
it is flush [Figure 70-90-10].
Important: Align the oil holes of the connecting rod Remove the carbon from the ring grooves. Measure the
and bushing. clearance between the ring and groove with a feeler
gauge [Figure 70-90-12].
Figure 70-90-11
ring. If the clearance still exceeds the allowable limit,
replace the piston.
Piston 2nd Factory Spec. 0.00157 - 0.00315 in.

ring ring (0,04 - 0,08 mm)
clear- Allowable limit 0.0059 in.
ance (0,15 mm)
Oil Factory Spec. 0.00079 - 0.00236 in.
ring (0,02 - 0,06 mm)
(0,15 mm)
B-3622
Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure
70-90-11].

1039 of 1161
CRANKSHAFT AND PISTONS (CONT'D) Connecting Rod - Alignment
Cylinder Bore - Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-90-13 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 70-90-15
B-4066
Use a gauge to check the inside measurement of the

cylinder bore [Figure 70-90-13].
Figure 70-90-14
B-4067
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-15].

the connecting rod.
Rod Alignment 0.002 in.

(0,05 mm)
A-2717
Measure the six points as shown in [Figure 70-90-14] to

find the maximum wear.
The specifications are as follows:
Cylinder Bore 3.425 - 3.4261 in.

(87,000 - 87,022 mm)
If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.

1040 of 1161
Crankshaft And Bearings Removal And Installation

2
Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
Page 70-90-1.)
Figure 70-90-16
1
2 5
4
P-47276
1
Install the bearing case cover (Item 1) with the casting
mark (Item 2) [Figure 70-90-18] in the upward position.
Tighten the bolts to 17 - 20 ft.-lb. (24 - 28 N•m) torque.
3
Figure 70-90-19
P-47274
Mark and remove the inside screws (Item 1) first, then

remove the outside screws (Item 2) [Figure 70-90-16].
NOTE: The inside bolts are different length than the

outside bolts.
Install two screws in the bearing case cover and remove

the cover (Item 3) [Figure 70-90-16].
Remove the two gaskets (Item 4) and oil seal (Item 5)

[Figure 70-90-16] from the cover.
B-23609
Figure 70-90-17
Before removing the crankshaft/main bearings, check the

end play. Install a dial indicator. Move the crankshaft
[Figure 70-90-19] to the flywheel side, zero the dial
indicator. Measure the end play by pulling the crankshaft
toward the gear case side.

the thrust washers [Figure 70-90-19].
1
End Play 0.006 - 0.012 in.
2 (0,15 - 0,31 mm)
(0,5 mm)
P-47275
Installation: Install the gaskets (Item 1) & (Item 2)

[Figure 70-90-17] as shown.

1041 of 1161
Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 70-90-20
B-4092
Remove the two bearing case bolts [Figure 70-90-22].
B-23610 Remove the bearing case and bearing.
Installation: Apply oil to the bolts and hand tighten

Remove the main bearing bolt 2 (Item 1) [Figure 70-90- before torquing.
20].
Bearing Case Bolt 1 34 - 38 ft.-lb.
Installation: Apply oil to the bolts and hand tighten 46 - 51 N•m
before torquing.
Figure 70-90-23
Bearing Case Bolt 2 51 - 54 ft.-lb.
69 - 74 N•m
Figure 70-90-21
PI-10021
Installation: When installing the main bearing case

P-47279 assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [Figure 70-90-23]. The thrust
washers oil grooves must face outward.
Remove the crankshaft/main bearing assembly from the
engine block [Figure 70-90-21].
NOTE: Turn the crankshaft as needed to allow the

crank pin journals to pass through the cut out
(Item 1) [Figure 70-90-21] of the engine block.
Mark the bearing case halves for correct installation.

1042 of 1161
Crankshaft And Bearings - Servicing
Figure 70-90-24
B-3618
Measure the O.D. of the crankshaft journal [Figure 70-

A-2763 90-26].
Calculate the oil clearance.

Put the crankshaft on V-blocks. Install a dial indicator on
the center journal [Figure 70-90-24]. If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
Turn the crankshaft at a slow rate to obtain the
misalignment (one half of the alignment measurement). Oil Factory Spec 0.002 - 0.005 in.
Clearance (0,050 - 0,122 mm.)
If the misalignment exceeds the allowable limit, replace
the crankshaft.
(0,20 mm)
Journal Allowable Limit 2.35909 - 2.35934 in.
Alignment 0.0031 in.
O.D. (59,921 - 59,940 mm)
(0,08 mm)
Bearing 1 Allowable Limit 2.362 - 2.364 in.
I.D. (59,990 - 60,043 mm)
Tighten the connecting rod bolts to 34 - 38 ft.-lb. (46 - 51
N•m) torque.
Figure 70-90-25
B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure

70-90-25].

1043 of 1161
CRANKSHAFT AND PISTONS (CONT'D) NOTE: DO NOT turn the crankshaft with the press
gauge installed. Incorrect measurements will
Crankshaft And Bearings - Servicing (Cont’d) be obtained.
Figure 70-90-27 Figure 70-90-28
PI-10024A B-23745
Remove the front bearing with the special removal tool If the clearance exceeds the allowable limit, replace the
[Figure 70-90-27]. bearing [Figure 70-90-28].
Installation: Clean the new bearing and bore, apply oil to Oil clearance Factory spec 0.00157 - 0.00409 in.
the bearing and bore. Install the new bearing with the (0,040 - 0,104 mm)
seam (Item 1) [Figure 70-90-27] towards the exhaust
manifold side, using the installation driver tool. Allowable limit 0.0079 in.
(0,20 mm)
Clean the crankshaft journal and bearing. Put a strip of Journal O.D. Allowable limit 2.35909 - 2.35934 in.
press gauge on the center journal.Install the main (59,921 - 59,940 mm)
bearing case halves and tighten the bolts. Remove the Bearing 2 I.D. Factory spec 2.361 - 2.363 in.
bearing case halves. (59,980 - 60,025 mm)

1044 of 1161
CRANKSHAFT AND PISTONS (CONT'D)
Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-29
B-23746

Oil Factory spec 0.002 - 0.004 in.

Clearance (0,040 - 0,104 mm)
(0,20 mm)
Crankshaft Factory spec 2.35909 - 2.35934 in.
O.D. (59,921 - 59,940 mm)
Bushing 2 Factory spec. 2.361 - 2.363 in.
I.D (59,980 - 60,025 mm)

1045 of 1161
CAMSHAFT AND TIMING GEARS Figure 70-100-3
Timing Gearcase Cover Removal And Installation
Remove the fuel injection pump. (See Fuel Shutoff

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

(See Cylinder Head Removal And Installation on Page
70-80-4.)
Figure 70-100-1 1
7.80” (200 mm) P-47256
Remove the speed control plate (Item 1) [Figure 70-100-

3].
Figure 70-100-4
P-47254
Bend a hook on the end of a 7.80 in. (200 mm) long,

0.050 in. (1,2 mm) diameter hard wire [Figure 70-100-1]. 1
Figure 70-100-2
P-47257
1 Remove the wire (Item 1) [Figure 70-100-4] from the

springs.
Installation: Do not drop the governor springs into the

gear case.
P-47255
Disconnect the two governor springs (Item 1) [Figure 70-

100-2].

1046 of 1161
CAMSHAFT AND TIMING GEARS (CONT'D) Figure 70-100-7
Timing Gearcase Cover Removal And Installation

(Cont'd)
Remove the crankshaft pulley nut.

N•m) torque.
Figure 70-100-5
P-47259
Remove the timing gearcase cover [Figure 70-100-7].
Figure 70-100-8
3
P-47258 2
Use a puller and remove the crankshaft pulley [Figure

70-100-5].
Figure 70-100-6
1
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2)

1 and oil slinger (Item 3) [Figure 70-100-8].
2
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2)

[Figure 70-100-6].
Remove the bolts from the timing gearcase cover.

N•m) torque.

1047 of 1161
CAMSHAFT AND TIMING GEARS (CONT'D) Timing Gears Backlash - Checking
Timing Gearcase Cover Removal And Installation When the gears are installed, check the backlash of the
(Cont'd) gears.
Figure 70-100-9 Figure 70-100-10
Oil Seal O-Rings
B-3617 P-47264
Installation: Install new O-rings and oil seal into the Install a dial indicator [Figure 70-100-10].
timing gearcase cover [Figure 70-100-9].
Hold one gear while turning the other gear [Figure 70-
100-10].
If the backlash exceeds the allowable limit, check the oil

clearance of the shaft and gear. If the oil clearance is
incorrect, replace the gear.
Crank Gear & Idler 0.0016 - 0.0043 in.

Gear (0,04 - 0,11 mm)
(0,15 mm)

1048 of 1161
CAMSHAFT AND TIMING GEARS (CONT'D) Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
Idler Gear And Shaft Removal And Installation collar.
Remove the timing gearcase cover. (See Timing Idler Gear End Play 0.0079 - 0.0201 in.
Gearcase Cover Removal And Installation on Page 70- (0,20 - 0,51 mm)
100-1.) Allowable Limit 0.035 in.
(0,9 mm)
Figure 70-100-11
Figure 70-100-13
1 2
P-47260
P-47262
Remove the snap ring (Item 1) and collar from the idler
gear shaft [Figure 70-100-11]. Align the holes (Item 1) on the camshaft gear with the
camshaft retainer plate bolts (Item 2) [Figure 70-100-13].
Installation: Make sure the timing marks are in correct Remove the bolts.
alignment when installing the timing gears [Figure 70-
100-11]. Installation: Tighten the camshaft retainer bolts to 17 -
20 ft.-lb. (24 - 28 N•m) torque.
Figure 70-100-12
Remove the camshaft from the engine block.
B-3699
Remove the idler gear (Item 1) [Figure 70-100-12].

1049 of 1161
CAMSHAFT AND TIMING GEARS (CONT'D)
Idler Gear And Shaft Removal And Installation

(Cont’d)
Figure 70-100-14
0.028 - 0.0781”
(0.07 - 0.22 mm)
PI-10002
Installation: Check the camshaft end play. If clearance

exceeds the allowable limit, replace the camshaft retainer
plate [Figure 70-100-14].
Camshaft End 0.028 - 0.0781 in.

Play (0,07 - 0,22 mm)
Allowable 0.018 in.
Limit (0,3 mm)

1050 of 1161
CAMSHAFT AND TIMING GEARS (CONT'D) Figure 70-100-17
Camshaft - Servicing
Figure 70-100-15
B-5001
Measure the cam lobes at their highest point [Figure 70-

P-47263 100-17].
If the measurement is less than the allowable limit,

Measure the cylinder block bore in the engine block replace the camshaft.
[Figure 70-100-15].
Cam (IN.) Specification 1.3224 in.
Figure 70-100-16 Height (33,59 mm)
(33,54 mm)
(EX.) Specification 1.3264 in.
(33,69 mm)
(33,64 mm)
A-2761
Measure the camshaft journal [Figure 70-100-16].
Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the camshaft.
Oil Clearance Factory spec 0.00197 - 0.00358 in.

(0,050 - 0,091 mm)
Limit (0,15 mm)
Journal O.D. Factory spec 1.57221 - 1.57284 in.
(39,934 - 39,950 mm)
Bore I.D. Factory spec 1.57480 - 1.57579 in.
(40,000 - 40,025 mm)

1051 of 1161
CAMSHAFT AND TIMING GEARS (CONT'D) Idler Gear And Shaft - Servicing
Camshaft - Servicing (Cont’d) Figure 70-100-19
Figure 70-100-18
PI-10003
A-2760
Measure the O.D. of the idler gear shaft [Figure 70-100-
19].
Put the camshaft in V-blocks. Install a dial indicator
[Figure 70-100-18]. Measure the I.D. of the idler gear bushing [Figure 70-
100-19].
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft. If the clearance exceeds the allowable limit, replace the
bushing.
Camshaft Alignment 0.002 in.
Allowable Limit (0,05 mm) Oil Clearance Factory 0.00098 - 0.00260 in.
Spec (0,025 - 0,066 mm)
Limit (0,1 mm)
Shaft O.D. Factory 1.49445 - 1.49508 in.
Spec (37,959 - 37,975 mm)
Bushing I.D. Factory 1.49606 - 1.49705 in.
Spec (38,000 - 38,025 mm)
Figure 70-100-20
PI-10004
Use a press and special driver tool to remove the old

bushing and install the new bushing [Figure 70-100-20].

1052 of 1161
1053 of 1161
FLYWHEEL AND HOUSING (HST MODELS) Figure 70-110-3
Flywheel Removal And Installation
Remove the fuel tank (See “Removal And Installation” on 1

page 50-40-1.)
Figure 70-110-1
2 P-84695
Remove the flywheel (Item 1) [Figure 70-110-3].
1 P-84692
Remove the six bolts (Item 1) and remove the dampener


N•m) torque.
Figure 70-110-2
P-84694
Remove the bolts (Item 1) [Figure 70-110-2] from the

flywheel.

N•m) torque.

1054 of 1161
FLYWHEEL AND HOUSING (HST MODELS) (CONT’D)
Flywheel Housing Removal And Installation
Figure 70-110-4
1
1
P-84696
Figure 70-110-5
1
1
2
1
1
1
P-77309
Remove the bolts (Item 1) and the housing (Item 2)

[Figure 70-110-5]

1055 of 1161
FLYWHEEL AND HOUSING (SST MODELS)
Flywheel Removal And Installation
Remove the clutch assembly. (See Removal And

Remove the fuel tank. (See Removal And Installation on

Page 50-40-1.)
Figure 70-111-1
P-95592
Remove the six bolts (Item 1) [Figure 70-111-1] from the

flywheel.
Figure 70-111-2
P-95593
Remove the flywheel (Item 1) [Figure 70-111-2].

1056 of 1161
FLYWHEEL AND HOUSING (SST MODELS) (CONT'D)
Flywheel Housing Removal And Installation
Figure 70-111-3
1
1
P-84696
Figure 70-111-4
1
1
2
1
1
1
P-77309
Remove the bolts (Item 1) and the housing (Item 2)

[Figure 70-111-4]

1057 of 1161
FAN
Remove the radiator. (See Radiator Removal And

Figure 70-120-1
1
P-84657
Installation: Tighten the bolts to 7 - 8 ft.-lb. (9 - 11 N•m)

torque.

1058 of 1161
1059 of 1161
CLUTCH ASSEMBLY (SST MODELS)
PROBLEM CAUSE
Clutch slip 1, 2, 3, 8, 9, 20
Clutch trailed 4, 5, 7, 8, 9
Bumping noise 2, 6, 9, 10, 11, 12, 13
Crashing noise 3, 14, 15
Vibration 11, 16, 17, 18, 19

1. Too little clutch pedal play
2. Grease or oil on clutch disc
3. Excessively worn clutch disc
4. Excessive clutch pedal play
5. Clutch disc dirty
6. Bent clutch disc or pressure plate
7. Broken clutch fork
8. Deformed clutch disc or pressure plate
9. Weak or broken diaphragm spring on pressure plate
10. Worn or dirty clutch disc boss
11. Bent gear shaft
12. Cracked or scratched pressure plate or flywheel
13. Worn clutch disc spline boss or gear shaft spline
14. Worn clutch disc spline boss
15. Stuck or dried thrust ball bearing
16. Worn or broken clutch disc rivet
17. Broken clutch parts
18. Improperly machined flywheel surface
19. Deflected engine crankshaft
20. Engine or transmission seal damaged, leaking

1060 of 1161
CLUTCH ASSEMBLY (SST MODELS) (CONT'D) Figure 70-130-3

1
2
Figure 70-130-1
P-95591
The clutch disc (Item 1) is not symmetrical. Install the

clutch disc with the protruding side of the hub (Item 2)
[Figure 70-130-3] towards the transmission side.
P-95588
Install the clutch alignment tool (Item 1) [Figure 70-130-

1].
Figure 70-130-2
1
1
1
P-95588
Remove the bolts (Item 1) and the clutch assembly (Item

2) [Figure 70-130-2].

N•m) torque.

1061 of 1161
CLUTCH ASSEMBLY (SST MODELS) (CONT'D) Clutch Pedal Play And Stopper Bolt Adjustment
Clutch Disc Inspection Figure 70-130-6
Figure 70-130-4
NA1941
5
1
3
Using a depth gauge, measure the depth from the disc to
rivet in at least 10 places [Figure 70-130-4]. If the
measurement is less than 0.012 inches (0,3 mm) replace
the clutch disc. 1.181 in.
2 (30,0 mm) 0.787-1.181 in.
Pressure Plate Inspection (20,0-30,0 mm)
Figure 70-130-5 NA1940
1 Press the clutch pedal (Item 1) by hand until clutch

resistance is felt measure the distance. If the
2 measurement is not 0.787-1.18 inch (20-30-mm) remove
the cotter pin, washer and pin (Item 2) turn the U link
(Item 3) to adjust the clutch rod (Item 4) [Figure 70-130-
6] length.
Loosen the lock nut and adjust the stopper bolt (Item 5)
[6] to 1.181 inch (30 mm).
1
Tighten the lock nut.
2
B23646
Place a straight edge (Item 1) on the pressure plate and

measure the clearance with a feeler gauge (Item 2)
[Figure 70-130-5] at several points.
If the clearance exceeds 0.008 inch (0,2 mm) replace the

pressure plate. When the pressure plate is worn around
its outside and its inside surface only is in contact with the
straight edge, replace it even if the clearance is within
allowable limit.

1062 of 1161
1063 of 1161
CLUTCH LEVER (SST MODELS)
1. Clutch Lever
2. Release Hub
3. Bearing
4. Clip
5. Fork
6. Spacer Washers
7. Bolt
8. Seal
9. Seal Plug
9
6
6
4
2
8
1
NA1943

1064 of 1161
CLUTCH LEVER (SST MODELS) (CONT’D) Figure 70-140-3
Disassembly
1
Separate the tractor. (See procedure “SEPARATING
THE TRACTOR (SST MODELS)” on page 40-110- 1).
Figure 70-140-1
1
1
P-95570
2
2 Remove the two bolts (Item 1) [Figure 70-140-3] from

the clutch fork.
Figure 70-140-4
P-95566
2
Rotate the clutch lever up until the forks (Item 1) come 1
out of the clips (Item 2) [Figure 70-140-1] and push the
hub / bearing assembly forward.
Figure 70-140-2
P-95571
Slide the clutch fork (Item 1) part way off the shaft (Item
2) and remove the two spacers (Item 3) [Figure 70-140-
4] from the keyway.
1
P-95569
Remove the hub / bearing assembly (Item 1) [Figure 70-


1065 of 1161
Figure 70-140-5
P-95657
Remove the seal plug (Item 1) [Figure 70-140-7] from

P-95572 the housing.
Figure 70-140-8
Remove the fork assembly (Item 1) and shaft (Item 2)
1
Figure 70-140-6
P-95575
Remove the bearing (Item 1) from the hub (Item 2)

P-95594 [Figure 70-140-8].

housing.

1066 of 1161
CLUTCH LEVER (SST MODELS) (CONT’D)
Inspection
Figure 70-140-9
P-95573
Inspect the fork shaft (Item 1) [Figure 70-140-9] for wear

and damage.
Figure 70-140-10
P-95574
Inspect the fork assembly (Item 1) [Figure 70-140-10] for

wear and damage.

1067 of 1161
Assembly
Figure 70-140-11
2
P-95657
Install the seal plug (Item 1) [Figure 70-140-13] into the

P-95575 housing.
Figure 70-140-14
Install the bearing (Item 1) onto the hub (Item 2) [Figure
70-140-11] until fully seated.
1
Figure 70-140-12 2
3
1
P-95571
Install the fork shaft (Item 1) into the housing while

P-95594 installing the fork (Item 2) [Figure 70-140-14].
Install the two spacers (Item 3) [Figure 70-140-14] into

Install the seal (Item 1) [Figure 70-140-12] into the the keyways.
housing.

1068 of 1161
Assembly (Cont’d)
2
Figure 70-140-15 2
3
2 3
1
P-95568
Slide the hub / bearing assembly (Item 1) onto the shaft

P-95570 while installing the forks (Item 2) behind the clips (Item 3)
[Figure 70-140-17].
Slide the fork shaft (Item 1) [Figure 70-140-15] into the Figure 70-140-18
housing.
Apply Loctite #220 or equivalent to the two bolts (Item 2)

[Figure 70-140-15] and tighten to 17 - 20 ft.-lb. (24 - 27
N•m) torque.
Figure 70-140-16
2 3 1
1
1
P-95567
Make sure the clips (Item 1) [Figure 70-140-18] enter the

groove on the back of the fork (both sides).
P-95577
Install the two clips (Item 1) into the hub (Item 2) [Figure
70-140-16].
Apply grease into the center groove (Item 3) [Figure 70-

140-16]
NOTE: Applying to much grease will shorten the

clutch life.

1069 of 1161
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . 80-120-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-40-2

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-2
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 80-190-1

EVAPORATOR / HEATER UNIT COVER . . . . . . . . . . . . . . . 80-191-1

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1 HVAC

FRONT AIR DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-192-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-90-1

Component Replacement And Refrigeration Leaks. . . . . . 80-90-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-2

1070 of 1161
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-10-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-30-1

HVAC CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-170-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-180-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-160-1

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-70-1

Air Conditioning Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-70-1
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-70-1
Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-70-1
RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-80-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-60-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-60-1
SIDE AIR DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-193-1

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . .80-130-1

Charging Procedure With A Manifold Gauge Set . . . . . . . . . . . .80-130-4
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-130-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . .80-100-1

Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . .80-100-1
Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . . . . . .80-100-2
TEMPERATURE / PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-200-1

1071 of 1161
HEATER COIL Figure 80-10-3
Drain the cooling system. (See Removing And Replacing 1


Page 50-200-1.)
Remove the evaporator / heater unit cover. (See

Figure 80-10-1
P-87863
1
Remove the heater coil (Item 1) [Figure 80-10-2] by
lifting straight up.
1 2
2
P-87861
Remove the two hose clamps (Item 1) and hoses (item 2)

[Figure 80-10-1] from the tubelines.
Figure 80-10-2
P-87862

1072 of 1161
1073 of 1161
BLOWER FAN

Page 50-200-1.)

Figure 80-20-1
P-87858
Remove the blower fan (Item 1) [Figure 80-20-1] by

lifting.
Figure 80-20-2
2
P-87860
Remove the nut (Item 1) and blower wheel (Item 2)

[Figure 80-20-2] (both sides.)
Inspect the fan motor, if the motor needs replacing, it

must be replaced as a complete unit.

1074 of 1161
1075 of 1161
HEATER VALVE
Remove the heater coil. (See Removal And Installation

on Page 80-10-1.)
Figure 80-30-1
1
P-87864
Remove the heater valve (Item 1) from the hose (Item 2)

[Figure 80-30-1].
Figure 80-30-2
2
P-87860
Remove the two screws (Item 1) and bracket (Item 2)

from the heater valve (Item 3) [Figure 80-30-2].

1076 of 1161
1077 of 1161
1078 of 1161
AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) Page 80-40-3 takes in heated, low pressure refrigerant gas through the suction valve (low
pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge valve
(high pressure side) on the condenser (Item 2) Page 80-40-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) Page 80-40-3 where impurities such as moisture and dirt are
filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still under
high pressure) flows to the expansion valve (Item 4) Page 80-40-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) Page 80-40-3. As the refrigerant
passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-pressure liquid
and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the evaporator. The hot
humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan (Item 6) Page 80-40-
3. Since the refrigerant is colder than the air, it absorbs the heat from the air and produces cooled air, which is pushed into
the cab by the fan. The moisture in the air condenses on the evaporator coil and drips into the drain pan, which directs the
water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

1079 of 1161
AIR CONDITIONING SYSTEM FLOW (CONT’D)
Chart
B-19987

1080 of 1161
1081 of 1161
COMPONENTS Figure 80-50-3
Identification
Figure 80-50-1
1
P-87326
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-50-

P-87255 3] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-50-1] extra liquid refrigerant until it is needed by the evaporator
is the pump that circulates the refrigerant throughout the and is located in front of the radiator on the right side
system. It raises the pressure of the refrigerant for heat behind the debris screen.
transfer through the condenser and evaporator.
Figure 80-50-4
NOTE: The A/C system (Compressor) is
recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-50-2
1
P-87327
Heater/Evaporator Unit: The heater/evaporator unit

[Figure 80-50-4] is located under the cab cover on top of
the tractor cab. The unit delivers the cold air for the A/C
P-87256 and warm air for heat into the cab. The unit contains the
blower, heat & A/C coils.
Condenser: The condenser (Item 1) [Figure 80-50-2] is

located in front of the radiator, and is the unit that
receives the high pressure, high temperature refrigerant
vapor from the compressor and condenses it into a high
temperature liquid.

1082 of 1161
COMPONENTS (CONT’D) Control Panel: The panel has four separate components.
Identification (Cont'd) Figure 80-50-7
Figure 80-50-5
1 3 4
P-87265
P-87328
Fan Switch: This is a four position rotary switch (Item 1)
[Figure 80-50-7]. When the fan switch is in the off
Expansion Valve: The expansion valve (Item 1) [Figure position the A/C will not engage, but the heat valve will
80-50-5] controls the amount of refrigerant entering the operate, as it is controlled by the ignition power.
evaporator coil.
A/C Switch: The A/C switch (Item 2) [Figure 80-50-7] will
Figure 80-50-6 be illuminated when the A/C is engaged.
Fan Potentiometer: The fan potentiometer (Item 3)
3 [Figure 80-50-7] controls which air vents blow air.
Potentiometer: The potentiometer (Item 4) [Figure 80-
50-7] controls the Heat Valve from fully Off to fully On.
4 This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
1
Figure 80-50-8
2
1
P-87330
Thermostat: The thermostat (Item 1) [Figure 80-50-6]

controls the temperature of the evaporator coil.
Heater Coil: The heater coil (Item 2) [Figure 80-50-6]

supplies the warm air into the cab by passing air through
the coil.
P-87329
Evaporator Coil: The evaporator coil (Item 3) [Figure 80-
50-6] cools and dehumidifies the air before it enters the
cab. Heater Valve: The heater valve (Item 1) [Figure 80-50-8]
is used to control the amount of engine coolant that flows
Heater/Evaporator Blower: The blower (Item 4) [Figure to the heater coil.
80-50-6] is used to push air through the heater and The heater valve is located under the cab cover on the
evaporator coils and into the cab. right side.

1083 of 1161
COMPONENTS (CONT'D)
Identification (Cont'd)
Figure 80-50-9
P-87331
Pressure Switch: The pressure switch (Item 1) [Figure

80-50-9] will disengage the compressor clutch at high
pressure readings which indicates loss of refrigerant.

1084 of 1161
1085 of 1161
SAFETY Figure 80-60-2
Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-60-1
P16399
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
P16398 gloves [Figure 80-60-2] to prevent frost bite if you should
get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-60-
1] when you are using R-134a, a leak detector, adjusting
service valves or the manifold gage set connectors. WARNING
Safety glasses or a transparent face shield are practical
safety items and one or the other is absolutely required.
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
WARNING • Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
In the event of a leak, wear safety goggles. Escaping • NEVER SMOKE when there is the possibility of
refrigerant can cause severe injuries to eyes. In even small amounts of 134A in the air.
contact with a flame, R134a refrigerant gives a toxic Any servicing work that involves release or addition
gas. of 134A to the system must be done by a competent
W-2371-0500 refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500

1086 of 1161
1087 of 1161
REGULAR MAINTENANCE Cleaning The Condenser
Fresh Air Filter Open the engine cover.(See Opening And Closing on
Page 10-20-1.)
Remove the fresh air filters. (See Removal And
Installation on Page 10-81-1) Remove the grill. See Removal And Installation on Page
50-91-1
Clean the filter by shaking or using low air pressure.
Figure 80-70-1
Replace the filter two to four times per year under normal
operating conditions, up to weekly under extremely dusty
operating conditions.
Air Conditioning Belt
Check the condition of the belt and adjust as needed

every 100 hours of operation. (See Belt Adjustment on 1
Page 10-161-1)
P-87256
Check the condenser (Item 1) [Figure 80-70-1] for mud

or dirt.
Remove the two debris screens.
Use air pressure or water pressure to clean the oil cooler/

condenser assembly.

1088 of 1161
1089 of 1161
RESISTOR Figure 80-80-3
Remove the cab cover. See Removal And Installation on

Page 50-200-1
Figure 80-80-1
P-87867
Remove the resistor [Figure 80-80-3].

1
P-87829
Unplug the connector (Item 1) [Figure 80-80-1] from the

resistor.
Figure 80-80-2
P-87866

1090 of 1161
1091 of 1161
GENERAL AIR CONDITIONING SERVICE It is necessary to check, replenish or replace the
GUIDELINES compressor oil in the following cases:
Compressor Oil 1. When the evaporator, condenser or receiver-drier is

replaced.
Figure 80-90-1
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
1
4. When any oil related problems occur in the cooling
cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
P-87255 filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

The compressor (Item 1) [Figure 80-90-1] is factory filled
and R-134a Oils.
with 9.0 fluid oz. of PAG oil (Poly Alkelene Glycol).
It is not necessary to frequently check or change the

compressor oil.

1092 of 1161
Compressor Oil Check Figure 80-90-2
The compressor oil should be checked as follows when

oil is being added to an in service excavator.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the 1
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See Charging Procedure With A
Manifold Gauge Set on Page 80-130-4)
P-86878
Open the cab door and windows.
Run the blower at maximum speed. Figure 80-90-3
Run the compressor for at least 20 minutes at 800-1200

RPM.
Remove the compressor from the excavator. (See

Removal And Installation on Page 80-140-1)
P-16534
Remove the oil drain plug (Item 1) [Figure 80-90-2] and

drain the oil through the connectors and the oil drain hole
[Figure 80-90-3].
Installation: Tighten the oil drain plug to 9.4 - 10.8 ft.-lb.

(13 - 15 N•m) torque.

1093 of 1161
GENERAL AIR CONDITIONING SERVICE NOTE: The suction port on the compressor is marked
GUIDELINES (CONT'D) with an S and is the larger port on the
compressor.
Compressor Oil Check (Cont'd)
Component Replacement And Refrigeration Leaks
Figure 80-90-4
Figure 80-90-6
N-22246
P-87326
NOTE: After draining the oil through the drain hole

and the connectors, extract the remaining oil Whenever the A/C system is opened to the atmosphere
through the discharge-side connector by or there has been a leak in the system, the receiver/drier
rotating the drive pulley (Item 1) [Figure 80-90- (Item 1) [Figure 80-90-6] must be changed.
4] several times by hand.
Never leave hose fittings, compressor fittings or
Measure the drained oil in a measuring cylinder.Check components uncapped while working on the A/C system.
the oil for contamination, dirt, metal shavings, or varnish
color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-90-5
P-86878
Add new compressor oil through the suction side

connector (Item 1) [Figure 80-90-5].
Installation: Add 9.0 fluid oz. of PAG oil.

1094 of 1161
1095 of 1161
SYSTEM TROUBLESHOOTING CHART
Blower Motor Does Not Operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Motor.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and clean
obstruction evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked to Repair of adjust.
Louvers, and air ducts.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
Insufficient cooling although air flow and compressor operation are normal

1. System low on The high side pressure will be low and bubbles may be Repair any leaks and recharge
refrigerant. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch Clutch slips. Replace or clean the clutch
surface. surface.
6. Open oil. Clutch does not engage and there is not reading when a Replace clutch.
circuit tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.

1096 of 1161
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting

Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86° - 96° F (30° -
38° C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210 - 265 PSI
Low pressure side pressure: 15 - 33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high.
As this is explained below, the following inspection is
only used when the low pressure side is too high.
1. Expansion valve opens Frost is present on the suction hose. Replace expansion valve
too far.
2. Defective compressor The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is disengaged.
Low pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles may be Repair any leaks and recharge the
present in sight glass on receiver drier. refrigerant to the correct level.
2. Clogged or closed The expansion valve's inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunction. The evaporator is frozen. Adjust thermostat's temperature
setting or probe placement or
replace thermostat.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the fan.
performance. Operating.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil charge The high pressure side will be high. Evacuate system. Remove oil
from condenser and compressor.
Measure oil from compressor and
add correct oil charge back into
compressor. Flush system with
nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.
High pressure side
Too low.
1. Low refrigerant charge. The high side pressure will be low and bubbles may be Repair any leaks and recharge the
present in sight glass on receiver drier. refrigerant to the correct level.

1097 of 1161
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)

System Pressures Equal
1. Clutch not operating See magnetic clutch related topics above.
2. Compressor not pumping. Equal high and low pressures. Replace compressor.

1098 of 1161
1099 of 1161
TEMPERATURE / PRESSURE
Chart
NORMAL EVAPORATOR RANGE NORMAL EVAPORATOR RANGE
TEMP F. PSIG TEMP F. PSIG

16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 166 320.10
92 108.20 170 340.80
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8° - 10° F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40° F to the ambient temperature to get
the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
Example: Ambient Temperature = 90° F

90° F
+40° F
130° F condenser temperature = 200 psig
Conditions and pressures will vary from system to system.

1100 of 1161
1101 of 1161
AIR CONDITIONING SERVICE
Chart
Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Customer:
Machine Serial Number:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain services required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

1102 of 1161
1103 of 1161
SYSTEM CHARGING AND RECLAMATION Figure 80-130-2

Page 10-20-1.) 1
Reclamation Procedure
Figure 80-130-1
1
N-23024
NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
P-87259 Refrigerant Identifier (Item 1) [Figure 80-130-2]
will determine the kind of refrigerant and any
possible harmful or dangerous substances
Locate the low pressure port (Item 1) and high pressure that may be present in the system. Thus
port (Item 2) [Figure 80-130-1]. preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL 1581 Recovery/Recycling/Recharging
WARNING Machine.
In the event of a leak, wear safety goggles. Escaping

refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
NOTE: This procedure is run with the Compact tractor

engine OFF, and the A/C switch in the OFF
position.

1104 of 1161
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Reclamation Procedure (Cont’d)
Figure 80-130-3
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
1 Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
P-87123 W-2373-0500
Remove the protective cap and connect the Refrigerant

Identifier to the low pressure hose (Item 1) [Figure 80-
130-3]. Figure 80-130-4
Connect the refrigerant identifier to a power source.
Follow the steps displayed on the refrigerant identifier

screen.
Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the Compact

tractor A/C.
If the refrigerant is dangerous or flammable, it must be N-22291

evacuated from the A/C system into a separate container
and properly and safely disposed of.
Use an approved recover/charging unit [Figure 80-130-
If R134a is found, evacuate the system. 4] to evacuate the system.
IMPORTANT: Only A/C trained technicians should Connect the reclaimer to the excavator A/C charge ports.
perform the reclaiming and recharging
procedure.

1105 of 1161
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-130-7
Reclamation Procedure (Cont’d)
Figure 80-130-5
N-22381
NOTE: The reclaimer unit has a complete step by

P-87260 step set of instructions [Figure 80-130-7] to
follow for reclamation and recharging of the
A/C system. A trained technician should
Connect the Red hose (Item 1) [Figure 80-130-5] to the follow these instructions as they may very
high pressure port and open the valve. slightly depending on the model and brand of
reclaimer used.
Connect the Blue hose (Item 1) [Figure 80-130-5] to the
low pressure port and open the valve.
Figure 80-130-6
N-22292
Turn the reclaimer unit to the ON position and follow the

on screen instructions [Figure 80-130-6].

1106 of 1161
Charging Procedure With A Manifold Gauge Set

Page 10-20-1.)
WARNING
gas.
W-2371-0500
Figure 80-130-8
P-87124
Connect the Yellow hose (Item 1) [Figure 80-130-9] to

the vacuum pump.
1
1
P-87262
Check to see that the hand valves (Item 1) [Figure 80-

130-8] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation Procedure on Page 80-130-1.)
Connect the gauges to the compact tractor A/C charge

ports.
Connect the Red hose (Item 2) [Figure 80-130-8] to the

high pressure port and open the valve.
Connect the Blue hose (Item 3) [Figure 80-130-8] to the

low pressure port and open the valve.

1107 of 1161

(Cont’d)
Figure 80-130-10
1
P-87172
1
A thermistor vacuum gauge (Item 1) [Figure 80-130-12]

can be used to determine the critical vacuum level during
P-87125 evacuation. it is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
Start the vacuum pump and open ISO-valve (Item 1) The thermistor vacuum gauge is used with the vacuum
[Figure 80-130-10] on the vacuum pump. pump [Figure 80-130-12].
Run the vacuum pump for at least 5 - 10 minutes to make Start the vacuum pump and open ISO-valve on the
sure that a vacuum has been pulled on the system. vacuum pump.
Close the ISO-valve (Item 1) [Figure 80-130-10] (which Be sure that both hand valves, and both charge port
isolates the vacuum pump from the A/C system) and turn valves are open.
OFF the vacuum pump.
Run the vacuum pump for at least 45 minutes to insure
Figure 80-130-11 that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
1 Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermister vacuum

gauge.
P-87261
Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-130-11]. Let stand for
5-10 minutes and recheck the pressure for changes.
If the pressure drops, this may be an indication of a leak

in the A.C system.
Determine the problem with the A/C system and repair it.

1108 of 1161

(Cont’d) 2
Figure 80-130-13
1
3
2 P-87265
Press the A/C (Item 1) [Figure 80-130-15] switch to ON

position.
P-87263
Turn the fan switch (Item 2) [Figure 80-130-15] to HIGH
position.
Place a refrigerant container with R134a (Item 1) on a
charging scale (Item 2) [Figure 80-130-13] and zero out Start the engine and run at medium speed.
the scale.
Watch the scale and run the system until the
Connect the yellow hose (Item 3) [Figure 80-130-13] predetermined amount of refrigerant is added to the A/C
from the manifold gauge set to the valve on the system.
refrigerant tank.
The A/C system holds 1.7 lb. (0,8 kg) of refrigerant.
Figure 80-130-14
Turn OFF the valve on the refrigerant container, and
hand valves on the manifold gauge set.
Turn OFF the engine, and remove the A/C charging

equipment from the Compact tractor.
1
P-87264
Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
80-130-14] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.

1109 of 1161
COMPRESSOR Figure 80-140-3

1
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-130-1)
Remove the air conditioning belt. (See Belt Replacement

on Page 10-161-1)
Figure 80-140-1
1
P-87879
Remove the two front mounting bolts (Item 1) and two

rear mounting bolts (Item 2) [Figure 80-140-3] from the
compressor.
1 Installation: Tighten the bolts to 17 - 20 ft.-lb. (24 - 27
N•m) torque.
P-87878 Remove the compressor.

from the compressor.
Figure 80-140-2
1
2
P-87877
Remove the bolt (Item 1) and two hoses (Item 2) [Figure

80-140-2].

1110 of 1161
1111 of 1161
CONDENSER Figure 80-150-2
Evacuate the A/C system. (See SYSTEM CHARGING 1

AND RECLAMATION on Page 80-130-1) 2
Remove the engine side covers. (See ENGINE SIDE 2

COVER on Page 50-100-1)
Remove the grill. (See Removal And Installation on Page

50-91-1)
Remove the air cleaner. (See Removal And Installation

on Page 70-40-1)
P-87939
Remove the battery. (See Removing And Installing
Battery on Page 60-20-1)
Remove the thumb screw (Item 1) and remove both
Figure 80-150-1 debris screens (Item 2) [Figure 80-150-2]
Figure 80-150-3
1
P-87938
P-87940
Reposition the air cleaner hose (Item 1) [Figure 80-150-
1] (As shown).
Remove the bolt (Item 1) from both ends of the cover
(Item 2) [Figure 80-150-3].

1112 of 1161
CONDENSER (CONT’D) Figure 80-150-6
Figure 80-150-4 2
P-87946
Remove the bolt (Item 1) and HIGH pressure hose (Item

P-87941 2) [Figure 80-150-6] from the condensor.
Figure 80-150-7
Figure 80-150-5
1
1
P-87947
P-87942 Remove the bolt (Item 1) and LOW pressure hose (Item
2) [Figure 80-150-7] from the condensor.
Unplug the connector (Item 1) [Figure 80-150-5] from

the pressure switch.

1113 of 1161
CONDENSER (CONT’D) Figure 80-150-10
Figure 80-150-8
P-87945
Remove the top bolt (Item 1) [Figure 80-150-10] (Both

P-87943 sides.)
Figure 80-150-11
Remove the bolt (Item 1) and reposition the horn (Item 2)
[Figure 80-150-8].
Figure 80-150-9 1
P-87948
Lift and remove the condensor (Item 1) [Figure 80-150-

P-87944 7].
Remove the lower bolt (Item 1) [Figure 80-150-9] (Both

sides.)

1114 of 1161
1115 of 1161
RECEIVER / DRIER Figure 80-160-3
Remove the condensor. (See Removal And Installation

on Page 80-150-1)
Figure 80-160-1
P-89091
1
Installation: Apply a thin film of A/C oil to the surface of a

new O-ring before installation [Figure 80-160-3].
P-87949
Figure 80-160-2
P-87950
Remove the receiver / dryer from the condensor by

pulling down [Figure 80-160-2].

1116 of 1161
1117 of 1161
HVAC CONTROL PANEL Figure 80-170-3

Page 50-200-1.)
Figure 80-170-1
1
2
1
P-87873
Remove the two electrical connectors (Item 1) [Figure

80-170-3].
Figure 80-170-4
P-87871
Pry up on the clip (Item 1) (as shown) and remove the

black cable and end (Item 2) [Figure 80-170-1] from the
fan potentiometer.
Figure 80-170-2 1
1 2
1
P-87874
Remove the two screws (Item 1) [Figure 80-170-4] (Both

ends.)
P-87872
Pry up on the clip (Item 1) (as shown) and remove the

grey cable and end (Item 2) [Figure 80-170-2] from the
potentiometer.

1118 of 1161
HVAC CONTROL PANEL (CONT’D)
Figure 80-170-5
P-87875
Remove the HVAC control panel [Figure 80-170-5].

1119 of 1161
PRESSURE SWITCH
Open the tailgate.
Figure 80-180-1
P-87331

from the pressure switch.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0500
Remove the pressure switch (Item 2) [Figure 80-180-1]

from the A/C high pressure hose.

1120 of 1161
1121 of 1161
EVAPORATOR / HEATER UNIT Figure 80-190-2
Drain the cooling system. (See Removing And Replacing


AND RECLAMATION on Page 80-130-1.) 1
WARNING 1
In the event of a leak, wear safety goggles. Escaping P-87827

gas. Remove the two A/C hoses (Item 1) [Figure 80-190-2]
W-2371-0500 from the expansion valve.
Cap and plug the hoses and expansion valve fittings with
the proper A/C caps and plugs.
Page 50-200-1.)
Figure 80-190-3
Remove the front air duct. (See Removal And Installation
on Page 80-191-1.) 1
Remove the side air duct. (See Removal And Installation
on Page 80-192-1.) 2
Figure 80-190-1
P-87828
1 Unplug the two connectors (Item 1) and remove the third

connector (Item 2) [Figure 80-190-3] from the evaporator
/ heater unit.
P-87826

1122 of 1161
EVAPORATOR / HEATER UNIT(CONT'D) Figure 80-190-6
Figure 80-190-4
2
2
3
1
1
1
P-87832
3
Remove the rear mounting nut (Item 1) [Figure 80-190-
P-87829 6].
Figure 80-190-7
Remove the two screws (Item 1) “P” clamps (Item 2) and
unplug the two connectors (Item 3) [Figure 80-190-4].
Figure 80-190-5
P-87831
2
1
Remove the left rear mounting nut (Item 1) [Figure 80-
P-87830 190-7].
Remove the drain tube (Item 1) from the tee fitting (Item
2) [Figure 80-190-5].

1123 of 1161
EVAPORATOR / HEATER UNIT(CONT'D) Figure 80-190-10
Figure 80-190-8
1 2
1
P-87839
1
Remove the drain tube (Item 1) from the tee fitting (Item
P-87836 2) [Figure 80-190-10].
Figure 80-190-11
Remove the two front mounting nuts (Item 1) [Figure 80-
190-8].
Figure 80-190-9
P-87838
Remove the right rear mounting nut (Item 1) [Figure 80-

P-87837 190-11].
Remove the two heater hoses (Item 1) [Figure 80-190-

9].

1124 of 1161
EVAPORATOR / HEATER UNIT(CONT'D)
Figure 80-190-12
P-87840
Remove the evaporator / heater unit [Figure 80-190-12].

1125 of 1161
EVAPORATOR / HEATER UNIT COVER Figure 80-191-3

2
Page 50-200-1.) 3

on Page 80-192-1.)
1
1
on Page 80-193-1.)
Figure 80-191-1 3
1 P-87829
2
Remove the two screws (Item 1) “P” clamps (Item 2) and
unplug the two connectors (Item 3) [Figure 80-191-3].
Figure 80-191-4
1
1
P-87828
1
Unplug the two connectors (Item 1) and remove the third 2

connector (Item 2) [Figure 80-191-1] from the cover. 2
Figure 80-191-2
P-87841
1 Carefully cut the foam seal (Item 1) at the housing seams

(Item 2) [Figure 80-191-4] using a sharp knife.
Repeat the above procedure on all four openings.
P-87830
Remove the thermostat connector (Item 1) [Figure 80-

191-2] from the cover by pushing upward.

1126 of 1161
EVAPORATOR / HEATER UNIT COVER (CONT'D)
Figure 80-191-5
P-87841
Remove the 39 screws [Figure 80-191-5].
Figure 80-191-6
P-87845
Remove the cover [Figure 80-191-6].

1127 of 1161
FRONT AIR DUCT Figure 80-192-3

Page 50-200-1.)
Figure 80-192-1
P-87835
Remove the air duct assembly [Figure 80-192-3].
P-87833
Remove the screw (Item 1) [Figure 80-192-1] from the

air duct (both sides).
Figure 80-192-2
P-87834
Remove the bolt (Item 1) [Figure 80-192-2] from the duct

(both sides).
Remove any tie straps as needed.

1128 of 1161
1129 of 1161
SIDE AIR DUCT Figure 80-193-3

1
Page 50-200-1.)
Figure 80-193-1
2
3 P-87824
2 Remove the bolt (Item 1) and clamp assembly (Item 2)

[Figure 80-193-3] from the left air duct.
1 Reposition the A/C hoses (Item 3) [Figure 80-193-3].

P-87822
Figure 80-193-4
Remove the temperature control cable (grey) (Item 1) 2

from the cover and cable end (Item 2) [Figure 80-193-1]
from the door linkage.
Figure 80-193-2 3
1
1
2 P-87825
Remove the two bolts (Item 1), screw (Item 2) and air
1 duct (Item 3) [Figure 80-193-4].
P-87823 The procedure for the right side air duct is the same.
Remove the selector control cable (black) (Item 1) from

the cover and the cable end (item 2) [Figure 80-193-2]
from the door linkage.

1130 of 1161
1131 of 1161
THERMOSTAT Figure 80-200-2
Remove the cab cover. (See Removal And Installation on 1

Page 50-200-1.)

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
evaporator / heater unit from the tractor.
Figure 80-200-1
P-87852
Remove the clip (Item 1) [Figure 80-200-2] from the

2 evaporator coil.
P-87846
Open the clip (Item 1) and remove the thermostat probe

(Item 2) [Figure 80-200-1].
NOTE: Mark the location of the clip before removal.

Reinstall the clip in the same location. Moving
the thermostat probe location in the
evaporator coil will affect air conditioning
performance.

1132 of 1161
1133 of 1161
EXPANSION VALVE Figure 80-210-2

2
1
Remove the left side air duct. (See Removal And
WARNING
In the event of a leak, wear safety goggles. Escaping P-87827
gas. Remove the two bolts (Item 1) and remove the expansion
W-2371-0500 valve (Item 2) [Figure 80-210-2].
Figure 80-210-3
Figure 80-210-1
P-87850
P-87827
The expansion valve is not serviceable and must be

Remove the nut (Item 1) and remove the two A/C hoses
replaced as an assembly [Figure 80-210-3].
(Item 2) [Figure 80-210-1] from the expansion valve.
Cap and plug the hoses and the expansion valve fittings
with proper A/C caps and plugs.

1134 of 1161
1135 of 1161
EVAPORATOR Figure 80-220-2


Page 50-200-1.)
Remove the expansion valve. (See Removal And


P-87856
NOTE: Mark the location of the probe before removal.
Reinstall the probe in the same location.
Moving the thermostat probe location in the Inspect the evaporator coil [Figure 80-220-2] for leaks
evaporator coil will affect air conditioning and replace as needed. Clean with low water or air
performance. pressure.
Figure 80-220-1
P-87854
Lift the evaporator (Item 1) [Figure 80-220-1] straight up

from the evaporator / heater unit.

1136 of 1161
1137 of 1161
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
Decimal And Millimeter Equivalent Chart. . . . . . . . . . . SPEC-40-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . SPEC-40-2
CT335 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3

Ballast (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Ballast (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-8
Compact Tractor Loader Lift Capacity . . . . . . . . . . . . . SPEC-10-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Dimensions (Standard Machine) . . . . . . . . . . . . . . . . . SPEC-10-3
Dimensions (With Optional Loader) . . . . . . . . . . . . . . . SPEC-10-4
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Loader (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-8
Maximum Drawbar Tongue Weight . . . . . . . . . . . . . . . SPEC-10-2
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Power Take-Off (PTO) System (Mid-PTO Optional) . . SPEC-10-7
Power Take-Off (PTO) System (Rear-PTO) . . . . . . . . . SPEC-10-7
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Three-Point Hitch Specifications . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-8
Towing Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-30-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
SPECIFICATIONS
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-20-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-20-1
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . SPEC-50-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
SPEC-1 CT335 Service Manual

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SPEC-2 CT335 Service Manual
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COMPACT TRACTOR CAPACITIES
Compact Tractor Loader Lift Capacity Ballast (Rear)
The compact tractor lift capacity with the loader and The correct rear ballast must be installed on the compact
standard bucket, correct rear ballast, and tires with the tractor for maximum loader lift capacity. Install a three-
correct load rating is listed in the chart below. point hitch ballast box (see chart below) and fill the rear
tires with liquid ballast. Both compact tractor rear tires
The following items will reduce the loader lift capacity:
must be filled to 75% full with calcium chloride mixture of
• Use of larger buckets or attachments which moved 5 lb. / Gal. of water (or 0,6 kg / liter of water).
the load center forward.
• The loader is equipped with the optional Bob-Tach
mounting system.
• If the weight of the rear ballast is reduced.
• Tires with a lower load rating are used.
Loader Lift Capacity Loader Lift Capacity

With Pin-On Bucket - With Optional Bob-Tach Mounting System -
Configuration 1 Configuration 2
C B A C D
B
Loader Lift Capacity

With Optional Bob-Tach Mounting System and Pallet Forks -
Configuration 3
C B E
A - Loader Lift Capacity at full height with Bucket (Model 8TL loader and Liquid Ballast B and Rear Ballast C installed) =
Measured at bucket pivot = 1650 lb. (748 kg)
Measured at 19.68 in. (500 mm) in front of pivot = 1300 lb. (589 kg)
Bucket weight - 68 in. (1727 mm) = 252 lb. (114 kg)
B - Liquid Ballast Weight =
Both rear tires filled to 75% full with calcium chloride mixture of 5 lb. / gal. of water (0,6 kg / liter of water).
C - Rear Ballast Weight = 810 lb. (366 kg)
D - Loader Lift Capacity at full height with Optional Bob-Tach Mounting System (Model 8TL loader and Liquid Ballast B
and Rear Ballast C installed) =
Bucket weight - 68 in. (1727 mm) = 250 lb. (113 kg)
E - Loader Lift Capacity at full height with Optional Bob-Tach Mounting System and Pallet Forks (Model 8TL loader and
Liquid Ballast B and Rear Ballast C installed) =
Measured at 24 in. (610mm) in front of pallet fork frame = 1000 lb. (453 kg)
Pallet Fork Frame and 42 in. (1067 mm) forks - weight = 364 lb. (165 kg)
SPEC-10-1 CT335 Service Manual

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COMPACT TRACTOR CAPACITIES (CONT’D) Towing Weight
Three-Point Hitch Specifications The maximum tow weight including the weight of the
trailer is (listed in the chart below).
Examples of the lift capacity of the three-point hitch with
front ballast are listed in the chart below.
Maximum Drawbar Tongue Weight
The following items will reduce the Three-Point Hitch lift
capacity: The maximum vertical load that can be applied to the
drawbar hitch is (listed in the chart below).
• Implements are used which move the load center
rearward. Ballast (Front)
The front mounted loader with attachment can be used

• If the weight of the front ballast is reduced. as a front ballast. A front ballast kit can be installed on
the front of the compact tractor (see chart below).
Three-Point Hitch Lift Capacity with Three-Point Hitch Lift Capacity with
NO Front Ballast - Configuration 1 Front Ballast Kit - Configuration 2
A B D
Three-Point Hitch Lift Capacity with

Loader as Front Ballast - Configuration 3 Towing
C
E
G
F
B-23617
A - Three-Point Hitch Lift Capacity (with NO front ballast)

Measured at 24 in. (610 mm) behind the lift points = 850 lb. (385 kg).
B - Three-Point Hitch Lift Capacity (with Front Ballast Kit D installed)
C - Three-Point Hitch Lift Capacity (With Front Ballast Weight E installed - 8TL loader and bucket)
D - Front Ballast Kit Weight = 300 lb. (136 kg)
E - Front Ballast Weight = 8TL loader and bucket installed
F - Maximum Drawbar Tongue Weight = 1433 lb. (650 kg)
G - Tow Weight (Including weight of trailer) = 7716 lb. (3500 kg)

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CT335 SPECIFICATIONS
Dimensions (Standard Machine)

• Dimensions are given for a compact tractor equipped with standard tires. All dimensions are shown in inches.
Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.
G H J K
E D
C
69.3 in.
(1761 mm)
112.4 in.
(2855 mm)
MS-2574S
134.3 in.
(3411 mm)
AG TIRES GENERAL PURPOSE TIRES TURF TIRES
A 93.6 (2377 mm) 91.7 (2329 mm) 91.3 (2319 mm)
B 81.0 (2057 mm) 79.1 (2009 mm) 78.7 (1999 mm)
C 33.0 (838 mm) 31.1 (790 mm) 30.7 (780 mm)
D 13.6 (345 mm) 11.9 (302 mm) 11.5 (292 mm)
D* 11.1 (282 mm) 9.4 (239 mm) 9.0 (229 mm)
E 6.2 (157 mm) 4.3 (109 mm) 3.9 (99 mm)
F 63.1 (1602 mm) 61.2 (1554 mm) 60.8 (1544 mm)
G N/A 76.9 (1953 mm) N/A
H N/A 54.9 (1394 mm) N/A
J + 54.5 (1384 mm) 48.8 (1240 mm) 51.3 (1303 mm)
J 50.2 (1275 mm) N/A N/A
K+ 66.9 (1699 mm) 64.8 (1646 mm) 65.3 (15659 mm)
K 62.6 (1590 mm) N/A N/A
* Equipped with optional mid-PTO, + Adjustable Rims set to the maximum width.

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CT335 SPECIFICATIONS (CONT’D)
Dimensions (With Optional Loader)
• Dimensions are given for a compact tractor equipped with General Purpose tires and the optional loader and bucket
and may vary with other types of buckets and tires. All dimensions are shown in inches. Respective metric dimensions
are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.
• Always use tires with the proper load rating.
68.5 in.
(1740 mm)
A
50°
B 21.4 in.
(544 mm)
C
22°
69.4 in.
E
(1763 mm)
MS-2574S
AG TIRES GENERAL PURPOSE TIRES TURF TIRES

A 118.3 (3005 mm) 116.4 (2957 mm) 116.0 (2946 mm)
B 98.1 (2492 mm) 96.2 (2443 mm) 95.8 (2433 mm)
C 92.3 (2344 mm) 90.4 (2296 mm) 90.0 (2286 mm)
D 77.5 (1969 mm) 75.6 (1920 mm) 75.2 (1910 mm)
E 2.1 (53 mm) 4.0 (102 mm) 4.4 (112 mm)
TURNING RADIUS (WITHOUT BRAKES) = 126 in. (3200 mm)

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Performance
Loader Lift Capacity at full height

(Model 8TL loader and correct rear ballast (See Ballast (Rear) on Page SPEC 10-1.)
Three-Point Hitch Lift Capacities

Lift capacity at 24 in. (610 mm) behind lift point (per SAE J283) = 1700 lb. (771 kg)
Maximum hydraulic lift capacity at 24 in. (610 mm) behind lift points
(measured at 15 in. (381 mm) above ground)* = 2475 lb. (1122 kg)
*NOTE: Hydraulic three-point lift capacity will vary depending on lift point height.
Drawbar Tongue Weight (Max) 1433 lb. (650 kg)

Tow Weight (Max) 7716 lb. (3500 kg)
Operating Weight
Standard Machine 3668 lb. (1664 kg)
Controls
Vehicle Steering Steering Wheel

Speed Range Lever in left console (Low - Neutral - Medium - Neutral - High)
Transmission Hydrostatic - dual foot pedals (forward and reverse) on the right floor console
Loader Hydraulics (If Equipped)
- Lift and Tilt Joystick Control Lever
Rear Remote Hydraulics (If Equipped)
- Rear Auxiliary Lever(s) in right console
Rear-PTO Switch in dash console
Mid-PTO (If Equipped) Lever below operator’s seat and switch in dash console
Engine Hand lever engine speed control; key-type starter switch
Starting Aid Automatic Glow Plugs - key activated
Brake Pedals Two foot pedals activate two wet disc (on left floor console)
Parking Brake Lever activated with brake pedals engaged

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Engine
Make / Model Daedong 3B183LWH Interim Tier IV

Fuel / Cooling Diesel / Liquid (Indirect Injection)
Horsepower, Maximum 38 HP (28,3 kW) @ 2600 RPM
High Idle RPM 2800 RPM
Low Idle RPM 1000 RPM
Number of Cylinders 3
Displacement 111.6 cu. in. (1,83 L)
Bore/Stroke 3.42 / 4.03 in. (87,0 mm / 102,4 mm)
Lubrication Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge (Dual Element)
Ignition Diesel-Compression
Engine Coolant Ethylene Glycol / Water Mixture
Starting Aid Automatic Glow Plugs
Hydraulic System
Pump Type Tandem Engine driven, gear type

Steering Pump Capacity 6.6 GPM (25,0 L/min.) @ 2600 RPM
Implement Pump Capacity 7.9 GPM (29,9 L/min.) @ 2600 RPM
System Relief at Quick Couplers 2560 PSI (177 bar)
Filter (Hydraulic) Full flow replaceable, 88 - 96 micron pore size
Steering Cylinders single acting,
Bore: 1.72 in. (43,8 mm)
Rod: 1.38 in. (35,0 mm)
Stroke: 7.28 in. (185,0 mm)
Control Valve - Loader (if equipped) Joystick control lever operated, open center, series type with float detent on lift.
Control Valve - Rear Remote Auxiliary Lever(s) operated, open center, series type.
Hydraulic (if equipped) (Full flow detentl couplers [A and C]) (Optional)
Fluid Lines Metric tubelines, hoses and fittings
Fluid Type (Hydraulic / Hydrostatic / FLUID, Transmission / Differential
Transmission)
Electrical
Alternator Belt driven, 50 amps, open

Battery 12 volts, 600 cold cranking amps @ 0° F (-18° C), 115 minute reserve capacity
Starter 12 volts, gear reduction type, 3.35 HP (2,5 kW)
Instrumentation Gauges: Engine Coolant Temperature, Fuel Gauge, Engine RPM
LCD Display: Hourmeter
Warning lights (Red): Parking Brake, Low Engine Oil Pressure, Low Battery Voltage,
Unlocked Brake Pedal.
Indicator Lights (Amber): Glow Plugs Activated, PTO Activated (Rear-PTO and Mid-PTO)
Front Wheel Assist, Cruise Control.
Indicator Lights (Green): Left and Right Turn Indicator, L - N - M - N - H.
Indicator Lights (Blue): High Beam Indicator.

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Power Take-Off (PTO) System (Rear-PTO)
Rear-PTO Live - SAE 1-3/8 inch 6 tooth spline

PTO Type TYPE 1 per ASABE S203
Operating Speed 540 RPM @ 2493 RPM engine speed
PTO Power 26.5 HP (19,7 kW)
Power Take-Off (PTO) System (Mid-PTO Optional)
Mid-PTO Live - 1.0 inch 15 tooth spline ASABE S431

Operating Speed 2000 RPM @ 2473 RPM engine speed
PTO Power
Drive System
Main Drive Fully hydrostatic, 4-wheel drive (rear wheel drive with front wheel assist)
Transmission Hydrostatic Drive with Low - Medium - High speed select lever
Final Drive Front and rear differentials
Wheel Bolts / Nuts Torque 166 ft. lb. (225 N•m)
Differential Differentials provided in both axles.
Rear includes pedal activated differential lock
Differential Fluid (Front) SAE 80W-90 gear lube
Differential Fluid (Rear) See Hydraulic / Hydrostatic / Transmission information
Travel Speed Range AG Tires Turf Tires General Purpose Tires

Forward and Reverse Low Range: 0 - 3.68 mph Low Range: 0 - 3.39 mph Low Range: 0 - 3.47 mph
speed: (0 - 5,9 km / hr.), (0 - 5,5 km / hr.), (0 - 5,6 km / hr.),
Medium Range: 0 - 6.35 mph Medium Range: 0 - 5.84 mph Medium Range: 0 - 5.98 mph
(0 - 10,2 km / hr.), (0 - 9,4 km / hr.), (0 - 9,6 km / hr.),
High Range: 0 - 15.65 mph High Range: 0 - 14.39 mph High Range: 0 - 14.73 mph
(0 - 25,2 km / hr.) (0 - 23,2 km / hr.) (0 - 23,7 km / hr.)
Steering
Steering Type Load Reaction Power Steering

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Capacities
Fuel 11.9 Gal. (45,0 L)

Engine Lubrication & Filter 5.8 qt. (5,5 L)
Engine Cooling System 8.4 qt. (7,9 L)
Hydraulic/Hydrostatic/Transmission 11.1 Gal. (42,0 L)
Reservoir
Front Axle 8.0 qt. (7,6 L) each
Tires
FRONT TIRES REAR TIRES

Standard Ag 7 - 16 (10 ply) Ag 12.4 - 24 (8 ply)
Optional Turf 27 x 8.5 -15 (10 ply) Turf 41 x 14 - 20 (4 ply)
General Purpose 27 x 10.5 - 15 (6 ply) General Purpose 43 x 16 - 20 (4 ply)
Recommended Inflation Pressure Without Loader With Loader * Without Loader With Loader
Ag 36 PSI (248 kPa) 60 PSI (414 kPa) 24 PSI (165 kPa) 32 PSI (221 kPa)
Turf 30 PSI (207 kPa) 60 PSI (414 kPa) 25 PSI (172 kPa) 25 PSI (172 kPa)
General Purpose 45 PSI (310 kPa) 45 PSI (310 kPa) 20 PSI (138 kPa) 20 PSI (138 kPa)
* Reduce travel speed to 5 MPH maximum with a fully loaded bucket. Maximum
tire inflation pressures for loader use are based on a 5 MPH cyclic load.
NOTE: Always use tires with the proper load rating.
NOTE: Foam filled tires are NOT approved for use on the Compact Tractor. Axle damage may occur with foam
filled tires. Warranty will be void if foam filled tires are used on this machine.
Loader (If Equipped)
System Relief at Quick Couplers 2560 PSI (177 bar)

Hydraulic Cylinders Double-acting; lift and tilt
Bore Diameter: Lift Cylinder 2.0 in. (50,8 mm)
Tilt Cylinder 2.0 in. (50,8 mm)
Rod Diameter: Lift Cylinder 1.375 in. (35 mm)
Tilt Cylinder 1.375 in. (35 mm)
Stroke: Lift Cylinder 17.69 in. (449 mm)
Tilt Cylinder 17.69 in. (449 mm)

1147 of 1161
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
Thread
SAE Grade 5 SAE Grade 8
Size
in-lb. 0.250 80 - 90 110 - 120
(N•m) (9,0 - 10,2) (12,4 - 13,6)
0.3125 180 - 200 215 - 240
(20,3 - 22,6) (24,2 - 27,1)
ft.-lb. 0.375 25 - 28 35 - 40
(N•m) (34 - 38) (47 - 54)
0.4375 40 - 45 60 - 65
(54 - 61) (81 - 88)
0.500 65 - 70 90 - 100
(88 - 95) (122 - 136)
0.5625 90 - 100 125 - 140
(122 - 136) (170 - 190)
0.625 125 - 140 175 - 190
(170 - 190) (240 - 260)
0.750 220 - 245 300 - 330
(300 - 330) (410 - 450)
0.875 330 - 360 475 - 525
(450 - 490) (645 - 710)
1.000 475 - 525 725 - 800
(645 - 710) (985 - 1085)
1.125 650 - 720 1050 - 1175
(880 - 975) (1425 - 1600)
1.250 900 - 1000 1475 - 1625
(1200 - 1360) (2000 - 2200)
1.375 1200 - 1350 2000 - 2200
(1630 - 1830) (2720 - 2980)
1.500 1500 - 1650 2600 - 2850
(2040 - 2240) (3530 - 3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680 - 5150)
1.750 2500 - 2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150 - 3500 5500 - 6100
(4270 - 4750) (7450 - 8300)
2.000 3800 - 4200 6500 - 7200
(5150 - 5700) (8800 - 9800)

1148 of 1161
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
MATERIAL
THREAD SIZE
(DIA. X PITCH) HEAD MARK
HEAD MARK 4 HEAD MARK 7 HEAD MARK 9
(NONE)
M6 6 - 7 ft.-lb. 6 - 7 ft.-lb. 7 - 8 ft.-lb. 9 - 10 ft.-lb.
0.24 in. (6 mm) (8 - 9 N•m) (8 - 9 N•m) (10 - 11 N•m) (12 - 14 N•m)
M8 13 - 15 ft.-lb. 13 - 15 ft.-lb. 17 - 20 ft.-lb. 22 - 25 ft.-lb.
0.31 in. (8 mm) (18 - 21 N•m) (18 - 21 N•m) (24 - 27 N•m) (30 - 34 N•m)
M 10 29 - 33 ft.-lb. 29 - 33 ft.-lb. 36 - 41 ft.-lb. 45 - 52 ft.-lb.
0.39 (10 mm) (39 - 45 N•m) (39 - 45 N•m) (48 - 56 N•m) (61 - 71 N•m)
0.47 (12 mm) (63 - 73 N•m) (63 - 73 N•m) (76 - 90 N•m) (103 - 117 N•m)
0.55 in. (14 mm) (108 - 125 N•m) (108 - 125 N•m) (124 - 147 N•m) (167 - 204 N•m)
0.63 in. (16 mm) (167 - 191 N•m) (167 - 191 N•m) (197 - 225 N•m) (260 - 304 N•m)
0.71 (18 mm) (246 - 284 N•m) (246 - 284 N•m) (275 - 318 N•m) (344 - 402 N•m)
0.79 (20 mm) (334 - 392 N•m) (334 - 392 N•m) (368 - 431 N•m) (491 - 568 N•m)

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HYDRAULIC FLUID SPECIFICATIONS
Specifications
Use Bobcat transmission / differential fluid.
DO NOT use automatic transmission fluids in the

compact tractor or permanent damage to the hydraulic
system will result.
Bobcat transmission / differential fluid is available. (See

FUEL, COOLANT AND LUBRICANTS on Page SPEC-
50-1.)
WARNING
W-2072-0807
When temperatures below zero degree F (-18° C) are

common, the compact tractor must be kept in a warm
building. Extra warm-up time must be used each time the
compact tractor 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 pump can cause damage in less than
60 seconds.
WARNING
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285

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1151 of 1161
CONVERSIONS
Decimal And Millimeter Equivalent Chart

1152 of 1161
CONVERSIONS (CONT’D)
U.S. To Metric Conversion Chart

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FUEL, COOLANT AND LUBRICANTS
Chart
Use this chart for correct selection of Fuel, Coolant and Lubricants.
RECOMMENDED SAE VISCOSITY NUMBER CAPACITY

RESERVOIR KIND OF FLUID
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE) REFILL
Engine oil w/ filter *Use SAE 5.8 qt. (5,5 L)
Viscosity Number
as Listed With
API Classification
CD or Better
Fuel Tank Diesel Fuel Temp. F° No. 2 No.1 11.9 Gal.

+15° (9°) 100% 0% (45,0 L)
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
Cooling System **Coolant Mixture 8.4 qt.
(7,9 L)
Transmission / Bobcat P/N 6687120 (1 qt.) Tank Cap. 11.1
Differential P/N 6988098 (1 Gal.) Gal. (42,0 L)
Fluid P/N 6988099 (1.5 Gal.)
Front Axle Gear Lube SAE-90W 8.0 qt. (7,6 L)
*ENGINE OIL SPECIFICATIONS ** COOLANT MIXTURE
When fuel sulphur content is less than 0.5% change the Ethylene Glycol (Factory Installed)
engine oil and filter as shown in the SERVICE
SCHEDULE. (See Chart on Page 10-70-1.) Add premixed coolant; 50% water and 50% Ethylene
glycol to the recovery tank if the coolant level is low.
Change engine oil and filter according to the following
chart if fuel sulphur content is above 0.5%. One gallon and one pint of Ethylene glycol mixed with
one gallon of water is the correct mixture of coolant to
FUEL SULPHUR CHANGE INTERVAL OF provide a -34° F (-37° C) freeze protection.
CONTENT ENGINE & OIL FILTER
Use a refractometer to check the condition of Ethylene
0.5 to 1.0% 1/2 of Regular Interval glycol in the cooling system.
Above 1.0% 1/4 of Regular Interval

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ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: CT335-1

Date: 15 November 2008
Product: Bobcat Compact Tractor
Model: CT335
Manual No: 6987078 (11-08)
The following Sections are a revision to the above Service Manual
. COVER 60-01
ALPHABETICAL INDEX ELECTRICAL SCHEMATICS
FOREWORD 60-10
60-52 ADDED
10-01 60-110 ADDED
10-81 ADDED 60-120 ADDED
10-110
10-161 ADDED 70-10
70-50
20-01
20-60 80-01 ADDED
20-61 80-10 ADDED
20-140 80-30 ADDED
80-40 ADDED
50-01 80-50 ADDED
50-10 80-60 ADDED
50-20 80-70 ADDED
50-40 80-90 ADDED
50-70 80-100 ADDED
50-110 80-120 ADDED
50-120 80-130 ADDED
50-130 80-150 ADDED
80-210 ADDED
80-220 ADDED
SPEC-10 ADDED
Printed in U.S.A.
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ROUTE TO
ATTENTION
PARTS MANAGER

Date: 15 November 2009
Model: CT335
Manual No: 6987078 (11-09)
. COVER
MAINTENANCE SAFETY 60-01
ALPHABETICAL INDEX 60-10
FOREWORD 60-30
60-130 ADDED
10-01 60-140 ADDED
10-130
10-140 70-10
70-50
20-01
20-10 SPEC-20
20-40
20-100
20-120
20-130
20-140
20-160
30-20
30-30
40-50
40-80
40-90
40-100
50-01
50-21
50-121
50-180
Printed in U.S.A.
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ROUTE TO
ATTENTION
PARTS MANAGER

Date: 15 December 2009
Model: CT335
Manual No: 6987078 (12-09)
. COVER 20-62
ALPHABETICAL INDEX 20-80
FOREWORD 20-90
20-100
10-01 20-120
10-60 20-140
10-61 20-150
10-70
10-81 30-01
10-130 30-10
10-161 30-20
10-170 30-30
10-180 30-40
10-200 30-50
10-210 30-60
10-220
10-230 40-01
10-240 40-10
10-241 40-21
10-250 40-30
10-251 40-31
10-260 40-40
10-270 40-50
10-280 40-60
10-290 40-61
40-70
Hydraulic Schematics 40-71
40-81
20-01 40-90
20-40 40-91
20-41 40-100
20-50 40-110
20-51
Continued on Next Page
Printed in U.S.A.
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50-01
50-20
50-21
50-30
50-31
50-50
50-70
50-71
50-80
50-110
50-111
50-130
50-131
50-132
50-180
50-200
50-230
50-231
Electrical Schematics
60-01
60-10
60-40
60-80
60-81
60-90
60-91
60-130
60-140
60-150
70-01
70-10
70-21
70-50
70-70
70-110
70-111
70-130
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Bobcat CT335 Compact Tractor Service Manual

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Bobcat CT335 Compact Tractor Service Manual

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Service Manual

CT335 Compact Tractor

HST - S/N ABH811001 & Above

6987078 (12-09) Printed in U.S.A. © Bobcat Company 2009

P-90216 B-23NEW B-23552

WRONG WRONG WRONG

B-23556 B-23525 B-23590

WRONG WRONG WRONG

B-235517 B-23564 B-6589

AIR CLEANER ........................................................ 70-01 ENGINE SPEED CONTROL PEDAL

CT335 Service Manual

HYDROSTATIC PUMP TESTING STEERING CYLINDER........................................... 20-01

CT335 Service Manual

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X HYDROSTATIC

COMPACT TRACTOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . .XII

COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL LOADER DRIVE SYSTEM

COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL THREE-

COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL CAB). . XV

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 ELECTRICAL

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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

I CT335 Service Manual

2. Check that ROPS mounting 9. Attachment locking pins must

4. Machine signs (decals) must 11. Check for correct function of

5. Travel control pedal(s) and 12. Check hydraulic fluid level,

6. Check for correct function of 13. Inspect for fuel, oil or

7. The parking brake must 14. Lubricate the compact tractor.

II CT335 Service Manual

17. Check the electrical charging 22. Check Safety Interlock

III CT335 Service Manual

IV CT335 Service Manual

V CT335 Service Manual

Use Safety Rules

• Read and follow instructions in the machine and the

• Check for underground lines before operating

• In addition to the design and configuration of

• Check that the implement is securely fastened to the

• Depress brake pedals (or make sure parking brake is

• Always start the machine from the operator’s seat.

• Operate the attachment / implement according to the

• The attachment / implement must be used ONLY on

• DO NOT make any adjustments or repairs on the

• Keep shields and guards in place. Replace if

VI CT335 Service Manual

• Use increased caution on slopes and near banks and

VII CT335 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Check the spark arrestor exhaust system regularly to

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

VIII CT335 Service Manual

Welding And Grinding

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Know where fire extinguishers and first aid kits are

IX CT335 Service Manual

Always use the serial number of the compact tractor Figure 2

The engine serial number is located on the top of the

P-78999 Loader Serial Number (Optional)

The compact tractor serial number plate is located on the

Explanation of machine Serial Number: