03 06 SM B250 LR PDF

B250
B Series
Service
Manual
S/N 572211001 & Above
6902715 (3-06)
Printed in U.S.A.
Bobcat Company 2006
MAINTENANCE SAFETY
WARNING
Instructions are necessary before operating or servicing machine. Read and

understand the Operation & Maintenance Manual, Operators 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
W-2003-0903
instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT
B-10731a
Never service the Bobcat Loader

Backhoe without instructions.
CORRECT
CORRECT
B-16768
B-16738
Always use an approved lift arm

support device when servicing the
loader backhoe with the lift arms
raised. Replace the lift arm support
device if damaged or missing.
Disconnecting or loosening any
hydraulic tubeline, hose, fitting
component, or part failure can
cause lift arms or backhoe boom
to drop.
Cleaning and maintenance are

required daily.
NEVER modify equipment or add
attachments not approved by
Bobcat.
WRONG
WRONG
WRONG
B-16730
B-16746
B-16719
Have good ventilation when

welding or grinding painted
parts.
Wear dust mask when grinding
painted parts. Toxic dust and gas
can be produced.
Vent exhaust to outside when

engine must be run for service.
Exhaust system must be tightly
sealed. Exhaust Fumes can kill
without warning.
Never work on loader backhoe

with lift arms raised unless
supported by an approved lift
arm support device.
Always lower the backhoe
bucket to the ground before
doing any maintenance.
WRONG
WRONG
WRONG
B-16571
B-16731
B-6589
Stop, cool and clean engine of

flammable
materials
before
checking fluids.
Never service or adjust machine
with the engine running unless
instructed to do so in the
manual.
Avoid contact with leaking
hydraulic fluid or diesel fuel
under pressure. It can penetrate
the skin or eyes.
Never fill fuel tank with engine
running, while smoking or when
near open flame.
Keep body, jewelry and clothing

away
from
moving
parts,
electrical contact, hot parts and
exhaust.
Wear eye protection to guard
from battery acid, compressed
springs, fluids under pressure
and flying debris when engines
are running or tools are used.
Use eye protection approved for
type of welding.
Keep engine cover closed except
for service. Close and latch
engine cover before operating
the loader backhoe.
Lead-acid batteries produce

flammable and explosive gases.
Keep arcs, sparks, flames and
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin on contact.
Wear protective clothing. If acid
contacts body, flush well with
water. For eye contact flush well
and get immediate medical
attention.
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.
MSW16-0805
ALPHABETICAL INDEX
AIR CLEANER ........................................................ 70-01
AIR CLEANER SERVICE ....................................... 10-01
ALTERNATOR ........................................................ 60-01
ALTERNATOR BELT............................................... 10-01
APPROVED LIFT ARM SUPPORT DEVICE .......... 10-01
ARM CYLINDER ..................................................... 20-01
ARM ........................................................................ 50-01
AXLE AND DIFFERENTIAL (FRONT) .................... 40-01
AXLE AND DIFFERENTIAL (REAR) ...................... 40-01
AXLE TOE-IN.......................................................... 10-01
BACKHOE CONTROL VALVE................................ 20-01
BATTERY................................................................ 60-01
BOB-TACH.............................................................. 50-01
BOOM ..................................................................... 50-01
BOOM CYLINDER .................................................. 20-01
BOOM LOCK PIN ................................................... 10-01
BRAKE CALIPER ................................................... 40-01
BUCKET ................................................................. 50-01
BUCKET CYLINDER .............................................. 20-01
CAB DOOR ............................................................. 50-01
CAB LIGHTS........................................................... 60-01
COMPONENTS ...................................................... 80-01
CONVERSIONS ................................................SPEC-01
DRIVESHAFT ......................................................... 40-01
DROP BOX ............................................................. 40-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENCLOSED CAB .................................................... 50-01
ENGINE .................................................................. 70-01
ENGINE COMPONENENTS AND TESTING ......... 70-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE COVER ......................................... 10-01, 50-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
ENGINE SIDE COVERS......................................... 50-01
ENGINE SPECIFICATIONS...............................SPEC-01
ENGINE SPEED CONTROL .................................. 70-01
FENDER ................................................................. 50-01
FLOOR PANELS..................................................... 50-01
FLYWHEEL ............................................................. 70-01
FLYWHEEL HOUSING ........................................... 70-01
FRONT AXLE .............................................. 10-01, 40-01
FRONT AXLE PIVOT FRAME ................................ 50-01
FRONT LIGHTS...................................................... 60-01
FRONT WIPER ....................................................... 60-01
FUEL LEVEL SENDER........................................... 60-01
FUEL SYSTEM ....................................................... 10-01
FUEL TANK............................................................. 50-01
HEATER FAN ..........................................................80-01

HEATER UNIT .........................................................80-01
HYDRAULIC FILTER HOUSING .............................20-01
HYDRAULIC FLUID RESERVOIR ..........................20-01
HYDRAULIC SYSTEM INFORMATION ..................20-01
HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS ............................................ SPEC-01
HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
HYDROSTATIC DRIVE MOTOR .............................30-01
HYDROSTATIC PUMP ............................................30-01
HYDROSTATIC SYSTEM INFORMATION..............30-01
HYDROSTATIC TESTING.......................................30-01
INSTRUMENT PANEL.............................................60-01
LIFT ARMS ..............................................................50-01
LIFT CYLINDER ......................................................20-01
LIFTING AND BLOCKING THE
LOADER BACKHOE ...............................................10-01
LOADER BACKHOE SPECIFICATIONS........... SPEC-01
LOADER BACKHOE TORQUE ......................... SPEC-01
LOADER CONTROL VALVE ...................................20-01
LUBRICATING THE LOADER BACKHOE ..............10-01
MAIN RELIEF VALVE ..............................................20-01
MUFFLER................................................................70-01
OIL COOLER...........................................................30-01
OPERATOR CAB ....................................................50-01
OPERATOR SEAT...................................................50-01
PARKING BRAKE....................................................40-01
PORT RELIEF VALVE
(BACKHOE CONTROL VALVE) .............................20-01
PORT RELIEF VALVE
(LOADER CONTROL VALVE)................................20-01
RADIATOR ..............................................................70-01
REAR AXLE .................................................10-01, 40-01
REAR WINDOW ......................................................50-01
REAR WIPER ..........................................................60-01
RECONDITIONING THE ENGINE ..........................70-01
RUBBER DRIVE COUPLER ...................................70-01
SAPR BRAKE CONTROL VALVE ...........................20-01

SAPR BRAKE CYLINDER ......................................20-01
SERVICE SCHEDULE ............................................10-01
SIDE SHIFT LOCK CYLINDER ...............................20-01
STABILIZER FRAME...............................................50-01
STABILIZER CYLINDER .........................................20-01
STEERING ANGLE ADJUSTMENT
(FRONT AXLE).......................................................40-01
GEAR PUMP .......................................................... 20-01
STEERING ANGLE ADJUSTMENT
GRILL...................................................................... 50-01
(REAR AXLE) .........................................................40-01
GRILL FRAME ........................................................ 50-01
STEERING CYLINDER (FRONT) ...........................20-01
STEERING CYLINDER (REAR)..............................20-01
Continued on next page
ALPHABETICAL INDEX (CONTD)

STEERING PUMP ...................................................20-01
STEERING VALVE ..................................................20-01
STARTER ................................................................60-01
SWING CYLINDER .................................................20-01
SWING FRAME .......................................................50-01
SWING LOCK PIN...................................................10-01
TILT CYLINDER ......................................................20-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS
FOR BOLTS..................................................... SPEC-01
TOWING THE LOADER BACKHOE .......................10-01
TRANSPORTING THE LOADER BACKHOE..........10-01
TRAVEL PEDAL ......................................................20-01
TROUBLESHOOTING.............................................70-01
TURBOCHARGER ..................................................70-01
TURN INDICATOR LIGHTS (FRONT).....................60-01
TURN INDICATOR LIGHTS (REAR) .......................60-01
X-CHANGE ..........................................................50-01
SAFETY &
MAINTENANCE
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
HYDRAULIC
SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
HYDROSTATIC
SYSTEM
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . X

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
DRIVE
SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 60-01
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
ENGINE
SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HEATER
SSPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
B250 Bobcat Loader Backhoe

Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that ROPS mounting
hardware is tightened and is
Bobcat approved.
9. Bob-Tach
wedges
and
linkages
must
function
correctly and be in good
condition.
2. The seat belt must be

correctly installed, functional
and in good condition.
10. Safety treads must be in good

condition.
3. Check lift arm support device,

replace if damaged.
11. Check for correct function of

indicator lamps (Optional on
some models.
4. Machine signs must be

legible and in the correct
location.
12. Check hydraulic fluid level,

engine oil level and fuel
supply.
5. Foot pedal must return to

neutral.
13. Inspect for fuel,

hydraulic fluid leaks.
6. Check for correct function of

the work lights
14. Lubricate the loader backhoe.
7. The parking brake

function correctly.
must
15. Check the condition of the

battery and cables.
8. Enclosure door latches must

open and close freely.
16. Inspect the air cleaner for

damage or leaks. Check the
condition of the element.
II
oil
or

Service Manual
17. Check the electrical charging

system.
20. Operate the loader and check

all functions.
18. Check tires for wear and

pressure.
21. Check
for
any
field
modification not completed.
19. Inspect for loosen or broken

parts or connections.
22. Recommend to the owner

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.
III

Service Manual
IV

Service Manual
SAFETY INSTRUCTIONS
The following publications provide information on the

safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol

This symbol with a warning statement means:
Warning, be alert! Your safety is involved!
Carefully read the message that follows.
The Delivery Report is used to assure that complete

instructions have been given to the new owner and
that the machine is in safe operating condition.
The Operation & Maintenance Manual delivered with

the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Machine signs (decals) instruct on the safe operation

and care of your Bobcat machine or attachment. The
signs and their locations are shown in the Operation
& Maintenance Manual. Replacement signs are
available from your Bobcat dealer.
An Operators Handbook fastened to the operator

cab. Its brief instructions are convenient 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.
The AEM Safety Manual delivered with the machine

gives general safety information.
The Service Manual and Parts Manual are available

from your dealer for use by mechanics to do shoptype service and repair work.
The Loader Backhoe Operator Training Course is

available through your local dealer or at
www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Loader Backhoe.
The Loader Backhoe Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operators
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-2003-0903
WARNING
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause
injury or death.
W-2044-1285
IMPORTANT
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284
SI LB-0206 SM

Service Manual
SAFETY INSTRUCTIONS (CONTD)

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

1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI LB-0206 SM
VI

Service Manual
SAFETY INSTRUCTIONS (CONTD)
Use the procedure in the Operation & Maintenance

Manual for connecting the battery and for jump
starting.
Use the procedure in the Operation & Maintenance

Manual for cleaning the spark arrestor muffler (if
equipped).
Fire Prevention
The machine and attachments have components that are
at high temperature under normal operating conditions.
The primary source of high temperatures is the engine
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or
sparks.
Figure 1
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the
emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
The operator cab, engine compartment, and engine

cooling system must be inspected every day and
cleaned if necessary to prevent fire hazard and
overheating.
Check all electrical wiring and connections for

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

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

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

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

SMOKING!
Know where fire extinguishers and first aid kits are

located and how to use them. Fire extinguishers are
available from your Bobcat dealer [Figure 1].
SI LB-0206 SM
VII

Service Manual
VIII

Service Manual
SERIAL NUMBER LOCATION
Engine Serial Number
Always use the serial number of the loader backhoe

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 2
Loader Backhoe Serial Number

Figure 1
P-47580
The engine serial number is located on the valve cover at

the right side of the engine [Figure 2].
DELIVERY REPORT
Figure 3
P-47578
The loader backhoe serial number plate is located under

the loader lift arm on the left side [Figure 1].
Explanation of loader Serial Number:
XXXX
Model 1.-Model/ Engine
Combination
XXXXX
Model 2.-Production
Sequence (Series)
1. The four digit Model/Engine Combination Module

number identifies the model number and engine
combination.
B-16315
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
backhoe is delivered. An explanation of the form must be
given to the owner. Make sure it is filled out completely
[Figure 3].
2. The five digit Production Sequence Number identifies

the order which the loader is produced.
IX

Service Manual
BOBCAT LOADER IDENTIFICATION
ARM
CYLINDER
BACKHOE
AUXILIARY
QUICK
COUPLER
OPERATION &
MAINTENANCE MANUAL
REAR
LIGHTS
LIFT ARM/BUCKET
TILT CONTROL
OPERATOR HANDBOOK
TRAVEL CONTROL
PEDAL
BUCKET
CYLINDER
LIFT ARMS
ARM
BACKHOE
X-CHANGE
LIFT
CYLINDER
SWING
LOCK PIN
BUCKET
BOOM
LOCK PIN
BACKHOE
STABILIZER
BOOM
FRONT LIGHTS
LIFT ARM
PARKING SUPPORT
BRAKE
DEVICE
*CANOPY/CAB
(ROPS/FOPS)
OPERATOR SEAT
WITH SEAT BELT
GRAB HANDLES
BACKHOE
CONTROL
ENGINE COVER
LOADER AUXILIARY
QUICK COUPLERS
TILT
CYLINDERS
LOADER
ENGINE
SPEED
CONTROL
BUCKET
STEPS
STEERING
VALVE
SAFETY
TREAD
TIRES
BUCKET - Several different buckets and other attachments are available for the Bobcat loader backhoe.
* ROPS, FOPS - Roll Over Protective Structure, Falling Object Protective Structure, per SAE j1040 and ISO 3471 and
Falling Object Protective Structure per SAE J1043 and ISO 3449, Level 1.
B-19952
B-19931

Service Manual
SAFETY &
MAINTENANCE
SAFETY & MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing The Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . 10-160-1
APPROVED LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . 10-20-1
Installing The Approved Lift Arm Support Device . . . . . . . 10-20-1
Removing The Approved Lift Arm Support Device . . . . . . 10-20-2
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
DRIVE
SYSTEM
BOOM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Engaging And Disengaging The Pin . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing The Oil And Filter . . . . . . . . . . . . . . . . . . . . . .
10-110-1
10-110-1
10-110-1
10-110-1
ENGINE
SERVICE
SPECIFICATIONS
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1
Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Air From The Fuel System . . . . . . . . . . . . . . .
10-100-1
10-100-1
10-100-1
10-100-1
10-100-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . .
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . .
Cleaning The Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . .
10-120-1
10-120-1
10-120-2
10-120-3
10-120-2
LIFTING AND BLOCKING THE LOADER BACKHOE . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
10-01

Service Manual
SAFETY & MAINTENANCE (CONTD)

LUBRICATING THE LOADER BACKHOE . . . . . . . . . . . . . . 10-170-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SWING LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Engaging The Swing Lock Pin . . . . . . . . . . . . . . . . . . . . . 10-190-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-180-1
10-180-1
10-180-1
10-180-1
TOWING THE LOADER BACKHOE . . . . . . . . . . . . . . . . . . . . 10-50-1

TRANSPORTING THE LOADER BACKHOE . . . . . . . . . . . . . 10-40-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
10-02

Service Manual
LIFTING AND BLOCKING THE LOADER BACKHOE
Figure 10-10-2
Procedure
WARNING
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow instructions can
cause injury or death.
W-2003-0199
P-35954
Lift the rear of the loader backhoe and install jackstands

[Figure 10-10-2].
Figure 10-10-1
Figure 10-10-3
B-7023
P-35953
Read the removal and installation, disassembly and

assembly, etc., completely to become familiar with the
procedure before beginning [Figure 10-10-1].
Lift the front of the loader backhoe and put jackstands

under the axle [Figure 10-10-3].
Always park the loader backhoe on a level surface.
Note:
Make sure the jackstands do not touch the

tires.
Stop the engine, and engage the parking brake.
WARNING
Put jackstands under the front and rear axle before
running the engine for service. Failure to use
jackstands can allow the machine to fall or move and
W-2461-0303
10-10-1

Service Manual
10-10-2

Service Manual
APPROVED LIFT ARM SUPPORT DEVICE
Figure 10-20-2
Most maintenance and service work can be done with the

lift arms lowered. If the lift arms are raised, use the
following procedures to install and remove the approved
lift arm support device:
WARNING
Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-49085
W-2059-0598
Install the approved lift arm support device (Item 1)

[Figure 10-20-2] over the lift cylinder rod.
WARNING
Figure 10-20-3
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Installing The Approved Lift Arm Support Device

Remove the bucket or attachment from the loader.
Figure 10-20-1
P-47556
Lower the lift arms slowly until the approved lift support
device is held securely [Figure 10-20-3].
1
2
P-47555
Remove the two pins (Item 1) and remove the approved

lift arm support device (Item 2) [Figure 10-20-1] from the
storage position.
Start the engine and raise the lift arms fully. Stop the
engine.
10-20-1

Service Manual
APPROVED LIFT ARM SUPPORT DEVICE (CONTD)

Removing The Approved Lift Arm Support Device
Figure 10-20-4
P-49085
Start the engine, and raise the lift arms approximately 2

inches (51 mm). Stop the engine and exit the loader
backhoe.
Remove the approved lift arm support device (Item 1)
[Figure 10-20-4].
Lower the lift arms fully.
Exit the loader backhoe.
Figure 10-20-5
2
1
P-47555
Put the approved lift arm support device (Item 1) in the

storage position. Install the two retaining pins (Item 2)
[Figure 10-20-5].
10-20-2

Service Manual
ENGINE COVER
Figure 10-30-3
Figure 10-30-1
1
P-33778
P-47608
Open the latch (Item 1) [Figure 10-30-1] on each side of

the engine cover.
Place the end of the support rod (Item 1) [Figure 10-303] into the hole located on the hood to hold the engine
cover open.
Raise the engine cover.

Figure 10-30-2
P-47607
Remove the engine cover support rod (Item 1) [Figure

10-30-2] from the storage position.
10-30-1

Service Manual
10-30-2

Service Manual
TRANSPORTING THE LOADER BACKHOE

Procedure
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
Be sure the transport and towing vehicles are of

adequate size and capacity. (See Performance on Page 3.)
Figure 10-40-1
1
P-47571
The rear of the trailer must be blocked or supported (Item

1) [Figure 10-40-1] when loading or unloading the loader
backhoe to prevent the front end of the trailer from raising
up.
Use the following procedure to secure the loader
backhoe to the transport vehicle to prevent the loader
backhoe from moving during sudden stops or when going
up or down slopes.
Lower the loader bucket.
Lower the backhoe bucket.
Stop the engine.
Engage the parking brake.
10-40-1

Service Manual
TRANSPORTING THE LOADER BACKHOE (CONTD)
Figure 10-40-4
Figure 10-40-2
P-47575
P-47573
P-47574
P-47572
Install chains at the rear of the machine [Figure 1040-2] front of the machine [Figure 10-40-3] and at the
backhoe [Figure 10-40-4].
Fasten each end of the chain to the transport vehicle.
Figure 10-40-3
P-32627
NOTE: For height restrictions the boom transport pin

and swing locking pin must not be engaged
when transporting the loader backhoe on a
trailer. The backhoe boom must be lowered
onto the trailer bed and chained.
P-47576
10-40-2

Service Manual
TOWING THE LOADER BACKHOE
Figure 10-50-3
Procedure
Place blocks in front and behind rear wheels.
1
Figure 10-50-1
1
2
1
P-42732
1
Rotate the tow valve (Item 1) [Figure 10-50-3]
counterclockwise approximately three turns.
Figure 10-50-4
P-33314
Remove the four mounting bolts (Item 1) and floor cover

(Item 2) [Figure 10-50-1].
Figure 10-50-2
1
2
P-49089
P-42731
Loosen the two jam nuts (Item 1) and turn the parking
brake linkage (Item 2) [Figure 10-50-4] approximately
two turns. (Record the exact amount of turns on the
parking brake linkage (Item 2). When putting the machine
back in service, you must turn the parking brake linkage
back to its original setting.)
Loosen the tow valve (Item 1) [Figure 10-50-2].

To prevent damage to the loader backhoe hydrostatic
system, the loader backhoe must be towed only a short
distance at slow speed. (Example: Moving the loader
backhoe onto a transport vehicle.
The towing chain (or cable) must be rated at 1-1/2 times
the weight of the loader. (See Performance on Page -3.)
NOTE: Be sure to retighten the tow valve and readjust
the parking brake linkage before operating the
loader backhoe after towing.
10-50-1

Service Manual
10-50-2

Service Manual
AXLE TOE-IN
Figure 10-60-2
Adjustment
Raise the lift arms and install the approved lift arm
support device. (See Installing The Approved Lift Arm
Support Device on Page 10-20-1.)
WARNING
W-2059-0598
The front axle and rear axle toe-in adjustment procedure

is the same. The front axle toe-in procedure is shown.
P-33665
Measure the exposed part of the cylinder rod on each

side of the steering cylinder housing making sure they
are the same length [Figure 10-60-2].
Figure 10-60-3
Figure 10-60-1
P-47567
P-47566
Turn the steering wheel until the front wheels are

positioned as shown [Figure 10-60-1].
Measure the distance between the centerline on the front

of the tires and compare it to the measurement taken
from the centerline on the backside of the tires [Figure
10-60-3]. The measurement must be equal.
10-60-1

Service Manual
AXLE TOE-IN (CONTD)

Figure 10-60-4
1
3
2
P-33666
If measurement is not the same, adjust the tie rod end

(Item 1) (both sides) by loosening the jam nut (Item 2).
Loosen or tighten the rod (Item 3) [Figure 10-60-4] on
both sides until the measurement is the same.
10-60-2

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

and understand the Operation & Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to
follow instructions can cause injury or death.
W-2003-0199
SERVICE SCHEDULE
ITEM
Engine Oil
Hydraulic Fluid
Fuel Filter
Engine Air System
Engine Cooling System
Lift Arms, Cyl., Bob-Tach Pivot
Pins, Wedges, Etc.
X-Change System
SERVICE REQUIRED
Hydraulic Oil Filter

Engine Air Filter
Hydraulic Reservoir
Differential Oil
Wheel Bearings
Flush the cooling system and add new coolant.

Replace the fluid and the filter.
Replace the differential oil.
Repack the wheel bearings.
Mirrors
Steering valve
Safety Signs and Safety Treads
Operator Cab
Indictors and Lights
Parking Brake
PRESS TO DRIVE System
Backup Alarm
Hydraulic Fluid, Hoses and
Tubelines
Front & Rear Differential
Wheel Nuts
Battery
Spark Arrestor Muffler
Alternator/Fan Belt
Fuel Filter
Steering King Pins
Engine Oil and Filter
8-10
50
100 250
500
1000
Check the oil level and add as needed.

Check fluid level and add as needed.
Remove trapped water.
Check for leaks and damaged components.
Clean debris from oil cooler, radiator & grill. Check coolant level.
Lubricate with multi-purpose lithium based grease.
Check for loose or damaged parts. Torque X-Change bolts to 130 ft.-lb.
(177 Nm)
Check for correct size, damaged tires and correct air pressure.
Check the condition of seat belt. Clean or replace seat belt retractors as
needed.
Clean and adjust as necessary
Check and adjust wheel alignment as required.
Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Check the fastening bolts, washers and nuts. Check the condition of the cab.
Check for correct operation of all indicators and lights.
Check operation, adjust as required.
Check for proper function.
Check operation. Repair or replace as required.
Check fluid level & add as needed. Check for damage and leaks. Repair or
replace as needed.
Check oil level. Add oil as needed.
Check for loose wheel nuts and tighten to 140 ft.-lb. (190 Nm) torque.
Check cables, connections and electrolyte level. Add distilled water as
needed.
Empty the spark chamber (if equipped).
Check tension and adjust as needed.
Replace filter element.
Lubricate with multi-purpose lithium based grease.
Replace oil & filter. Use CD or better grade oil and Bobcat filter.
Replace the filter element.
Replace the air filter element.
Tires
Seat Belt, Seat Belt Retractors
HOURS
Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
Replace hydraulic filter element after the first 50 hours and every 500 hours thereafter.
First oil and filter change must occur at 50 hours: 250 hours thereafter.
Replace the engine air filter element after the first 50 hours and every 500 hours thereafter.
Or every 12 months.
10-70-1

Service Manual
10-70-2

Service Manual
AIR CLEANER SERVICE
Figure 10-80-2
Replacing The Filter

(See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service interval.
Raise the loader lift arms and install the Approved Lift
Arm Support Device. (See Installing The Approved Lift
Arm Support Device on Page 10-20-1.)
Open the engine cover. (See ENGINE COVER on Page
10-30-1.)
Figure 10-80-1
P-47702PP-47702
33510
Remove the filter element and cover from the housing

[Figure 10-80-2].
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install a new element onto the housing cover.
Install filter element/cover [Figure 10-80-2].
Tighten the filter cover nut (Item 1) [Figure 10-80-1].

P-47611PP-47611
33509
Loosen the filter cover nut (Item 1) [Figure 10-80-1].
10-80-1

Service Manual
10-80-2

Service Manual
ENGINE COOLING SYSTEM
Figure 10-90-2
Coolant Replacement
WARNING
1
Do not remove radiator cap when the engine is hot.

You can be seriously burned.
W-2070-1285
P-47707
Stop the engine, open the engine cover.

Figure 10-90-1
Open the radiator drain valve (Item 1) [Figure 10-90-2] at

the bottom of radiator. Drain the coolant into a container.
Figure 10-90-3
1
P-33673
When the engine is cool, loosen and remove the radiator

cap (Item 1) [Figure 10-90-1].
Remove the engine side covers. (See Removal And
Installation on Page 50-60-1.)
P-47706
Open the engine block drain valve (Item 1) [Figure 1090-3] and drain the coolant into a container.
After all the coolant is removed, close both drain valves.
Recycle or dispose of coolant in an environmentally safe
manner.
Mix the coolant in a separate
Specifications on Page SPEC-50-1.)
container.
(See
NOTE: The loader backhoe is factory filled with

ethylene glycol. DO NOT mix propylene glycol
with ethylene glycol.
10-90-1

Service Manual
ENGINE COOLING SYSTEM (CONTD)

Coolant Replacement (Contd)
Add premixed coolant; 50% water and 50% ethylene
glycol to the recover tank if the coolant level is low.
One gallon of ethylene glycol mixed with one gallon of
water is the correct mixture of coolant to provide a -34 F
(-37 C) freeze protection.
Use a refractometer to check the condition of ethylene
glycol in your cooling system.
Fill the radiator with the premixed coolant until it is full.
Run the engine at idle speed for about 5-10 minutes to
remove the air from the cooling system (leave the
radiator cap off during this operation).
Stop the engine. Check the coolant level and add as
needed to bring it up to the radiator filler neck. Install the
radiator cap and tighten.
10-90-2

Service Manual
FUEL SYSTEM
Figure 10-100-2
WRONG
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
The following is one suggested blending guideline which
should prevent fuel gelling during freezing temperature:
Temp. F (C)
Above +15 (-9)

Down to -20 (-29)
Below -20 (-29)
No. 2
100%
50%
0%
No. 1
0%
50%
100%
B-16729
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2]
Contact your fuel supplier for local recommendations.

Filling The Fuel Tank
Install and tighten the fuel fill cap (Item 1) [Figure 10100-1].
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
Fuel Filter
Raise the lift arms and install an approved lift arm support
device. (See Installing The Approved Lift Arm Support
Device on Page 10-20-1.)
Figure 10-100-1
WARNING
W-2059-0598

service interval for removing water from, or replacing the
fuel filter.
P-47609
Open the engine cover. (See ENGINE COVER on Page

10-30-1.)
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
10-100-1

Service Manual
FUEL SYSTEM (CONTD)
WARNING
Fuel Filter (Contd)

Removing Water
Diesel fuel or hydraulic fluid under pressure can

penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Figure 10-100-3
W-2072-0496
2
Figure 10-100-4
P-33513
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter.
Replacing The Element
P-33513
Remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter

housing.
Turn the engine over with the starter until fuel flows from
the vent with no air bubbles.
Remove the air from the fuel system. (See below.)
Close the vent (Item 1) [Figure 10-100-4].
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Removing Air From The Fuel System

After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system before starting the engine.
10-100-2

Service Manual
ENGINE LUBRICATION SYSTEM
Oil Chart
Checking Engine Oil
Figure 10-110-2
RECOMMENDED SAE VISCOSITY NUMBER
Check the engine oil level every day before starting the
engine for the work shift.
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
Figure 10-110-1
P-47610
Open the engine cover and remove the dipstick (Item 1)

[Figure 10-110-1].
Keep the oil level between the marks on the dipstick.
Replacing The Oil And Filter
Engine oil is also used to provide engine cooling. Check
oil level every day for correct engine lubrication and
cooling.
Use a good quality motor oil that meets the API Service
Classification of CD or better. (See Oil Chart on Page 10110-1.)

service interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature. Stop
the engine.
Figure 10-110-3
P-33668
Remove the drain plug (Item 1) [Figure 10-110-3].
10-110-1

Service Manual
ENGINE LUBRICATION SYSTEM (CONTD)
Stop the engine. and check for leaks at the oil filter.
Replacing The Oil And Filter (Contd)
Remove the dipstick (Item 2) [Figure 10-110-5] and

check the oil level.
Drain the oil into a container and recycle or dispose of

used oil in an environmentally safe manner.
WARNING
Reinstall the drain plug.

Figure 10-110-4

W-2103-1285
Figure 10-110-6
1
P-47705
Remove the oil filter (Item 1) [Figure 10-110-4].
Clean the filter housing surface.

Use a genuine Bobcat filter only.
P-32743
Put oil on the filter gasket. Install the filter and hand
tighten.
Add oil as needed if it is not at the top mark on the

dipstick (Item 1) [Figure 10-110-6].
Figure 10-110-5
Install the dipstick and close the engine cover.
P-47704
Remove the fill cap (Item 1) [Figure 10-110-5]. Put 4.3

qts. (4 L) oil in the engine.
Start the engine and let it run for several minutes.
10-110-2

Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
Figure 10-120-2
Checking And Adding Fluid

Use only recommended fluid in the hydraulic system.
(See Specifications on Page SPEC-50-1.)
Put the loader backhoe on a flat level surface.

Remove the boom lock pin. (See Engaging And
Disengaging The Pin on Page 10-140-1.)
Remove the swing lock pin. (See Engaging The Swing
Lock Pin on Page 10-190-1.)
Retract the arm and bucket cylinders, put the bucket on
the ground.
P-47627
Lower the lift arms and tilt the Bob-Tach fully back.
Remove the fill cap (Item 1) [Figure 10-120-2].
Stop the engine.
Figure 10-120-3
Figure 10-120-1
P-47628
P-47626
Check that the fluid level in the sight gauge [Figure 10120-1] is 2/3 to 3/4 full.
Check the condition of the fill strainer [Figure 10-120-3].

The screen must be installed in the fill neck when adding
oil.
Add the fluid as needed to bring the level on the sight
gauge to 2/3 to 3/4 full.
Install the fill cap (Item 1) [Figure 10-120-2].
WARNING
W-2103-1285
10-120-1

Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONTD)
Figure 10-120-6
Cleaning The Cooler

Figure 10-120-4
P-32803
Loosen and remove the hydraulic filter cap (Item 1)

[Figure 10-120-6].
1
P-47629
Figure 10-120-7
The hydraulic oil cooler (Item 1) [Figure 10-120-4] is
located behind the grill.
Use low air pressure or water pressure to clean the oil
cooler.
Replacing Hydraulic/Hydrostatic Filter
Figure 10-120-5
P-33455
1
Remove the plastic spacer [Figure 10-120-7].
P-47631
Remove the four mounting bolts (Item 1) and cover (Item

2) [Figure 10-120-5].
10-120-2

Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONTD)
Replacing Hydraulic Fluid
Replacing Hydraulic/Hydrostatic Filter (Contd)
Remove the fill cap.
Figure 10-120-8
Figure 10-120-9
P-33454B
P-32809
Remove the hydraulic filter element [Figure 10-120-8]

and dispose of it in an environmentally safe manner.
Remove the drain plug (Item 1) [Figure 10-120-9] and

drain the fluid into a container.
Install the new hydraulic filter, spacer and cap.
Recycle or dispose of used fluid in an environmentally

safe manner.
Start the engine, engage the parking brake and operate

the loader hydraulic controls.
WARNING
Stop the engine and check for leaks at the filter.

Install the floor panel (Item 2) and four mounting bolts
(Item 1) [Figure 10-120-5].
Check the fluid level in the reservoir and add as needed.

W-2103-1285
WARNING
W-2072-0496
10-120-3

Service Manual
10-120-4

Service Manual
REAR AXLE
Checking Oil Level
Figure 10-130-1
P-33950
With the machine on a level surface, remove the plug

(Item 1) [Figure 10-130-1]. The oil level should be at the
bottom edge of the plug hole.
Add SAE 80-90 gear oil through the hole if the oil level is
below the hole.
Install and tighten the plug.
Draining Oil
Figure 10-130-2
P-33682
With the machine on a level surface remove the plug

(Item 1) [Figure 10-130-2] and drain into a container.
Recycle or dispose of the used lubricant in an
environmentally safe manner.
10-130-1

Service Manual
10-130-2

Service Manual
FRONT AXLE
Checking Oil Level
Figure 10-131-1
P-33669
With the machine on a level surface, remove the plug

(Item 1) [Figure 10-131-1]. The oil level should be at the
bottom edge of the plug hole.
Add SAE 80-90 gear oil through the hole if the oil level is
below the hole.
Draining Oil
With the machine on a level surface remove the cover
(Item 2) [Figure 10-131-1] and drain into a container.
Recycle or dispose of the used lubricant in an
environmentally safe manner.
10-131-1

Service Manual
10-131-2

Service Manual
BOOM LOCK PIN
Figure 10-140-2
Engaging And Disengaging The Pin

Figure 10-140-1
1
2
1
P-47594
When transporting the backhoe, install the boom lock pin

(Item 1) in the transport position as shown and install the
retainer pin (Item 2) [Figure 10-140-2].
P-47593
When the backhoe is in operation, store the boom lock

pin (Item 1) [Figure 10-140-1] in the storage brackets on
the swing frame.
WARNING
AVOID CRUSHING HAZARD

Do not lean over controls.
Engage and disengage the boom lock pin and
swing lock pin with the engine off.
Do not operate the loader controls from outside
the operators area.
W-2425-0302
10-140-1

Service Manual
10-140-2

Service Manual
Figure 10-150-3
BOB-TACH
Inspection And Maintenance
Bob-Tach
Wedge
Figure 10-150-1
Wedge Must Contact

Lower Edge Of Hole
In the Attachment
P-32761
B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
P-32760
Move the Bob-Tach levers to engage the wedges [Figure

10-150-1]. The levers and wedges must move freely.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-150-1].
If the wedge does not contact the lower edge of the hole
[Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1 for the correct service interval.)
P-32757
10-150-1

Service Manual
10-150-2

Service Manual
ALTERNATOR BELT
Figure 10-160-2
Adjusting The Alternator Belt
WARNING
W-2059-0598
Stop the engine and engage the parking brake.
Remove the side cover from the left side.
P-47622
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force [Figure 10-160-2].
Tighten the adjustment and mounting bolts (Item 1)
[Figure 10-160-1].
Figure 10-160-1
1
P-47623
Loosen alternator mounting and adjustment bolts (Item 1)

[Figure 10-160-1].
10-160-1

Service Manual
10-160-2

Service Manual
LUBRICATING THE LOADER BACKHOE
Figure 10-170-3
Lubricate the loader as specified in the SERVICE

SCHEDULE (See SERVICE SCHEDULE on Page 10-701.) for the best performance of the loader.
Record the operating hours each time you lubricate the
loader backhoe.
Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader backhoe.
Figure 10-170-1
P-47635
3. Lift Arm Pivot Pin (Both sides) [Figure 10-170-3].

Figure 10-170-4
P-47632
1. Rod End Lift Cylinder (Both sides) [Figure 10-170-1].

Figure 10-170-2
P-47636
4. Base End Tilt Cylinder (Both sides) [Figure 10-1704].

2
P-47634
2. Base End Lift Cylinder (Both sides) [Figure 10-1702].
10-170-1

Service Manual
LUBRICATING THE LOADER BACKHOE (CONTD)

Figure 10-170-5
Figure 10-170-7
6
10
7
P-47637
P-33690
5. Rod End Tilt cylinder (Both sides) [Figure 10-170-5].
9. Front Axle (Both sides) [Figure 10-170-7].
6. Bob-Tach Wedge (Both sides) [Figure 10-170-5].
Figure 10-170-8
7. Tilt Link Pivot Pin (Both sides) [Figure 10-170-5].

Figure 10-170-6
10
8
8
P-33689
10. Front Axle Pivot Pin [Figure 10-170-8].

P-47638
8. Bob-Tach Pivot Pin (Both sides) [Figure 10-170-6].
10-170-2

Service Manual
Figure 10-170-11
Figure 10-170-9
11
15
12
13
P-47642
13
P-47640
15. Bucket Cylinder Base End [Figure 10-170-11].

11. Bucket Cylinder Pivot Pin [Figure 10-170-9].
Figure 10-170-12
12. Bucket Cylinder Rod End [Figure 10-170-9].

16
13. Bucket Link Pivot [Figure 10-170-9].

Figure 10-170-10
P-47643
14
16. Arm Cylinder Rod End [Figure 10-170-12].
P-47641
14. Dipper Arm Bucket Pivot [Figure 10-170-10].
10-170-3

Service Manual
LUBRICATING THE LOADER BACKHOE (CONTD
Figure 10-170-15
Figure 10-170-13
19
17
P-47646
P-47645
19. Boom Cylinder Base End [Figure 10-170-15].

17. Arm Cylinder Base End [Figure 10-170-13].
Figure 10-170-16
Figure 10-170-14
20
18
P-47648
P-47644
20. Boom Cylinder Rod End [Figure 10-170-16].

18. Arm Pivot Pin [Figure 10-170-14].
Figure 10-170-17
21
21
P-47649
21. Swing Cylinder (Both sides) [Figure 10-170-17].

10-170-4

Service Manual
Figure 10-170-20
Figure 10-170-18
22
24
22
P-33959
P-47650
24. Parking Brake Cable [Figure 10-170-20].

22. Boom Swing Pin [Figure 10-170-18].
Figure 10-170-21
Figure 10-170-19
25
23
P-33670
P-47651
25. Front Universal Joint [Figure 10-170-21].

23. Boom Pivot Pin [Figure 10-170-19].
10-170-5

Service Manual
Figure 10-170-24
Figure 10-170-22
28
26
28
P-47659
P-33671
28. Side Shift Frame (Both sides) [Figure 10-170-24].

26. Rear Universal Joint [Figure 10-170-22].
Figure 10-170-25
Figure 10-170-23
29
27
P-47660
27
P-33960
29. Cab Door Hinges (upper and lower both sides) If

equipped [Figure 10-170-25]
27. Rear Axle (Both sides) [Figure 10-170-23].
10-170-6

Service Manual
TIRE MAINTENANCE
Tire Pressure
Wheel Nuts
Front tire pressure - 55 PSI (379 kPa)
Figure 10-180-1
Rear tire pressure - 55 PSI (379 kPa)

NOTE: Always replace the tires with the same size
tires.
WARNING
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.
W-2078-1285
P-47558

service interval to check the wheel nuts. The correct
torque is 140 ft.-lb. (190 Nm) torque [Figure 10-180-1].
Tire Mounting
Check the tires regularly for wear, damage and pressure.
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
Tires are to be repaired only by an authorized person

using the proper procedures and safety equipment.
Tires and rims must always be checked for correct size
before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and
cause serious injury or death.
During inflation of the tire, check the tire pressure
frequently to avoid over inflation.
10-180-1

Service Manual
10-180-2

Service Manual
SWING LOCK PIN
Figure 10-190-2
Engaging The Swing Lock Pin

NOTE: When using both the boom lock pin and the
swing lock pin, the boom lock pin should be
installed first.
NOTE: Attachments wider than a 16 inch backhoe

bucket can contact the stabilizer when the
backhoe boom is side shifted and fully swung
to the side. These attachments must be
removed before engaging the swing lock pin.
Figure 10-190-1
P-47700
Move the boom to the left or right, stop the engine,

engage the parking brake and exit the loader backhoe.
Remove the retainer pin (Item 1) [Figure 10-190-2] and
install the swing lock pin (Item 2) [Figure 10-190-2], by
lowering it into the mating boss on the swing frame.
Figure 10-190-3
P-47699
With the swing lock pin (Item 1) [Figure 10-190-1] in the

storage position, engage the parking brake, start the
engine.
WARNING
AVOID CRUSHING HAZARD

Do not lean over controls.
Engage and disengage the boom pin and swing
lock pin lock with the engine off.
Do not operate the loader controls from outside
the operators area.
P-47596
Install the retainer pin (Item 1) [Figure 10-190-3].
W-2425-0302
10-190-1

Service Manual
10-190-2

Service Manual
HYDRAULIC SYSTEM
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-20-1
20-20-8
20-20-1
20-20-6
20-20-5
20-20-2
BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Arm Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Boom Swing Valve Section . . . . . . . . . . . . . . . . . . . . . . . 20-60-24
Boom Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-21
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Inlet/Outlet Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Left Stabilizer Valve Section. . . . . . . . . . . . . . . . . . . . . . . 20-60-17
Outlet Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-27
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Right Stabilizer Valve Section . . . . . . . . . . . . . . . . . . . . . 20-60-14
Tilt Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-21-1
20-21-9
20-21-1
20-21-7
20-21-6
20-21-3
BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-23-1
20-23-9
20-23-1
20-23-7
20-23-6
20-23-3
GEAR PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-80-1
20-80-3
20-80-5
20-80-2
20-80-1
HYDRAULIC FILTER HOUSING. . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-71-1
20-71-3
20-71-2
20-71-1
HYDRAULIC
SYSTEM
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
20-01

Service Manual
HYDRAULIC SYSTEM (CONTD)

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Strainer Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-7
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Auxiliary Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-14
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Inlet/Outlet Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Lift Arm Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Tilt Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-2
Testing The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
PORT RELIEF VALVE (BACKHOE CONTROL VALVE) . . . . . . . . . . . . 20-41-1
Testing And Adjusting (Arm Control) . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Testing And Adjusting (Boom Control) . . . . . . . . . . . . . . . . . . . . . . . 20-41-3
Testing And Adjusting (Boom Swing Control) . . . . . . . . . . . . . . . . . 20-41-5
PORT RELIEF VALVE (LOADER CONTROL VALVE) . . . . . . . . . . . . . 20-42-1
Testing And Adjusting (Bucket Tilt) . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Testing And Adjusting (Front Auxiliary) . . . . . . . . . . . . . . . . . . . . . . 20-42-3
SAPR BRAKE CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
20-02

Service Manual

SAPR BRAKE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
20-120-1
20-120-6
20-120-4
20-120-3
20-120-1
SIDE SHIFT LOCK CYLINDER. . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-25-1
20-25-5
20-25-4
20-25-3
20-25-1
STABILIZER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-10
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-6
STEERING CYLINDER (FRONT) . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-32-1
20-32-6
20-32-9
20-32-5
20-32-1
STEERING CYLINDER (REAR) . . . . . . . . . . . . . . . . . . . . . . .

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-33-1
20-33-5
20-33-8
20-33-4
20-33-1
STEERING PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-12
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Alignment Procedure . . . . . . . . . . . . . . . . . . . . . .
20-110-1
20-110-2
20-110-1
20-110-2
20-03

Service Manual

SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-22-1
20-22-7
20-22-9
20-22-1
20-22-5
20-22-4
20-22-2
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30-1
20-30-7
20-30-1
20-30-5
20-30-4
20-30-2
TRAVEL PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-04
20-100-1
20-100-3
20-100-2
20-100-1

Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
B250 "B SERIES"
(S/N 572211001 AND ABOVE)
(PRINTED FEBRUARY 2004)
V-0360legend
LEGEND
1
HYDRAULIC RESERVOIR
Capacity . . . . . . . 54 Qts. (51 L)
21 CHARGE PUMP
8.2 GPM (31,05 L/min) at 3000 RPM
SCREEN (Suction)
W/By-Pass . . . . . . . 4 PSI (0.28 kBar)
22 SHUTTLE VALVE - Control Pressure
HYDRAULIC FILTER ELEMENT
23 RELIEF VALVE - Control Pressure
24 SHUTTLE RELIEF VALVE

FILTER BY-PASS . . . . . . .
36 PSI (2.5 kPa)

25 DRIVE MOTOR SHUTTLE VALVE
DIFFERENTIAL PRESSURE SWITCH

Normally Closed
CHARGE BUILD-UP
BREATHER/FILL CAP
OIL COOLER
RELIEF VALVE . . . . . . .
10
26 NEUTRAL PRESSURE SWITCH

27 TOW VALVE
28 PRIORITY VALVE - Steering
29 RELIEF VALVE
2465 PSI (170 Bar)
PORT RELIEF VALVE

TILT CYLINDER (Rod & Base) 4060 PSI (280 Bar)
11 PORT RELIEF VALVE

AUXILIARY (Male & Female)
31
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP
32 SERVO PISTON - Swash Plate

3625 PSI (250 Bar)

BACKHOE SWING CYLINDER (Rod & Base)
2900 PSI (200 Bar)
BACKHOE BOOM CYLINDER (Base)
2828 PSI (195 Bar)
BACKHOE BUCKET CYLINDER (Rod)
3480 PSI (240 Bar)
15 ORIFICE (Boom Rod)
30 RELIEF VALVE (2)
0.12 inch (3,0 mm)
16 LOAD CHECK VALVE (2)
33 ORIFICE - 0.04 inch (1,0 mm)

34 GEAR PUMP
11,76 GPM (44,6 L/min) at 3000 RPM
35 SOLENOID ACTIVATED DIRECTIONAL CONTROL
VALVE - SAPR BRAKE
36 SAPR BRAKE - SPRING APPLIED - HYDRAULIC
PRESSURE RELEASE
37 SOLENOID ACTIVATED DIRECTIONAL CONTROL
VALVE - FRONT AUXILIARY COUPLERS
38
CHECK VALVE

BACKHOE ARM CYLINDER (Rod)
3045 PSI (210 Bar)

BACKHOE BOOM CYLINDER (Rod)
3045 PSI (210 Bar)
18 ORIFICE (Lift Base)

BACKHOE ARM CYLINDER (Base)
2828 PSI (195 Bar)
0.15 inch (3,7 mm)
19 RELIEF/REPLENISHING VALVE - HIGH

PRESSURE . . . . . . . 3625 PSI (250 Bar)
20 RELIEF VALVE - Charge Pressure
377 PSI (26 Bar)
Printed in U.S.A.
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
V-0360le (1-14-04)
BACKHOE HYDRAULIC CONTROL VALVE
HYDRAULIC/HYDROSTATIC SCHEMATIC
B250 "B Series"
37
LOADER HYDRAULIC CONTROL VALVE
11
12
TILT
10
SWING CYLINDERS
Printable Version Click Here
LIFT
10
AUX
(PRINTED February 2004)

V-0360
11
12
SWING
13
15
P
BOOM CYLINDER
FRONT AUXLIARY
QUICK COUPLERS
39
BOOM
LOCK VALVE
16
18
R.H.
STABILIZER
HYDRAULIC FILTER GROUP
LOCK VALVE
FEMALE
LIFT
CYLINDERS
IN
TILT
CYLINDERS
MALE
FRONT AUXLIARY
QUICK COUPLERS
L.H.
STABILIZER
16
14
FOOT PEDAL
RIGHT STABILIZER
CYLINDER
MALE
LEFT STABILIZER
CYLINDER
FEMALE
BUCKET CYLINDER
25
5
M1
M2
OUT
BUCKET
ARM CYLINDER
2
24
26
23
HYDRAULIC OIL RESERVOIR
ARM
22
R/CF
EF
20
19
27
GEAR PUMP
30
32
P
31
28
LOAD SENSING
STEERING UNIT
17
33
SIDE SHIFT LOCK

CYLINDERS
DRIVE MOTOR
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER
40
M
B
29
21
HYDROSTATIC PUMP GROUP
34
WORKING CIRCUIT
PILOT CIRCUIT
DRAIN CIRCUIT
COMPONENTS
35
36
38
P
Sapr Brake
V-0360 (1-14-04)
HYDRAULIC SYSTEM INFORMATION
20-10-1

Service Manual
HYDRAULIC SYSTEM INFORMATION (CONTD)
20-10-2

Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT'D)
20-10-3

Service Manual
20-10-4

Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT'D)
WARNING
Troubleshooting
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.
Check for correct function after adjustments, repairs

or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM
CAUSE
The hydraulic system will not operate.

The transmission warning light comes ON when hydraulics are operating.
Slow hydraulic system action.
Hydraulic action is not smooth.
Lift arms go up slowly at full engine RPM.
The lift arms come down with the lever in neutral position.
1, 2, 3, 6
1, 2
1, 2, 4, 8
1, 3, 4, 5
1, 2, 4, 5, 6, 7
7, 8, 9
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See Specifications on Page SPEC-50-1.)
6. Using the loader for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.
20-10-5

Service Manual
Figure 20-10-2
HYDRAULIC SYSTEM INFORMATION (CONTD)

Description
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-50253
Figure 20-10-1
1
2
The loader backhoe is equipped with two control valves.

The loader control valve (Item 1) [Figure 20-10-1] is
located under the operator seat and controls the loader
lift arm cylinders, bucket cylinders, front auxiliary
couplers and the optional rear auxiliary couplers.
The second control valve (backhoe control valve) (Item
1) [Figure 20-10-2] is located in the backhoe control
panel. It controls the boom cylinder, arm cylinder, bucket
cylinder, swing cylinders and stabilizer cylinders.
P-33329
There is one main relief valve (Item 2) [Figure 20-10-1]

that is located on the loader control valve. It also works
as the main relief valve for the backhoe control valve.
20-10-6

Service Manual
ARM CYLINDER
Figure 20-20-3
Checking
2
Set the bucket flat on the work surface.

Stop the engine. Engage the parking brake.
Figure 20-20-1
1
2
P-50514
Install the pivot pin (Item 1) [Figure 20-20-3].
Install a hoist and lifting strap (Item 2) [Figure 20-20-3] to

support the arm assembly.
With the parking brake engaged, start the engine and
fully retract the arm cylinder.
P-50512
Remove the snap ring (Item 1) and washer (Item 2)

[Figure 20-20-1].
Figure 20-20-2
With the engine off, move the backhoe control levers to

relieve hydraulic pressure.
Figure 20-20-4
1
P-50513
Support the cylinder (Item 1) and remove the pivot pin

(Item 2) [Figure 20-20-2]. Lower the cylinder onto a
wood block.
P-50516
Remove the hose (Item 1) [Figure 20-20-4] from the

base of the cylinder.
20-20-1
B250 Loader Backhoe

Service Manual
ARM CYLINDER (CONTD)
Removal And Installation
Checking (Contd)
Set the bucket flat on the work surface.

Stop the engine, engage parking brake.
WARNING
Operate the backhoe control levers to relieve hydraulic

pressure.
Hydraulic fluid escaping under pressure can have

sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-5
IMPORTANT
damage the system.
I-2003-0888
Figure 20-20-6
1
1
P-50517
Install a plug (Item 1) [Figure 20-20-5] on the hose and

tighten.
P-50512
With the parking brake engage, start the engine and

retract the arm cylinder.
If there is any leakage from the base end fitting (Item 2)
[Figure 20-20-5] on the arm cylinder, remove the
cylinder for repair or replacement.

[Figure 20-20-6].
20-20-2
B250 Loader Backhoe

Service Manual
WARNING
Removal And Installation (Contd)

Figure 20-20-7

immediately.
W-2145-0290
2
1
Figure 20-20-9
1
1
P-50513
Support the cylinder (Item 1) and remove the pivot pin

(Item 2) [Figure 20-20-7]. Lower the cylinder onto a
wood block.
Figure 20-20-8
P-50516
2
Remove the two hoses (Item 1) [Figure 20-20-9].
NOTE: Mark the hoses for correct assembly.
1
Figure 20-20-10
1
P-50514
Install the pivot pin (Item 1) [Figure 20-20-8].

support the arm assembly.

P-50518

Install a hoist and lifting strap (Item 1) [Figure 20-20-10]

to lift and support the cylinder.
Remove the snap ring and washer (Item 2) [Figure 2020-10].
20-20-3
B250 Loader Backhoe

Service Manual

Figure 20-20-11
P-50520
Remove the pivot pin (Item 1) [Figure 20-20-11].

Figure 20-20-12
P-50519
Remove the cylinder [Figure 20-20-12].
20-20-4
B250 Loader Backhoe

Service Manual

Parts Identification
1. Tube
2. Case
3. Nut
4. Piston
5. Ring
6. O-ring
7. Spacer
8. O-Ring
9. Backup Washer
10. Head
11. Seal
12. Seal
13. Rod
7
5
6
13
4
3
12
11
1
10
9
8
B-6942A
20-20-5
B250 Loader Backhoe

Service Manual
Figure 20-20-15
Disassembly
Use the following tool to disassemble the cylinder:
1
MEL1075
Figure 20-20-13
1
P-50083
Remove the rod assembly (Item 1) [Figure 20-20-15]

from the housing.
Figure 20-20-16
1
P-50077
Put the base end of the cylinder in a vise (Item 1) and

support the cyinder with a wood block (Item 2) [Figure
20-20-13].
Figure 20-20-14
P-50079
Put the rod end of the cylinder in a vise (Item 1) and

support the cylinder rod with a wood block (Item 2)
[Figure 20-20-16].
P-50078
Use a gland nut wrench (MEL 1075) and remove the

head gland (Item 1) [Figure 20-20-14].
20-20-6
B250 Loader Backhoe

Service Manual
Figure 20-20-19
Disassembly (Contd)
Figure 20-20-17
P-50081
Remove the spacer (Item 1) and head gland (Item 2)

[Figure 20-20-19].
P-50080
Figure 20-20-20
Remove the nut (Item 1) and the piston (Item 2) [Figure
20-20-17].
Figure 20-20-18
3
3
2
1
2
1
P7422
Remove the O-ring (Item 1), backup washer (Item 2) and

O-ring (Item 3) [Figure 20-20-20] from the head gland.
P7430
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-20-18].
20-20-7
B250 Loader Backhoe

Service Manual
Assembly
Disassembly (Contd)
Wash the cylinder parts in solvent and dry with

compressed air.
Figure 20-20-21
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Lubricate all O-rings and seals with hydraulic oil during

installation.
Figure 20-20-22
1
P-50082
Remove the wiper (Item 1) and rod seal (Item 2) [Figure

20-20-21] from the head gland.
P-50082
Install the wiper (Item 1) and rod seal (Item 2) [Figure

20-20-22] in the head gland.
Figure 20-20-23
3
1
P74227
Install the O-ring (Item 3), backup washer (Item 2) and Oring (Item 1) [Figure 20-20-23] on the head gland.
20-20-8
B250 Loader Backhoe

Service Manual
Figure 20-20-26
Assembly (Contd)
Figure 20-20-24
P-50080
1
Clean and dry the cylinder rod threads. Install the piston
(Item 1). Apply Loctite 242 or equivelant to the cylinder
rod threads and install the nut (Item 2) [Figure 20-20-26].
P-50081
Install the head gland (Item 1) and spacer (item 2)

[Figure 20-20-24] onto the cylinder rod.
Installation: Tighten the nut to 105 ft.-lb. (142 Nm)

torque.
Figure 20-20-25
Figure 20-20-27
3
2
3
P7430
P-50083
Install the O-ring (Item 2) and seal (Item 1) onto the

Install the rod assembly (Item 1), into the housing (Item
2) and tighten the head gland (Item 3) [Figure 20-20-27].
20-20-9
B250 Loader Backhoe

Service Manual
20-20-10
B250 Loader Backhoe

Service Manual
BOOM CYLINDER
Figure 20-21-2
Checking
Extend the backhoe arm out and lower the boom to the
ground. Stop the engine. Engage the parking brake.
pressure.
WARNING
immediately.
W-2145-0290
P-50593
Remove the pivot pin retainer bolt (Item 1) [Figure 2021-2].

Installation: Tighten the bolt to 18-19 ft.-lb. (24-26 Nm)
torque.
Figure 20-21-1
Figure 20-21-3
P-50592
P-50594

lift and support the cylinder.
20-21-1
B250 Loader Backhoe

Service Manual
BOOM CYLINDER (CONTD)
Figure 20-21-6
Checking (Contd)
Figure 20-21-4
1
P-50596

P-50597
Figure 20-21-7
Remove the nut (Item 1) and remove the hose clamps
(Item 2) [Figure 20-21-4].
Figure 20-21-5
1
P-50598
Reposition the cylinder [Figure 20-21-7].

P-50595
20-21-2
B250 Loader Backhoe

Service Manual
Checking (Contd)
Extend the backhoe arm out and lower the boom to the
ground. Stop the engine. Engage the parking brake.
pressure.
Figure 20-21-8
WARNING

immediately.
W-2145-0290
P-50599
Figure 20-21-10
base end of the cylinder.
Figure 20-21-9
1
2
1
P-50592

to lift and support the cylinder.
P-50590
Install a plug (Item 1) [Figure 20-21-9] in the hose and

tighten.
fully retract the boom cylinder. If there is any leakage
from the base end fitting (Item 2) [Figure 20-21-9]
remove the cylinder for repair or replacement.
20-21-3
B250 Loader Backhoe

Service Manual
Figure 20-21-13

Figure 20-21-11
P-50597
Remove the nut (Item 1 and remove the hose clamps

(Item 2) [Figure 20-21-13].
P-50593
Figure 20-21-14
torque.
Figure 20-21-12
1
P-50595
P-50594
20-21-4
B250 Loader Backhoe

Service Manual
Figure 20-21-17

Figure 20-21-15
P-50599

P-50596
NOTE: Mark hoses for correct assembly.

IMPORTANT
Figure 20-21-16

damage the system.
I-2003-0888
Figure 20-21-18
P-50598
Reposition the cylinder (Item 1) [Figure 20-21-16].
P-50601
20-21-5
B250 Loader Backhoe

Service Manual

1. Tube
2. Case
3. Nut
4. Piston
5. Ring
6. O-ring
7. Spacer
8. O-Ring
9. Backup Washer
10. Head
11. Seal
12. Seal
13. Rod
7
5
6
13
4
3
12
11
1
10
9
8
B-6942A
20-21-6
B250 Loader Backhoe

Service Manual
Figure 20-21-21
Disassembly
1
MEL1075-Spanner Wrench
Figure 20-21-19
1
P-50083

from the housing.
Figure 20-21-22
1
P-50077

20-21-19].
Figure 20-21-20
P-50079

[Figure 20-21-22].
P-50078

20-21-7
B250 Loader Backhoe

Service Manual
Figure 20-21-25
Disassembly (Contd)
Figure 20-21-23
P-50081

[Figure 20-21-25].
P-50080
Figure 20-21-26
20-21-23].
Figure 20-21-24
3
3
2
1
2
1
P7422

P7430

20-21-8
B250 Loader Backhoe

Service Manual
Assembly
Disassembly (Contd)

compressed air.
Figure 20-21-27

installation.
Figure 20-21-28
1
P-50082

P-50082

Figure 20-21-29
3
1
P74227
20-21-9
B250 Loader Backhoe

Service Manual
Figure 20-21-32
Assembly (Contd)
Figure 20-21-30
P-50080
1
P-50081


torque.
Figure 20-21-31
Figure 20-21-33
3
2
3
P7430
P-50083

2) and tighten the head gland (Item 3) [Figure 20-21-33]
20-21-10
B250 Loader Backhoe

Service Manual
SWING CYLINDER
Figure 20-22-2
Checking
Install the swing lock pin. (See Engaging The Swing Lock
Pin on Page 10-190-1.)

Operate the control levers to relieve hydraulic pressure.
WARNING
immediately.
W-2145-0290
P-50656

base end of the cylinder.
Figure 20-22-3
Figure 20-22-1
1
2
2
P-50657

tighten.
P-50654
Remove the pivot pin retainer bolt (Item 1) and the pivot
pin (Item 2) [Figure 20-22-1].

retract the swing cylinder.

torque.

[Figure 20-22-3] remove the cylinder for repair or
replacement.
20-22-1

Service Manual
SWING CYLINDER (CONTD)
Figure 20-22-5

The backhoe must be side shifted to the left to remove
the left swing cylinder, or to the right for removal of the
right swing cylinder.
Pin on Page 10-190-1.) Stop the engine. Engage the
parking brake. Operate the control levers to relieve
hydraulic pressure.
WARNING
P-50658

immediately.
W-2145-0290
Remove the four bolts (Item 1) [Figure 20-22-5].

Installation: Tighten the bolts to 70 ft.-lb. (95 Nm)
torque.
Figure 20-22-6
Figure 20-22-4
P-50659
Remove the plate (Item 1) [Figure 20-22-6].
P-50654
Remove the pivot pin retainer bolt (Item 1) and the pivot
pin (Item 2) [Figure 20-22-4].
torque.
20-22-2

Service Manual
Figure 20-22-8

Figure 20-22-7
1
P-50662
Remove the swing cylinder [Figure 20-22-8].

P-50661

IMPORTANT
damage the system.
I-2003-0888
20-22-3

Service Manual

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Housing
Bushing
Grease Fitting
Seal
O-Ring
Wiper
Back-up Ring
Piston
Head
Nut
Rod
6
3
4
9
5
7
5
11
8
5
4
2
2
10
B-22638s
20-22-4

Service Manual
Figure 20-22-11
Disassembly
MEL1075
Figure 20-22-9
P-50667

from the housing.
Figure 20-22-12
P-50665
Place the cylinder in a vise [Figure 20-22-9].

Figure 20-22-10
P-50668
Place the rod end of the cylinder in a vise and support it

with a wood block [Figure 20-22-12].
P-50666
Use a gland nut wrench (MEL1075) and remove the head

gland (Item 1) [Figure 20-22-10].
20-22-5

Service Manual
Figure 20-22-15
Disassembly (Contd)
Figure 20-22-13
P-50672
P-50669
Remove the seal (Item 1) and O-ring (Item 2) [Figure 2022-15] from the piston.
Figure 20-22-16
Remove the nut (Item 1) [Figure 20-22-13].

Figure 20-22-14
1
P-50673
P-50670
Remove the head gland (Item 1) [Figure 20-22-16].
Remove the piston (Item 1) [Figure 20-22-14].
20-22-6

Service Manual
Assembly
Disassembly (Contd)

compressed air.
Figure 20-22-17
installation.
Figure 20-22-19
2
P-50625
Remove the wiper (Item 1) and seal (Item 2) [Figure 2022-17] from the head.
Figure 20-22-18
P7422
Install the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-22-19] on the head gland.
Figure 20-22-20
2
1
P7422
Remove the two O-rings (Item 1) and backup ring (Item

2) [Figure 20-22-18].
2
1
P-50625
Install the wiper (Item 1) and seal (Item 2) [Figure 20-2220] in the head gland.
20-22-7

Service Manual
Figure 20-22-23
Assembly (Contd)
Figure 20-22-21
1
1
P-50670
Install the piston (Item 1) [Figure 20-22-23] onto the

cylinder rod.
P-50673
Figure 20-22-24
Install the head gland (Item 1) [Figure 20-22-21] onto the
cylinder rod.
Figure 20-22-22
1
1
P-50669
Clean and dry the cylinder rod threads and apply

LOCTITE 271 or equivalent. Install the nut (Item 1)
[Figure 20-22-24].
P-50672
Install the O-ring (Item 1) and seal (Item 2) [Figure 2022-22] onto the piston.

torque.
20-22-8

Service Manual
Bushing Removal And Installation
Assembly (Contd)
Inspect all bushings and replace as necessary.
Figure 20-22-25
Figure 20-22-27
P-50667
P-50660
Install the rod assembly (Item 1) [Figure 20-22-25] into

the housing.
Remove the bushings (Item 1) [Figure 20-22-27].
Figure 20-22-26
NOTE: For correct assembly note the direction of the

bushing as it is removed.
Installation: Install the bushings until they are flush with
the support.
1
Figure 20-22-28
P-50666
Use a gland nut wrench (MEL1075) to tighten the head

P-50663
Remove the bushings (Item 1) [Figure 20-22-28].

Installation: Install the bushings until they are flush with
the support.
20-22-9

Service Manual

Bushing Removal And Installation (Contd)
Figure 20-22-29
P-50664
Remove the bushings (Item1) [Figure 20-22-29].

Installation: Install the bushings until they are flush.
20-22-10

Service Manual
BUCKET CYLINDER
Figure 20-23-3
Checking
Remove the bucket. (See the Operation & Maintenance
manual for the correct procedure.)
1
Figure 20-23-1
P-50583
1
Remove the pivot plate (Item 1) [Figure 20-23-3].
Figure 20-23-4
2
P-50588
Install the boom lock pin (Item 1) in the transport position

(as shown) and install the retainer pin (Item 2) [Figure
20-23-1].
1
Stop the engine, move the control levers to release any

hydraulic pressure.
Figure 20-23-2
1
P-50584
Remove the pivot pin assembly (Item 1) [Figure 20-234].

2
P-50581
Remove the snap rings (Item 1) and washers (Item 2)

[Figure 20-23-2].
20-23-1
B250 Loader Backhoe

Service Manual
BUCKET CYLINDER (CONTD)
WARNING
Checking (Contd)
Figure 20-23-5

immediately.
W-2145-0290
2
Figure 20-23-7
1
2
P-49086
Remove the U-bolt (Item 1) and reposition the auxiliary

hydraulic couplers (Item 2) [Figure 20-23-5].
1

fully retract the bucket cylinder.
P-50613

Install a plug (Item 1) [Figure 20-23-7] on the hose and

tighten.
Figure 20-23-6
retract the arm cylinder.
[Figure 20-23-7] on the arm cylinder, remove the
1
P-50522

base of the cylinder.
20-23-2
B250 Loader Backhoe

Service Manual
Figure 20-23-10

Remove the bucket. (See Operation & Maintenance
manual for the correct procedure.)
1
Figure 20-23-8
P-50583
1
Remove the pivot plate (Item 1) [Figure 20-23-10].
2
Figure 20-23-11
P-50588
Install the boom lock pin (Item 1) in the transport position

(as shown) and install the retainer pin (Item 2) [Figure
20-23-8].
Stop the engine, move the control levers to release any
hydraulic pressure.
Figure 20-23-9
1
1
P-50584
2
Remove the pivot pin assembly (Item 1) [Figure 20-2311].
2
P-50581
Remove the snap rings (Item 1) and washers (Item 2)

[Figure 20-23-9].
20-23-3
B250 Loader Backhoe

Service Manual
Figure 20-23-14

Figure 20-23-12
1
P-50614
1
Remove the hose (Item 1) [Figure 20-23-14].
P-49086

hydraulic couplers (Item 2) [Figure 20-23-12].
IMPORTANT
Figure 20-23-13

damage the system.
I-2003-0888
Figure 20-23-15
P-50522
1
2
WARNING
immediately.
P-50528
Install a hoist and lifting strap (Item 1) to lift and support

the cylinder. Remove the snap ring and washer (Item 2)
[Figure 20-23-15].
W-2145-0290
20-23-4
B250 Loader Backhoe

Service Manual

Figure 20-23-16
P-50529

Figure 20-23-17
1
P-50530
Remove the bucket cylinder (Item 1) [Figure 20-23-17].
20-23-5
B250 Loader Backhoe

Service Manual

1. Tube
2. Case
3. Nut
4. Piston
5. Ring
6. O-ring
7. Spacer
8. O-Ring
9. Backup Washer
10. Head
11. Seal
12. Seal
13. Rod
7
5
6
13
4
3
12
11
1
10
9
8
B-6942A
20-23-6
B250 Loader Backhoe

Service Manual
Figure 20-23-20
Disassembly
1
MEL1075
Figure 20-23-18
1
P-50083

from the housing.
Figure 20-23-21
1
P-50077

20-23-18].
Figure 20-23-19
P-50079

[Figure 20-23-21].
P-50078

20-23-7
B250 Loader Backhoe

Service Manual
Figure 20-23-24
Disassembly (Contd)
Figure 20-23-22
P-50081

[Figure 20-23-24].
P-50080
Figure 20-23-25
20-23-22].
Figure 20-23-23
3
3
2
1
2
1
P7422

P7430

20-23-8
B250 Loader Backhoe

Service Manual
Assembly
Disassembly (Contd)

compressed air.
Figure 20-23-26

installation.
Figure 20-23-27
1
P-50082

P-50082

Figure 20-23-28
3
1
P74227
20-23-9
B250 Loader Backhoe

Service Manual
Figure 20-23-31
Assembly (Contd)
Figure 20-23-29
P-50080
1
P-50081


torque.
Figure 20-23-30
Figure 20-23-32
3
2
3
P7430
P-50083

20-23-10
B250 Loader Backhoe

Service Manual
STABILIZER CYLINDER
Figure 20-24-2
Checking
Retract the stabilizer. Stop the engine and engage the
parking brake.
WARNING

immediately.
W-2145-0290
Figure 20-24-1
P-50604
Remove the tubeline clamp (Item 1) [Figure 20-24-2].

Installation: Tighten the clamp bolt to 18-19 ft.-lb. (24-26
Nm) torque.
Figure 20-24-3
3
2
1
1
P-50603
Check only one cylinder at a time. Remove the cover bolt

(Item 1) and the cover (Item 2) [Figure 20-24-1].
P-50627
Remove the tubeline (Item 1) from the base end of the

cylinder. Install a plug (Item 2) [Figure 20-24-3] in the
tubeline and tighten.
With the parking brake engaged start the engine and
retract the stabilizer cylinder.
If there is any leakage from the fitting (Item 3) [Figure 2024-3] remove the cylinder for repair or replacement.
20-24-1

Service Manual
STABILIZER CYLINDER (CONTD)
Figure 20-24-5

Lower the stabilizer to the ground. Stop the engine and
engage the parking brake.
WARNING
immediately.
W-2145-0290
P-50604

Installation: Tighten the clamp bolt to 18-19 ft.-lb. (24-26
Nm) torque.
Figure 20-24-4
Figure 20-24-6
2
P-50603
P-50652
Remove the cover bolt (Item 1) and the cover (Item 2)

[Figure 20-24-4].
Remove the two tubelines (Item 1) [Figure 20-24-6].

NOTE: Mark tubelines for correct assembly.
IMPORTANT
damage the system.
I-2003-0888
20-24-2

Service Manual
Figure 20-24-9

Figure 20-24-7
P-50607
Remove the pin (Item 1) [Figure 20-24-9].

P-50608
Figure 20-24-10
Install a hoist to lift and support the cylinder [Figure 2024-7].
1
Figure 20-24-8
P-50609
Remove the snap ring (Item 1) [Figure 20-24-10].

P-50606
20-24-3

Service Manual

Figure 20-24-11
1
P-50610

Figure 20-24-12
P-50612
20-24-4

Service Manual

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Housing
O-Ring
Fitting
Plug
Lock Valve
Tube
Seal
Back-up Ring
Wiper
Piston
Head
Nut
Rod
4
2
4
3
3
2
1
9
7
5
2
11
2
6
8
2
10
2
13
12
b-22634s
20-24-5

Service Manual
Figure 20-24-14
Disassembly
Use the following tool to disassemble the cylinder.
MEL1075-Gland Nut Wrench
IMPORTANT
damage the system.
I-2003-0888
1
P-50616
Mark the position of the load lock (Item 1) [Figure 20-2414] and remove.
Figure 20-24-13
Figure 20-24-15
2
P-50615
P-50617
Place the base end of the cylinder in a vise [Figure 2024-13].
Remove the three O-rings (Item 1) and three backup

washers (Item 2) [Figure 20-24-15]. Replace as needed.
Note the position of O-rings and backup washers for
correct assembly.
20-24-6

Service Manual
Figure 20-24-18
Disassembly (Contd)
Figure 20-24-16
P-50620

from the housing.
P-50618
Figure 20-24-19
Remove the plug (Item 1) [Figure 20-24-16].
Figure 20-24-17
P-50621
Place the rod end of the cylinder in a vise [Figure 20-2419].
P-50619
Use a gland nut wrench (MEL-1075) and remove the

20-24-7

Service Manual
Figure 20-24-22
Disassembly (Contd)
Figure 20-24-20
1
1
P-50626
Remove the head gland (Item 1) [Figure 20-24-22].

P-50622
Figure 20-24-23
Remove the nut (Item 1) and piston (Item 2) [Figure 2024-20].
Figure 20-24-21
3
2
2
1
P7422
Remove the thick O-ring (Item 1) backup washer (Item 2)

and thin O-ring (Item 3) [Figure 20-24-23] from the head
gland.
P7430

20-24-8

Service Manual

Disassembly (Contd)
Figure 20-24-24
2
1
P-50625
Remove the wiper seal (Item 1) and rod seal (Item 2)

[Figure 20-24-24].
20-24-9

Service Manual
Figure 20-24-27
Assembly
Clean all parts with solvent and dry with compressed air.
Inspect all parts for wear or damage. Replace any worn
or damaged parts. Lubricate all O-rings and seals with
clean hydraulic fluid before installation.
Figure 20-24-25
1
P-50626
Install the head gland (Item 1) [Figure 20-24-27].

Figure 20-24-28
3
1
2
1
P-50625
2
Install the rod seal (Item 1) and wiper seal (Item 2)
[Figure 20-24-25].
Figure 20-24-26
P7430
1
3
Install the O-ring (Item 1) and backup washer (Item 2)

onto the piston (Item 3) [Figure 20-24-28].
P7422
Install the thin O-ring (Item 1), backup washer (Item 2)

and thick O-ring (Item 3) [Figure 20-24-26] on the head
gland.
20-24-10

Service Manual
Figure 20-24-31
Assembly (Contd)
Figure 20-24-29
P-50620
Place the base end of the cylinder housing in a vise and

install the rod assembly (Item 1) [Figure 20-24-31].
P-50623
Figure 20-24-32
Install the piston (Item 1) [Figure 20-24-29].
Figure 20-24-30
1
P-50619
Use a gland nut wrench (MEL1075) to tighten the head

P-50622
Apply LOCTITE 242 or equivalent to the cylinder rod

threads and install the nut (Item 1) [Figure 20-24-30].
torque.
20-24-11

Service Manual
Figure 20-24-35
Assembly (Contd)
Figure 20-24-33
1
P-50616
Install the load lock (Item 1) [Figure 20-24-35] and

tighten to the position recorded earlier.
P-50618
Install the plug (Item 1) [Figure 20-24-33].

Figure 20-24-34
2
1
P-50617
Install the three O-rings (Item 1) and backup washers

(Item 2) [Figure 20-24-34].
20-24-12

Service Manual
SIDE SHIFT LOCK CYLINDER
Figure 20-25-2

Pin on Page 10-190-1.)
1
Lower the backhoe to the ground.
pressure.
Figure 20-25-1
P-50721

Figure 20-25-3
1
P-40780
Rotate the sideshift lock lever (Item 1) [Figure 20-25-1]

to the unlocked position.
P-50722
WARNING
Remove the 4 bolts (Item 1) [Figure 20-25-3].

immediately.

torque.
W-2145-0290
20-25-1

Service Manual
SIDE SHIFT LOCK CYLINDER (CONTD)

Figure 20-25-4
P-50723
Remove the lock cylinder (Item 1) [Figure 20-25-4].
20-25-2

Service Manual

1.
2.
3.
4.
5.
Piston
Wear Band
Seal
Housing
Grease Fitting
MS2111
20-25-3

Service Manual
Figure 20-25-7
Disassembly
1
Figure 20-25-5
1
P-50726
P-50724
Remove the 2 wear bands (Item 1) and seal (Item 2)

[Figure 20-25-7].
Remove the lock plate (Item 1) [Figure 20-25-5].

Figure 20-25-6
1
P-50725
Remove the piston (Item 1) [Figure 20-25-6].
20-25-4

Service Manual
Figure 20-25-10
Assembly

compressed air.
Lubricate seal and wear bands with hydraulic oil during
assembly.
Figure 20-25-8
P-50724
1
Install the lock plate (Item 1) [Figure 20-25-10].
2
P-50726
Install the 2 wear bands (Item 1) and seal (Item 2)

[Figure 20-25-8].
Figure 20-25-9
1
P-50725
Install the piston (Item 1) [Figure 20-25-9].

Use a good quality lithium based multi-purpose grease
and apply 2 to 3 pumps of lubricant to the grease fitting.
20-25-5

Service Manual
20-25-6

Service Manual
TILT CYLINDER
Figure 20-30-2
Checking
Remove attachment from the Bob-Tach.
Lower the lift arms to the ground, fully retract the tilt
cylinders.
Stop the engine, engage the parking brake.

Operate the control lever to relieve hydraulic pressure.
WARNING

immediately.
W-2145-0290
Figure 20-30-1
P-50511

tighten.
retract the cylinder.
[Figure 20-30-2], remove the cylinder for repair or
replacement.
P-50014
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-30-1] from the base end of the tilt
cylinder.
20-30-1

Service Manual
TILT CYLINDER (CONTD)
Figure 20-30-4

Lower the lift arms to the ground.
1
Operate control levers to relieve hydraulic pressure.
WARNING
immediately.
W-2145-0290
P-50568
Remove the pivot pin retainer nut and washer (Item 1)

[Figure 20-30-4].
Installation: Tighten the nut to 90-100 ft.-lb. (125-140
Nm) torque.
Figure 20-30-3
Figure 20-30-5
1
P-50015
P-50569

Remove the pin retainer bolt (Item 1) [Figure 20-30-5].
Installation: Tighten the bolts to 32-35 ft.-lb. (43-47 Nm)
torque.
IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses,
damage the system.
I-2056-0793
20-30-2

Service Manual
Figure 20-30-8

Figure 20-30-6
1
1
2
P-50019
Remove the pivot pin retainer bolt (Item 1) and remove

the pivot pin (Item 2) [Figure 20-30-8].
P-50570


torque.
Figure 20-30-9
Figure 20-30-7
P-50020
P-50571

Remove the rod end pivot pin (Item 1) [Figure 20-30-7].
20-30-3

Service Manual

1. Tube
2. Case
3. Nut
4. Piston
5. Ring
6. O-ring
7. Spacer
8. O-Ring
9. Backup Washer
10. Head
11. Seal
12. Seal
13. Rod
7
5
6
13
4
3
12
11
1
10
9
8
B-6942A
20-30-4

Service Manual
Figure 20-30-12
Disassembly
1
MEL1075
Figure 20-30-10
1
P-50083

from the housing.
Figure 20-30-13
1
P-50077

20-30-10].
Figure 20-30-11
P-50079

[Figure 20-30-13].
P-50078

20-30-5

Service Manual
Figure 20-30-16
Disassembly (Contd)
Figure 20-30-14
P-50081

[Figure 20-30-16].
P-50080
Figure 20-30-17
20-30-14].
Figure 20-30-15
3
3
2
1
2
1
P7422

P7430

20-30-6

Service Manual
Assembly
Disassembly (Contd)

compressed air.
Figure 20-30-18

installation.
Figure 20-30-19
1
P-50082

P-50082

Figure 20-30-20
3
1
P74227
20-30-7

Service Manual
Figure 20-30-23
Assembly (Contd)
Figure 20-30-21
P-50080
1
P-50081


torque.
Figure 20-30-22
Figure 20-30-24
3
2
3
P7430
P-50083

20-30-8

Service Manual
LIFT CYLINDER
Figure 20-31-2
Checking
Lower the lift arms. Stop the engine.
1
Engage the parking brake and exit the machine.
WARNING
immediately.
W-2145-0290
Figure 20-31-1
P-50009P36039

tighten.
Engage the parking brake. Start the engine and retract
the lift cylinder.
If there is any leakage from the fitting, remove the
P-50008
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-31-1] which goes to the base end of
the lift cylinder.
20-31-1

Service Manual
LIFT CYLINDER (CONTD)
Figure 20-31-4

Lower the lift arms, engage the parking brake, stop the
engine.
WARNING
immediately.
W-2145-0290
P-50012

Figure 20-31-3
Figure 20-31-5
1
1
2
P-50008
P-50011
Remove the two hoses from the lift cylinder (Item 1)

[Figure 20-31-3].
NOTE: Mark hoses for correct installation. Install
caps and plugs.
Remove the pivot pin retainer bolt (Item 1) [Figure 2031-5] from the rod end of the cylinder.
Installation: Tighten the retainer bolt and nut to 18-20 ft.lb. (24-27 Nm) torque.
Remove the rod end pivot pin (Item 2) [Figure 20-31-5].
Lower the cylinder.
20-31-2

Service Manual

Figure 20-31-6
P-50010
Remove the retainer bolt (Item 1) and retainer (Item 2)

[Figure 20-31-6].
Installation: Tighten the retainer bolt and nut to 18-20 ft.lb. (24-27 Nm) torque.
Remove the cylinder.
20-31-3

Service Manual

1. Tube
2. Case
3. Nut
4. Piston
5. Ring
6. O-ring
7. Spacer
8. O-Ring
9. Backup Washer
10. Head
11. Seal
12. Seal
13. Rod
7
5
6
13
4
3
12
11
1
10
9
8
B-6942A
20-31-4

Service Manual
Figure 20-31-9
Disassembly
1
MEL1075
Figure 20-31-7
1
P-50083
Remove the rod assembly (Item 1) [Figure 20-31-9] from

the housing.
Figure 20-31-10
1
P-50077

20-31-7].
Figure 20-31-8
P-50079

[Figure 20-31-10].
P-50078

20-31-5

Service Manual
Figure 20-31-13
Disassembly (Contd)
Figure 20-31-11
P-50081

[Figure 20-31-13].
P-50080
Figure 20-31-14
20-31-11].
Figure 20-31-12
3
3
2
1
2
1
P7422

P7430

20-31-6

Service Manual
Assembly
Disassembly (Contd)

compressed air.
Figure 20-31-15

installation.
Figure 20-31-16
1
P-50082

P-50082

Figure 20-31-17
3
1
P74227
20-31-7

Service Manual
Figure 20-31-20
Assembly (Contd)
Figure 20-31-18
P-50080
1
P-50081


torque.
Figure 20-31-19
Figure 20-31-21
3
2
3
P7430
P-50083

20-31-8

Service Manual
STEERING CYLINDER (FRONT)
Figure 20-32-3

Lift and block the loader backhoe. (See Procedure on
Page 10-10-1.)
Remove the side covers. (See Removal And Installation

on Page 50-60-1.)
Figure 20-32-1
P-40326
Measure length of tie rod (Item 1) to ball joint (Item 2)

[Figure 20-32-3]. Record length for correct assembly.
1
Figure 20-32-4
P-40324
2
Remove the tie rod nut (Item 1) [Figure 20-32-1].
Installation: Tighten nut to 55-60 ft.-lb. (75-85 Nm)
torque.
1
Figure 20-32-2
1
P-40327
Loosen jam nut (Item 1). Remove the tie rod (Item 2)
[Figure 20-32-4].
2
P-40325
Remove the tie rod (Item 1) from the arm (Item 2) [Figure
20-32-2].
20-32-1

Service Manual
STEERING CYLINDER (FRONT) (CONTD)
Figure 20-32-7

Figure 20-32-5
2
1
P-40330
1
Measure length of tie rod (Item 1) to ball joint (Item 2)
[Figure 20-32-7] Record length for correct assembly.
P-40328
Figure 20-32-8
torque.
2
Figure 20-32-6
1
1
2
P-40331
Loosen the jam nut (Item 1). Remove the tie rod (Item 2)
[Figure 20-32-8].
P-40329
20-32-6].
20-32-2

Service Manual
Figure 20-32-11

Figure 20-32-9
P-40790
Remove the left steering cylinder hose (Item 1) [Figure

20-32-11]
P-40787
Figure 20-32-12
Remove the right steering cylinder hose (Item 1) [Figure
20-32-9].
IMPORTANT

damage the system.
I-2003-0888
P-40789
Figure 20-32-10
Remove the fitting (Item 1) [Figure 20-32-12]
P-40788
Remove the fitting (Item 1) [Figure 20-32-10].
20-32-3

Service Manual
Figure 20-32-15

Figure 20-32-13
1
2
1
P-40338
Remove the steering cylinder (Item 1) [Figure 20-32-15].

P-50084
Remove the five nuts (Item 1) on the left wheel. Remove

the wheel (Item 2) [Figure 20-32-13].
Installation: Tighten nuts to 140 ft.-lb. (190 Nm) torque.
Figure 20-32-14
1
1
P-40336
Remove the three steering cylinder mounting bolts (Item

1) [Figure 20-32-14].
Installation: Tighten bolts to 55-60 ft.-lb. (75-85 Nm)
torque.
20-32-4

Service Manual

CYLINDER
JOINT
NUT
TIE ROD
O-RING
ROD
HEAD
BOLT
SEAL
10
WIPER
4
3
2
9
7
2
3
10
6
5
3
9
5
9
10
B-19711A
20-32-5

Service Manual
Figure 20-32-18
Disassembly And Assembly

Figure 20-32-16
1
1
P-40166
1
Figure 20-32-19
P-40165
Mark the ball joints (Item 1) [Figure 20-32-16] for correct

assembly to steering cylinder.
Figure 20-32-17
1
CUT
3.500
0.8750
3.500
P-40167
Place both halves of the hardwood block around the rod.

Clamp the blocks in a vise [Figure 20-32-18] and
[Figure 20-32-19].
1.500
NOTE: Do not use anything other than hardwood

blocks to grip the rod, or the rod will be
damaged.
B-14674
To remove the ball joint from the rod, a holding fixture will
have to be made from a 1.500 inch thick x 3.500 inch
wide x 3.500 inch long (38 mm thick x 89 mm wide x 89
mm long) piece of hardwood. Drill a 0.8750 inch (22 mm)
hole in the center of the hardwood block. Cut the block
lengthwise [Figure 20-32-17].
Apply moderate heat to ball joint (Item 1) [Figure 20-3218] and (Item 1) [Figure 20-32-19] to break thread
sealant. Remove the ball joints (Item 1) [Figure 20-3218] and (Item 1) [Figure 20-32-19].
NOTE: Ball joint is threaded into rod end.
20-32-6

Service Manual
Figure 20-32-22
Disassembly And Assembly (Contd)

Figure 20-32-20
1
2
P-40170
Remove the O-ring (Item 1) [Figure 20-32-22] Replace

as necessary.
P-40168
Figure 20-32-23
Mark the head (Item 1) to the cylinder (Item 2) [Figure
20-32-20] for correct assembly.
1
Figure 20-32-21
P-40171
P-40169
Remove the wiper (Item 1) [Figure 20-32-23] Replace as

necessary.
Remove the head (Item 1) [Figure 20-32-21].
20-32-7

Service Manual
Figure 20-32-26

2
Figure 20-32-24
P-40174
Remove the wear ring (Item 1) from the piston (Item 2)

[Figure 20-32-26]. Replace as necessary.
P-40172
Figure 20-32-27
Remove the seal (Item 1) [Figure 20-32-24] Replace as
necessary.
Figure 20-32-25
2
2
1
1
P-40175
Remove the sealing ring (Item 1) from the piston (Item 2)

P-40173
Remove the rod (Item 1) from the cylinder (Item 2)

[Figure 20-32-25].
20-32-8

Service Manual
Figure 20-32-30

1
Figure 20-32-28
P-40179
Remove the seal (Item 1) [Figure 20-32-30]. Replace as

necessary.
P-40176
Inspection
Remove the O-ring (Item 1) from the piston (Item 2)
Figure 20-32-29
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of
material can get into the system and cause damage.
Figure 20-32-31
1
P-40178
P-40180
Remove the wiper (Item 1) from the cylinder (Item 2)

Inspect the cylinder (Item 1) [Figure 20-32-31] for

scratches, scoring or cracks. Replace as needed.
20-32-9

Service Manual

Figure 20-32-32
P-40177
Inspect the rod (Item 1) for scratches and scoring.

Inspect the piston (Item 2) [Figure 20-32-32] for scoring
and cracks. Replace as needed
20-32-10

Service Manual
STEERING CYLINDER (REAR)
Figure 20-33-3

Remove the rear axle. (See Drive Axle Disassembly on
Page 40-31-8.)
NOTE: Set axle assembly on a secure work surface.
Figure 20-33-1
2
P-40848
Measure length of the tie rod (Item 1) to ball joint (Item 2)

Figure 20-33-4
P-40845
1
torque.
2
Figure 20-33-2
P-40851
Loosen jam nut (Item 1) and remove the tie rod (Item 2)
[Figure 20-33-4].
2
P-40846
20-33-2].
20-33-1

Service Manual
STEERING CYLINDER (REAR) (CONTD)
Figure 20-33-7

Figure 20-33-5
1
1
P-40849
Measure length of the (Item 1) to ball joint (Item 2)

P-40844
Figure 20-33-8
1

torque.
Figure 20-33-6
2
1
P-40850
Loosen jam nut (Item 1). Remove the tie rod (Item 2)
[Figure 20-33-8].
P-40847
20-33-6].
20-33-2

Service Manual
Figure 20-33-11

Figure 20-33-9
1
1
1
P-40854
Remove the steering cylinder (Item 1) [Figure 20-33-11].

P-40852
Remove the fittings (Item 1) [Figure 20-33-9].

Figure 20-33-10
1
P-40853
Remove the three steering cylinder mounting bolts (Item

1) [Figure 20-33-10].
torque.
20-33-3

Service Manual

1.
CYLINDER
2.
JOINT
3.
NUT
4.
TIE ROD
5.
O-RING
6.
ROD
7.
HEAD
8.
BOLT
9.
SEAL
10.
WIPER
4
9
7
2
10
3
4
6
5
3
5
9
10
B19711A
20-33-4

Service Manual
Figure 20-33-14

Figure 20-33-12
1
1
P-40166
1
Figure 20-33-15
P-40165
Mark the ball joints (Item 1) [Figure 20-33-12] for correct

assembly to steering cylinder.
Figure 20-33-13
1
CUT
3.500
0.8750
3.500
P-40167
Place both halves of the hardwood block around the rod.

Clamp the blocks in a vise [Figure 20-33-14] and
[Figure 20-33-15].
1.500
NOTE: Do not use anything other than hardwood

blocks to grip the rod, or the rod will be
damaged.
B-14674
To remove the ball joint from the rod, a holding fixture will
have to be made from a 1.500 inch thick x 3.500 inch
wide x 3.500 inch long (38 mm thick x 89 mm wide x 89
mm long) piece of hardwood. Drill a 0.8750 inch (22 mm)
hole in the center of the hardwood block. Cut the block
lengthwise [Figure 20-33-13].
Apply moderate heat to ball joint (Item 1) [Figure 20-3314] and (Item 1) [Figure 20-33-15] to break thread
sealant. Remove the ball joints (Item 1) [Figure 20-3314] and (Item 1) [Figure 20-33-15].
NOTE: Ball joint is threaded into rod end.
20-33-5

Service Manual
Figure 20-33-18

Figure 20-33-16
1
2
P-40170
Remove the O-ring (Item 1) [Figure 20-33-18] Replace

as necessary.
P-40168
Figure 20-33-19
Mark the head (Item 1) to the cylinder (Item 2) [Figure
20-33-16] for correct assembly.
1
Figure 20-33-17
P-40171
P-40169
Remove the wiper (Item 1) [Figure 20-33-19] Replace as

necessary.
Remove the head (Item 1) [Figure 20-33-17].
20-33-6

Service Manual
Figure 20-33-22

2
Figure 20-33-20
P-40174
Remove the wear ring (Item 1) from the piston (Item 2)

P-40172
Figure 20-33-23
Remove the seal (Item 1) [Figure 20-33-20] Replace as
necessary.
Figure 20-33-21
2
2
1
1
P-40175
Remove the sealing ring (Item 1) from the piston (Item 2)

P-40173
Remove the rod (Item 1) from the cylinder (Item 2)

[Figure 20-33-21].
20-33-7

Service Manual
Figure 20-33-26

1
Figure 20-33-24
P-40179

necessary.
P-40176
Inspection
Remove the O-ring (Item 1) from the piston (Item 2)
Figure 20-33-25

Figure 20-33-27
1
P-40178
P-40180
Remove the wiper (Item 1) from the cylinder (Item 2)

Inspect the cylinder (Item 1) [Figure 20-33-27] for

scratches, scoring or cracks. Replace as needed.
20-33-8

Service Manual

Inspection (Contd)
Figure 20-33-28
P-40177
Inspect the rod (Item 1) for scratches and scoring.

Inspect the piston (Item 2) [Figure 20-33-28] for scoring
and cracks. Replace as needed
20-33-9

Service Manual
20-33-10

Service Manual
MAIN RELIEF VALVE

Testing The Main Relief Valve
With the parking brake engaged, start the engine and run
at low RPM until the hydraulic fluid is at operating
temperature 140-160F (60-71C)
Figure 20-40-1
Figure 20-40-3
1
1
P-33329
P-47582
The main relief valve is located on the loader control

valve under the operator seat.
All testing is done with the hydraulic oil at operating
temperature and engine at full RPM.
With the hydraulic fluid at operating temperature, run the

engine at full RPM. Press the PRESS TO DRIVE button
(Item 1) [Figure 20-40-3]. Push the loader lift arm control
lever forward until the loader lift arms are completely
lowered.
Block the front and rear of the Loader Backhoe. (See

Procedure on Page 10-10-1.)
The main relief valve pressure should be 2465 PSI

(16996 kPa).
Remove the operator seat.

If adjustment is needed, See Adjustment on Page 20-402.
(See
Removal
And

loader lift arm valve section.
Figure 20-40-2
P-33324
Install a tee fitting and gauge as shown to the loader lift

arm valve section [Figure 20-40-2].
20-40-1

Service Manual
MAIN RELIEF VALVE (CONTD)

Adjustment
Figure 20-40-4
P-33326
Loosen and remove the cap (Item 1) [Figure 20-40-4].

Figure 20-40-5
P-33327
Turn the adjustment screw (Item 1) [Figure 20-40-5]

clockwise to increase the pressure or counterclockwise
to decrease the pressure.
NOTE: One 1/4 turn in clockwise rotation will
increase the pressure approximately 300 PSI
(2069 kPa).
Install and tighten the cap (Item 1) [Figure 20-40-4].
Retest the main relief valve after adjustment.
20-40-2

Service Manual
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)
Figure 20-41-2
Testing And Adjusting (Arm Control)
Figure 20-41-1
1
2
P-50676
P-50675
Remove the cover from the backhoe control panel. (See

Removal And Installation on Page 60-70-1.)
Remove the four tubeline clamp bolts (Item 1) and
tubeline clamp (Item 2) [Figure 20-41-1].
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat
hydraulic fluid or use SAE 10W-30 motor oil.
Remove the tubeline (Item 3) [Figure 20-41-1] from the
arm control section.
Install the hand pump hose and a pressure gauge (Item

1) [Figure 20-41-2] (minimum of 5000 PSI) into the valve
section work port in which the port relief valve is located.
Pressurize this section with the hand pump until the port
relief valve opens and make a note of the pressure
reading.
The correct reading should be:
Rod End
Base End
3045 PSI (210 Bar)

2828 PSI (195 Bar)
If the port relief pressure setting needs to be adjusted,

release the hand pump pressure valve.
Remove the cap (Item 2) [Figure 20-41-2].
Figure 20-41-3
P-50677
Remove the first locking plug (Item 1) [Figure 20-41-3].
20-41-1

Service Manual

(CONTD)
Testing And Adjusting (Arm Control) (Contd)
Figure 20-41-4
P-50678
Turn the adjusting screw (Item 1) [Figure 20-41-4]

clockwise to increase the pressure and counterclockwise
to reduce the pressure.
NOTE: 1/4 turn is approximately 300 PSI (21 Bar)
when the correct pressure setting is obtained,
tighten the locknut while holding the
adjustment screw from turning.
Adjust the port relief valve until the correct setting is
obtained.
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-1285
20-41-2

Service Manual

(CONTD)
Figure 20-41-6
2
Testing And Adjusting (Boom Control)
Figure 20-41-5
2
P-50679
P-50675

boom section.

1) [Figure 20-41-6] (minimum of 5000 PSI) into the valve
section work port in which the port relief valve is located.
reading.
Rod End
Base End
3045 PSI (210 Bar)

2828 PSI (195 Bar)

Figure 20-41-7
P-33429
20-41-3

Service Manual

(CONTD)
Testing And Adjusting (Boom Control) (Contd)
Figure 20-41-8
P-33430

obtained.
WARNING
Engine is running.
W-2019-1285
20-41-4

Service Manual

(CONTD)
Figure 20-41-10
Testing And Adjusting (Boom Swing Control)

1
Figure 20-41-9
2
P-50682
P-50675

boom swing section.

1) [Figure 20-41-10] (minimum of 5000 PSI) into the
valve section work port in which the port relief valve is
located. Pressurize this section with the hand pump until
the port relief valve opens and make a note of the
pressure reading.
NOTE: The two boom swing cylinders are connected
together in a T configuration so pressure
readings for the base of one cylinder will be
the same as the pressure reading for the rod
end of the opposite cylinder. The correct
reading should be : 2900 PSI (200 Bar).
Figure 20-41-11
P-50683
20-41-5

Service Manual

(CONTD)
Testing And Adjusting (Boom Swing Control)
(Contd)
Figure 20-41-12
P-50684

obtained.
WARNING
Engine is running.
W-2019-1285
20-41-6

Service Manual
PORT RELIEF VALVE (LOADER CONTROL VALVE)

Rod End
Base End
Testing And Adjusting (Bucket Tilt)
4000 PSI (27500 kPa)

4000 PSI (27500 kPa)
Figure 20-42-1
Figure 20-42-3
P-33330

(See
Removal
And
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
P-33340


loader bucket tilt section.
Figure 20-42-2
1
P-33331
Install the hand pump hose and a pressure gauge

minimum of 5000 PSI) into the valve section work port in
which the port relief valve is located [Figure 20-42-2].
reading.
20-42-1

Service Manual

(CONTD)
Testing And Adjusting (Bucket Tilt) (Contd)
Figure 20-42-4
P-33341

NOTE: 1/4 turn is approximately 300 PSI (2069 kPa)
obtained.
WARNING
Engine is running.
W-2019-1285
20-42-2

Service Manual

(CONTD)

Rod End
Base End
Testing And Adjusting (Front Auxiliary)
4000 PSI (27500 kPa)

4000 PSI (27500 kPa)
Figure 20-42-5
Figure 20-42-7
1
1
P-33330

(See
Removal
And
P-33334
Remove the battery. (See Removal And Installation on

Page 60-20-1.)

front auxiliary valve section.
Figure 20-42-6
P-33333
Install the hand pump hose and a pressure gauge

(minimum of 5000 PSI) into the valve section work port in
which the port relief valve is located [Figure 20-42-6].
reading.
20-42-3

Service Manual

(CONTD)
Testing And Adjusting (Front Auxiliary) (Contd)
Figure 20-42-8
P-33335

NOTE: 1/4 turn is approximately 300 PSI (2069 kPa)
obtained.
WARNING
Engine is running.
W-2019-1285
20-42-4

Service Manual
LOADER CONTROL VALVE
Figure 20-50-2
IMPORTANT
1
damage the system.
I-2003-0888
P-35373

Rotate the battery disconnect lever counterclockwise to
disconnect the battery from the system.
Remove the dust cover (Item 1) [Figure 20-50-2].

Figure 20-50-3
With engine stopped, loader in lowered position, operate

the control levers to relieve hydraulic pressure.
Remove the seat. (See Removal And Installation on
Page 50-20-1.)
1
2
Figure 20-50-1
P-35372
Remove the bolt (Item 1) [Figure 20-50-3].

1
Loosen jam nut (Item 2) [Figure 20-50-3].
Remove the lever.
P-35370
Remove the auxiliary control lever (Item 1) [Figure 2050-1].
20-50-1

Service Manual
LOADER CONTROL VALVE (CONTD)

Figure 20-50-4
P-33329
Remove the hoses [Figure 20-50-4] from the control

valve.
Figure 20-50-5
P-35371
Remove the three mounting bolts (Item 1) [Figure 20-505].

torque.
Remove the control valve.
20-50-2

Service Manual

Figure 20-50-6
2
3
4
1
P-338572
ITEM
B250 LOADER BACKHOE
Inlet/Outlet Valve Section
Lift Arm Valve Section
Tilt Valve Section
Auxiliary Valve Section
20-50-3

Service Manual
Figure 20-50-9
IMPORTANT

damage the system.
I-2056-0793
2
P-38574
Figure 20-50-7
Remove the 3 locknuts (Item 1) and turnbuckles (Item 2)
[Figure 20-50-9].
Figure 20-50-10
2
P-38572
Mark all of the sections of the control valve for proper

installation [Figure 20-50-7].
P-38575
Remove all hydraulic fittings.

Remove the 5 bolts (Item 1 and mount bracket (Item 2)
[Figure 20-50-10].
Figure 20-50-8
P-38573
Remove the 3 bolts (Item 1) and control plate (Item 2)

[Figure 20-50-8].
20-50-4

Service Manual
Figure 20-50-13
Figure 20-50-11
P-38578
2
P-38576
Remove the inlet/outlet valve section (Item 1) [Figure 2050-13].

Remove the 4 bolts (Item 1) and plate (Item 2) [Figure
20-50-11].
Figure 20-50-14
Figure 20-50-12
1
1
P-38579
P-38577
Remove the 3 O-rings (Item 1) [Figure 20-50-14] from

the valve section.
Remove the thru-bolt nuts and washers (Item 1) [Figure
20-50-12].
20-50-5

Service Manual
Figure 20-50-17
Inlet/Outlet Valve Section (Contd)

Figure 20-50-15
4
3
1
2
1
P-38584
Remove the main relief valve assembly (Item 1), spring

retainer (Item 2), spring (Item 3) and poppet (Item 4)
[Figure 20-50-17].
P-38580
Remove the plug (Item 1) [Figure 20-50-15] from the

valve section.
Figure 20-50-18
Figure 20-50-16
1
3
1
P-38586
Remove the O-ring (Item 1), cap (Item 2) and washer

(Item 3) [Figure 20-50-18].
P-38582
Remove the O-ring (Item 1) [Figure 20-50-16] from the

plug.
Measure and record the distance from the end of the

adjusting screw to the shoulder of the fitting [Figure 2050-18].
20-50-6

Service Manual
Figure 20-50-21

Figure 20-50-19
1
1
P-38589

the valve section.
P-38587
Figure 20-50-22
Remove the adjusting screw (Item 1) [Figure 20-50-19].
Figure 20-50-20
1
P-38590
Remove the retainer (Item 1) [Figure 20-50-22] from the

valve section.
P-38588
Remove the lift arm valve section (Item 1) [Figure 20-5020].
20-50-7

Service Manual
Figure 20-50-25
Lift Arm Valve Section (Contd)

Figure 20-50-23
1
1
P-38593
Remove the spool assembly (Item 1) [Figure 20-50-25].

P-38591
Figure 20-50-26
retainer.
Figure 20-50-24
2
1
P-38594
Remove the snap ring (Item 1) and cap (Item 2) [Figure

20-50-26].
1
P-38592
20-50-8

Service Manual
Figure 20-50-29

Figure 20-50-27
1
2
6
4
1
P-38598
Remove the large spring retainer (Item 1), spring (Item

2), small spring retainer (Item 3), washer (Item 4), and
bolt (Item 5) from the cover (Item 6) [Figure 20-50-29].
P-38596
Use a flat blade screw driver to loosen the spring

assembly (Item 1) [Figure 20-50-27].
Figure 20-50-30
Figure 20-50-28
4
1
3
2
P-38599
1
Loosen the plug (Item 1) [Figure 20-50-30].
P-38597
Remove the cover (Item 1), seal (Item 2) and O-ring

(Item 3) from the spool (Item 4) [Figure 20-50-28].
20-50-9

Service Manual
Tilt Valve Section
Figure 20-50-33
Figure 20-50-31
3
2
1
P-38602
P-38600
Remove the tilt valve section (Item 1) [Figure 20-50-33].

Remove the plug (Item 1), spring (Item 2) and poppet
(Item 3) [Figure 20-50-31].
Figure 20-50-34
Figure 20-50-32
1
P-38603

the bucket valve section.
P-38601

plug.
20-50-10

Service Manual
Figure 20-50-37
Tilt Valve Section (Contd)

Figure 20-50-35
1
P-38607
Remove the 2 O-rings (Item 1), seal (Item 2) and cap

(Item 3) [Figure 20-50-37] from each port relief valve.
P-38604
Figure 20-50-38
Loosen the 2 port relief valves (Item 1) [Figure 20-5035].
Figure 20-50-36
3
2
1
1
P-38608

actuating end of the spool (Item 3) [Figure 20-50-38].
P-38605
Remove the 2 port relief valves (Item 1) [Figure 20-5036].
20-50-11

Service Manual
Figure 20-50-41

Figure 20-50-39
P-38611
1
Remove the spool assembly (Item 1) [Figure 20-50-41].
P-38609
Figure 20-50-42
Loosen the 2 bolts (Item 1) [Figure 20-50-39].
Figure 20-50-40
P-38612
1
2
Remove the bolt (Item 1) [Figure 20-50-42].
P-38610
Remove the bolts (Item 1) and cover (Item 2) [Figure 2050-40].
20-50-12

Service Manual
Figure 20-50-45

Figure 20-50-43
3
2
7
6
4
P-38550
3
(Item 3) [Figure 20-50-45].
2
1
P-38613
Figure 20-50-46
Remove the bolt (Item 1), spring retainer (Item 2), spring
(Item 3), spring retainer (Item 4), seal (Item 5) and O-ring
1
Figure 20-50-44
P-38601

plug.
P-38614
20-50-13

Service Manual
Figure 20-50-49
Auxiliary Valve Section

Figure 20-50-47
P-38555
Lower the boot (Item 1) and loosen the pin (Item 2)

[Figure 20-50-49].
P-38551
Figure 20-50-50
Remove the auxiliary valve section (Item 1) [Figure 2050-47].
Figure 20-50-48
3
P-38556
1
Remove the pin (Item 1), boot (Item 2) and actuator (Item
3) [Figure 20-50-50].
P-38552

the auxiliary valve section.
20-50-14

Service Manual
Figure 20-50-53
Auxiliary Valve Section (Contd)

Figure 20-50-51
5
2
1
1
4
P-38559

P-38571
Figure 20-50-54
Installation: Install the end of the actuator (Item 1) into
the hole (Item 2) in the spool. Align the hole (Item 3) in
the actuator with the pin holes (Item 4) and install the pin
(Item 5) [Figure 20-50-51].
Figure 20-50-52
P-38558
2
Remove the 4 bolts (Item 1) [Figure 20-50-54] from the
cover.
P-38557
Remove the 4 bolts (Item 1) and cover (Item 2) [Figure

20-50-52].
20-50-15

Service Manual
Figure 20-50-57

Figure 20-50-55
P-38563
2
Use a flat blade screw driver to loosen the bolt (Item 1)
[Figure 20-50-57].
P-38560
Figure 20-50-58
Remove the cover (Item 1) and spool assembly (Item 2)
[Figure 20-50-55].
Figure 20-50-56
3
2
2
1
P-38564
1
Remove the spacer (Item 1), bolt (Item 2) and cover
(Item 3) [Figure 20-50-58].
P-38561
Remove the snap ring (Item 1) and cap (Item 2) [Figure

20-50-56].
20-50-16

Service Manual
Figure 20-50-61
1

Figure 20-50-59
1
P-38567
P-38565
Figure 20-50-62
Use a flat blade screw driver to loosen the bolt (Item 1)
[Figure 20-50-59].
Figure 20-50-60
1
2
6
3
1
P-38568
7
Remove the port relief valves (Item 1) [Figure 20-50-62].
P-38566
20-50-17

Service Manual
Figure 20-50-65

Figure 20-50-63
P-38550

(Item 3) [Figure 20-50-65].
P-38607
Figure 20-50-66
Remove the 2 O-rings (Item 1), cap (Item 2) and seal
(Item 3) [Figure 20-50-63] from each port relief valve.
1
Figure 20-50-64
P-38601
1
P-38570

plug.
20-50-18

Service Manual
BACKHOE CONTROL VALVE
Figure 20-60-2
IMPORTANT
damage the system.
I-2003-0888
P-50674
Shift the trunion to 1 side for better access to the

backhoe control valve.
Install the approved boom lock pin. (See Engaging And
Figure 20-60-3

Figure 20-60-1
2
1
2
P-65071
Disconnect the harness connector (Item 1) and auxiliary

hydraulic control wires (Item 2) [Figure 20-60-3].
NOTE: Mark wires for correct assembly.
P-52026
Remove the 2 bolts (Item 1) [Figure 20-60-1] (both

sides).
Remove the cover.
20-60-1

Service Manual
BACKHOE CONTROL VALVE (CONTD)
Figure 20-60-6

1
Figure 20-60-4
3
1
2
P-65070
2
Remove all tubelines (Item 1) [Figure 20-60-6].
P-50728
NOTE: Mark the tubelines for correct assembly.

Remove the lever (Item 1), the 2 cover bolts (Item 2) and
cover (Item 3) [Figure 20-60-4].
Figure 20-60-7
Figure 20-60-5
1
4
2
1
2
1
3
P-65072
Remove the 2 upper control valve mounting bolts (Item 1)

and loosen the 2 lower control valve mounting bolts (Item
2) [Figure 20-60-7]. Remove the control valve.
P-50730
Remove the 6 bolts (Item 1) and 2 levers (Item 2).

Loosen the 2 jam nuts (Item 3) and remove the 2 levers
(Item 4) [Figure 20-60-5].
Installation: Tighten the bolts to 18 to 19 ft.-lb. (24 to 26

Nm) torque.
WARNING
immediately.
W-2145-0290
20-60-2

Service Manual

10
9
10
P-38946
ITEM
B250 LOADER BACKHOE
Bracket Valve Section
Right Stabilizer Valve Section
Left Stabilizer Valve Section
Boom Valve Section
Boom Swing Valve Section
Outlet Valve Section
Port Relief
10
Plug
20-60-3

Service Manual
Figure 20-60-9

1
IMPORTANT
1

damage the system.
1
2
2
I-2003-0888
P-50733
Figure 20-60-8
Remove the 6 lock nuts (Item 1) and turnbuckle hardware
(Item 2) [Figure 20-60-9].
Figure 20-60-10
2
1
1
1
P-50732
Remove all the hydraulic fittings (Item 1) [Figure 20-608].
P-50833
NOTE: Mark location of fittings for correct assembly.

Remove the 5 bolts (Item 1) and bracket (Item 2) [Figure
20-60-10].
20-60-4

Service Manual
Figure 20-60-13
Figure 20-60-11
1
1
2
1
P-50735
P-50834
Remove the inlet/outlet section (Item 1) [Figure 20-6013]

Remove the 4 bolts (Item 1) and the plate (Item 2)
[Figure 20-60-11] (both sides).
Figure 20-60-14
Assembly: Apply LOCTITE 242 or equivalent to threads

of bolts.
Figure 20-60-12
P-50736
1
Remove the 3 O-rings (Item 1) [Figure 20-60-14]
P-50734
Remove the thru-bolt nuts and washers (Item 1) [Figure

20-60-12].
Installation: Tighten nuts to 32 to 35 ft.-lb. (43 to 47
Nm) torque.
20-60-5

Service Manual
Figure 20-60-17

Figure 20-60-15
1
P-50739
Remove the side shift lock valve (Item 1) [Figure 20-6017].
P-50737
Figure 20-60-18
Remove the nut (Item 1) and fitting (Item 2) [Figure 2060-15].
Figure 20-60-16
2
1
2
1
P-50740
Remove the O-ring (Item 1) and washer (Item 2) [Figure

20-60-18].
P-50738
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-60-16].
20-60-6

Service Manual

Figure 20-60-19
1
P-50741
Remove the plug (Item 1) and nut (Item 2) [Figure 20-6019].

Figure 20-60-20
P-50744
Remove the spool (Item 1) and the 2 O-rings (Item 2)

[Figure 20-60-20].
20-60-7

Service Manual
Figure 20-60-23
Arm Valve Section

Figure 20-60-21
3
2
P-38960

1
P-38958
Figure 20-60-24
Remove the arm valve section (Item 1) [Figure 20-6021].
Figure 20-60-22
1
P-38961
1
P-38959

the arm valve section.
20-60-8

Service Manual
Figure 20-60-27
Arm Valve Section (Contd)

Figure 20-60-25
7
6
5
4
2
1
2
P-38964
P-38962
Remove the spool assembly (Item 1). Check the spool for
scratches, or wear. Replace as needed. Remove the
Figure 20-60-28
Figure 20-60-26
1
1
P-38965

P-38963
Loosen the bolt (Item 1) [Figure 20-60-26].

Assembly: Tighten the bolt to 6 ft.-lb. (8,0 Nm) torque.
20-60-9

Service Manual
Figure 20-60-31

1
Figure 20-60-29
3
2
P-38968
P-38966
Figure 20-60-32
Remove the plug (Item 1) spring (Item 2) and poppet
(Item 3) [Figure 20-60-29]. Check the spring and poppet
for damage or wear.
Figure 20-60-30
1
1
P-38969

P-38967

plug. Replace as needed.
20-60-10

Service Manual
Tilt Valve Section
Figure 20-60-34
Figure 20-60-33
1
2
P-38971
P-38970
Remove the bucket valve section (Item 1) [Figure 20-6034].

Remove the 2 O-rings (Item 1). washer (Item 2) and cap
(Item 3) [Figure 20-60-33] Replace O-rings and washer
as needed.
Figure 20-60-35
1
P-38972

the bucket valve section.
20-60-11

Service Manual
Figure 20-60-38

Figure 20-60-36
P-38975
3
2
scratches or wear. Replace as needed. Remove the
P-38973

Figure 20-60-39
Figure 20-60-37
1
1
P-38963
1
P-38974

20-60-12

Service Manual
Figure 20-60-42

Figure 20-60-40
3
2
7
6
2
1
P-38977

for damage or wear.
P-38964
Figure 20-60-43
Figure 20-60-41
P-38978
1
P-38976

20-60-13

Service Manual
Figure 20-60-46
Right Stabilizer Valve Section

Figure 20-60-44
2
1
P-38981
1
[Figure 20-60-46].
P-38979
Figure 20-60-47
Remove the right stabilizer valve section (Item 1) [Figure
20-60-44]
Figure 20-60-45
P-38982
1
3) [Figure 20-60-47].
P-38980

the stabilizer valve section.
20-60-14

Service Manual
Figure 20-60-50
Right Stabilizer Valve Section (Contd)

Figure 20-60-48
2
3
5
1
3
1
4
2
P-38984

actuating end of spool (Item 3) [Figure 20-60-50].
P-38571
Figure 20-60-51
(Item 5) [Figure 20-60-48].
Figure 20-60-49
1
1
P-38974
2
P-38983
Remove the 4 bolts (Item 1). Remove the cover (Item 2)

[Figure 20-60-49].
20-60-15

Service Manual
Figure 20-60-54

7
Figure 20-60-52
6
5
4
3
2
1
2
P-38987
P-38985
Figure 20-60-55
Figure 20-60-53
1
P-38614

P-38986

20-60-16

Service Manual
Left Stabilizer Valve Section
Figure 20-60-58
Figure 20-60-56
1
3
2
1
P-38988
P-38550
Remove the left stabilizer valve section (Item 1) [Figure

20-60-58]
for damage or wear.
Figure 20-60-59
Figure 20-60-57
P-38980

the stabilizer valve section.
P-38601

20-60-17

Service Manual
Figure 20-60-62
Left Stabilizer Valve Section (Contd)

Figure 20-60-60
5
1
4
4
2
P-38571
1
(Item 5) [Figure 20-60-62].
P-38981

[Figure 20-60-60].
Figure 20-60-63
Figure 20-60-61
1
2
P-38983
3
P-38982
Remove the 4 bolts (Item 1). Remove the cover (Item 2)

[Figure 20-60-63].
3) [Figure 20-60-61].
20-60-18

Service Manual
Figure 20-60-66

Figure 20-60-64
1
2
2
3
P-38985
P-38984

Figure 20-60-67
Figure 20-60-65
P-38986
P-38974

20-60-19

Service Manual
Figure 20-60-70

Figure 20-60-68
7
3
2
6
5
4
3
2
1
P-38550

for damage or wear.
P-38987
Figure 20-60-71
Figure 20-60-69
P-38601
1
P-38614

20-60-20

Service Manual
Figure 20-60-74
Boom Valve Section

Figure 20-60-72
1
2
P-38960

actuating end of the spool (Item 3) [Figure 20-60-74]
P-38989
Figure 20-60-75
Remove the boom valve section (Item 1) [Figure 20-6072].
Figure 20-60-73
1
1
P-38961
1
P-38959

the boom valve section.
20-60-21

Service Manual
Figure 20-60-78
Boom Valve Section (Contd)

Figure 20-60-76
7
6
5
4
2
1
1
2
P-38964
P-38962
scratches or wear. Replace a needed. Remove the cover
(Item 2) [Figure 20-60-76].
Figure 20-60-79
Figure 20-60-77
1
P-38965
1
P-38963

20-60-22

Service Manual
Figure 20-60-82

1
Figure 20-60-80
3
2
P-38968
Loosen the 2 port relief valves (Item 1) [Figure 20-60-82]

P-38966
Figure 20-60-83
for damage or wear.
Figure 20-60-81
P-38969
Remove the 2 port relief valves (Item 1) [Figure 20-6083]

P-38967

20-60-23

Service Manual
Figure 20-60-86

Figure 20-60-84
P-38939
1
2
3
the boom swing section.
P-38970
Figure 20-60-87
Remove the 2 O-rings (Item 1), washer (Item 2) and cap
(Item 3) [Figure 20-60-84]. Replace O-rings and washer
as needed.
Boom Swing Valve Section
Figure 20-60-85
3
1
P-38936

1
P-38938
Remove the boom swing valve section (Item 1) [Figure

20-60-85].
20-60-24

Service Manual
Figure 20-60-90
Boom Swing Valve Section (Contd)

Figure 20-60-88
1
1
P-38963
1
P-38935

Remove the 2 bolts (item 1) [Figure 20-60-88].
Figure 20-60-91
Figure 20-60-89
7
6
2
1
2
P-38964
P-38940
20-60-25

Service Manual
Figure 20-60-94

Figure 20-60-92
1
P-38967
1
Remove the O-ring (Item 10 [Figure 20-60-94] from the
P-38941
Figure 20-60-95
Figure 20-60-93
1
P-38942
1
Loosen the 2 port relief valves (Item 1) [Figure 20-60-95]
P-38966

for damage or wear.
20-60-26

Service Manual
Outlet Valve Section
Figure 20-60-98
Figure 20-60-96
2
1
1
P-38937
P-38943
Inspect outlet valve section (Item 1) and thru-bolts (Item

2) [Figure 20-60-98] for wear and damage. Replace as
needed.
Figure 20-60-97
P-38944
Remove the 2 O-rings (Item 1), washer (Item 2) and cap

(Item 3) [Figure 20-60-97] Replace O-rings and washer
as needed.
20-60-27

Service Manual
20-60-28

Service Manual
HYDRAULIC FLUID RESERVOIR
Figure 20-70-2
3
Remove the right engine side cover. (See Removal And
Remove the front floor panels. (See FLOOR PANELS on
Page 50-30-1.)
1
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid
on Page 10-120-3.)
P-36815
Figure 20-70-1
Disconnect the harness connector (Item 1) [Figure 2070-2].

Remove the hose (Item 2) and two tubelines (Item 3)
[Figure 20-70-2].
Figure 20-70-3
1
P-36814

P-36818
IMPORTANT
Remove the front hose (Item 1) [Figure 20-70-3].

damage the system.
I-2056-0793
20-70-1

Service Manual
HYDRAULIC FLUID RESERVOIR (CONTD)

Figure 20-70-4
P-50155
Figure 20-70-5
P-50154
Support the reservoir. Remove the mounting bolts (Item

1) [Figure 20-70-4] & [Figure 20-70-5].
torque.
Remove the reservoir.
20-70-2

Service Manual
HYDRAULIC FLUID RESERVOIR (CONTD)
Figure 20-70-8
Strainer Removal And Installation
Remove the filter housing (See Removal And Installation

on Page 20-71-1.)
Figure 20-70-6
2
P-36859
Remove the strainer (Item 1) [Figure 20-70-8] from the

inlet tube.
NOTE: The strainer is threaded on to the tube.
P-36857
Figure 20-70-9
Remove the twelve reservoir cover bolts (Item 1) and
hose (Item 2) [Figure 20-70-6].
Installation: Tighten bolts to 4-5 ft.-lb. (5-6 Nm) torque.
Figure 20-70-7
1
1
P-36860
Wash the strainer in solvent and dry with compressed air.

Inspect strainer for any damage. Inspect bypass (Item 1)
[Figure 20-70-9] for correct operation. Replace strainer
as necessary.
P-36858
Reverse the removal procedure to install reservoir

strainer.
Remove the reservoir cover (Item 2) [Figure 20-70-7].
20-70-3

Service Manual
20-70-4

Service Manual
HYDRAULIC FILTER HOUSING
Figure 20-71-2

Remove the right front floor panel. (See Right Front

Panel Removal And Installation on Page 50-30-1.)
Figure 20-71-1
P-36848
Remove the two mounting bolts (Item 1) [Figure 20-712].

torque.
Figure 20-71-3
P-36815
1
Remove the two tubelines (Item 1). Disconnect the
harness connector (Item 2) [Figure 20-71-1].
NOTE: Mark tubelines for correct assembly.
IMPORTANT
damage the system.
P-36849
Remove the filter housing (Item 1) [Figure 20-71-3] from

hydraulic reservoir.
I-2003-0888
20-71-1

Service Manual
HYDRAULIC FILTER HOUSING (CONTD)
Figure 20-71-6
Disassembly
Remove the filter housing (See Removal And Installation
on Page 20-71-1.)
Figure 20-71-4
1
1
P-36852
Remove the spacer (Item 1) [Figure 20-71-6].

Figure 20-71-7
P-36850

base.
Figure 20-71-5
P-36853
Remove the bypass housing (Item 1) from the base (Item

2) [Figure 20-71-7].
P-36851
Remove the cover (Item 1) [Figure 20-71-5].
20-71-2

Service Manual
Figure 20-71-10
Disassembly (Contd)
Figure 20-71-8
P-36856
Inspect the bypass valves and springs [Figure 20-7110].
P-36854
Assembly
Remove the filter (Item 1) from the bypass housing (Item
2) [Figure 20-71-8].
Wash filter housing parts in solvent and dry with

compressed air.
Figure 20-71-9
Inspect filter housing parts for damage. Replace any
damaged parts or replace assembly as necessary.
Figure 20-71-11
2
1
1
2
P-36855
Inspect the one way check valve (Item 1) in the bypass

housing (Item 2) [Figure 20-71-9] for closing and free
movement.
P-36854
Install the filter (Item 1) into bypass housing (Item 2)

[Figure 20-71-11].
20-71-3

Service Manual
Figure 20-71-14
Assembly (Contd)
Figure 20-71-12
2
1
P-36851
Install the cover (Item 1) [Figure 20-71-14].

P-36853
Figure 20-71-15
Install the bypass housing (Item 1) into base (Item 2)
[Figure 20-71-12].
Figure 20-71-13
1
1
P-36850
Install the base O-ring (Item 1) [Figure 20-71-15].

P-36852
Install the filter housing into reservoir cover.
Install the spacer (Item 1) [Figure 20-71-13].
20-71-4

Service Manual
GEAR PUMP
Figure 20-80-2

Remove the front floor panel. (See FLOOR PANELS on
Page 50-30-1.)
IMPORTANT
damage the system.
1
P-50046
I-2056-0793

Figure 20-80-3
WARNING
1
immediately.
W-2145-0290
Figure 20-80-1
1
P-50049
Remove the mounting bolts (Item 1) [Figure 20-80-3].

1
Installation: Tighten bolts to 32 to 35 ft.-lb. (43 to 47

Nm) torque.
Remove the pump.
P-50045
20-80-1

Service Manual
GEAR PUMP (CONTD)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Bolt
Washer
Cover
Pin
O-ring seal
Housing
Seal ring
Backup ring
Drive gear
Idler gear
Gear holder
Bottom housing
Seal
Snap ring
4
4
11
10
12
14
13
8
11
MS2107S
20-80-2

Service Manual
GEAR PUMP (CONTD)
Figure 20-80-6
IMPORTANT
damage the system.
I-2003-0888
P-50064
Figure 20-80-4
Remove the 4 bolts (Item 1) [Figure 20-80-6] and
remove the cover.
Assembly: Tighten the bolts to 37 ft.-lb. (50 Nm) torque.
Figure 20-80-7
3
P-50051
Mark the pump housing for correct assembly and remove

the fittings (Item 1) [Figure 20-80-4].
Figure 20-80-5
P-50054
Remove the gear holder (Item 1) from the housing (Item

2) [Figure 20-80-7].
Assembly: The position of the small opening (Item 3) on
the gear holders will point towards the port (Item 4)
[Figure 20-80-7] on the housing.
1
P-50053
Inspect the O-rings (Item 1) [Figure 20-80-5] and replace

as necessary.
20-80-3

Service Manual
GEAR PUMP (CONTD)
Figure 20-80-10

1
Figure 20-80-8
1
P-50057
Remove the O-rings (Item 1) [Figure 20-80-10] from the

housing.
P-50055
Figure 20-80-11
Remove the backup ring (Item 1) and seal ring (Item 2)
[Figure 20-80-8] from the gear holder.
Assembly: The seal ring (Item 2) is installed onto the
gear holder first, followed by the backup ring (Item 1)
[Figure 20-80-8].
1
Figure 20-80-9
1
P-50058
Remove both pump gears and holder (Item 1) [Figure

20-80-11] from the body.
P-50056
Remove the upper housing (Item 1) [Figure 20-80-9].
20-80-4

Service Manual
GEAR PUMP (CONTD)
Figure 20-80-14

1
Figure 20-80-12
P-50060
Remove the snap ring (Item 1) [Figure 20-80-14] from

the bottom housing.
P-50059
Figure 20-80-15
Remove holder (Item 1) [Figure 20-80-12] from the
gears.
Figure 20-80-13
1
1
2
P-50061
Remove the shaft seal (Item 1) [Figure 20-80-15].

P-50055
Inspection
Remove the backup ring (Item 1) and seal ring (Item 2)
[Figure 20-80-13] from the gear holder.
Assembly: The seal ring (Item 2) [Figure 20-80-13] is
installed onto the gear holder first, followed by the
backup ring.
Clean all parts in clean solvent and use air pressure to

dry them. Do not use or paper because of small pieces of
Inspect the drive gear and idler gear for rough surfaces
and wear.
Check the bushings in the end housings.
Replace the parts as needed.
20-80-5

Service Manual
20-80-6

Service Manual
STEERING PUMP
Figure 20-90-2

Rotate battery disconnect lever counterclockwise to
disconnect battery from system.
Remove the instrument panel. (See Removal And

1
Figure 20-90-1
P-38020
Remove the four steering pump mounting nuts and

washers (Item 1) [Figure 20-90-2].
1
1
Installation: Tighten nuts to 32-35 ft.-lb. (43-47 Nm)

torque.
Figure 20-90-3
P-38083
Remove the hoses (Item 1) [Figure 20-90-1] from the

steering pump.
1
IMPORTANT
damage the system.
P-38021
Remove the steering pump (Item 1) [Figure 20-90-3].
I-2003-0888
20-90-1

Service Manual
STEERING PUMP (CONTD)

1. Bolt
2. End Cap
3. Spacer Washer
4. O-Ring
5. Geroler Assembly
6. Drive Shaft
7. Valve Plate
8. Spool
9. Sleeve
10. Springs
11. Drive Pin
12. Spool
13. Check Ball
14. Housing
15. Thrust Washer
16. Thrust Bearing
17. Guad Ring
18. Seal Housing
19. Seal
20. Ball Seat
21. Poppet
22. Spring
23. Plug
24. Ball Retainer
25. Washer
26. Spring Seat
4
5
6
4
7
4
10
21
23
22
23
25
26
4
9
13
20
11
22
23
24
24
13
14
15
16
12
15
13
17
4
19
13
20
18
23
22
24
20-90-2
MS1525

Service Manual
Figure 20-90-6
Disassembly
Figure 20-90-4
1
1
P-38076
Remove the two priority valve mounting bolts (Item 1)

[Figure 20-90-6].
P-38074
Remove the priority valve.

Remove the four nuts and washers (Item 1) and remove
the steering shaft (Item 2) [Figure 20-90-4].
Figure 20-90-7
Figure 20-90-5
1
1
P-38077
P-38075
Remove the five O-rings (Item 1) [Figure 20-90-7] from

the priority valve.
Mark the housing for correct assembly [Figure 20-90-5].
IMPORTANT
damage the system.
I-2003-0888
20-90-3

Service Manual
Figure 20-90-10
Disassembly (Contd)
Figure 20-90-8
1
2
3
4
P-38037
Mark the location of the metering spool (Item 1) [Figure

20-90-10] and remove.
P-38081
Figure 20-90-11
Remove the plug (Item 1), washers (Item 2), spool (Item
3), spring (Item 4) and valve cap (Item 5) [Figure 20-908] from the housing.
Figure 20-90-9
1
P-38038
Remove the six end cap bolts and washers (Item 1)

[Figure 20-90-11].
P-38036
Mark the pump housing for correct assembly [Figure 2090-9].
20-90-4

Service Manual
Figure 20-90-14
Disassembly (Contd)
Figure 20-90-12
1
P-38041
Remove the spacer washer (Item 1) [Figure 20-90-14].

P-38039
Figure 20-90-15
Remove the end cap (Item 1) [Figure 20-90-12].
1
Figure 20-90-13
P-38042
Remove the geroler assembly assembly (Item 1) [Figure

20-90-15].
P-38040
Remove and discard the O-ring (Item 1) [Figure 20-9013].
20-90-5

Service Manual
Figure 20-90-18
Disassembly (Contd)
Figure 20-90-16
P-38045
Remove the valve plate (Item 1) [Figure 20-90-18].

P-38043
Figure 20-90-19
geroler assembly.
1
Figure 20-90-17
P-38046

housing.
P-38044
Remove the drive shaft (Item 1) [Figure 20-90-17].
20-90-6

Service Manual
Figure 20-90-22
Disassembly (Contd)
1
Figure 20-90-20
1
P-38051
Remove the check ball (Item 1) [Figure 20-90-22] from

each port.
P-38047
Figure 20-90-23
Mark the location of the two ports (Item 1) [Figure 20-9020] for correct assembly.
Figure 20-90-21
P-38052
Remove the ball retainer (Item 1) [Figure 20-90-23].

P-38048
Remove the spool (Item 1) [Figure 20-90-21] from each

port.
20-90-7

Service Manual
Figure 20-90-26
Disassembly (Contd)
Figure 20-90-24
P-38070
Remove the thick washer, (Item 1), thrust bearing (Item

2) and washer (Item 3) [Figure 20-90-26] from the spool.
P-38053
Figure 20-90-27
Remove the check ball (Item 1) [Figure 20-90-24].
Figure 20-90-25
2
1
1
3
P-38072
Remove the drive pin (Item 1) [Figure 20-90-27].
P-38069
Remove the control spool/sleeve assembly (Item 1) from

the metering end of the housing (Item 2) [Figure 20-9025].
NOTE: When removing the spool, keep the drive pin
(Item 3) [Figure 20-90-25] horizontal. If the pin
becomes vertical, it may drop from the spool
and get caught in an oil passage inside the
housing.
20-90-8

Service Manual
Figure 20-90-30
Disassembly (Contd)
Figure 20-90-28
1
2
1
P-38055
Remove the seal (Item 1) [Figure 20-90-30] and discard.

P-38073
Figure 20-90-31
Remove the spool (Item 1) from the sleeve (Item 2)
[Figure 20-90-28].
NOTE: If the spool and sleeve will not slide or rotate
within each other freely or in the housing,
they must be replaced.
1
Figure 20-90-29
1
P-38056
Remove the O-ring/quad ring (Item 1) [Figure 20-90-31]

and discard.
P-38096
Remove the springs (Item 1) [Figure 20-90-29] from the

spool.
NOTE: There are six springs positioned three per side
and back to back.
20-90-9

Service Manual
Figure 20-90-34
Disassembly (Contd)
Figure 20-90-32
1
2
1
P-38062
Remove the spring (Item 1) [Figure 20-90-34].

P-38064
Figure 20-90-35
Remove the plug (Item 1) [Figure 20-90-32].
NOTE: The following procedures will be performed on
the second port (Item 2) [Figure 20-90-32].
Figure 20-90-33
1
P-38061
Remove the poppet (Item 1) [Figure 20-90-35].
P-38063
Record the number of turns, while turning the plug (Item

1) [Figure 20-90-33] in to seat it. Record the number of
turns for correct assembly.
Remove the plug.
20-90-10

Service Manual
Figure 20-90-38
Disassembly (Contd)
1
Figure 20-90-36
P-38067
Remove the check valve (Item 1) [Figure 20-90-38].

P-38060
Figure 20-90-39
Remove the check ball (Item 1) [Figure 20-90-36].
1
Figure 20-90-37
P-38068
Remove the O-ring (Item 1) [Figure 20-90-39] and

discard.
P-38066
Remove the plug (Item 1), washer (Item 2), spring seat
(Item 3), spring (Item 4) and poppet (Item 5) [Figure 2090-37] from the housing.
20-90-11

Service Manual
Assembly
Inspection
IMPORTANT
Figure 20-90-40

damage the system.
I-2003-0888
Prior to assembly, clean and lightly oil all parts.
Figure 20-90-42
1
P-38073
1
Inspect the spool (Item 1) and sleeve (Item 2) [Figure
20-90-40] for any damage or wear. Replace as needed.
Figure 20-90-41
1
P-38068
Install the O-ring (Item 1) [Figure 20-90-42].

Figure 20-90-43
1
P-38098
Inspect the drive shaft (Item 1) [Figure 20-90-41] for

damage or wear.
P-38067
Install the check valve (Item 1) [Figure 20-90-43] and

tighten until fully seated.
20-90-12

Service Manual
Figure 20-90-46
Assembly (Contd)
Figure 20-90-44
1
P-38061
1
2
Install the poppet (Item 1) [Figure 20-90-46].
3
P-38066
Figure 20-90-47
Install the poppet (Item 1), spring (Item 2), spring seat
(Item 3), washer (Item 4) and plug (Item 5) [Figure 2090-44] into the port.
1
Figure 20-90-45
P-38062
Install the spring (Item 1) [Figure 20-90-47].
P-38060
Install the check ball (Item 1) [Figure 20-90-45] into the

port.
NOTE: The following procedures will be performed on
the second port.
20-90-13

Service Manual
Figure 20-90-50
Assembly (Contd)
Figure 20-90-48
1
1
P-38056
Install the quad ring/O-ring seal assembly (Item 1)

[Figure 20-90-50].
P-38063
Figure 20-90-51
Install the plug (Item 1) [Figure 20-90-48] the correct
number of turns recorded earlier.
Figure 20-90-49
P-38055
Install the seal (Item 1) [Figure 20-90-51].

P-38064
Install the plug (Item 1) [Figure 20-90-49].
20-90-14

Service Manual
Figure 20-90-54
Assembly (Contd)
Figure 20-90-52
P-38072
Install the drive pin (Item 1) [Figure 20-90-54].

P-38096
Figure 20-90-55
Install the springs (Item 1) [Figure 20-90-52] into the
spool.
3
NOTE: There are six springs and should be

positioned three per side and back to back.
Figure 20-90-53
2
1
2
P-38071
Install the thick washer (Item 1), thrust bearing (Item 2)

and washer (Item 3) [Figure 20-90-55] onto the spool.
P-38073
Install the spool (Item 1) into the sleeve (Item 2) [Figure

20-90-53].
NOTE: The spool should turn freely inside the sleeve.
20-90-15

Service Manual
Figure 20-90-58
Assembly (Contd)
Figure 20-90-56
1
2
1
P-38052
3
Install the check ball retainer (Item 1) [Figure 20-90-58]
and tighten.
P-38069
Figure 20-90-59
Install the control spool/sleeve assembly (Item 1) into the
metering end of the housing (Item 2) [Figure 20-90-56].
1
NOTE: When installing the spool assembly keep the

drive pin (Item 3) [Figure 20-90-56] horizontal.
If the pin becomes vertical it may drop from
the spool and get caught in an oil passage
inside the housing.
Figure 20-90-57
1
P-38051
Install the check ball (Item 1) [Figure 20-90-59] in each

port.
P-38053
Install the check ball (Item 1) [Figure 20-90-57] in the

port.
20-90-16

Service Manual
Figure 20-90-62
Assembly (Contd)
1
Figure 20-90-60
P-38045
Install the valve plate (Item 1) [Figure 20-90-62].

P-38048
Figure 20-90-63
Install the spool (Item 1) [Figure 20-90-60] in each port.
Figure 20-90-61
2
P-38099
NOTE: The pin (Item 2) must be parallel with the

housing (Item 3) [Figure 20-90-63].
P-38046
Install the O-ring (Item 1) [Figure 20-90-61] in the

housing.
Align the groove (Item 1) in the drive shaft with the drive
pin (Item 2) [Figure 20-90-63] and install the drive shaft.
20-90-17

Service Manual
Figure 20-90-66
Assembly (Contd)
1
Figure 20-90-64
2
2
P-44865
Install the outer gear (Item 1) onto the star (Item 2)

[Figure 20-90-66] and align the bolt holes without
disengaging the drive shaft.
P-44864
To assure proper geroler alignment, mark the top of the

drive shaft (Item 1) (as shown) parallel to the port face
(Item 2) [Figure 20-90-64].
Figure 20-90-67
Install the O-ring (Item 3) [Figure 20-90-64] into the

valve plate groove.
Figure 20-90-65
P-38040
Install the spacer washer (Item 1) and O-ring (Item 2)

[Figure 20-90-67].
3
P-44863
Install the geroler star (Item 1) [Figure 20-90-65] onto

the valve plate and drive shaft.
NOTE: Align the star valleys (Item 2) of the star with
the mark on the drive gear (Item 3) [Figure 2090-65].
20-90-18

Service Manual
Figure 20-90-70
Assembly (Contd)
Figure 20-90-68
3
4
P-38081
Install the plug (Item 1), washer (Item 2), spool (Item 3),
spring (Item 4) and valve cap (Item 5) [Figure 20-90-70]
into the housing.
P-38038
Align the marks made earlier and install the end cap
using the six bolts (Item 1) [Figure 20-90-68]. Do not
tighten the bolts at this time.
Figure 20-90-71
1
Figure 20-90-69
P-38077
Install the five O-rings (Item 1) [Figure 20-90-71] onto

the priority valve.
P-38037
Install the metering spool (Item 1) [Figure 20-90-69].

Tighten metering spool and bolts to 8-13 ft.-lb. (5.9-9.5
Nm) torque in a criss cross pattern.
20-90-19

Service Manual

Assembly (Contd)
Figure 20-90-72
1
1
P-38076
Install the priority valve (Item 1) onto the pump housing

and tighten the two bolts (Item 2) [Figure 20-90-72] to 8
ft.-lb. (5.9 Nm) torque.
Figure 20-90-73
P-38074
Install the steering shaft onto the steering pump and

tighten the four studs (Item 1) [Figure 20-90-73] to 13 ft.lb. (9.5 Nm) torque
20-90-20

Service Manual
TRAVEL PEDAL
Figure 20-100-2

Page 50-30-1.)
IMPORTANT
P-38095

damage the system.
Remove the 4 mounting bolts (Item 1) [Figure 20-100-2].

Nm) torque.
I-2003-0888
Remove the travel pedal.

Figure 20-100-1
P-38091
Remove the 4 hoses (Item 1) [Figure 20-100-1].

20-100-1

Service Manual
TRAVEL PEDAL (CONTD)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Safety Tread
Retainer Clip
Pedal Angle Plate
Bolt
Pin
Nut
Set Screw
Adjustment Screw
Pedal
Washer
Mount Plate
Retainer Plate
Plunger Housing
Seal
O-ring
Plunger
Piston
Spring
spool
Plug
Housing
1
2
12
3
13
5
14
6
15
4
2
6
16
8
2
9
2
17
5
4
18
4
10
10
19
11
20
21
MS2112S
20-100-2

Service Manual
Figure 20-100-5

Figure 20-100-3
3
2
2
P-38160
Back the set screw (Item 1) out of the pin (Item 2).
Remove the pin (Item 3) and pedal (Item 4) [Figure 20100-5].
P-38155
Remove the 2 retainer clips (Item 1) and pins (Item 2)

(both sides).Remove the pedal angle plate (Item 3)
[Figure 20-100-3].
Installation: Algin the set screw (Item 1) with the hole in

the pin (Item 2) [Figure 20-100-5].
Figure 20-100-6
Figure 20-100-4
2
1
1
1
P-38161
P-38157
Loosen the locknut (Item 1) and set screw (Item 2)

[Figure 20-100-4].
Remove the 4 bolts (Item 1) and the mount plate (Item 2)

[Figure 20-100-6].
20-100-3

Service Manual
Figure 20-100-9

Figure 20-100-7
1
2
P-38164
Remove the retainer plate (Item 1) and rod (Item 2) from

the plunger housing (Item 3) [Figure 20-100-9].
1
P-38162
Remove the 2 bolts (Item 1) from both plunger

assemblies (Item 2) [Figure 20-100-7].
NOTE: The plunger assemblies are under spring
pressure and may become dislodged when
the bolts are removed.
Figure 20-100-8
1
1
P-38163
Remove the 2 plunger assemblies (Item 1) [Figure 20100-8].
20-100-4

Service Manual
Figure 20-100-12

Figure 20-100-10
1
1
P-38168
Remove the retainer (Item 1) [Figure 20-100-12] from

the rod.
P-38165
Figure 20-100-13
Figure 20-100-11
1
1
P-38169
P-38167
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20100-10] from the plunger housing.
Remove the 2 spool assemblies (Item 1) [Figure 20-10013].
Installation: Make sure the lip (Item 1) [Figure 20-10011] on the seal is installed to the inside of the plunger
body.
20-100-5

Service Manual
Figure 20-100-16

Figure 20-100-14
1
1
2
P-38172
Remove the 2 springs (Item 1) [Figure 20-100-16].

P-38170
Figure 20-100-17
Compress the spring (Item 1) to remove the retainer
(Item 2) [Figure 20-100-14].
Figure 20-100-15
5
4
3
1
2
1
P-38173
Remove the 2 plugs (Item 1) [Figure 20-100-17].

P-38171
Remove the retainer (Item 1), piston (Item 2), spring

(Item 3) and washer (Item 4) from the spool (Item 5)
[Figure 20-100-15].
20-100-6

Service Manual

Figure 20-100-18
1
P-38174
Do NOT remove the 4 fittings (Item 1) [Figure 20-10018] or the fittings and housing will be damaged
20-100-7

Service Manual
20-100-8

Service Manual
STEERING VALVE
Figure 20-110-2

Raise lift arms and install an approved lift arm support
IMPORTANT
damage the system.
I-2003-0888
P-35746
Remove 4 hoses (Item 1) [Figure 20-110-2] from the

steering valve.
Figure 20-110-1
NOTE: Mark hoses for correct installation.
Installation: Tighten the bolts to 18 to 19 ft.-lb. (24 to 26
Nm) torque.
Remove the steering valve.
P-50257
Remove the bolt (Item 1) [Figure 20-110-1] from the

steering valve handle.
Remove the handle.
Remove the left engine side cover. (See Removal And
20-110-1

Service Manual
STEERING VALVE (CONTD)
Figure 20-110-5
Description
NOTE: The steering lever must be in the closed
position (Item 1) [Figure 20-110-3] before
driving.
NOTE: This lever CANNOT be used to select a 2 or 4

wheel steering mode.
Figure 20-110-3
P-47606
With the engine running, turn the steering wheel to the

left fully.
Stop the engine.
1
Move the valve lever (Item 1) [Figure 20-110-5] to the

OPEN position as shown.
Move the rear tire by hand until it touches the axle stop
[Figure 20-110-6].
P-47605
The loader backhoe is equipped with a steering valve

(Item 1) [Figure 20-110-3] that should be used as
needed to correct and maintain proper wheel alignment.
Start the engine, turn the steering wheel to the left

making sure the front tires touch the axle stop.
Wheel Alignment Procedure
Stop the engine. Move the valve (Item 1) [Figure 20-1103] to the CLOSED position as shown.
Start the engine.
Repeat steps as needed.
Figure 20-110-4
Figure 20-110-6
P-47563A
P-47564
Using the loader bucket and stabilizers, lift the machine

off the ground approximately 2 in. (51 mm) [Figure 20110-4].
20-110-2

Service Manual
SAPR BRAKE CYLINDER
Figure 20-120-2

Figure 20-120-1
P-49512
Remove the retainer clip and pin (Item 1) [Figure 20120-2] from the caliper linkage bell crank.
P-52522
Figure 20-120-3
Lower stabilizers to the ground. Place blocks in front of
and behind the rear wheel [Figure 20-120-1].
IMPORTANT
damage the system.
I-2003-0888
P-52513
WARNING
Remove the retainer clip and pin (Item 1) [Figure 20120-3] from the parking brake cable bell crank.

immediately.
W-2145-0290
20-120-1

Service Manual
SAPR BRAKE CYLINDER (CONTD)
Figure 20-120-6

1
Figure 20-120-4
P-52512
Remove the mounting bolt and washers (Item 1) [Figure

20-120-6].
P-52514
Remove the cylinder.

Remove the retainer clip and pin (Item 1) [Figure 20120-4] from the SAPR cylinder bell crank.
Figure 20-120-5
P-52511
20-120-2

Service Manual

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Dust Cover
Clevis
Nut
Housing
Spring
Piston/Rod Assembly
Seal
Backup Ring
O-ring
Fitting
2
1
10
5
9
4
8
7
MS2109S
20-120-3

Service Manual
Figure 20-120-9
Disassembly
1
Figure 20-120-7
P-52505
Place cylinder in a vise as shown. Using a spanner

wrench remove the rod end housing (Item 1) [Figure 20120-9].
P-52503
Remove the dust cover (Item 1) [Figure 20-120-7].
Figure 20-120-10
Figure 20-120-8
1
P-52507
P-52504
Measure and record the length of the exposed cylinder

rod threads [Figure 20-120-10].
Remove the bell crank (Item 1). Place a mark on the
housing threads (Item 2) [Figure 20-120-8] for correct
assembly.
20-120-4

Service Manual
Figure 20-120-13
Disassembly (Contd)
1
Figure 20-120-11
P-52508
Remove the seal (Item 1) and backup ring (Item 2)

[Figure 20-120-13].
P-52506
Remove the nut (Item 1) and the rod and spring

Figure 20-120-12
P-52509
Remove the 2 springs (Item 1) [Figure 20-120-12].
20-120-5

Service Manual
Figure 20-120-16
Assembly
1

compressed air.
installation.
3
2
Figure 20-120-14
P-52506
1
Install the rod and spring assembly (Item 1) into the
housing (Item 2) and install the nut (Item 3) [Figure 20120-16].
Figure 20-120-17
P-52508
Install the backup ring (Item 1) and seal (Item 2) [Figure

20-120-14].
1
Figure 20-120-15
P-52507
Tighten the nut (Item 1) [Figure 20-120-17] to the length

recorded during disassembly.
P-52509
Install the 2 springs (Item 1) [Figure 20-120-15] onto the

rod assembly.
20-120-6

Service Manual
Figure 20-120-20
Assembly (Contd)
1
Figure 20-120-18
P-52503
Install the dust cover (Item 1) [Figure 20-120-20].

P-52505
Place the base end of the cylinder in a vise and install the
rod end housing (Item 1) [Figure 20-120-18]. Tighten the
housing to the mark recorded earlier.
Figure 20-120-19
1
P-52504
Install the bell crank (Item 1) [Figure 20-120-19].
20-120-7

Service Manual
20-120-8

Service Manual
SAPR BRAKE CONTROL VALVE
Figure 20-121-2

Figure 20-121-1
1
1
1
P-52495

P-52522
Figure 20-121-3
Lower stabilizers to the ground. Place blocks in front of
and behind the rear wheel [Figure 20-121-1].
IMPORTANT
damage the system.
1
1
I-2003-0888
P-52510
Remove the 2 mounting bolts (Item 1) and valve (Item 2)

[Figure 20-121-3].
WARNING
immediately.
W-2145-0290
20-121-1

Service Manual
SAPR BRAKE CONTROL VALVE (CONTD)

1.
2.
3.
4.
5.
6.
Nut
O-ring
Solenoid
Coil
O-ring/Back-up Ring Set
Housing
2
5
B-22853
20-121-2

Service Manual
SAPR BRAKE CONTROL VALVE (CONTD)
Figure 20-121-6

1
Figure 20-121-4
1
2
3
P-52502
Remove the 2 O-rings (Item 1) the O-ring and backup

ring sets (Item 2 & 3) [Figure 20-121-6].
P-52498
Remove the retainer nut (Item 1) and solenoid (Item 2)

[Figure 20-121-4].
Note the order of O-ring and backup ring sets for correct
assembly.
Figure 20-121-7
Figure 20-121-5
1
P-52501
P-52499
Remove the 3 fittings (Item 1) [Figure 20-121-7].

Remove the shaft (Item 1) [Figure 20-121-5].
20-121-3

Service Manual
20-121-4

Service Manual
HYDROSTATIC SYSTEM
HYDROSTATIC DRIVE MOTOR. . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-30-1
30-30-9
30-30-3
30-30-7
30-30-2
30-30-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-24
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-22
SAFETY &
MAINTENANCE
HYDRAULIC
SYSTEM
DRIVE
SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Pump Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
30-01

Service Manual
30-02

Service Manual
HYDROSTATIC SYSTEM INFORMATION
WARNING
Troubleshooting Chart
The following Troubleshooting Chart is provided for
assistance locating and correcting problems which are
only.
Check for correct function after adjustments, repairs

or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
Problem
Excessive noise in the hydrostatic pump.
Hydrostatic pump overheating.
System not developing pressure.
Loss of fluid.
No drive in one direction.
Loss of hydrostatic power under load.
Loader moves with foot pedal in neutral.
Slow or no drive.
Cause
1, 2, 3, 4, 5
1, 4, 6 7, 13
1, 8, 9, 10
11, 12
5, 8, 9
5, 8, 10, 17, 18
14, 18
5, 8, 9, 10, 15, 16, 17, 18
Key To Correct Cause

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Low fluid in the reservoir.

Air in the system.
Incorrect hydraulic fluid.
Excessive internal wear.
Lack of charge pressure.
Oil cooler dirty or cooler fan not working.
Engine not being operated at correct RPM.
High pressure relief valve not working correctly.
Hydrostatic pump replenishing valve not working correctly.
Tow valve in open position.
Leaking tubelines.
Hydrostatic motor seal leaking.
Fluid temperature fan switch not working correctly.
Travel pedal not adjusted correctly.
Charge relief valve is not working correctly.
Hydraulic pump is not working correctly.
Hydrostatic motor is damaged.
Hydrostatic pump is damage.
30-10-1

Service Manual
HYDROSTATIC SYSTEM INFORMATION (CONTD)
IMPORTANT
Replenishing Valve Function

The functions of the replenishing valves are:

damage the system.
Figure 10-50-8
CHARGE OIL
I-2003-088
FUNCTION 1
FUNCTION 2
Valve Moves for Charge

Oil Replacement
Valve Stays on Seat to Hold

High Pressure for Drive
B-2804
To give replacement fluid to the low pressure side of

the hydrosttic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling: Function 1
To keep high pressure fluid out of the low pressure

side of the hydrostatic circuity: Funtion 2
30-10-2

Service Manual
OIL COOLER
Figure 30-20-2
Rotate battery disconnect lever counterclockwise to
Remove the grill. (See Removal And Installation on Page
50-40-1.)
1
P-50142
Figure 30-20-1

Nm) torque.
Figure 30-20-3
P-50141
Remove the 2 tubelines (Item 1) [Figure 30-20-1].

NOTE: Mark oil cooler for correct installation.
1
P-50143
IMPORTANT
Remove the oil cooler [Figure 30-20-3].

damage the system.
I-2056-0793
30-20-1

Service Manual
OIL COOLER (CONTD)

1.
2.
3.
Oil Cooler
Washer
Plug
MS2126
30-20-2

Service Manual
HYDROSTATIC DRIVE MOTOR
Figure 30-30-2

1

Page 50-30-1.)
Figure 30-30-1
P-50147

lift and support drive motor.
Figure 30-30-3
1
P-50144
Remove the three hoses (Item 1) [Figure 30-30-1] from

the drive motor.
1
NOTE: Mark hoses for correct assembly
P-50147
IMPORTANT
damage the system.
I-2056-0793
Remove the six drive motor mounting bolts (Item 1)

[Figure 30-30-3].
torque.
Slide drive motor forward and remove.
30-30-1

Service Manual
HYDROSTATIC DRIVE MOTOR (CONTD)

1
2
3
5
5
2
5
2
5
2
6
6
2
9
7
10
11
12
7
13
1 SEAL
2 BEARING
3 HOUSING
14 1
15
4 O-RING
16
5 WASHER
17
6 KEYED COUPLER
7 SEAL RING
8 DRIVE LINK
9 WEAR PLATE
10 ROTOR
11 VANE
12 STATOR
13 MANIFOLD
14 RING
15 COMMUTATOR
16 END COVER
17 BOLT
B-19613
30-30-2

Service Manual
Figure 30-30-6
Disassembly
1
Figure 30-30-4
P-50024
P-50022
Remove the washers (Item 1) [Figure 30-30-6] from the

fittings. Inspect and replace as necessary.
Figure 30-30-7
Remove the shaft key (Item 1) [Figure 30-30-4].

Figure 30-30-5
1
P-38853
P-50023
Mark drive motor housing for correct assembly [Figure

30-30-7].
Remove the fittings (Item 1) [Figure 30-30-5].
30-30-3

Service Manual
Figure 30-30-10
Disassembly (Contd)
Figure 30-30-8
P-50029
Remove the sealing ring (Item 1) [Figure 30-30-10].

P-38854
Figure 30-30-11
Remove the seven end cover bolts (Item 1) [Figure 3030-8].
Figure 30-30-9
1
P-38857
Remove the spacer (Item 1) [Figure 30-30-11].

P-38855
Remove the end cover (Item 1) [Figure 30-30-9].
30-30-4

Service Manual
Figure 30-30-14
Disassembly (Contd)
Figure 30-30-12
1
2
1
P-38860

P-38858
Figure 30-30-15
Remove the sealing ring (Item 1). Remove the control
washer (Item 2) [Figure 30-30-12].
Figure 30-30-13
1
1
P-38861
Remove the sealing ring (Item 1) [Figure 30-30-15] from

valve plate.
P-38859

the control washer.
30-30-5

Service Manual
Figure 30-30-18
Disassembly (Contd)
Figure 30-30-16
1
P-38864
Remove the spacer plate (Item 1) [Figure 30-30-18].

P-38862
Figure 30-30-19
Remove the gerotor assembly (Item 1) [Figure 30-3016].
NOTE: Keep the gerotor assembly together. If rollers
are removed install them back in the original
bore.
Figure 30-30-17
1
P-38865
Remove the multi-spline shaft (Item 1) [Figure 30-3019].
P-38863

gerotor.
30-30-6

Service Manual
Inspection
Disassembly (Contd)

Figure 30-30-20
Figure 30-30-22
2
1
P-38866
P-38872
Remove the sealing ring (Item 1) and thrust bearing (Item

2) [Figure 30-30-20].
Check the shaft (Item 1) [Figure 30-30-22] for wear or

damage in the spline and bearing surface areas. Replace
as needed.
Figure 30-30-21
Figure 30-30-23
1
3
2
P-38867
2
Remove the shaft (Item 1) from the housing (Item 2)
[Figure 30-30-21].
1
P-38871
Inspect the shaft seal (Item 1), thrust bearing (Item 2)

and needle bearing (Item 3) [Figure 30-30-23] replace
as needed.
30-30-7

Service Manual
Figure 30-30-26
Inspection (Contd)
Figure 30-30-24
P-38859
Check the control washer (Item 1) [Figure 30-30-26] for

wear or scratches. Replace as needed.
P-38869
Figure 30-30-27
Inspect the outer shaft seal (Item 1) and roller bearing
(Item 2) [Figure 30-30-24] replace as needed.
Figure 30-30-25
P-38861
Check the valve plate (Item 1) [Figure 30-30-27] for wear

or scratches. Replace as needed.
P-38863
Check gerotor (Item 1) [Figure 30-30-25] for wear

scratches or cracks. If there is any defect in the gerotor,
the assembly must be replaced.
30-30-8

Service Manual
Figure 30-30-29

Inspection (Contd)
Figure 30-30-28
P-38872
Install the shaft (Item 1) into the housing (Item 2) [Figure

30-30-29].
P-38856
Figure 30-30-30
Check the end cover (Item 1) [Figure 30-30-28] for wear
or scratches. Replace as needed.
Assembly
IMPORTANT
damage the system.
P-38867
I-2003-0888
Clean and lightly oil all parts. Prior to assembly.
Line up key way on shaft (Item 1) with center of the two

fitting bores (Item 2) [Figure 30-30-30].
30-30-9

Service Manual
Figure 30-30-33
Assembly (Contd)
Figure 30-30-31
1
2
P-38864
Install the spacer plate (Item 1) [Figure 30-30-33].

P-38866
Figure 30-30-34
Install the sealing ring (Item 1) and thrust bearing (Item 2)
[Figure 30-30-31].
1
Figure 30-30-32
P-38863
Install the sealing ring (Item 1) [Figure 30-30-34].

P-38865
Figure 30-30-35
Install the multi-spline shaft (Item 1) [Figure 30-30-32].
P-38862
Install the gerotor assembly (Item 1) [Figure 30-30-35].

30-30-10

Service Manual
Figure 30-30-38
Assembly (Contd)
Figure 30-30-36
1
P-38860
Install the valve plate (Item 1) [Figure 30-30-38].

P-38873
Figure 30-30-39
Rotate the gerotor gear so one lobe (Item 1) is in line with
the shaft key way (Item 2) using the center of the fitting
bores (Item 3) [Figure 30-30-36] for timing of motor as
shown.
Figure 30-30-37
P-38859
Install the sealing ring (Item 1) into control washer (Item

2) [Figure 30-30-39].
P-38861
Install the sealing ring (Item 1) [Figure 30-30-37] into

valve plate.
30-30-11

Service Manual
Figure 30-30-42
Assembly (Contd)
Figure 30-30-40
2
1
P-50029
Install the sealing ring (Item 1) into the end cover (Item 2)
[Figure 30-30-42].
P-38858
Figure 30-30-43
Install the sealing ring (Item 1) and control washer (Item
2) [Figure 30-30-40].
Figure 30-30-41
P-38855
Install the end cover (Item 1) [Figure 30-30-43].

P-38857
Install the spacer plate (Item 1) [Figure 30-30-41].
30-30-12

Service Manual
Figure 30-30-46
Assembly (Contd)
1
Figure 30-30-44
P-50023
Install the fittings (Item 1) [Figure 30-30-46].

P-38854
Figure 30-30-47
Install the seven bolts (Item 1) [Figure 30-30-44].
Installation: Tighten the bolts in a criss cross pattern to
45-55 ft.-lb. (61-75 Nm) torque.
Figure 30-30-45
P-50022
Install the shaft key (Item 1) [Figure 30-30-47]

2
P-50024
Install the washer (Item 1) onto the fitting. Apply Loctite

sealant 515 or equivalent to the fitting threads (Item 2)
[Figure 30-30-45].
30-30-13

Service Manual
30-30-14

Service Manual
HYDROSTATIC PUMP
Figure 30-40-2

1
WARNING
immediately.
W-2145-0290
P-50066
IMPORTANT
Figure 30-40-3

damage the system.
I-2056-0793
Drain the hydraulic reservoir. (See Contents Page 2001.)

Page 50-30-1.)
Remove the gear pump. (See Removal And Installation
on Page 20-80-1.)
P-50067
Figure 30-40-1
P-50065

30-40-1

Service Manual
HYDROSTATIC PUMP (CONTD)
Figure 30-40-6

Figure 30-40-4
P-50074
P-50068
Install a hoist and lifting bracket to lift and support the

hydrostatic pump [Figure 30-40-6].
Figure 30-40-7

Figure 30-40-5
P-50075
1
P-50069
Remove the mounting bolt (Item 1) [Figure 30-40-7]

(both sides).
Nm) torque.
30-40-2

Service Manual

Figure 30-40-8
P-50076
Remove the hydrostatic pump [Figure 30-40-8].
30-40-3

Service Manual

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Charge Pump
O-ring
Alignment Pin
Bearing
Valve Plate
Replenishing Valve
Spool
Spring
Spring Seat
Plug
Washer
Poppet
Pin
Fitting
Jam Nut
Adjustment Screw
Back-up Ring
Metering Spool
Bolt
Ring Gear
Gear
Snap Ring
Coupler
Key
Bearing Race
Flange
Bearing
Manifold
10
16
8
11
10
15
14
2
13
18
17
2
9
8
2
9
8
12
7
15
16
10
14
11
19
3
2
9
9
10
2
8
3 9
10
20
16
10
21
7
2
9
10
13
8
2
10
8
11
6 2
28
12
2
10
2
15
2
8
2
11
14
13
10
19
10
9
10
8
2
22
23
10
24
27
22
25
26
11
19
11
19
MS-21195
30-40-4

Service Manual

Parts Identification (Contd)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Pump Housing
O-ring
Plug
Washer
Bolt
Shaft
Bearing
Snap Ring
Seal
Shaft Retainer
Spring
Cylinder Block
Pin
Retaining Ball
Retaining Ring
Piston
Swashplate
Plate
Actuator
Actuator Block
Bearing Race
Bearing Cage
Servo Housing
End Cover
Adjustment Screw
Nut
Spring Seat
Servo Piston
26
26
5
20
27
24
2
25
11
27
21
19
28
17
18
26
22
23
2 24
22
5
5
21
17
2 25
26
13
8
10
8
4
7
5
4
6
16
3
14
4
15
13
12
11
4
8
MS-21205
30-40-5

Service Manual
Figure 30-40-11
Disassembly
1
IMPORTANT
damage the system.
I-2003-0888
P-38494
Figure 30-40-9
Remove and discard the 6 O-rings (Item 1) [Figure 3040-11].
Figure 30-40-12
P-40606
With the pump on a work surface, mark the power limiter

housings for correct assembly [Figure 30-40-9].
P-38495
Figure 30-40-10
P-40607
Remove the 2 bolts and lock washers (Item 1) [Figure

30-40-10] and remove the power limiter.
30-40-6

Service Manual
Figure 30-40-15
Disassembly (Contd)
Figure 30-40-13
1
1
1
1
P-38498
Remove the 2 plugs (Item 1) [Figure 30-40-15].

P-38496
Figure 30-40-16
Remove the five plugs (Item 1) [Figure 30-40-13].
Figure 30-40-14
1
P-38499
Remove the washers (Item 1) [Figure 30-40-16] from the

plugs and replace as needed.
P-38497
Remove the washer (Item 1) [Figure 30-40-14] from the

plugs and replace as needed.
30-40-7

Service Manual
Figure 30-40-19
Disassembly (Contd)
Figure 30-40-17
2
1
P-38501
Remove and discard the O-ring (Item 1) [Figure 30-4019] from the plug.
P-38502
Figure 30-40-20
Figure 30-40-18
P-38504
P-38500
Remove the plug (Item 1) [Figure 30-40-17] & [Figure

30-40-18] and spring (Item 2) [Figure 30-40-17] &
[Figure 30-40-18].
Slide the spool partially out of the housing and remove

the shim pack (Item 1) [Figure 30-40-20].
NOTE: Mark the housing for shim pack location.
30-40-8

Service Manual
Figure 30-40-23
Disassembly (Contd)
Figure 30-40-21
5
4
3
2
1
1
P-38508
Remove the lube cooling adjusting screw (Item 1), pin

(Item 2), spring seat (Item 3), spring (Item 4) and
metering spool (Item 5) [Figure 30-40-23].
P-38505
Remove the spool (Item 1) [Figure 30-40-21] from the

manifold.
Figure 30-40-24
Figure 30-40-22
1
1
P-38507
P-38506
Before removing the lube cooling adjusting screw (Item

1) [Figure 30-40-22] measure and record the correct
adjustment.
30-40-9

Service Manual
Figure 30-40-27
Disassembly (Contd)
Figure 30-40-25
P-38511
Remove the adjusting screw (Item 1) [Figure 30-40-27].

P-38509
NOTE: Do not loosen the jam nut.

Remove the second manifold assembly [Figure 30-4025]
Figure 30-40-28
Figure 30-40-26
P-38512
P-38510
Remove and discard the 6 O-rings (Item 1) [Figure 3040-26]
30-40-10

Service Manual
Figure 30-40-31
Disassembly (Contd)
Figure 30-40-29
4
3
3
2
1
P-38515
Remove the plug (Item 1) washer (Item 2), retainer (Item

3) and check valve assembly (Item 4) [Figure 30-40-31]
P-38513
Figure 30-40-32
Remove the spring seat (Item 1), spring (Item 2), spring
seat/orifice (Item 3) and spool (Item 4) [Figure 30-4029].
Figure 30-40-30
1
2
P-38516
3
1
Remove the plug (Item 1) and washer (Item 2) [Figure

30-40-32].
2
P-38514
Remove the plug (Item 1) washer (Item 2) and pin (Item

3) [Figure 30-40-30].
30-40-11

Service Manual
Figure 30-40-35
Disassembly (Contd)
1
Figure 30-40-33
3
2
1
P-40609
Remove the servo (Item 1) [Figure 30-40-35] from the

pump housing.
P-38517
Figure 30-40-36
Remove plug (Item 1), washer (Item 2) and orifice (Item
3) [Figure 30-40-33].
Figure 30-40-34
1
1
1
P-40610
Remove and discard the O-ring (Item 1) [Figure 30-4036]
P-40608
Remove the 6 bolts and lock washers (Item 1) [Figure

30-40-34].
30-40-12

Service Manual
Figure 30-40-39
Disassembly (Contd)
Figure 30-40-37
1
1
1
P-40613

servo end cap. Remove the 4 bolts from the other end
cap.
P-40611
Before removing the adjustment screw (Item 1) [Figure

30-40-37] measure and record the correct adjustment.
Figure 30-40-40
Remove the adjustment screw (Item 1) [Figure 30-4037].

Figure 30-40-38
P-40614
Mark the servo housing for correct assembly [Figure 3040-40]

P-40612
Before removing the servo adjustment screw (Item 1)

[Figure 30-40-38] measure and record the correct
adjustment.
Remove the servo adjustment screw (Item 1) [Figure 3040-38].
30-40-13

Service Manual
Figure 30-40-43
Disassembly (Contd)
Figure 30-40-41
1
1
P-40617
Remove and discard the 2 backup rings (Item 1) [Figure

30-40-43] from the housing.
P-40615
Mark the housing for correct assembly.

Remove the servo piston assembly (Item 1) [Figure 3040-41] from the housing.
Figure 30-40-44
Figure 30-40-42
1
1
1
P-40618
P-40616
Remove the 4 bolts (Item 1) and remove the mounting

flange (Item 2) [Figure 30-40-44]
Remove and discard the O-rings (Item 1) [Figure 30-4042] from the servo piston end caps.
30-40-14

Service Manual
Figure 30-40-47
Disassembly (Contd)
Figure 30-40-45
1
1
2
P-40621
Remove the gear assembly (Item 1) and the coupler key

(Item 2) [Figure 30-40-47].
P-40619
Figure 30-40-48
Remove and discard the O-ring (Item 1) [Figure 30-4045]
Figure 30-40-46
1
1
P-40622
Remove the coupler assembly (Item 1) [Figure 30-4048]
P-40620
Remove the bearing (Item 1) [Figure 30-40-46]. Replace

as needed.
30-40-15

Service Manual
Figure 30-40-51
Disassembly (Contd)
Figure 30-40-49
1
1
P-40625
Remove the washer (Item 1) [Figure 30-40-51] from the

fitting.
P-40623
Figure 30-40-52
Mark the housing and remove the four bolts (Item 1)
[Figure 30-40-49] and remove the charge pump.
3
Figure 30-40-50
1
P-40626
Remove the plug (Item 1), washer (Item 2) and spring

(Item 3) [Figure 30-40-52].
P-40624
Remove the 2 fittings and washers (Item 1). Remove the

O-ring (Item 2) [Figure 30-40-50] and discard.
30-40-16

Service Manual
Figure 30-40-55
Disassembly (Contd)
Figure 30-40-53
1
P-40629
Remove the replenishing valve (Item 1) [Figure 30-4055].
P-40627
Figure 30-40-56
Remove the replenishing valve (Item 1) [Figure 30-4053].
Figure 30-40-54
P-40630

P-40628
Remove the plug (Item 1), washer (Item 2), and spring
(Item 3) [Figure 30-40-54].
30-40-17

Service Manual
Figure 30-40-59
Disassembly (Contd)
Figure 30-40-57
1
1
P-40632
Before removing the adjustment screw (Item 1) [Figure

30-40-59] measure and record the correct adjustment.
P-40631
Remove the metering spool (Item 1) [Figure 30-40-57]
Remove the adjustment screw (Item 1) [Figure 30-4059]
Figure 30-40-58
Figure 30-40-60
3
2
P-38545
P-38547
Remove the backup ring (Item 1) and O-ring (Item 2)

[Figure 30-40-58].
Remove the pin (Item 1), spring seat (Item 2), spring
(Item 3) and poppet (Item 4) [Figure 30-40-60].
30-40-18

Service Manual
Figure 30-40-63
Disassembly (Contd)
1
Figure 30-40-61
P-40634

housing.
P-40633
Figure 30-40-64
Inspect the bearing (Item 1) [Figure 30-40-61] and
replace as needed.
1
Figure 30-40-62
P-40635

P-38548
Inspect the bearing (Item 1) [Figure 30-40-62] and

replace as needed.
30-40-19

Service Manual
Figure 30-40-67
Disassembly (Contd)
Figure 30-40-65
1
1
P-40638
Remove the shaft assembly (Item 1) [Figure 30-40-67]

P-40636
Figure 30-40-68
Lay the housing on its side and remove the cylinder
block/piston assembly (Item 1) [Figure 30-40-65] from
the drive shaft.
Figure 30-40-66
P-40639
Remove the swash plate assembly (Item 1) [Figure 3040-68]

P-40637
30-40-20

Service Manual
Figure 30-40-71
Disassembly (Contd)
Figure 30-40-69
1
P-40645
Remove the actuator block (Item 1) [Figure 30-40-71]

from the swash plate arm.
P-40640
Remove the swash plate bearings (Item 1) [Figure 3040-69].

Figure 30-40-70
P-38660
Remove the swash plate bearing races (Item 1) [Figure

30-40-70].
30-40-21

Service Manual
Figure 30-40-74
Inspection
Figure 30-40-72
P-40648
Check the swash plate bearings (Item 1) [Figure 30-4074] for wear and damage. Replace as needed.
Figure 30-40-75
P-40646
2
1
Check the wear plate (Item 1) and charge pump gears
(Item 2) [Figure 30-40-72] for damage or wear.
Figure 30-40-73
P-38664
Check each piston (Item 1) and piston shoe (Item 2)

[Figure 30-40-75] for wear or scratches.
P-40647
Check the swash plate assembly surface, it must be

smooth and free of scratches [Figure 30-40-73].
30-40-22

Service Manual
Figure 30-40-78
Inspection (Contd)
Figure 30-40-76
2
P-40651
Inspect the shaft seal (Item 1). Replace if needed.

Remove and discard the o-ring (Item 2) [Figure 30-4078].
P-40649
Check the cylinder block bores for wear or scratches

[Figure 30-40-76].
If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.
Figure 30-40-77
1
P-40650
Check the shaft for wear or damage in the spline and

bearing areas [Figure 30-40-77].
Check the bearing for correct operation. If bearing
replacement is required, remove the snap ring (Item 1)
and remove the bearing (Item 2) [Figure 30-40-77].
30-40-23

Service Manual
Figure 30-40-81
Assembly
IMPORTANT

damage the system.
I-2003-0888
P-40645
Clean and lightly oil all parts. Prior to assembly.

Install the actuator block (Item 1) [Figure 30-40-81] onto
the servo arm.
Figure 30-40-79
Figure 30-40-82
1
P-38660
Install the swash plate bearing races (Item 1) [Figure 3040-79] into the housing. Note the offset in each race.
P-40639
Carefully install the swash plate (Item 1) [Figure 30-4082] into the housing.
Figure 30-40-80
P-40640
Assemble and lubricate the bearing cage (Item 1)

[Figure 30-40-80] and install on the bearing races.
30-40-24

Service Manual
Figure 30-40-85
Assembly (Contd)
Figure 30-40-83
P-40636
Install the cylinder block/piston assembly (Item 1)

[Figure 30-40-85] over the drive shaft and onto the
swash plate.
P-40638P38656
Lubricate the o-ring (Item 1) and install the shaft

Figure 30-40-86
Figure 30-40-84
1
P-38547
P-40637
Install the poppet (Item 1), spring (Item 2), spring seat
(Item 3) and pin (Item 4) [Figure 30-40-86].
Install the snap ring (Item 1) [Figure 30-40-84].
30-40-25

Service Manual
Figure 30-40-89
Assembly (Contd)
Figure 30-40-87
1
P-38543
Install the metering spool (Item 1) [Figure 30-40-89] into

the housing.
P-38546
Figure 30-40-90
Install the adjustment screw (Item 1) [Figure 30-40-87]
into the housing to the correct adjustment recorded
earlier.
Figure 30-40-88
1
1
P-40630
Apply Loctite RC609 or equivalent to the fitting (Item 1)

[Figure 30-40-90] and install.
P-38545
Install a new back-up ring (Item 1) and o-ring (Item 2)

[Figure 30-40-88] onto the metering spool.
30-40-26

Service Manual
Figure 30-40-93
Assembly (Contd)
1
Figure 30-40-91
P-40627
Install the replenishing valve (Item 1) [Figure 30-40-93].

P-38541
Figure 30-40-94
Install the replenishing valve (Item 1) [Figure 30-40-91].
2
Figure 30-40-92
2
1
P-40626
Install the spring (Item 1), washer (Item 2) and plug (Item
3) [Figure 30-40-94].
P-40628
Install the spring (Item 1), washer (Item 2) and plug (Item
3) [Figure 30-40-92].
30-40-27

Service Manual
Figure 30-40-97
Assembly (Contd)
Figure 30-40-95
1
P-38671
1
Apply assembly grease to the valve plate.
P-40625
Install the washer (Item 1) [Figure 30-40-95] onto the

fitting.
Install the valve plate onto the charge pump. Note the
slot (Item 1) must go around the pin (Item 2) [Figure 3040-97].
Figure 30-40-98
Figure 30-40-96
P-40653
P-40624
Install the o-ring (Item 1) [Figure 30-40-98].

Apply Loctite RC609 or equivalent to the fittings (Item 1)
[Figure 30-40-96] and install.
30-40-28

Service Manual
Figure 30-40-101
Assembly (Contd)
Figure 30-40-99
1
1
P-40622
Install the coupler (Item 1) [Figure 30-40-101].

P-40634
Figure 30-40-102
Install the o-ring (Item 1) [Figure 30-40-99] onto the
housing.
Figure 30-40-100
2
1
1
P-40621
Install the coupler key (Item 1). Apply assembly lube and
install the gear assembly (Item 2) [Figure 30-40-102]
over the coupler key.
P-40623
Carefully turn the charge pump assembly over and place

on the main housing.
Install the four bolts (Item 1) [Figure 30-40-100] and
tighten to 90 ft.-lb. (122 Nm) torque.
30-40-29

Service Manual
Figure 30-40-105
Assembly (Contd)
Figure 30-40-103
1
1
P-40617
Install the new back-up rings (Item 1) [Figure 30-40-105]

into the housing.
P-40619
Figure 30-40-106
Install the o-ring (Item 1) [Figure 30-40-103] into the
mounting flange.
Figure 30-40-104
1
2
P-40616P38525
Install a new o-ring (Item 1) on the servo end cap. Install

a new O-ring (Item 2) [Figure 30-40-106] on the end cap.
P-40618
Install the mounting flange (Item 1) and four bolts (Item 2)

[Figure 30-40-104]. Tighten the bolts to 55 ft.-lb. (75
Nm) torque.
30-40-30

Service Manual
Figure 30-40-109
Assembly (Contd)
Figure 30-40-107
P-40612
1
Install the servo adjustment screw (Item 1) [Figure 3040-109] into the housing to the correct adjustment
recorded earlier.
P-40615
Lightly lubricate the back-up rings in the housing and

install the servo piston (Item 1) [Figure 30-40-107] into
the housing.
Figure 30-40-110
Figure 30-40-108
1
P-40610
Install the new o-ring (Item 1) [Figure 30-40-110] onto

the servo housing.
P-40613
Install the 4 mounting bolts (Item 1) [Figure 30-40-108]

and tighten on both end caps.
30-40-31

Service Manual
Figure 30-40-113
Assembly (Contd)
Figure 30-40-111
1
2
3
P-38517
Install the orifice (Item 1), washer (Item 2) and plug (Item
3) [Figure 30-40-113].
P-40609
Figure 30-40-114
Apply Loctite 545 sealant or equivalent to the mounting
surface (Item 1) [Figure 30-40-111] on the servo
housing.
Align the actuator block (Item 2) with the servo piston
groove (Item 3) [Figure 30-40-111] and install the servo
housing.
1
Figure 30-40-112
2
1
P-38516
Install the washer (Item 1) and plug (Item 2) [Figure 3040-114].
P-40608
Install the 6 bolts and washers (Item 1) [Figure 30-40112] and tighten to 14 ft.-lb. (20 Nm) torque.
30-40-32

Service Manual
Figure 30-40-117
Assembly (Contd)
Figure 30-40-115
1
2
3
1
P-38513
3
Install the spool (Item 1), spring seat/orifice (Item 2),
spring (Item 3) and spring seat (Item 4) [Figure 30-40117].
P-38515
Install the check valve assembly (Item 1), retainer (Item

2), washer (Item 3) and plug (Item 4) [Figure 30-40-115].
Figure 30-40-118
Figure 30-40-116
3
1
P-38512
1
2
P-38514
Install the pin (Item 1), washer (Item 2) and plug (Item 3)
[Figure 30-40-116].
30-40-33

Service Manual
Figure 30-40-121
Assembly (Contd)
Figure 30-40-119
P-38509
Install the second manifold onto the housing [Figure 3040-121].
P-38511
Figure 30-40-122
Install the adjusting screw (Item 1) [Figure 30-40-119]
and tighten to 25 ft.-lb. (35 Nm) torque.
Figure 30-40-120
1
P-38507
1
P-38510
Install the 6 o-rings (Item 1) [Figure 30-40-120].
30-40-34

Service Manual
Figure 30-40-125
Assembly (Contd)
Figure 30-40-123
1
1
2
3
5
P-38505
4
Lubricate and install the spool (Item 1) [Figure 30-40125] into the manifold.
P-38508
Figure 30-40-126
Install the metering spool (Item 1), spring (Item 2), spring
seat (Item 3), pin (Item 4) and adjusting screw (Item 5)
[Figure 30-40-123].
Figure 30-40-124
1
P-38504
Install the shim pack (Item 1) [Figure 30-40-126] onto

the spool.
P-38506
NOTE: Install the shim pack as recorded earlier.

Tighten the adjusting screw (Item 1) [Figure 30-40-124]
into the housing to the correct adjustment recorded
earlier.
30-40-35

Service Manual
Figure 30-40-129
Assembly (Contd)
Figure 30-40-127
P-38501

plug.
P-38501
Figure 30-40-130
plug.
Figure 30-40-128
1
2
P-38502
1
2
Install the spring (Item 1) and plug (Item 2) [Figure 3040-130].
P-38500
Install the spring (Item 1) and plug (Item 2) [Figure 3040-128].
30-40-36

Service Manual
Figure 30-40-133
Assembly (Contd)
2
Figure 30-40-131
1
2
1
P-38497
Install the washer (Item 1) onto the plug (Item 2) [Figure

30-40-133].
P-38499
Figure 30-40-134
Install the washer (Item 1) onto the plug (Item 2) [Figure
30-40-131].
Figure 30-40-132
1
1
1
P-38496
1
Install the 5 plugs (Item 1) [Figure 30-40-134] into the
housing.
P-38498
Install the plugs (Item 1) [Figure 30-40-132] into the

manifold.
30-40-37

Service Manual
Figure 30-40-137
Assembly (Contd)
Figure 30-40-135
1
P-38493
1
P-38495
Install the top manifold (Item 1) with the washers and

bolts (Item 2) [Figure 30-40-137] tighten to 90 ft.-lb. (122
Nm) torque
Install the fitting (Item 1) [Figure 30-40-135].

Figure 30-40-136
P-38494P38496
Install the 6 o-rings (Item 1) [Figure 30-40-136].
30-40-38

Service Manual
HYDROSTATIC TESTING
Figure 30-50-2
Pump Adjustment
The testing of the hydrostatic pump must be done in the
following order:
CHARGE PRESSURE
FLUSHING VALVE
TORQUE LIMITER
All testing is done with the hydraulic oil at 150 F (66 C)
The hydraulic hoses, tubelines and fittings are 24 DIN
cone metric fittings.

P-42707
To test the charge pressure, stop the engine and engage

the parking brake. Raise the machine and install
jackstands. (See Procedure on Page 10-10-1.)
WARNING
With the park brake engaged, hydraulic fluid temperature

at 150 F (66 C), start the engine and set the engine to
1000 RPM. Record pressure on the gauge (Item 1)
[Figure 30-50-2]
The correct pressure should be 320 psi (2206 kPa).
Put jackstands under the front and rear axle before

running the engine for service. Failure to use
jackstands can allow the machine to fall or move and
Stop the engine.

Figure 30-50-3
W-2461-0303
Remove the left front floor panel. (See Left Front Panel
Figure 30-50-1
P-42710
2
If the pressure is incorrect, loosen the jam nut (Item 1) on
the relief valve. Turn the adjustment screw (Item 2)
[Figure 30-50-3] clockwise to increase the pressure or
counterclockwise to decrease the pressure.
P-42703A
Tighten the jam nut (Item 1) [Figure 30-50-3].

charge port and install a 1000 psi (6895 kPa) gauge.
forward travel test port and install a 10,000 psi (68950
kPa) gauge.
Retest the charge pressure after adjustment.

NOTE: If the charge pressure was adjusted the
flushing valve test must be performed. If no
adjustment was made continue to the Torque
Limiter Test.
30-50-1

Service Manual
HYDROSTATIC TESTING (CONTD)
Figure 30-50-5
Pump Adjustment (Contd)
3
1
Figure 30-50-4
2
1
2
P-42706
If the pressure drop is incorrect, locate the flushing valve

adjustment (Item 1) [Figure 30-50-5] on the right side of
the hydrostatic pump facing forward.
P-42707
To test the flushing valve, make sure the park brake is

engaged, hydraulic fluid temperature is at 150 F (66 C),
start the engine and engage the press to drive. Set the
engine to 1000 RPM. Record the pressure on the gauge
(Item 1) [Figure 30-50-4] in the charge port.
Apply slight pressure to the forward travel pedal (Item 2)
and release. The gauge (Item 1) [Figure 30-50-4] will
drop 30 psi (207 kPa) less than recorded pressure, then
return to recorded pressure. The correct pressure drop
should be 30 psi (207 kPa).
Loosen the jam nut (Item 2) and turn the adjustment

screw (Item 3) [Figure 30-50-5] counterclockwise to
increase the pressure drop or clockwise to decrease the
pressure drop.
Tighten the jam nut (Item 2) [Figure 30-50-5]. Retest the
flushing valve.
Figure 30-50-6
Stop the engine.
3
1
P-42708
Locate the torque limiter adjustment (Item 1) [Figure 3050-6] on the bottom right side of the hydrostatic pump.
With the engine off, loosen the jam nut (Item 2) on the
torque limiter and turn the adjustment screw (Item 3)
[Figure 30-50-6] clockwise two full turns.
30-50-2

Service Manual
HYDROSTATIC TESTING (CONTD)

Pump Adjustment (Contd)
Figure 30-50-7
P-42709
With the hydraulic fluid temperature at 150 F (66 C)

and the parking brake engaged, start the engine. Engage
the press to drive, set the engine to full RPM. Operate the
travel pedal (Item 1) in the forward travel position until the
maximum pump drive pressure is recorded on the gauge
(Item 2) [Figure 30-50-7].
With the engine running turn the torque limiter
adjustment screw (Item 3) counterclockwise until the
maximum drive is reduced by approximately 100 psi
(6895 kPa). Tighten the jam nut (Item 1) [Figure 30-506].
Stop the engine.
Remove pressure gauges.
Install test port plugs. Remove the jackstands. Install left
front floor panel.
Do the following operational tests. See examples below.
Example: If the machine characteristic is, the engine rpm
drops too easily, back out the torque limiter screw 1/4
turn and retest.
Example: If the machine characteristic is, low drive
force, turn in the torque limiter screw 1/4 turn and retest.
30-50-3

Service Manual
30-50-4

Service Manual
DRIVE SYSTEM
AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . 40-41-1
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-35
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-16
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-22
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . 40-41-15
Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-47
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-8
Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . 40-41-7
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-2
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-28
Pinion Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 40-41-24
Pinion Group Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-27
Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . 40-41-23
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . 40-41-44
Steering Knuckle Disassembly. . . . . . . . . . . . . . . . . . . . . 40-41-12
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . 40-41-11
Wheel Hub/Spindle Assembly . . . . . . . . . . . . . . . . . . . . . 40-41-50
Wheel Hub/Spindle Disassembly . . . . . . . . . . . . . . . . . . . . 40-41-3
Wheel Hub/Spindle Parts Identification . . . . . . . . . . . . . . . 40-41-2
AXLE AND DIFFERENTIAL (REAR). . . . . . . . . . . . . . . . . . . . 40-31-1
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-35
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-16
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-22
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . 40-31-15
Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-47
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-8
Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . 40-31-7
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-2
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-28
Pinion Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 40-31-24
Pinion Group Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-27
Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . 40-31-23
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . 40-31-44
Steering Knuckle Disassembly. . . . . . . . . . . . . . . . . . . . . 40-31-12
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . 40-31-11
Wheel Hub/Spindle Assembly . . . . . . . . . . . . . . . . . . . . . 40-31-50
Wheel Hub/Spindle Disassembly . . . . . . . . . . . . . . . . . . . . 40-31-3
Wheel Hub/Spindle Parts Identification . . . . . . . . . . . . . . . 40-31-2
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
40-20-1
40-20-6
40-20-4
40-20-3
40-20-1
40-01

Service Manual
DRIVE SYSTEM (CONTD)

DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
DROP BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-12
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . .
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . .
40-10-1
40-10-4
40-10-2
40-10-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
STEERING ANGLE ADJUSTMENT (FRONT AXLE) . . . . . . . 40-42-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42-1
STEERING ANGLE ADJUSTMENT (REAR AXLE) . . . . . . . . 40-32-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32-1
40-02

Service Manual
PARKING BRAKE
Figure 40-10-3
Lever Removal And Installation

Figure 40-10-1
1
P-38616
Remove the pin retainer clip (Item 1) and washer (Item 2)

[Figure 40-10-3].
P-50254
Figure 40-10-4
Lower the stabilizers, stop the engine and block the rear
wheels [Figure 40-10-1].
Figure 40-10-2
P-38617

P-32804
Release the parking brake lever (Item 1) [Figure 40-102] as shown.
40-10-1

Service Manual
PARKING BRAKE (CONTD)
Cable Removal And Installation
Lever Removal And Installation (Contd)
Block the rear wheels and release brake lever. (See

Lever Removal And Installation on Page 40-10-1.)
Figure 40-10-5
Page 50-30-1.)
Figure 40-10-7
1
1
P-38618

Nm) torque.
P-52491
Measure and record the length of the brake cable threads

[Figure 40-10-7].
Figure 40-10-6
Figure 40-10-8
P-38619
P-52492
Remove the parking brake lever (Item 1) [Figure 40-106].
Remove the retainer clip and pin (Item 1) [Figure 40-108].
40-10-2

Service Manual
Figure 40-10-11
Cable Removal And Installation (Contd)

Figure 40-10-9
P-38617

P-52493
Figure 40-10-12
Remove the clevis (Item 1), jam nut (Item 2) and dust
cover (Item 3). Pull the cable through the bracket (Item 4)
[Figure 40-10-9].
Figure 40-10-10
1
1
P-38624
2
Raise the cable boot (Item 1) [Figure 40-10-12].
P-38616
Remove the pin retainer clip (Item 1) and washer (Item 2)

[Figure 40-10-10].
40-10-3

Service Manual
Adjustment
Cable Removal And Installation (Contd)
Figure 40-10-15
Figure 40-10-13
1
1
P-32804
P-38625
Remove the cable retainer clip (Item 1) [Figure 40-1013].
Push parking brake lever (Item 1) forward and down to

disengage the parking brake. To adjust the parking brake
twist the handle [Figure 40-10-15]. Twisting the handle
clockwise will increase the force applied
Figure 40-10-14
P-38626
Lower and remove the cable (Item 1) [Figure 40-10-14].
40-10-4

Service Manual
BRAKE CALIPER
Figure 40-20-3
Remove the drop box. (See Removal And Installation on

Page 40-60-1.)
Figure 40-20-1
3
1
P-50159
Rotate brake disc (Item 1) to line up hole (Item 2) with

upper caliper mount bolt (Item 3) [Figure 40-20-3].
Remove the bolt.
Figure 40-20-4
P-50156
Remove the 2 bolts (Item 1) [Figure 40-20-1]. (Both

sides)

Nm) torque.
Figure 40-20-2
3
P-50158
Rotate brake disc (Item 1) to line up hole (Item 2) with

lower caliper mount bolt (Item 3) [Figure 40-20-4]
Remove the bolt.
1

Nm) torque.
P-50157
Remove the drop box mount bracket (Item 1) [Figure 4020-2].
40-20-1

Service Manual
BRAKE CALIPER (CONTD)
Figure 40-20-7

Figure 40-20-5
1
1
P-50162
Remove the 2 brake disc mount bolts (Item 1) [Figure

40-20-7].
P-50160
Remove the brake disc.

Remove the brake caliper (Item 1) [Figure 40-20-5].
Figure 40-20-6
1
2
P-50161

Nm) torque.
Remove the drive hub (Item 2) [Figure 40-20-6].
40-20-2

Service Manual

1
2
3
4
5
6
7
8
9
10
11
Snap Ring
Screw
Link
Arm
Lever
Pin
Pad
Caliper
Bolt
Disc
Bushing
1
2
6
4
11
5
6
4
3
7
11
10
1
7
6
2
9
9
B-19693
40-20-3

Service Manual
Figure 40-20-10

Figure 40-20-8
1
1
P-40205
Inspect the pin (Item 1) [Figure 40-20-10] for damage or

wear. Replace as needed.
P-50163
Figure 40-20-11
Remove the roll pin (Item 1) and turnbuckle linkage (Item
2) [Figure 40-20-8].
1
2
Figure 40-20-9
2
3
P-50165
Remove the pin (Item 1) and lever (Item 2) [Figure 4020-11].
P-50164
Remove the snap ring (Item 1), pin (Item 2) and caliper
arm (Item 3) [Figure 40-20-9]. Inspect the caliper arm for
damage or wear. Replace as needed.
40-20-4

Service Manual
Figure 40-20-14

Figure 40-20-12
3
2
1
P-50170
Remove the snap ring (Item 1), pin (Item 2) and caliper
arm (Item 3) [Figure 40-20-14]. Inspect the caliper arm
for damage or wear. Replace as needed.
P-50169
Remove the snap ring (Item 1), pin (Item 2) and linkage
assembly (Item 3) [Figure 40-20-12]. Inspect for damage
or wear. Replace as needed.
Figure 40-20-15
Figure 40-20-13
1
P-40205

P-40205

40-20-5

Service Manual
Adjustment
Lift and block the machine. (See Procedure on Page 1010-1.)
Figure 40-20-16
Remove the center floor panel. (See FLOOR PANELS on
Page 50-30-1.)
1
Disengage the hand lever parking brake.
Figure 40-20-18
P-50171
Remove the brake pads (Item 1) [Figure 40-20-16].

Inspect the brake pads for damage or wear. Replace as
needed.
P-49510
Figure 40-20-17
1
Remove the retainer clip and pin (Item 1) [Figure 40-2018] from the parking brake bell crank.
Reposition the parking brake cable.

Figure 40-20-19
2
1
P-50173
Remove the bushings (Item 1). Inspect the bushings and

caliper (Item 2) [Figure 40-20-17] for damage or wear.
Replace as needed
P-49512
Remove the retainer clip (Item 1) [Figure 40-20-19] from

the brake cylinder bell crank pin. Start the engine and
press the Press to Drive Button.
40-20-6

Service Manual
Figure 40-20-21
Adjustment (Contd)
Figure 40-20-20
1
1
P-49514
Figure 40-20-22
P-49513
Remove the pin (Item 1) [Figure 40-20-20] from the

brake cylinder bell crank.
Stop the engine.
1
P-49516
There are two brake caliper adjustment screws, one on

each caliper arm (Item 1) [Figure 40-20-21] and [Figure
40-20-22].
Turning the adjustment screws will change the amount of
clearance between the brake caliper and the caliper
arms. The brake caliper is properly adjusted when the
clearance between the brake caliper and caliper arms is
between 2-4 mm.
Turn the adjustment screws in
approximately 1 to 2 turns at a time.
equal
amounts,
Start the engine and activate the Press to Drive Button.
40-20-7

Service Manual
Figure 40-20-25
Adjustment (Contd)
Figure 40-20-23
1
P-49511
When the correct dimensions are achieved install the

brake cylinder bell crank pin retainer clip (Item 1) [Figure
40-20-25].
P-49513
Install the brake cylinder bell crank pin (Item 1) [Figure

40-20-23].
Figure 40-20-26
Stop the engine.

Figure 40-20-24
P-49510
Install the pin and retainer clip (Item 1) [Figure 40-20-26]

for the hand lever parking brake bell crank.
P-49517
Using a feeler gauge measure the clearance between the

brake caliper and the caliper arms [Figure 40-20-24].
Start the loader backhoe, press the Press to Drive Button

and move the machine forward and backward while
listening for any signs of the brake dragging. If the
brake appears to be dragging repeat the adjustment
procedure.
If dimensions are not correct repeat the procedure until

correct dimensions are obtained.
40-20-8

Service Manual
REAR AXLE
Figure 40-30-3
Removal
Page 50-30-1.)
Figure 40-30-1
1
P-50144
Remove the three hoses (Item 1) [Figure 40-30-3] from

the drive motor.
P-52516
IMPORTANT
Raise the rear of the machine and install jackstands on

the rear of the loader backhoe frame [Figure 40-30-1].
Remove the driveshaft. (See Removal And Installation on
Page 40-50-1.)

damage the system.
I-2003-0888
Figure 40-30-2
Figure 40-30-4
P-49512
P-52517
Remove the left hose (Item 1) [Figure 40-30-4] from the

steering cylinder.
40-30-1

Service Manual
REAR AXLE (CONTD)
Figure 40-30-7
Removal (Contd)
Figure 40-30-5
2
1
P-40837
Support the rear axle assembly using jacks under the

axle (Item 1) and drop box mount bracket (Item 2)
[Figure 40-30-7].
P-52520
Remove the right hose (Item 1) [Figure 40-30-5] from the

steering cylinder.
Figure 40-30-8
Figure 40-30-6
1
P-52485
Loosen the two bolts (Item 1) on the right mounting

bracket. Remove the four bolts (Item 2) [Figure 40-30-8].
P-52521
Remove the five wheel nuts and washers (Item 1)

[Figure 40-30-6] from each rear wheel.
Remove both rear wheels.
40-30-2

Service Manual
REAR AXLE (CONTD)
Figure 40-30-11
Removal (Contd)
Figure 40-30-9
1
1
P-52482
1
Remove the four bolts (Item 1) [Figure 40-30-11] from
the left mounting bracket.
P-52483
Figure 40-30-12
Support the mounting bracket (Item 1) and remove the
two bolts (Item 2) [Figure 40-30-9]. Reposition mounting
bracket and SAPR brake assembly away from axle
assembly.
1
Figure 40-30-10
P-40842
Remove the two axle mounting bolts (Item 1) [Figure 4030-12] from each side of the axle.
P-40839
Loosen the two bolts (Item 1) [Figure 40-30-10] on the

left mounting bracket.
40-30-3

Service Manual
REAR AXLE (CONTD)
Figure 40-30-15
Removal (Contd)
Figure 40-30-13
1
P-40842
Raise the floor jacks slowly and install the two axle
mounting bolts (Item 1) [Figure 40-30-15] on each side
of the axle. Tighten to 188-210 ft.-lb. (255-285 Nm)
torque.
P-40843
Lower the axle assembly slowly. Roll the axle assembly

out from under the frame [Figure 40-30-13].
Figure 40-30-16
Installation
Figure 40-30-14
1
P-52482
Install the four mounting bolts (Item 1) [Figure 40-30-16].

Tighten the bolts to 32-35 ft.-lb. (43-47 Nm) torque.
P-40843
Roll the axle assembly under the frame [Figure 40-3014].
40-30-4

Service Manual
REAR AXLE (CONTD)
Figure 40-30-19
Installation (Contd)
Figure 40-30-17
P-52520
Install the right hose (Item 1) [Figure 40-30-19] to the

steering cylinder.
P-40839
Figure 40-30-20
Tighten the two mounting bolts (Item 1) [Figure 40-3017] to 55-60 ft.-lb. (75-85 Nm) torque.
Figure 40-30-18
1
1
2
3
P-52517
Install the left hose (Item 1) [Figure 40-30-20] to the

steering cylinder.
P-52485
Install the two bolts (Item 1) into the right mounting

bracket (Item 2). Tighten bolts to 55-60 ft.-lb. (75-85 Nm)
torque. Install the four bolts (Item 3) [Figure 40-30-18].
Tighten the bolts to 32-35 ft.-lb. (43-47 Nm) torque.
Remove the floor jacks.
40-30-5

Service Manual
REAR AXLE (CONTD)
Figure 40-30-23
Figure 40-30-21
2
2
1
P-52521
Install both rear wheels (Item 1) and tighten the wheel

nuts (Item 2) [Figure 40-30-23] to 140 ft.-lb. (190 Nm)
torque.
P-50144
Install the three hoses (Item 1) [Figure 40-30-21] to the

drive motor.
Figure 40-30-24
Figure 40-30-22
1
P-52516
Raise the rear of the machine and remove the jackstands

[Figure 40-30-24].
P-49512
Install the retainer clip and pin (Item 1) [Figure 40-30-22]

to the caliper linkage bell crank
Install the front floor panel. (See FLOOR PANELS on

Page 50-30-1.)
Install the driveshaft. (See Removal And Installation on

Page 40-50-1.)
40-30-6

Service Manual
AXLE AND DIFFERENTIAL (REAR)

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
Pinion or ring gear tooth broken
1, 2, 3, 4, 5, 6
Pinion teeth pitted
5, 11
Axle housing bent
12, 13
Worn or pitted bearings
3, 5, 6, 10, 11, 14
Oil leakage
6, 8, 9, 14, 15
Excessive wear on input shaft splines
3, 16, 17, 19
Pinion teeth fatigue
7, 12, 17, 19
Side gear spline worn
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
KEY TO CORRECT CAUSE

1.
2.
3.
4.
5
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Excessive gear load

Incorrect gear adjustment (excessive play)
Pinion nut loose
Incorrect gear adjustment (insufficient play)
Insufficient lubrication
Contaminated oil
Incorrect lubrication
Worn bearings
Operation at high temperature
Low oil level
Excessive use
Overloaded
Accident
Normal Wear
Lip seal damaged
Pinion axle play
Continuous overload
Excessive pinion axle play
Vehicle intensively operated or overloaded
Wheel loose
Beam housing bent
40-31-1

Service Manual
AXLE AND DIFFERENTIAL (REAR) (CONTD)

General Information
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the
machine, although the wheel hub, steering knuckle and
drive axle procedures may be done with the axle
assembly installed in the machine. For complete axle
repair, the following must be done.
Remove the steering cylinder. (See Removal And
Wheel Hub/Spindle Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1
2
5
8
10
11
3
6
13
9
12
12
Plug
Bolt
Pin
Flange
Lockwasher
Snap ring
Washer
Hub nut
Lock ring
Nut
Stud
Bearing
Hub
Spacer
Seal
Bushing
Spindle
14
15
16
2
16
17
15
B-23365
40-31-2

Service Manual
Figure 40-31-3
Wheel Hub/Spindle Disassembly

1
IMPORTANT
damage the system.
I-2003-0888
P-65076
Figure 40-31-1
Figure 40-31-4
2
1
1
P-65074
Remove the 14 flange bolts (Item 1) [Figure 40-31-1].

P-65077
Figure 40-31-2
Remove the spacer washer (Item 1) and set screw, (Item
2) [Figure 40-31-4].
1
P-65075
Install 2 flange bolts (Item 1) in the location shown,

tighten the bolts equally to remove the flange (Item 2)
[Figure 40-31-2].
40-31-3

Service Manual
Figure 40-31-7
Wheel Hub/Spindle Disassembly (Contd)

Figure 40-31-5
1
P-65080
Remove the outer bearing (Item 1) [Figure 40-31-7].

P-65078
Figure 40-31-8
Remove the hub nut (Item 1) [Figure 40-31-5].
Figure 40-31-6
P-65081
Remove the hub assembly (item 1) [Figure 40-31-8].

P-65079
Remove the lock ring (Item 1) [Figure 40-31-6].
40-31-4

Service Manual
Figure 40-31-11

1
Figure 40-31-9
1
P-40088
Remove the inner bearing (Item 1) [Figure 40-31-11].

P-65082
Figure 40-31-12
Remove the spacer ring (Item 1) [Figure 40-31-9] from
the spindle.
NOTE: The spacer ring may come off when the hub
assembly is removed.
Remove the bushing (Item 2) [Figure 40-31-9] if worn or

damaged.
Figure 40-31-10
1
P-40087
Remove the inner race (Item 1) [Figure 40-31-12].
P-40089
Remove the seal (Item 1) [Figure 40-31-10] from the

hub.
40-31-5

Service Manual
Figure 40-31-15

Figure 40-31-13
P-65085
Remove the spindle [Figure 40-31-15].

P-40084
Figure 40-31-16
Remove the outer race (Item 1) [Figure 40-31-13].
Figure 40-31-14
1
1
2
P-65086
Remove the seal (Item 1) and bushing (Item 2) [Figure

40-31-16] from the spindle.
P-65084
Remove the 10 spindle mounting bolts (Item 1) [Figure

40-31-14].
40-31-6

Service Manual

Drive Axle Parts Identification
1.
2.
3.
4.
5.
Drive shaft (outer)

Bearing
Snap ring
Yoke
Drive shaft (inner)
5
3
4
3
1
2
B-23364
40-31-7

Service Manual
Figure 40-31-19
Drive Axle Disassembly

Figure 40-31-17
P-23017
Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-31-19].
P-65087
Remove the drive axle from the axle housing [Figure 4031-17].
NOTE: The bottom bearing cup will not be completely

removed.
Figure 40-31-20
Figure 40-31-18
P-23021
P-23016
Put the drive axle in a vise and remove the 2 snap rings
(Item 1) [Figure 40-31-18] across from each other.
Turn the shaft over and remove the bearing cup (Item 1)
[Figure 40-31-20].
40-31-8

Service Manual
Figure 40-31-23
Drive Axle Disassembly (Contd)

Figure 40-31-21
1
1
2
P-23022
Remove the two snap rings (Item 1) [Figure 40-31-23]

from the yoke.
P-23020
Figure 40-31-24
Drive the cross (Item 1) [Figure 40-31-21] down to push
the opposite bearing cup through the yoke.
NOTE: The (outer) drive shaft (Item 2) [Figure 40-3121] may fall out of the yoke.
Figure 40-31-22
1
1
P-23023
Using two different size sockets (Item 1) [Figure 40-3124] and vice, press one bearing cup into the yoke while
pushing the opposite bearing cup through the yoke.
P-23019
and remove the outer drive shaft (Item 2) [Figure 40-3122].
40-31-9

Service Manual
Figure 40-31-27

Figure 40-31-25
1
1
P-23026
Remove the bearing cup (Item 1) and cross (Item 2)

[Figure 40-31-27] from the yoke.
P-23024
Remove the bearing cup (Item 1) [Figure 40-31-25].

Figure 40-31-26
P-23025
Press the second bearing cup through the yoke [Figure

40-31-26].
40-31-10

Service Manual

Steering Knuckle Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Grease fitting
Bolt
Pin
Arm
King pin (upper)
Shim
Steering knuckle
King pin (lower)
Washer
Bearing
Seal
Bushing
3
4
5
6
10
11
11
12
9
8
2
2
11
1
10
B-23367
40-31-11

Service Manual
Figure 40-31-30
Steering Knuckle Disassembly

1
Figure 40-31-28
1
P-65097
Remove and record the number of shims (Item 1)

[Figure 40-31-30].
P-65093
Figure 40-31-31
1
Figure 40-31-29
P-65096
Remove the bearing (Item 1) [Figure 40-31-31] from the

king pin/arm.
P-65095
Remove the upper king pin/arm assembly [Figure 40-3129].

NOTE: The arm may come off the upper king pin.
40-31-12

Service Manual
Figure 40-31-34
Steering Knuckle Disassembly (Contd)

Figure 40-31-32
1
1
1
P-65091
P-65088

[Figure 40-31-34] from the lower king pin.
Figure 40-31-35

Figure 40-31-33
1
P-65092
P-65090

king pin.
Remove the lower king pin [Figure 40-31-33].
40-31-13

Service Manual
Figure 40-31-38

Figure 40-31-36
1
P-65166
Remove the seal (Item 1) and race (Item 2) [Figure 4031-38] from the upper and lower pivots as needed.
P-65098
Lift and remove the knuckle assembly [Figure 40-31-36].

Figure 40-31-37
P-65099

40-31-37].
40-31-14

Service Manual

Differential Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1
2
3
4
4
4
5
Shim
Bearing
Housing
Differential plate
Friction plate
Drive plate
Gear (pinion)
Washer
Gear
Shaft
Spider
Pin
Shaft
Cover
Bolt
8
10
5
6
11
4
8
9
12
10
13
4
6
5
14
5
5
15
5
B-23367
40-31-15

Service Manual
Figure 40-31-41
Differential Disassembly
Figure 40-31-39
1
P-40093
Remove the 9 bolts (Item 1) and remove the cover (Item

2) [Figure 40-31-41].
P-65083
Figure 40-31-42
Place the axle assembly on a secure work surface
[Figure 40-31-39].
Remove the wheel hub/spindle (both sides). (See Wheel
Hub/Spindle Disassembly on Page 40-31-3.)
Remove the drive axle (both sides). (See Drive Axle
Disassembly on Page 40-31-8.)
Remove the knuckle assembly (both sides). (See
Steering Knuckle Disassembly on Page 40-31-12.)
Figure 40-31-40
1
P-40094
Remove the gasket (Item 1) [Figure 40-31-42] from the

axle housing.
P-40090

drain fluid into an approved container and dispose of in
an environmentally safe manner.
40-31-16

Service Manual
Figure 40-31-45
Differential Disassembly (Contd)

Figure 40-31-43
P-40098
Lift and remove the differential assembly [Figure 40-3145].
P-40096
Check and record the backlash of the differential [Figure

40-31-43].
NOTE: The bearing cup and shim (Item 1) [Figure 4031-45] will be removed at this time. Do not mix
parts from left to right.
Figure 40-31-44
Figure 40-31-46
2
1
2
2
1
P-40097
Rotate the axle housing down, mark the location of the

bearing clamps (Item 1) and remove the 4 bolts (Item 2)
[Figure 40-31-44].
P-40099
Remove the bearing (Item 1) [Figure 40-31-46] (both

sides) from the differential.
NOTE: Do not mix the bearings from left to right.
Remove the bearing clamps (Item 1) [Figure 40-31-44].
40-31-17

Service Manual
Figure 40-31-49

Figure 40-31-47
1
2
P-40102
Separate the differential housing [Figure 40-31-49].

P-65165
Figure 40-31-50
Support the differential assembly in a vise. Remove the
12 bolts (Item 1) and ring gear (Item 2) [Figure 40-3147].
Figure 40-31-48
P-40103
Remove the friction plates/differential plates and gear

from housing [Figure 40-31-50].
P-40101
Mark the differential housing (Item 1) [Figure 40-31-48]

for correct assembly.
40-31-18

Service Manual
Figure 40-31-53

Figure 40-31-51
2
P-40109
Remove the center shaft (Item 1) [Figure 40-31-53].

P-40104
Figure 40-31-54
Remove the friction plates/differential plates (Item 1) from
the gear (Item 2) [Figure 40-31-51].
Figure 40-31-52
P-40111
1
Remove the gear/thrust washer (both sides) [Figure 4031-54].
P-40108
Remove the center roll pin (Item 1) [Figure 40-31-52].
40-31-19

Service Manual
Figure 40-31-57

Figure 40-31-55
P-40122
Remove the spider shaft [Figure 40-31-57].

P-40115
Figure 40-31-58
Remove the roll pin [Figure 40-31-55] (both sides).
Figure 40-31-56
P-40123
P-40118
Remove the side gear/thrust washer (both sides) [Figure

40-31-58].
Remove the half shaft [Figure 40-31-56] (both sides).
40-31-20

Service Manual

Figure 40-31-59
P-40124
Remove the pinion gear (Item 1) [Figure 40-31-59].

Figure 40-31-60
P-40125
Remove the friction plates/differential plates (Item 1)

[Figure 40-31-60].
40-31-21

Service Manual
Figure 40-31-63
Differential Inspection
1
Figure 40-31-61
P-40114
Inspect the thrust washers (Item 1) [Figure 40-31-63] for

P-23942
Figure 40-31-62
P-23945
Inspect the pinion gears [Figure 40-31-61] & [Figure 4031-62] for broken or damaged teeth.
If either gear is damaged, replace all gears.
40-31-22

Service Manual

Pinion Group Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Nut
Washer
O-ring
Flange
Cover
Seal
Bearing
Shim
Shim
Shim
Pinion shaft
Pinion gear
12
11
7
10
9
7
6
5
4
B-23362
40-31-23

Service Manual
Figure 40-31-66
Pinion Group Disassembly

Figure 40-31-64
P-65182
Remove the washer (Item 1) [Figure 40-31-66].

P-65148
Figure 40-31-67
Pry the peened over nut [Figure 40-31-64] out of the
shaft groove.
Figure 40-31-65
1
2
P-65183
1
2
Remove the O-ring (Item 1) [Figure 40-31-67].

P-65176

NOTE: Install 2 bolts (Item 2) [Figure 40-31-65]in the
drive flange to help keep from rotating.
40-31-24

Service Manual
Figure 40-31-70
Pinion Group Disassembly (Contd)

Figure 40-31-68
1
P-65156
Remove and discard the seal (Item 1) [Figure 40-31-70].

P-65184
Figure 40-31-71
Remove the drive flange (Item 1) [Figure 40-31-68].
Figure 40-31-69
P-65157
Remove the bearing (Item 1) [Figure 40-31-71].

P-65155
Support the back of the pinion shaft and remove from the
housing using a soft hammer [Figure 40-31-69].
40-31-25

Service Manual
Figure 40-31-74

Figure 40-31-72
P-65160

P-65158
Figure 40-31-75
Remove and record the shim pack from the bearing
[Figure 40-31-72].
NOTE: The shim pack may stay in the housing when
the bearing is removed.
Figure 40-31-73
P-65161
1
P-65159
Remove the shim shaft (Item 1) [Figure 40-31-73].
40-31-26

Service Manual
Pinion Group Inspection
Figure 40-31-78
Figure 40-31-76
2
1
P-40140
P-40138
Inspect the pinion gear (Item 1) and shaft splines (Item 2)

[Figure 40-31-78] for broken or damaged teeth or
splines.

Figure 40-31-77
1
P-40139
Remove the shim (Item 1) from the shaft (Item 2) [Figure

40-31-77].
40-31-27

Service Manual
Figure 40-31-81
Pinion Group Assembly
IMPORTANT

damage the system.
I-2003-0888
P-65168
Figure 40-31-79
Install the bearing (Item 1) onto the false pinion tool Item
2) [Figure 40-31-81]].
Figure 40-31-82
1
P-65162
Install the outer race [Figure 40-31-79].

Figure 40-31-80
P-65167
Install the bearing/false pinion assembly (Item 1) [Figure

40-31-82] into the center housing.
P-40142
Install the inner race [Figure 40-31-80].

Before assembly, clean and lightly oil all parts.
40-31-28

Service Manual
Figure 40-31-85
Pinion Group Assembly (Contd)

2
Figure 40-31-83
2
1
1
1
2
2
P-65172
Install both bearing clamps (Item 1) and bolts (Item 2)

[Figure 40-31-85].
P-65169
Do not overtighten the bolts.

Install the outer bearing (Item 1) and lock nut (Item 2)
[Figure 40-31-83].
NOTE: Tighten the lock nut to eliminate any bearing
end play. DO NOT overtighten.
Figure 40-31-84
P-65171
Install the false differential tools [Figure 40-31-84] into

the axle housing (as shown).
40-31-29

Service Manual
Figure 40-31-88

Figure 40-31-86
1
P-40141
To determine the thickness of the shim or shims to be

installed between the pinion and bearing, subtract the
value stamped on the pinion (Item 1) [Figure 40-31-88]
from the value X.
P-65173
Figure 40-31-87
Figure 40-31-89
1
B-23370
MS1199
Using a depth gauge (Item 1) [Figure 40-31-86] &

[Figure 40-31-87] measure through the reference hole in
the dummy pinion.
Measure distance X (distance between the axis of the
differential bearings and the point at which the pinion
head is supported, or base of the bearing [Figure 40-3187].
Select the shim [Figure 40-31-89] from the chart below.

SHIM THICKNESS RANGE
Thick
40-31-30
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4

Service Manual
Figure 40-31-92

Figure 40-31-90
2
1
2
1
1
2
P-65169
1
1
Remove the lock nut (Item 1) and outer bearing (Item 2)
[Figure 40-31-92].
P-65172
Figure 40-31-93
Remove the 4 bolts (Item 1) and remove the bearing
clamps (Item 2) [Figure 40-31-90].
Figure 40-31-91
P-65167
Remove the bearing/false pinion assembly (Item 1)

[Figure 40-31-93].
P-65171
Remove the false differential tools from the housing

[Figure 40-31-91].
40-31-31

Service Manual
Figure 40-31-96

Figure 40-31-94
1
2
P-25694
Install the bearing (Item 1) [Figure 40-31-96] onto the

pinion shaft until it is fully seated.
P-65168
Figure 40-31-97
false pinion.
Figure 40-31-95
P-65159
Install the pinion gear assembly into the center housing

and install the spacer shim (Item 1) [Figure 40-31-97]
into the pinion.
P-25706
Install the shims selected (Item 1) [Figure 40-31-95] onto

the pinion shaft.
NOTE: Install the shims (removed earlier) as a way to

determine the correct preload for the pinion
bearings.
NOTE: The beveled edge of the shims must go

towards the gear.
40-31-32

Service Manual
Figure 40-31-100

Figure 40-31-98
1
2
1
P-65178
Install the washer and nut (Item 1) [Figure 40-31-100]

and gradually tighten the nut to 121 to 182 ft.-lb. (164 to
246 Nm) torque.
P-65174
Install the outer bearing (Item 1) [Figure 40-31-98] onto

the pinion shaft.
NOTE: Install 2 bolts (Item 2) [Figure 40-31-100] in the

NOTE: Drive the outer bearing onto the shaft, have an

assistant place a second hammer on the
pinion head to absorb the impact.
Figure 40-31-101
Figure 40-31-99
1
P-65175
P-65154
Install the drive flange (Item 1) [Figure 40-31-99]

NOTE: Do not install the seal at this time.
Attach one end of a light rope to the drive flange and

make 2 or 3 complete wraps around the drive flange,
attach a spring scale perpendicular to the housing to
measure the rolling torque on the bearings [Figure 4031-101].
The preloading adjustment is determined by increasing
or decreasing the total shim value created by the spacer
and shims inserted onto the pinion shaft next to the outer
bearing.
40-31-33

Service Manual

Figure 40-31-102
MS1199
Select a shim [Figure 40-31-102] from the chart below

until there is 1.0 lb. (0,07 kg) of smooth and continuous
rolling torque measured on the spring scale.
SHIMS
Thick
0.10
0.25
0.30
0.50
26.50 26.53
40-31-34

Service Manual
Figure 40-31-105
Differential Assembly
Figure 40-31-103
P-40123
Install the side gear/thrust washer (both sides) [Figure

40-31-105].
P-40125
Figure 40-31-106
Install the plates (Item 1) [Figure 40-31-103] into the
housing, beginning with a steel drive plate and
alternating between steel and friction.
NOTE: The thick washer must be on top (next to gear).

Figure 40-31-104
1
P-40122
Install the spider shaft (Item 1) [Figure 40-31-106]

between the side gears.
P-40124
Install the pinion gear (Item 1) [Figure 40-31-104] onto

the plate assembly.
NOTE: Make sure the plates remain in the correct
position.
40-31-35

Service Manual
Figure 40-31-109
Differential Assembly (Contd)

Figure 40-31-107
P-40111
1
40-31-109].
P-40121
Figure 40-31-110
Install the half shaft (Item 1) [Figure 40-31-107] in the
housing and through the side gear.
Figure 40-31-108
P-40109
Install the center shaft (Item 1) [Figure 40-31-110] in the

housing through both side gears and spider shaft.
P-40115
Align the roll pin hole and install the roll pin (Item 1)
[Figure 40-31-108] through the spider shaft side gear
and half shaft.
Repeat above procedure for the other side gear.
40-31-36

Service Manual
Figure 40-31-113

Figure 40-31-111
P-40103
Install the gear/plate assembly into the housing [Figure

40-31-113].
P-40108
Figure 40-31-114
Align the roll pin hole in the center shaft with the spider
shaft and install the roll pin (Item 1) [Figure 40-31-111].
Figure 40-31-112
1
1
P-40101
Align the marks (Item 1) [Figure 40-31-114] and install

the cover.
P-40107
Install the plates (Item 1) [Figure 40-31-112] onto the

gear, beginning with the thick washer followed by a
friction plate and alternating between steel and friction.
NOTE: The thick washer must be next to the gear.
40-31-37

Service Manual
Figure 40-31-117

Figure 40-31-115
1
1
P-40098
Install the differential assembly into the axle housing

along with both bearing cups (Item 1) and both shims
(Item 2) [Figure 40-31-117].
1
P-65165
Support the differential assembly in a vise and position

the ring gear (Item 1) [Figure 40-31-115].
Figure 40-31-118
2
Apply Loctite 270 or equivalent to the 12 bolts (Item 2)

[Figure 40-31-115]. Install and tighten the bolts to 58 ft.lb. (78 Nm) torque.
2
1
1
Figure 40-31-116
2
P-40097
Install both bearing clamps (Item 1) as marked earlier

onto the bearing cup and install the 4 bolts (Item 2)
[Figure 40-31-118].
NOTE: It may be necessary to use a soft hammer to
properly set the bearings in position.
P-65179
Install the bearing (Item 1) [Figure 40-31-116] until it is

fully seated (both sides).
40-31-38

Service Manual
Figure 40-31-120

Figure 40-31-119
P-65175
P-40096
Position a magnetic-base dial gauge on the axle housing

in the position shown [Figure 40-31-119]. Lock the pinion
and move the ring gear. Record the backlash measured.
Repeat this procedure on two or more ring gear positions
to obtain an average value.
The correct backlash value should be between 0.0059 to
0.0098 in. (0.15 to 0.25 mm).
To adjust the backlash value replace both shims, select a
shim from the chart below.
NOTE: All preloadings must be measured without the

seal.
If the total preload is under the permissible range,
increase the thickness of the shim equally on both sides
of the differential, while retaining the value of the pinion
ring gear backlash.
If the total preload is above the permissible range,
decrease the thickness of the shim equally on both sides
ring gear backlash.
SHIM RANGE
Thick

attach the spring scale to the opposite end of the rope.
Pull the scale perpendicular to the housing to measure
the rolling torque on the bearings. The value is 1.0 lb.
(0,07 kg) [Figure 40-31-120].
4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4
Once the pinion/ring gear backlash has been determined

the total preload of the pinion ring gear bearings must be
measured, to verify that it falls within the permissible
limits.
Check the wear pattern of the pinion/ring gear teeth.
40-31-39

Service Manual
Figure 40-31-123

Figure 40-31-121
B-16059
Excessive contact on flank of tooth - adjust the backlash

[Figure 40-31-123].
B-16057
Figure 40-31-124
Correct Pattern - If pinion/ring gear has been properly
adjusted, wear pattern (contact) should be shown
[Figure 40-31-121].
Figure 40-31-122
1
1
P-40095
Once the wear pattern is correct, apply Loctite 270 or

equivalent to the 4 bolts (Item 1) [Figure 40-31-124] and
B-16058
Excessive contact on tooth edge - adjust the backlash

[Figure 40-31-122].
40-31-40

Service Manual
Figure 40-31-127

Figure 40-31-125
2
P-65176
Remove the lock nut and washer (Item 1) [Figure 40-31127].
P-65146
Figure 40-31-128
Remove and clean the cover (Item 1) [Figure 40-31-125]
and mounting surface on the axle housing (Item 2)
[Figure 40-31-124].
Install the drain plug (Item 2) [Figure 40-31-125].
Figure 40-31-126
1
1
2
P-65184
Remove the drive flange (Item 1) [Figure 40-31-128]

2
2
P-40093
Using a new gasket, apply Loctite 542 or equivalent

to the bolts. Install the gasket and cover (Item 1) to
the axle housing and tighten the 9 bolts (Item 2)
[Figure 40-31-126] to 28 ft.-lb. (39 Nm) torque.
40-31-41

Service Manual
Figure 40-31-131

Figure 40-31-129
P-65183
Install a new O-ring (Item 1) [Figure 40-31-131] onto the

pinion shaft.
1
P-65180
Figure 40-31-132
Install the new seal (Item 1) [Figure 40-31-129] into the
housing until it is seated 0.1377 in. (3,5 mm) in from the
flange end.
2
Figure 40-31-130
1
2
P-65178
1
P-65184
Install the drive flange (Item 1) [Figure 40-31-130].

246 Nm) torque.
Remove the two bolts (Item 2) [Figure 40-31-132] from
the drive flange.
40-31-42

Service Manual

Figure 40-31-133
P-65150
Stake the ring nut, using a hammer and punch [Figure

40-31-133].
40-31-43

Service Manual
Figure 40-31-136
Steering Knuckle Assembly

Figure 40-31-134
1
P-65098
Install the knuckle assembly [Figure 40-31-136].

P-65166
Figure 40-31-137
Install a new race (Item 1) and seal (Item 2) [Figure 4031-134] in the upper and lower pivots as needed.
Figure 40-31-135
1
P-65092
Lubricate and install the bearing (Item 1) [Figure 40-31137] onto the lower king pin.
P-65099
Install the bushing (Item 1) and seal (Item 2) [Figure 4031-135] in the end of the axle housing.
40-31-44

Service Manual
Figure 40-31-140
Steering Knuckle Assembly (Contd)

Figure 40-31-138
P-65096
Lubricate and install the bearing (Item 1) [Figure 40-31140] onto the upper king pin/arm.
P-65091
Figure 40-31-141
Install the shims (Item 1) [Figure 40-31-138] removed
earlier, onto the lower king pin.
Figure 40-31-139
2
2
P-65097
Install the shims (Item 1) [Figure 40-31-141].

P-65088
Install the lower king pin (Item 1) using the 4 bolts (Item
2) [Figure 40-31-139]. Do not tighten the bolts at this
time.
40-31-45

Service Manual

Figure 40-31-142
P-65093
Install the upper king pin/arm (Item 1) using the 4 bolts

(Item 2) [Figure 40-31-142]. Tighten the bolts to 88 ft.-lb.
(120 Nm) torque.
40-31-46

Service Manual
Figure 40-31-145
Drive Axle Assembly

Figure 40-31-143
P-23029
Press the bearing cup into the yoke [Figure 40-31-145].

P-23027
Figure 40-31-146
Partially install a new bearing cup (Item 1) [Figure 40-31143] into the yoke.
Figure 40-31-144
P-23030
Install the second bearing cup into the yoke and press
onto the cross [Figure 40-31-146].
P-23028
NOTE: Use care not to lose or drop any needle

bearings out of position.
Install the cross (Item 1) [Figure 40-31-144] into the
bearing cup.
40-31-47

Service Manual
Figure 40-31-149
Drive Axle Assembly (Contd)
Figure 40-31-147
P-23032
P-23023
Figure 40-31-150
Fully press the two bearing cups into the drive shaft yoke
[Figure 40-31-147].
Figure 40-31-148
1
1
P-23033
P-23022
Install the cross/shaft assembly into the bearing cup

[Figure 40-31-150].
Install the 2 snap rings (Item 1) [Figure 40-31-148].
40-31-48

Service Manual
Figure 40-31-153

Figure 40-31-151
P-65099
Lightly lubricate the new seal and bushing [Figure 40-31153].
P-23035
Figure 40-31-154
Figure 40-31-152
P-65087
Install the drive axle into the axle housing aligning the
shaft with the splines [Figure 40-31-154].
NOTE: Use care not to damage the seal.
P-23016
Make sure the bearing cups are fully seated and install
both snap rings (Item 1) [Figure 40-31-152].
40-31-49

Service Manual
Figure 40-31-157
Wheel Hub/Spindle Assembly

Figure 40-31-155
P-40086
Install the inner bearing race in the wheel hub [Figure

40-31-157].
P-65086
Figure 40-31-158
Install a new bushing (Item 1) and seal (Item 2) [Figure
40-31-155] in the spindle.
Figure 40-31-156
2
1
P-40085
3
Install the outer bearing race in the wheel hub [Figure
40-31-158].
P-65084
Install the spindle assembly (Item 1) onto the axle

housing using the 10 mounting bolts (Item 2) [Figure 4031-156] and tighten to 58 ft.-lb. (78 Nm) torque.
NOTE: The groove (Item 3) [Figure 40-31-156] in the
spindle should be in the position shown.
40-31-50

Service Manual
Figure 40-31-161
Wheel Hub/Spindle Assembly (Contd)

Figure 40-31-159
1
1
2
P-65082
Install a new bushing (Item 1) [Figure 40-31-161] if worn

or damaged.
P-40088
Lubricate and install the inner bearing (Item 1) [Figure

40-31-159].
Install the spacer ring (Item 2) [Figure 40-31-161] onto

the spindle.
Figure 40-31-162
Figure 40-31-160
P-65081
P-40089
Install the hub [Figure 40-31-162].

40-31-51

Service Manual
Figure 40-31-165

Figure 40-31-163
P-65078
Install the hub nut (Item 1) [Figure 40-31-165] and

tighten.
P-65080
Lubricate and install the outer bearing (Item 1) [Figure

40-31-163].
NOTE: After the hub nut has been tightened, back the
nut off approximately 1/4 of a turn.
Figure 40-31-166
Figure 40-31-164
2
3
2
1
P-65077
P-65079
Install the set screw (Item 1) [Figure 40-31-166].

Install the lock ring (Item 1) [Figure 40-31-164].
Install the spacer washer (Item 2) [Figure 40-31-166].
NOTE: Align the notch (Item 2) on the lock ring with
the groove (Item 3) [Figure 40-31-164] in the
spindle.
40-31-52

Service Manual

Figure 40-31-167
P-65076

Figure 40-31-168
1
P-65074
Install the flange (Item 1) using the 14 bolts (Item 2)

[Figure 40-31-168].
Apply Loctite 270 or equivalent and tighten to 25 to
28 ft.-lb. (35 to 39 Nm) torque.
Install the steering cylinder.
(See
Removal
And
Check the axle toe-in. (See Adjustment on Page 10-601.)
40-31-53

Service Manual
40-31-54

Service Manual
STEERING ANGLE ADJUSTMENT (REAR AXLE)
Figure 40-32-3
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 40-32-1
1
B-23371
Adjust the stop (Item 1) [Figure 40-32-3] as needed.

Tighten the lock nut to 110 ft.-lb. (50 Nm) torque.
Figure 40-32-4
2
B-16065
Install the identical, straight bars (Item 1) onto the wheel

hub and secure them using lug nuts. Turn the steering
wheel completely to one side. Place a straight bar (Item
2) [Figure 40-32-1] on the pinion shaft.
Figure 40-32-2
B-23372
Turn the steering wheel completely to the other side

[Figure 40-32-4] and repeat above procedure.
32 35
Degrees
B-16066
Using an angle gauge, adjust the bolt (Item 1) [Figure

40-32-3] to obtain a reading of between 32 to 35 degrees
[Figure 40-32-2].
40-32-1

Service Manual
40-32-2

Service Manual
FRONT AXLE
Figure 40-40-3
Removal
Figure 40-40-1
P-40790
Remove the left steering cylinder hose (Item 1) [Figure

40-40-3].
P-50252
IMPORTANT
Raise the front of the machine and install jack stands on

the frame behind the front axle [Figure 40-40-1].
Page 40-50-1.)

damage the system.
I-2003-0888
Figure 40-40-2
Figure 40-40-4
P-50085
P-40787
Remove the five lug nuts and washers (Item 1) [Figure

40-40-2] from each front wheel.
Remove both front wheels.
Remove the right steering cylinder hose (Item 1) [[Figure

40-40-4]
40-40-1

Service Manual
FRONT AXLE (CONTD)
Figure 40-40-7
Removal (Contd)
Figure 40-40-5
P-40517
Lower the jack slowly. Roll the axle out from under the
frame [Figure 40-40-7]
P-40522
Using a jack, support the front axle [Figure 40-40-5].

Figure 40-40-6
P-40516
Remove the two axle mounting bolts (Item 1) [Figure 4040-6] from each side of the axle.
40-40-2

Service manual
FRONT AXLE (CONTD)
Figure 40-40-10
Installation
Figure 40-40-8
P-40787
Install the right steering cylinder hose (Item 1) [Figure

40-40-10].
P-40517
Figure 40-40-11
Roll the axle assembly under the frame [Figure 40-40-8]
Figure 40-40-9
1
1
P-40790
Install the left steering cylinder hose (Item 1) [Figure 4040-11].
P-40516
Raise the jack slowly and install the two axle mounting
bolts (Item 1) [Figure 40-40-9] on each side of the axle
and tighten to 188-210 ft.-lb. (255-285 Nm) torque.
40-40-3

Service Manual
FRONT AXLE (CONTD)

Figure 40-40-12
1
2
P-50085
Install both front wheels (Item 1) and tighten lug nuts

(Item 2) [Figure 40-40-12] to 140 ft.-lb. (190 Nm) torque.
Install the driveshaft.
Figure 40-40-13
P-50252
Raise the front of the machine and remove the jack

stands (Item 1) [Figure 40-40-13].
Install the engine side covers
40-40-4

Service manual
AXLE AND DIFFERENTIAL (FRONT)

The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
PROBLEM
CAUSE
Pinion or ring gear tooth broken
1, 2, 3, 4, 5, 6
Pinion teeth pitted
5, 11
Axle housing bent
12, 13
Worn or pitted bearings
3, 5, 6, 10, 11, 14
Oil leakage
6, 8, 9, 14, 15
Excessive wear on input shaft splines
3, 16, 17, 19
Pinion teeth fatigue
7, 12, 17, 19
Side gear spline worn
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
KEY TO CORRECT CAUSE

1.
2.
3.
4.
5
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Excessive gear load

Incorrect gear adjustment (excessive play)
Pinion nut loose
Incorrect gear adjustment (insufficient play)
Insufficient lubrication
Contaminated oil
Incorrect lubrication
Worn bearings
Operation at high temperature
Low oil level
Excessive use
Overloaded
Accident
Normal Wear
Lip seal damaged
Pinion axle play
Continuous overload
Excessive pinion axle play
Vehicle intensively operated or overloaded
Wheel loose
Beam housing bent
40-41-1

Service Manual
AXLE AND DIFFERENTIAL (FRONT) (CONTD)

General Information
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the
machine, although the wheel hub, steering knuckle and
drive axle procedures may be done with the axle
assembly installed in the machine. For complete axle
repair, the following must be done.
Remove the steering cylinder. (See Removal And
Wheel Hub/Spindle Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1
2
5
8
10
11
3
6
13
9
12
12
Plug
Bolt
Pin
Flange
Lockwasher
Snap ring
Washer
Hub nut
Lock ring
Nut
Stud
Bearing
Hub
Spacer
Seal
Bushing
Spindle
14
15
16
2
16
17
15
B-23365
40-41-2

Service Manual
Figure 40-41-3
Wheel Hub/Spindle Disassembly

1
IMPORTANT
damage the system.
I-2003-0888
P-65076
Figure 40-41-1
Figure 40-41-4
2
1
1
P-65074
Remove the 14 flange bolts (Item 1) [Figure 40-41-1].

P-65077
Figure 40-41-2
Remove the spacer washer (Item 1) and set screw, (Item
2) [Figure 40-41-4].
1
P-65075
Install 2 flange bolts (Item 1) in the location shown,

tighten the bolts equally to remove the flange (Item 2)
[Figure 40-41-2].
40-41-3

Service Manual
Figure 40-41-7

Figure 40-41-5
1
P-65080
Remove the outer bearing (Item 1) [Figure 40-41-7].

P-65078
Figure 40-41-8
Remove the hub nut (Item 1) [Figure 40-41-5].
Figure 40-41-6
P-65081
Remove the hub assembly (item 1) [Figure 40-41-8].

P-65079
Remove the lock ring (Item 1) [Figure 40-41-6].
40-41-4

Service Manual
Figure 40-41-11

1
Figure 40-41-9
1
P-40088
Remove the inner bearing (Item 1) [Figure 40-41-11].

P-65082
Figure 40-41-12
Remove the spacer ring (Item 1) [Figure 40-41-9] from
the spindle.
NOTE: The spacer ring may come off when the hub
assembly is removed.
Remove the bushing (Item 2) [Figure 40-41-9] if worn or

damaged.
Figure 40-41-10
1
P-40087
P-40089
Remove the seal (Item 1) [Figure 40-41-10] from the

hub.
40-41-5

Service Manual
Figure 40-41-15

Figure 40-41-13
P-65085
Remove the spindle [Figure 40-41-15].

P-40084
Figure 40-41-16
Figure 40-41-14
1
1
2
P-65086

40-41-16] from the spindle.
P-65084
Remove the 10 spindle mounting bolts (Item 1) [Figure

40-41-14].
40-41-6

Service Manual

Drive Axle Parts Identification
1.
2.
3.
4.
5.
Drive shaft (outer)

Bearing
Snap ring
Yoke
Drive shaft (inner)
5
3
4
3
1
2
B-23364
40-41-7

Service Manual
Figure 40-41-19
Drive Axle Disassembly

Figure 40-41-17
P-23017
Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-41-19].
P-65087
Remove the drive axle from the axle housing [Figure 4041-17].
NOTE: The bottom bearing cup will not be completely

removed.
Figure 40-41-20
Figure 40-41-18
P-23021
P-23016
Put the drive axle in a vise and remove the 2 snap rings
(Item 1) [Figure 40-41-18] across from each other.
[Figure 40-41-20].
40-41-8

Service Manual
Figure 40-41-23

Figure 40-41-21
1
1
2
P-23022
Remove the two snap rings (Item 1) [Figure 40-41-23]

from the yoke.
P-23020
Figure 40-41-24
Drive the cross (Item 1) [Figure 40-41-21] down to push
the opposite bearing cup through the yoke.
NOTE: The (outer) drive shaft (Item 2) [Figure 40-4121] may fall out of the yoke.
Figure 40-41-22
1
1
P-23023
Using two different size sockets (Item 1) [Figure 40-4124] and vice, press one bearing cup into the yoke while
pushing the opposite bearing cup through the yoke.
P-23019
and remove the outer drive shaft (Item 2) [Figure 40-4122].
40-41-9

Service Manual
Figure 40-41-27

Figure 40-41-25
1
1
P-23026
Remove the bearing cup (Item 1) and cross (Item 2)

[Figure 40-41-27] from the yoke.
P-23024
Remove the bearing cup (Item 1) [Figure 40-41-25].

Figure 40-41-26
P-23025
Press the second bearing cup through the yoke [Figure

40-41-26].
40-41-10

Service Manual

Steering Knuckle Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Grease fitting
Bolt
Pin
Arm
King pin (upper)
Shim
Steering knuckle
King pin (lower)
Washer
Bearing
Seal
Bushing
3
4
5
6
10
11
11
12
9
8
2
2
11
1
10
B-23367
40-41-11

Service Manual
Figure 40-41-30
Steering Knuckle Disassembly

1
Figure 40-41-28
1
P-65097

[Figure 40-41-30].
P-65093
Figure 40-41-31
1
Figure 40-41-29
P-65096

king pin/arm.
P-65095
Remove the upper king pin/arm assembly [Figure 40-4129].

NOTE: The arm may come off the upper king pin.
40-41-12

Service Manual
Figure 40-41-34

Figure 40-41-32
1
1
1
P-65091
P-65088

[Figure 40-41-34] from the lower king pin.
Figure 40-41-35

Figure 40-41-33
1
P-65092
P-65090

king pin.
Remove the lower king pin [Figure 40-41-33].
40-41-13

Service Manual
Figure 40-41-38

Figure 40-41-36
1
P-65166
Remove the seal (Item 1) and race (Item 2) [Figure 4041-38] from the upper and lower pivots as needed.
P-65098
Lift and remove the knuckle assembly [Figure 40-41-36].

Figure 40-41-37
P-65099

40-41-37].
40-41-14

Service Manual

Differential Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1
2
3
4
4
4
5
Shim
Bearing
Housing
Differential plate
Friction plate
Drive plate
Gear (pinion)
Washer
Gear
Shaft
Spider
Pin
Shaft
Cover
Bolt
8
10
5
6
11
4
8
9
12
10
13
4
6
5
14
5
5
15
5
B-23367
40-41-15

Service Manual
Figure 40-41-41
Differential Disassembly
Figure 40-41-39
1
P-40093
Remove the 9 bolts (Item 1) and remove the cover (Item

2) [Figure 40-41-41].
P-65083
Figure 40-41-42
Place the axle assembly on a secure work surface
[Figure 40-41-39].
Remove the wheel hub/spindle (both sides). (See Wheel
Hub/Spindle Disassembly on Page 40-41-3.)
Remove the drive axle (both sides). (See Drive Axle
Disassembly on Page 40-41-8.)
Remove the knuckle assembly (both sides). (See
Steering Knuckle Disassembly on Page 40-41-12.)
Figure 40-41-40
1
P-40094
Remove the gasket (Item 1) [Figure 40-41-42] from the

axle housing.
P-40090

drain fluid into an approved container and dispose of in
an environmentally safe manner.
40-41-16

Service Manual
Figure 40-41-45

Figure 40-41-43
P-40098
Lift and remove the differential assembly [Figure 40-4145].
P-40096
Check and record the backlash of the differential [Figure

40-41-43].
NOTE: The bearing cup and shim (Item 1) [Figure 4041-45] will be removed at this time. Do not mix
parts from left to right.
Figure 40-41-44
Figure 40-41-46
2
1
2
2
1
P-40097
Rotate the axle housing down, mark the location of the

bearing clamps (Item 1) and remove the 4 bolts (Item 2)
[Figure 40-41-44].
P-40099
Remove the bearing (Item 1) [Figure 40-41-46] (both

sides) from the differential.
NOTE: Do not mix the bearings from left to right.
Remove the bearing clamps (Item 1) [Figure 40-41-44].
40-41-17

Service Manual
Figure 40-41-49

Figure 40-41-47
1
2
P-40102
Separate the differential housing [Figure 40-41-49].

P-65165
Figure 40-41-50
Support the differential assembly in a vise. Remove the
12 bolts (Item 1) and ring gear (Item 2) [Figure 40-4147].
Figure 40-41-48
P-40103
Remove the friction plates/differential plates and gear

from housing [Figure 40-41-50].
P-40101
Mark the differential housing (Item 1) [Figure 40-41-48]

for correct assembly.
40-41-18

Service Manual
Figure 40-41-53

Figure 40-41-51
2
P-40109
Remove the center shaft (Item 1) [Figure 40-41-53].

P-40104
Figure 40-41-54
Remove the friction plates/differential plates (Item 1) from
the gear (Item 2) [Figure 40-41-51].
Figure 40-41-52
P-40111
1
Remove the gear/thrust washer (both sides) [Figure 4041-54].
P-40108
Remove the center roll pin (Item 1) [Figure 40-41-52].
40-41-19

Service Manual
Figure 40-41-57

Figure 40-41-55
P-40122
Remove the spider shaft [Figure 40-41-57].

P-40115
Figure 40-41-58
Remove the roll pin [Figure 40-41-55] (both sides).
Figure 40-41-56
P-40123
P-40118
Remove the side gear/thrust washer (both sides) [Figure

40-41-58].
Remove the half shaft [Figure 40-41-56] (both sides).
40-41-20

Service Manual

Figure 40-41-59
P-40124
Remove the pinion gear (Item 1) [Figure 40-41-59].

Figure 40-41-60
P-40125
Remove the friction plates/differential plates (Item 1)

[Figure 40-41-60].
40-41-21

Service Manual
Figure 40-41-63
Differential Inspection
1
Figure 40-41-61
P-40114
Inspect the thrust washers (Item 1) [Figure 40-41-63] for

P-23942
Figure 40-41-62
P-23945
Inspect the pinion gears [Figure 40-41-61] & [Figure 4041-62] for broken or damaged teeth.
If either gear is damaged, replace all gears.
40-41-22

Service Manual

Pinion Group Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Nut
Washer
O-ring
Flange
Cover
Seal
Bearing
Shim
Shim
Shim
Pinion shaft
Pinion gear
12
11
7
10
9
7
6
5
4
B-23362
40-41-23

Service Manual
Figure 40-41-66
Pinion Group Disassembly

Figure 40-41-64
P-65182
Remove the washer (Item 1) [Figure 40-41-66].

P-65148
Figure 40-41-67
Pry the peened over nut [Figure 40-41-64] out of the
shaft groove.
Figure 40-41-65
1
2
P-65183
1
2
Remove the O-ring (Item 1) [Figure 40-41-67].

P-65176

NOTE: Install 2 bolts (Item 2) [Figure 40-41-65]in the
40-41-24

Service Manual
Figure 40-41-70

Figure 40-41-68
1
P-65156
Remove and discard the seal (Item 1) [Figure 40-41-70].

P-65184
Figure 40-41-71
Figure 40-41-69
P-65157

P-65155
Support the back of the pinion shaft and remove from the
housing using a soft hammer [Figure 40-41-69].
40-41-25

Service Manual
Figure 40-41-74

Figure 40-41-72
P-65160

P-65158
Figure 40-41-75
Remove and record the shim pack from the bearing
[Figure 40-41-72].
NOTE: The shim pack may stay in the housing when
the bearing is removed.
Figure 40-41-73
P-65161
1
P-65159
Remove the shim shaft (Item 1) [Figure 40-41-73].
40-41-26

Service Manual
Pinion Group Inspection
Figure 40-41-78
Figure 40-41-76
2
1
P-40140
P-40138
Inspect the pinion gear (Item 1) and shaft splines (Item 2)

[Figure 40-41-78] for broken or damaged teeth or
splines.

Figure 40-41-77
1
P-40139
Remove the shim (Item 1) from the shaft (Item 2) [Figure

40-41-77].
40-41-27

Service Manual
Figure 40-41-81
Pinion Group Assembly
IMPORTANT

damage the system.
I-2003-0888
P-65168
Figure 40-41-79
Install the bearing (Item 1) onto the false pinion tool (Item
2) [Figure 40-41-81]].
Figure 40-41-82
1
P-65162
Install the outer race [Figure 40-41-79].

Figure 40-41-80
P-65167
Install the bearing/false pinion assembly (Item 1) [Figure

40-41-82] into the center housing.
P-40142
Install the inner race [Figure 40-41-80].

Before assembly, clean and lightly oil all parts.
40-41-28

Service Manual
Figure 40-41-85

2
Figure 40-41-83
2
1
1
1
2
2
P-65172
Install both bearing clamps (Item 1) and bolts (Item 2)

[Figure 40-41-85].
P-65169
Do not overtighten the bolts.

Install the outer bearing (Item 1) and lock nut (Item 2)
[Figure 40-41-83].
NOTE: Tighten the lock nut to eliminate any bearing
end play. DO NOT overtighten.
Figure 40-41-84
P-65171
Install the false differential tools [Figure 40-41-84] into

the axle housing (as shown).
40-41-29

Service Manual
Figure 40-41-88

Figure 40-41-86
1
P-40141
To determine the thickness of the shim or shims to be

installed between the pinion and bearing, subtract the
value stamped on the pinion (Item 1) [Figure 40-41-88]
from the value X.
P-65173
Figure 40-41-87
Figure 40-41-89
1
B-23370
MS1199
Using a depth gauge (Item 1) [Figure 40-41-86] &

[Figure 40-41-87] measure through the reference hole in
the dummy pinion.
Measure distance X (distance between the axis of the
differential bearings and the point at which the pinion
head is supported, or base of the bearing [Figure 40-4187].
Select the shim [Figure 40-41-89] from the chart below.

SHIM THICKNESS RANGE
Thick
40-41-30
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4

Service Manual
Figure 40-41-92

Figure 40-41-90
2
1
2
1
1
2
P-65169
1
1
Remove the lock nut (Item 1) and outer bearing (Item 2)
[Figure 40-41-92].
P-65172
Figure 40-41-93
Remove the 4 bolts (Item 1) and remove the bearing
clamps (Item 2) [Figure 40-41-90].
Figure 40-41-91
P-65167
Remove the bearing/false pinion assembly (Item 1)

[Figure 40-41-93].
P-65171
Remove the false differential tools from the housing

[Figure 40-41-91].
40-41-31

Service Manual
Figure 40-41-96

Figure 40-41-94
1
2
P-25694
Install the bearing (Item 1) [Figure 40-41-96] onto the

pinion shaft until it is fully seated.
P-65168
Figure 40-41-97
false pinion.
Figure 40-41-95
P-65159
Install the pinion gear assembly into the center housing

and install the spacer shim (Item 1) [Figure 40-41-97]
into the pinion.
P-25706
Install the shims selected (Item 1) [Figure 40-41-95] onto

the pinion shaft.
NOTE: Install the shims (removed earlier) as a way to

determine the correct preload for the pinion
bearings.
NOTE: The beveled edge of the shims must go

towards the gear.
40-41-32

Service Manual
Figure 40-41-100

Figure 40-41-98
1
2
1
P-65178

246 Nm) torque.
P-65174
Install the outer bearing (Item 1) [Figure 40-41-98] onto

the pinion shaft.
NOTE: Install 2 bolts (Item 2) [Figure 40-41-100] in the

NOTE: Drive the outer bearing onto the shaft, have an

assistant place a second hammer on the
pinion head to absorb the impact.
Figure 40-41-101
Figure 40-41-99
1
P-65175
P-65154
Install the drive flange (Item 1) [Figure 40-41-99]

NOTE: Do not install the seal at this time.

attach a spring scale perpendicular to the housing to
measure the rolling torque on the bearings [Figure 4041-101].
The preloading adjustment is determined by increasing
or decreasing the total shim value created by the spacer
and shims inserted onto the pinion shaft next to the outer
bearing.
40-41-33

Service Manual

Figure 40-41-102
MS1199
Select a shim [Figure 40-41-102] from the chart below

until there is 1.0 lb. (0,07 kg) of smooth and continuous
rolling torque measured on the spring scale.
SHIMS
Thick
0.10
0.25
0.30
0.50
26.50 26.53
40-41-34

Service Manual
Figure 40-41-105
Differential Assembly
Figure 40-41-103
P-40123
Install the side gear/thrust washer (both sides)[Figure

40-41-105].
P-40125
Figure 40-41-106
Install the plates (Item 1) [Figure 40-41-103] into the
housing, beginning with a steel drive plate and
alternating between steel and friction.
NOTE: The thick washer must be on top (next to gear).

Figure 40-41-104
1
P-40122
Install the spider shaft (Item 1) [Figure 40-41-106]

between the side gears.
P-40124
Install the pinion gear (Item 1) [Figure 40-41-104] onto

the plate assembly.
NOTE: Make sure the plates remain in the correct
position.
40-41-35

Service Manual
Figure 40-41-109

Figure 40-41-107
P-40111
1
40-41-109].
P-40121
Figure 40-41-110
Install the half shaft (Item 1) [Figure 40-41-107] in the
housing and through the side gear.
Figure 40-41-108
P-40109
Install the center shaft (Item 1) [Figure 40-41-110] in the

housing through both side gears and spider shaft.
P-40115
Align the roll pin hole and install the roll pin (Item 1)
[Figure 40-41-108] through the spider shaft side gear
and half shaft.
Repeat above procedure for the other side gear.
40-41-36

Service Manual
Figure 40-41-113

Figure 40-41-111
P-40103
Install the gear/plate assembly into the housing [Figure

40-41-113].
P-40108
Figure 40-41-114
Align the roll pin hole in the center shaft with the spider
shaft and install the roll pin (Item 1) [Figure 40-41-111].
Figure 40-41-112
1
1
P-40101
Align the marks (Item 1) [Figure 40-41-114] and install

the cover.
P-40107
Install the plates (Item 1) [Figure 40-41-112] onto the

gear, beginning with the thick washer followed by a
friction plate and alternating between steel and friction.
NOTE: The thick washer must be next to the gear.
40-41-37

Service Manual
Figure 40-41-117

Figure 40-41-115
1
1
P-40098
Install the differential assembly into the axle housing

along with both bearing cups (Item 1) and both shims
(Item 2) [Figure 40-41-117].
1
P-65165
Support the differential assembly in a vise and position

the ring gear (Item 1) [Figure 40-41-115].
Figure 40-41-118
Apply Loctite 270 or equivalent to the 12 bolts (Item 2)

[Figure 40-41-115]. Install and tighten the bolts to 58 ft.lb. (78 Nm) torque.
2
2
1
1
Figure 40-41-116
2
P-40097
Install both bearing clamps (Item 1) as marked earlier

onto the bearing cup and install the 4 bolts (Item 2)
[Figure 40-41-118].
NOTE: It may be necessary to use a soft hammer to
properly set the bearings in position.
P-65179
Install the bearing (Item 1) [Figure 40-41-116] until it is

fully seated (both sides).
40-41-38

Service Manual
Figure 40-41-120

Figure 40-41-119
P-65175
P-40096
Position a magnetic-base dial gauge on the axle housing

in the position shown [Figure 40-41-119]. Lock the pinion
and move the ring gear. Record the backlash measured.
Repeat this procedure on two or more ring gear positions
to obtain an average value.
The correct backlash value should be between 0.0059 to
0.0098 in. (0.15 to 0.25 mm).
To adjust the backlash value replace both shims, select a
shim from the chart below.
NOTE: All preloadings must be measured without the

seal.
If the total preload is under the permissible range,
increase the thickness of the shim equally on both sides
ring gear backlash.
If the total preload is above the permissible range,
decrease the thickness of the shim equally on both sides
ring gear backlash.
SHIM RANGE
Thick

attach the spring scale to the opposite end of the rope.
Pull the scale perpendicular to the housing to measure
the rolling torque on the bearings. The value is 1.0 lb.
(0,07 kg) [Figure 40-41-120].
4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4
Once the pinion/ring gear backlash has been determined

the total preload of the pinion ring gear bearings must be
measured, to verify that it falls within the permissible
limits.
Check the wear pattern of the pinion/ring gear teeth.
40-41-39

Service Manual
Figure 40-41-123

Figure 40-41-121
B-16059
Excessive contact on flank of tooth - adjust the backlash

[Figure 40-41-123].
B-16057
Figure 40-41-124
Correct Pattern - If pinion/ring gear has been properly
adjusted, wear pattern (contact) should be shown
[Figure 40-41-121].
Figure 40-41-122
1
1
P-40095
Once the wear pattern is correct, apply Loctite 270 or

equivalent to the 4 bolts (Item 1) [Figure 40-41-124] and
B-16058
Excessive contact on tooth edge - adjust the backlash

[Figure 40-41-122].
40-41-40

Service Manual
Figure 40-41-127

Figure 40-41-125
2
P-65176
Remove the lock nut and washer (Item 1) [Figure 40-41127].
P-65146
Figure 40-41-128
Remove and clean the cover (Item 1) [Figure 40-41-125]
and mounting surface on the axle housing (Item 2)
[Figure 40-41-124].
Install the drain plug (Item 2) [Figure 40-41-125].
Figure 40-41-126
1
1
2
P-65184
Remove the drive flange (Item 1) [Figure 40-41-128]

2
2
P-40093
Using a new gasket, apply Loctite 542 or equivalent

to the bolts. Install the gasket and cover (Item 1) to
the axle housing and tighten the 9 bolts (Item 2)
[Figure 40-41-126] to 28 ft.-lb. (39 Nm) torque.
40-41-41

Service Manual
Figure 40-41-131

Figure 40-41-129
P-65183
Install a new O-ring (Item 1) [Figure 40-41-131] onto the

pinion shaft.
1
P-65180
Figure 40-41-132
Install the new seal (Item 1) [Figure 40-41-129] into the
housing until it is seated 0.1377 in. (3,5 mm) in from the
flange end.
2
Figure 40-41-130
1
2
P-65178
1
P-65184
Install the drive flange (Item 1) [Figure 40-41-130].

246 Nm) torque.
the drive flange.
40-41-42

Service Manual

Figure 40-41-133
P-65150
Stake the ring nut, using a hammer and punch [Figure

40-41-133].
40-41-43

Service Manual
Figure 40-41-136
Steering Knuckle Assembly

Figure 40-41-134
1
P-65098
Install the knuckle assembly [Figure 40-41-136].

P-65166
Figure 40-41-137
Install a new race (Item 1) and seal (Item 2) [Figure 4041-134] in the upper and lower pivots as needed.
Figure 40-41-135
1
P-65092
Lubricate and install the bearing (Item 1) [Figure 40-41137] onto the lower king pin.
P-65099
Install the bushing (Item 1) and seal (Item 2) [Figure 4041-135] in the end of the axle housing.
40-41-44

Service Manual
Figure 40-41-140

Figure 40-41-138
P-65096
Lubricate and install the bearing (Item 1) [Figure 40-41140] onto the upper king pin/arm.
P-65091
Figure 40-41-141
Install the shims (Item 1) [Figure 40-41-138] removed
earlier, onto the lower king pin.
Figure 40-41-139
2
2
P-65097
Install the shims (Item 1) [Figure 40-41-141].

P-65088
Install the lower king pin (Item 1) using the 4 bolts (Item
2) [Figure 40-41-139]. Do not tighten the bolts at this
time.
40-41-45

Service Manual

Figure 40-41-142
P-65093
Install the upper king pin/arm (Item 1) using the 4 bolts

(Item 2) [Figure 40-41-142]. Tighten the bolts to 88 ft.-lb.
(120 Nm) torque.
40-41-46

Service Manual
Figure 40-41-145
Drive Axle Assembly

Figure 40-41-143
P-23029
Press the bearing cup into the yoke [Figure 40-41-145].

P-23027
Figure 40-41-146
Figure 40-41-144
P-23030
P-23028

Install the cross (Item 1) [Figure 40-41-144] into the
bearing cup.
40-41-47

Service Manual
Figure 40-41-149
Figure 40-41-147
P-23032
P-23023
Figure 40-41-150
Fully press the two bearing cups into the drive shaft yoke
[Figure 40-41-147].
Figure 40-41-148
1
1
P-23033
P-23022
Install the cross/shaft assembly into the bearing cup

[Figure 40-41-150].
Install the 2 snap rings (Item 1) [Figure 40-41-148].
40-41-48

Service Manual
Figure 40-41-153

Figure 40-41-151
P-65099
Lightly lubricate the new seal and bushing [Figure 40-41153].
P-23035
Figure 40-41-154
Figure 40-41-152
P-65087
Install the drive axle into the axle housing aligning the
shaft with the splines [Figure 40-41-154].
NOTE: Use care not to damage the seal.
P-23016
Make sure the bearing cups are fully seated and install
both snap rings (Item 1) [Figure 40-41-152].
40-41-49

Service Manual
Figure 40-41-157
Wheel Hub/Spindle Assembly

Figure 40-41-155
P-40086
Install the inner bearing race in the wheel hub [Figure

40-41-157].
P-65086
Figure 40-41-158
Install a new bushing (Item 1) and seal (Item 2) [Figure
40-41-155] in the spindle.
Figure 40-41-156
2
1
P-40085
3
Install the outer bearing race in the wheel hub [Figure
40-41-158].
P-65084
Install the spindle assembly (Item 1) onto the axle

housing using the 10 mounting bolts (Item 2) [Figure 4041-156] and tighten to 58 ft.-lb. (78 Nm) torque.
NOTE: The groove (Item 3) [Figure 40-41-156] in the
spindle should be in the position shown.
40-41-50

Service Manual
Figure 40-41-161

Figure 40-41-159
1
1
2
P-65082
Install a new bushing (Item 1) [Figure 40-41-161] if worn

or damaged.
P-40088
Lubricate and install the inner bearing (Item 1) [Figure

40-41-159].
Install the spacer ring (Item 2) [Figure 40-41-161] onto

the spindle.
Figure 40-41-162
Figure 40-41-160
P-65081
P-40089
Install the hub [Figure 40-41-162].

40-41-51

Service Manual
Figure 40-41-165

Figure 40-41-163
P-65078
Install the hub nut (Item 1) [Figure 40-41-165] and

tighten.
P-65080
Lubricate and install the outer bearing (Item 1) [Figure

40-41-163].
NOTE: After the hub nut has been tightened, back the
nut off approximately 1/4 of a turn.
Figure 40-41-166
Figure 40-41-164
2
3
2
1
P-65077
P-65079
Install the set screw (Item 1) [Figure 40-41-166].

Install the lock ring (Item 1) [Figure 40-41-164].
Install the spacer washer (Item 2) [Figure 40-41-166].
NOTE: Align the notch (Item 2) on the lock ring with
the groove (Item 3) [Figure 40-41-164] in the
spindle.
40-41-52

Service Manual

Figure 40-41-167
P-65076

Figure 40-41-168
1
P-65074
Install the flange (Item 1) using the 14 bolts (Item 2)

[Figure 40-41-168].
Apply Loctite 270 or equivalent and tighten to 25 to
28 ft.-lb. (35 to 39 Nm) torque.
Install the steering cylinder.
(See
Removal
And
Check the axle toe-in. (See Adjustment on Page 10-601.)
40-41-53

Service Manual
40-41-54

Service Manual
STEERING ANGLE ADJUSTMENT (FRONT AXLE)
Figure 40-42-3
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 40-42-1
1
B-23371
Adjust the stop (Item 1) [Figure 40-42-3] as needed.

Tighten the lock nut to 110 ft.-lb. (50 Nm) torque.
Figure 40-42-4
2
B-16065
Install the identical, straight bars (Item 1) onto the wheel

hub and secure them using lug nuts. Turn the steering
wheel completely to one side. Place a straight bar (Item
2) [Figure 40-42-1] on the pinion shaft.
Figure 40-42-2
B-23372
Turn the steering wheel completely to the other side

[Figure 40-42-4] and repeat above procedure.
32 35
Degrees
B-16066
Using an angle gauge, adjust the bolt (Item 1) [Figure

40-42-3] to obtain a reading of between 32 to 35 degrees
[Figure 40-42-2].
40-42-1

Service Manual
40-42-2

Service Manual
DRIVESHAFT
Figure 40-50-3

Page 10-10-1.)
Figure 40-50-1
1
2
1
P-40341
Remove the four flange mounting bolts (Item 1) [Figure

40-50-3]

torque.
P-40339
Figure 40-50-4
Install a jack stand (Item 1) to support the driveshaft.
Remove the four flange mounting bolts (Item 2) [Figure
40-50-1]
torque.
Figure 40-50-2
2
1
P-40342
Separate the flanges (Item 1). Remove the driveshaft

(Item 2) [Figure 40-50-4].
P-40340
Separate the flanges (Item 1) [Figure 40-50-2].
40-50-1

Service Manual
40-50-2

Service Manual
DROP BOX
Figure 40-60-3

Page 10-10-1.)

Page 40-50-1.)
Remove the hydrostatic drive motor. (See Removal And
Figure 40-60-1
P-40378
Raise the caliper arm (Item 1) [Figure 40-60-3] over

caliper.
Figure 40-60-4
1
P-49512
Figure 40-60-2
P-52487
Position the arm as shown [Figure 40-60-4]

1
2
P-40377
Remove the snap ring (Item 1) and the pin (Item 2)

[Figure 40-60-2] from the front caliper arm.
40-60-1

Service Manual
DROP BOX (CONTD)
Figure 40-60-7

Figure 40-60-5
1
P-52484
1
Install a chain and hoist (Item 1) [Figure 40-60-7] to lift
and support the drop box.
P-40380
Figure 40-60-8
Remove the nut and washer (Item 1) [Figure 40-60-5]
from the drop box mounting bracket.
Figure 40-60-6
1
1
P-40384
1
Remove the 4 bolts (Item 1) [Figure 40-60-8] from
mounting bracket.
P-40381
Remove the 3 nuts and washers (Item 1) [Figure 40-606] from the drop box mounting bracket.

Nm) torque.
Installation: Tighten nuts to 55 to 60 ft.-lb. (75 to 85

Nm) torque.
40-60-2

Service Manual
DROP BOX (CONTD)
Figure 40-60-11

Figure 40-60-9
1
2
1
P-52481
Remove the 2 bolts (Item 1) [Figure 40-60-11] and

remove the bracket (Item 2) [Figure 40-60-10]
P-52483
Remove the 2 bolts (Item 1). Remove the bracket (Item

2) [Figure 40-60-9].

Nm) torque.
Figure 40-60-12

Nm) torque.
Figure 40-60-10
1
P-52480
2
Remove the drop box [Figure 40-60-12]
P-52482

mounting bracket.
Nm) torque.
40-60-3

Service Manual
DROP BOX (CONTD)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Bolt
Lock Tab
Flange Retainer
Drive Flange
Washer
Output Bearing Flange
Shim Pack
Seal
Input Bearing Flange
Nut
Plug
Cover
Bearing Cup
Bearing
Output Gear
Input Gear
Stud
Housing
Cap
Spring
O-ring
Fitting
Dowel Pin
11
5
22
21
17
20 5
4
19
13
18
23
14
17
8
13
14
16
14
5
11
10
13
5
15
14
13
12
8
4
2
7
6
1
1
MS2118S
40-60-4

Service Manual
DROP BOX (CONTD)
Figure 40-60-15
Disassembly
Figure 40-60-13
1
P-40423
Remove the flange retainer washer (Item 1) [Figure 4060-15]
P-40421
Figure 40-60-16
Install a chain and hoist (Item 1) to lift and support the
drop box. Remove the drain plug (Item 2) [Figure 40-6013] and drain the fluid.
Figure 40-60-14
2
P-40424

P-40422
Place the drop box on a secure work surface. Bend the

bolt lock tab (Item 1) away from the bolts. Remove the
two bolts (Item 2) [Figure 40-60-14].
40-60-5

Service Manual
DROP BOX (CONTD)
Figure 40-60-19
Disassembly (Contd)
Figure 40-60-17
1
1
P-40427
Install 2 bolts (Item 1) into bearing flange (Item 2) [Figure

40-60-19] and separate from the drop box.
P-40425
Figure 40-60-20
Mark the drop box for correct assembly [Figure 40-6017].
Figure 40-60-18
1
1
1
P-40428
Remove the input bearing flange (Item 1) [Figure 40-6020].
P-40426
Remove the 8 bearing flange bolts (Item 1) [Figure 4060-18].
40-60-6

Service Manual
DROP BOX (CONTD)
Figure 40-60-23
Disassembly (Contd)
1
Figure 40-60-21
P-40431
Remove the output bearing flange (Item 1) [Figure 4060-23].
P-40429
Figure 40-60-24
necessary.
1
Figure 40-60-22
P-40432

necessary.
P-40430

bearing flange.
40-60-7

Service Manual
DROP BOX (CONTD)
Figure 40-60-27
Disassembly (Contd)
1
Figure 40-60-25
P-40435
Remove the 8 nuts and washers (Item 1) [Figure 40-6027].
P-40433
Figure 40-60-28
Remove the input gear bearing shim pack (Item 1)
[Figure 40-60-25]
Figure 40-60-26
1
P-40436
Install 2 bolts (Item 1) and separate the drop box (Item 2)

[Figure 40-60-28].
P-40434
Remove the output gear bearing shim pack (Item 1)

[Figure 40-60-26].
NOTE: Mark the shim pack for correct assembly.
40-60-8

Service Manual
DROP BOX (CONTD)
Figure 40-60-31
Disassembly (Contd)
Figure 40-60-29
1
P-40439
Remove the output bearing cup (Item 1) [Figure 40-6031] from the drop box cover. Replace as needed.
P-40437
Figure 40-60-32
Remove the drop box cover (Item 1) [Figure 40-60-29].
Figure 40-60-30
1
1
P-40440
Remove the input gear (Item 1) [Figure 40-60-32] from

the drop box.
P-40438
Remove the input bearing cup (Item 1) [Figure 40-60-30]

from the drop box cover. Replace as needed.
40-60-9

Service Manual
DROP BOX (CONTD)
Figure 40-60-35
Disassembly (Contd)
Figure 40-60-33
1
P-40443
Remove the output bearing cup (Item 1) [Figure 40-6035] from the drop box. Replace as needed.
P-40441
Figure 40-60-36
Remove the output gear (Item 1) [Figure 40-60-33] from
the drop box.
Figure 40-60-34
1
P-40444
Remove the output seal (Item 1) [Figure 40-60-36] from

the drop box. Replace as necessary.
P-40442
Remove the input bearing cup (Item 1) [Figure 40-60-34]

from the drop box. Replace as needed.
40-60-10

Service Manual
DROP BOX (CONTD)
Figure 40-60-39
Disassembly (Contd)
Figure 40-60-37
1
1
P-40449

output gear. replace as needed.
P-40446
Figure 40-60-40
input gear. Replace as needed.
Figure 40-60-38
1
P-40450

output gear. Replace as needed.
P-40447
Remove the other bearing (Item 1) [Figure 40-60-38]

from the input gear. Replace as needed.
40-60-11

Service Manual
DROP BOX (CONTD)
Assembly
Inspection
Figure 40-60-43

them.
Figure 40-60-41
P-40445
Install the drop box output seal (Item 1) [Figure 40-6043]
1
P-40448
Figure 40-60-44
Inspect the input gear for wear, flaking, cracks and
damage (Item 1). Inspect sealing surface area (Item 2)
[Figure 40-60-41] for grooves, pitting or damage.
1
Figure 40-60-42
P-40443
Install the output bearing cup (Item 1) [Figure 40-60-44]

into the drop box.
2
1
P-40451
Inspect the output gear for wear, flaking, cracks and

damage (Item 1). Inspect sealing surface area (Item 2)
[Figure 40-60-42] for grooves, pitting or damage.
40-60-12

Service Manual
DROP BOX (CONTD)
Figure 40-60-47
Assembly (Contd)
Figure 40-60-45
1
2
P-40453
Install the bearing (Item 1) onto the input gear (Item 2)

[Figure 40-60-47]. Install the second bearing onto the
other side of the input gear.
P-40442
Install the input bearing cup (Item 1) [Figure 40-60-45]

into the drop box.
NOTE: Install both bearings until fully seated.

Figure 40-60-48
Figure 40-60-46
1
2
3
1
2
P-40456
P-40452
Install the bearing (Item 1) onto the output gear (Item 2)

[Figure 40-60-46]. Install the second bearing onto the
other side of the output gear.
Place the drop box on blocks. Install the output gear

(Item 1) with threaded holes in shaft up. Install the input
gear (Item 2) into drop box. Apply Loctite gasket
eliminator 515 or equivalent sealant to sealing surface
(Item 3) [Figure 40-60-48]
NOTE: Install both bearings until fully seated.
40-60-13

Service Manual
DROP BOX (CONTD)
Figure 40-60-51
Assembly (Contd)
Figure 40-60-49
2
1
P-40454
Install the seal (Item 1) [Figure 40-60-51] into the output

bearing flange.
P-40457
Figure 40-60-52
Install the drop box cover (Item 1) Install the 8 nuts and
washers (Item 2) and tighten to 32 to 35 ft.-lb. (43 to 47
Nm) torque. Install the output bearing cup (Item 3) and
input bearing cup (Item 4) [Figure 40-60-49].
Figure 40-60-50
1
P-40455
Install the seal (Item 1) [Figure 40-60-52] into the input

bearing flange.
3
3
P-40458
Install the output bearing shim pack (Item 1) and the input
bearing shim pack (Item 2). Apply Loctite Gasket
Eliminator 515 or equivalent sealant to sealing surface
(Item 3) [Figure 40-60-50].
40-60-14

Service Manual
DROP BOX (CONTD)
Figure 40-60-55
Assembly (Contd)
Figure 40-60-53
2
3
4
1
P-40461
Install the 2 bolts (Item 1) and tighten to 18 to 19 ft.-lb.

(24 to 26 Nm) torque. Bend the lock tab (Item 2) [Figure
40-60-55] to lock bolts.
P-40459
Install the output bearing flange (Item 1) and the input

bearing flange (Item 2). Tighten the four bolts (Item 3)
and the 8 bolts (Item 4) [Figure 40-60-53] to 32 to 35 ft.lb. (43 to 47 Nm) torque.
Install the drop box into the loader backhoe. Remove the
fill plug, add SAE 80-90 until oil level is to the bottom of
the fill hole.
Figure 40-60-54
P-40460
Install the drive flange (Item 1) and retainer washer (Item

2) [Figure 40-60-54].
40-60-15

Service Manual
40-60-16

Service Manual
MAIN FRAME
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Arm Pivot Bushing Removal And Installation. . . . . . . . . . 50-120-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . .
Pivot Pin Bushing Removal And Installation . . . . . . . . . .
SAFETY &
MAINTENANCE
50-110-1
50-110-3
50-110-5
50-110-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Boom Pivot Bushing Removal And Installation . . . . . . . . 50-130-2
DRIVE
SYSTEM
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Backhoe Bucket Teeth Removal And Installation . . . . . . 50-160-1
Loader Bucket Teeth Removal And Installation . . . . . . . . 50-160-1
MAIN FRAME
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200-1

ENCLOSED CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11-1
Cab Mount Removal And Installation. . . . . . . . . . . . . . . . . 50-11-8
ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
ENGINE SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
FLOOR PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Front Panel Removal And Installation. . . . . . . . . . . . .
Rear Panel Removal And Installation . . . . . . . . . . . . . . . .
Right Front Panel Removal And Installation . . . . . . . . . . .
FRONT AXLE PIVOT FRAME . . . . . . . . . . . . . . . . . . . . . . .
Bushing Removal And Installation . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-30-1
50-30-1
50-30-2
50-30-1
50-180-1
50-180-3
50-180-2
50-180-1
50-01

Service Manual
MAIN FRAME (CONTD)

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . 50-90-2
GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
GRILL FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Not Available At Time Of Printing. . . . . . . . . . . . . . . . . . . . 50-10-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
STABILIZER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
SWING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 50-140-3
X-CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
50-02

Service Manual
OPERATOR CAB
Not Available At Time Of Printing

50-10-1
50-10-2

Service Manual
ENCLOSED CAB
Figure 50-11-2

Lower stabilizers to the ground.
Lower backhoe bucket flat to ground.
1
1

Drain the engine coolant. (See Coolant Replacement on

Page 10-90-1.)
(See
Removal
P-42123
And
Remove the front and rear floor panels. (See FLOOR

PANELS on Page 50-30-1.)
Remove the four roof mounting nut covers (Item 1)

[Figure 50-11-2].
Figure 50-11-3
Remove the engine speed control. (See Removal And

Remove the steering pump. (See Removal And
1
Figure 50-11-1
1
P-42122
Remove the four mounting bolts (Item 1) [Figure 50-113].

torque.
P-52522
Place blocks in front and behind the rear wheel [Figure

50-11-1].
50-11-1

Service Manual
ENCLOSED CAB (CONTD)
Figure 50-11-6

Figure 50-11-4
1
1
1
P-50674
Remove the four bolts (Item 1) and remove the tubeline

clamp assembly (Item 2) [Figure 50-11-6].
P-42124
Figure 50-11-7
Remove the roof (Item 1) [Figure 50-11-4].
Figure 50-11-5
1
1
2
2
P-50727
Disconnect the harness connector (Item 1) and auxiliary

hydraulic control wires (Item 2) [Figure 50-11-7].
P-52026
Remove the two bolts (Item 1) [Figure 50-11-5] (both

sides).
50-11-2

Service Manual
Figure 50-11-9
WARNING
1

immediately.
W-2145-0290
P-52525
Remove the four travel pedal mounting bolts (Item 1)

[Figure 50-11-9].
IMPORTANT
damage the system.

torque.
Figure 50-11-10
I-2003-0888
Figure 50-11-8
1
1
P-52526
Move the travel pedal (Item 1) [Figure 50-11-10] to the

position shown.
P-50729
Remove all tubelines (Item 1) [Figure 50-11-8].

NOTE: Mark the tubelines for correct assembly.
50-11-3

Service Manual
Figure 50-11-13

Figure 50-11-11
1
1
P-52529
1
Move the fuse box (Item 1) [Figure 50-11-13] to the
position shown.
P-52527
Figure 50-11-14
Remove the four fuse box mounting bolts (Item 1)
[Figure 50-11-11].
Installation: Tighten bolts to 4-5 ft.-lb. (5,5 to 6,5 Nm)
torque.
Figure 50-11-12
2
1
2
1
1
P-42135
Remove the frame ground cable (Item 1) from the battery

disconnect (Item 2) [Figure 50-11-14].
P-52528
Remove the two bolts (Item 1) and remove the right side
fuse box bracket (Item 2) [Figure 50-11-12].
Installation: Tighten bolts to 4-5 ft.-lbs. (5,5-6,5 Nm)
torque.
50-11-4

Service Manual
Figure 50-11-17

Figure 50-11-15
1
1
P-42138
Raise the dust cover (Item 1) [Figure 50-11-17].

P-42136
Figure 50-11-18
Remove the positive (+) cable (Item 1) [Figure 50-11-15]
from the battery.
Figure 50-11-16
1
P-42139
Remove the control lever mounting bolt (Item 1) and

remove the control lever (Item 2) [Figure 50-11-18].
P-42137
Installation: Tighten bolt to 4-5 ft.-lb. (5-6 Nm) torque.

Route the positive (+) cable and ground cables under the
cab as shown [Figure 50-11-16].
50-11-5

Service Manual
Figure 50-11-21

Figure 50-11-19
P-42142
Remove the two heater hoses (Item 1) [Figure 50-1121].
P-42140

Remove the three mounting bolts (Item 1) [Figure 50-1119] from the loader control valve.
Figure 50-11-22

torque.
Figure 50-11-20
1
P-42143
Remove the ground mounting bolt (Item 1) [Figure 5011-22].

P-42141
Remove the connector (Item 2) [Figure 50-11-22] and

move the harness through the cab opening.
Lower the control valve into the opening in the cab as
shown [Figure 50-11-20].
50-11-6

Service Manual
Figure 50-11-25

1
Figure 50-11-23
P-42146
Secure the harness (Item 1) [Figure 50-11-25] to the

cab.
P-42144
Figure 50-11-26
Remove the three park brake mounting bolts (Item 1),
Remove the cable E clip (Item 2) [Figure 50-11-23].
Remove the cable and park brake lever assembly,
torque.
Figure 50-11-24
P-42147
1
Install a hoist to lift and support the cab [Figure 50-1126].
1
P-52523
Disconnect the harness (Item 1) [Figure 50-11-24].
50-11-7

Service Manual
Cab Mount Removal And Installation
Figure 50-11-29
Figure 50-11-27
1
1
P-38023
P-38009
With the cab removed, remove the four mounting bolts

(Item 1) [Figure 50-11-29].
Remove the cab mounting bolts (Item 1) [Figure 50-1127].
Installation: Tighten bolts to 118-133 ft.-lbs. (160-180
Nm) torque.

torque,
Figure 50-11-30
Figure 50-11-28
P-38024
P-52519
Remove the mount (Item 1) [Figure 50-11-30].

Remove the cab [Figure 50-11-28].
Replace as needed.
50-11-8

Service Manual
OPERATOR SEAT
Figure 50-20-1
1
1
P-35704

Installation: Tighten bolts to 11-12.5 ft.-lb. (15-17 Nm)
torque.
Figure 50-20-2
1
P-35744

Installation: Tighten bolts to 4-5 ft.-lb. (5.5-6.5 Nm)
torque.
Remove the seat.
50-20-1

Service Manual
50-20-2

Service Manual
FLOOR PANELS
Right Front Panel Removal And Installation
Left Front Panel Removal And Installation
Figure 50-30-3
Figure 50-30-1
1
1
1
1
1
1
P-33312
P-33314

Figure 50-30-4
Figure 50-30-2
1
P-33313
P-33315
Remove the floor panel (Item 1) [Figure 50-30-4].

50-30-1

Service Manual
FLOOR PANELS (CONTD)

Rear Panel Removal And Installation
Figure 50-30-5
1
1
P-35110

Figure 50-30-6
P-35111
50-30-2

Service Manual
GRILL
Figure 50-40-1
P-50135
Remove the three bolts (Item 1) [Figure 50-40-1] (both

sides).
Installation: Tighten the bolts to 7-7.5 ft.-lb. (9.5-10.5
Nm) torque.
Figure 50-40-2
P-50136
Remove the grill [Figure 50-40-2]
50-40-1

Service Manual
50-40-2

Service Manual
GRILL FRAME
Raise the hoist until the weight of the grill frame is

supported by the hoist.

Figure 50-50-3
Remove the grill (See Removal And Installation on Page

50-40-1.)
Open the engine cover. (See Removal And Installation
on Page 50-80-1.)
Figure 50-50-1
1
P-50139
Remove the two bolts (Item 1) [Figure 50-50-3] from the

grill frame. (both sides)
Installation: The side covers must be installed before

tightening the bolts (Item 1) [Figure 50-50-3]. Tighten the
bolts to 55-60 ft.-lb. (75-85 Nm) torque.
Figure 50-50-4
P-50137
Remove the bolts (Item 1) [Figure 50-50-1] from the grill

frame.
Installation: The side covers must be installed before
tightening the bolts (Item 1) [Figure 50-50-1]. Tighten the
bolts to 7-7.5 ft.-lb. (9,5-10,5 Nm) torque.
Remove the side covers. (See Removal And Installation
on Page 50-60-1.)
Figure 50-50-2
1
P-50140
Remove the grill frame [Figure 50-50-4].
P-50138

on the grill frame.
50-50-1

Service Manual
50-50-2

Service Manual
ENGINE SIDE COVERS
Figure 50-60-3

Figure 50-60-1
1
1
P-50257
Remove the bolt (Item 1) [Figure 50-60-3] for the

steering valve handle.
Remove the handle.
Figure 50-60-4
P-50255
Release both engine cover latches (Item 1) [Figure 5060-1].
Figure 50-60-2
2
1
1
1
P-50258
Remove the six side cover mounting bolts (Item 1) and

remove the side cover (Item 2) [Figure 50-60-4].
P-50256
Open the engine cover and put the support rod (Item 1)
[Figure 50-60-2] in the hole in the hood.
50-60-1

Service Manual
50-60-2

Service Manual
FENDER
Figure 50-70-3

Figure 50-70-1
2
P-35708
Remove the fender [Figure 50-70-3].
P-35745
Remove the four foot guard mounting bolts (Item 1).

Remove the foot guard (Item 2) [Figure 50-70-1].
torque.
Figure 50-70-2
P-35707
Remove the four fender mount bolts (Item 1) [Figure 5070-2].

Installation: Tighten the bolts to 4-5 ft.-lb. (5.5-6.5 Nm)
torque.
50-70-1

Service Manual
50-70-2

Service Manual
ENGINE COVER
Figure 50-80-3


Figure 50-80-1
P-36040
Remove the engine cover (Item 1) [Figure 50-80-3].
P-35397
Remove the engine cover bolts (Item 1) [Figure 50-80-1]

(both sides).
Figure 50-80-2
P-36041
Open the latch (Item 1) [Figure 50-80-2] (both sides).
50-80-1

Service Manual
50-80-2

Service Manual
FUEL TANK
Figure 50-90-2

Page 50-30-1.)
1
P-40462A
WARNING
Remove plug (Item 1) [Figure 50-90-2].

Drain the fuel tank.

Installation: Tighten plug to 32-35 ft.-lb. (43-47 Nm)
torque.
Figure 50-90-3
W-2072-0496
Figure 50-90-1
1
2
P-50149
Place stands under the fuel tank [Figure 50-90-3].
1
P-36875
Remove wires (Item 1) [Figure 50-90-1] from sender.

NOTE: Mark hoses and wires for correct assembly.
50-90-1

Service Manual
FUEL TANK (CONTD)
Fuel Fill Screen Removal And Installation
Figure 50-90-5
Figure 50-90-4
P-50150
P-50148
Remove the fuel fill cap (Item 1) [Figure 50-90-5].

Figure 50-90-6
Remove the tank.

torque.
1
P-50151
Remove the fuel fill screen (Item 1) [Figure 50-90-6]

from the tank. Check the screen for damage and replace
if necessary.
50-90-2

Service Manual
LIFT ARMS
Figure 50-100-2

2
Remove the Bob-Tach. (See Removal And Installation on

Page 50-110-1.)
Remove the loader tilt cylinders (See Removal And
2
1

Lower the lift arms to the ground.
Relieve hydraulic pressure by moving the loader control
lever with the engine off.
P-50532
NOTE: Mark the hoses for correct installation.
WARNING
Remove the two hoses (Item 1) [Figure 50-100-2] from

the tubelines.

immediately.
W-2145-0290
Install caps and plugs.

the tubeline clamps (both sides).
Remove the hoses and tubelines (both sides).
torque.
Figure 50-100-1
IMPORTANT

damage the system.
I-2056-0793
1
P-50531
Remove the two coupler mounting bolts (Item 1) and two

tubeline clamping bolts (Item 2) [Figure 50-100-1].
50-100-1

Service Manual
LIFT ARMS (CONTD)
Figure 50-100-5

Figure 50-100-3
P-50534
Figure 50-100-6
P-33467
Remove the two plugs (Item 1) [Figure 50-100-3].

Raise the engine cover.
Figure 50-100-4
P-50533
Position the lifting straps [Figure 50-100-5] and [Figure

50-100-6] and chain hoist in the arrangement shown to
lift and support the lift arms.
Raise the hoist until the weight of the lift arm is supported
by the hoist.
P-33461
Remove the bolt and nut (Item 1) [Figure 50-100-4] from

the lift arm pivot pins (both sides).
torque.
Lower the engine cover.
50-100-2

Service Manual
LIFT ARMS (CONTD)
Figure 50-100-9

Figure 50-100-7
P-50538
Remove the lift arm pivot pin [Figure 50-100-9] (both

sides).
P-50536
Figure 50-100-10
Remove the pivot pin retainer bolt (Item 1) [Figure 50100-7] from the rod end of the lift cylinder (both sides).
torque.
Figure 50-100-8
P-50539
Lift and remove the loader lift arm assembly [Figure 50100-10].
P-50537
Remove the lift cylinder pivot pin (Item 1) [Figure 50100-8] and lower the cylinders (both sides).
50-100-3

Service Manual
50-100-4

Service Manual
BOB-TACH
Figure 50-110-3

Figure 50-110-1
P-50438
1
Remove the pivot pin (Item 1) and spacers (Item 2)
[Figure 50-110-3]. (Both sides)
P-50452
Figure 50-110-4
Tilt the Bob-Tach forward so it is parallel to the floor, set
the Bob-Tach on blocks (Item 1) [Figure 50-110-1].
Figure 50-110-2
P-50439
Support the pivot link (Item 1) [Figure 50-110-4] in the

position shown. (Both sides)
P-50453
Remove the retainer bolt (Item 1) [Figure 50-110-2] from

the lower Bob-Tach pivot link. (Both sides)
Installation: Tighten the retainer bolts to 18-19 ft.-lb. (2426 Nm) torque.
50-110-1

Service Manual
BOB-TACH (CONTD)
Figure 50-110-7

Figure 50-110-5
P-50442
1
Remove the Bob-Tach.
P-50440
NOTE: Always inspect the Bob-Tach pivot pin

bushings and bushings in lift arms for wear or
damage. Replace as needed.
Remove the retainer bolt (Item 1) [Figure 50-110-5].

Installation: Tighten the retainer bolts to 18-19 ft.-lb. (2426 Nm) torque.
Figure 50-110-6
P-50441
Remove the pivot pin (Item 1) and spacers (Item 2)

[Figure 50-110-6] from Bob-Tach. (Both sides)
50-110-2

Service Manual
BOB-TACH (CONTD)
Figure 50-110-10
Bob-Tach Lever And Wedge

Figure 50-110-8
P-33474
1
Remove the stop bolt (Item 1) [Figure 50-110-10] and
nut.
P-50452
Figure 50-110-11
Use the following procedure to remove and install the
Bob-Tach lever, spring, and wedge.
Tilt the Bob-Tach forward so it is parallel with the floor, set
the Bob-Tach on blocks (Item 1) [Figure 50-110-8].
1
Figure 50-110-9
5
4
P-33475
Remove the clevis assembly (Item 1) [Figure 50-110-11].
2
1
P-33473
Remove the lever mounting nut (Item 1), washer (Item 2)

spring (Item 3), lever (Item 4) and bolt (Item 5) [Figure
50-110-9].
Before installation of the parts, put grease on the BobTach handle pivot (Item 6) [Figure 50-110-9]
Installation: Tighten the nut to 25-28 ft.-lb. (34-38 Nm)
torque.
50-110-3

Service Manual
BOB-TACH (CONTD)
Figure 50-110-14
Bob-Tach Lever And Wedge (Contd)

Figure 50-110-12
1
P-33479
Remove the wedge (Item 1) [Figure 50-110-14]

P-33476
Replace the wedge if it is worn, bent or damaged.

Loosen the bolt (Item 1) [Figure 50-110-12] on the clevis
assembly.
Figure 50-110-13
4
3
2
1
P-33477
Remove the bolt (Item 1), handle pivot (Item 2), spring
(Item 3) and clevis (Item 4) [Figure 50-110-13].
Replace any worn or damaged parts as needed.
Before installation of the parts, put grease on the handle
pivot (Item 2), and bolt (Item 1) [Figure 50-110-13].
Reverse the removal procedure to install the Bob-Tach
lever and wedge assembly.
50-110-4

Service Manual
BOB-TACH (CONTD)
Pivot Pin Bushing Removal And Installation
Figure 50-110-15
P-33486
Remove and replace the bushing (Item 1) [Figure 50110-15] with a driver tool and hammer.
Figure 50-110-16
P-33487
Using a driver tool, install the bushing into the lift arm
[Figure 50-110-16].
50-110-5

Service Manual
50-110-6

Service Manual
ARM
Figure 50-120-3

2
Remove the backhoe bucket. (See Operation &

Maintenance Manual for correct removal procedure.)
Install the backhoe boom lock pin. (See Engaging And

Figure 50-120-1
P-50514
Install the pivot pin (Item 1). Install a hoist and lifting strap
(Item 2) [Figure 50-120-3] to lift and support the arm.

With the engine OFF, move the backhoe control levers to
P-50512
Figure 50-120-4
[Figure 50-120-1].
Figure 50-120-2
2
1
P-49086

hydraulic hoses (Item 2) [Figure 50-120-4].
P-50513
Support the cylinder (Item 1) on a wood block and

remove the pivot pin (Item 2) [Figure 50-120-2] and
lower the cylinder.

50-120-1
ARM (CONTD)
IMPORTANT

Figure 50-120-5

damage the system.
I-2003-0888
Figure 50-120-7
P-50522

bucket cylinder.
Figure 50-120-6
P-50524

1

torque.
Figure 50-120-8
P-50523

bucket cylinder.
Reposition the hoses through the opening in the top of
the arm.
P-50525
50-120-2

Service Manual
ARM (CONTD)
Arm Pivot Bushing Removal And Installation
Figure 50-120-10
Figure 50-120-9
1
1
P-50527
P-50526
Remove the bushing (Item 1) [Figure 50-120-10] (both

sides).
Remove the arm (Item 1) [Figure 50-120-9].
Installation: Fully seat the bushings in the arm.

50-120-3
50-120-4

Service Manual
BOOM
Figure 50-130-2

Remove the arm. (See Removal And Installation on Page
50-120-1.)
WARNING

immediately.
W-2145-0290
Remove the arm cylinder. (See Removal And Installation

on Page 20-20-2.)
P-52035
Remove the hose clamps (Item 1) [Figure 50-130-2].

Reposition the auxiliary hydraulic hoses.
Lower boom to the ground.
IMPORTANT

pressure.
Remove the boom cylinder.
(See
Removal
And

damage the system.
I-2003-0888
Figure 50-130-1
Figure 50-130-3
1
1
1
P-52036
P-52037
Remove the auxiliary hydraulic hose clamp (Item 1)

[Figure 50-130-1].
Remove the four hoses (Item 1) [Figure 50-130-3].

NOTE: Mark hoses for correct installation.
50-130-1

Service Manual
BOOM (CONTD)
Figure 50-130-6

Figure 50-130-4
P-52040
Remove the boom [Figure 50-130-6].

P-52038
Boom Pivot Bushing Removal And Installation

Install a hoist and lifting strap to lift and support the boom
[Figure 50-130-4].
Figure 50-130-7
Figure 50-130-5
P-52041
Remove the bushing (Item 1) [Figure 50-130-7] (both

sides).
P-52039
Remove the pivot pin retainer bolt (Item 1) and pivot pin
(Item 2) [Figure 50-130-5].
Installation: Fully seat the bushing in the boom.

torque.
50-130-2

Service Manual
SWING FRAME
Figure 50-140-3

50-120-1.)
Remove the boom. (See Removal And Installation on
Page 50-130-1.)
Figure 50-140-1
1
P-52044
Pull all hoses through the hose guide ring (Item 1) and
reposition them to the side of the swing frame. Remove
the hose guide ring (Item 1) [Figure 50-140-3].
Figure 50-140-4
P-52042
1
Remove the swing cylinder pivot pin retainer bolts (Item
1) [Figure 50-140-1].
torque.
Figure 50-140-2
P-52045
Install the boom cylinder pivot pin and retainer bolt. Install
a hoist and lifting strap (Item 1) [Figure 50-140-4] to lift
and support the swing frame.
1
P-52043
Remove the pivot pins (Item 1) [Figure 50-140-2].
50-140-1

Service Manual
SWING FRAME (CONTD)
Figure 50-140-7

Figure 50-140-5
P-52051
2
Remove the swing frame [Figure 50-140-7].
P-52047
Remove the lower swing frame pivot pin retainer bolt

(Item 1) and pivot pin (Item 2) [Figure 50-140-5].
Installation: Tighten bolt to 18-19 ft.-lb. (24-26 Nm)
torque.
Figure 50-140-6
2
P-52048
Remove the upper swing frame pivot pin retainer bolt

(Item 1) and pivot pin (Item 2) [Figure 50-140-6].
torque.
50-140-2

Service Manual
SWING FRAME (CONTD)

Figure 50-140-8
P-52236
Figure 50-140-9
P-52237
Remove the bushings (Item 1) [Figure 50-140-8] and

[Figure 50-140-9].
Installation: Center new bushings in bores.
50-140-3

Service Manual
50-140-4

Service Manual
X-CHANGE
Figure 50-150-3

Remove the bucket. (See the Operation & Maintenance
Manual for the correct removal procedure.
Figure 50-150-1
1
P-50583
Remove the plate (Item 1) [Figure 50-150-3].

Figure 50-150-4
P-50588
Install the boom lock pin (Item 1) [Figure 50-150-1].

pressure.
Figure 50-150-2
1
P-50584
1
Remove the link (Item 1) [Figure 50-150-4].
Figure 50-150-5
1
P-50582
Remove the snap rings and washers (Item 1) [Figure 50150-2].
P-50585
Remove the retainer pin (Item 1) [Figure 50-150-5].

50-150-1
X-CHANGE (CONTD)
Figure 50-150-6
2
1
P-50586
Remove the spacer (Item 1) and washer (Item 2) [Figure

50-150-6].
Figure 50-150-7
P-50587
Remove the pin (Item 1) and remove the X-Change (Item

2) [Figure 50-150-7] from the arm.
50-150-2

Service Manual
BUCKET
Loader Bucket Teeth Removal And Installation
Backhoe Bucket Teeth Removal And Installation
Figure 50-160-3
Figure 50-160-1
1
P-35650
P-35226
Remove the two bolts (Item 1) [Figure 50-160-3], nuts

and washers.
Remove the two bolts (Item 1) [Figure 50-160-1], nuts
and washers.
Figure 50-160-4

torque.
Figure 50-160-2
1
P-35651
Remove the bucket teeth (Item 1) [Figure 50-160-4].

P-35199
Remove the bucket teeth (Item 1) [Figure 50-160-2].
50-160-1

Service Manual
50-160-2

Service Manual
STABILIZER FRAME
Figure 50-170-2

50-120-1.)
Remove the boom. (See Removal And Installation on

Page 50-130-1.)
Remove the swing frame. (See Removal And Installation
on Page 50-140-1.)
Remove the swing cylinders. (See Removal And

P-52243
Lower stabilizers to the ground.

pressure.
Install the swing cylinder mount plate (Item 1). Install a

hoist and lifting strap (Item 2) [Figure 50-170-2] to lift and
support the trunion.
Figure 50-170-3
WARNING
immediately.
W-2145-0290
Figure 50-170-1
P-52244
Remove the two nuts (Item 1) [Figure 50-170-3].

Installation: Tighten the nuts until they are firmly seated
against the trunion. Do not overtighten and deflect the
trunion, it must slide freely on the stabilizer frame.
1
P-52239
Pull the swing cylinder hoses (Item 1) through the

trunion. Remove the side shift lock cylinder hose (Item 2)
[Figure 50-170-1].
50-170-1

Service Manual
STABILIZER FRAME (CONTD)
Figure 50-170-6

Figure 50-170-4
1
1
P-52246
Remove the trunion (Item 1) and plate (Item 2) [Figure

50-170-6].
P-52240
Figure 50-170-7
Remove the plate and spacers (Item 1) [Figure 50-1704].
Figure 50-170-5
1
1
1
P-52247
Remove the stabilizer cylinder hoses (Item 1) [Figure 50170-7].
P-52245
Remove the two nuts (Item 1) [Figure 50-170-5].

Installation: Tighten the nuts until they are firmly seated
against the trunion. Do not overtighten and deflect the
trunion, it must slide freely on the stabilizer frame.
50-170-2

Service Manual
STABILIZER FRAME (CONTD)
Figure 50-170-10

Figure 50-170-8
P-52251
Remove the swing frame [Figure 50-170-10].

P-52248
Install a hoist and lifting strap to lift and support the

stabilizer frame [Figure 50-170-8].
Figure 50-170-9
P-52249
Remove the three mount bolts (Item 1) [Figure 50-170-9]

(both sides).
torque.
50-170-3

Service Manual
50-170-4

Service Manual
FRONT AXLE PIVOT FRAME
Figure 50-180-3
Removal
1
Remove the front axle. (See Drive Axle Disassembly on

Page 40-41-8.)
Remove the grill frame. (See Removal And Installation
on Page 50-50-1.)
Figure 50-180-1
P-50567
Remove the pivot pin retainer bolts (Item 1) [Figure 50180-3]

Figure 50-180-4
P-50565
Install a jack to lift and support the front axle pivot frame
[Figure 50-180-1].
Figure 50-180-2
P-50566
Remove the pivot pin (Item 1) [Figure 50-180-4] and

slowly lower the jack.
1
P-50564
Remove the pivot pin nut (Item 1) [Figure 50-180-2].
50-180-1

Service Manual
FRONT AXLE PIVOT FRAME (CONTD)
Installation
Removal (Contd)
Figure 50-180-6
Figure 50-180-5
2
1
2
P-40527
P-40527
Raise the axle pivot frame (Item 1) into place and install
the shim pack (Item 2) [Figure 50-180-6].
Remove the shim pack (Item 1) and remove the axle
pivot frame (Item 2) [Figure 50-180-5].
Figure 50-180-7
NOTE: Mark location of shim pack for correct

assembly.
P-50566
Install the pivot pin (Item 1) [Figure 50-180-7]
50-180-2

Service Manual
Figure 50-180-10
Figure 50-180-8
1
1
P-40528
P-50567
Remove the bushing (Item 1) [Figure 50-180-10].

Install the pivot pin retainer bolts (Item 1) [Figure 50-1808] and tighten to 32-35 ft.-lb. (43-47 Nm) torque.
Figure 50-180-11
Remove the jack.

Figure 50-180-9
3
1
1
P-40529
2
Inspect the bushing (Item 1) [Figure 50-180-11] for wear
or damage. Replace as needed.
P-40531
Install the pivot pin nut (Item 1) and tighten until end play
in shim pack (Item 2) is removed. Do not over tighten the
nut. Axle pivot (Item 3) [Figure 50-180-9] must move
freely.
50-180-3

Service Manual

Bushing Removal And Installation (Contd)
Figure 50-180-12
2
3
P-40530
Install bushing (Item 1) into axle pivot (Item 2). Install lip
of bushing (Item 3) [Figure 50-180-12] until flush with
axle pivot.
Figure 50-180-13
P-40532
Inspect axle pivot pin (Item 1) [Figure 50-180-13] for

wear or damage. Replace as needed.
50-180-4

Service Manual
REAR WINDOW
Figure 50-190-3

Figure 50-190-1
1
3
P-42007
Remove the pivot assembly (Item 1) from the window

frame (Item 2) [Figure 50-190-3].
NOTE: The pivot assembly is under tension.
P-42004
Figure 50-190-4
Disconnect the harness connector (Item 1) and remove
the harness (Item 2) from the mounting tab (Item 3)
[Figure 50-190-1].
1
Figure 50-190-2
P-42008
Rotate the pivot assembly (Item 1) [Figure 50-190-4]

away from the window frame.
P-42005

torque.
50-190-1

Service Manual
REAR WINDOW (CONTD)
Figure 50-190-7

Figure 50-190-5
P-42010
Rotate the pivot assembly (Item 1) [Figure 50-190-7]

away from the window frame.
P-42006
Figure 50-190-8
torque.
Figure 50-190-6
P-42011
Unlatch the window (Item 1) [Figure 50-190-8].

1
P-42009
Remove the pivot assembly (Item 1) from the window

frame (Item 2) [Figure 50-190-6].
NOTE: The pivot assembly is under tension.
50-190-2

Service Manual
REAR WINDOW (CONTD)
Figure 50-190-11

Figure 50-190-9
P-42014
1
Remove the window [Figure 50-190-11].
P-42012
Move the lower window frame (Item 1) [Figure 50-190-9]

outward.
Figure 50-190-10
3
1
P-42013
Lower the window frame (Item 1) and remove the roller

(Item 2) from the track (Item 3) [Figure 50-190-10].
50-190-3

Service Manual
50-190-4

Service Manual
CAB DOOR
Figure 50-200-3

Figure 50-200-1
P-42017
Remove the cab door [Figure 50-200-3].
P-42015
Figure 50-200-2
P-42016
Lift and support the cab door separating the upper hinge
(Item 1) [Figure 50-200-1] and the lower hinge (Item 1)
[Figure 50-200-2].
50-200-1

Service Manual
50-200-2

Service Manual
ELECTRICAL SYSTEM AND ANALYSIS

ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Alternator Regulator Test With Voltmeter. . . . . . . . . . . . . . 60-30-4
Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Full Field Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-30-7
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . 60-30-12
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-11
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-11
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . .
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . .
60-20-1
60-20-1
60-20-2
60-20-3
CAB LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-53-1

Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-53-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 60-53-3
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-10-1
60-10-2
60-10-2
60-10-1
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
FRONT WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 60-50-3
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
REAR WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
60-01

Service Manual
ELECTRICAL SYSTEM AND ANALYSIS (CONTD)

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-14
Checking The Starter In The Loader . . . . . . . . . . . . . . . . . 60-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-13
TURN INDICATOR LIGHTS (FRONT) . . . . . . . . . . . . . . . . . . 60-51-1
TURN INDICATOR LIGHTS (REAR). . . . . . . . . . . . . . . . . . . . 60-52-1
60-02

Service Manual
WIRING SCHEMATIC
B250 "B SERIES"
(PRINTED DECEMBER 2003)
V-0466
Printable Version Click Here
200
FUSE/RELAY CENTER
03
04
85
86
200
85
86
30
87
FLASHING UNIT
PRESSURE SW ITCH
12
87
01
11
15
87A
31
48
PRESSURE SW ITCH
15
FILTER OIL PRESSURE
84
A
B
FUEL PUMP
A B
NOTE: This wire is not

used on all machines.
C009
KILL SWITCH
REAR
REAR
G
F
E
G
F
E
102
100
101
A B
41
40
HORN SW ITCH
102
100
101
103
AUXILIARY
POWER SOCKET
C 017
A B
49 49 15 30 L R 30b
C018
SWITCH
C 015
49
7
5
100
87A
OPTION LIGHTS
A B
C 019
102
15A
15A
30
82
C020
66
13
13
10A
A X
B 58
46
15A
20A
A
B
A B
6
15A
65
26 or 43
7.5A
20A
7.5A
E9
28
23
31
LIGHTS
BREAKER
OPTION
CAB
22
21
EMPTY
POSITION
OPTION
CAB
27
POSITION
EMPTY
20
OPTION
20A
46
25
20A
19
23
15A
18
40
17
12
16
84
15
BACK UP ALARM
E10
24
PRESS TO OPERATE
KILL SWITCH
C D B A
C008
FUEL
C D B A
GLOW PLUGS
HYD. FILTR
25
59
80
8
SOLENOID
HYD. PRESSURE LIGHT

LIGHT
73
73
57
57
83
A
B
D
C018
D
C
B
A
101
201
12
02
6
201
D
C
B
A
29
30
E
WATER TEMPERATURE
ENGINE
GAUGE
COOLANT
29
30
80
SENDER
36
HOURS METER
21
HORN FRONT
V
30
36
29
03
GAUGE
NC
200
TIMER
FUEL QUANTITY
59
C 014
35
D
E
F
G
H
26 or 43 C
27
29
30
C
A
B
8
12
02
30b
R
L
30
15
49
49a
C006
C
A
B
D
E
F
G
H
FRONT
C003
80
8
25
59
BUTTON
CONTROL LIGHT
FUEL SENDER
11
B B
Y Y 16
3
11
16
5
55
D
G
B
A
C
E
F
H
F
D
E
C
A
B
G
H
41
16
11
3
7
12
55
ENGINE OIL PRESSURE

SWITCH
CONTROL LIGHT
LOW OIL PRESSURE
HORN SW ITCH
FRONT
8
2
21
4
1
17
37
E
D
C
G
F
H
B
A
C 001
41
12
C002
ALTERNATOR
G
C
D
A
E
F
B
H
IGNITION SW ITCH
4
21
2
37
8
1
17
OFF
RUN
GLOW PLUG
START
WORK LIGHTS
RIGHT SIDE
55
55
SWITCH
SWITCH
WORKING LIGHTS
WORKING LIGHTS
FRONT
REAR
A
C
H
B
D
E
G
F
65
66
82
83
30
22
60
40
29
A B C D
D C B A
17
40
55
17
13
1
2
3
1
2
3
13
13
35
ALTERNATOR
5
9
HR
14
36
50
C 011
C005
GLOW PLUGS
29
14
19
55
D C B A
C007
37
60
17
37
WORK LIGHTS REAR
A B C D
31
2
24
15
23
A
B
C 013
LEFT SIDE
C004
37
A
B
2
1
13
A
BATTERY
DISCONECT
BATTERY
22
FRONT
37
STARTER
C 012
A
(12-3-03) V-0466
NO
60
8
2
21
4
1
37
17
TURN AND ROAD LIGHTS
TURN LIGHTS FRONT

40
61
61
SWITCH
ROAD LIGHTS
SWITCH
WORKING LIGHTS
REAR
ROAD LIGHTS FRONT

LEFT SIDE
RIGHT SIDE
ROAD LIGHTS REAR

17
CHANGE OVER SWITCH

TURN LIGHTS
17
60
E
D
C
G
F
A
B
H
65
66
40
TURN LIGHTS
REAR
55
40
17
A
B
C
D
C 007
C 005
40
61
A
D
C
B
C 010
17
60
37
61
60
C
D
B
A
40
60
A
B
C
D
A
C
H
B
D
E
F
G
C 004
PART OF STANDARD WIRING HARNESS
C 001
WIRING SCHEMATIC
OPTIONS
B250 "B SERIES"
(PRINTED DECEMBER 2003)
V-0467
A
C
H
B
D
E
G
F
65
66
82
83
60
40
61
61
40
60
CAB
27
73
57
HEATER MOTOR
C 006
FRONT WIPER
57
73
A
B
C
D
43
73
57
43
82
SWITCH HEATER MOTOR
V
M
29
30
C
A
B
D
E
F
G
H
C 003
PART OF STANDARD WIRING HARNESS
REAR WIPER
43
V
M
WATER TEMPERATURE GAUGE
(12-4-03) V-0467
ELECTRICAL SYSTEM INFORMATION
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
only.

Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow instructions can
W-2003-0199
PROBLEM
SOLUTION#
Battery will not take charge.

Alternator will not charge.
Starter will not turn the engine.
1, 2, 3, 4, 5
1, 2, 5
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 the solenoid is damaged.
9. Check the fuses.
60-10-1

Service Manual
ELECTRICAL SYSTEM INFORMATION (CONTD)
Fuse Location
Description
Figure 60-10-2
Figure 60-10-1
1
15 16 17 18 19 20
22
23
28
MS1403
P-33309
The electrical system is protected from overload by fuses

under the fuse panel cover [Figure 60-10-1].
The loader backhoe has a 12 volt, negative ground
alternator charging system. The electrical system is
protected by fuses located on the front panel and below
the operator seat [Figure 60-10-1].
Remove the cover to check or replace the fuses.

The location and sizes are shown below and [Figure 6010-2].
The fuses will protect the electrical system when there is

an electrical overload. The reason of the overload must
be found before starting the engine again.
60-10-2
REF
1
2
3
4
15
16
17
18
19
20
22
23
28
DESCRIPTION
Front/Rear Horn
Auxiliary Outlet
Backup alarm
Wipers
Dash
Front/rear lights
Hydraulic Filter
Cab Heater
Road Lights
Direction Indicators
Rear Auxiliary Hydraulics
Fuel Pump
Press to Drive
AMP.
15
20
10
15
7.5
20
7.5
15
20
10
10
15
15

Service Manual
BATTERY
Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
1
1
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
Figure 60-20-1
P-32798
Remove the two bolts (Item 1) and hold down clamp

(Item 2) [Figure 60-20-2].
Remove the battery part way.
Figure 60-20-3
2
1
1
1
P-33780
P-32799
Remove the four bolts (Item 1) and remove the battery

box cover (Item 2) [Figure 60-20-1].
Always disconnect the negative (-) cable (Item 1) [Figure

60-20-3] first to prevent sparks.
Disconnect the positive (+) cable (Item 2) [Figure 60-203].
Remove the battery.
60-20-1

Service Manual
BATTERY (CONTD)
Servicing The Electrical System
Removal And Installation (Cont'd)
WARNING
Figure 60-20-4

minutes.
W-2065-1296
P9589
Figure 60-20-6
Figure 60-20-5
P9588
P9590
Installation: Always clean the terminals and cable ends

when installing a new battery as shown in [Figure 60-204] & [Figure 60-20-5].
The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution as shown in [Figure 60-20-6].
When installing the battery in the loader, do not touch any

metal parts with the battery terminal posts.
Clean the terminals and cable ends as shown in figure

[Figure 60-20-4] and [Figure 60-20-5].
Connect and tighten the battery cables. Connect the

negative (-) cable last to prevent sparks.
Check the electrolyte level in the battery. Add distilled

water as needed.
Put battery saver P/N (6664458) or grease on the battery
terminals and cable ends to prevent corrosion.
60-20-2

Service Manual
BATTERY (CONTD)
Figure 60-20-8
Using A Booster Battery (Jump Starting)

If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and
disconnect the battery cables.
The key must be OFF. The booster battery must be 12

volt.
WARNING
P-33539

minutes.
Connect the end of the second cable to the negative (-)

terminal of the booster battery. Connect the other end of
the same cable (Item 1) [Figure 60-20-8] to the loader
backhoe frame near the engine.
Start the engine.

WARNING
W-2065-1296
Keep arcs, sparks flames and lighted tobacco away

from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Remove the battery box cover.

Figure 60-20-7
Do not jump start or charge a frozen or damaged

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

W-2066-1296
IMPORTANT
P-33493
Connect the end of the first cable to the positive (+)

terminal of the booster battery. Connect the other end of
the same cable (Item 1) [Figure 60-20-7] to the positive
terminal on the loader backhoe battery.
Damage to the alternator can occur if:

Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
60-20-3

Service Manual
BATTERY (CONTD)
Using A Booster Battery (Jump Starting) (Contd)
After the engine has started, remove the ground (-) cable
(Item 1) [Figure 60-20-8] first.
Remove the cable from the positive terminal (Item 1)
[Figure 60-20-7].
60-20-4

Service Manual
ALTERNATOR
Figure 60-30-2
Adjusting The Alternator Belt
WARNING
W-2059-0598
Remove the side cover from the left side.
P-47622
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force [Figure 60-30-2].
Tighten the adjustment and mounting bolts (Item 1)
[Figure 60-30-2].
Figure 60-30-1
Description
Figure 60-30-3
1
1
3
2
1
P-47623
5
Loosen alternator mounting and adjustment bolts (Item 1)
[Figure 60-30-1].
P-35312A
P-35312
The output terminal (Item 1) [Figure 60-30-3].

The battery or power sensing terminal (Item 2) [Figure
60-30-3].
The ignition terminal (Item 3) [Figure 60-30-3].
Open terminal not used in the loader harness (Item 4)
[Figure 60-30-3].
Access hole for full field test (Item 5) [Figure 60-30-3].
60-30-1

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-5
Tests
Perform the following alternator tests in this order:
Alternator Output Test: Tests the alternator and regulator
output.
Full Field Test: Tests the maximum amperage output of

the alternator.
Alternator Regulator Test: Tests the regulator voltage

output.
Alternator Output Test
P-35308
Rotate the battery disconnect lever clockwise to restore

power from the battery.
WARNING
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-1285
at full RPM.
The ammeter reading should be between 35 and 40
amps.
If the ammeter reading is less than 35 amps do the full
field test.

Disconnect the red wire (Item 1) [Figure 60-30-4] from
the alternator. Connect that wire to the negative (-) side
of the ammeter (Item 1) [Figure 60-30-5].
Connect the positive (+) side of the ammeter to the
output terminal at the alternator (Item 2) [Figure 60-305].
Figure 60-30-4
P-35305
60-30-2

Service Manual
ALTERNATOR (CONTD)
Alternator Regulator Test
Full Field Test
Figure 60-30-7
at full RPM.
Figure 60-30-6
1
1
P-35681
Disconnect the fuel stop solenoid connector (Item 1)

[Figure 60-30-7].
P-35311
Turn the lights on (if equipped) and crank the engine for
30 seconds to discharge the battery.
Place a small screw driver in the test port (Item 1)
[Figure 60-30-6] to provide a ground to the alternator
case. This will give maximum amperage output from the
alternator.
NOTE: The Full Field Test should only last long
enough to get ammeter reading to prevent
damage to the alternator.
The ammeter reading should be above 35 amps.
Connect the fuel stop solenoid connector.

at full RPM.
The ammeter reading should be around 35 amps and
slowly decrease with alternator output.
If ammeter reading is low or does not decrease with time,
replace the alternators regulator.
If the ammeter reading is low, repair or replace the

alternator.

Reconnect the alternator wires.
WARNING
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Rotate the battery disconnect lever clockwise to restore

power from the battery.
NOTE: The alternator regulator test can also be run
using a voltmeter.
W-2050-1285
60-30-3

Service Manual
ALTERNATOR (CONTD)
Alternator Regulator Test With Voltmeter
Figure 60-30-8
2
P-35314
Connect the positive (+) voltmeter lead to the positive (+)

battery terminal (Item 1) [Figure 60-30-8].
Connect the negative (-) voltmeter lead to the negative () battery terminal (Item 2) [Figure 60-30-8].
Start the engine, engage the parking brake and run at full
RPM.
The voltmeter should read between 13.9 and 14.7 volts.
If the voltmeter reading is not within this range, replace
the alternators regulator.
60-30-4

Service Manual
ALTERNATOR (CONTD)
Remove the alternator belt from the alternator.
Figure 60-30-11

Open the engine cover, remove the cover from the left
side of the engine.
Figure 60-30-9
P-35309
Remove the adjusting bolt (Item 1) and mounting bolt and

nut (Item 2) [Figure 60-30-11].
Remove the alternator.
1
P-35305
Disconnect the wiring harness (Item 1) [Figure 60-30-9]

from the alternator.
Remove the red wire (Item 2) [Figure 60-30-9].
Figure 60-30-10
P-35304
Loosen the alternator adjusting bolt (Item 1) [Figure 6030-10].

60-30-5

Service Manual
ALTERNATOR (CONTD)
1. Nut
2. Pulley
3. Spacer
4. Frame Assy.
5. Stud
6. Bearing
7. Plate
8. Screw
9. Screw
10. Rotor Assy.

11. Bearing
12. Cover
13. Frame End
14. Nut
15. Insulator
16. Nut
17. Bolt
18. Rectifier
19. Regulator
20. Screw
21. Brush
22. Spring
23. Screw
24. Screw
25. Brush
26. Cover
27. Bolt
10
9
4
12
11
7
8
2
26
27
24
3
25
16
1
15
22 23
21
14
13
20
19
17
18
60-30-6

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-14
Pulley Removal And Installation

Remove the alternator from the machine. (See Removal
And Installation on page 5.)
Figure 60-30-12
1
P10051
Assembly: Tighten the pulley nut [Figure 60-30-14] as

shown to 70-94 ft.-lb. (94-127 Nm) torque.
P10048
Wrap a V-belt in the alternator pulley and clamp the

pulley into a vise as shown [Figure 60-30-12]. Do not
cover tighten vise.
Figure 60-30-13
P10050
Using a box end wrench (Item 1) [Figure 60-30-13] (22

mm) loosen and remove the nut (Item 1) [Figure 60-3012] while the pulley shaft (Item 2) [Figure 60-30-12] is
held firmly with a 6-point socket (Item 2) [Figure 60-3013] (10 mm).
NOTE: A six point box end wrench should be used, a
twelve point box end wrench may damage the
corners of the nut.
60-30-7

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-17

1
Figure 60-30-15
2
2
1
1
3
P10032
Remove the three screws (Item 1) and remove the

regulator (Item 2) [Figure 60-30-17].
P10020
Remove the three screws (Item 1), the nut and insulator
(Item 2) and remove the end cover (Item 3) [Figure 6030-15].
NOTE: The lengths of the screws are different, and

must be marked prior to disassembly. If the
wrong screw is used, damage to the alternator
may occur.
Figure 60-30-16
Figure 60-30-18
2
1
1
1
2
1
P10031
P10033
Remove the two screws (Item 1) and remove the brush

holder (Item 2) [Figure 60-30-16].
Loosen the four screws (Item 1) that hold the rectifier

lead wires. Unwrap and straighten the rectifier lead wires
from the screws, and lift the rectifier (Item 2) [Figure 6030-18] from the stator.
60-30-8

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-21

2
Figure 60-30-19
1
P10037
Support the alternator housing (Item 1) [Figure 60-3021] on blocks.
P10034
Remove the two bolts (Item 1) and two nuts (Item 2)

[Figure 60-30-19].
Figure 60-30-20
With the nut (Item 2) [Figure 60-30-21] on the pulley

shaft, tap the rotor out of the bearing. A press may be
needed if the bearing is stuck to the rotor shaft.
NOTE: Care should be used not to damage the fan,
slip ring, etc.
Figure 60-30-22
P10036
Remove the four screws (Item 1) and remove the retainer

plate (Item 2) [Figure 60-30-22].
P10035
Using a puller (Item 1) [Figure 60-30-20], remove the

rear housing as shown.
60-30-9

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-25
Figure 60-30-23
1
P10042
Remove the bearing (Item 1)from the rotor shaft, using a

puller (Item 2) [Figure 60-30-25].
P10039
Support the alternator housing (Item 1) [Figure 60-3023] on blocks, and press the bearing from the housing.
NOTE: A vise with padded jaws may be used to

secure the rotor assembly. Do not over
tighten the vise.
Figure 60-30-24
P10040
Assembly: Press a new bearing in the housing [Figure

60-30-24].
60-30-10

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-28
Rotor Continuity Test

Figure 60-30-26
P10041
Measure the slip ring shaft [Figure 60-30-28].

P10043
Standard measurement is 0.57 inches (14,45n mm)

allowable limit is 0.55 inches (14,0 mm).
Touch the probes to the slip rings [Figure 60-30-26].
The ohmmeter should read approximately 2.9 ohms.
Check the slip ring for stained or rough surfaces, use fine
sandpaper to clean shaft.
If there is no continuity, replace the rotor.
Stator Continuity Test
Figure 60-30-27
Figure 60-30-29
P13179
P13177
Check the continuity across the slip rings (Item 1) to the

core of the rotor (Item 2) [Figure 60-30-27] with an
ohmmeter.
Check the continuity across each of the four leads of the

stator coil with an ohmmeter [Figure 60-30-29].
If there is no continuity, replace the stator.
If there is continuity, replace the rotor.
60-30-11

Service Manual
ALTERNATOR (CONTD)
Figure 60-30-32
Rotor Continuity Test (Contd)

Figure 60-30-30
1
2
P1
P2
P4
P3
P10047
Test 3: Touch the positive (+) test probe (Item 1) to the

ground terminals, touch the (-) negative test probe (Item
2) [Figure 60-30-32] to the P1, P2, P3 and P4 terminals.
There should be a reading.
P13178
Check the continuity across each stator coil lead to the

core (Frame Assembly) with an ohmmeter [Figure 6030-30]
Test 4: Reverse the positions of the test probes from test

3, there should be no reading.
Rectifier Continuity (Diode) Test
Brush Length
Figure 60-30-31
Figure 60-30-33
2
P1
P2
P4
P3
P10046
P10044
Test 1: Touch the positive (+) test probe (Item 1) to the

positive terminal. Touch the negative (-) test probe (Item
2) [Figure 60-30-31] to the P1, P2, P3 and P4 terminals.
There should be no reading.
Measure the length of the brush protruding from the

brush holder [Figure 60-30-33].
Standard measurement is 0.41 inches (10,5 mm)
allowable limit is 0.18 inches (4,5 mm).
Test 2: Reverse the positions of the test probes from Test

1, there should be a reading.
60-30-12

Service Manual
STARTER
Installation: Tighten the starter mounting bolts to 25-28

ft.-lb. (34-38 Nm) torque.

Checking The Starter In The Loader
Stop the engine and open the engine cover.
Remove the left side cover.
NOTE: The starter is removed from the loader for

clarity.

disconnect battery from system
The key switch must be in the OFF position.

The battery must be at full charge.
Make note of the wiring connections on the starter to

ensure correct installation.
The cable connections on the battery must be clean and

tight.
Figure 60-40-1
Figure 60-40-3
1
2
1
P-35109
P9975
Disconnect the plug (Item 1) and three wires (Item 2)

[Figure 60-40-1] from the starter.
Connect a jumper wire between battery terminal (Item 1)

and the solenoid terminal (Item 2) [Figure 60-40-3].
Figure 60-40-2
If the starter turns but does not turn the engine, the
starter drive has a defect.
1
2
P-35303
Remove the starter mounting bolts (Item 1 & 2) [Figure

60-40-2].
Remove the starter.
60-40-1

Service Manual
STARTER (CONTD)
Checking The Starter In The Loader (Contd)
Figure 60-40-4
2
1
P9976
Connect a jumper wire between the battery terminal

(Item 1) and motor terminal (Item 2) [Figure 60-40-4].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.
60-40-2

Service Manual
STARTER (CONTD)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Bearing
Armature
Bearing
Frame
Brush Spring
Brush Holder
Cover
Bolt
Bolt
Bolt
Cover
9
7
5
4
3
2
1
11
12
15
10
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Gasket
Switch
Nut
Washer
Nut
Washer
Roller
Retainer
Idler Gear
Ball
Spring
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Housing
Screw
Washer
O-ring
Housing
O-ring
Snap Ring
Collar
Pinion Gear
Spring seat
Spring
Clutch
Spring
Pinion Shaft
14
16
20
19
18
17
13
15
23
22
16
14
21
36
35
34
33
25
32
26
24
30
28
29
31
27
29
D-2297
60-40-3

Service Manual
STARTER (CONTD)
Figure 60-40-7
Disassembly
Figure 60-40-5
1
1
N-15021
Remove the frame (Item 1) [Figure 60-40-7] from the

magnetic switch.
N-15019
Figure 60-40-8
Remove the cable (Item 1) [Figure 60-40-5] from the
magnetic switch.
Mark the frame and magnetic switch (Item 2) [Figure 6040-5]
Figure 60-40-6
1
1
N-15022
Remove the screws (Item 1) from the brush cover (Item

2) [Figure 60-40-8].

N-15020
Remove the bolts (Item 1) [Figure 60-40-6].
60-40-4

Service Manual
STARTER (CONTD)
Figure 60-40-11
Disassembly (Cont'd)
Figure 60-40-9
2
1
1
1
N-15025
Remove the bearings (Item 1) [Figure 60-40-11] from

both ends of the armature.
N-15023
Figure 60-40-12
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 60-409].
NOTE: The brushes are non-replaceable. If the
brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
positive brushes).
Remove the brush holder (Item 3) [Figure 60-40-9] from
the end of the armature.
Figure 60-40-10
1
N-15026
Remove the bolts (Item 1) [Figure 60-40-12] from the

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

the frame.
60-40-5

Service Manual
STARTER (CONTD)
Figure 60-40-15
Figure 60-40-13
2
1
N-15029
Remove the idler gear (Item 1), rollers (Item 2) and

retainer (Item 3) [Figure 60-40-15].
1
N-15027
Figure 60-40-16
Remove the starter housing (Item 1) [Figure 60-40-13]
from the magnetic switch.
Figure 60-40-14
N-15042
In order to remove the snap ring from the pinon shaft, a

tube 0.605 inches (15,4 mm) in diameter by 2.0 inches
(50,8 mm) in length is needed [Figure 60-40-16].
1
N-15028
Remove the ball (Item 1) [Figure 60-40-14] from the

pinion shaft.
60-40-6

Service Manual
STARTER (CONTD)
Figure 60-40-19
Figure 60-40-17
1
N-15047

N-15045
Figure 60-40-20
Install the tube (Item 1) [Figure 60-40-17] in over the
running clutch.
Figure 60-40-18
2
4
3
1
N-15053
2
Remove the collar (Item 1), pinion (Item 2) spring (Item 3)
and spring seat (Item 4) [Figure 60-40-20].
N-15046
Press down on the starter carrier (Item 1) to extend the

pinion shaft. Press down on the pinion (Item 2) [Figure
60-40-18].
Press the collar (Item 3) [Figure 60-40-18] down to gain
access to the snap ring.
60-40-7

Service Manual
STARTER (CONTD)
Figure 60-40-23
Figure 60-40-21
N-15035

starter housing.
N-15033
Figure 60-40-24
Remove the pinion shaft (Item 1), and spring (Item 2)
[Figure 60-40-21] from the starter drive.
Figure 60-40-22
1
1
N-15030
Remove the spring (Item 1) [Figure 60-40-24] from the

magnetic switch.
N-15034
Remove the over running clutch (Item 1) [Figure 60-4022].
60-40-8

Service Manual
STARTER (CONTD)
Inspection And Repair
Figure 60-40-27
Figure 60-40-25
B-14455
N-15031
Inspect the brush cover for discoloration, indication the

starter has been overheated.
Remove the bolts (Item 1) [Figure 60-40-25] from the
magnetic switch cover.
Figure 60-40-26
Inspect the pinion teeth for wear and damage.

Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-27]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
Figure 60-40-28
N-15032
Remover the cover (Item 1), gasket (Item 2) and switch

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

touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-28]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.
60-40-9

Service Manual
STARTER (CONTD)
Figure 60-40-31
Inspection And Repair (Cont'd)

Figure 60-40-29
B-14460
Measure the segment mica depth (Item 1) [Figure 60-4031].
N-15037
Service Limit - 0.008 inch (0,2 mm)

Armature Winding Continuity Test: Use a circuit tester,
touch the probes to two commutator segments [Figure
60-40-29]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
replace the armature.
If it is worn, replace the armature.

Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using
#400 sand paper.
Figure 60-40-30
Figure 60-40-32
B-14458
N-15039
Commutator Run-Out Test: check the commutator runout as shown in [Figure 60-40-30].
Service Limit - 0.020 inch (0,4 mm)
Check the field windings for wear and damage.

Check all the connections for clean and tight solder
joints.
If the commutator exceeds the service limit, repair as

needed.
Field Winding Ground Test: Using a circuit tester, touch

one probe to the field winding end of the brush and the
other probe to the surface of the frame [Figure 60-4032]. There should be no continuity. If there is continuity,
the field windings are grounded.
Replace the field windings.
60-40-10

Service Manual
STARTER (CONTD)
should be no continuity. If there is continuity, replace or

repair.
Inspection and Repair (Cont'd)

Figure 60-40-35
Figure 60-40-33
1
N-15043
N-15040
Field Windings Continuity Test: Using a circuit tester,

touch one probe to the wire and the other probe to the
brush [Figure 60-40-33]. There must be continuity. If
there is no continuity, the field windings are opencircuited. Replace the yoke if the field windings have an
open circuit.
Inspect the over clutch (Item 1) [Figure 60-40-35], it

must rotate freely in the direction of the starter rotation
and lock in the opposite rotation.
Figure 60-40-34
N-15059
Inspect the brushes for wear and damage.

Replace the brush holder or yoke assembly if the
brushes are worn or damaged.
Check brush spring, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-40-34]. There
60-40-11

Service Manual
STARTER (CONTD)
Figure 60-40-37
Inspection and Repair (Cont'd)
50
The following tests should be done without the armature

assembly. Install the magnetic switch in the switch
housing.
M.T. . . .
Main Terminal to which the main cable from

the battery is connected.
C.....
C-Terminal to which the wire from the field

windings is connected.
50 . . . .
50-Terminal to which the wire from the starting switch or stator relay is connected.
M.T.
B-14470
NOTE: Each test should be performed a short time (3

to 5 seconds) to prevent the magnetic switch
winding from burning. Each test should be
performed with 12 volts.
Hold-In Test: With the same conditions as in the pull-in

test, open the connecting Terminal C [Figure 60-40-37].
The pinion should remain in the engaged position.
Figure 60-40-36
Figure 60-40-38
50
50
M.T.
M.T.
B-14471
B-14469
Pull-In Test: Connect the wires as shown in [Figure 6040-36]. When connecting Terminal C and M.T. are
closed, the pinion should engage.
Return Test: With the same conditions as in the hold-in

test, open the connecting Terminal 50 [Figure 60-40-38].
The pinion should return immediately.
60-40-12

Service Manual
STARTER (CONTD)
No Load Test
Figure 60-40-39
Ammeter
50
M.T.
C
Starter
B-14440
The following test should be done after reassembling the

starter:
Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the 50 terminal [Figure 60-40-39]. Connect
the negative wire tot he starter body. Using a jumper wire,
connect the 50 terminal to the main terminal.
The starter should show smooth and steady rotation
immediately after the pinion is engaged. It should draw
less than the specified current.
Service Limit - 220 Amp. Maximum Draw
60-40-13

Service Manual
STARTER (CONTD)
Figure 60-40-42
Assembly
Figure 60-40-40
1
2
N-15030
Install the spring (Item 1) [Figure 60-40-42] on the

magnetic switch.
N-15032
Figure 60-40-43
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
Install the switch plunger (Item 1), gasket (Item 2) and
cover (Item 3) [Figure 60-40-40] on the switch housing.
Figure 60-40-41
N-15035
Install the O-ring (Item 1) [Figure 60-40-43] in the starter

housing.
N-15031
Install the bolts (Item 1) [Figure 60-40-41].
60-40-14

Service Manual
STARTER (CONTD)
Figure 60-40-46
Assembly (Cont'd)
Figure 60-40-44
1
N-15042
In order to install the pinion and snap ring on the pinion

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

in the starter housing.
Figure 60-40-47
Figure 60-40-45
1
N-15044
N-15033
Install the tube (Item 1) [Figure 60-40-47] in the over

running clutch.
Install the spring (Item 1) and pinion shaft (Item 2)
[Figure 60-40-45] in the over running clutch.
60-40-15

Service Manual
STARTER (CONTD)
Figure 60-40-50
Assembly (Cont'd)
Place the starter drive on the bench, and press down on
the starter drive housing.
Figure 60-40-48
1
N-15056
Install the pinion (Item 1) [Figure 60-40-50].

Figure 60-40-51
N-15054
Install the spring seat (Item 1) [Figure 60-40-48] on the

pinion shaft.
Figure 60-40-49
1
N-15057
Install the collar (Item 1) [Figure 60-40-51].
N-15055
Install the spring (Item 1) [Figure 60-40-49].
60-40-16

Service Manual
STARTER (CONTD)
Figure 60-40-54
Assembly (Cont'd)
Figure 60-40-52
1
1
2
N-15041
Install the rollers (Item 1) [Figure 60-40-54] in the

retainer.
N-15047
Figure 60-40-55
Install the snap ring (Item 1). Pull the collar (Item 2)
[Figure 60-40-52] over the snap ring.
Figure 60-40-53
2
N-15029
1
Install the roller/retainer assembly (Item 1) [Figure 6040-55] on the starter housing.
N-15058
With the pinion shaft extended, extend and release the

pinion (Item 1) [Figure 60-40-53]. The pinion must return
to the fully retracted position.
Install the idler gear (Item 2) [Figure 60-40-55] over the

roller/retainer assembly.
60-40-17

Service Manual
STARTER (CONTD)
Figure 60-40-58
Assembly (Cont'd)
Figure 60-40-56
N-15026
Install the two bolts (Item 1) [Figure 60-40-58]. Tighten

the bolts to 60-104 in.-lb. (7-12 Nm) torque.
N-15028
Figure 60-40-59
Install the ball (Item 1) [Figure 60-40-56] in the pinion
shaft.
Figure 60-40-57
2
N-15025
Install the bearings (Item 1 & 2) [Figure 60-40-59] on

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

magnetic switch.
60-40-18

Service Manual
STARTER (CONTD)
Figure 60-40-62
Assembly (Cont'd)
Figure 60-40-60
N-15049
Install the frame (Item 1) [Figure 60-40-62] over the

armature.
N-15048
Install the armature (Item 1) [Figure 60-40-60] in the

magnetic switch housing.
NOTE: Make sure the tab (Item 2) [Figure 60-40-62] on

the frame is aligned with the slot in the
magnetic switch housing.
Figure 60-40-61
Figure 60-40-63
1
2
1
N-15050
N-15051A
Install the new O-rings (Item 1) [Figure 60-40-61] on

both ends of the frame.
Install the brush holder (Item 1) [Figure 60-40-63] on the

armature.
Using a needle nose pliers, pull the spring (Item 2) back
and install the brushes (Item 3) [Figure 60-40-63].
60-40-19

Service Manual
STARTER (CONTD)
Figure 60-40-66
Assembly (Cont'd)
Figure 60-40-64
N-15019
Install the cable (Item 1) [Figure 60-40-66] on the

terminal. Tighten the terminal to 4-7 ft.-lb. (5-9 Nm)
torque.
N-15052
Install the brush cover (Item 1) and screws (Item 2)

[Figure 60-40-64].
Figure 60-40-65
1
1
N-15020
Install the thru bolts (Item 1) [Figure 60-40-65]. Tighten

the bolts to 60-104 in.-lb. (7-12 Nm) torque.
60-40-20

Service Manual
FRONT LIGHTS
Figure 60-50-3
Bulb Removal And Installation

Figure 60-50-1
1
P-36802
Remove the harness connector (Item 1) [Figure 60-50-3]

from the bulb.
Figure 60-50-4
P-47570
Rotate the battery disconnect lever (Item 1) [Figure 6050-1] counterclockwise to disconnect the battery from the
system .
Figure 60-50-2
P-36803
Rotate the bulb retainer (Item 1) [Figure 60-50-4] and

remove.
P-36801
Remove the four screws (Item 1) [Figure 60-50-2] while

supporting the lamp.
60-50-1

Service Manual
FRONT LIGHTS (CONTD)

Bulb Removal And Installation (Contd)
Figure 60-50-5
P-36804
Remove the bulb (Item 1) [Figure 60-50-5] from the

lamp.
Figure 60-50-6
2
1
P-36805
Installation: Align the tangs (Item 1) on the bulb with the

notches (Item 2) [Figure 60-50-6] in the lamp. Install the
bulb.
NOTE: Do not touch the glass part of the bulb, any
dirt or oil will shorten the service life of the
bulb.
60-50-2

Service Manual
FRONT LIGHTS (CONTD)
Figure 60-50-9
Housing Removal And Installation

Figure 60-50-7
P-36905A
Remove the harness (Item 1) [Figure 60-50-9] from the

housing.
P-36801
Figure 60-50-10
Remove the four screws (Item 1) [Figure 60-50-7] while
supporting the lamp.
Figure 60-50-8
1
P-36906A
While supporting the housing assembly, remove the

mounting nut (Item 1) [Figure 60-50-10].
P-36902
Loosen the two screws (Item 1) and remove the wires

(Item 2) [Figure 60-50-8].
NOTE: Mark the wires for correct assembly.
Remove the front turn indicator light (See Bulb Removal
And Installation on Page 60-51-1.)
60-50-3

Service Manual
60-50-4

Service Manual
TURN INDICATOR LIGHTS (FRONT)
Figure 60-51-3

1
Figure 60-51-1
P-36809
Rotate the bulb (Item 1) [Figure 60-51-3] to unlock and

remove.
Figure 60-51-4
P-36806
Remove the two screws (Item 1) and remove the lens

(Item 2) [Figure 60-51-1].
1
Figure 60-51-2
2
2
P-36810
Installation: Align the tang (Item 1) on the bulb with the

slot (Item 2) [Figure 60-51-4] in the lamp. Insert the bulb
and rotate.
1
P-36808
Remove the lamp assembly (Item 1) from the housing.

Remove the two harness connectors (Item 2) [Figure 6051-2] and remove the lamp.
60-51-1

Service Manual
60-51-2

Service Manual
TURN INDICATOR LIGHTS (REAR)
Figure 60-52-3

Figure 60-52-1
1
P-36914
Apply slight side movement to unlock and remove the tail

light bulb (Item 1) [Figure 60-52-3].
P-36811
Remove the two screws (Item 1) and remove the lens

(Item 2) [Figure 60-52-1].
Figure 60-52-2
P-36812
Remove the turn indicator bulb (Item 1) [Figure 60-52-2]

while gently pushing in to unlock and remove the bulb.
60-52-1

Service Manual
60-52-2

Service Manual
CAB LIGHTS
Figure 60-53-3

Figure 60-53-1
2
P-36797
Support the lamp assembly (Item 1). Remove both

connectors (Item 2) [Figure 60-53-3] and remove the
lamp.
P-36795
Carefully remove the lamp guard (Item 1) [Figure 60-531].

Figure 60-53-4
Figure 60-53-2
P-36798
P-36796
Remove the bulb retainer clip (Item 1) [Figure 60-53-4].

Remove the two screws (Item 1) and lamp retainers (Item
2) [Figure 60-53-2].
60-53-1

Service Manual
CAB LIGHTS (CONTD)

Bulb Removal And Installation (Contd)
Figure 60-53-5
P-36799
Remove the bulb (Item 1) [Figure 60-53-5] from the lamp

housing.
Figure 60-53-6
2
P-36800
Installation: Align the tangs (Item 1) on the lamp

housing with the notches (Item 2) [Figure 60-53-6] on
the bulb. Insert the bulb.
NOTE: Do not touch the glass part of the bulb, any
dirt or oil will shorten the service life of the
bulb.
60-53-2

Service Manual
CAB LIGHTS (CONTD)
Figure 60-53-9
Housing Removal And Installation

Remove the bulb. (See Bulb Removal And Installation on
Page 60-53-1.)
1
Figure 60-53-7
1
P-36909

Figure 60-53-10
P-36907
1
Remove the harness (Item 1) [Figure 60-53-7] from the
lamp housing.
Figure 60-53-8
1
P-36910
Remove the housing (Item 1) [Figure 60-53-10] from the

operators cab.
P-36908
Remove the nut cover (Item 1) [Figure 60-53-8].
60-53-3

Service Manual
60-53-4

Service Manual
FUEL LEVEL SENDER
Figure 60-60-3

Remove the front left floor panel. (See Left Front Panel
Figure 60-60-1
P-40272
Remove the sender [Figure 60-60-3]

NOTE: Lower float arm to bottom of tank to remove
sender.
P-40270
Remove the wires (Item 1) [Figure 60-60-1].

Figure 60-60-2
P-40271
Remove the five bolts (Item 1) [Figure 60-60-2] from the

send unit.
Installation: Tighten bolts to 2-2.5 ft.-lb. (2.5-3.5 Nm)
torque.
60-60-1

Service Manual
60-60-2

Service Manual
INSTRUMENT PANEL
Figure 60-70-3

Stop the engine, engage parking brake. Rotate battery
disconnect lever counterclockwise to disconnect the
battery from the system.
Figure 60-70-1
P-50268
Remove the steering wheel (Item 1) [Figure 60-70-3]

Figure 60-70-4
P-50266
Remove the steering wheel cover (Item 1) [Figure 60-701]
1
Figure 60-70-2
1
1
2
P-50270
1
Remove the ten lower cover bolts (Item 1) [Figure 60-704] and lower cover (Item 2) [Figure 60-70-4].
P-50267
Remove the nut and washer (Item 1) [Figure 60-70-2].

torque.
60-70-1

Service Manual
INSTRUMENT PANEL (CONTD)
Figure 60-70-7
Figure 60-70-5
1
P-50275
Remove the instrument panel (Item 1) [Figure 60-70-7]

P-50271
Disconnect all connectors (Item 1) [Figure 60-70-5] from

the instrument panel.
NOTE: Mark the connectors for correct assembly.
Figure 60-70-6
1
1
P-50272
Remove the two panel mounting bolts (Item 1) [Figure

60-70-6].
60-70-2

Service Manual
FRONT WIPER
Figure 60-80-3

1
Figure 60-80-1
P-40995

Figure 60-80-4
P-40994
Unplug the front wiper motor connector (Item 1) [Figure

60-80-1] from the harness.
Figure 60-80-2
1
2
P-40996
Remove the arm (Item 1) and washer (Item 2) [Figure

60-80-4] from the shaft.
P-40992
Open the arm cover (Item 1) [Figure 60-80-2].
60-80-1

Service Manual
FRONT WIPER (CONTD)
Figure 60-80-7

Figure 60-80-5
1
P-40999
Remove the wiper arm (Item 1) [Figure 60-80-7].

P-40997
Figure 60-80-8
Open the wiper arm cover (Item 1) [Figure 60-80-5].
Figure 60-80-6
1
P-42000

P-40998
Have an assistant support the wiper motor,

Remove the arm retainer nut (Item 1) [Figure 60-80-6].
60-80-2

Service Manual
FRONT WIPER (CONTD)
Figure 60-80-11

Figure 60-80-9
P-42003
2
Remove the wiper motor [Figure 60-80-11].
P-42001
Remove the nut (Item 1) and spacer (Item 2) [Figure 6080-9].

Figure 60-80-10
P-42002
Remove the arm pivot nut (Item 1) [Figure 60-80-10].
60-80-3

Service Manual
60-80-4

Service Manual
REAR WIPER
Figure 60-90-3

Figure 60-90-1
P-40986
Remove the arm retainer nut (Item 1) [Figure 60-90-3].

1
Figure 60-90-4
P-40993
Disconnect the harness connector (Item 1) [Figure 6090-1].

Figure 60-90-2
1
P-40987
Remove the wiper arm (Item 1) [Figure 60-90-4] from the

wiper.
P-40985
Open the wiper arm cover (Item 1) [Figure 60-90-2].
60-90-1

Service Manual
REAR WIPER (CONTD)
Figure 60-90-7

Figure 60-90-5
P-40990
1
Remove the nut (Item 1) [Figure 60-90-7] and washer.
P-40988
Figure 60-90-8
Remove the two covers (Item 1) [Figure 60-90-5].
Figure 60-90-6
P-40991
Remove the wiper motor [Figure 60-90-8].

P-40989
Remove the nut (Item 1) and spacer (Item 2) [Figure 6090-6].
60-90-2

Service Manual
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-60-1
Checking Engine Compression . . . . . . . . . . . . . . . . . . . . . 70-60-1
Checking Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Checking Fuel Injector, Nozzles. . . . . . . . . . . . . . . . . . . . 70-60-11
Checking Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-60-6
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . 70-60-8
Fuel Injector Nozzles Removal And Installation. . . . . . . . . 70-60-9
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . 70-60-4
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . 70-60-3
Thermostat Removal And Installation . . . . . . . . . . . . . . . 70-60-12
Water Pump Removal And Installation . . . . . . . . . . . . . . 70-60-13
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Cable Removal And Installation. . . . . . . . . . . . . . . . . . . . . 70-20-2
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . 70-100-1
FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
70-01

Service Manual
ENGINE SERVICE (CONTD)

RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . 70-80-1
Camshaft Removal And Installation . . . . . . . . . . . . . . . . . 70-80-20
Checking Crankshaft Journal And Block Bearing . . . . . . 70-80-36
Checking Crankshaft Journal And Main Bearing . . . . . . . 70-80-37
Checking Engine Cylinder Bore . . . . . . . . . . . . . . . . . . . . 70-80-33
Checking Piston Top Clearance. . . . . . . . . . . . . . . . . . . . 70-80-13
Checking The End Play Of The Crankshaft . . . . . . . . . . . 70-80-39
Checking The Piston And Connecting Rod . . . . . . . . . . . 70-80-30
Combustion Chamber Removal And Installation . . . . . . . 70-80-18
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . 70-80-31
Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . 70-80-33
Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-38
Crankshaft Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-39
Crankshaft Front Seal Removal And Installation . . . . . . . . 70-80-5
Crankshaft Removal And Installation . . . . . . . . . . . . . . . . 70-80-34
Cylinder Head Disassembly And Assembly. . . . . . . . . . . 70-80-14
Cylinder Head Removal And Installation . . . . . . . . . . . . . 70-80-12
Engine Speed Control Plate Removal And Installation . . . 70-80-6
Engine Timing Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-80-40
Exhaust Manifold Removal And Installation. . . . . . . . . . . . 70-80-7
Fuel Camshaft Gear And Governor Shaft Gear . . . . . . . . 70-80-41
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . 70-80-22
Governor Fork Lever Removal And Installation . . . . . . . . 70-80-28
Governor Shaft Removal And Installation . . . . . . . . . . . . 70-80-25
Idle Limit And Fuel Limit Adjustment . . . . . . . . . . . . . . . . . 70-80-7
Idler Gear And Camshaft Gear . . . . . . . . . . . . . . . . . . . . 70-80-41
Idler Gear And Fuel Camshaft Gear . . . . . . . . . . . . . . . . 70-80-41
Idler Gear Removal And Installation . . . . . . . . . . . . . . . . 70-80-19
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . 70-80-24
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . 70-80-3
Piston Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-30
Piston Ring Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-31
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-32
Push Rod Removal And Installation . . . . . . . . . . . . . . . . 70-80-10
Rocker Arm Removal And Installation . . . . . . . . . . . . . . . . 70-80-9
Servicing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 70-80-15
Tappet Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-11
Timing Gear Backlash, Idler Gear And Crankshaft . . . . . 70-80-40
Timing Gear Case Cover Removal And Installation. . . . . . 70-80-1
Valve Cover Removal And Installation . . . . . . . . . . . . . . . . 70-80-8
Water Flange Removal And Installation. . . . . . . . . . . . . . 70-80-11
RUBBER DRIVE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
70-02

Service Manual
ENGINE SERVICE (CONTD)

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70-03
70-120-1
70-120-1
70-120-1
70-120-1

Service Manual
70-04

Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
PROBLEM
Slow cranking speed.
Engine will not start.
Difficult to start.
No power from engine.
Engine is mis-firing.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough.
Vibration.
High oil pressure.
Overheating.
Too much crankcase pressure.
Poor compression.
Start and stop.
CAUSE
1, 2, 3, 4
2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 23, 24, 25, 26, 28, 29
8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
4, 31, 32, 33, 34, 35, 37, 38, 39, 52
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
22, 27, 29, 30, 40, 49
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
9, 10, 11
70-10-1

Service Manual
TROUBLESHOOTING (CONT'D)
Chart (Cont'd)

1. Battery capacity low.
2. Bad electrical connections.
3. Faulty starter motor.
4. Incorrect grade of oil.
5. Low cranking speed.
6. Fuel tank empty.
7. Faulty stop control operation.
8. Plugged fuel line.
9. Plugged fuel filter.
10. Restriction in the air cleaner.
11. Air in the fuel system.
12. Faulty fuel injection pump.
13. Faulty fuel injectors.
14. Broken injection pump drive.
15. Incorrect injection pump timing.
16. Incorrect valve timing.
17. Poor compression.
18. Plugged fuel tank vent.
19. Incorrect grade of fuel.
20. Exhaust pipe restriction.
21. Cylinder head gasket leaking.
22. Overheating.
23. Cold running.
24. Incorrect tappet adjustment.
25. Sticking valves.
26. Incorrect high pressure fuel lines.
27. Worn cylinder bores.
28. Worn valve and seat.

29. Broken or worn piston rings.
30. Worn valve stems or guides.
31. Worn or damaged bearings.
32. Not enough oil in the oil pan.
33. Switch is defective.
34. Oil pump worn.
35. Relief valve is stuck open.
36. Relief valve is stuck closed.
37. Broken relief valve spring.
38. Faulty suction pipe.
39. Plugged oil filter.
40. Piston seizure.
41. Incorrect piston height.
42. Faulty engine mounting.
43. Incorrect alignment of flywheel.
44. Faulty thermostat.
45. Restriction in water jacket.
46. Loose alternator belt.
47. Plugged radiator.
48. Plugged breather pipe.
49. Plugged breather pipe.
50. Damaged valve stem deflectors.
51. Coolant level to low.
52. Plugged oil pump pipe strainer.
53. Broken valve spring.
70-10-2

Service Manual
ENGINE SPEED CONTROL
Remove washers and friction plates (Item 2) [Figure 7020-2].

Figure 70-20-3
Figure 70-20-1
2
1
P-50280
Remove rotating plate (Item 1) [Figure 70-20-3].
P-50264
Figure 70-20-4
Rotate the battery disconnect lever (Item 1) [Figure 7020-1] counterclockwise to disconnect the battery from
system.
Remove the seat (See Removal And Installation on Page

50-20-1.)
Remove the engine speed control lever, friction adjusting
nut and washer (Item 2) [Figure 70-20-1].
Installation: Do not over tighten the friction nut.
Figure 70-20-2
P-35384
Remove the four engine speed control mounting bolts

(Item 1) [Figure 70-20-4].
P-50279
Remove engine speed control lever and travel stop

washers as an assembly (Item 1) [Figure 70-20-2].
NOTE: Mark the position of all washers and friction
plates for correct assembly.
70-20-1

Service Manual
ENGINE SPEED CONTROL (CONTD)
Figure 70-20-6

Figure 70-20-5
1
P-35679
Remove the cable clevis pin (Item 1) [Figure 70-20-6].

P-35383
Figure 70-20-7
Remove the control lever assembly (Item 1) from the
cable (Item 2) [Figure 70-20-5].
NOTE: The cable is threaded into the engine speed
control housing.
Cable Removal And Installation

P-35678

disconnect the battery from system.
Remove the seat. (See Removal And Installation on
Page 50-20-1.)
Loosen cable jam nut (Item 1) [Figure 70-20-7]. Remove

the cable from mounting bracket.
Remove the cable.
Remove the engine speed control lever. (See Removal

Open engine cover. Remove right engine side cover.
(See Removal And Installation on Page 50-60-1.)
70-20-2

Service Manual
MUFFLER
Figure 70-30-3

Raise the lift arm and install the approved lift arm support
Open the engine cover.
Figure 70-30-1
P-36037
2
Remove the muffler [Figure 70-30-3].
P-35394
Remove the exhaust clamp (Item 1) and remove the two

mounting bolts (Item 2) [Figure 70-30-1].
Figure 70-30-2
P-35392
Remove the exhaust clamp (Item 1) [Figure 70-30-2].
70-30-1

Service Manual
70-30-2

Service Manual
AIR CLEANER
Remove the engine side cover from the right side.
Figure 70-40-1
2
P-35695
Loosen the hose clamp (Item 1) [Figure 70-40-1] and

remove from the turbo.
remove the hose from the air cleaner housing.
Figure 70-40-2
P-35696

Remove the air cleaner housing and intake hose from the
machine (Item 3) [Figure 70-40-1].
70-40-1

Service Manual
70-40-2

Service Manual
RADIATOR
Figure 70-50-2

Drain the coolant from the radiator. (See Coolant
Replacement on Page 10-90-1.)
Remove the grill. (See Removal And Installation on Page
50-40-1.)
Remove the oil cooler. (See Removal And Installation on

Page 30-20-1.)
on Page 50-50-1.)
Remove the air cleaner housing. (See Removal And
P-35686
Loosen the lower radiator hose clamp (Item 1) [Figure

70-50-2] and remove the hose.
Figure 70-50-3
Figure 70-50-1
1
P-50562
P-35687
Remove the two bolts and tubeline clamps (Item 1)

[Figure 70-50-3].
Loosen the upper radiator hose clamp (Item 1) [Figure

70-50-1] and remove the hose.
70-50-1

Service Manual
RADIATOR (CONTD)
Figure 70-50-4
P-50563
Remove the two bolts (Item 1) [Figure 70-50-4] from the

radiator bracket.
Remove the radiator bracket.
Figure 70-50-5
P-36000
Remove the mounting bolts (Item 1) [Figure 70-50-5]

from each side of radiator.
Remove the radiator.
70-50-2

Service Manual
ENGINE COMPONENTS AND TESTING
Figure 70-60-2
Checking Engine Compression

The tools listed will be needed to do the following
procedure:
MEL10630-Engine Compression Kit
MEL1546-Compression Test Adapter
Warm the engine.
Clean the area around the fuel injection pump and the
fuel injectors thoroughly.
Remove the fuel injector nozzels from the engine. (See
Fuel Injector Nozzles Removal And Installation on Page
70-60-9.)
P-33348
Connect the compression gauge to the adapter [Figure

70-60-2].
Figure 70-60-1
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 seconds
each time and take the average reading.
1
The correct compression for the engine is 412-469 PSI
(2840,7-3233,8 kPa) with no more than 10% difference
between the cylinders.
P-33287
Install the compression adapter (Item 1) [Figure 70-60-1]

in the cylinder head.
70-60-1

Service Manual
ENGINE COMPONENTS AND TESTING (CONTD)
Figure 70-60-5
Checking Glow Plugs

Figure 70-60-3
P13106
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-60-5].
P13101
Disconnect the engine harness wire and glow plug

connecting strap (Item 1) [Figure 70-60-3].
The reading must be 0.9 ohms. If the resistance is

infinite, the coil of the glow plug is broken and must be
replaced.
Figure 70-60-4
Repeat the procedure for each glow plug.

Replace each glow plug as needed. (See Glow Plug
P13102
Use an ohmmeter to check the glow plugs [Figure 70-604].
70-60-2

Service Manual
Figure 70-60-8
Glow Plug Removal And Installation

Rotate the battery disconnect switch to counterclockwise
to disconnect the power supply from the battery.
Figure 70-60-6
1
P13104
Loosen and remove the glow plugs (Item 1) [Figure 7060-8].

Installation: Tighten the glow plugs to 5-10 ft.-lb. (6,813,6 Nm).
P-33282
Figure 70-60-9
Disconnect the engine harness wire (Item 1) [Figure 7060-6] from the glow plug.
Figure 70-60-7
P-4307
2
Photo [Figure 70-60-9] shows the glow plug assembly
removed from the engine. Inspect the glow plugs and
replace when necessary.
P13101
Remove the nuts (Item 1) [Figure 70-60-7] from the top

of each glow plug.
Remove the glow plug connecting strap (Item 2) [Figure
70-60-7].
70-60-3

Service Manual
Figure 70-60-12
Fuel Shut-Off Solenoid Removal And Installation

Figure 70-60-10
P13109
Remove the solenoid from the engine [Figure 70-60-12]

and replace if needed.
P-35101
Disconnect the engine wiring harness (Item 1) [Figure

70-60-10] from the fuel shut-off solenoid.
Figure 70-60-11
1
1
P-35296
Remove two mounting bolts (Item 1) [Figure 70-60-11]

from the fuel shut-off solenoid.
NOTE: Engine is removed for photo clarity.
70-60-4

Service Manual
Figure 70-60-13
Checking Fuel Injection Pump

The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on
the performance of the engine. Be sure to clean the area
around the injection pump and injectors before removal
to prevent contamination from dirt.
WARNING

1
P13138
Connect a pressure gauge (Item 1) to the long leg of the

test tubeline (Item 2) [Figure 70-60-13] and tighten.
W-2072-0496
Connect the short leg of the tubeline to the fitting at the

fuel injection pump (Item 3) [Figure 70-60-13].

procedure:
Rotate the engine, with the starter, to increase the

pressure 1990-2133 PSI (13721-14707 kPa).
MEL1237-Adapter Fuel Line

MEL1173A-Pressure Gauge
With the pressure at 1990-2133 PSI (13721-14707 kPa),

it should hold this for 5 seconds or more.
To check the initial discarge pressure, remove the high

pressure tubelines from the fuel injection pump. (See
Fuel Injection Pump Removal And Installation on Page
70-60-6.)
If the time is less than the allowable limit, replace the

injection pump.
70-60-5

Service Manual
60-15] when removing or tightening the high

pressure fuel lines.
Fuel Injection Pump Removal And Installation

Installation: Tighten the high pressure fuel line nuts to

18-25 ft.-lb. (24-33 Nm).
Let the engine cool and clean the area around the
injection pump and injectors thoroughly.
Figure 70-60-16
Figure 70-60-14
P13119
Remove the high pressure fuel lines (Item 1) [Figure 7060-16] from the engine.
P13101
Disconnect the high pressure fuel lines (Item 1) [Figure

70-60-14] from the fuel injectors.
NOTE: Hold the banjo fitting nuts (Item 2) [Figure 7060-14] when removing or tightening the high
Remove the fuel shut-off solenoid (Item 2) [Figure 70-6016]. (See Fuel Shut-Off Solenoid Removal And
Figure 70-60-17

18-25 ft.-lb. (24-33 Nm).
1
1
Figure 70-60-15
1
1
P13126
Remove the six mounting bolts (Item 1) [Figure 70-6017] from the intake manifold. Remove the intake manifold
from the engine.
2
P13105
Installation: Replace the manifold gasket. Tighten the

mounting bolts to 16-20 ft.-lb. (22-27 Nm) torque.
NOTE: Hold the banjo fitting nuts (Item 2) [Figure 7070-60-6

Service Manual
Figure 70-60-20
Fuel Injection Pump Removal And Installation

(Contd)
2
Figure 70-60-18
1
2
2
P13128
P13127
Disconnect the fuel inlet hose (Item 1) [Figure 70-60-18]

from the injection pump.
Installation: The fuel rack pin (Item 1) [Figure 70-60-19]

on the injection pump must be aligned with the notch
(Item 1) [Figure 70-60-20] located inside the injection
pump chamber. Use the throttle lever (Item 2) [Figure
70-60-20] on the side of the injection pump chamber to
align the notch.
Figure 70-60-21
Remove the four mounting bolts (Item 2) [Figure 70-6018] from the top of the injection pump.
Installation: Tighten the mounting bolts to 16-20 ft.-lb.
(22-27 Nm) torque.
Figure 70-60-19
1
1
P13130
Install the shim(s) (Item 1) [Figure 70-60-21] on the

injection pump mounting surface. See Fuel Injection
Pump Timing on Page 70-60-8 for information on number
of shims used.
P13129
Install the injection pump in the engine.

Remove the injection pump from the engine [Figure 7060-19].
70-60-7

Service Manual
Turn the flywheel counterclockwise until fuel flows from

the delivery valve holder and into the plastic tube.

Fuel Injection Pump Timing
Continue rotating the engine slowly until the fuel begins

to rise in the plastic tube (Item 1) [Figure 70-60-22].
IMPORTANT
Figure 70-60-23
Do not attempt to maintain or adjust unless you are

trained and have the correct equipment.
I-2028-0289
Timing the injection pump is done by changing the

number of shims between the injection pump and the
injection pump mounting surface.
1
Remove the engine assembly. (See Removal And

Remove flywheel housing.
(See
Removal
And
Remove starter. (See Removal And Installation on Page

60-40-1.)
Disconnect the high pressure fuel lines from the injection
pump and the injectors. (See Fuel Injection Pump
Remove the fuel injectors. (See Fuel Injection Pump
P-35295
At this point look at the timing mark (located on the

flywheel) for proper alignment (Item 1) [Figure 70-60-23]
When the timing mark is aligned as shown the timing is
correct for the injection pump, which is 18-20 degrees
B.T.D.C.
Figure 70-60-24
Remove the fuel shut-off solenoid. (See Fuel Shut-Off

Solenoid Removal And Installation on Page 70-60-4.)
Figure 70-60-22
P13130
Add or subtract shim(s) (Item 1) [Figure 70-60-24] as

needed to adjust the fuel delivery timing.
Shims are available in thickness of 0.20 mm, 0.25 mm
and 0.30 mm. Combine these shims for adjustments.
P13132
Install a short plastic tube (Item 1) [Figure 70-60-22] in

the number one cylinder port of the injection pump. The
tube should fit tight in the port and point upward.
Addition of shim(s) (0.0020 inch, 0.05 mm) delays the

injection timing by approximately 0.5 degree.
Move the fuel lever on the injection pump to full fuel

position (or full throttle).
Reduction of shim(s) (0.0020 inch, 0.05 mm) advances

the injection timing by approximately 0.5 degree.
70-60-8

Service Manual
NOTE: Hold the banjo fitting nuts (Item 2) [Figure 7060-25] when removing or tightening the high
Fuel Injector Nozzles Removal And Installation

18-25 ft.-lb. (24-33 Nm).
WARNING
Figure 70-60-26

W-2072-0496
These are some engine problems caused by damaged

injector nozzles.
2
The engine is hard to start or will not start
Engine operation is not smooth.
The engine will not idle correctly.
Bad engine performance.
The engine exhaust smoke is black, white or blue.
P13105

70-60-26] from the injection pump.
Remove the injector nozzles from the engine and test the
injectors only after engine performance shows that there
may be damage.
NOTE: Hold the delivery valve holder nuts (Item 2)

[Figure 70-60-26] when removing or
tightening the high pressure fuel lines.

Let the engine cool and clean the area around the
injection pump and injectors thoroughly.

18-25 ft.-lb. (24-33 Nm).
Figure 70-60-27
Figure 70-60-25
2
2
P13119
P13101
Remove the high pressure tubelines [Figure 70-60-27].

70-60-9

Service Manual

Fuel Injector Nozzles Removal And Installation
(Contd)
Figure 70-60-28
2
1
1
P13121
Remove the fuel return hoses (Item 1) [Figure 70-60-28]

from the banjo fittings.
Remove the three banjo fitting nuts (Item 2) [Figure 7060-28] from the fuel injector nozzles.
Remove the banjo fittings from the fuel injectors.
Figure 70-60-29
P13120
Remove the fuel injector nozzles from the engine [Figure

70-60-29].
Installation: Tighten the injectors to 22-36 ft.-lb. (29-49
Nm) torque.
70-60-10

Service Manual
Figure 70-60-31
Checking Fuel Injector, Nozzles

procedure:
OEM 1064-Injector Nozzle Tester
OEM 1065-Accessory Set
Figure 70-60-30
A-2513
Connect the injector nozzle to the tester with the nozzle

in the down position [Figure 70-60-31].
Slowly operate the hand lever of the test pump until the
injector nozzle vavle opens. The pressure must be 19902133 PSI (13721-14707 kPa).
If the pressure is not correct, disassemble the injector

nozzle and add or remove spacers (Item 1) [Figure 7060-30].
B-14862A
NOTE: You can adjust the release pressure of the

injector nozzle by adding or removing
spacers (Item 1) from the top of the nozzle
spring (Item 2) [Figure 70-60-30]. The release
pressure must be 1990-2133 PSI (13721-14707
kPa).
WARNING
NOTE: When assembling the injector nozzle, tighten

the nozzle nut (Item 3) [Figure 70-60-30] to 3651 ft.-lb. (49-69 Nm) torque. Any higher
torque will cause slow action of the valve.
Check for inside leakage. Operate the hand lever until
the pressure is almost enough to open the injector valve.
Make a record of the pressure. Release the hand lever.
Check the pressure decrease to 10 seconds. The nozzle
has damage if the pressure decrease i smore than 740
PSI (5162 kPa) in 10 seconds.
W-2072-0496
70-60-11

Service Manual
Figure 70-60-34
Checking Fuel Injector, Nozzles (Contd)
Figure 70-60-32
2
Spring
CORRECT
WRONG
Pressure
Pin
Holder
Nozzle
Body
Needle
Valve
P13267
Remove thermostat (Item 1) [Figure 70-60-34] and

replace if necessary.
A-2621
Check the spray pattern of the nozzle for the following

conditions [Figure 70-60-32].
Always replace the thermostat gasket (Item 2) [Figure

70-60-34].
Fuel comes out the side of the nozzle.

Has fuel drops coming from the nozzle.
Has a flow (solid stream) coming from the nozzle.
Any of the above conditions show a defect or a dirty
injector nozzle. Clean the nozzle that does not operate
correctly and check again.
Thermostat Removal And Installation
Figure 70-60-33
P-35094

the thermostat housing.
Installation: Tighten bolts to 87-100 in.-lb. (9,8-11,3
Nm) torque.
70-60-12

Service Manual
Figure 70-60-36
Water Pump Removal And Installation
Figure 70-60-35
1
1
1
1
1
1
P13265
Remove the seven mounting bolts (Item 1) [Figure 7060-36] from the water pump.
P13013
Remove the four mounting bolts (Item 1) from the belt

pulley (Item 2) [Figure 70-60-35] and remove the pulley
from the water pump.
NOTE: The bolts may vary in length. Keep the bolts in
their original location.
Installation: Tighten the mounting bolts to 87-100 in.-lb.

(9,8-11,3 Nm) torque.
Remove the water pump from the engine.
Check the water pump for wear and replace if needed.
Thoroughly clean the area between the water pump and
the block flange.
Install a new water pump gasket and install the water
pump.
70-60-13

Service Manual
70-60-14

Service Manual
ENGINE
Figure 70-70-3

2
Figure 70-70-1
P-35100
Disconnect the engine temperature wire (Item 1) [Figure

70-70-3].
Disconnect the wire (Item 2) [Figure 70-70-3] from the
glow plugs.
P-47569
Rotate the battery disconnect switch (Item 1) [Figure 7070-1] to the position shown, to disconnect the power
supply from the battery.
NOTE: Mark all wires for correct installation.

Figure 70-70-4

on Page 50-50-1.)
Remove the air cleaner housing. (See Removal And
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
1
Remove the radiator. (See Removal And Installation on

Page 70-50-1.)
Figure 70-70-2
P-35681
Disconnect the wiring harness connector (Item 1) [Figure

70-70-4] from the fuel shutoff solenoid.
2
P-35683
Remove the four mounting bolts (Item 1) and rear

mounting bolt (Item 2) [Figure 70-70-2] and remove the
exhaust pipe.
70-70-1

Service Manual
ENGINE (CONTD)
Figure 70-70-7

Figure 70-70-5
1
P-35678
1
Loosen the jam nut (Item 1) [Figure 70-70-7] and
remove the engine speed control cable.
P-35680

remove the fuel line.
NOTE: Mark the location of the jam nut for correct

assembly.
Figure 70-70-8
NOTE: Install caps and plugs.

Figure 70-70-6
P-35677
1
Remove the ground strap (Item 1) [Figure 70-70-8].
P-35679
Remove the engine speed control cable (Item 1) [Figure

70-70-6].
70-70-2

Service Manual
ENGINE (CONTD)
Figure 70-70-11

Figure 70-70-9
P-35674
1
Disconnect the wire (Item 1) [Figure 70-70-11] from the
oil pressure sending unit.
P-35676
Figure 70-70-12
Remove the fuel return line (Item 1) [Figure 70-70-9]
from the tee fitting.
NOTE: Install caps and plugs.
Figure 70-70-10
P-35109
Disconnect the connector (Item 1) [Figure 70-70-12]

from the starter.
Remove the two wires (Item 2) [Figure 70-70-12] from
the starter.
P-35107
Disconnect the two wires (Items 1) [Figure 70-70-10]

from the alternator.
Remove the two front floor panels. (See FLOOR

PANELS on Page 50-30-1.)
70-70-3

Service Manual
ENGINE (CONTD)
Figure 70-70-15

Figure 70-70-13
P-35644
Using a chain and hoist, lift and support the engine

[Figure 70-70-15].
P-35672
Figure 70-70-16
Using a chain and hoist, lift and support the hydrostatic
pump assembly [Figure 70-70-13].
Figure 70-70-14
1
1
1
P-35647
Remove the two engine mounting bolts (Item 1) [Figure

70-70-16] from each side of the engine.
P-35670
Remove the hydrostatic pump mounting bolt (Item 1)

[Figure 70-70-14] (both sides).
70-70-4

Service Manual
ENGINE (CONTD)
Figure 70-70-19

Figure 70-70-17
P-35302
Remove the mount (Item 1) [Figure 70-70-19].

P-35645
Replace as needed.
Lift and remove the engine assembly [Figure 70-70-17].
Mount Replacement
Figure 70-70-18
P-35301
With the engine removed, remove the bottom motor

mount nut (Item 1) [Figure 70-70-18].
70-70-5

Service Manual
70-70-6

Service Manual
RECONDITIONING THE ENGINE
Figure 70-80-3
Timing Gear Case Cover Removal And Installation
Figure 70-80-1
1
1
1
1
1
1
1
1
1
P13270
NOTE: The bolts may vary in length. Keep the bolts in

their original location.
P13266
Remove crankshaft pulley bolt (Item 1) [Figure 70-80-1].

from the timing case cover, and remove the cover.
Installation: Tighten crankshaft pulley bolt to 101-116 ft.lb. (137-157 Nm) torque.
Installation: Tighten the mounting bolts to 7.2-8.3 in.-lb.

(9,8-11,3 Nm) torque.
Figure 70-80-2
Clean the surface of timing cover.

Figure 70-80-4
1
2
P13268
1
P13271
Remove the crankshaft pulley (Item 1) [Figure 70-80-2]

from the crankshaft.
Installation: When installing the crankshaft pulley on the
crankshaft, align the timing marks (Item 2) [Figure 7080-2].
Remove the timing cover gasket (Item 1) [Figure 70-804].
70-80-1

Service Manual
RECONDITIONING THE ENGINE (CONTD)
Figure 70-80-7
Timing Gear Case Cover Removal And Installation

(Contd)
Figure 70-80-5
1
P13279
1
1
Installation: Install the timing case cover, then install the

crankshaft collar with the tapered side (Item 1) [Figure
70-80-7] toward the O-ring.
1
P13272
Figure 70-80-8
Remove the O-rings (Item 1) [Figure 70-80-5] from the
timing case cover.
Figure 70-80-6
P13276
P13345
Remove the crankshaft collar (Item 1) [Figure 70-80-6]

from the crankshaft.
NOTE: The idle adjustment spring (Item 1) [Figure 7080-8] is located inside the timing case cover.
Be careful not to damage. Replace if
necessary. (See Idle Limit And Fuel Limit
Adjustment on Page 70-80-7.)
NOTE: The collar may stay in the gearcase cover,

when the cover is removed.
crankshaft and replace with a new O-ring.
70-80-2

Service Manual
Figure 70-80-11
Oil Pump Removal And Installation

Remove timing gear case cover. (See Timing Gear Case
Cover Removal And Installation on Page 70-80-1.)
1
Figure 70-80-9
1
1
P13275
2
1
Replace the front crankshaft seal (Item 1) [Figure 70-8011].
1
1
Figure 70-80-12
P13272

from the back of the oil pump.
(7,9-12,8 Nm) torque.
Remove the rear cover (Item 2) [Figure 70-80-9].
Figure 70-80-10
P13317
Measure the clearance between the lobes of the inner

rotor and the outer rotor with a feeler gauge [Figure 7080-12].
The clearance between inner rotor and outer is 0.00240.0071 inch (0,06-0,18 mm), with an allowable limit of
0.0118 inch (0,3 mm). If the clearance exceeds the
allowable limit, replace the oil pump rotor assembly.
P13273
Remove the oil pump rotor assembly (Item 1) [Figure 7080-10] and check for wear.
70-80-3

Service Manual
Figure 70-80-15
Oil Pump Removal And Installation (Contd)

Figure 70-80-13
P13272
Install the oil pump cover (Item 1) [Figure 70-80-15] and

tighten the cover bolts to 70-113 in.-lb. (7,9-12,8 Nm
torque.
P13316
Measure the clearance between the outer rotor and the

pump body with a feeler gauge [Figure 70-80-13].
Figure 70-80-16
The clearance between outer rotor and the pump body is

0.0039-0.0071 inch (0,100-0,180 mm) with an allowable
limit of 0.0213 inch (0,54 mm). If the clearance exceeds
the allowable limit, replace the oil pump rotor assembly.
Figure 70-80-14
P13273
Remove the cover and measure the width of the pressed

plastic gauge (Item 1) [Figure 70-80-16].
The end clearance between the inner rotor and the oil
pump cover should be 0.0098-0.0295 inch. (0,025-0,75
mm) with an allowable limit of 0.0089 inch. (0,225 mm).
P13273
Put a strip of plastic gauge (Item 1) [Figure 70-80-14]

onto the rotor face.
If the clearance exceeds the allowable limit, replace the

oil pump rotor assembly.
70-80-4

Service Manual
Figure 70-80-19
Crankshaft Front Seal Removal And Installation

Figure 70-80-17
1
P-13278
Remove the crankshaft collar (Item 1) [Figure 70-80-19].

P13266
Figure 70-80-20
Remove the crankshaft pulley bolt (Item 1) [Figure 7080-17] and remove the crankshaft pulley.
Installation: Tighten crankshaft pulley bolt to 101-116 ft.lb. (137-157 Nm) torque.
2
1
Figure 70-80-18
P13277

crankshaft.
1
Remove the front seal (Item 2) [Figure 70-80-20] from

the timing gear case cover.
P13268
Replace the seal.

When installing the crankshaft pulley on the crankshaft,
be sure the timing marks are aligned (Item 1) [Figure 7080-18].
Replace the O-ring.
70-80-5

Service Manual
Figure 70-80-23
Crankshaft Front Seal Removal And Installation

(Contd)
Figure 70-80-21
1
2
3
P-35300
Remove the speed control plate from the mounting bolts

and unhook the governor spring (Item 1) from the
governor compensation lever (Item 2) [Figure 70-80-23].
P13279
Install the crankshaft collar with the tapered side (Item 1)

[Figure 70-80-21] toward the O-ring.
Check the return spring (Item 3) [Figure 70-80-23] and

internal parts for wear and replace if needed.
Figure 70-80-24
Engine Speed Control Plate Removal And Installation

Figure 70-80-22
1
1
1
P13285
Remove start spring (Item 1) [Figure 70-80-24].
P-35298
Check for wear and replace if needed.

Remove the mounting bolts and nuts (Item 1) [Figure 7080-22] from the engine speed control plate.
Installation: Tighten mounting bolts and nuts to 87-100
in-lb. (9,8-11,3 Nm) torque.
70-80-6

Service Manual
Figure 70-80-27
Idle Limit And Fuel Limit Adjustment
Figure 70-80-25
P13286
2
Remove the exhaust manifold from the engine and
remove the exhaust manifold gasket (Item 1) [Figure 7080-27] from the engine.
P-35102
The idle limit adjustment (Item 1) and the fuel limit

adjustment (Item 2) [Figure 70-80-25] have sealed caps.
Installation: Replace the exhaust manifold gasket.

Tighten the mounting nuts to 12-14 ft.-lb. (16-19 Nm)
torque.
NOTE: See your authorized Kubota dealer for proper

adjustment before removing the caps.
Exhaust Manifold Removal And Installation
Figure 70-80-26
1
1
1
P-35299
Remove the mounting nuts (Item 1) [Figure 70-80-26]

from the exhaust manifold.
70-80-7

Service Manual
Figure 70-80-30
Valve Cover Removal And Installation

Remove the air cleaner assembly (See Removal And
Figure 70-80-28
2
1
1
P13293
Remove the breather element plate (Item 1) [Figure 7080-30].

Remove the breather element (Item 2) [Figure 70-8030].
P-35093
Check element and clean or replace as needed.

Remove the nuts (Item 1) [Figure 70-80-28] from the
valve cover.
Installation: Tighten valve cover nuts to 5.1-6.5 in.-lb.
(6,9-8,8 Nm) torque.
Remove the valve cover.
Figure 70-80-29
P13295
Remove the mounting bolts (Item 1) from the breather oil

shield (Item 2) [Figure 70-80-29].
(2,7-4,1 Nm) torque.
70-80-8

Service Manual
Figure 70-80-33
Rocker Arm Removal And Installation

Figure 70-80-31
1
P13312
Remove the rocker arm shaft washers (Item 1) [Figure

70-80-33].
P13288
Remove the engine. (See Removal And Installation on

Page 70-40-1.)
Remove the rocker arm assembly (Item 2) [Figure 7080-33] from the rocker arm shaft.
Figure 70-80-34
Remove the valve cover. (See Valve Cover Removal And

Remove the three mounting nuts from the rocker arms
bracket (Item 1) [Figure 70-80-31], and remove the
rocker arms from the head.
Figure 70-80-32
P13308
Measure the outside diameter of the rocker arm shaft.

[Figure 70-80-34].
The measurement should be
(11,973-11,984 mm) in diameter.
0.4714-0.4718
inch
P13311

the rocker arm shaft.
70-80-9

Service Manual

Rocker Arm Removal And Installation (Contd)
Make sure the piston is on top dead center when making

the adjustment and adjust the clearance to 0.005-0.007
inch (0,12-0,18 mm).
Figure 70-80-35
Push Rod Removal And Installation

Figure 70-80-37
P13314
P13291
Measure the inside diameter of the rocker arm [Figure

70-80-35].
Remove the six push rods (Item 1) [Figure 70-80-37].

The measurement should be
(12,000-12,018 mm) in diameter.
0.4724-0.4731
inch
NOTE: Mark the push rods to prevent interchanging
when installing.
The clearance between the rocker arm shaft and the

rocker arm should be 0.006-0.0018 inch (0,016-0,045
mm) with an allowable limit 0.0039 (0,10 mm).
Check for wear and replace if needed.
If the measurement exceeds the allowable limit replace

the rocker arm or rocker arm shaft.
Figure 70-80-36
1
P13289
Installation: Tighten the three rocker arm mounting nuts

(Item 1) [Figure 70-80-36] to 16-20 ft.-lb. (22-27 Nm)
torque.
Adjust the valve clearance using a feeler gauge (Item 2)
[Figure 70-80-36].
70-80-10

Service Manual
Water Flange Removal And Installation
Tappet Removal And Installation
Figure 70-80-39
Figure 70-80-38
1
1
1
1
P13296
P13294
Remove the four mounting bolts (Item 1) [Figure 70-8039] from the engine head.
Remove the six tappets (Item 1) [Figure 70-80-38] from
the crankcase.
NOTE: Mark the tappets to prevent interchanging
when installing.
Remove water flange from the head.

Installation: Replace the water flange gasket as needed.
Tighten the mounting bolts to 87-100 in.-lb. (9,8-11,3
Nm) torque.
Check the tappets for wear. The inside diameter of the

tappet guide is 0.787-0.7882 inch (20,000-20,021 mm).
The outside diameter of the tappet is 0.7858-0.7866
(19,959-19,980 mm).
The clearance between the tappet and the guide is
0.008-0.0024 inch (0,020-0,062 mm) with an allowable
limit 0.0028 inch (0,07 mm).
If wear exceeds the allowable limit, replace the tappets.
NOTE: If the tappets have to be changed because of
excess wear. Check the camshaft for wear
and replace if needed. (See Camshaft
70-80-11

Service Manual
Figure 70-80-42
Cylinder Head Removal And Installation

Removal
Figure 70-80-40
1
A-2773
Put oil on the cylinder head bolts and tighten to 47-51 ft.lb. (64-69 Nm) torque. Use the tightening sequence as
shown in [Figure 70-80-42]. Allow the head to set for at
least a 1/2 hour. Then check the torque of the head bolts
again using the sequence shown in [Figure 70-80-42].
1
P13290
Remove the fourteen mounting bolts (Item 1) [Figure 7080-40] and remove the head.
Installation
Figure 70-80-41
2
1
P13403
Clean the head and the block.

Replace the head gasket (Item 1) and O-ring (Item 2)
[Figure 70-80-41].
70-80-12

Service Manual
Figure 70-80-44
1
Checking Piston Top Clearance
Remove the cylinder head. (See Cylinder Head Removal

Figure 70-80-43
P13300
Figure 70-80-45
2
2
P13297
Bring the piston (Item 1) [Figure 70-80-43] to top dead

center.
Fasten a 0.06 inch (1,5 mm) diameter by 0.20-0.28 inch
(5,1-7,1 mm) piece of solder (Item 2) [Figure 70-80-43]
to four spots on the piston with grease.
Put the piston to bottom dead center.
Install the cylinder head and tighten the cylinder head
bolts to specification. (See Cylinder Head Removal And
Turn the crankshaft until the piston goes over top dead
center.
P13299
Remove the cylinder head and measure the squeezed

solder wire (Item 1) [Figure 70-80-44] & [Figure 70-8045].
The top clearance between the piston and the head
should be 0.0217-0.0276 inch (0,55-0,70 mm).
If the measurement is not within specified value, check
the oil clearance of the crankpin journal and the piston
pin. (See Crankshaft Removal And Installation on Page
70-80-34.) Also check the oil clearance between the
crankshaft journals and the crankshaft bearings. (See
Checking Engine Cylinder Bore on Page 70-80-33.)
70-80-13

Service Manual
Assembly
Cylinder Head Disassembly And Assembly
Install the valves.
Disassembly
Put oil on the valve seal and install the valve seal on the
valve.
Figure 70-80-46
Install the valve spring and the retainer.
1
Install the spring collet and the valve cap.
P13302
Figure 70-80-47
Spring
Collets
Cap
Valve
Seal
Retainer
P13303
Using a valve compression tool (Item 1) [Figure 70-8046], remove the valve cap and the valve spring collet
[Figure 70-80-47].
Remove the seal on the valve and remove the valve from
the cylinder head.
Repeat this procedure for all valves.
70-80-14

Service Manual

Servicing The Cylinder Head
The correct width of the valve seat for both intake and
exhaust, is 0.083 inch (2,1 mm). The seat angle is 45 for
the exhaust valve and 60 for the intake valve.
Clean the surface of the cylinder head.
Figure 70-80-50
C
Figure 70-80-48
A
B
D
Corrected
Surface of
Valve Seat
Valve Contrating
Width
D
0.083 (2,1 mm)
Uncorrected
Surface of
Valve Seat
A-45 cutter
B-15 cutter
C-65 or 70 cutter
D-45 valve surface
MC-2185
P13298
Use the following steps to grind the valve seats [Figure

70-80-50].
Put a straight edge on the cylinder head [Figure 70-8048].
Put a feeler gauge (Item 1) [Figure 70-80-48] between
the straight edge and the surface of the cylinder head.
The maximum distortion of the cylinder head surface is
0.0019 inch ( 0.05 mm).
If the measurement is more than the specification,
remove the combustion chambers (See Combustion
Chamber Removal And Installation on Page 70-80-18),
then grind the cylinder head.
Item A-Use a 45 cutter to grind the surface of the valve

seat.
Item B-Use a 15 cutter to grind the front surface of the
valve seat.
Item C-Use A 65 or 70 cutter to grind the rear surface of
the valve seat to finish the seat of a 0.083 inch (2,1 mm)
width.
Item D-Grind the valve surface to a 45 angle.
Clean the surface of the valve seat area.

Figure 70-80-49
P13306
Measure the width of the valve seat [Figure 70-80-49].

70-80-15

Service Manual

Servicing The Cylinder Head (Contd)
The measurement must be 0.0014-0.0025 inch (0,0350,065 mm). Replace the valve guide and valves as
needed.
Figure 70-80-51
Figure 70-80-53
P13305
P13301
Install the valve in the seat and check the depth [Figure
70-80-51].
The specification for the depth of the valve is 0.00200.0060 (-0,05-0,15 mm). Allowable limit 0.016 inch (0,4
mm).
Measure the valve spring [Figure 70-80-53]. The length

of the spring must be 1.457-1.476 inch (37,0-37,5 mm).
Replace the valve spring if it does not meet the
specification.
Figure 70-80-54
NOTE: If the measurement is more than the

specifications add the correct thickness
washer under the valve spring to keep the
correct tension on the spring.
Clean the valve guide.
Install the valve in the cylinder head.
Figure 70-80-52
P13304
Check the valve spring with a square to make sure it is

straight [Figure 70-80-54]. Replace the spring if it is not
straight.
P13310
Install a dial indicator gauge (Item 1) [Figure 70-80-52].

Measure the clearance of the valve guide and the valve.
70-80-16

Service Manual

Servicing The Cylinder Head (Contd)
Figure 70-80-55
A-2759
Put the valve spring in a tester [Figure 70-80-55].

Push down on the spring 1.22 inches (31 mm). The
compression load must be 26.4 lbs. (11,97 kg). Replace
the valve spring if it does not meet these specifications.
70-80-17

Service Manual
Figure 70-80-58
Combustion Chamber Removal And Installation

Figure 70-80-56
P13290
Remove the combustion chamber by using a blunt punch

through the injector ports (Item 1) [Figure 70-80-58]. Tap
the punch with a hammer and remove the combustion
chamber.
P13305
Locate the combustion chamber (Item 1) [Figure 70-8056] in the head.
Figure 70-80-59
NOTE: Mark the combustion chambers so they do

not get interchanged between cylinders.
Figure 70-80-57
3
1
2
1
P13467
P13467
4
Grind the cylinder head.
3
Grind the same amount of material from the combustion
chamber at points (Item 1 & 2) [Figure 70-80-59].
B-15124
Locate the notch on the combustion chamber edge (Item

1) (inset). Scribe a line (Item 2) [Figure 70-80-57] at that
point on the cylinder head for locating purposes.
Installation: Install two 9 mm dowels in the head bolt

holes (Item 3). Place a straight edge against the dowels
and scribe a line (Item 4) [Figure 70-80-57].
Align the notch on the combustion chamber (Item 1) with
the scribe line on the head (Item 4) [Figure 70-80-57],
and install the chamber.
70-80-18

Service Manual
Figure 70-80-62
Idler Gear Removal And Installation
Figure 70-80-60
2
1
P13346

from the idler shaft.
P13345
Remove the shaft.

Remove the timing gear case cover. (See Timing Gear
Case Cover Removal And Installation on Page 70-80-1.)
Figure 70-80-63
Remove the crankshaft collar (Item 1) and O-ring (Item 2)

[Figure 70-80-60].
Figure 70-80-61
1
P13368
2
With a micrometer measure the outside diameter of the
idler gear shaft (Item 1) [Figure 70-80-63].
P13343
The measurement should

(25,967-25,980 mm).
be
1.0233-1.0228
inch

the idler gear shaft.
Remove the flat washer.
Remove the idler gear (Item 2) [Figure 70-80-61].
70-80-19

Service Manual
Remove the mounting bolts from the camshaft mounting

plate.
Idler Gear Removal And Installation (Contd)

(9,8-11,3 Nm) torque.
Figure 70-80-64
Remove the camshaft.

1
Figure 70-80-66
P13365
2
Check the inside diameter of the idler gear bushing (Item
1) [Figure 70-80-64]. The measurement should be
1.0236-1.0244 inch (26,000-26,021 mm), with an
allowable limit of 0.0039 inch (0,10 mm).
busing.
Align the oil hole in bushing (Item 2) [Figure 70-80-64]
with oil hole in sprocket, when installing the new bushing.
P13367
Check the key (Item 2) [Figure 70-80-66] from the

camshaft.
Check the camshaft gear (Item 1) [Figure 70-80-66] and
the key way in the gear and the camshaft for wear and
replace if needed.
Camshaft Removal And Installation

Remove the tappets from the block. (See Tappet
Figure 70-80-65
1
P13344
Align the holes (Item 1) [Figure 70-80-65] in the gear on

the camshaft with the mounting plate bolts.
70-80-20

Service Manual
Figure 70-80-69

Figure 70-80-67
P13347
Figure 70-80-70
P13363
Support the camshaft with V-blocks [Figure 70-80-67].

Measure the height of the intake and exhaust cams at
their highest point with a micrometer.
The measurement should be:
Intake
Allowable Limit
Exhaust
Allowable Limit
1.1339 inch (28,80 mm)

1.1319 inch (28,75 mm)
1.1417 inch (29,00 mm)
1.1398 inch (28,95 mm)
P13348
If the measurement is less than the allowable limit

replace the camshaft.
Figure 70-80-68
Measure the cylinder block bore inside diameter for the

camshaft with an inside micrometer [Figure 70-80-69] &
[Figure 70-80-70].
P13351
Measure the camshaft journal outside diameter (Item 1)

[Figure 70-80-68] with a micrometer. The measurement
should be 1.4147-1.3799 inch (35,934-35,050 mm).
70-80-21

Service Manual
Remove the fuel camshaft from the block.
Figure 70-80-73
Figure 70-80-71
1
2
P13366
P13364
Remove the three mounting bolts (Item 1) from the

injection pump gear (Item 2) [Figure 70-80-73].
Check the camshaft alignment by supporting the
camshaft in V-blocks. Set a dial indicator with its tip on
the center journal at a right angle [Figure 70-80-71].
Rotate the camshaft on the V-blocks and get the
misalignment, which is half of the measurement.

(9,8-11,3 Nm) torque.
Figure 70-80-74
The measurement should be 0.0004 inch (0,01 mm).

If the misalignment exceeds the allowable limit, replace
the camshaft.
4
Fuel Camshaft Removal And Installation
Figure 70-80-72
2
1
1
P13369
Remove the fuel cam (Item 1) and the cam washer (Item
2) [Figure 70-80-74] from the camshaft gear.
Installation: When installing the fuel cam and washer to
the cam shaft gear align the timing marks (Item 3) on the
fuel cam with the timing marks (Item 4) [Figure 70-80-74]
on the camshaft gear.
P13349
Remove the two mounting bolts (Item 1) and remove the

fuel camshaft stop (Item 2) [Figure 70-80-72].
(9,8-11,3 Nm) torque.
70-80-22

Service Manual

Fuel Camshaft Removal And Installation (Contd)
Figure 70-80-75
2
P13370
Remove the nut (Item 1) [Figure 70-80-75] from the

camshaft.
Installation: Tighten the nut to 43-51 ft.-lb. (58,3-69,2
Nm) torque.
Remove the injection pump gear (Item 2) [Figure 70-8075] from the fuel camshaft.
Figure 70-80-76
1
P13373
Check the key (Item 1) [Figure 70-80-76] and the

keyways in the gear and on the shaft for wear and
replace if needed.
Check the bearings (Item 2) [Figure 70-80-76] for wear
and replace as needed.
70-80-23

Service Manual
Figure 70-80-79
Oil Pan Removal And Installation

2
Figure 70-80-77
1
1
P13318
Clean the oil pickup tube screen (Item 1) [Figure 70-8079].
P13309
Remove the oil pan mounting bolts (Item 1) [Figure 7080-77], and remove the oil pan.
Installation: Tighten pan mounting bolts to 87-100 in.-lb.
(9,8-11,3 Nm) torque, in a diagonal order from the
center.
Figure 70-80-78
Check the O-ring (Item 2) [Figure 70-80-79] and replace

if worn.
Use care not to damage O-ring when installing the oil
pickup tube.
NOTE: Clean the surface of the oil pan and the block
thoroughly. And apply a new liquid gasket to
the oil pan before installing.
1
2
P13313
Remove the mounting bolt (Item1) and remove the oil

pickup tube (Item 2) [Figure 70-80-78].
70-80-24

Service Manual
Figure 70-80-82
Governor Shaft Removal And Installation

1
Figure 70-80-80
1
P13352
Remove the governor shaft assembly (Item 1) [Figure

70-80-82] from the front of the block.
P13357
Figure 70-80-83
Remove the fuel camshaft plug (Item 1) [Figure 70-8080] from the block.
Figure 70-80-81
1
P13362
NOTE: The set screw (Item 1) [Figure 70-80-83] must

be removed to remove the rear governor shaft
bearing.
P13358

the governor shaft.
Check the governor gear bushing (Item 2) [Figure 70-8082] and replace if needed.
70-80-25

Service Manual
Figure 70-80-86
Governor Shaft Removal And Installation (Contd)

Figure 70-80-84
P13379
Check the parts from the governor shaft for wear and
replace if needed [Figure 70-80-86].
P13360
Figure 70-80-87
Remove the set screw (Item 1) [Figure 70-80-84] from
the block
1
Figure 70-80-85
1
P13371
Remove the governor gear holder and governor gear

(Item 1) [Figure 70-80-87] from the governor shaft.
P13359

NOTE: The bearing must be driven out toward the
front of the block.
70-80-26

Service Manual
Figure 70-80-90

Figure 70-80-88
2
2
1
P13377
Remove the governor weight holder (Item 1) [Figure 7080-90] from governor shaft.
P13378
Remove the governor gear (Item 1) from the gear holder

(Item 2) [Figure 70-80-88].
Remove the governor sleeve (Item 2) and thrust washer

(Item 3) [Figure 70-80-90] from governor shaft.
Check all parts and replace if needed.
Figure 70-80-89
1
P13374
Remove the governor weight shafts (Item 1) from the

governor weights (Item 2) [Figure 70-80-89].
Remove the governor weights.
Remove the rollers (Item 3) [Figure 70-80-89] from the
governor weights.
70-80-27

Service Manual
Figure 70-80-93
Governor Fork Lever Removal And Installation

Figure 70-80-91
P13356
Remove the fork lever cover and gasket from the block.
P13285
Remove the governor fork lever collar (Item 1) [Figure

70-80-93] from the block.
Remove the speed control plate. (See Engine Speed
Control Plate Removal And Installation on Page 70-806.)
Figure 70-80-94
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 70-60-6.)
2
1
Figure 70-80-92
P13353
Remove the governor fork lever shaft (Item 1) and outer

bearing (Item 2), using a metric tap (Item 3) [Figure 7080-94] screwed into the threads of the fork lever shaft for
leverage.
1
P13354
Remove the two mounting bolts (Item 1) from fork lever

shaft cover (Item 2) [Figure 70-80-92]
Remove the fork compensating lever and fork lever from

the block.
70-80-28

Service Manual

Figure 70-80-95
P13355
Remove the inside governor fork lever bearing (Item 1)

[Figure 70-80-95].
Figure 70-80-96
2
1
3
P13372
Check the parts for wear and replace as needed [Figure

70-80-96].
NOTE: The washer (Item 1) goes between the fork
(Item 2) and the fork compensating lever (Item
3) [Figure 70-80-96] when being installed.
70-80-29

Service Manual
Checking The Piston And Connecting Rod
Piston Removal And Installation
Figure 70-80-99
Figure 70-80-97
1
1
2
2
P13398
P13381
Measure the piston hole with an inside micrometer

[Figure 70-80-99].
Remove the connecting rod bolts (Item 2) [Figure 70-8097].
torque.
The specifications are 0.8661-0.8687 inch (22,00022,013 mm). The allowable wear limit is 0.8673 inch
(22,03 mm).
Figure 70-80-100
Figure 70-80-98
2
1
P13401
P13400
Remove the piston rings (Item 1) [Figure 70-80-98] from

the piston.
Measure the piston pin (Item 1) with a micrometer and

the connecting rod bushing (Item 2) [Figure 70-80-100]
with an inside micrometer.
Remove the piston (Item 2) from the connecting rod (Item

3) by removing the piston pin (Item 4) [Figure 70-80-98].
The specifications for the outside diameter of the piston

pin are 0.8662-0.8666 inch (22,002-22,011 mm).
The specification for the inside diameter of the
connecting rod bushing are 0.8671-0.8677 inch (22,02522,040 mm).
The clearance between the piston pin and the connecting
rod bushing is 0.0006-0.0015 inch (0,014-0,038 mm) with
an allowable limit of 0.0059 (0,15 mm).
70-80-30

Service Manual
Piston Ring Gap
Connecting Rod Alignment
Figure 70-80-102
Figure 70-80-101
1
P13402
B-4067
NOTE: Check the I.D. of the connecting rod small end

bushing, because it is used for this check,
make sure it is not worn. (See Checking The
Piston And Connecting Rod on Page 70-8030.)
Put the piston ring in the engine cylinder [Figure 70-80102]. Use a piston to push the ring to the lower part of the
cylinder liner.
Measure the ring gap with a feeler gauge (Item 1)
[Figure 70-80-102].
The specifications are as listed below:
Install the piston pin into the connecting rod.
Top Ring
Second Ring
Oil Ring
Install the connecting rod on the connecting rod

alignment tool [Figure 70-80-101].
Put a gauge over the piston pin and move it against the
face plate.
If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the
face plate.
0.0098-0.0157 inch (0,25-0,40 mm)

0.0098-0.0157 inch (0,25-0,40 mm)
0.0098-0.0157 inch (0,25-0,040 mm)
The allowable wear limit for all the rings is 0.0492 inch
(1,25 mm).
If the ring gap exceeds the allowable limit, replace the
ring.
The allowable wear limit is 0.0020 inch (0,05 mm).

If the measurement exceeds the allowable limit, replace
the connecting rod.
70-80-31

Service Manual
If the clearance still exceeds the allowable limit after

replacing the ring, replace the piston.
Piston Ring Installation

Figure 70-80-103
1
2
3
B-3614
P13393
Remove the carbon from the ring grooves in the piston.

Install the rings on the piston [Figure 70-80-103].
Position the top ring so the gap is not lined up with the
piston pin. Position the other rings so there is a gap every
90.
NOTE: The top ring (Item 1) [Figure 70-80-103] (Inset)
is a 1/2 flat key stone type ring and must be
installed with the flat side toward the bottom
of the piston as shown.
NOTE: The second ring (Item 2) [Figure 70-80-103]
(inset) must be installed with the notch down
as shown.
NOTE: The oil ring (Item 3) [Figure 70-80-103] (inset)
must be installed as shown.
NOTE: Measure the clearance between the ring and
the ring groove in the piston, with a feeler
gauge.
The clearance between compression ring (Item 2)
[Figure 70-80-103] and the ring groove is 0.0033-0.0044
inch (0,085-0,112 mm) with an allowable limit of 0.0079
inch (0,20 mm).
The clearance between the oil ring (Item 3) [Figure 7080-103] and the ring groove is 0.008-0.0021 inch (0,0200,055 mm) with an allowable limit of 0.0059 inch (0,15
mm).
ring.
70-80-32

Service Manual
Checking Engine Cylinder Bore
Connecting Rod Installation
Figure 70-80-106
Install the connecting rod to the piston.

Figure 70-80-104
P13384
Figure 70-80-107
P13393
Figure 70-80-105
P13382
Use a micrometer to measure the inside diameter of the

cylinders [Figure 70-80-106] & [Figure 70-80-107].
P13396
NOTE: The arrow (Item 1) [Figure 70-80-104] on the

piston must point in the direction of the
numbers (Item 1) [Figure 70-80-105] on the
connecting rod and the connecting rod cap.
The alignment arrow and numbers must be
installed pointing opposite of the camshaft
and in the same cylinder it was removed from.
To find the maximum wear, measure the inside diameter

of the cylinder in three different locations. The inside
diameter specification is 2.9921-2.9929 inches (76,00076,019 mm). The allowable wear limit is 0.0059 inch
(+0,15 mm).
NOTE: When the cylinder has more wear than the
specifications the block can be bored and
honed one time. The oversize cylinder inside
diameter is +0.0197 inch (+0,5 mm). Be sure to
use the correct oversize piston and rings to
match the cylinder.
70-80-33

Service Manual
Figure 70-80-109
Crankshaft Removal And Installation
1
1
Remove the engine from the loader. (See Removal And

1
2
Remove engine starter. (See Removal And Installation

on Page 60-40-1.)
1
1
Remove engine flywheel. (See Removal And Installation

on Page 70-100-1.)
Remove the engine cylinder head. (See Cylinder Head

1
1
P13380
Remove the engine oil pan. (See Oil Pan Removal And
Remove the pistons. (See
Piston
Removal
And
Remove the nine mounting bolts (Item 1) from the

crankshaft bearing case cover (Item 2) [Figure 70-80109].
(9,8-11 Nm) torque.
Figure 70-80-108
Figure 70-80-110
1
1
1
P13381
Remove the two main bearing mounting bolts (Item 1)

[Figure 70-80-108].
Installation: Tighten the mounting bolts to 36-40 ft.-lb.
(49-53,9 Nm) torque.
P13375
Remove the crankshaft from the rear of the engine

[Figure 70-80-110].
Check the gasket (Item 1) [Figure 70-80-110] and
replace.
70-80-34

Service Manual
Figure 70-80-113
Crankshaft Removal And Installation (Contd)

Figure 70-80-111
1
2
1
P13387
1
1
Mark the main bearing caps (Item 1) [Figure 70-80-113].

P13386
Remove the main bearing cap bolts (Item 2) [Figure 7080-113].

Remove the eight mounting bolts (Item 1) [Figure 70-80111] from the crankshaft bearing case cover and remove
the cover.
Figure 70-80-112
Installation: Tighten the main bearing cap bolts to 22-25

ft.-lb. (24,4-34,3 Nm) torque.
NOTE: Since diameters of main bearings vary, install
the caps back on the bearings as they are
removed. Install them in the order they were
marked from the gear case side. When
installing the main bearing cap assemblies
face the mark (FLYWHEEL) on the
assemblies, toward the flywheel end of the
crankshaft.
Figure 70-80-114
1
P13388
Replace the crankshaft bearing case cover gasket (Item

1) [Figure 70-80-112].
1
1
Replace the oil seal (Item 2) [Figure 70-80-112].
1
P13397
Check the thrust bearings (Item 1) [Figure 70-80-114],

located on the rear main bearing only, and replace if
worn.
NOTE: When replacing the thrust bearings be sure to
install the oil groove facing outward.
70-80-35

Service Manual
Figure 70-80-117
Checking Crankshaft Journal And Block Bearing

Figure 70-80-115
1
1
P13391
The outside diameter of the crankshaft number one

journal (Item 1) [Figure 70-80-117] is 1.8872-1.8878 inch
(47,934-47,950 mm).
P13385
Measure the inside diameter of the front crankshaft

bearing (Item 1) [Figure 70-80-115].
The oil clearance between the crankshaft and the

crankshaft bearing is 0.0013-0.0045 inch (0,034-0,114
mm) with an allowable limit of 0.0079 inch (0,2 mm).
Figure 70-80-116
P13383
The crankshaft bearing inside diameter is 1.8891-1.8917

inch (47,984-48,048 mm).
70-80-36

Service Manual
Figure 70-80-120
Checking Crankshaft Journal And Main Bearing

Figure 70-80-118
P13394
Remove the bolts and remove the main bearing cap and
measure with the plastic gauge scale [Figure 70-80120], to get oil clearance.
P13395
Clean the crankshaft journal and crankshaft bearing.

Put a strip of plastic gauge (Item 1) [Figure 70-80-118]
on the main bearing.
The oil clearance between crankshaft and crankshaft

number two bearing is 0.0013-0.0037 inch (0,034-0,095
The oil clearance between the crankshaft and crankshaft
number three bearing is 0.0013-0.0037 inch (0,034-0,095
Figure 70-80-119
1
The oil clearance between the crankshaft and crankshaft

number four bearing is 0.0013-0.0039 inch (0,034-0,098
crankshaft bearing.
P13392
Install the main bearing cap (Item 1) [Figure 70-80-119]

on the main bearing.
70-80-37

Service Manual
Figure 70-80-123
Crankshaft Removal And Installation (Contd)

Figure 70-80-121
P13383
Measure the connecting rod bearings [Figure 70-80-122]

& [Figure 70-80-123]. The measurement should be
1.5750-1.5768 inches (40,004-40,050 mm).
P13391
The measurement for the outside diameter of crankshaft

number two journal (Item 1) and crankshaft number three
journal (Item 2) [Figure 70-80-121] is 1.8872-1.8878 inch
(47,934-47,950 mm).
Figure 70-80-124
The crankshaft bearing inside diameter for number tow

and three journals are 1.8891-1.8909 inch (47,98448,029 mm).
The measurement for the outside diameter of the
crankshaft number four journal (Item 3) [Figure 70-80121] is 2.0041-2.0449 inch (51,921-51,940 mm).
The crankshaft bearing inside diameter for number four
journal is 2.0462-2.0480 inches (51,974-52,019 mm).
P13390
Connecting Rod Journal
Measure the connecting rod journals [Figure 70-80-124].
Figure 70-80-122
The measurement should be 1.5732-1.5738 inches

(39,959-39,975 mm).
The oil clearance between the crankpin and the crankpin
bearing is 0.0011-0.0036 (0,029-0,091 mm) with an
allowable limit of 0.0079 inch (0,2 mm).
P13399
70-80-38

Service Manual
Crankshaft Alignment
Checking The End Play Of The Crankshaft
Figure 70-80-126
Move the crankshaft toward the crankshaft pulley end.

Figure 70-80-125
P13389
Support the crankshaft with V-blocks and set a dial

indicator on one of the center journals at a right angle
[Figure 70-80-126].
P13376
Set a dial indicator (Item 1) [Figure 70-80-125] to the

crankshaft.
Rotate the crankshaft on the V-blocks and get the

misalignment (half of the measurement).
Measure the end play by pushing the crankshaft toward

flywheel end.
The measurement should be 0.0008 inch (0,02 mm).
The end play should be between 0.0059-0.0122 inch

(0,15-0,31 mm) with an allowable limit of 0.0197 inch (0,5
mm).
If the misalignment exceeds the allowable limit, replace

the crankshaft.
If the measurement exceeds the allowable limit replace

the thrust bearings. (See Crankshaft Removal And
70-80-39

Service Manual

Engine Timing Installation
Align the timing marks between the idler gear and the
crankshaft (Item 2), the camshaft (Item 3) and the fuel
camshaft (Item 4) [Figure 70-80-128].
Figure 70-80-127
Timing Gear Backlash, Idler Gear And Crankshaft

Figure 70-80-129
1
2
P13346
P13271
Install the crankshaft (Item 1) [Figure 70-80-127]. (See

Crankshaft Removal And Installation on Page 70-80-34.)
Install the camshaft (Item 2) [Figure 70-80-127]. (See
Camshaft Removal And Installation on Page 70-80-20.)
Install the governor shaft (Item 3) [Figure 70-80-127].
(See Governor Shaft Removal And Installation on Page
70-80-25.)
Set a dial indicator (lever type) with its tip on a gear tooth
of the idler gear (Item 1) [Figure 70-80-129].
Hold the crankshaft gear (Item 2) [Figure 70-80-129] and
move the idler gear.
Check the amount of movement on the dial indicator.
Install the fuel camshaft (Item 4) [Figure 70-80-127].

(See Fuel Camshaft Removal And Installation on Page
70-80-22.)
The measurement should be 0.0013-0.0045 inch (0,0320,115 mm) with an allowable limit of 0.0059 inch (0,15
mm).
Figure 70-80-128
If the backlash exceeds the allowable limit, check the oil

clearance between idler gear shaft and the idler gear
bushing. (See Idler Gear Removal And Installation on
Page 70-80-19.)
3
If the clearance is within the allowable limit, replace the

idler gear.
2
1
P13269
Install the idler gear (Item 1) [Figure 70-80-128] on the

idler shaft. (See Idler Gear Removal And Installation on
Page 70-80-19.)
70-80-40

Service Manual
If after replacing the camshaft gear the backlash exceeds

the allowable limit check the fuel camshaft bearings.
(See Fuel Camshaft Removal And Installation on Page
70-80-22.)
Idler Gear And Camshaft Gear

Figure 70-80-130
Fuel Camshaft Gear And Governor Shaft Gear

of the governor shaft gear (Item 4) [Figure 70-80-130].
1
3
Hold the fuel camshaft gear (Item 3) [Figure 70-80-130]

and move the fuel camshaft gear.
2
mm).
If backlash exceeds the allowable limit replace the
governor shaft gear.
P13271
of the camshaft gear (Item 1) [Figure 70-80-130].
Hold the idler gear (Item 2) [Figure 70-80-130] and move
the camshaft gear.
If after replacing the governor shaft gear the backlash

exceeds the allowable limit check the governor shaft
bearings. (See Governor Shaft Removal And Installation
on Page 70-80-25.)

mm).
If backlash exceeds allowable limit replace the camshaft
gear.
If after replacing the camshaft gear the backlash exceeds
the allowable limit check the camshaft bearing. (See
Camshaft Removal And Installation on Page 70-80-20.)
Idler Gear And Fuel Camshaft Gear
of the fuel camshaft gear (Item 3) [Figure 70-80-130].
Hold the idler gear (Item 2) [Figure 70-80-130] and move
the fuel camshaft gear.
mm).
If backlash exceeds the allowable limit replace the fuel
camshaft gear.
70-80-41

Service Manual
70-80-42

Service Manual
FLYWHEEL HOUSING
Figure 70-90-3

Remove the engine assembly. (See Removal And
NOTE: Set engine assembly on a secure work
surface.
Remove starter (See Removal And Installation on Page
60-40-1.)
Figure 70-90-1
P-35286
Remove flywheel housing from the engine [Figure 7090-3].
P-35284
Install a lifting bracket and hoist to lift and support the

flywheel housing [Figure 70-90-1].
Figure 70-90-2
P-35285
Loosen and remove the nine flywheel housing mount

bolts [Figure 70-90-2].
Installation: Tighten the two bolts (Item 1) [Figure 7090-2] to 40-45 ft.-lb. (54-61 Nm) torque. Tighten the
remaining mounting bolts to 20-23 ft.-lbs. (27-31 Nm)
torque.
70-90-1

Service Manual
70-90-2

Service Manual
FLYWHEEL
Ring Gear Removal And Installation
NOTE: The lead chamfer on ring gear tooth must face

the starter.

Page 70-40-1.)
Figure 70-100-2
Remove the flywheel housing (See Removal And

Remove the rubber drive coupler (See Removal And

Mark the location of the flywheel for correct installation.
Figure 70-100-1
1
P-35293
The ring gear (Item 1) [Figure 70-100-2] on the flywheel

is an interference fit. Heat the ring gear enough to
expand it and hit it with a hammer to remove it evenly.
Clean the outer surface of the flywheel to give it a smooth
fit.
Clean the new ring gear and heat it to a maximum
temperature of 428F (220C).
P-35292
Remove the six flywheel mounting bolts (Item 1) [Figure

70-100-1]. Remove the flywheel.
Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.
Installation: Apply Loctite #242 or equivalant to the bolts

70-100-1

Service Manual
70-100-2

Service Manual
RUBBER DRIVE COUPLER
Disassembly
Figure 70-110-3

Page 70-40-1.)
Remove the flywheel housing. (See Removal And

Figure 70-110-1
1
1
1
P-35289
Put the coupler assembly in a vise and remove the three

bolts (Item 1) [Figure 70-110-3].
Figure 70-110-4
1
P-35287
Remove the three drive coupler mounting bolts (Item 1)

[Figure 70-110-1]. Remove the coupler.
Installation: Apply (Loctite 242) or equivalent to the bolts
Figure 70-110-2
1
2
P-35294
Remove the drive coupler (Item 1) from the rubber

housing (Item 2) [Figure 70-110-4].
Inspect the drive coupler (Item 1) [Figure 70-110-4] for
damage and replace as needed.
1
P-35288
NOTE: When the drive coupler is installed correctly

the recessed part of the coupler (Item 1)
[Figure 70-110-2] is in position shown.
70-110-1

Service Manual
RUBBER DRIVE COUPLER (CONTD)

Disassembly (Contd)
Figure 70-110-5
P-35290
Inspect the rubber housing [Figure 70-110-5] and

damage and replace as needed.
Install the drive coupler into the rubber housing, apply
(Loctite #242) or equivalent to the bolts and tighten to 2530 ft.-lb. (30-40 Nm) torque.
70-110-2

Service Manual
TURBOCHARGER
Figure 70-120-2
Checking
Inspect the turbine fins and the turbo housing for
damage.
Spin turbine by hand. Turbine should spin freely.

If the turbine is damaged replace the turbocharger.
Check the oil tubelines for leaks.
Description
2
P-50494
WARNING
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Figure 70-120-1
The oil supply for the turbo flows from the fitting (Item 1)
on the front of the engine to the turbocharger and returns
to the engine block through the fitting (Item 2) [Figure
70-120-2].
The turbocharger
serviceable.
internal
components
are
not

Raise lift arms and install approved lift arm support
Open engine cover. (See ENGINE COVER on Page 1030-1.)
1
Remove left engine side cover. (See Removal And
P-50443
The turbocharger (Item 1) [Figure 70-120-1] is placed

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than
atmospheric pressure to the intake. It is lubricated by oil
from the main galley.
WARNING
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
70-120-1

Service Manual
TURBOCHARGER (CONTD)
Figure 70-120-5
Figure 70-120-3
2
P-50447
1
Remove the oil supply line fitting (Item 1) and the brass
washer(s) (Item 2) [Figure 70-120-5] from the
turbocharger.
P-50443
Remove the compressor outlet hose (Item 1) [Figure 70120-3] from the turbo.
Installation: Tighten to 12-15 ft.-lb. (16,0-20,3 Nm)

torque.
Figure 70-120-4
Figure 70-120-6
1
1
1
P-50444
P-50448
Remove the air cleaner hose (Item 2) [Figure 70-120-4]

from the turbocharger.
Remove the mounting bolts (Item 1) from the oil return

line (Item 2) [Figure 70-120-6].
Installation: Tighten to 84-132 in.-lb. (9,5-15,0 Nm)
torque.
70-120-2

Service Manual
TURBOCHARGER (CONTD)
Figure 70-120-9

Figure 70-120-7
1
1
P-50451
1
Remove the turbo (Item 1) [Figure 70-120-9] from the
exhaust manifold.
P-50449
Remove the three mount nuts and washers (Item 1)

[Figure 70-120-7].
Installation: Tighten the nuts to 17-20 ft.-lb. (23-27 Nm)
torque.
Figure 70-120-8
1
1
1
P-50450
Remove the three mounting bolts (Item 1) [Figure 70120-8] from the exhaust muffler flange.
torque.
70-120-3

Service Manual
70-120-4

Service Manual
HEATER
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
HEATER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
SAFETY &
MAINTENANCE
HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1

DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
SERVICE
HEATER
80-01

Service Manual
80-02

Service Manual
COMPONENTS
Figure 80-10-3
Identification
1
Figure 80-10-1
P-42225
HEATER FAN: The heater fan is located behind the grill

(Item 1) [Figure 80-10-3] and is used to push air through
the heater and into the cab.
P-42702
HEATER UNIT: The heater (Item 1) [Figure 80-10-1] is

located in the right rear corner of the operator cab. The
unit delivers the warm air for heat into the cab. The unit
contains the blower, heater coil and heater valve.
Figure 80-10-4
Figure 80-10-2
P-42700
HEATER VALVE: The heater valve (Item 1) [Figure 8010-4] is used to control the amount of engine coolant that
flows to the heater coil.
1
P-42237
HEATER COIL: The heater coil (Item 1) [Figure 80-10-2]

supplies the warm air into the cab by passing air through
the coil.
80-10-1

Service Manual
COMPONENTS (CONTD)
Identification (Contd)
Figure 80-10-5
P-47581
FAN SWITCH: The fan switch (Item 1) [Figure 80-10-5]

is a two position switch, high and low speeds
80-10-2

Service Manual
HEATER FAN
Figure 80-20-3

1
Figure 80-20-1
1
1
P-42226
Disconnect the two wires (Item 1) [Figure 80-20-3].

P-42237

Remove the four mounting bolts (Item 1) [Figure 80-201] from the backside of the heater grill.
Figure 80-20-4
1
Installation: Tighten the bolts to 5 ft.-lb. (7 Nm) torque.

Figure 80-20-2
1
1
P-42235
Remove the three fan motor mounting bolts (Item 1)

[Figure 80-20-4].
P-42225
Remove the heater grill (Item 1) [Figure 80-20-2] from

the outside of the cab.
80-20-1

Service Manual
HEATER FAN (CONTD)

Figure 80-20-5
P-42236
Remove the blower motor [Figure 80-20-5].
80-20-2

Service Manual
HEATER UNIT
Figure 80-30-3

1

Drain engine coolant. (See Coolant Replacement on
Page 10-90-1.)
Figure 80-30-1
2
P-42225
Remove the heater grill (Item 1) [Figure 80-30-3].

Figure 80-30-4
1
P-42223
Loosen the two hose clamps (Item 1) and remove the

hoses (Item 2) [Figure 80-30-1].
NOTE: Cap hoses and fittings to prevent coolant loss.
1
Figure 80-30-2
3
2
P-42226
Disconnect the three wires (Item 1) and remove the

harness (Item 2) from the clip (Item 3) [Figure 80-30-4].
P-42224
Remove the four heater grill mounting bolts (Item 1)

[Figure 80-30-2].
Installation: Tighten bolts to 4-5 ft.-lb. (5,5-6,5 Nm)
torque.
80-30-1

Service Manual
HEATER UNIT (CONTD)

Figure 80-30-5
P-42227
Remove the four nuts and washers (Item 1) [Figure 8030-5].

Figure 80-30-6
P-42228
Remove the heater assembly [Figure 80-30-6].
80-30-2

Service Manual
HEATER UNIT (CONTD)
Figure 80-30-9
Figure 80-30-7
2
1
P-42231
Remove the four screws (Item 1) and remove the heater

grill (Item 2) [Figure 80-30-9]
P-42229
Figure 80-30-10
Remove the mounting frame (Item 1) [Figure 80-30-7].
NOTE: Mark frame for correct assembly to heater.
Figure 80-30-8
2
1
P-42232
Remove the nuts (Item 1) and remove the heater control

valve (Item 2) [Figure 80-30-10].
P-42230
Installation: Tighten nuts to 7-7.5 ft.-lb. (9,5-10,5 Nm)

torque.
Remove the heater fan housing (Item 1). Remove the
four mounting bolts (Item 2) [Figure 80-30-8].
80-30-3

Service Manual
HEATER UNIT (CONTD)

Figure 80-30-11
P-42233
Remove the control valve seal (Item 1) [Figure 80-3011].

Figure 80-30-12
P-42234
Remove the heater core (Item 10 [Figure 80-30-12].
80-30-4

Service Manual
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grinding Specifications for the Crankshaft. . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-20-1
SPEC-20-2
SPEC-20-3
SPEC-20-1
SPEC-20-2
SPEC-20-1
SPEC-20-1
SPEC-20-1
SPEC-20-5
SPEC-20-4
SPEC-20-3
SPEC-20-3
SPEC-20-2
SPEC-20-4
SPEC-20-2
SPEC-20-1
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . SPEC-50-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
LOADER BACKHOE SPECIFICATIONS . . . . . . . . . . . . .
Backhoe Rated Load Capacity (Per SAE J31) . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Backhoe Dimensions . . . . . . . . . . . . . . . . . . . .
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-10-1
SPEC-10-2
SPEC-10-4
SPEC-10-3
SPEC-10-4
SPEC-10-4
SPEC-10-3
SPEC-10-1
SPEC-10-3
SPEC-10-4
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SPECIFICATIONS
SERVICE
LOADER BACKHOE TORQUE. . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-40-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-1
SPEC-01

Service Manual
SPEC-02

Service Manual
LOADER BACKHOE SPECIFICATIONS

Loader Backhoe Dimensions
Dimensions are given for loader backhoe equipped with standard dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
231.2
(5872)
149
(3788)
95
(2407)
45
101
(2575)
74
(1887)
40
66.5
(1690)
56
(1411)
71
(1797)
5,2
(133)
169.2
(4298)
127
(3220)
91.5
(2324)
152.5
(3875)
33.5
(850)
189.1
(4804)
63
(1600)
61.2
(1555)
B-19888
Changes of structure or weight distribution of the loader

backhoe can cause changes in control and steering
response and can cause failure of the loader backhoe
parts.
SPEC 10-1

Service Manual
LOADER BACKHOE SPECIFICATIONS (CONTD)

Backhoe Rated Load Capacity (Per SAE J31)
This chart shows the backhoe lifting capacity with the load applied at the bucket hinge pin and the machine equipped
as outlined below.
These figures are actual measured values, stated in pounds, and rated to SAE J31 (MAR86) standards. Stability
limited values are indicated with an asterisk (*) and are shown in light-face type. All values shown with bold-face
characters are hydraulically limited.
These values are based on a machine equipped as follows: 63 Loader Bucket (6962363) 16 Backhoe Bucket
(6715501) 55 psi (379 kPa) Tire Pressure.
Figures above the line are capacities over end. Figures below the line are capacities through the swing arc, with the
swing frame fully side-shifted.
Large arc shows boom lift capacity with dipper fully extended. Small arc shows dipper lift capacity with boom fully
raised.
ALL LOAD VALVES ARE IN POUNDS
B-19983
SPEC 10-2

Service Manual

Performance
B250
Rated Operating Capacity (Per ISO
14397)
2265 lbs. (1027 Kg)
Tipping Load
4715 lbs. (2138 Kg)
Operating Weight
6770 lbs. (3071 kg)
SAE Breakout Force-Lift

-Tilt
Travel Speed
4.0 MPH (6.4 km/hr)
Controls
Vehicle Steering
Direction is controlled with steering wheel
Loader Hydraulics Lift and Tilt
Hand operated lever
Loader Auxiliary Hydraulics
Hand operated lever
Backhoe Auxiliary Hydraulics (Option)
Button operated
Engine
Hand lever throttle: Key-type starter switch and shutdown.
Starting Aid
Glow Plugs Automatically activated by instrument panel.
Secondary Brake
Parking Brake
Hand lever activated

Hand Lever activated and button activated parking brake. Button activated
system is a spring applied pressure release (SAPR) system.
Engine
Make/Model
KUBOTA/D1105T
Fuel/Cooling
Diesel/Liquid (Antifreeze mixture)
Horsepower (SAE Net)
31.5 HP (23.4 kW) @ 3000 RPM
Maximum Governed RPM
3200 RPM
Torque @ 1600 RPM (SAE Net)

Number of Cylinders
Three
Displacement
68.53 cu. in. (1.123 L)
Bore/Stroke
3.07 x 3.09 (78 x 78.4)
Lubrication
Pressure System W/Filter
Crankcase Ventilation
Closed Breathing
Air Induction
Air Cleaner
Dry replaceable cartridge
Ignition
Diesel-Compression
Maximum Governed RPM

High Idle RPM
3100-3200 RPM
Low Idle RPM
850-950 RPM
SPEC 10-3

Service Manual

Electrical
B250
Alternator
Belt Driven, 90 amps; open
Battery
12 volt; 1000 cold cranking amps @ 0F (-18C); 180 minute reserve capacity
Starter
12 volt; Gear Type; (1,0 kW)
Instrumentation (Standard)
Gauges: Hourmeter, Fuel, Engine Coolant Temperature

Warning Lights: Fuel Level, Glow Plugs, System Voltage, Engine Coolant
Temperature, Engine Oil Pressure, Hydraulic Oil Temperature, Engine Air Filter
& Hydraulic Filter.
Drive System
Main Drive
Hydrostatic four wheel drive
Transmission/Final Drive
Hydrostatic
Engine to Drive Sprocket

Reduction
Minimum Engine to Track
Reduction
Capacities
Fuel
14.5 gals. (55 L)
4.8 qts. (4.5 L)
Hydraulic/Hydro. Reservoir
13.5 gals. (51 L)
Hydraulic/Hydro. System (incl

reservoir)
18.8 gals. (71 L)
Rear Differential
2.6 qts. (2.5L)
Engine Oil Change w/Filter
4.3 qts. (4 L)
Tires
Front
10-16.5
Rear
10-16.5
Recommended Pressure
Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
SPEC 10-4

Service Manual
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Engine Compression
@ 200 to 300 RPM (Operating Temperature)
412-469 PSI (2841-3234 kPa)
Fuel Injection Nozzles

Opening Pressure
Fuel Tightness Nozzle Seat
1990-2133 PSI (13721-14707 kPa)

Dry Nozzle at 1848 PSI (12742 kPa)
Fuel Injection Pump

Fuel Tightness Plunger
Limit Permitted
Fuel Tightness of Delivery Valve
Limit Permitted
Injection Timing
2133 PSI (14707 kPa)

10 sec: initial pressure drop from 2133-1990 PSI (14707-13721 kpa)
5 sec: initial pressure drop from 2133-1990 PSI (14707-13721 kpa)
18.0-20.0 degrees B.T.D.C.
Cylinder Head
Cylinder Distortion Limit
0.0020 (0,05 mm) in 4 (100 mm)

of the length of the cylinder head surface.
0.0413-0.0453 (1,05-1,15 mm)
0.0079 (0,2 mm)
0.0217-0.0453 (1,05-1,15 mm)
412-469 PSI (2840-3234 kPa)
48-51 ft.-lb. (65-69 Nm)
Thickness of Gasket
Thickness of Gasket Shim
Top Clearance
Compression
Head Bolt Torque
Valves
Valve Seat Width
Valve Seat Angle Intake
O.D. of Valve Stem Exhaust
I.D. of Valve Guides
Clearance Between Valve Stem & Guide
Limited Permitted
Depth of Valve
Limit Permitted
Valve Clearance (Cold)
0.0835 (2,12 mm)

60 degrees
0.2740-0.2746 (6,960-6,975 mm)
0.2760-0.2765 (7,010-7,025 mm)
0.0014-0.0025 (0,035-0,065 mm)
0.004 (0,1 mm)
0.035-0.043 (0,9-1,1 mm)
0.51 (1,3 mm)
0.0057-0.0072 (0,145-0,185 mm)
SPEC-20-1

Service Manual
ENGINE SPECIFICATIONS (CONTD)

parentheses.
Valve Springs
Free Length
Limit Permitted
Fitted Length
Load to Compress To Fitted Length
Limit Permitted
Limit Permitted for Spring being Straight
1.457-1.476 (37,0-37,5)
1.437 (36,5 mm)
1.22 (31,0 mm)
26.4 lbs. (11,98 kg)
22.5 lbs. (10,2 kg)
0.039 (1,0 mm)
Rocker Arms
O.D. of Rocker Arm Shaft
I.D. of Rocker Arm Bushings
Clearnace Between Rocker Arm & Bushing
Limit Permitted
0.4714-0.4718 (11,973-11,984 mm)

0.4724-0.4731 (12,000-12,018 mm)
0.0006-0.0018 (0,016-0,045 mm)
0.039 (0,10 mm)
Camshaft
O.D. of Camshaft Bearing Journal
I.D. of Camshaft Bearing
Clearance Between Camshaft Bearing & Journal
Limit Permitted
Alignment of the Camshaft
Cam Lobe Height Intake
Exhaust
Limit Permitted Intake
Exhaust
Gear Backlash
Limit Permitted
1.4147-1.3799 (35,934-35,950 mm)

1.4173-1.4183 (36,000-36,025 mm)
0.0020-0.0036 (0,050-0,091 mm)
0.0047 (0,12 mm)
0.0004 (0,01 mm)
1.1339 (28,80 mm)
1.1417 (29,00 mm)
1.1319 (28,75 mm)
1.1398 (29,95 mm)
0.0013-0.0045 (0,032-0,115 mm)
0.0059 (0,15 mm)
Cylinders
Cylinder Liner I.D.
Allowable Limit
Oversized Cylinder Liner I.D.
Allowable Limit
3.2677-3.2686 (83,0-83,022)
+0.0059 (+0,15)
3.2874-3.2883 (83,5-83,522)
+0.0059 (+0,15)
SPEC-20-2

Service Manual

parentheses.
Piston Rings
Ring Gap, Top Ring
Ring Gap, 2nd Ring
Ring Gap, Oil Ring
Limit Permitted
Side Clearance of Ring Groove:
Top Ring
2nd Ring
Oil Ring
0.0118-0.0177 (0,30-0,45 mm)

0.0118-0.0177 (0,30-0,45 mm)
0.0098-0.0157 (0,25-0,40 mm)
0.0492 (1,25 mm)
Can not measure accurately
0.0033-0.0048 (0,081-0,122 mm)
0.0008-0.0021 (0,020-0,055 mm)
Pistons
I.D. of Piston Bosses
Limit Permitted
O.D. of Piston Pin
I.D. of Connecting Rod Bushing (Small End, Fitted)
Clearance Between Piston Pin & Bushing (New Engine)
Service Parts
Limit Permitted
Connecting Rod Alignment
Limit Permitted
Oversize Piston
0.8611-0.8687 (22,002-22,011 mm)

0.8662-0.8666 (22,002-22,011 mm)
0.8671-0.8677 (22,025-22,040 mm)
0.0006-0.0015 (0,014-0,038 mm)
0.0006-0.0026 (0,015-0,066 mm)
0.0059 (0,15 mm)
0.0020 (0,05 mm)
0.020 (0,5 mm)
Crankshaft
Crankshaft Alignment
O.D. of Crankshaft Journal #1
I.D. of Crankshaft Bearing #1
Oil Clearance Between Crankshaft Journal & Bearing #1
Limit Permitted
O.D. of Crankshft Journal #2
Limit Permitted
O.D. of Crankshaft Journal #3
Limit Permitted
SPEC-20-3
0.0008 (0,02 mm)

1.8872-1.8878 (47,934-47,950 mm)
1.8892-1.8917 (47,984-48,048 mm)
0.0013-0.0045 (0,034-0,114 mm)
0.0079 (0,2 mm)
1.8872-1.8878 (47,934-47,950 mm)
1.8891-1.8909 (47,984-48,029 mm)
0.0013-0.0037 (0,034-0,095 mm)
0.0079 (0,2 mm)
2.0441-2.0449 (51,921-51,940 mm)
2.0462-2.0480 (51,974-52,019 mm)
0.0013-0.0039 (0,034-0,098 mm)
0.0079 (0,2 mm)

Service Manual

parentheses.
Oil Pump
Oil Pressure @ Rated RPM
Limit Permitted
Oil Pressure @ Idle Speed
Clearance Between Inner and Outer Rotor
Limit Permitted
Clearance Between Outer Rotor & Pump Body
Limit Permitted
End Clearance Between Rotor & Cover
Limit Permitted
28-64 PSI (196-441 kPa)

21.3 PSI (147.1 kPa)
7 PSI (49 kPa)
0.0024-0.0071 (0,06-0,18 mm)
0.0118 (0,3 mm)
0.0039-0.0071 (0,10-0,18 mm)
0.0213 (0,54 mm)
0.0098-0.295 (0,025-0,75 mm)
0.089 (0,225 mm)
Thermostat
Opening Temperature (Starting)
(Fully Open)
157-162F (69.5-72.5C)
203F (95C)
SPEC-20-4

Service Manual

Grinding Specifications for the Crankshaft
If the standard-size bearing cannot be used due to excessive wear of the crankpin and crank journals, use undersize or
oversize bearings.
3
1
3
2
B
2
4
B-5928
Undersize and Oversize Bearings

If the standard size bearing cannot be employed due to excessive wear of the crankpin and crank journal, employ
undersize or oversize bearings.
For under size or oversize bearing use, use the precautions noted below.
1. Grind the crankpin corner (1) and journal corner (2) with a wheel which has specified round corner and width without
shoulder.
Item 1
Item 2
.1102-.1260 inch (2.8-3.2 mm)

.0906-.1063 inch (2.3-2.7 mm)
2. Be sure to chamfer the oil hole (3) circumference to .04-.06 inch (1,5 mm) radius with an oil stone
3. The crankpin (4) must be fine-finished to higher than (.8-S).
4. The crank journal (5) must be fine-finished to higher than (.8-S).
5. The crank journal side surface (C) must be fine-finished to higher than (.8-S).
SPEC-20-5

Service Manual

Grinding Specifications for the Crankshaft (Contd)
If the standard-size bearing cannot be used due to excessive wear of the crankpin and crank journal, use undersize or
oversize bearings.
Ref.
SIZE
-0.008 in.
-0,2 mm
-0.016 in.
-0,4 mm
-0.008 in.
-0,2 mm
-0.016 in.
-0,4 mm
-0.008 in.
-0,2 mm
-0.016 in.
-0,4 mm
-0.008 in.
-0,2 mm
-0.008 in.
-0,2 mm
-0.008 in.
-0,2 mm
-0.008 in.
-0,2 mm
CODE NUMBER
16241-2391-1
16241-2392-1
16241-2393-1
16241-2394-1
16241-2395-1
16241-2396-1
16241-2397-1
16241-2398-1
19202-2397-1
15521-2396-1
19202-2398-1
15521-2396-1
DESCRIPTION
DIMENSION
Crankshaft Bearing #1
(0.2 minus)
(0.4 minus)
(0.2 minus)
(0.4 minus)
(0.2 minus)
(0.4 minus)
Crank pin Bearing
(0.2 minus)
Crank pin Bearing
(0.4 minus)
Thrust Bearing 2 (0.2 +)
1.8793-1.8799 in.
47,734-47,750 mm
1.8714-1.8720 in.
47,534-47,550 mm
1.8793-1.8799 in.
47,734-47,750 mm
1.8714-1.8720 in.
47,534-47,550 mm
2.0363-2.0370 in.
51,721-51,740 mm
2.0284-2.0291 in.
51,521-51.540 mm
1.5653-1.5659 in.
39,759-39,775 mm
1.5574-1.5581 in.
39,559-39,575 mm
1.1102-1.1122 in.
28,20-28,25 mm
1.1181-1.1201 in.
28,40-28,45 mm
SPEC-20-6
MARK
020US
040US
020US
040US
020US
040US
020US
040US
0.20 OS
0.40 OS

Service Manual
LOADER BACKHOE TORQUE

Specifications
ITEM
FT.-LB.
Air Cleaner Mounting Bolts

Alternator Pulley Nut
Arm Cylinder Pivot Pin Retainer Bolt
Bob-Tach Pivot Pin Bolts
Bob-Tach Lever Pivot Bolt
Boom Cylinder Pivot Pin Retainer Bolts
Bucket Cylinder Pivot Pin Retainer Bolt
Camshaft Retainer Plate Bolts
Connecting Rod Bolts
Crankshaft Pulley Nut
Cylinder Head Bolts
Drive Coupler Mounting Bolts
Engine Mounting Bolts
Floor Panel Mounting Bolts
Flywheel Bolts
Fuel Camshaft Retainer Plate Bolts
Fuel Tank Mounting Bolts
Glow Plug
Grill Frame Mount Bolts
High Pressure Fuel Lines
Hydraulic Reservoir Mounting Bolts
Hydraulic Filter Housing Mounting Bolts
Hydrostatic Motor Mounting Bolts
Hydrostatic Pump Mounting Bolts
Idler Gear Shaft Bolts
Injection Pump Mounting Bolts & Nuts
Injection Nozzles
Injector Nozzle Body
Main Bearing Mounting Bolts
Main Bearing Cap Bolts
Main Relief Valve
Operator Cab Fastening Nuts
Rear Bearing Case Cover Bolts
Seat Belt Fastening Bolts
Seat Mounting Bolts
Seat Bar Pivot Bolts
Steering Linkage Lock Nuts
Tilt Cylinder Pivot Pin Retainer Bolt
Timing Gearcase Cover Bolts
Travel Pedal Mounting Bolts
Wheel Nuts
18-19
50
18-19
190
25-28
18-19
18-19
7-8
30-34
101-116
48-51
25-28
32-35
4-5
40-43
7-8
55-60
15-18
55-60
18-25
55-60
32-35
55-60
90-100
7-8
17-20
36-51
43-58
36-40
22-25
35-40
118-133
13-15
21-24
11-12.5
25-28
42-46
18-19
13-17
25-28
140
SPEC-30-1
NM
24-26
68
24-26
260
34-38
24-28
24-26
9-11
41-46
137-157
64-69
34-37
43-47
5.5-6.5
54-59
9-11
75-85
20-24
75-85
24-33
75-85
43-47
75-85
125-140
9-11
23-27
46-69
59-79
49-54
29-34
47-54
160-180
18-20
29-32
15-17
34-38
57-63
24-26
18-23
35-39
190

Service Manual
SPEC-30-2

Service Manual
TORQUE SPECIFICATIONS FOR BOLTS

Torque For General Metric Bolts
THREAD SIZE
(DIA. X PITCH)
MATERIAL
HEAD MARK 4
HEAD MARK 7
HEAD MARK 10
6-9 ft.-lb.
(8-12 Nm)
13-18 ft.-lb.
(18-24 Nm)
22-30 ft.-lb.
(30-41 Nm)
36-50 ft.-lb.
(49-68 Nm)
3-4 ft.-lb.
(4-5 Nm)
6-7 ft.-lb.
(8-9 Nm)
11-16 ft.-lb.
(15-22 Nm)
22-30 ft.-lb.
(30-41 Nm)
40-54 ft.-lb.
(54-73 Nm)
58-80 ft.-lb.
(79-108 Nm)
6-9 ft.-lb.
(8-12 Nm)
18-25 ft.-lb.
(24-34 Nm)
36-50 ft.-lb.
(49-68 Nm)
69-87 ft.-lb.
(94-118 Nm)
116-137 ft.-lb.
(157-186 Nm)
M 5 x 0.8
M 6 x 1.0
M 8 x 1.25
M 10 x 1.25
M 12 x 1.25
M 14 x 1.5
SPEC-40-1

Service Manual
SPEC-40-2

Service Manual
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS

Specifications
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not available, use 10W-30 or 10W-40
SAE Motor Oil (5W-30 for 0F [-18C] and Below).
DO NOT use automatic transmission fluids in the loader or permanent damage to the transmission will result.
WARNING
W-2072-0496
When temperatures below zero degree F (-18C) are common, the loader must be kept in a warm building. Extra warmup time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and
it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by
TRANS light ON) can cause transmission damage in less than 60 seconds.
WARNING
During cold weather (32F [0C] 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 -20F (-30C), 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 0F (-18C) if possible.
W-2027-1285
SPEC-50-1

Service Manual
SPEC-50-2

Service Manual
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
SPEC-60-1

Service Manual
SPEC-60-2

Service Manual
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
B250-1
1 January 2004
Bobcat Loader Backhoe
B250 B Series
6902715 (12-03)
The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:
TAKE OUT
PUT IN
REVISION DESCRIPTION
20-01 through 20-04

20-20-1 & 20-20-2
20-21-1 & 20-21-2
20-23-1 & 20-23-2
20-30-1 & 20-30-2
20-90-1 through 20-90-20
50-01 & 50-02
50-50-1 & 50-50-2
50-100-1 & 50-100-2
50-110-1 & 50-110-2
50-120-1 & 50-120-2
50-150-1 & 50-150-2
50-180-1 & 50-180-2
60-01 & 60-02
60-40-1 & 60-40-2
60-70-1 & 60-70-2
70-01 through 70-04
70-20-1 & 70-20-2
70-50-1 & 70-50-2
70-120-1 & 70-120-2
SPEC-20-1 through SPEC-20-6
20-01 through 20-04

20-20-1 through 20-20-10
20-21-1 through 20-21-10
20-23-1 through 20-23-10
20-30-1 through 20-30-8
20-90-1 through 20-90-20
50-01 & 50-02
50-50-1 & 50-50-2
50-100-1 through 50-100-4
50-110-1 through 50-110-6
50-120-1 through 50-120-4
50-150-1 & 50-150-2
50-180-1 through 50-180-4
60-01 & 60-02
60-40-1 through 60-40-20
60-70-1 & 60-70-2
70-01 through 70-04
70-20-1 & 70-20-2
70-50-1 & 70-50-2
70-120-1 through 70-120-4
SPEC-20-1 through SPEC-20-6
Revised text
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Printed in U.S.A.
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
B250-2
1 March 2004
B250 B Series
6902715 (12-03)

TAKE OUT
PUT IN
ALPHABETICAL INDEX
20-01 through 20-04
20-22-1 & 20-22-2
20-24-1 & 20-24-2
20-25-1 & 20-25-2
20-41-1 & 20-41-2
20-60-1 & 20-60-2
40-01 & 40-02

40-20-1 & 40-20-2
40-21-1 through 40-21-6
40-30-1 & 40-30-2
40-60-1 & 40-60-2
50-01 & 50-02
50-11-1 & 50-11-2
50-130-1 & 50-130-2
50-140-1 & 50-140-2
50-170-1 & 50-170-2
ALPHABETICAL INDEX
20-01 through 20-04
20-22-1 through 20-22-10
20-24-1 through 20-24-12
20-25-1 through 20-25-6
20-41-1 through 20-41-6
20-60-1 through 20-60-28
20-120-1 through 20-120-8
20-121- through 20-121-4
40-01 & 40-02
40-20-1 through 40-20-4
40-21-1 through 40-21-8
40-30-1 through 40-30-6
40-60-1 through 40-60-16
50-01 & 50-02
50-11-1 through 50-11-8
50-130-1 & 50-130-2
50-140-1 through 50-140-4
50-170-1 through 50-170-4
Revised text
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SPEC 10-1 through SPEC 10-6
SPEC 10-1 through SPEC 10-6
Revised text
Printed in U.S.A.
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
B250-3
November 1 2005
B250 B Series
6902715 (12-03)

TAKE OUT
PUT IN
ALPHABETICAL INDEX
ALPHABETICAL INDEX
Revised text
20-01
20-25
20-60
20-80
20-100
20-110
20-120
20-121
20-01
20-25
20-60
20-80
20-100
20-110
20-120
20-121
Revised text
Revised text
Revised text
Revised text
Revised text
Revised text
Revised text
Revised text
30-01
30-20
30-40
30-01
30-20
30-40
Revised text
Revised text
Revised text
40-01
40-10
40-20
40-21
40-01
40-10
40-20
Revised text
Revised text
Revised text
Moved to section 40-20
Added text
Added text
Added text
Added text
Revised text
40-60
40-31
40-32
40-41
40-42
40-60
Printed in U.S.A.
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
B250-4
23 March 2006
B250
6902715 (12-03)
B250 Service Manual (P/N 6902715) Dated (3-06) contains updated service information which replaces the
previous B250 Service Manual (P/N 6902715) Dated (12-03).
Printed in U.S.A.

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B250

Bobcat Company 2006

Instructions are necessary before operating or servicing machine. Read and

Never service the Bobcat Loader

Always use an approved lift arm

Cleaning and maintenance are

Have good ventilation when

Vent exhaust to outside when

Never work on loader backhoe

Stop, cool and clean engine of

Keep body, jewelry and clothing

Lead-acid batteries produce

HEATER FAN ..........................................................80-01

SAPR BRAKE CONTROL VALVE ...........................20-01

ALPHABETICAL INDEX (CONTD)

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . X

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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

B250 Bobcat Loader Backhoe

2. The seat belt must be

10. Safety treads must be in good

3. Check lift arm support device,

11. Check for correct function of

4. Machine signs must be

12. Check hydraulic fluid level,

5. Foot pedal must return to

13. Inspect for fuel,

6. Check for correct function of

14. Lubricate the loader backhoe.

7. The parking brake

15. Check the condition of the

8. Enclosure door latches must

16. Inspect the air cleaner for

B250 Bobcat Loader Backhoe

17. Check the electrical charging

20. Operate the loader and check

18. Check tires for wear and

19. Inspect for loosen or broken

22. Recommend to the owner

B250 Bobcat Loader Backhoe

B250 Bobcat Loader Backhoe

The following publications provide information on the

Safety Alert Symbol

The Delivery Report is used to assure that complete

The Operation & Maintenance Manual delivered with

Machine signs (decals) instruct on the safe operation

An Operators Handbook fastened to the operator

The AEM Safety Manual delivered with the machine

The Service Manual and Parts Manual are available

The Loader Backhoe Operator Training Course is

The Loader Backhoe Safety Video is available from

B250 Bobcat Loader Backhoe

SAFETY INSTRUCTIONS (CONTD)

Call Before You Dig

B250 Bobcat Loader Backhoe

SAFETY INSTRUCTIONS (CONTD)

Use the procedure in the Operation & Maintenance

Use the procedure in the Operation & Maintenance

Flammable debris (leaves, straw, etc.) must be removed

Do not use the machine where exhaust, arcs, sparks

The operator cab, engine compartment, and engine

Check all electrical wiring and connections for