8530114-Bobcat 742b 743b Skid Steer Loader Service Repair Workshop Manual Instant Download

7 4 2 B 7 4 3 B
6720772 (792)
Service Manual
Printed in U.S.A.
Melroe Company 1992
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
CORRECT
CORRECT
B-10731a
B-12365
B-7469
Never service the Bobcat SkidSteer Loader without instructions.
Use the correct procedure to lift or lower operator cab.
Cleaning and maintenance are required daily.
WRONG
WRONG
WRONG
B-11799
B-15231
B-15280
Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.
Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.
Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.
WRONG
WRONG
WRONG
B-6590
Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader 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 rear door closed except for service. Close and latch door before operating the loader.
B-6580 B-16102
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.
B-6589 B-16102
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM 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.
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
742B, 743B Loader 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 the ROPS/FOPS (Including sidescreens) is in good condition and is not modified. 2. Check that ROPS mounting hardware is tightened and is Melroe approved. 9. Enclosure door latches must open and close freely.
10. BobTach wedges and linkages must function correctly and be in good condition. 11. Safety treads must in good condition.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.
12. Check for correct function of indicator lamps (Optional on some models).
5. Machine signs must be legible and in the correct location.
13. Check hydraulic fluid level, engine oil level and fuel supply.
6. Steering levers and foot pedals must return to neutral.
14. Inspect for fuel, oil or hydraulic fluid leaks.
7. Check for correct function of the work lights.
15. Lubricate the loader.
8. The parking brake function correctly.
must
16. Check the condition of the battery and cables.
17. Inspect the air cleaner for damage or leaks. Check the condition of the element.
18. Check the electrical charging system.
19. Check tires for wear and pressure.
20. Inspect for loose or broken parts or connections.
21. Operate the loader and check all functions.
22. Check for any field modification not completed.
23. Check for correct function of the Bobcat Interlock Control System (BICS) before the machine is returned to the customer. Recommend to the owner that all necessary corrections be made before the machine is returned to service.
ii
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read 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. Failure to follow instructions can cause injury or death. The following publications provide information on the safe use and maintenance of the loader and attachments:
W20030797
The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer. shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are The loader has a plastic 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 the following languages: French, German, Italian, Dutch & Spanish editions.
The EMI Safety Manual (available in Spanish) delivered with the loader 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 SkidSteer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish versions.
The Bobcat SkidSteer Loader Safety Video is available from your Bobcat Dealer.
Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death. W20441285
This notice identifies procedures which must be followed to avoid damage to the machine.
I20190284
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.
iii
SAFETY INSTRUCTIONS (Contd) Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.
Know where fire extinguisher and first aid kit are located and how to use them. Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating. damaged part.
Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or antifreeze. Do not use ether or starting fluids on this engine. It has a glow plug. These starting aids can cause explosion and injure
you or bystanders.
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.
Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear 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! Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
P03705
iv
SERIAL NUMBER LOCATIONS Always use the serial number of the loader when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the grill [A]. Explanation of loader Serial Number: XXXX XXXXX Module 2. Production Sequence (Series) Module 1. Model/Engine Version The four digit Model/Engine Combination module number identifies the model number and engine combination. This number (in parenthesis beside the model number) is used in the Service Manual to more easily identify the standard, optional and field accessory equipment included or available for each specific model. The five digit Production Sequence Number identifies the order which the loader is produced. ENGINE SERIAL NUMBER (743B) The serial number is located at the fuel injection pump side on the engine block [B]. ENGINE SERIAL NUMBER (742B) The serial number is located at top left surface of the engine block [C].
P00144
P00208
B09644
DELIVERY REPORT The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [D].
BOBCAT SKID STEER LOADER IDENTIFICATION

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772ContentsSection
FRONT LIGHTS (OPT.) SEAT BAR GRAB HANDLES STEERING LEVER
OPERATOR SEAT
SEAT BELT
QUICK COUPLERS TILT CYLINDER
BUCKET SEAT BAR
SAFETY TREAD BUCKET STEPS OPERATOR CAB (ROPS & FOPS)
REAR LIGHT (OPT.) UPRIGHTS
LIFT ARM SUPPORT DEVICE
LIFT ARM
GRILL
LIFT CYLINDER
REAR DOOR *TIRES * TIRES Flotation tires are shown. THE Bobcat loader is basedequipped with standard tires.
B07377 C02878
BUCKET Several different buckets and other attachments are available for the Bobcat loader. ROPS, FOPS RollOver Protective Structure, Falling Object Protective Structure, per SE J1040 and SAE J1043. The Bobcat loader is baseequipped with a standard operator cab as shown. 742B, 743B Loader Service Manual
vi
PREVENTIVE MAINTENANCE Page Number AIR CLEANER SERVICE (743B) Replacement Of The Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 AIR CLEANER SERVICE (742B) Replacement Of The Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ALTERNATOR BELT ADJUSTMENT (743B) Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 ALTERNATOR BELT ADJUSTMENT (742B) Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ENGINE COOLING SYSTEM (743B) Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . 116 ENGINE COOLING SYSTEM (742B) Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . 118 ENGINE LUBRICATION SYSTEM (743B) Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 ENGINE LUBRICATION SYSTEM (742B) Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Replacement Of The Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 FINAL DRIVE TRANSMISSION (Chaincase) Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 FUEL SYSTEM (743B) Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 110 110 111
PREVENTIVE MAINTENANCE
FUEL SYSTEM (742B) Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 GOVERNOR (742B) Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Governor Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 124 Removing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
PREVENTIVE MAINTENANCE (Contd) Page Number LIFT ARM SUPPORT DEVICE To Disengage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 To Engage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 LUBRICATING THE BOBCAT LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 OPERATOR CAB Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PARKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 SEAT BAR RESTRAINT SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPARK ARRESTOR MUFFLER Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 TIRE MAINTENANCE Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 TRANSPORTING THE BOBCAT LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 USING A BOOSTER BATTERY (Jump Starting) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 UJOINT LUBRICATION Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10
SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. Instructions are necessary before operating or servicing machine. Read 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. Failure to follow instructions can cause injury or death.
W20030797
SERVICE SCHEDULE ITEM

Engine Oil Engine Air Cleaner Engine Cooling System Tires Seat Belt, Seat Bar & Pedal Interlocks. Safety Signs & Safety Tread Lift Arm, Cyl., BobTach, Pivot Pin Fuel Filter (743B) Operator Cab Wheel Nuts Battery Hydraulic Fluid, Tubelines & Hoses Alternator Drive Belt Chaincase Controls & Brake Engine Oil & Filter Spark Arrestor Muffler Governor Oil Level (742B) Governor Shaft (742B) Seat Bar Steering Shaft Pivots Hyd./Hydro. Filters UJoint Fuel Filter Hyd. Reservoir Breather Cap Chaincase Hydraulic Reservoir Case Drain Filter
HOURS
810 50 100 250 500 1000
SERVICE REQUIRED
Check the oil level & add oil as needed. Replace the outer filter element only when the read ring shows in the indicator window. Check for leaks & damaged components. Clean debris from shrouds & grill. Check coolant level in the recovery tank & add as needed. Check for damaged tires & correct air pressure. Check the condition of seat belt. Check the seat bar & pedal interlocks for correct operation. Check for damaged signs (decals) & safety treads. Replace any signs or safety treads that are damaged or worn. Add grease to the fittings until extra grease shows. Remove water from tilter. Check the fastening bolts, washers & nuts. Check the condition of the cab. Check for loose wheel nuts. Tighten to correct torque if loose. Check the electorlite level. Check battery cables for corrosion. Check that the battery cables are tight. Check covers. Check the fluid level & add as needed. Check for damage & leaks & replace as needed. Check the tension & adjust as needed. Check the fluid level & add as needed. Check operation & adjust as needed. Replace the oil & the engine oil filter. Remove the plug & clean the spark chamber. Check level, if low, add oil. Grease or oil the shaft. Grease pivot as needed. Grease two fittings. Add oil to steering shaft. Replace filter elements. Grease three fittings with correct grease. Replace the filter element. Replace breather cap. Replace the fluid. Replace the hydraulic fluid. Replace the filter.
Check wheel nut torque every 8 hours for the first 24 hours. Also replace hydrostatic filter element when the transmission warning light stays on for five minutes after the hydrostatic fluid is at operating temperature. Or every 12 months. Replace case drain filter in the event of any Hydraulic/Hydrostatic System failure. Revised Sept. 93 11 742B, 743B Loader Service Manual
A
Instructions are necessary before operating or servicing machine. Read 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. Failure to follow instructions can cause injury or death [A]. LIFTING AND BLOCKING THE LOADER Procedure Always park the loader on a level surface.
B07023
W20030797
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
W20170286
Put floor jack under the rear of the loader [B]. Lift the rear of the loader and install jackstands [B].
B09331
Put the floor jack under the front the loader [C]. Lift the front of the loader and put jackstands [C]. NOTE: Make sure the jackstands do not touch the tires.
B09332
12
PARKING THE BOBCAT LOADER Procedure Stop the Bobcat loader on level ground. Lower the lift arms fully and put the edge of the bucket on the ground. Pull the throttle all the way backward. Turn the key switch to the OFF position.
SUPPORT
B02668
AVOID INJURY OR DEATH

Before you leave the operators seat: Lower the lift arms, put the attachment flat on the ground. Stop the engine. Engage the parking brake. Raise seat bar, move pedals until both lock.
W20451086
Engage the parking brake. Lift the seat bar and make sure the foot pedals are in the locked position. Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel. TRANSPORTING THE BOBCAT LOADER
C02563 B07384
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.
W20580494
A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A]. The rear of the trailer must be blocked or supported [A] when loading or unloading the loader to prevent the front end of the trailer from raising up. Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up and down slopes [B]. Lower the bucket or attachment to the floor. Stop the engine. Engage the parking brake. Install chains at the front and rear of the loader as shown in figure [B]. 13
B07383
LIFT ARM SUPPORT DEVICE
Never work on a machine with the lift arms up unless the lift arms are secured by a 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.
W20590991 P00147
To Engage Lift Arm Support Device Maintenance and service work can be done with lift arms lowered. If the lift arms are raised, use the following procedure: Put jackstands under the rear corners of the loader. Disconnect the spring from the lift arm support device retaining pin, hold onto the support device and remove the retaining pin [A]. Lower the lift arm support device on top of the lift cylinder. Hook the free end of the spring to the lift arm support device so there will be no interference with the support device engagement [B]. With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Raise the lift arms, until the lift arm support device is on the lift cylinder rod [C]. Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine. Raise the seat bar and move pedals until both pedals lock. Install pin into the rear of the lift arm support device below the cylinder rod.
P00192
To Disengage Lift Arm Support Device Remove the pin from the lift arm support device. Connect the spring from the lift arm support device to the bracket below the lift arms [D]. With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod. Lower the lift arms. Stop the engine. Raise the seat bar and move pedals until both pedals lock. Disconnect the spring from the bracket. Raise the support device into storage position and insert pin through lift arm support device and bracket [A]. Connect spring to pin. 14
P00148 P00193
OPERATOR CAB The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged.
Nut Washer Bolt
Plate Bushing Washer

MC01181
Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.
W20691285
P00150
Raising The Operator Cab Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Page 14.)
Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death.
W20140895
P00151
P00152
Loosen the nut (both sides) at the corner of the operator cab [A]. Remove the nut and plate (both sides) [B]. Remove the bolt and washer (both sides) [B]. Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [C].
P00153
Lowering The Operator Cab Pull down on the bottom of the operator cab until it stops at the latching mechanism. Release the latching mechanism and pull the cab all the way down [D]. Install bolt and washer from underneath the fender. Install the plate and nut [B]. Tighten the nuts to 4050 ft.lbs. (5468 Nm) torque [A].
P00154
Revised May 96
15
SEAT BAR RESTRAINT SYSTEM Description The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to the neutral position.
A
Clean & Lubricate
P00155

The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly. W21051285 Seat Bar Inspection
Clean Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground. Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed. Pull the seat bar down, lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms should stop. Lower the seat bar, lower the lift arms and place the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt. Seat Bar Maintenance Clean any debris or dirt from the moving parts [A] & [B]. Inspect the linkage bolts and nuts for tightness. The correct torque is 2528 ft.lbs. (3438 Nm). Use a general purpose grease to lubricate the seat bar pivot points at each side of the cab [A]. If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.
P00156
Revised May 96
16
AIR CLEANER SERVICE (743B) Replacement Of The Filter Element See the SERVICE SCHEDULE Page 11 for the interval to service the air cleaner system. Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight. Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator (Item 1) [A]. NOTE: Push the button on the condition indicator (see Inset) and start the engine. If the red ring does not show, do not replace the filter element [A].
P00162
1
P00161
B
Service the air cleaner as follows: Remove the dust cover wing nut [B].
P00212
Remove the dust cover [C].
P00213
Remove the wing nut at the large air filter element [D].
P00214
17
AIR CLEANER SERVICE (743B) (Contd) Replacement Of The Filter Element (Contd) Remove the large filter element. NOTE: Make sure all sealing surfaces are free of dirt and debris. Install the new filter element and tighten the wing nut. Install the dust cover and tighten the wing nut.
P00215
Only replace the inner filter element under the following conditions [B]. Replace the inner filter element every third time the outer filter is replaced. Replace the inner filter element when the red ring still shows in the condition indicator window after the outer filter is replaced.
P00216
Record the operating hours of the loader on the decal (Item 1) [C] inside the rear door.
P00169
18
AIR CLEANER SERVICE (742B) Replacement Of The Filter Element See the SERVICE SCHEDULE Page 11 for the interval to service the air cleaner system Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight. Service the air cleaner as follows: NOTE: Before replacing the filter element, push the button on the condition indicator (Inset) and, start the engine [A] . If the red ring does not show, do not replace the filter element. Loosen the clamp on the dust cup [A]. Remove the dust cup [B].
P0705 P00705 P0705
P00707
P00708
Remove the wing nut [C].
P00703
Remove the element [D]. Check the air cleaner housing for holes or corrosion. Install the new filter element. Install the dust cup so the arrow on the cup is up. Tighten the clamp. All the hoses and clamps must be tight. Push the button on the condition indicator to remove the red ring.
P00712
19
FUEL SYSTEM (743B) Fuel Specifications Use only clean, high quality fuel. Use Grade No. 2 fuel above 40F. (4C.). Use Grade No. 1 fuel at temperatures below 40F. (4C.). Filling The Fuel Tank
Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.
W20630887
P00196
WRONG
Remove the fuel fill cap [A]. 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 [B]. Install and tighten the fuel fill cap [A]. Fuel Filter
B06586
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.
W21031285
See the SERVICE SCHEDULE Page 11 for the service interval when to remove the water from the fuel filter. Turn the fuel shutoff valve clockwise to shutoff the fuel supply [C]. Loosen the drain at the bottom of the filter element (Item 1) [D] to drain the water from the filter [D]. Open the shutoff valve [C]. See the SERVICE SCHEDULE Page 11 for the service interval when to replace the fuel filter. Clean the area around the fuel filter. Close the shutoff valve [C]. Use a wrench to loosen the fuel filter bolt (Item 2) [D]. Remove the water trap and fuel filter (Item 3) [D]. Replace the seals as needed. Install the new filter element and water trap. Tighten the fuel filter bolt. Open the shutoff valve [C]. 110
P00194
D
2
1
P00170
FUEL SYSTEM (743B) (Contd) Removing Air From The Fuel System After replacing the fuel 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. Open the rear door. The engine must be cool. Open the vent plug (Item 1) [A]. Operate the hand pump (Item 2) [A] until fuel flows from the vent plug with no air bubbles. Tighten the vent plug. Operate the hand pump until it feels solid.
A
1
P00171
B
Move the engine speed control to minimum RPM. Open the valve (Item 1) [B] and squeeze the hand pump several times. Start the engine. When the engine runs smoothly, close the valve (Item 1) [B].
P00217
W21031285
111
FUEL SYSTEM (742B) Fuel Specifications Use leaded or unleaded gasoline in the engine.
Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.
W20630887 P00704
Filling The Fuel Tank Remove the filler cap [A]. Use a clean, approved safety container to add fuel. The key switch must be in the OFF position and the engine cool. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING [B]. After the fuel has been added install the filler cap and tighten.
WRONG
B06586
Fuel Filter See the SERVICE SCHEDULE Page 11 for the interval to service the fuel filter. Close the valve on the fuel line (Item 1) [C]. Remove the filter element. Install the new filter element. All connections must be tight. Open the valve at the fuel tank [C].
P00713
W21031285
112
ENGINE LUBRICATION SYSTEM 743B) Checking Engine Oil Check the oil level every day. Stop the engine and remove the dipstick [A]. Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Classification of CC, CD or CE. (See Oil Chart.) Replacing Oil And Filter See the SERVICE SCHEDULE Page 11 for the service interval for replacing the engine oil and filter. Use the following procedure to replace the oil and filter: Run the engine until it is at operating temperature. Stop the engine. Open the rear door and remove the cap from the end of the hose and drain the oil into a container [B]. Remove the filter [C]. Clean the filter housing surface. Put clean oil on the gasket of the new filter install the filter and tighten hand tight. Remove the oil filler cap [D]. Use a good quality motor oil that meets API Service Classification of CC, CD or CE. (See Oil Chart.) RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)
C34 29 23 18 13 7 1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
P00180
P00176
SAE 40 or 20W50
SAE 10W30
SAE 15W40
SAE 5W30
SAE 30W
SAE 20W20
P00209
SAE 10W
F30 20
10
+10
+20 +30
+40 +50 +60
+70
+80 +90 +100 +110 +120 +130 +140
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL: USE API CLASSIFICATION CC, CD or CE)
P00177
Revised Sept. 93
113
ENGINE LUBRICATION SYSTEM (743B) (Contd) Replacing Oil And Filter (Contd) Fill to capacity [A]. (See SPECIFICATION Section 8.) Start the engine and let it run for about 5 minutes. Check for leaks at the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick. Install the oil filler cap NOTE: DO NOT overfill the crankcase.
P00203
Record the operating hours of the loader on the decal inside the rear door [B].
W21031285 P00169
114
ENGINE LUBRICATION SYSTEM (742B) Checking Engine Oil Check the oil level every day. Stop the engine and remove the dipstick [A]. Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Classification of SF or SG. (See Oil Chart.) RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)
C34 29 23 18 13 7 1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
P00720
SAE 40 or 20W50
SAE 10W30
B
SAE 5W30
SAE 15W40
SAE 30W
SAE 20W20
SAE 10W
F30 20
10
+10
+20 +30
+40 +50 +60
+70
+80 +90 +100 +110 +120 +130 +140
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SF or SG) Replacement Of Oil And Filter See the SERVICE SCHEDULE Page 11 for the service interval for replacing the engine oil. Use the following procedure to replace the engine oil and filter: Run the engine until it is at operating temperature. Stop the engine. Open the rear door. Remove the drain plug and drain oil into a container [B]. Remove the oil filter [C]. Clean the filter housing surface. Put clean oil on the gasket of the new filter. Install the filter and tighten hand tight. Install the oil plug. Remove the filler cap on the rocker arm cover. Put 4 quarts (4L) of oil in the engine. (See the Oil Chart.) Start the engine and let it run for about 5 minutes. Stop the engine. Check for leaks and check the oil level. Add oil as needed if it is not at the top mark on the dipstick. Record the operating hours on the decal inside the rear door [D].
P00706
P00722
P00169
115
ENGINE COOLING SYSTEM (743B) Coolant Level Check the cooling system every day to prevent overheating, loss of performance or engine damage. Open the rear door. The coolant recovery tank (Item 1) [A] must be at the FULL COLD mark when engine is cool. Add premixed coolant, 50 % water and 50% antifreeze to the recovery tank if the coolant level is low.
P00178
B
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.
W20191285
Cleaning The Cooling System Open the rear door. Remove the access panels at the blower housing [B]. Remove the rear grill. (See MAIN FRAME Section 5.) Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler [C]. If debris is a problem, check with your dealer about the special debris screens.
P00187
P00146
Removing Coolant From The Cooling System Remove the rear grill. (See MAIN FRAME Section 5.) Remove the radiator cap [D].
P00145
116
ENGINE COOLING SYSTEM (743B) (Contd) Removing Coolant From The Cooling System (Contd) Connect a hose to the coolant drain valve (Item 1) [A] or use a funnel to keep coolant from getting into the engine compartment. Open the valve and drain coolant into a container. When all the coolant is removed close the valve. Fill the radiator with premixed coolant and install the radiator cap.
P00174
Fill the coolant recover tank 1/3 full with premixed coolant [B]. Check the radiator cap for correct pressure rating or overheating can result. Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt. Replace damaged parts immediately to prevent leaks and overheating. Install the rear grill.
P00178
117
ENGINE COOLING SYSTEM (742B) Coolant Level Check the cooling system every day to prevent overheating, loss of performance or engine damage. The coolant recovery tank (Item 1) [A] must be at the FULL COLD mark when engine is cool. Fill with premixed coolant, 50 % antifreeze. water and 50%
P00724
Do not remove radiator cap when the engine is hot. You can be seriously burned.
W20701285
B
1
Cleaning The Cooling System Open the rear door. Remove the access panels at the blower housing. Remove the rear grill. (See MAIN FRAME Section 5.) Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler. If debris is a problem, check with your dealer about the special debris screens. Check the radiator cap (Item 1) [B] for correct pressure rating or overheating can result. Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt. Replace damaged parts immediately to prevent leaks and overheating. Removing Coolant From The Cooling System To remove the coolant from the engine and radiator, use the following procedure: Remove the rear grill. (See MAIN FRAME Section 5.) Remove the radiator cap (Item 1) [B]. Remove the radiator hose [C]. Drain the coolant into a container [D]. Fill the radiator with premixed coolant, 50% water and 50% antifreeze. Fill the coolant recovery tank so it is 1/3 full.
B09901
P00145
B09960
118
ALTERNATOR BELT ADJUSTMENT (743B) Adjusting The Alternator Belt Stop the engine. Loosen the mounting bolt (Item 1) [A] and adjustment bolt (Item 2) [A]. Move the alternator to set the belt tension at 5/16 inch (8 mm) movement between pulleys with 15 pounds (67 N) of force. Tighten the adjustment bolt and mounting bolt.
2 1
5/16 (8 mm)
P00204
119
ALTERNATOR BELT ADJUSTMENT (742B) Adjusting The Alternator Belt To adjust the belt tension, use the following procedure: Stop the engine. Remove the belt shield [A].
P09640
Loosen the bolts that mount the alternator [B].
P09639
Move the alternator until the belt tension permits 1/4 inch movement at the middle of the belt with 20 lbs. (9 kg) of force. Tighten the bolts [B].
B09641
120
GOVERNOR (742B) Governor Belt Adjustment To adjust the belt tension, use the following procedure: Stop the engine. Remove the belt shield [A].
P00732
Loosen the bolts that mount the governor [B].
P00735
Move the governor until the belt tension permits 1/4 inch (6,3 mm) movement at the middle of the belt with 20 lbs. (9 kg) of force. Tighten the bolts [C]. Governor Adjustment To adjust the governor linkage, use the following procedure: Stop the engine. Loosen the screws (Item 1) [C] on the governor arm. Hold the governor arm in the closed position. Tighten the screws. Install the belt shield before starting the engine. Governor Oil Level See the SERVICE SCHEDULE Page 11 for the service interval for checking the governor oil level. Use the following procedure: Remove the check plug (Item 1) [D] at the rear of the governor. If oil flows out the hole, the level is adequate. If no oil flows out the hole, remove the fill plug (Item 2) [D] at the top of the governor and add SAE 10W30 or 10W40 until oil flows from the check plug hole. Install the plug and tighten. Revised July 96 121
C
1
P02046
P00745
USING A BOOSTER BATTERY (Jump Starting) Procedure
743B
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.
W20651296 P00202
742B
If it is necessary to use an extra battery to start the engine, BE CAREFUL There must be one person in the operators seat and one person to connect and disconnect the battery cables. The ignition must be in the OFF position. The booster battery to be used must be 12 volt. Connect the end of the first cable to the positive terminal (+) of the booster battery. Connect the other end of the same cable to the loader battery positive (+) terminal [A] or [B]. Connect the end of the second cable to the negative terminal () of the booster battery. Connect the other end of second cable to the engine and/or starter solenoid [A] or [B]. Keep the cables away from moving parts. Start the engine. (Also See Preheat Condition in the Operation & Maintenance Manual.) Remove the cable from the loader battery. Close the rear door.
B09645
B09646
Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 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.
W20661296
122
HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid Use only recommended fluid in the hydraulic/hydrostatic system. (See SPECIFICATIONS Section 8 for the correct fluid.) To check the fluid in the reservoir, use the following procedure: Put the loader on a level surface. Lower the lift arms and lay the attachment flat on the ground. Stop the engine. Hydraulic fluid must show in the sight glass (Item 1) [A].
P00163
If the fluid is not seen in the sight glass, remove the filler cap from the reservoir [B].
P00165
Add fluid to the reservoir until it shows in the sight glass [C]. Replace the filler cap.
P00166
123
HYDRAULIC/HYDROSTATIC SYSTEM (Contd) Hydraulic/Hydrostatic Filter Replacement See the SERVICE SCHEDULE Page 11 for the correct service interval. Stop the engine. Open the rear door. Clean the area around the filter housing. Remove the filter element (Item 1) [A] or [B]. Clean the surface of the filter housing head where the filter element seal contacts the filter housing. Lubricate the rubber gasket with grease. Install the filter element and hand tighten [A] or [B]. Operate the loader and check for leaks at the filter. Check fluid level in the reservoir and add as needed. Removing The Hydraulic Fluid See the SERVICE SCHEDULE Page 11 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.
743B
P00181
742B
P00726
Remove the filler cap from the reservoir [C].
Remove the screen from the fill pipe [D]. Remove fluid from the hydraulic reservoir with a hydraulic transfer pump or a hand operated suction pump. Wash the screen in clean solvent. Install the screen in the fill pipe. Remove the filter element and install a new filter element. Add hydraulic/hydrostatic fluid to the reservoir. (See SPECIFICATIONS Section 8 for the correct fluid.) DO NOT fill above the sight glass. Operate the loader. Stop the engine and check the fluid level. Add as needed.
P00165
W21031285 P00164
124
SPARK ARRESTOR MUFFLER

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772PreventiveMaintenanceSectionPart1of2
Cleaning Procedure See the SERVICE SCHEDULE Page 11 for correct service interval. Do not operate the loader with a defective exhaust system.
This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation. If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC. Make reference to local laws and regulations for spark arrestor requirements.
I20220595
P00188
Stop engine an allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.
W20111285
Stop the engine. Open the rear door. Remove the plug at the bottom of the muffler (Item 1) [A].
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.
W20501285
Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.
W20681285
Start the engine. Wearing safety goggles, have a second person hold a block of wood over the outlet of the muffler (with the engine running) for about 10 seconds. Stop the engine and install the plug. Close the rear door.
125
TIRE MAINTENANCE Wheel Nuts See the SERVICE SCHEDULE Page 11 for the service interval to check the wheel nuts. The correct torque is 105115 ft.lbs. (142156 Nm) [A]. Tire Rotation Check the tires regularly for wear, damage and pressure. (See SPECIFICATIONS Section 8 for the correct tire pressure.) Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [B]. It is important to keep the same size tires on each side of the loader to avoid excessive wear. If different sizes are used, each tire will be turning at a different speed and cause excessive wear. The tread bars of all the tires must face the same direction. Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader. Tire Mounting Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage. 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 excess pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid overinflation.
P00167
C01965
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. W20781285
FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/hydrostatic system. (See SPECIFICATIONS Section 8.) To check the chaincase oil level, use the following procedure: Drive the loader onto a level surface. Stop the engine. Remove the plug (Item 1) [A] at the front of the chaincase housing.
A
1
P00168
If oil can be reached with the tip of the your finger through the hole the oil level is correct. If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.
127
LUBRICATING THE BOBCAT LOADER Procedure Lubricate the Bobcat loader as specified in the SERVICE SCHEDULE Page 11 for the best performance of the loader. Always use a good quality lithium based multipurpose grease when you lubricate the loader. Apply the lubricant until the extra grease shows. Lubricate the following locations on the loader: 1. Rod End Lift Cylinder (both sides) [A].
A
1
P00175
2. Base End Lift Cylinder (both sides) [B].
P00190
3. Lift Arm Pivot Pin (both sides) [C].
P00189
4. Base End Tilt Cylinder [D].
D
4
P00172
128
LUBRICATING THE BOBCAT LOADER (Contd) Procedure (Contd) 5. Rod End Tilt Cylinder [A].
P00168
6. BobTach Pivot Pin (both sides) [B]. 7. BobTach Wedge (both sides) [B].
7
P00173
8. 250 Hours: Steering Lever Shaft (2) [C].
P00198
9. 250 Hours: Steering Lever Shaft Bearings (2) [D].
D
9 9
P00191
P00195
129
UJOINT LUBRICATION
742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772PreventiveMaintenanceSectionPart2of2
Procedure See the SERVICE SCHEDULE Page 11 for the service interval when to lubricate the Ujoint grease fittings. Raise the operator cab. (See Page 15.) Use the special Ujoint grease (P/N 6599719) to assure correct lubrication for the Ujoint.
A
B03371
P00200
REMOTE START SWITCH Procedure The tool listed will be needed to do the following procedure: MEL1138A Remote Start Switch The remote start switch is required when the operator cab is int he raised position for service and the service technician needs to start the engine. The wire harness must be separated at the operator cab and engine wiring harness connectors. Place the loader on jackstands before centering the steering linkage, checking the main relief valve, or check pump flow.
B09842
W20170286
The remote start switch is connected to the engine harness connector. This remote start switch is required when the service technician is adjusting the steering linkage or checking the hydraulic or hydrostatic system
130
HYDRAULIC SYSTEM Page Number HYDRAULIC CONTROL PEDALS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 HYDRAULIC CONTROL VALVE Adjusting The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Main Relief Valve W/Auxiliary Couplers (Opt.) . . . . . . . . Checking The Main Relief Valve W/O Auxiliaries . . . . . . . . . . . . . . . . . . Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 27 28 29 210 HYDRAULIC SYSTEM
HYDRAULIC FLUID FILTER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 HYDRAULIC FLUID RESERVOIR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 HYDRAULIC PUMP Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . 212 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 HYDRAULIC SYSTEM INFORMATION Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Straight Thread Oring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 22 22 22
LIFT CYLINDER Checking The Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 PEDAL INTERLOCK LINKAGE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 PORT BLOCK Case Drain Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Cold Weather ByPass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 TILT CYLINDER Checking The Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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.
W20041285
PROBLEM The hydraulic system will not operate. Slow hydraulic system action. Hydraulic action is not smooth. Lift arms go up slowly at full engine RPM. The lift arms or BobTach will move when the pedal is in neutral position. The lift arms come down with the pedal in the neutral position.
CAUSE 1, 2, 3 1, 3, 4, 5, 6 1, 4, 5, 6, 7 1, 3, 4, 6, 7, 8, 9 4 4, 9, 10
KEY TO CORRECT THE CAUSE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. The fluid level is not correct. The pedal linkage is disconnected. The hydraulic pump has damage. The pedal linkage is not adjusted correctly. Relief Valve is not at the correct pressure. Suction leak on the inlet side of the hydraulic pump. Fluid is cold. Internal leak in the lift cylinder(s). External leak from the lift cylinder(s). Leaking seal in port relief valve, lift section.
21
742, 743B Loader Service Manual
HYDRAULIC SYSTEM INFORMATION
Mark a Line on Nut Flats of Both Nuts
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.
I20030888
Tighten to Correct Amount from Chart
A01897
Flare Connections Use the following procedure to tighten the flare fitting: Tighten the nut until it makes contact with the seat. Make a mark across the flats of both the male and female parts of the connection [A]. Use the chart to find the correct tightness needed [B]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.
Tube Size Rotate No. Wrench Size Outside Dia. Thread Size of Hex Flats 5/8 5/16 1/2 20 21/2 11/16 7/8 1 11/4 13/8 2 21/4 3/8 1/2 5/8 3/4 1 11/4 11/2 9/16 18 3/4 16 7/8 14 11/16 12 15/16 12 15/8 12 17/8 12 2 2 11/2 2 1 3/4 1 3/4 1 1/2 3/4
Oring Face Seal Connection When the fitting is tightened, you can feel when the fitting is tight to eliminate leakage caused by under or over torqued fittings. Use vaseline petroleum jelly to hold the Oring in position until the fittings are assembled [C].
B07575
Straight Thread Oring Fitting Lubricate the Oring before installing the fitting. Loosen the jam nut and install the fitting. Tighten the jam nut until the washer is tight against the surface [D]. Tubelines And Hoses Replace any tubelines that are bent or flattened. They will restrict flow, which will slow hydraulic action and cause heat. Replace hoses which show signs of wear, damage or weather cracked rubber. Always use two wrenches when loosening and tightening hose or tubeline fittings. 22
A01852
D
Nut Washer Oring Oring Nut Washer
LIFT CYLINDER Checking The Lift Cylinder(s) Lower the lift arms. Stop the engine. Activate the lift pedal to release the hydraulic pressure. Open the rear door.
B09855
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.
W20720496
Disconnect the hose from the tubeline which comes from the base end of the lift cylinder; left [A], right [B]. Only check one cylinder at a time. Put a plug in the tubeline. Put the parking brake in the lock position and lower the seat bar. Start the engine and push the top (toe) of the lift pedal. If there is any leakage from the open port, remove the lift cylinder for repair. Repeat the procedure to check the lift cylinder on the other side. Removal And Installation Stop the engine. Activate the lift pedal to release the hydraulic pressure. Raise the operator cab. (See PREVENTIVE MAINTENANCE Section 1.) Remove the lock bolt and nut at the rod end of the lift cylinder [C].
B09856
B09795
Installation: Tighten the bolt and nut to 1820 ft.lbs. (2427 Nm) torque. Remove the rod end pin [D].
B09794
23
LIFT CYLINDER (Contd) Removal And Installation (Contd) Remove the lock bolt at the base end pivot pin [A].
B09896
Remove the base end pivot pin [B].
B09857
Disconnect the hydraulic hoses at the tubelines; left [C], right [D]. Slide the cylinder forward and remove it from the loader. SEE THE COMPONENT REPAIR MANUAL FOR HYDRAULIC CYLINDERS FOR DISASSEMBLY AND ASSEMBLY PROCEDURE.
B09855
B09856
24
TILT CYLINDER Checking The Tilt Cylinder Remove the bucket or attachment. Roll the BobTach frame fully backward. Stop the engine. Activate the tilt pedal to release the hydraulic pressure.
W20720496
B09787
Disconnect the hose which goes to the base end of the tilt cylinder [A]. Put a plug in the hose. Put the parking brake in the locked position and lower the seat bar. Start the engine and push the bottom (heel) of the tilt pedal. If there is leakage from the open port, remove the tilt cylinder for repair. Removal And Installation Remove the bucket or attachment. Roll the BobTach frame fully forward. Stop the engine. Push the tilt pedal to release the hydraulic pressure. Disconnect the hydraulic hoses [A]. Remove the nut at the rod end pivot pin [B]. Installation: Tighten the nut to 1820 ft.lbs. (2427 Nm) torque. Remove the rod end pivot pin [C]. NOTE: See MAIN FRAME Section 5 to install the rod end seals. Remove the lock bolt at the base end pivot pin [D]. Installation: Tighten the bolt and nut to 1820 ft.lbs. (2427 Nm) torque.
CD08710 CD08709
B04402
25
TILT CYLINDER (Contd) Removal And Installation (Contd) Remove the base end pivot pin [A]. Remove the tilt cylinder from the loader lift arms. SEE THE COMPONENT REPAIR MANUAL FOR HYDRAULIC CYLINDERS FOR DISASSEMBLY AND ASSEMBLY.
B04401
26
HYDRAULIC CONTROL VALVE Checking The Couplers (Opt.) Main Relief Valve W/Auxiliary
The tools listed will be needed to do the following procedure: MEL1238 Hydraulic Tester MEL10006 Hydraulic Test Kit Stop the engine. Activate the right steering lever to release the hydraulic pressure. Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
B04371
Connect the hydraulic tester to the auxiliary quick couplers [A].
The hydraulic tester must be in the fully open position before you start the engine.
I20240284
W20170286
Start the engine and run at idle RPM. Engage the right steering lever into the detent position. Watch the flow meter at the hydraulic tester to make sure the flow is correct. Increase the engine RPM to maximum. There should be 12.1 GPM (45,8 L/min.) free flow. Turn the restrictor control. at the tester, until the main relief valve opens. The correct pressure for the main relief valve is 11501400 PSI (1551416548 kPa) free flow at the quick couplers. If not, stop the engine. Replace or adjust the main relief valve. (See Page 29.) When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.
W20060284
27
HYDRAULIC CONTROL VALVE (Contd) Checking The Main Relief Valve W/O Auxiliaries The tools listed will be needed to do the following procedure: MEL1238 Hydraulic Tester MEL10006 Hydraulic Test Kit Stop the engine. Activate the tilt pedal to release the hydraulic pressure. Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
Disconnect the hydraulic hoses at the tilt cylinder [A]. Connect the hydraulic tester to the tilt cylinder hoses [B]. Have a second person in the operator seat, with the seat bar in the down position and the parking brake in the locked position. Start the engine and run at idle RPM. Push the tilt pedal at the top (toe) or bottom (heel) until the hydraulic tester shows the correct fluid flow through the flow meter. Increase the engine RPM to maximum. There should be 12.1 GPM (45,8 L/min.) free flow.
B09787
B09849
Turn the restrictor control, at the tester, to increase the pressure until the main relief valve opens. The correct pressure is 22502400 PSI (1551416548 kPa) free flow. If not, stop the engine. Replace or adjust the main relief valve. (See Page 29.)
W20501285
28
HYDRAULIC CONTROL VALVE (Contd) Main Relief Valve Removal And Installation Stop the engine. Activate the hydraulic controls to release the hydraulic pressure. Open the rear door. Raise the operator cab. (See PREVENTIVE MAINTENANCE Section 1.) Clean the area around the control valve. The main relief valve (Item 1) [A] is located at the rear of the control valve. NOTE: It may be necessary to disconnect some tubelines for better clearance to the main relief valve.
B09891
B
Use a deep socket and extension, remove the main relief valve [B]. Installation: Always us NEW Orings, when installing the main relief valve. Clean and inspect the relief valve and replace as needed.
B09894
Adjusting The Main Relief Valve Clean the area around the main relief valve. Remove the cap from the main relief valve [C].
B09892
Loosen the lock nut. Use an allen wrench and adjust the main relief valve [D]. Check the main relief valve with the hydraulic tester again, until the pressure setting is correct. (See Page 27 or 28.)
B09893
29
HYDRAULIC CONTROL VALVE (Contd) Removal And Installation
I20030888
B09819
B
Stop the engine. Activate the hydraulic controls to release the hydraulic pressure. Lift and block the loader. MAINTENANE Section 1.) (See PREVENTIVE
B09859
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Raise the operator cab. MAINTENANCE Section 1.)
(See
PREVENTIVE
Clean the area around the control valve. Remove the port block from the loader. (See Page 214.) Disconnect the hose from the control valve [A]. Disconnect the linkage at the control valve [B] & [C].
B09821
Disconnect all the tubelines from the control valve [D].
B09858
210
HYDRAULIC CONTROL VALVE (Contd) Removal And Installation (Contd) Remove the mounting bolts and nuts from the control valve [A] & [B]. Installation: Tighten the mounting bolts and nuts to 180200 in.lbs. (2123 Nm) torque. SEE THE COMPONENT REPAIR MANUAL FOR HYDRAULIC CONTROL VALVE DISASSEMBLY AND ASSEMBLY PROCEDURE.
B09818
B09809
211
HYDRAULIC PUMP Checking The Output Of The Hydraulic Pump The tools listed will be needed to do the following procedure: MEL1238 Hydraulic Tester MEL10006 Hydraulic Test Kit NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. Lift and block the loader. MAINTENANCE Section 1.) Raise the operator cab. MAINTENANCE Section 1.) (See (See
B09860
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PREVENTIVE PREVENTIVE 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.
I20030888
Disconnect the OUTLET hose at the pump. Connect the INLET hose of the tester to the OUTLET of the hydraulic pump [A]. Connect the OUTLET hose from the tester to the hose which was removed from the pump [A]. NOTE: Make sure the restrictor control on the tester is fully open. Disconnect both hoses at the tilt cylinder and install plugs. Start the engine and run at idle RPM. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full RPM. Warm the hydraulic fluid to 140F. (60C.) by turning the restrictor control on the tester to about 1000 PSI (6895 kPa). DO NOT exceed system relief pressure. Open the restrictor control and record the free flow GPM (L/min.) at full RPM. Activate the tilt pedal. Record the highest pressure PSI (kPa) and flow GPM (L/min.) at full RPM. The high pressure flow must be at least 80% of free flow. %= HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM) X 100
A low percentage may indicate a failed hydraulic pump or it may be caused by air in the system. Make sure all the air is removed from the system. Refer to the SPECIFICATIONS Section 8 for system relief pressure and full RPM. The system relief pressure must be per specifications before the test is run. Revised May 96 212 742B, 743B Loader Service Manual
HYDRAULIC PUMP (Contd) Removal And Installation
I20030888
CD09061
B
Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE Remove the fluid from the hydraulic fluid reservoir. Disconnect the hose at the hydraulic pump [A]. Disconnect the hose at the outlet of the pump [B].
CD09062
Remove the pump mounting bolts. Installation: Tighten the bolts to 2528 ft.lbs. (3438 Nm) torque. Remove the hydraulic pump [C].
CD09060
Installation: Install a new large Oring (Item 1) [D]. SEE THE COMPONENT REPAIR MANUAL FOR HYDRAULIC PUMPS FOR DISASSEMBLY AND ASSEMBLY PROCEDURE.
1
CD09059
Revised May 96
213
PORT BLOCK Removal And Installation The tool listed will be needed to do the following procedure: MEL1272 Plug and Cap Set
I20030888
B09790
Remove the fluid from the hydraulic fluid reservoir. Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Clean the area around the port block. Disconnect the hydraulic pump hose from the port block [A].
B09811
Disconnect the inlet hose [B]. Disconnect the wire at the sender switch [C].
B09812
Disconnect the case drain hoses at the port block [D].
B09803
214
PORT BLOCK (Contd) Removal And Installation (Contd) Disconnect the tee fitting at the port block [A].
B09791
Remove the nut which fastens the port block to the mounting bracket [B].
B09814
Remove the port block from the mounting bracket [C].
B09789
Cold Weather ByPass Valve Disconnect the tee fitting. Remove the fitting from the port block [D]. NOTE: When installing the fitting make sure to tighten the fitting to get the correct spring tension on the poppet.
B09815
215
PORT BLOCK (Contd) Cold Weather ByPass Valve (Contd) Remove the poppet and spring [A]. Clean and inspect the parts. Check the seat in the fitting for damage. Always use new Oring when installing the fitting.
B09802
Case Drain Relief Valve Remove the plug at the port block [B].
B09788
Remove the spring and poppet [C]. Clean and inspect the parts. Always use new Oring when installing the plug.
B09801
216
HYDRAULIC FLUID RESERVOIR Removal And Installation Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Use a transfer pump or hand pump and remove the fluid from the hydraulic reservoir. Disconnect the oulet hose at the reservoir [A].
B04920
Remove the bolt at the holding strap [B]. Remove the hydraulic reservoir from the loader.
B09864
217
HYDRAULIC CONTROL PEDALS Removal And Installation Remove the bolt and nut at the linkage [A]. Check the rubber bushing in the pedal for wear and replace as needed.
B08831
Remove the two mounting bolts [B].
B09793
Remove the pedal from the loader [C]. Adjustment After installing the pedal, adjust the pedal so that there is clearance under the rear of the pedal and the valve spool will travel full stroke without the pedal hitting.

Adjust locking tabs on pedal control linkage so that lift and tilt control pedals are locked in neutral when the seat bar is up.
W21041285
B08833
218
PEDAL INTERLOCK LINKAGE Installation If the pedal interlock linkage was removed, use the following procedure to install the linkage [A]. Install the bolts (Item 1) [A] from the outside the fender. Install the plastic washer (Item 2) [A]. Install the interlock (Item 3) [A]. Install the plastic washer (Item 4) [A]. Put LOCTITE #242 on the threads of the bolts. Install the special nuts (Item 5) [A]. make sure the special nut goes tight against the fender and that the plastic washer (Item 2 & 4) [A] go over the shoulder of the the special nut. Tighten the special nut to 25 ft.lbs. (34 Nm) torque.
A
5 4 2 1
3
D01548

Adjust locking tabs on pedal control linkage so that lift and tilt control pedals are locked in neutral when the seat bar is up.
W21041285
1
B04043
Adjustment Check that the pedal interlock linkage is free and locks the pedals when returned to neutral position. Check that the tab goes into the slot at the interlock [B]. If not, loosen the bolts (Item 1) [B] and adjust the tab for engagement. Installation: Tighten the bolts to 25 ft.lbs. (34Nm) torque.
219
HYDRAULIC FLUID FILTER HOUSING

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772HydraulicSystemSection
Removal And Installation Remove the hydraulic filter. Remove the hoses and tubelines from the filter head. Remove the filter head [A].
B04904
Put the filter head in a vise. Remove the cap, spring and poppet [B]. Check the poppet and the seating area for damage. Replace the parts as needed. NOTE: Always use new Orings when installing the bypass valve.
B04906
220
HYDROSTATIC SYSTEM Page Number FRONT PANEL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 HYDROSTATIC MOTOR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 HYDROSTATIC PUMP Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking High Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Pump Rear Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 312 313 318 317 314 318 HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION High Pressure Relief/Replenishing Valve Function . . . . . . . . . . . . . . . . . 32 STEERING LEVERS Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Repairing The Steering Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 STEERING LINKAGE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Repairing The Pintle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9) UNLESS OTHERWISE SPECIFIED.
Revised July 96
TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death.
W20041285
PROBLEM No drive on one side, in one direction. No drive on one side in both directions. The loader does not move in a straight line. The hydrostatic system is overheating. The warning light comes ON (Low charge pressure).
CAUSE 1, 2, 3, 4, 5 2, 3, 5, 6, 7, 8 2, 3, 4, 6, 8, 9, 10 4, 11, 12, 13, 14, 15 11, 15, 16, 17, 18
KEY TO CORRECT THE CAUSE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. The hydrostatic system has a fluid leak. The steering linkage needs adjustment. The high pressure replenishing valve(s) are damaged. the shuttle valve in the hydrostatic motor is not working correctly. The valve plate seals in the hydrostatic motor are damaged. The hydrostatic pumps have damage. The final drive chain is broken. The hydrostatic motor has damage. the tires do not have the correct tire pressure. The tires are not the same size. The hydraulic fluid is not at the correct level. The oil cooler has a restriction. The temperature sending switch is not operating correctly. The control valve is not operating correctly. The loader is not being operated at the correct RPM. The sender is defective. Pump is defective or worn hydrostatics. Hydraulic filter is plugged.
31
HYDROSTATIC SYSTEM INFORMATION
CHARGE OIL
I20030888
FUNCTION 1
Valve Moves for Charge Oil Replacement
High Pressure Relief/Replenishing Valve Function The valves for forward movement are different from the valves for reverse travel. The high pressure relief/replenishing valves for forward travel, also release very high pressure. The functions of the replenishing valves are: 1. To give replacement fluid to the low pressure side of the hydrostatic circuit. Replacement fluid is needed because of normal internal leakage and the controlled flow to the oil cooler for cooling; Function 1 [A] and Function 1 [B]. 2. To keep high pressure fluid out of the low pressure side of the hydrostatic circuitry; Function 2 [A] and Function 2 [B]. 3. To release high pressure caused by moving forward with a heavy load on the loader, Function 3 [A].
FUNCTION 2
Valve Stays on Seat to Hold High Pressure for Drive
FUNCTION 3
Valve Release Very High Pressure to Protect System

B02805
B
CHARGE OIL
Valve Moves for Charge Oil Replacement
FUNCTION 1
Valve Stays on Seat to Hold High Pressure for Drive
FUNCTION 2
B02804
32
FRONT PANEL Removal And Installation
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CD12707
Raise the lift arms and install the lift arm support devise. (See PREVENTIVE MAINTENANCE Section 1.) Stop the engine. Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Remove the nut at the parking brake pedal [A].
Using a drill, remove the pop rivet heads from the parking brake linkage rubber boot [B].
CD12832
Slide the rubber boot away from the front panel [C].
CD12709
Remove the bolts at the foot rests (both sides) [D].
CD12710
33
FRONT PANEL (Contd) Removal And Installation (Contd) Remove all the bolts at the left side of the front panel [A].
B09833
Remove all the bolts at the right side of the front panel [B].
B09837
Remove the hand grip by plugging the hole at the bottom of the steering lever and using air pressure to remove the hand grip (both sides) [C].
B07876
Lift and remove the front panel from the loader frame [D].
B09922
34
STEERING LEVERS Removal And Installation Remove the front panel. (See Page 33.) Disconnect the steering linkage at the steering levers [A]. Installation: Tighten the bolts and nuts to 23 ft.lbs. (31 Nm) torque. Disconnect the auxiliary linkage from the steering levers if so equipped.
B09908
Hold the nuts inside the loader frame [B] and remove the bolts at the pivot bearing [C].
B09832
B09989
Remove the bolts and nuts at the pivot bearing [D].
B09988
35
STEERING LEVERS (Contd) Removal And Installation (Contd) Lift and remove the steering lever assembly from the loader [A].
B09854
Repairing The Steering Levers Remove the rubber bushings and teflon bushings from the steering levers. Install new rubber bushings into the steering levers, using two sockets and a vise [B].
B
Washer Neoprene Bushing
B10030
B10032
Install new teflon bushings when installing the two steering assemblies together [C].
B10031
36
STEERING LINKAGE Steering Linkage Adjustment Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. Raise the operator cab. MAINTENANCE Section 1.) (See
B09908
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PREVENTIVE
Connect a remote start switch. (See PREVENTIVE MAINTENANCE Section 1.) Loosen the nuts and bolts at both steering levers [A]. Loosen the nuts and bolts at the front and rear pintle levers [B]. Start the engine and run at idle RPM.
B09970
Loosen the bolts that connect the front and rear pintle levers to the pintle lever bars [C]. Move the steering lever for the rear pintle arm, until the tires do not mover (neutral).
Push the top (slotted hole) of the pintle bar (Item 1) [D] against the lobe on the pintle lever with the transmission still in neutral. Tighten the rear pintle bar bolts to 28 ft.lbs. (38 Nm) torque. Move the steering lever, fro the front pintle lever, until the tires do not run (neutral). Push the pintle bar (Item 2) [D] against both lobes of the pintle lever with the transmission still in neutral. Tighten the front pintle bar bolts to 28 ft.lbs. (38 Nm) toque. Move both steering levers backward and forward and let the transmission return to neutral. If the transmission does not return to neutral, repeat the adjustment again. Install new lock nuts at the steering linkage and tighten to 23 ft.lbs. (31 Nm) torque. Revised July 96
B09888
1 2
C02556
37
STEERING LINKAGE (Contd) Removal And Installation Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Disconnect the steering linkage at both pintle levers [A]. Installation: Install new lock nuts and tighten to 23 ft.lbs. (31 Nm) torque.
B09970
At the centering spring bolt loosen the lock nut and turn the bolt out of the bracket [B].
B09897
Loosen the bolt at the rear pintle lever [C].
B09841
Loosen the bolt at the front pintle lever [D]. Installation: Install the key in the pintle shaft. Tighten the pintle lever bolt to 1820 ft.lbs. (2427 Nm) torque.
B09902
Revised July 96
38
STEERING LINKAGE (Contd) Removal And Installation (Contd) Remove the guide bar, bushings and pintle levers as an assembly [A]. Installation: Adjust the steering linkage for neutral. (See Page 37.)
B09910
Repairing The Pintle Lever Remove the bolt at the lobes on the pintle lever [B]. Installation: Tighten the bolts to 2528 ft.lbs. (3438 Nm) torque. Remove the rubber bushing from the pintle lever.
B04476
Install a new rubber bushing into the pintle lever [C].
Neoprene Bushing
Washer
B04388
Press the rubber bushing into the pintle lever, using two sockets and a vise [D].
B04471
39
HYDROSTATIC MOTOR Removal And Installation
I20030888
CD12835
B
Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE Remove the bolts from the motor cover [A]. Remove the motor cover [B].
CD12836
Mark both high pressure hoses for correct installation. Disconnect both high pressure hoses from the motor [C] & [D].
CD12837
CD12838
310
HYDROSTATIC MOTOR (Contd) Removal And Installation (Contd) Disconnect the case drain hose (Item 1) [A].
CD12839
Remove the bolts from the motor mounting flange [B]. Installation: Tighten the bolts to 90100 ft.lbs. (122136 Nm) torque.
B12840
Remove the hydrostatic motor from the motor carrier [C]. NOTE: When connecting the high pressure hoses, See Page 317 for the correct hose routing. SEE THE COMPONENT REPAIR MANUAL FOR HYDROSTATIC MOTOR DISASSEMBLY AND ASSEMBLY PROCEDURE.
B12841
311
HYDROSTATIC PUMP Checking Charge Pressure The tool listed will be needed to do the following procedure: MEL1173 Test Kit List and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
CD12842
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(See
PREVENTIVE
Connect the remote start switch. (See PREVENTIVE MAINTENANCE Section 1.) Disconnect the wires from the charge pressure switch [A].
B09839
Remove the charge pressure switch (Item 1) [A]. Connect a pressure gauge to the port. Start the engine and check the charge pressure. The correct pressure is 95115 PSI (655793 kPa). Charge Pressure Relief Valve Remove the plug at the charge pressure relief valve [B]. Remove the poppet and spring [C]. Check the parts for wear or damage.
B09905
312
HYDROSTATIC PUMP (Contd) Checking High Pressure Relief Valves Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
B09885
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(See
PREVENTIVE
NOTE: To remove the high pressure relief valve from the left side of the hydrostatic pump, you must remove the steering linkage. (See Page 38.) If there is a loss of drive in one direction, to one side of the loader, use this procedure to check the high pressure replenishing valves: Remove the plugs at the right and left side of the hydrostatic pump [A] & [C]. Remove the high pressure relief valve and the replenishing valves [B] & [D]. Exchange the valves (put in opposite ports) and check for loss of drive on the opposite side of the loader. If there is a loss of drive to the opposite side of the loader, the valve which controls that side of the loader must be replaced.
B09907
B09840
B09904
313
HYDROSTATIC PUMP (Contd) Removal And Installation Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
CD12843
W20170286
B
Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE Remove the fluid from the hydraulic fluid reservoir. Disconnect the steering linkage at the steering levers and pintle lever [A]. Installation: Tighten the bolts and nuts to 23 ft.lbs. (31 Nm) torque. See Page 37 for neutral adjustment. Disconnect the wire at the port block [B].
CD12844
Disconnect the wires at the charge pressure sending switch [C].
CD12842
Disconnect the outlet hose from the hydraulic pump [D].
CD12845
314
HYDROSTATIC PUMP (Contd) Removal And Installation (Contd) Disconnect the inlet hose for the hydraulic pump [A].
CD12846
Disconnect the hose from the tee fitting on the top of the pump [B].
B12847
Disconnect the hose from the port block [C].
CD12848
Disconnect the high pressure hoses from the hydrostatic motor (both sides) [D].
CD12837
315
HYDROSTATIC PUMP (Contd) Removal And Installation (Contd) Loosen the mounting bolts for the fuel tank/hydraulic reservoir mounting strap. Lift the fuel tank for clearance. Remove the left mounting bolt, washers, rubber bushing and nut [A].
CD12849
Remove the right mounting bolt, washers, rubber bushing and nut [B]. Installation: See Page 317 for the correct hydrostatic pump mounting height. Connect chain hoist to the hydrostatic pumps.
CD12850
Remove the nuts and bolts at the front mounting bracket [C]. Slide the hydrostatic pumps forward and out of the ujoint at the engine. Lift the pump from the loader. Installation: Make alignment of the splines at the hydrostatic pump shaft and ujoint when installing the pumps. Use special lubricant (P/N 6599719) on the Ujoint splines. SEE THE COMPONENT REPAIR MANUAL FOR HYDROSTATIC PUMP FOR DISASSEMBLY AND ASSEMBLY PROCEDURE.
CD12851
316
HYDROSTATIC PUMP (Contd) Hydrostatic Pump Rear Mount If the rear pump mount is removed, make sure to not the location of the washer(s) between the mount and the frame. These washers (Item 1) [A] must be installed at the correct location to give the pump and engine the correct alignment.
10.00 .06 (254 mm) 1.52
Engine Mounting Plate

B06938
High Pressure Hose Routing Make sure to connect the high pressure hoses to the correct ports of the hydrostatic pumps and motors [B].
Tow Valves
Front of Loader
I20030888
C02767
The tool listed will be needed to do the following procedure: MEL11792 Towing Tool Clean the area around the two high pressure relief valves on the pumps. Remove the plug, spring and high pressure relief from the front and rear pump [C]. Install the towing tools (Item 1 & 2) and then only install the plugs [D]. Now the loader can be moved (towed) at a slow speed (2 MPH) for a short distance such as 75 to 100 feet (23 to 30 m). NOTE: Make sure to remove the tow tools before trying to operate the loader.
B09846
B09847
Revised July 96
317
DRIVE SYSTEM Page Number AXLE SEAL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 AXLE, SPROCKET AND BEARINGS Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 CHAINCASE FLUID Replacing the Chaincase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 DRIVE CHAIN Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 MOTOR CARRIER Disassembly And Assembly (Early Models) . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Block And Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Transmission Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 410 410 49 47 41 44 46 46 42 DRIVE SYSTEM
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9) UNLESS OTHERWISE SPECIFIED.
Revised Sept. 93
PARKING BRAKE Adjustment When the parking brake is in good condition and adjusted correctly, it will keep the loader from moving when the steering levers are moved. Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Turn the nut (Item 1) [A] to adjust eh parking brake. There must be 3/4 inch (19 mm) movement from the top of the cover (not the bolt head) to the bottom edge (heel) of the brake pedal.
P02450
NOTE: If the correct adjustment can not be obtained by turning the nut, the brake lever must be adjusted using the following procedure. Loosen the nut (Item 1) [A]. Disconnect the spring from the brake lever [B].
P02294
Remove the adjustment nuts on the brake lever. Loosen the bolt on the brake lever [C]. Do not remove the bolt.
P02291
Use a pry bar and hammer, pry up on the lever and hit the bolt with the hammer until the brake lever is loose [D]. Remove the bolt and brake lever. Turn the brake block shaft counterclockwise until the brake pads make contact with the brake discs. Install the brake lever. Install the bolt and tighten to 6570 ft.lbs. (8895 Nm) torque. Adjust the parking brake again.
P02296
Revised Sept. 93
41
PARKING BRAKE (Contd) Removal And Installation Raise the lift arms. (See PREVENTIVE MAINTENANCE Section 1.) Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Remove the nut from the lift pedal linkage [A]. Remove the front panel. (See HYDROSTATIC SYSTEM Section 3.) Remove the steering lever assembly. HYDROSTATIC SYSTEM Section 3.) (See
P02430
Disconnect the lift linkage from the control valve spool [B].
P02285
Remove the nut from the linkage crossmember bolt [C].
P02299
Remove the linkage crossmember [D]. Remove the plastic washer (Item 1) [D] and check for wear and replace as needed.
P02297
Revised Sept. 93
42
PARKING BRAKE (Contd) Removal And Installation (Contd) NOTE: If the brake block and pads are going to be disassembled, loosen the brake lever bolt [A]. Use a pry bar and hammer, pry up on the lever and hit the bolt until the brake lever is loose [B]. Installation: Tighten the bolt to 6570 ft.lbs. (8895 Nm).
P02291
P02295
Remove all the cover bolts. [C].
P02298
Remove the cover/brake block assembly [D]. Installation: Clean and dry the cover. Clean the surface on the chaincase where the cover sets. Use a new gasket under the cover. Align the brake discs so they are centered and inbetween the brake pads [A]. NOTE: Some early loaders used a sealant to seal covers. A gasket now available is recommended.
P01732
Revised Sept. 93
43
PARKING BRAKE (Contd) Brake Block And Pads Remove the brake lever bolt [A]. Assembly: Tighten the bolt to 6570 ft.lbs. (8895 Nm) torque.
CD08829
Remove the brake lever [B].
CD08830
Remove the bolt from the brake block [C]. Assembly: Tighten the bolts to 6570 ft.lbs. (8895 Nm) torque.
P01725
Remove the guide and pads [D]. Assembly: Note location of pads and spacers. Check the pads for wear and replace them as needed [D].
P01737
Revised Sept. 93
44
PARKING BRAKE (Contd) Brake Block And Pads (Contd) Remove the bolts which fasten the brake block to the cover [A]. Assembly: Tighten the bolts to 6570 ft.lbs. (8895 Nm) torque.
CD08834
Remove the brake block [B]. Assembly: Clean and dry the brake block. Put a bead of R.T.V. sealant on the brake block. NOTE: Do Not use excessive R.T.V. sealant on the block. Make sure the brake shaft does not rub.
CD08835
Remove the shaft from the brake block [C]. Assembly: Always install a new Oring when the shaft is installed. Make sure the shaft rotates freely in the cover.
CD08836
Revised Sept. 93
45
PARKING BRAKE (Contd) Brake Disc Removal And Installation To remove the brake discs, the following items must be removed: Remove the center cover. (See Page 42.) Remove the front cover. (See HYDROSTATIC SYSTEM Section 3.)
D02188
Remove the brake disc snap ring (Item 1) [B].
B
1
P01733
Remove the brake discs through the front cover hole [C]. Check the brake discs for damage. Replace the brake discs as needed. DO NOT grind the brake discs.
Rear Transmission Cover Installation When installing the rear cover on the transmission always use three shoulder bolts where shown [D].
P01731
See your Bobcat loader dealer for the correct shoulder bolts. Tighten the bolts to 2025 ft.lbs. (2734 Nm) torque. NOTE: Be sure the warning decal is installed on the inside of the left fender.
LOCATION
MC01707
Revised Sept. 93
46
MOTOR CARRIER Shaft Seal Replacement The tools listed will be needed to do the following procedure: MEL1399 Axle Seal Tool MEL1402 Carrier Seal Tool Remove the hydrostatic motor. (See HYDROSTATIC SYSTEM Section 3.) Use a plier and pull the seal carrier from the motor carrier [A].
P02097
Remove the old Oring and replace with a new Oring [B].
P01741
Remove the old seals from the seal carrier. Install the seal carrier on the axle seal tool (MEL1399) [C].
CD08845
Install the two seals on the shaft of the motor carrier seal tool (face the seal lips with one inward and one outward) [D].
CD09948
Revised Sept. 93
47
MOTOR CARRIER (Contd) Shaft Seal Replacement (Contd) Install the two seals and shaft into the top half of the seal carrier tool [A].
CD09949
Install the seals/tool assembly into the motor carrier seal housing [B]. Hit the tool with a hammer to seat the seals into the housing.
CD09950
Install the seal/seal carrier housing into the motor carrier [C].
CD08853
Install the seal carrier installation tool into the seal carrier housing. Hit the tool with a hammer until the seal housing is fully seated [D].
CD08852
Revised Sept. 93
48
MOTOR CARRIER (Contd) Removal And Installation (Later Models) Raise the lift arms. (See PREVENTIVE MAINTENANCE Section 1.) Lift and block the loader. MAINTENANCE Section 1.) Raise the operator cab. MAINTENANCE Section 1.) (See (See PREVENTIVE PREVENTIVE
Remove the front panel/steering levers assembly. (See HYDROSTATIC SYSTEM Section 3.) Remove the parking brake/cover assembly. (See Page 42.) Remove the fluid from the chaincase. (See Page 419.) Remove the front axle and sprocket. (See Page 414.) Remove the hydrostatic motor. (See HYDROSTATIC SYSTEM Section 3.) Remove from the motor carrier mounting bolts from inside the chaincase [A]. Installation: Tighten the bolts to 125140 ft.lbs. (170190 Nm) torque. Move the motor carrier housing toward the rear of the chaincase. Remove the rear drive chain from the motor carrier sprockets [B]. Remove the front drive chain from the motor carrier sprockets. Remove the motor carrier assembly from the chaincase [C].
P01735
P01734
P01736
Installation: When installing the motor carrier with through holes in the flange, either a gasket or sealant can be used. Put sealant between the bolt heads and the chaincase to prevent leakage [D]. NOTE: With mounting bolts in place and loose, center the motor carrier for equal slack of front and rear chains.
P01730
Revised Sept. 93
49
MOTOR CARRIER (Contd) Disassembly And Assembly (Later Models) Use [A] as a guide to disassemble and assemble the motor carrier. The correct shaft end play is 0.008 inch (0,2 mm) and is controlled by the snap ring (item 5) [A]. The snap ring (Item 5) [A] comes in two different widths. (See Parts Microfiche for the correct part numbers.) See Page 47 for seal installation.
LATER MODELS
Lip Faces IN
3 4
Lip Faces OUT
1. 2. 3. 4.
Shaft Bearing Race Snap Ring
5. 6. 7. 8.
Snap Ring Oring Seal Adapter Seal

TS01131
Disassembly And Assembly (Early Models) Use [B] to disassemble and assemble the motor carrier. The correct shaft end play is 0.008 inch (0,2 mm) and is controlled by the snap ring (Item 7) [B]. The snap ring (Item 7) [B] comes in two different widths. (See Parts Microfiche for the correct part numbers.) See Page 47 for seal installation.
B
1
EARLY MODELS
4 5
6 3 2 Lip Faces 7 8 9 IN 10
1. 2. 3. 4. 5.
Shaft Bearing Race Snap Ring Spacer
6. 7. 8. 9. 10.
Housing Snap Ring Oring Seal Adapter Seal
Lip Faces OUT
C03083
Revised Sept. 93
410
AXLE SEAL Removal And Installation The tools listed will be needed to do the following procedure: MEL1242 PortaPower MEL1399 Axle Seal Tool To loosen the axle hub bolt do the following: With the loader on the ground, use the correct size socket and large breaker bar to loosen the hub bolt. Lift and block the loader. MAINTENANCE Section 1.) Remove the tire/wheel assembly. Installation: Tighten the wheel nuts to 105115 ft.lbs. (142156 Nm) torque. Remove the bolt and washer [A]. Installation: tighten the bolt to 575625 ft.lbs. (780848 Nm) torque. Install wheel nuts on two studs straight across from each other. Use a hammer to remove the wheel studs [B]. (See PREVENTIVE
CD08855
CD08856
Remove the wheel nut and studs from the hub [C]. Installation: After the hub has been removed, use a hammer to install the wheel studs in the hub.
CD08857
Revised Sept. 93
411
AXLE SEAL (Contd) Removal And Installation (Contd) Install a puller on the wheel hub [A].
CD08858
A slidehammer or PortaPower can be used to remove the hub. A PortaPower is used in the following sequence. Install a spacer on the end of the axle and against the PortaPower ram [B].
NEVER STAND INLINE OF THE HUB WHEN REMOVING A HUB FROM AN AXLE. The hub has a tapered fit on the axle end and can come off the axle with great force and cause serious injury.
W21860395
CD08859
Remove the hub from the axle [B]. Remove the key from the axle [C].
CD08860
Drill a small hole into the axle seal [D].
CD08861
Revised Sept. 93
412
AXLE SEAL (Contd) Removal And Installation (Contd) Install a puller and remove the axle seal [A]. NOTE: Check the seal area on the shaft for wear. If necessary order an axle repair sleeve from Melroe Parts Sales. (See your dealer when ordering parts.)
CD08862
Installation: Install the new seal on the axle and into the axle tube [B]. Installation: Install the seal driver tool over the axle [B].
CD08863
Installation: Use a hammer, install the new axle seal until the tool is flush with the edge of the axle tube [C].
CD08864
Revised Sept. 93
413
AXLE, SPROCKET AND BEARINGS Removal And Installation the tools listed will be needed to do the following procedure: MEL1242 PortaPower MEL1202B Axle Bearing Service Set NOTE: The procedure shown for removal and installation of the axle, sprocket and bearings is for a front axle, this procedure is the same for the rear axle. Raise the lift arms. (See PREVENTIVE MAINTENANCE Section 1.) Lift and block the loader. MAINTENANCE Section 1.) Raise the operator cab. MAINTENANCE Section 1.) (See (See PREVENTIVE PREVENTIVE
P02091
Remove the front panel/steering lever assembly. (See HYDROSTATIC SYSTEM Section 3.) Remove the front and/or rear cover depending which axle is being removed. Remove the fluid from the chaincase. (See Page 419.) Loosen the axle sprocket bolt when the hub bolt is being removed [A]. Installation: Tighten the axle sprocket bolt to 220245 ft.lbs. (298332 Nm) torque. Remove the axle hub. (See Page 411.) Install the PortaPower ram between the two sprockets [B]. Push the axle out until the ram is at the end of the stroke. Add a spacer and push the axle out again. Repeat this procedure until the axle is out of the sprocket [C].
P02092
CD08867
Remove the axle sprocket from the chaincase [D].
P02101
Revised Sept. 93
414
AXLE, SPROCKET AND BEARINGS (Contd) Removal And Installation (Contd) Remove the inner bearing from the chaincase [A]. Installation: Pack the outer and inner bearings with grease before installing them.
P02107
If the other side axle, sprocket and bearings are removed with one axle removed, use spacer plates and the PortaPower ram [B].
P02105
Install the bearing cup puller tool into the axle tube [C].
B07627
Pull the bearing cup from the axle tube [D].
B07686
Revised Sept. 93
415
AXLE, SPROCKET AND BEARINGS (Contd) Removal And Installation (Contd) Use a long rod and bearing cup tool to remove the inner bearing cup [A].
B07687
Use the correct size driver, install the outer bearing cup [B].
B07679
Install the long threaded rod into the axle tube. Install the correct size bearing cup driver tool. Install the washer and nut [C].
B07680
Inside the chaincase, install the bearing cup driver tool, washer and nut [D].
B07681
Revised Sept. 93
416
AXLE, SPROCKET AND BEARINGS (Contd) Removal And Installation (Contd) Hold the nut inside the chaincase [A].
B07683
Turn the nut on the outside of the axle tube until the inner bearing cup is on its seat [B].
B07682
Use a press to remove the bearing from the axle [C]. Turn the axle around and press the new bearing into position on the axle [C].
B07691
B07692
Added Sept. 93
417
DRIVE CHAIN Removal And Installation The tools listed will be needed to do the following procedure: MEL1242 PortaPower MEL1037 Chain Link Tool Raise the lift arms. (See PREVENTIVE MAINTENANCE Section 1.) Lift and block the loader. MAINTENANCE Section 1.) Raise the operator cab. MAINTENANCE Section 1.) (See (See PREVENTIVE PREVENTIVE
P02091
Remove the front panel/steering lever assembly. (See HYDROSTATIC SYSTEM Section 3.) Remove the parking brake/cover assembly. (See Page 42.) Remove the hydrostatic pump. (See HYDROSTATIC SYSTEM Section 3.) Remove the front and rear cover. Remove the fluid from the chaincase. (See Page 419.) Remove the front axle sprocket bolt [A]. Installation: Tighten the axle sprocket bolt to 220245 ft.lbs. (298332 Nm) torque. Install a PortaPower ram between the two sprockets [B]. Push the axle out until the ram is at the end of the stroke. Add a spacer and repeat the procedure until the axle is out of the sprocket. Remove the motor carrier. (See Page 49.) Remove the front and rear drive chain from the chaincase [C].
P02092
P02109
Installation: If a new chain is installed, a connector link must be used to connect the chain together. Use a chain link tool and #80 chain adapter. Use a large wrench to hold the tool while pressing the chain link. Tighten the chain link tool bolt to 180 ft.lbs. (244 Nm) torque to press the chain link onto the chain [D].
B13504
Revised Sept. 93
418
CHAINCASE FLUID Replacing The Chaincase Fluid Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Remove the chaincase cover and/or brake assembly. (See Page 44.) Use a transfer pump to remove the fluid from the chaincase [A].
B05202
Use clean rags to remove any fluid that the pump did not remove and clean the chaincase [B]. Use only recommended replacement fluid. Clark Bobcat Fluid (P/N 6563328) or 10W30 or 10W40 Class SE Motor Oil to fill the chaincase with 9 gals. (34 L.) fluid. Install the transmission cover(s). Lower the operator cab.
B03988
Added Sept. 93
419
MAIN FRAME Page Number BOBTACH BobTach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 FUEL TANK Fuel Level Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 LIFT ARMS Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 OPERATOR CAB Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 OPERATOR CAB GAS CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 REAR DOOR Door Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 REAR GRILL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 MAIN FRAME
OPERATOR CAB Removal And Installation Remove the stop blocks at the rear of the operator cab [A]. Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
B09780
After the stop blocks are removed and the operator cab has a rear window, REMOVE THE REAR WINDOW to prevent damage to the rear window. I21200297 Disconnect the wiring harness connectors [B].
CD12854
Remove the electrical clamp at the harness [C].
CD12855
Install a bar at the balance point of the operator cab. Install a chain hoist [D].
B09782
51
OPERATOR CAB (Contd) Removal And Installation (Contd) At the gas cylinder upper pin, remove the retainer clip (both sides) [A].
B08511
Remove the upper pin from the gas cylinder (both sides) [B]. Installation: Install the lower pivot pin first, use a screwdriver to hold the gas cylinder and install the top pivot pin [B].
B08510
Remove the retainer clip at the lower pivot pin (both sides) [C].
B09889
Remove the lower pivot pin (both sides) [D].
B09890
52
OPERATOR CAB (Contd) Removal And Installation (Contd) Remove the gas cylinder (both sides) [A].
B08509
Remove the nuts from the pivot bolts [B]. Installation: Tighten the pivot bolts to 2535 ft.lbs. (3447 Nm) torque.
B09783
Use a punch to remove the pivot bolt (both sides) [C]. Lift the operator cab from the loader using the chain hoist.
B08539
53
OPERATOR CAB GAS CYLINDER Removal And Installation Remove the stop blocks at the rear of the operator cab [A]. Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
B09780
Remove the retainer clip at the upper pivot pin [B]. Remove the upper pivot pin [B].
B08511
B08510
Remove the retainer clip at the lower pivot pin [C]. Remove the lower pivot pin [C]. Installation: Install the lower pivot pin first, use a screwdriver to hold the gas cylinder and install the top pivot pin.
B09889
B09890
Remove the gas cylinder from the loader [D].
B08509
54
REAR DOOR Door Latch Adjustment Loosen the set screw [A].
B05772
Loosen the nut (Item 1) [B]. Turn the bolt (Item 2) [B] in or out, until the door contacts both the top and bottom of the loader frame (Item 1) [C] with the lever in the latched position. NOTE: It takes approximately 50 lbs. of force to push the lever down when the latch is adjusted correctly.
2 1
B07385
With the set screw up, the flanges at the bolt (Item 2) [C] must be to the sides so that the set screw aligns with the flat surface at the end of the bolt [C]. Tighten the set screw [A]. Tighten the nut (Item 1) [B] to 6570 ft.lbs. (8895 Nm) torque.
C
1
B07226
1
B04099
55
REAR DOOR (Contd) Removal And Installation Install a chain hoist on the rear door [A].
B04568
Use a punch and hammer, remove both hinge pins [B]. Lift the door from the loader frame.
B04131
56
REAR GRILL Removal And Installation Remove the bolts along the top edge of the rear grill [A].
P00179
Remove the bolts along the bottom of the rear grill [B].
P00182
Lift the rear grill up and away from the loader [C].
P00184
57
BOBTACH Removal And Installation Tilt the BobTach fully forward until the front edge is on the floor [A]. Stop the engine. Move the hydraulic controls to release the hydraulic pressure.
CD08942
Remove the retainer bolt from the pivot pin [B]. Installation: Tighten the retainer bolt to 1820 ft.lbs. (2427 Nm) torque.
CD08709
Remove the grease fitting from the pivot pin [C].
CD08889
Use a punch and hammer, remove the tilt cylinder rod end pivot pin [D].
CD08710
58
BOBTACH (Contd) Removal And Installation (Contd) Remove the hydraulic cylinder rod end. Remove the seals [A].
CD08713
Installation: Put a piece of shim stock on each side over the seals. Install the rod end into the BobTach frame [B].
CD08714
Remove the grease fitting from the BobTach frame for the pivot pin (both sides) [C]. NOTE: The grease fitting at the pivot pin must be removed because the grease can cause a lock and the pivot pin can not be pushed into the BobTach frame.
CD08890
Loosen the bolt at the BobTach pivot pin (both sides) [D]. Installation: Tighten the bolt to 130140 ft.lbs. (176190 Nm) torque.
CD08891
59
BOBTACH (Contd) Removal And Installation (Contd) Hit the bolt to start the pivot pin into the BobTach frame (both sides) [A]. Remove the bolt. Use a punch to push the pivot pin all the way into the BobTach frame. Installation: A long bolt may be needed to turn into the pivot pin. Pull the pivot pin into the lift arms. Remove the BobTach frame from the lift arms.
CD08892
Remove the seal dust cup (both sides) [B].
CD08893
Remove the rubber seal (both sides) [C].
CD08894
Turn the bolt into the pivot pin. Remove the pivot pin from the BobTach frame [D]. Check for wear and damage. Replace the pivot pins as needed.
CD08895
510
BOBTACH (Contd) BobTach Lever And Wedge Use the following procedure to remove and install the BobTach lever, spring and wedge: Remove the nut from the BobTach lever [A]. Installation: Tighten the nut to 2528 ft.lbs. (3438 Nm) torque.
CD08896
Remove the bushing and spring [B].
CD08897
Remove the BobTach lever [C].
CD08898
Use a punch and hammer, remove the roll pin from the BobTach wedge and spring bolt clevis assembly [D].
CD08899
511
BOBTACH (Contd) BobTach Lever And Wedge (Contd) Remove the spring, bolt and clevis assembly [A].
CD08900
If the spring is damaged, put the assembly in the vise and remove the bolt [B]. Replace the worn or damaged parts as needed.
CD08901
Remove the wedge from the BobTach frame [C]. Always replace bent or broken wedges.
CD08902
512
LIFT ARMS Removal And Installation Roll the BobTach frame fully forward. Stop the engine. Activate the hydraulic controls to release the hydraulic pressure. Remove the BobTach frame. (See Page 58.) Fasten chains and chain hoist to the lift arms [A].
B02801
Put a floor jack under the lift arms [B]. Raise the lift arms, with the floor jack, until the pivot pin at the rod end of the lift cylinder can be removed.
B04543
Remove the lock nut and bolt [C]. Installation: Tighten the bolt and nut to 1820 ft.lbs. (2427 Nm) torque.
B09795
Remove the pins at the rod end of the lift cylinder (both sides) [D]. Lower the lift arms. Remove the floor jack.
B09794
513
LIFT ARMS (Contd) Removal And Installation (Contd) Remove the lock nut and bolt [A]. Installation: Tighten the bolt and nut to 1820 ft.lbs. (2427 Nm) torque. Tighten the chain hoist.
B04544
Use a punch and soft hammer, remove the pivot pin at the lift arm (both sides) [B] Raise the lift arms with the chain hoist and remove them from the loader frame.
B04545
514
FUEL TANK Removal And Installation Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Use a transfer pump to remove the fuel from the fuel tank. Remove the harness plate over and above the hydraulic reservoir.
CD06271
Disconnect the wires at the fuel sender [B].
CD06272
Remove the fuel hoses from the tank fittings [C].
CD06273
Remove the fuel hoses at the shutoff valve [D].
CD06274
515
FUEL TANK (Contd)

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772MainFrameSection
Removal And Installation (Contd) Remove the fuel tank holding strap bolt [A]. Remove the fuel tank from the loader.
CD06275
Fuel Tank Sender Switch Remove the harness plate from the top of the fuel tank [B]. Remove the wires from the sender.
CD06271
Remove the screws from the sender [C].
B12340
Remove the sender switch from the fuel tank [D].
B12341
516
ELECTRICAL SYSTEM Page Number ALTERNATOR Alternator Output Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Regulator Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Alternator Output (Old Style) . . . . . . . . . . . . . . . . . . . . . . . Checking The Alternator Regulator (Old Style) . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier (Diode) Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (743B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (742B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 67 64 65 612 69 613 66 68 68 613 613 612 612
ALTERNATOR BELT SHIELD (743B) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 BATTERY Checking The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ELECTRICAL SYSTEM INFORMATION Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 STARTER Checking The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (743B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation (742B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing The Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615 617 615 616 617 619 620 ELECTRICAL SYSTEM
TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
61
ELECTRICAL SYSTEM INFORMATION Description The loader has a 12 volt, negative ground electrical system. There are two main circuits. 1. The charging circuit has an alternator (with builtin regulator) and a battery. 2. The starting circuit has glow plugs, starter motor and solenoid for starting the engine. Optional equipment for the loader are front and rear lights, windshield wiper, horn and backup alarm. The electrical system is protected by two fuses installed in the instrument panel. Fuses protect the electrical system from an overload. Instructions are necessary before operating or servicing machine. Read 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. Failure to follow instructions can cause injury or death [A].
W20030797
TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM Battery will not take a charge. Alternator will not charge. Starter will not turn the engine.
CAUSE 1, 2, 3, 4, 5 1, 2, 5 2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE 1. 2. 3. 4. 5. 6. 7. 8. 9. Alternator belt is loose or damaged. Battery connections are dirty or loose. Battery is damaged. The ground connection is not making a good contact. The alternator is damaged. The engine is locked. The starter is damaged. The wiring or the solenoid is damaged. Check the fuses.
61
BATTERY Checking The Battery The tool listed will be needed to do the following procedure: MEL10004 Battery Tester To make a safe and complete check of the battery, see the Battery Manual (P/N 6566047). The Battery Manual has all the information needed for checking and servicing the battery. Replace the battery as needed.
P00183
B
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.
W20651296
P00186
DO NOT remove the vent caps from the battery while charging the battery. The battery vent caps will decrease the possibility of battery being exploded by an external spark. Removal And Installation Disconnect the negative () cable first. Disconnect the positive (+) cable [A]. Remove the nuts and bolts from the holddown clamp [B]. Remove the holddown clamp. Remove the battery from the loader.
62
ALTERNATOR BELT SHIELD (743B) Removal And Installation Disconnect the negative () battery cable. Remove the bolt at the timing case cover [A].,
P00247
Remove the bolt at the bottom of the alternator mounting bracket [B].
P00248
Remove the bolt from the thermostat housing [C].
P00207
Remove the belt shield [D].
P00206
Revised Sept. 93
63
ALTERNATOR Checking The Alternator Output (Old Style)
REAR VIEW OF ALTERNTOR OLD 6632211
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. Lift and block the loader. MAINTENANCE Section 1.) (See
W20170286
MC01813
PREVENTIVE
Disconnect the negative () cable from the battery. Disconnect the orange wire (Item 1) [B] from the alternator. Connect that wire to the negative () side of the ammeter. Connect the positive (+) side of the ammeter to the output terminal on the alternator (Item 2) [B]. Disconnect the fuel shutoff valve. Connect the negative () cable to the battery. Turn on the lights and crank the engine for 30 seconds to discharge the battery. Open the fuel shutoff valve. Start the engine and run at 2600 RPM.
CD06325
1 2
The ammeter reading should be between 4555 amps. @ 2600 RPM. If the reading is low, remove the screws and pull the regulator cover away from the alternator. Disconnect the battery and connect a jumper wire from the alternator output terminal (Item 1) [C] to the regulator terminal (Item 2) [C]. Connect the battery cable, start the engine and check the ammeter. If the reading is within the rated amperage (4555 amps. @ 2600 RPM) replace the diode trio.
B09570
Revised Sept. 93
64
ALTERNATOR (Contd) Checking The Alternator Regulator (Old Style) (Contd) Connect the positive (+) voltmeter lead to the positive (+) battery terminal and connect the negative () voltmeter lead to the negative () terminal [A].
W20170286
B03710 B08068
B
W20501285
1 2
Start and run the engine at 15002000 RPM. The voltmeter reading should be between 13.914.7 volts [A]. If the reading is low, stop the engine and disconnect the battery. Remove the screws and pull the regulator cover away from the alternator. Connect the jumper wire from the ground stud (Item 1) [B] to the brush terminal (Item 2) [B] (the tan wire). Connect the battery and start the engine. Run at 1500 RPM. DO NOT allow the meter to exceed 16 volts. If the reading is 14.5 or above, replace the regulator. If the reading is 14.5 or below, repair or replace the alternator.
B09569
Revised Sept. 93
65
ALTERNATOR (Contd) Test the New Style alternator as follows: a. Alternator Output Test b. Rectifier (Diode) Test c. Alternator Regulator Test Alternator Output Test (New Style)
REAR VIEW OF ALTERNTOR New 6661611
MC01813
B
1
W20170286
Lift and block the loader. MAINTENANCE Section 1.)
(See
PREVENTIVE
Disconnect the negative () cable from the battery. Disconnect the red wire (Item 1) [B] from the alternator. Connect that wire to the negative () side of the ammeter. Connect the positive (+) side of the ammeter to the output terminal on the alternator (Item 2) [B]. Disconnect the fuel stop solenoid connector. Connect the negative () cable to the battery. Turn on the lights and crank the engine for 30 seconds to discharge the battery. Connect the fuel stop solenoid, start the engine and run at 2600 RPM. The ammeter reading should be between 4555 amps. at 2600 RPM. If the reading is low, remove the screws and pull the regulator cover away from the alternator. Rectifier (Diode) Test (New Style) The alternator is removed from the loader for clarity purposes [C]. Disconnect the negative () cable from the battery. Install the wires in their original location on the back of the alternator. Connect a jumper wire (Item 1) [C] to the alternator output terminal and the regulator terminal. Connect the battery negative () cable. Start the engine and run at 2600 RPM. If the reading is within 4555 amps. at 2600 RPM replace the rectifier (diode) assembly or replace the alternator. If the reading is low, do the Alternator Regulator Test. Revised Sept. 93 66 742B, 743B Loader Service Manual
P01360
Output Terminal
Regulator Terminal
P01304
ALTERNATOR (Contd) Alternator Regulator Test (New Style)
A
Negative
W20501285
Positive
P01308
Connect the positive (+) voltmeter lead to the positive (+) battery terminal [A]. Connect the negative () voltmeter lead to the negative () battery terminal [A]. Start the engine and run at 15002000 RPM. The voltmeter should read between 13.914.7 volts. If the reading is low stop the engine and disconnect the battery negative () cable. The alternator is removed from the loader for clarity purposes [B]. Remove the wires from the back of the alternator. Remove the regulator cover from the back of the alternator. Install the wires on the back of the alternator. Connect a jumper wire (Item 1) [B] from the brush terminal to the ground stud. Connect the negative () battery cable and start the engine. Run at 1500 RPM. If the voltmeter reading is 14.5 or above replace the regulator. If the voltmeter reading is below 14.5, repair or replace the alternator.
B
Ground Stud
Brush Terminal
1
P01364
Revised Sept. 93
67
ALTERNATOR (Contd) Removal And Installation (743B) Remove belt shield. (See Page 63.) Disconnect the negative () cable from battery. Disconnect the wires from the back of the alternator. Remove the adjusting bolt [A].
P00211
Remove the mounting bolt and nut [B]. Remove the alternator.

Never service or adjust the machine when the engine is running unless instructed to do so in the manual.
W20120497 P00210
Removal And Installation (742B) Remove the belt Shield. (See ENGINE SERVICE Section 7.) Disconnect the negative () cable at the battery. Disconnect the alternator connector from the electrical harness [C]. Disconnect the orange lead at the alternator.
B09881
Remove the adjusting bolt [D]. Remove the mounting bolt [D]. Remove the alternator from the mounting bracket.
B09939
Revised Sept. 93
68
ALTERNATOR (Contd) Disassembly And Assembly (Old Style) Disassemble the alternator as shown in figure [A]. Remove the three bolts (Item 4) [A] holding halves together. Pry the halves apart. Use a soft jaw vise to hold the rotor while removing the pulley nut (Item 1) [A]. Remove the front case half (Item 5) [A] from the rotor using a plastic hammer or press. Unsolder the stator wires from the rectifier to test the stator and rectifier. Use a needle nose plier to remove the wires.
A
1 2 7 4 5 6 3 6 8 9 16
10 11 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Nut Pulley Fan Bolt Case Half (Front) Bearing Rotor Slip Ring Stator Heat Sink (+)
12
13 15
11. 12. 13. 14. 15.
Heat Sing () Case Half (Rear) Condenser Assy. Brush Holder Regulator D01760
Use the following procedures with an ohmmeter to test the rotor: Touch both probes on the slip rings. There must be a 3 to 5 ohm reading [B].
B09375
Touch one probe to the shaft and one probe to a slip ring, then touch the other slip ring. There must be maximum resistance [C].
B09376
Revised Sept. 93
69
ALTERNATOR (Contd) Disassembly And Assembly (Old Style) (Contd) Use the following procedure with an ohmmeter to test the stator: Touch two wire ends of the stator with the probes, take a reading. Move one probe to the other wire. The reading should be the same [A].
B09380
Test the ground by touching one probe on the metal surface of the stator and the other probe on the bare wire. There must be no needle movement [B].
B09378
Use the following procedure with a circuit tester to test the rectifier: Touch the positive probe to the positive diode holder and the negative probe to each diode terminal. There must be continuity [C].
B09377
Reverse the probes and check the continuity in the other direction. There must be no continuity.
B09385
Revised Sept. 93
610
ALTERNATOR (Contd) Disassembly And Assembly (Old Style) (Contd) Touch the negative probe to the negative diode holder and the positive probe to each diode terminal. There must be continuity [A].
B09377
Reverse the probe and check the continuity in the other direction. There must be no continuity [B]. Check the brushes for wear. The maximum of exposed brushes should be 0.125 inch (3,0 mm). Replace broken or rusted brush springs.
B09385
Assembly: Reverse the order of disassembly. Place the rotor in soft jaws when tightening the shaft nut. Tighten to 50 ft.lbs. (68 Nm) torque [C].
B09383
Revised Sept. 93
611
ALTERNATOR (Contd) Disassembly and Assembly (New Style) Disassemble the alternator as shown [A]. Remove the regulator cover and regulator. Remove the four bolts holding halves together. Pry the halves apart (use a press if needed). Use a soft jaw vise to hold rotor while removing pulley nut. Remove front case half from the rotor using a plastic hammer or press. Unsolder the stator leads from the rectifier. Remove the stator.
A
1 2 7 4 5 6 3 6 8 9 16
10 11 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Nut Pulley Fan Bolt Case Half (Front) Bearing Rotor Slip Ring Stator Heat Sink (+)
12
13 15
11. 12. 13. 14. 15.
Heat Sing () Case Half (Rear) Condenser Assy. Brush Holder Regulator D01760
Stator Continuity Test Use an ohmmeter to test the stator. Touch the probes to two of the bare stator wires [B]. Move one of the probes to the third wire. The readings should be the same. If there is no continuity, replace the stator.
P01369
Stator Ground Test Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [C]. There should be no continuity. Replace the stator if there is continuity.
P01386
Revised Sept. 93
612
ALTERNATOR (Contd) Rotor Continuity Test Touch the probes to the slip rings [A]. The ohmmeter should read between 3.06533.85 ohms. If there is no continuity replace the rotor.
P01365
Rotor Ground Test Touch one probe to one of the slip rings and the other probe to the rotor shaft [B]. There should be no continuity. Replace the rotor if there is continuity.
P01378
Rectifier Continuity (Diode) Test NOTE: In the diode tests there should be continuity in one direction only. If the diode being tested shows no continuity or continuity in both directions, replace the rectifier assembly. Touch the probes to the terminals of each diode and read the meter [C]. Reverse the probes to check the diode in the other direction. There should be continuity in one direction only.
P01373
Touch one probe to the diode and the other probe to the connected heatsink and read the meter [D]. Reverse the probes to check the diode in the other direction. There should be continuity in one direction only.
Touch on Bottom Heat Sink

P01370
Revised Sept. 93
613
ALTERNATOR (Contd) Rectifier Continuity (Diode) Test (New Style) (Contd) Touch one probe to the diode and the other probe to the connected heatsink and read the meter [A]. Reverse the probes to check the diode in the other direction. There should be continuity in one direction only.
Touch on Center Heat Sink

P01390
Assembly (New Style) Reverse the order of disassembly. Do not assemble the rear case half. Place the rotor in soft jaws when tightening the shaft nut. Tighten to 50 ft.lbs. (68 Nm) torque [B]. Install the rear case half and the remaining parts.
P01808
Revised Sept. 93
614
STARTER Checking The Starter The key switch must be in the OFF position. The battery must be at full charge. The cable connections on the battery must be clean and tight. Connect a jumper wire between S terminal and BAT terminal [A]. If the starter turns but does not turn the engine, the starter drive has a defect.
A
Bat S M
Jumper Wire
Cranking Motor
A01992
Connect a jumper wire between the M terminal and the BAT terminal [B]. If the starter turns, the defect is in the solenoid. If the starter does not turn, the starter is defective.
B
Bat S M
Jumper Wire
Cranking Motor
A01991
Removal And Installation (743B) Disconnect the negative () cable from the battery. Mark the wires on the starter and solenoid. Disconnect the wires [C].
P01180
Remove the stator mounting bolts [D]. Installation: Tighten the bolts to 2528 ft.lbs. (3438 Nm) torque. Remove the starter.
P01182
Revised Sept. 93
615
STARTER (Contd) Removal And Installation (742B) Disconnect the negative () cable at the battery. Disconnect the positive (+) cable at the starter solenoid [A].
P09880
Disconnect all the wires at the starter solenoid [B].
B09879
Remove the two bolts at the starter heat shield [C].
B09937
Remove the starter mounting bolts [D]. Remove the starter from the engine.
B09936
Added Sept. 93
616
STARTER (Contd) Parts Identification
3 2 4 1
5 6 9 8 19 7
10
13 12 11
14
15
16
17
18 20
21 26 22 25 24
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. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Screw Solenoid Bolt Lever Washer Nut Plug Washer Housing Drive Washer Bushing Ring Stop Drive Drive Support Support Drive Shaft Washer Washer Washer Screw Brush Frame Assy. Gasket Pin Armature Support Bolt Spacer Bearing Armature Bearing Spring Holder Assy. Brush Screw Oring Frame Washer Screw Bolt
23 27 22 21 35 28 29 30 34 31 34 39 38
32
33
36
37
40
D02119
Added Sept. 93
617
STARTER (Contd) Disassembly And Assembly Remove the starter thrubolts [A].
CD08924
Remove the screws for the brush holders [B].
CD08925
Remove the starter end cap [C].
CD08926
Remove the starter housing/armature assembly from the reduction gear drive [D].
CD08927
Added Sept. 93
618
STARTER (Contd) Disassembly And Assembly (Contd) Remove the armature and brushes from the starter housing [A].
CD08928
Remove the bolts from the reduction gear housing [B].
CD08929
Remove the reduction gear housing [C].
CD08930
Replacing The Brushes Remove the screws at the brushes [D]. Remove the screws at the brush leads. Remove the old brushes. Install the new brushes and make sure to tighten the screws. Assembly of the starter: Reverse the order of disassembly. Put a small amount of grease on the splines of the armature and the bushings. Add or remove shims at the drive end of the armature to adjust the end play.
B09940
Added Sept. 93
619
STARTER (Contd)
742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772ElectricalSystemSection
Cleaning and Inspection Use a brush and air pressure to clean the drive, field coils, armature and starter housing. NOTE: Do not use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip. Check the following items: Armature Broken or burned insulation. Loose connections at commutator. Open or grounded circuits [C] & [D]. Worn shaft or bearings. Rough commutator. Brush Holders Broken springs. Broken insulation. Spring tension. Field Coils Broken or burned insulation. Electrical continuity. Brush connections. Drive Gears Worn teeth. Tooth engagement.
A01995
A01994
Field Coils Broken or burned insulation Electrical continuity [C]. Brush connections.
B02122
Drive Gear: Worn teeth Tooth engagement (drive gear must engage ring gear by 1/2 the depth of the ring gear tooth) To test for ground, use a test light and touch one probe to the body and the other probe to the field winding end of the brush. The lamp should not light [D].
B09576
Added Sept. 93
620
ENGINE SERVICE Page Number KUBOTA ENGINE (742B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1 MITSUBISHI ENGINE (742B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1
ENGINE SERVICE KUBOTA (743B)
MITSUBISHI (742B)
7A3
ENGINE SERVICE (Contd) (Kubota 743B)
Page Number
BLOWER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A11 CYLINDER HEAD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A19 7A15 7A19 7A14 7A15 7A17
ENGINE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A8 ENGINE ASSEMBLY Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing The Camshaft And Timing Gears . . . . . . . . . . . . . . . . . . . . . Installing The Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A33 7A35 7A33 7A33
ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A3 ENGINE FLYWHEEL AND UJOINT Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A12 Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A12 ENGINE REPAIR Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Liner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing The Connecting Rods And Pistons . . . . . . . . . . . . . . . . . . . . Timing Gear, Camshaft And Oil Pump Removal . . . . . . . . . . . . . . . . . Timing Gear And Camshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A28 7A29 7A20 7A30 7A31 7A23 7A26 7A22 7A25 7A31
FUEL FILTER Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2 Replacing The Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2 FUEL INJECTION PUMP Checking The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A3 Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A4 FUEL INJECTION NOZZLES Checking the Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A6 GLOW PLUGS Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2 MUFFLER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A13 RADIATOR AND OIL COOLER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A10 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1
7A1
KUBOTA (743B)
PROBLEM Engine will not turn over with the starter. Engine will not start or is difficult to start. Engine misses, runs irregularly or stops. Engine overheats. To much engine vibration. KEY TO CORRECT THE CAUSE 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. 29. 30. Battery has lost its charge. Loose battery connections. Loose starter connections. Damaged starter switch. Broken starter switch. Damaged starter solenoid. Wrong starting procedure. No fuel in tank. Air cleaner is dirty. Fuel vent in cap has restricted. Fuel line has air leak, dirt or water. Damaged fuel lift pump. Hydraulic/Hydrostatic load on engine. Damage to fuel injection system Crankcase oil is thick. Check glow plugs. Check preheat solenoid. Check the fuel shutoff button. Delivery valve nuts not tightened. Fuel injection set wrong. Dirty fuel, or fuel filter restricted. Poor compression. Wrong fuel. Water in the fuel Engine is overloaded. Dirty engine oil. Exhaust system has restriction. Injection timing is wrong. Loose engine mounts. Worn rubber mounts.
CAUSE 1, 2, 3, 4, 5, 6 7, 8, 9, 10, 11, 12, 13, 14, 15, 15, 17, 18, 19 20, 21, 22, 23, 24 25, 26, 27, 28 29, 30
7A1
FUEL FILTER Replacing The Fuel Filter See SERVICE SCHEDULE Page 11 for correct service intervals. To replace the fuel filter element: Clean the filter areas. Shutoff the fuel at the fuel tank. Remove the bolt from the top of the filter housing (Item 1) [A]. Remove the element and the rubber seal from the housing. Install a new rubber seal on the housing and put a small amount of oil on the rubber seal. Install the new filter element in the container and install on the filter head. Hand tighten only. Open the fuel shutoff valve at the tank until the fuel filter container is full. Tighten the bolt to prevent leakage. Removing Air From The Fuel System After replacing of the fuel 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. Open the rear door. The engine must be cool. Open the vent plug (Item 2) [A]. Operate the hand pump (Item 3) [A] until fuel flows from the vent plug (Item 2) [A] with no air bubbles. Tighten the vent plug. Operate the hand pump until it feels solid. Move the throttle control to minimum ROM. Loosen the valve (Item 1) [B] and squeeze the hand pump several times. Start the engine. When the engine runs smoothly, close the valve (Item 1) [B]. GLOW PLUGS Checking Disconnect the glow plug cables and leads. Use an ohmmeter to check the glow plugs. Touch one probe to the end of the glow plug and the other probe to the body of glow plug [C]. The reading must be between 1 and 2. If the resistance is zero ohms the glow plug has a short circuit. If the resistance is infinite the coil of the flow plug is broken. Repeat the procedure for each glow plug.
A
1
3 2
B03916
P00217
P01807
Revised Sept. 93
7A2
ENGINE COMPRESSION Checking The tool listed will needed to do the following procedure: MEL1063 ENGINE COMPRESSION KIT The engine must be warm. Disconnect the glow plug wires. Remove the glow plugs. Install the compression adapter in the glow plug hole. Connect the compression gauge. Run the engine with the starter. Do the compression test at least twice. The compression must be at least 75% of 427469 PSI (29443233 kPa) with no more than 50 PSI (345 kPa) difference between cylinders. 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. Removal and Installation Clean the area around the injection pump. Disconnect the fuel shutoff linkage (Item 1) [A] Disconnect the fuel inlet hoses (Item 2) [A]. Disconnect the high pressure tubelines (Item 3) [A]. Installation: Tighten the delivery valve nuts to 2936 ft.lbs. (3948 Nm) torque.
A
2
1 4
B10779
B
1
Delivery Valve Nuts
B04111
Do not attempt to maintain or adjust unless you are trained and have the correct equipment. Do not bend the high pressure fuel injection tubes when removing or installing them.
I20290289
I20280289
Remove the side cover (Item 4) [A]. Remove the four mounting nuts. Installation: Tighten the nuts to 1720 ft.lbs. (2327 Nm) torque. Put the pin in the control rack in alignment with the slot in the engine block (Item 1) [B]. Remove the injection pump. NOTE: Make sure the same number of shims are installed under the injection pump. The shims are used for engine timing. Installation: When the injection pump is installed, make sure the pin (Item 2) [B] on the control rack is correctly installed on the fork lever. If the slot is not installed correctly, the engine will run over maximum speed and serious damage can result. Revised July 96 7A3 742B, 743B Loader Service Manual
FUEL INJECTION PUMP (Contd) Timing The Injection Pump Timing of the fuel system is done by changing the number of shims between the injection pump and the engine block, The timing of the fuel injection pump will be later when a shim is added, and earlier when a shim si removed.
W20720496
B03611
B
1
Remove the number 1 cylinder injector tubeline from the injector pump. Install a short pipe to the outlet of the number 1 cylinder injector port. Point the pipe up (vertical). With a fuel supply to the injection pump, rotate the engine in a clockwise direction. Fuel must flow from the pipe when the fixed mark F1 on the crankshaft pulley and the point comes into alignment [A]. The correct timing for the engine is 25 degrees B.T.D.C. (#1 cylinder). Add or subtract shims (Item 1) [B] as needed to adjust the delivery time of the fuel. Each shim will change the timing 1.5 degrees.
B11493
7A4
FUEL INJECTION PUMP (Contd) Checking The Injection Pump The tools listed will be needed to do the following procedure: MEL1237 Adapter Fuel Line MEL11731 Pressure Gauge To check the discharge pressure at the fuel injection pump, use the following procedure: Disconnect a high pressure fuel line (Item 1) [A] at the pump. Loosen the other end of the same high pressure line so it can be turned away from the fitting.
A
1
B09577
Connect the adapter fuel line (Item 1) [B] to the fitting. Connect the pressure gauge (Item 2) [B]. Rotate the engine, with the starter, until the pressure raises. Then turn the engine by hand until the pressure gauge reads 1400 PSI (9653 kPa). Align F1 on crankshaft pulley. The injection pump must hold the 1400 PSI (9653 kPa) for at least 5 seconds. If not, replace or repair the injection pump.
2
B09578
7A5
FUEL INJECTOR NOZZLES
W20720496
B11664
Some problems caused by faulty injector nozzles: The engine is hard to start or will not start. Rough engine operation and idle. The engine will not have full power. The engine exhaust smoke is black, white or blue. Removal And Installation The tool listed will be needed to do the following procedure: MEL1181 Nozzle Wrench
1
B11523
Do not bend the high pressure fuel injection tubes when removing or installing them.
I20290289
Disconnect the high pressure fuel lines at the fuel injector [A]. Disconnect the high pressure fuel lines at the injection pump [B]. Remove the high pressure lines [C]. Disconnect the low pressure hoses (Item 1) [D] at the injectors. Use the special tool and remove the fuel injector from the cylinder head. Installation: Tighten the delivery valve nuts (Item 1) [B] to 2936 ft.lbs. (3949 Nm) torque. Tighten the nozzle holder to 2236 ft.lbs. (3029 Nm) in the cylinder head.
B11663
D
1
B11586
7A6
FUEL INJECTOR NOZZLES (Contd) Checking the Nozzles You can adjust the release pressure of the injector by adding or removing spacers (Item 1) [A] at the top of the nozzle spring (Item 2) [A]. Each 0.0039 inch (0,01 mm) spacer will change the release pressure about 142 PSI (979 kPa). The release pressure must be 19202133 PSI (1323814707 kPa). Connect the injector nozzle to the tester with the nozzle down. Use tools MEL10018 & MEL10019.
2 1
B04103
Operate the hand lever at a slow rate and not the opening pressure. If the pressure is not correct, disassemble the injector nozzle and add or remove spacers. Assemble the injector nozzle and check the pressure again. When you assemble the injector nozzle, tighten the nozzle body (Item 3) [A] to 4358 ft.lbs. (5979 Nm) torque. NOTE: Do not over tighten, or slow action of the valve will occur. Check for inside leakage. Operate the hand lever until the pressure is almost enough to open the injector valve. Record the pressure. Release the hand lever. Check the pressure decrease for 10 seconds. If the pressure decrease is more than 740 PSI (5102 kPa) in 10 seconds, the nozzle is damaged. Check that the spray pattern is correct [B]. The spray pattern is not correct if any of the following occur: Fuel comes out of the side of the nozzle. Drops of fuel are present at the nozzle. The nozzle does not have an even flow coming from the nozzle.
B
CORRECT WRONG
Spring Pressure Pin Holder Nozzle Body Needle Valve
A02621
Do not disassemble or test the injector nozzles unless you have the correct service and testing tools.
I21210297
W20720496
7A7
ENGINE Removal And Installation Open the rear door and clean the engine area. Disconnect the battery cables, ground cable first. Remove the coolant from the engine. The radiator cap must be loosened to drain coolant. Connect a hose to the valve or use a funnel to keep coolant from getting into the engine compartment. Open the valve (Item 1) [A] and drain coolant into a container. Turn the lever (Item 1) [A] on the valve. When all the coolant is removed close the valve. Close the shutoff valve. Remove the exhaust pipe from the manifold [B].
P00174
P01178
Remove the radiator hoses [C].
P01177
Remove the fuel return hose [D].
P01176
7A8
ENGINE (Contd) Removal And Installation (Contd) Disconnect the battery cable and wires from the starter [A]. Remove the bolts which mount the relays to the loader frame. Remove the fuel inlet line at the fuel filter.
P01180
Disconnect the air cleaner hose [B]. Disconnect the throttle linkage at the injector pump. Disconnect the engine wiring harness from the operator cab wiring harness.
P01179
Remove the engine mounting bolts [C]. Installation: Tighten the engine mounting bolts to 6570 ft.lbs. (8895 Nm) torque.
P01181
Remove the engine from the loader [D]. Installation: Have a second person put their hand into the pump area. Align the coupler ujoint on the splined shaft of the hydrostatic pump. If the splines do not match, turn the engine with the crankshaft nut socket (MEL1234). Slide the engine into the loader.
B04727
7A9
RADIATOR AND OIL COOLER Removal And Installation Remove the coolant from the cooling system. Remove the panels from the blower housing [A]. Remove the rear grill. (See MAIN FRAME Section 5.) Disconnect the overflow hose from the radiator. Drain the coolant tank and remove the tank. Disconnect the radiator hoses from the radiator.
P00187
Disconnect the tubeline from the oil cooler [B]. Disconnect the hose from the oil cooler.
B04762
Remove the radiator mounting bolts. Installation: Tighten the bolts to 1516 ft.lbs. (2123 Nm) torque. Remove the radiator/oil cooler assembly. Remove the radiator mounting bolts (Item 1) [C]. Remove the radiator from the mounting frame. Remove the oil cooler mounting bolt (Item 2) [C] and nuts. Remove the oil cooler from the mounting brackets. Installation: Fill the radiator with premixed coolant (50% water and 50% antifreeze). Fill the coolant recovery tank 1/3 full with premixed coolant.
E01500 E01591
7A10
BLOWER HOUSING Removal And Installation Remove the engine. (See Page 7A8.) Remove the radiator, oil cooler assembly. (See Page 7A10.) Disconnect the fuel lines from the fuel filter [A].
B04746
Remove the center nut from the blower housing [B].
B04760
Remove the bottom bolt from the blower housing [C].
B04747
Remove the blower housing [D].
B04748
7A11
ENGINE FLYWHEEL AND UJOINT Removal And Installation Remove the engine. (See Page 7A8.) Remove the four bolts at the ujoint mounting flange [A]. Installation: Put LOCTITE on the four bolts. Tighten the bolts to 2528 ft.lbs. (4348 Nm) torque.
B08698
Remove the ujoint from the flywheel [B]. MEL1187 Socket
B08699
Bend the locking tabs away from the bolt flats [C]. Installation: Bend the locking tabs against the bolt flats.
Remove the flywheel bolts [D]. Installation: Tighten the bolts to 7280 ft.lbs. (98108 Nm) torque.
C02673
D
Flywheel Ring Gear The ring gear on the flywheel is an interference fit. Heat the ring gear enough to expand it and hit it with a hammer, evenly to remove it. Clean the outer surface of the flywheel to give a smooth fit. Clean the new ring gear and heat it to a temperature of 450500F (232260C). Fit the ring gear over the flywheel. Make sure the gear is on its seat correctly. 7A12
B04776
MUFFLER Removal And Installation Remove the rear grill. (See MAIN FRAME Section 5.) Remove the exhaust pipe from the muffler [A].
B04775
Remove the bolts holding the muffler [B].
B04761
7A13
CYLINDER HEAD Removal Remove the nuts from the valve cover and remove the valve cover [A].
C02559
Disconnect the injector tubelines. Remove the injector nozzles and the copper gasket [B]. Remove the intake manifold. Remove the belt shield and remove the alternator.
B04091
Remove the rocker arm [C]. Remove the push rods. Remove the water return pipe. Remove the cylinder head bolts.
A02764
Remove the cylinder head [D]. Remove the cylinder head gasket and the Orings.
B04120
7A14
CYLINDER HEAD (Contd) Disassembly NOTE: There may be a shim under the head gasket. Use the shim over again or replace it with the same size shim. Remove the valve cap (Item 1) [A] and the valve spring collet (Item 2) [A]. Remove the valve spring retainer (Item 3) [A]. Remove the spring (Item 4) [A]. Remove the seal (Item 5) [A] and the valve (Item 6) [A]. Remove the thermostat [B].
4
Spring
Cap Collets Retainer
5
B04122
Valve Seal
B03643
Servicing Use the tool listed for the following procedure: MEL1098 Valve Lapper Clean the surface of the cylinder head. Put a straight edge (Item 1) [C] on the cylinder head. NOTE: Do not put the straight edge across the combustion chamber. Put a feeler gauge (Item 2) [C] between the straight edge and the surface of the cylinder head.
A02735
The maximum distortion of the cylinder head surface is 0.002 inch ( 0,005 mm). If the measurement is more than the specifications, the cylinder head must be planed. NOTE: Place a soft brass rod through the injector hole and tap the combustion chamber out before planing the head. Plane the same amount from the bottom side of the combustion chamber before installing it back in the head. Clean the valve surface. Measure the width of the valve seat [D].
B03632
7A15
CYLINDER HEAD (Contd) Servicing (Contd) The correct width of the valve seat is 0.0827 inch (2,1 mm) and the seat angle is 45 degrees. Grind the valve seats as follows: Use a 45 cutter to grind the surface of the valve seat [A]. Use a 15 cutter to grind the front surface of the valve seat [A]. Use a 65 or 75 cutter to grind the rear surface of the valve seat to finish the seat to a 0.0827 inch (2,1 mm) width [A]. Grind the valve surface to a 45 angle. Install the valve in the seat and check the depth [B]. The specifications for the depth of the valve is 0.04330.0512 inch (1,091,30 mm). If the measurement is more than the specification, add the correct thickness of the washer under the valve spring to keep the correct tension on the spring. Clean the valve guide. Install the valve in the cylinder head. Install the dial indicator. Measure the clearance of the valve guide and the valve [C]. The measurement (0,040,06 mm). must be 0.00160.0023 inch
A
B
Valve Contacting Width
Uncorrected Surface of Valve Seat A 45 cutter B 15 cutter C 65 or 70 cutter
Corrected Surface of Valve Seat
A02729
B03634
If the measurement exceeds the limit, replace the valve guide. (See Page 7A21 for valve guide installation.) Ream the new guide to the correct dimensions. Measure the valve spring. The length of the spring must be 1.64171.6614 inch (41,742,2 mm). Replace the valve spring if it does not meet these specifications. Check the valve spring with a combination square to make sure it stands straight. Replace it if is not straight [D].
B03698
B03680
7A16
CYLINDER HEAD (Contd) Servicing (Contd) Put the valve spring in a tester [A]. Push down on the spring 1.3839 inch (35,15 mm). The compression load must be 22.526.5 lbs. (100118 N). Replace the valve spring if it does not meet these specifications.
A02759
Measure the inside diameter of the rocker arm bushing (Item 1) [B] and the shaft diameter (Item 2) [B]. The inside of the rocker bushing is 0.55130.5529 inch (14,014,04 mm). If the measurements are not within the specifications replace the needed parts.
B03697
Valve Guide Installation Use the tools listed to replace the valve guides: Pressfit tool Auxiliary fitting Margin adjustment jig See figure [C] for dimensions to make the pressfit tool.
C
8.000 (203,2 mm) 3.150 (80 mm)
1.600 (40,6 mm)
80.800 (20,3 mm) See figure [D] for dimensions to make the auxiliary fitting.
0.510 12,95 mm)
0.303 (7,7 mm)

MC01389
D
0.590 (14,99 mm) R 0.155 (3,9 mm)
Auxiliary Fitting
0.200 (5,08 mm)
MC01390
7A17
CYLINDER HEAD (Contd) Valve Guide Installation (Contd) See figure [A] for dimensions to make the margin adjustment jig.
A
Margin Adjustment Jig 0.700 R 0.260 (17,8 mm) (6,6 mm)
0.394 (10,0 mm)
MC01390
Use the following procedure to replace exhaust (Item 1) [B] and inlet (Item 2) [B] valve guides. Remove the cylinder head. (See Page 7A14.) Ream the new valve guide to the correct dimensions. Use the pressfit tool to remove the old valve guide from the cylinder head.
B
1
Exhaust Valve Guide
2
Inlet Valve Guide
B13321
Slide the auxiliary fitting (Item 1) [C] over the narrow end of the pressfit tool until it makes contact with the middle section of the tool. Slide the valve guide (Item 2) [C] over the narrow end of the pressfit tool until it makes contact with the auxiliary fitting. Position the margin adjustment jig (Item 3) [C] above the valve guide hole. Press the valve guide into the valve guide hole until the auxiliary fitting meets the margin adjustment jig. The amount of valve guide protrusion will be thickness of the margin adjustment jig which is 0.394 inch (10,0 mm).
C
1 3
B13320
Revised Sept. 93
7A18
CYLINDER HEAD (Contd) Assembly Install the valves. Put oil in the valve seal and install the seal on the valve. Install the valve spring and retainer. Install the spring collet and the valve cap. Install the thermostat. NOTE: If a new cylinder head is installed be sure to install the screw plugs which are shipped with the new cylinder head. Installation Install a new gasket and Oring. Install a shim if there was one removed. Install the cylinder head on the engine block. Put oil on the bolts and nuts and tighten to the following torque: Flange Head Bolt . . . . . . . . . 6568 ft.lbs. (8892 Nm) Bolt W/Washer 5861 ft.lbs. . . . . . . . . . . . (7983 Nm) Use the tightening sequence as shown [A]. Lower the piston which is to be measured for the clearance, between the cylinder head and the piston. Put a piece of solder in the injector port. Make sure the solder does not touch the valves [B]. Turn the engine manually. Remove the solder and measure it. The thickness must be 0.0280.035 inch (0,70,9 mm). If the measurement is not in the specifications, remove the cylinder head and add the correct shim between the cylinder head the engine block. Install the cylinder head and tighten the bolts and nut [A]. NOTE: Be sure to torque the bolts and nuts again after the engine has been operated for 30 minutes. Install the push rods.
B03624
B04068
0.00570.0073 in. (0,1450,185 mm)
A02730
Install the water return pipe. Install the rocker arms. Tighten the rocker arm holding nuts to 15 ft.lbs. (20 Nm) torque. Install the alternator, belt and shield. Install the intake manifold. Install the injector nozzle with a new copper gasket. Tighten to 2236 ft.lbs. (3049 mm) torque. Install the injector tubelines. Adjust the valve clearance. Make sure the piston is at T.D.C. when making the adjustment [C]. Install the valve cover. 7A19 742B, 743B Loader Service Manual
ENGINE REPAIR Remove the cylinder head. (See Page 7A14.) Remove the push rods. Remove the starter. (See ELECTRICAL SYSTEM Section 6.) Remove the injector pump. (See Page 7A3.) Gearcase Removal Remove the governor spring from the governor fork [A] & [B].
Detach Governor Spring on the Side of Fork Lever (2)
Gearcase
Fork Lever
B11493
B03676
Remove the plate (Item 1) [C] for speed control and the governor spring (Item 2) [C].
C
1 2
B03647
Remove the valve tappets [D].
B13367
Revised Sept. 93
7A20
ENGINE REPAIR (Contd) Gearcase Removal (Contd) Remove the start spring from the gearcase [A] & [B].
Gearcase
Fork Lever (2) Straighten the washer on the crankshaft sheave. Remove the nut and washer. Installation: Tighten the nut to 101110 ft.lbs. (137149 Nm) torque. After installation, bend the washer on the sheave.
Detach Start Spring on the Side of the Gearcase
B11493
B03678
The tool listed will be needed for the following procedure: MEL1234 Crankshaft Nut Socket Use a puller and remove the engine crankshaft sheave [C]. Remove the key. Remove the bolts from the gearcase.
B03694
Remove the gearcase [D].
B04095
7A21
ENGINE REPAIR (Contd) Timing Gear, Camshaft And Oil Pump Removal Remove the crankshaft collar (Item 1) [A], Oring, oil slinger and the gear collar. Remove the snap ring on the idler gear.
1
B03637
Remove the idler gear (Item 1) [B]. Remove the idler gear collar (Item 2) [B] from the shaft. Straighten the washer on the bolt for the camshaft stop. Remove the bolt for the camshaft stop.
2
B03699
Remove the camshaft [C]. Remove the three bolts that hold the fork lever on the fuel camshaft. Remove the stop for the fuel camshaft.
B03655
Remove the fuel camshaft and the fork lever at the same time [D].
B03649
7A22
ENGINE REPAIR (Contd) Timing Gear, Camshaft And Oil Pump Removal (Contd) Remove the crankshaft gear with a puller [A]. Remove the key. Straighten the washer on the gear of the oil pump. Remove the bolt on the gear of the oil pump.
B03686
Remove the gear pump (Item 1) [B]. Remove the oil pump bolt. Remove the oil pump (Item 2) [B].
B
1
B03658
Pistons And Crankshaft Removal Remove the oil pan. Remove the screen [C]. NOTE: Do not damage the Oring. Straighten the washer on the connecting rod bolts. Remove the connecting rod bolts.
B04124
B03688
NOTE: Two types of bolts are used [D]. Install in matched pairs only. Do not mix on same rod. Remove the cap and the bearing from the connecting rod [C]. Installation: Tighten the rod cap bolts to torque as follows: Machine Bolt (13 mm size head0 2731 ft.lbs. (3742 Nm) Forged Bolt (12 mm size head) 3336 ft.lbs. (4549 Nm)
D
Tightening Torque 3336 ft.lbs. (4549 Nm) 12 mm Cold Forged Flange Bolt
7A23
ENGINE REPAIR (Contd) Piston And Crankshaft Removal (Contd) Remove the piston from the engine block [A]. NOTE: Be sure the pistons are marked so they will be returned to the same cylinder. Straighten the washer on the flywheel bolts. Remove the bolts from the flywheel. Use a puller to remove the flywheel. Straighten the washer on the bolts that hold the main bearing in position. Remove the main bearing bolts from the engine block [B]. Installation: Tighten the main bearing bolts to 4751 ft.lbs. (6469 Nm) torque.
B03625
B03644
Straighten the washer on the bolts that hold the main bearings in position. Remove the bolts. Install two bolts in the rear cover and pull the cover out [C].
B03648
Remove the crankshaft from the rear of the engine [D]. NOTE: Do not damage the crankshaft removing it from the engine block. when
Straighten the washer on the bolts of the main bearings.
B04126
7A24
ENGINE REPAIR (Contd)

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772EngineServiceSectionPart1of5
Piston And Crankshaft Removal (Contd) Remove the bolts from the bearing cap halves [A]. Remove the halves of the main bearings. NOTE: When installing the bearing cap halves, make sure to position the markings on the bearing caps toward the flywheel. Thrust washers must be installed with oil grooves facing outward.
B04092
Timing Gear And Camshaft Service Measure the camshaft bearing in the engine block [B]. The specification is 1.57481.5758 inch (4040,03 mm). The wear limit is 0.0020.0036 (0,050,09 mm).
B03620
Measure the camshaft journal [C]. The specification is 1.57221.5728 inches (39,93439,950 mm). The wear limit is 0.0020.0036 inch (0,050,09 mm). If the measurements are not within the specifications replace the needed parts. Put the camshaft on Vblocks. Put a dial indicator on the journals. Turn the camshaft at a slow rate.
A02761
The wear limit is 0.0008 inch (0,02 mm) [D]. If the camshaft measurements are not within the specification replace the needed parts.
A02760
7A25
ENGINE REPAIR (Contd) Timing Gear And Camshaft Service (Contd) Make a measurement of the highest point on each camshaft lobe [A]. The specifications are 1.3134 inches (33,36 mm). The wear limit is 1.3115 inches (33,31 mm).
B05001
NOTE: After the crankshaft is installed, check the clearance for the camshaft gear. Install a dial gauge. Hold one gear while turning the other gear [B]. The specification is 0.0060.0045 inches (0,150,11 mm). The wear limit is 0.0118 inch (0,3 mm).
B03672
Servicing The Connecting Rods And Pistons Remove the piston rings (Item 1) [C]. Remove the piston pin (Item 2) [C].
C
2
B03621
NOTE: Make sure to mark the piston and the connecting rod so they will be assembled correctly [D].
D
1. Align the marks with each other. 2. Face the marks toward the injection pump.
A02903
7A26
ENGINE REPAIR (Contd) Servicing (Contd) The Connecting Rods And Pistons
Measure the piston pin hole [A]. The specifications are 0.90550.9060 inch (2323,013 mm). The wear limit is 0.9076 inch (23,053 mm).
A02733
Measure the piston pin (Item 1) [B] and the connecting rod busing (Item 2) [B]. The clearance specification is 0.00060.0026 inch (0,00150,07 mm). The allowable limit is 0.0059 inch (0,149 mm) If the clearance exceeds the allowable limit, replace the part. NOTE: When the replacement bushing is installed, be sure to drill the oil hole in the bushing. Deburr the hole after drilling [B].
2 1
B03633
Put the piston ring on the bottom of the cylinder. Check the clearance of the ring gap [C]. The specification is 0.00180.0177 inch (0,0460,45 mm). The wear limit is 0.0492 inch (1,25 mm). Install the connecting rod on the tool for checking connecting rod alignment.
B03622
Check the clearance at the piston pin area [D]. The specifications are 0.0008 inch ( 0,02 mm). The wear limit is 0.0020 inch (0,05 mm). NOTE: Be sure the bushing diameter of the connecting rod is within specification.
B04067
7A27
ENGINE REPAIR (Contd) Crankshaft Service NOTE: If a new crankshaft is used, be sure the plugs that come with the crankshaft are installed in the crankshaft or engine damage will occur. Put the crankshaft on Vblocks. Put a dial indicator on the center journal and turn the crankshaft slowly [A]. The specifications are 0.0008 inch (0,02 mm). The wear limit is 0.0031 inch (0,08 mm). Check the inside diameter of the crankshaft bearing in the engine block [B]. The specification is 2.04652.0488 inches (51,9852,039 mm). The wear limit is 0.0079 inch (0,2 mm).
A02763
B03631
Check the outside diameter of the #1 crankshaft journal [C]. The specification is 2.04412.0449 inches (51,9251,94 mm). The wear limit is 0.0079 inch (0,2 mm).
B03618
Check the connecting rod bearings [D]. The specifications are 1.73271.7343 inches (44,0144,05 mm). The wear limit is 0.0079 inch (0,2 mm).
120
A02727
7A28
ENGINE REPAIR (Contd) Crankshaft Service (Contd) Check the connecting rod journals [A]. The specifications are 1.73071.7313 inches (43,95943,975 mm). The wear limit is 0.0079 inch (0,2 mm).
A02716
If the connecting rod journals are not within specifications grind the journals as follows [B]. a. Crankshaft corner radius must be 0.127R inch .0079 inch (3,5R 0,2 mm). b. The oil hole must be chamfered to 0.03940.0591R inch (1,01,5R mm).
A B
A Install the crankshaft and check the end play [C]. Normal end play is 0.00590.0122 inch (0,150,31 mm). Replace the thrust bearings on the main bearing if end play exceeds 0.020 inch (0,5 mm).
A02716
B09565
Cylinder Liner Service Check the inside diameter of the cylinder liner [D]. The tools listed will be used for the following procedure: MEL1060 Ridge Reamer MEL1180 Dry Liner Puller
B04066
7A29
ENGINE REPAIR (Contd) Cylinder Liner Service (Contd) To find the maximum wear check the inside diameter in three different locations [A]. The specifications are 3.22833.2292 inches (8282,021 mm). The wear limit is + 0.0059 inch (+ 0,15 mm). When the cylinder liner has more wear than specifications, bore and hone the cylinder to 3.24803.2489 inches (82,49982,522 mm). NOTE: Make sure you use the correct oversize pistons and rings.
A02727
If the cylinder liner is not within the specifications, replace the cylinder liner. These are dry liners. Remove the cylinder liners. Clean and rub oil in the bores of the engine block. Clean and put oil on the outside of the cylinder liners. Install the cylinder liners into the engine block with the inside and outside diameter chamfered end down. The top of the liner must be even with the top of the engine block machined surface. After installation bore and hone the cylinder liner to 3.22833.2291 inches (8282,019 mm). Lubrication System The lubrication system consists of a trochoid rotortype driven oil pump, oil filter cartridge, oil pressure regulating valve, oil switch, and oil filter [B]. Oil is siphoned by the oil pump (b) from the oil pan (o) through the oil filter (a), where the oil is kept at 4164 PSI (290441 kPa) by an oil pressure regulating valve (c) installed in the gearcase. The oil flows towards the filter cartridge where it will be further filtered. To insure the supply of lubricating oil, a bypass valve (d) is provided, the valve opens when the filter element (e) is restricted from the filter cartridge, the pressurized oil is then distributed into two area; some will be fed through crankshaft passages to the crank pin bearing and the rest to the rocker arm shaft (i) through the frame. Oil then returns to the oil pan by gravity. The oil pressure switch (m) will indicate when oil pressure drops below 7 PSI (48 kPa). The oil pressure switch is connected to the oil pressure gauge in the dash panel. If the pressure reads low or zero while the engine is in normal operation, stop the engine immediately and check the oil level.
J K L
G N
B C
E D O
(a) (b) (c) (d) (e) (f) (g) (h)
Pump Screen A Oil Pump Pressure Regulating Valve ByPass Valve Filter Element (i) Rocker Arm Shaft Crankshaft (j) Rocker Arm Piston (k) Push Rod Idle Gear (l) Tappet (m) Oil Pressure Switch (n) Camshaft (o) Oil Pan B09194
7A30
ENGINE REPAIR (Contd) Oil Pump Service Check the clearance between the inner and outer rotor [A] The clearance for the inner rotor is 0.00390.0063 inches (0,0990,160 mm). The wear limit is 0.0079 inch (0,2 mm).
B03616
Check the clearance between the outer rotor and the body of the oil pump [B]. The clearance for the outer rotor is 0.00430.0075 inches (0,110,19 mm). At full rated engine speed, the normal oil pressure is 4256 PSI (290386 kPa) and a minimum of 35 PSI (241 kPa).
A02732
Water Pump Service Remove the water pump from the gearcase [C].
B05318
Put the water pump is a vise and remove the nut [D]. Remove the pulley using a puller. Remove the key. Remove the snap ring.
B05324
7A31
ENGINE REPAIR (Contd) Water Pump Service (Contd) Drive the shaft out of the impeller side [A].
B05325
Install the new seal [B]. Install the shaft Put the water pump in a vise and tighten the nut to 5057 ft.lbs. (6877 Nm) torque. Install the water pump assembly on the gearcase with a new gasket.
A02783
7A32
ENGINE ASSEMBLY Crankshaft Installation Install the main bearing case on the crankshaft journals with marks toward the flywheel end. Tighten the bolts to 2125 ft.lbs. (2834 Nm) torque. Install the thrust bearing with the oil grooves to the outside. Install the crankshaft in the engine block. Each main bearing is numbered for correct location. Make sure the oil holes in the main bearings are in alignment with the holes in the engine block [A]. Install the main bearing case bolts and tighten to 4750 ft.lbs. (6468 Nm) torque. Install new seals int he crankshaft rear cover. Install the rear cover and tighten the bolts to 1315 ft.lbs. (1820 Nm) torque. Installing The Pistons. The tools listed will be needed for the following procedure: MEL1063 Ring Compressor MEL1064 Piston Ring Expander Assemble the connecting rod to the piston. NOTE: Make sure the marks on the piston and the connecting rod are in the same direction. Install the rings on the piston [B]. Position the top ring so the gap is not lines up with the piston pin. Position the other rings so there is a gap every 90. Use a ring compressor to install the pistons in the engine block with the marks away from the camshaft. Align the bearing cap on the connecting rod [C]. Put oil on the bolts, install them in the bearing caps and tighten to 2630 ft.lbs. (3541 Nm) torque. Install the oil pump tube and screen. Install a new oil pan gasket and install the oil pan. Installing The Camshaft And Timing Gears Install the oil pump and tighten the bolts to 6072 in.lbs. (6,78,1 Nm) torque [D]. Install the gear and tighten the nut. Install the key and the gear on the crankshaft.
A
Main Bearing Case
Case Bolt
A02736
Alignment Marks
B03614
A02731
B03658
7A33
ENGINE ASSEMBLY (Contd) Instaling The Camshaft And Timing Gears (Contd) Install the fuel camshaft and the fork lever at the same time [A]. Install the stop bolt on the fork lever. Tighten the bolt to 6072 in.lbs. (6,88,1 Nm) torque. Install the bolts and tighten to 1315 ft.lbs. (1820 Nm) torque.
B03649
Install the camshaft and tighten the bolts to 1315 ft.lbs. (1820 Nm) torque [B].
B03655
Install the idle gear [C].
B03699
Make sure the timing marks are in correct alignment [D]. Install the snap ring on the idler gear shaft.
Gear Marks
Cam Gear Injection Pump Gear Oil Pump Drive Gear Idle Gear Crank Gear
A02771
7A34
ENGINE ASSEMBLY (Contd) Installing The Camshaft And Timing Gears (Contd) Install the oil slinger (Item 1) [A]. Put oil on the Oring and install the Oring (Item 2) [A] and the collar (Item 3) [A].
A
1 3
2
B04098
Gearcase Installation Install the Oring and the oil seal in the gearcase cover [B]. NOTE: Put oil on the oil seal. Install the gearcase cover and bolts. Tighten the bolts to 1315 ft.lbs. (1820 Nm) torque. Install the crankshaft sheave and tighten the nut to 101116 ft.lbs. (137157 Nm) torque.
Orings Oil Seal

B03617
Install the start spring [C].
B03678
Install the speed control plate and governor spring [D]. NOTE: Do not drop the governor spring into the gearcase.
B03647
7A35
ENGINE ASSEMBLY (Contd)

Gearcase Installation (Contd) Connect the governor spring [A]. Install the injector pump. (See Page 7A3.) Install the cylinder head. (See Page 7A19.) Install the engine. (See Page 7A9.)
B03676
7A36
ENGINE SERVICE (Contd) (Mitsubishi 742B)
Page Number
CAMSHAFT Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B29 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B29 CARBURETOR Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND MAIN BEARINGS Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Oil Clearance (Plastic Gauge) . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B11 7B7 7B11 7B12 7B11 7B10 7B43 7B44 7B45 7B43 7B44 7B45 7B43
CYLINDER HEAD Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B31 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B30 CYLINDER LINERS Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B42 DISTRIBUTOR Checking Centrifugal Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Vacuum Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B6 7B6 7B6 7B5 7B5
ENGINE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B15 ENGINE BELT SHIELD Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B14 ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B3 ENGINE FLYWHEEL & UJOINT Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B24 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B24 ENGINE MUFFLER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B23 FRONT CASE AND OIL PAN Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B51 FRONT CASE SEAL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B54 FUEL PUMP Checking The Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7B1
MITSUBISHI (742B)
7B13 7B13 7B13 7B13

ENGINE SERVICE (Contd) (Mitsubishi 742B (Contd)
Page Number
IGNITION TIMING Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B4 OIL COOLER AND BLOWER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B19 OIL PUMP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B52 7B52 7B53 7B52 7B37 7B36 7B37 7B38 7B36
PISTON PIN Assembly Of The Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B40 Installation Of The Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B41 Removal Of The Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B40 RADIATOR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B22 ROCKER ARMS Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B25 THERMOSTAT Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B56 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B56 TIMING BELT Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B46 7B49 7B48 7B47
TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1 VALVES Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reconditioning The Valve & Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B32 7B33 7B32 7B34 7B33 7B34
VALVE CLEARANCE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B2 WATER PUMP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B55 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B55
7B0
PROBLEM Slow cranking speed. Engine will not start. Rough idle. Abnormal combustion. Engine noise. Acceleration insufficient. Power insufficient. Too much fuel consumption. Too much engine oil. consumption. Excessive engine vibration. Overheating. High Oil Pressure. 1, 2, 3, 4
CAUSE
2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 9, 13, 14, 15, 16 9, 11, 14, 17, 18, 19, 20, 21 8, 14, 22, 23, 24, 25, 26, 27, 28, 29 5, 9, 11, 31, 32 5, 8, 9, 11, 12, 13, 14, 15, 17, 18, 21, 26, 31, 33, 34 8, 9, 11, 12, 13, 14, 15, 16, 18, 26, 32 26, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45 9, 11, 17, 31, 34, 45, 46 9, 11, 13, 20, 30, 47, 48, 49, 50 4, 51, 52 KEY TO CORRECT THE CAUSE
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.
Battery capacity low. Bad electrical connections. Faulty starter motor. Incorrect grade of oil. Burnt valve. Intake manifold gasket leaking. Carburetor mounting loose. Piston, rings & cylinder worn. Cylinder head gasket leaking. Faulty electrical wiring. Faulty ignition system. Fuel system problem. Restriction in the air cleaner. Valve clearance not correct. Worn valves and seats. Worn valve stems or guides. Vale stuck. Weak valve springs. Carbon accumulated in combustion chamber. Restriction in the water jacket Carburetor mixture too lean. Worn or damaged bearings. Connecting rod bent. Piston or piston pin worn. Burnt piston. Piston rings damaged.
7B1
27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.
Excessive camshaft end play. Crankshaft thrust bearing worn. Timing belt worn. Water pump or fan belt faulty. Poor compression. Carburetor accelerator pump faulty. Overheating. Cold running. Oil pan drain plug is loose. Oil pan bolts are loose. Oil pan gasket is faulty. Timing gear cover is loose or gasket is broken. Crankshaft front seal leaking. Crankshaft rear seal leaking. Valve cover gasket is leaking. Fuel pump loose or faulty gasket. Oil filter mounting loose. Plugged oil return hole. Piston rings stuck. Faulty engine mounting. Exhaust pipe restriction. Faulty thermostat. Plugged radiator. Coolant level low. Switch is defective. Pressure relief sticking closed.
VALVE CLEARANCE Adjustment NOTE: Always set the valve clearance after the cylinder head bolts are tightened to the correct torque. Warm the engine until it is at operating temperature. Valve clearance [A]. Intake Valve . . . . . . . . . . . . . . 0.006 inch (0,15 mm) Hot Exhaust Valve . . . . . . . . . . . . 0.010 inch (0,25 mm) Hot Stop the engine. Remove the valve cover. Position the piston at T.D.C. Loosen the lock nut. Adjust the valve clearance by turning the adjusting bolt and measuring with a feeler gauge [B]. Tighten the lock nut. Repeat the procedure for each set of valves. Start the engine, run at idle speed and check the clearance again. Make adjustment as needed.
A
Exhaust 0.010 (0,25 mm) Hot
Intake 0.0006 (0,15 mm) Hot
B09720
B09716
7B2
ENGINE COMPRESSION Checking The tool listed will be needed to do the following procedure: OEM1073 Compression Gauge & Hose The engine must be at operating temperature. Remove the spark plugs [A]. Installation: Tighten the spark plugs to 1822 ft.lbs. (2430 Nm) torque.
B09883
Connect a compression gauge [B]. The engine should be turning at about 250 RPM. The compression should be about 150 PSI (1024 kPa) with no more than 10% difference between cylinders.
B09882
7B3
IGNITION TIMING Procedure Mark the crankshaft pulley notch and 5 BTDS mark with chalk [A]. Connect the timing light to the No. 1 spark plug wire. Connect the negative and positive cables of the timing light to the correct battery terminals.
B09941
When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.
W20060284
Disconnect the vacuum line. Start the engine. Run the engine speed at 600650 RPM. Check the timing setting [B].
B09943
If the timing is not correct, loosen the distributor mounting nut [C]. Turn the distributor until the timing is at at 5 BTDC. At 2800 RPM and vacuum line off, the timing should advance 10.
B09942
7B4
DISTRIBUTOR Removal And Installation Turn the crankshaft until No. 1 piston is at T.D.C. on compression stroke. Disconnect the negative battery cable. Remove the distributor cap [A]. Disconnect the vacuum hose.
B09701
Remove the distributor mounting nut [B].
B09700
Installation: Align the mating mark (Item 1) [C] on the distributor housing with the mark on the distributor gear.
Point Gap Adjustment Remove the distributor cap. Remove the rotor. Turn the crankshaft until the points are wide open. Check the breaker point gap with a feeler gauge, if it is out of specifications, adjust as follows: Breaker Point Gap . . . . . . . . . . . . . . . . 0.0180.021 inch (0,480,53 mm) Loosen the two lock screws. Put a screwdriver blade into the hole (Item 1) [D]. Adjust the points to the correct specifications. Tighten the two lock screws. Lock Screw NOTE: After the breaker points are adjusted, you must time the engine. (See Page 7B4.) 7B5
B09784 B09678
D
Breaker Point Gap
Contact Arm
DISTRIBUTOR (Contd) Disassembly And Assembly Use the following procedure to disassemble and assemble the distributor [A]: Remove the rotor (Item 3) [A]. Remove the snap ring from the spindle of the breaker base (Item 7) [A]. Remove the screws holding the vacuum advance (Item 21) [A] and removal. Disconnect the wires and remove the terminal. Remove the breaker points. Remove the cam assembly. Remove the springs (Item 10) [A] and weights (Item 9) [A]. Remove the roll pin (Item 19) [A] from the gear (Item 20) [A]. Remove the gear and shaft assembly. Checking Centrifugal Advance Run the engine at the idle low RPM. Remove the vacuum hose. Slowly increase the engine RPM to check advance.
5 1 2 7 6 12 8 9 10 13 10 11 3 4
21 22
18 17 16
20
1. Excessive Advance Weak Springs or broken. 2. Insufficient Advance Faulty operation of the centrifugal weights or cam. 14 Checking Vacuum Advance 15 Set engine speed at 2800 RPM. Check advance by disconnecting and connecting the vacuum hose. Timing should advance 10. For an accurate check, connect a vacuum pump and run engine at idle RPM. Slowly apply vacuum to check advance. 1. Excessive Advance Weak vacuum control spring or broken. 2. Insufficient Advance Breaker plate binding or diaphragm broken. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cap Carbon Contact Rotor Wire Arm Support Wire Breaker Base Cam Weight Spring Shaft 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
19
Washer Oil Seal Terminal Packing Housing Oring Washer Roll Pin Gear Vacuum Control Condenser
B09824
7B6
CARBURETOR
A
Pilot Jet
Pilot Air Jet No. 1
Pilot Air Jet No. 2
Fuel
Ignition Switch Fuel Air Bypass
Solenoid
Primary Main Jet Bypass Screw
Mixture Adjusting Screw
Pilot Outlet
Throttle Valve
B09714
Description The lowspeed system provides airfuel mixture for smooth lowspeed engine operation for lightload performance [A]. Fuel from the float chamber is sent through the main jet and fuel passage to the pilot jet where the fuel is metered. At the same time, air is fed through the venturi air orifice and pilot air jet No. 2 to the pilot air jet No. 1 where the air is metered then, air is mixed with the fuel. The flow of airfuel mixture is adjusted by the bypass screw and enters the air horn through the bypass hole and pilot outlet. It mixes with a small amount of air that goes past the closed or slightly open throttle valve. The final mixture flows into the cylinders. The mixture adjusting screw is provided for adjusting airfuel mixture necessary for idle. The bypass screw is for adjusting the flow of fuel to the bypass hole which provides mixture for engine operation from off idle to a medium load operation. The fuel shutoff solenoid, in the lowspeed system, functions as follows: When the key switch is ON it opens the valve to open the fuel line. When the key switch is OFF it closes the fuel feed line and prevents spontaneous running of the engine. 742B, 743B Loader Service Manual
7B7
CARBURETOR (Contd) Description (Contd) The idle compensator is operated by a bimetal element [A]. When the carburetor ambient temperature rises during idle operation, the bimetal bends enough to open the compensator valve. Now additional air, from the air horn, can flow through the air passage directly to the intake manifold. This leans out the mixture to make up for added gasoline vapor coming from the float chamber.
Bimetal Element Valve
Air Passage
B09713
The main metering system functions as follows [B]: The wider the throttle valve opens, the faster the air flow is in the venturi. As the vacuum becomes greater, the main nozzle will inject fuel. The main metering system is provided with the bleed valve pressfitting into the inner venturi and the main air jet. Fuel metered by the main jet is bled by air from the main air jet and enters the bleed pipe through the holes. The main nozzle flows the fuel into the engine. If percolation of the fuel is present along the main well, vapor can escape from the main air jet through outside bleed pipe, thus preventing fuel from spurting from the main nozzle.
Primary Inner Venturi
Main Venturi
Main Air Jet
Main Well
Main Jet
B09712
7B8
CARBURETOR (Contd) Description (Contd) The enrichment system does the following functions [A]: This system provides additional fuel to the main metering system during highspeed large torque operation. The diaphragm is actuated by intake manifold vacuum and spring to open or close the fuel feed line. During partial throttle operation, the manifold vacuum is applied to the vacuum chamber and acts on the diaphragm to close the valve against spring force. When the throttle is opened, manifold vacuum decreases. This allows the diaphragm spring to open the valve. Now, more fuel from the float chamber can flow through the valve into the enrichment jet. The acceleratorpump system does the following functions [B]: Rapid opening of the throttle, requires a sudden demand for additional fuel. Fuel from the inlet check valve is sent tot he pump nozzle through the outlet check valve by movement of the diaphragm. The diaphragm is pushed by the pump lever linked to the throttle valve. When the engine is decelerated, the diaphragm is pushed back by the spring and the chamber is refilled with fuel.
Valve
Vacuum Chamber Spring Enrichment Jet

B09711
B
Valve Weight Check Valve
Pump Jet
Pump Lever
Membrane Inlet Check Valve
B09726
7B9
CARBURETOR (Contd) Removal And Installation Disconnect the air cleaner hose at the carburetor air horn. Disconnect the wire at the shutoff fuel solenoid [A].
B09872
Disconnect the choke cable. Disconnect the fuel line [B]. Disconnect the vacuum hose.
B09933
Disconnect the throttle linkage (Item 1) [C].
C
1
B09873
Remove the four mounting nuts [D]. Lift the carburetor from the intake manifold.
B09874
7B10
CARBURETOR (Contd) Disassembly And Assembly Disassemble and assemble the carburetor as shown [A]. Use the correct tools to prevent burrs or scratches. Keep the parts neatly and in order to prevent wrong assembly. Do not remove the inner venturi unless it is necessary. Do not remove the bypass screw unless it is necessary. Do not disassemble the throttle shaft or remove the plug in the throttle plate. Inspection Clean the parts thoroughly with carburetor solvent. Use air pressure to blow fuel passages and other parts dry. Check the needle valves for correct contact, replace as needed. Check the screen diaphragm and pilot screw seats for damage. Check the throttle valve for wear and damage and be sure the plug in the throttle plate is tight. Check the linkage for correct function. Check the acceleration pump for correct function as follows: Fill the pump chamber with fuel, operate the throttle lever and check for fuel spraying condition from the accelerator nozzle. Push the connecting rod of the depression chamber, plug the vacuum passage with a finger, release the connecting rod and check for leakage from the diaphragm. Check the float for being deformed, leakage, damage to the lip, wear of the float lever pin hole and the float lever bracket. Adjustment If the float level is out of alignment with the level mark, adjust the float by adding or removing the number of packings at the needle valve seat [A]. a slight difference of the float level from the level mark does not effect the carburetor or engine performance, it is normal if the float is in the circle of the level mark.
3 4 1 7 6 5 13 8 9 19 17 10 18 20 16 12 11 14 15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Float Float Chamber Cover Screen Needle Main Body Main Jet Enrichment Body Assembly Diaphragm Pump Cover Throttle Body Choke Connecting Rod Inner Venturi Pilot Jet Choke Operating Lever Speed Adjustment Screw Bypass Screw throttle Stop Lever Abutment Plate Throttle Lever Mixture Adjustment Screw
D01771
Packing
Level Mark
When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.
Sight Glass Float 7B11

B09727
W20060284
CARBURETOR (Contd) Adjustment (Contd) Set the engine idle speed (Item 1) [A] to 850950 RPM at operating temperature. Turn the idle fuel adjustment (Item 2) [A] in until the engine RPM decreases. Make a note of this position. Turn the idle fuel adjustment (Item 2) [A] out until the engine RPM decreases. Adjust the idle fuel adjustment between the two positions.
1
B09870
W20501285
B
2 3
Governor Adjustment NOTE: Adjust engine timing. (See Page 7B4.) Loosen three governor mounting bolts. Adjust governor belt tension to 1/4 inch movement at middle of belt. Keep governor level and tighten the bolts. Disconnect throttle rod (Item 1) [B]. Hold carburetor linkage (Item 3) [B] and governor linkage (Item 4) [B] against their stops and tighten the screws (Item 2) [B]. Check the governor throttle lever for maximum travel. Start the engine. Check that the engine idle speed is at 700750 RPM while holding governor lever against the idle stop. Set the throttle lever fast position stop bolt (Item 1) [C] at rear of slot. Push throttle lever fully forward. Set engine RPM at 29002975 RPM by adjusting the ball joint (Item 3) [B] and high speed stop on the governor. Pull throttle lever back until carburetor lever is against the idle stop screw. Set and tighten the slow position stop bolt (Item 2) [C] against the throttle lever.
4 1
N07058
N07076
Revised July 96
7B12
FUEL PUMP Removal And Installation Disconnect the fuel lines from the fuel pump [A].
B09704
Remove the three bolts from the fuel pump [B]. Installation: Put Threebond 4A Sealant between the cylinder head and gasket.
B09680
Remove the fuel pump from the cylinder head [C]. Inspection Check the rocker arm for smooth operation. Also check the spring for being weak and the pin for wear. Check the pump body and cover for cracks and damage. Check The Fuel Pump Disconnect the outlet hose from the fuel pump. Connect a gauge to the port.
B09681
Start the engine and measure the delivery pressure. If not within specifications, replace as needed. Delivery . . . . . . . . . . . . . . . . 2.11 qts. (2 L) @ 5000 RPM Closed Delivery Pressure . . 3.75 PSI (25,534,5 kPa) Fuel Filter the fuel filter is located in front of the air cleaner [D]. Change the fuel filter every 500 hours of loader operation.
B09903
7B13
ENGINE BELT SHIELD Removal And Installation Remove the bolt from the belt shield above the alternator [A].
B09836
Remove the bolt from the governor bracket [B]. Remove the bolt below the governor which fastens the belt shield to the engine block.
B09966
Remove the bolt from the alternator mounting bracket [C].
B09965
Remove the belt shield from the engine [D].
B09640
7B14
ENGINE Removal And Installation Lift and block the loader. MAINTENANCE Section 1.) (See PREVENTIVE
Remove the battery from the loader. (See ELECTRICAL SYSTEM Section 6.) Remove the rear grill. (See MAIN FRAME Section 5.) Raise the operator cab. MAINTENANCE Section 1.) (See PREVENTIVE
Disconnect the wire from the charge pressure switch [A].
B09967
B
Disconnect the wire from the port block [B].
B09812
C
Disconnect the electrical connectors from the electrical harness [C]. Remove the belt shield. (See page 7B14.)
B09808
D
Remove the radiator hose from the water pump [D].
B09901
7B15
ENGINE (Contd) Removal And Installation (Contd) Drain the coolant into a container [A]. Installation: Make sure to premix the water (50%) and ethylene glycol (50%) before adding it to the cooling system.
B09960
Remove the radiator hose from the thermostat housing [B].
B09834
Disconnect the air cleaner hose [C]. Turn the fuel shutoff to the OFF position on the fuel tank.
B09835
Disconnect the fuel line from the fuel pump [D].
B09900
7B16
ENGINE (Contd) Removal And Installation (Contd) Mark all the wires from the coil and resistor for correct installation. Disconnect all the wires from the resistor and coil [A]. Disconnect the ground cable from the engine block behind the governor. Disconnect the throttle rod from the governor.
B09899
Remove the clamp from the exhaust pipe [B]. Disconnect the exhaust pipe.
B09961
Disconnect the wires from the starter solenoid [C]. Mark the wires at the starter solenoid for correct installation.
B09982
Remove the four bolts, washers and nuts from the engine mounting plate [D].
B09962
7B17
ENGINE (Contd) Removal And Installation (Contd) Hook one end of the chain hoist into the lift hook on the water pump end of the engine [A].
B09838
Lift the engine a small amount and slide it toward the rear of the loader until the engine mounting plate is just over the rear edge of the loader frame [B].
B09980
Lower the chain hoist. Connect the other end of the chain hoist to the lift hook on the flywheel end of the engine [C].
B09913
Lift the engine. Slide it out of the loader frame [D]. Installation: Move the engine into the loader until the ujoint is in the blower housing. Have a second person reach behind the blower housing (at the hydrostatic pumps) and guide the ujoint on the splines of the hydrostatic pump shaft.
B09981
7B18
OIL COOLER AND BLOWER HOUSING Removal And Installation Remove the engine from the loader. (See Page 7B15.) Remove the bolts from the blower housing cover plate [A].
B09955
Remove the cover plate [B].
B09954
Disconnect the tubeline from the filter housing [C].
B09953
Disconnect the tubeline from the oil cooler [D].
B09952
7B19
OIL COOLER AND BLOWER HOUSING (Contd) Removal And Installation (Contd) Remove the tubeline from the blower housing [A].
B09951
Disconnect the other tubeline from the oil cooler [B].
B09950
Disconnect the tubeline beside the blower housing [C].
B09949
Remove the tubeline from the blower housing [D].
B09945
7B20
OIL COOLER AND BLOWER HOUSING (Contd) Removal And Installation (Contd) Remove the bolt and nut from the bottom of the blower housing [A].
B09948
Remove the blower housing from the loader [B].
B09944
Remove the nuts from both sides of the oil cooler [C].
B09947
Lower and remove the oil cooler from the loader [D].
B09946
7B21
RADIATOR Removal And Installation Remove the oil cooler and blower housing from the loader. (See Page 7B19.) Remove the engine muffler. (See Page 7B23.) Disconnect the overflow hose from the radiator [A].
B09957
Remove both radiator hoses from the radiator [B].
B09956
Remove the three bolts along the back edge of the radiator [C]. Remove the three bolts along the front edge of the radiator.
B09958
Lift the radiator from the loader [D].
B09911
7B22
ENGINE MUFFLER Removal And Installation Remove the rear grill. (See MAIN FRAME Section 5.) Remove the two bolts at the back edge of the muffler [A].
B09959
Remove the four bolts from the bottom of the muffler [B]. Remove the muffler exhaust pipe clamp. NOTE: The spark chamber plug may have to be removed so there is enough clearance for the muffler to be removed.
B09979
Remove the muffler from the loader [C].
B09977
Remove the plate between the muffler and the radiator.
B09978
7B23
ENGINE FLYWHEEL AND UJOINT Removal And Installation Remove the four bolts from the ujoint mounting flange [A]. Installation: Put LOCTITE on the bolt and tighten to 2528 ft.lbs. (3438 Nm) torque. Remove the ujoint.
B09935
Remove the bolts from the cooling fan [B]. Installation: Tighten the bolts to 1517 ft.lbs. (223 Nm) torque. Remove the cooling fan.
B09934
Remove the bolts from the flywheel [C]. Installation: Tighten the bolts to 5560 ft.lbs. (7581 Nm) torque. Remove the flywheel. Flywheel Ring Gear the ring gear on the flywheel is an interference fit. Heat the ring gear enough to expand it and hit the ring gear with a hammer, evenly, to remove it. Clean the outer surface of the flywheel to give the ring gear a smooth fit. Clean the new ring gear and heat it to a temperature of 450500 F. (232260 C.). Fit the ring gear over the flywheel. Make sure the gear is on its seat correctly.
B09898
7B24
ROCKER ARMS
Removal Remove the valve cover. Remove the front upper cover from the timing belt. Turn the crankshaft until No. 1 cylinder is at T.D.C. compression stroke. Make alignment of the mark on the camshaft sprocket (Item 1) [A] with the timing mark (Item 2) [A] at the upper cover back plate. Make a mark on the timing belt (Item 3) [A] in alignment with the other marks. Remove the camshaft bolt. Put a small piece of old timing belt (Item 1) [B] between the sprocket and sprocket holder. Do this to prevent the camshaft sprocket from lowering to such an extent that the timing belt comes off.
A
1
B09718
DO NOT turn the crankshaft after the camshaft sprocket is removed because engine timing will be changed.
1
B9717
I21220297
C
Remove the camshaft spacer [C]. Remove the back plate for the upper cover. Remove the bolts from the bearing caps for the camshaft. Remove the front seal fro the camshaft. Remove the rocker arms, rocker shaft and bearing cap assembly.
B09719
7B25
ROCKER ARMS (Contd) Removal (Contd) Mark the rocker arms for correct assembly. Remove the bearing caps, wave washers, springs and rocker arms as shown [A].
*
Spring (common to both rocker shafts) Free length 2.10 (53 mm)
# 45 ft.lbs. (56 Nm) * 1415 ft.lbs. (1720 Nm)

B09771
Inspection Check the rocker arm surface that contacts the cam lobe and the adjusting bolt ends that contact the valve stem [B]. If worn or damaged, replace the rocker arm. Check the rocker arm shaft for damage. Replace the parts as needed. Installation The tool listed will be needed to do the following procedure:
B09724
MEL1299 Camshaft Seal Tool Install the right and left shafts into the front bearing cap. Temporarily install the bolts to hold the shafts. Make sure the end slots (Item 1) [C] at the front of the shaft are in the up position. Install the rocker arms, springs and bearing caps in the order shown [A]. Make sure to install the wave washer in the right direction [A]. After the rear bearing cap is installed, temporarily install the bolts to hold them in position. Camshaft Front Bearing Cap
C
Right Rocker Shaft
1
Left Rocker Shaft
B09724
7B26
ROCKER ARMS (Contd) Installation (Contd) Install the assembled rocker arm shaft assembly into the cylinder head.
A
Key
Position the camshaft key, at the front end, as shown [A]. Install the bolts in the camshaft bearing caps. Tighten the bolts to 1415 ft.lbs. (1920 Nm) torque. 41
B09723
Use the camshaft seal installation tool and install the camshaft oil seal [B]. Put engine oil on the seal lips before installing the seal.
B
Oil Seal
B09721
Use a hammer and install the seal [C]. Install the back plate for the upper cover.
Oil Seal
Camshaft Oil Seal Installer

B09785
Put oil on the outer surface of the camshaft spacer and install the spacer [D].
B09719
7B27
ROCKER ARM (Contd) Installation (Contd) Pull the camshaft sprocket up, and install it on the camshaft [A].
B09717
When the dowel pin hole on the camshaft sprocket does not align with the dowel pin at the end of the spacer, the camshaft can be turned by hitting the projections at the No. 2 camshaft journal [B]. NOTE: Make sure the crankshaft is not turned for correct alignment of the dowel pin and dowel pin hole. Install the bolt at the camshaft sprocket and tighten to 3643 ft.lbs. (4958 Nm) torque. NOTE: Check to make sure the timing marks are still in alignment. Install the upper front cover. Adjust the valve clearance. Clearance (Cold) Intake . . . . . . . . . . . . . . . . . . . . . . . 0.03 inch (0,08 mm) Exhaust . . . . . . . . . . . . . . . . . . . . . . 0.07 inch (0,18 mm) Temporarily install the valve cover. Start the engine, run until at operating temperature. Set the valve clearance. (See Page 7B2.) Before installing the valve cover, put Sealant on the half plug at the cylinder head [C]. Install the valve cover and tighten the bolts to 4860 in.lbs. (5,46,8 Nm) torque.
Pistons
No 2 Cylinder Exhaust Cam No 2 Cylinder No 2 Journal Intake Cam B09722
B09693
7B28
CAMSHAFT Removal And Installation Remove the rocker arms, rocker and shaft and bearing cap. (See Page 7B25.) Installation: Lubricate the camshaft lobes and bearing journals before installing the camshaft. Tighten the camshaft sprocket bolt to the correct torque [A].
A
* Rear End Identification Mark
* 3643 ft.lbs. (4958 Nm) Inspection Check the camshaft journals for wear, scratches or seizure. If the journal is excessively worn, replace the camshaft. Check the cam lobes for the correct specification [B]. Cam Lobe Height . . . . . . . . . . . . 1.4331 inch (36,4 mmj) Service Limit . . . . . . . . . . . . . . 0.020 inch (0,5 mm) Camshaft End Play . . . . . . . . . . . . . . . 0.0020.006 inch (0,050,15 mm)
B09770
B09760
7B29
A
*
Apply Sealant to both surfaces.
Do not apply sealant. * 5154 ft.lbs. (6973 Nm) Cold # 1114 ft.lbs. (1519 Nm) CYLINDER HEAD Removal And Installation The tool will be needed to do the following procedure: MEL1297 Head Bolt Tool Remove the coolant from the coolant system. Disconnect the radiator hose. Remove the spark plug wires. Remove the distributor. (See Page 7B5.) Remove the fuel pump. (See Page 7B13.) Remove the exhaust manifold. Remove the intake manifold and carburetor. Installation: Put sealant on both surfaces around the water hole [A]. Remove the rocker arms, rocker shaft, bearing caps and camshaft. (See Page 7B25.) Use the special tool to remove the cylinder head bolts [B]. Remove the cylinder head bolts in the sequence shown to prevent cylinder head warpage [C].
B09768 B09694 B09769
Removing Head Bolt Sequence
7B30
CYLINDER HEAD (Contd) Removal And Installation (Contd) Installation: Tighten the bolts to 25 ft.lbs. (34 Nm) torque in the sequence shown [A]. Tighten to 5154 ft.lbs. (6973 Nm) torque in the sequence shown [A]. Remove the cylinder head. Remove the cylinder head gasket. Installation: Use a new cylinder head gasket and do not use sealant on the gasket. Inspection Clean the cylinder head of all carbon deposits. Remove the valves. (See Page 7B32.) Check the cylinder head surface by using a straight edge in the direction of A, B, etc. [B]. Standard Dimension . . . . 0.002 inch (0,05 mm) or less Service Limit . . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm) If the cylinder head surface exceeds the service limit, either replace or grind the cylinder head.
Installing Head Bolt Sequence
B09767
B09764
7B31
VALVES Removal The tool listed will be needed to do the following procedure: MEL1296 Valve Stem Seal Installation Remove the cylinder head from the engine block. (See Page 7B30.) Mark the valves so they will be returned to their original position when assembled. Remove the valve spring locks, using a spring compressor [A]. Remove the spring retainer, spring, spring seat and valve [A].
1 2 4 5 6 8 7 6
1 2 3 5
11 13 10 12
1. 2. 3. 4. 5. 6. 7. Remove the valve stem seals with a plier and discard [B]. Before reassembly, check the valves, valve seats and guides. Installation Make sure the cylinder head is clean. Install the spring seal on the valve guide. Use the special tool, install the valve stem seal into position. DO NOT turn the seal when installing it. The seal is installed in the specified position by the special tool. Incorrect installation of the seal will affect the seal lip I.D. and eccentricity, resulting in oil leakage down the valve guide. Put oil on the valve stems and install. Install the valve springs and spring retainer. Use a spring compressor and install the valve spring locks. Tap the valve stem with a hammer a small amount to seal the valve stem locks [C].
Valve Stem Lock Retainer Seal (Intake) Seal (Exhaust) Spring Spring Seat Guide (Intake)
8. 9. 10. 11. 12. 13.
Guide (Exhaust) Cylinder Head Exhaust Seal Intake Seat Exhaust Valve Intake Valve
B09774
B09766
C
Stem Seal Installer
B09765
7B32
VALVES (Contd) Reconditioning The Valve And Valve Seat Use the correct equipment to grind the valve and valve seats. The angle of the intake and exhaust valves is 45 [A]. The valve head thickness is as listed [A]. Standard . . . . . . . . . . . . . . . . . . . . . . 0.059 inch (1,5 mm) Service Limit . . . . . . . . . . . . . . . . . 0.039 inch (1,0 mm) Check the valve stem tip for being pitted, correct the stem tip by grinding. This must be limited to a minimum. Grind the valve seat, using a valve seat cutter (hand operated) or grinding equipment [B].
Thickness
45
B08202
B09762
Make sure the valve seat has the correct contact width [C].
Exhaust
Intake
25 45 60 Contact width (0.9 to1.3 mm 0,035 to 0,051 inch
25 45 60
B09761
Valve Seat Inserts Remove the valve seat insert which has been worn out by cutting down its wall thickness with a cutter as shown [D]. Machine the insert hole to the correct oversize with a cutter or reamer as shown [D]. Heat the cylinder head to 120F. (50C.) and press fit the oversize insert into the machined hole. After installation, grind the insert to the correct angle and check the depth of the valve [C].
0.0190.04 (0,51,0 mm)
0.012 R (0,3 mm)
0.012 (0,3 mm) New Hole
Cutting Down 0.0190.04 (0,51,0 mm) 0.006 (0,15 mm)
B09914
7B33
VALVES (Contd) Valve Guide The tool listed will be needed to do the following procedure: MEL1298 Valve Guide Installation & Removal Check the valve guides for wear with a dial indicator [A]. If the movement is more than listed specifications, replace the valve guide. Intake: Standard . . . . . . . 0.00120.0024 inch (0,030,06 mm) Service Limit . . . . . . . . . . . . . . . . 0.004 inch (0,15 mm) Exhaust: Standard . . . . . . . 0.00200.0035 inch (0,050,09 mm) Service Limit . . . . . . . . . . . . . . . . 0.006 inch (0,15 mm) NOTE: Make sure to check the valve stem for wear before replacing the valve guide. Heat the cylinder head to a temperature of about 480F. (250C.). Use the correct tool and press the valve guide out of the cylinder head [B]. Check the SPECIFICATIONS Section 8 for the correct oversize valve guide.
0.40 inch (10 mm)
B08205
B09763
Ream each bore in the cylinder head to the correct size at normal temperature. Heat the cylinder head to about 480F. (250C.) and quickly press the valve guide into position using the correct special tool [C]. The correct tool, ensures the guide is pressed in the specified depth.
0.5390.563 (13,714,3 mm)
B09732
Valve Spring Check the free length and inclination of the exhaust and intake springs [D]. New Free Length . . . . . . . . . . . . . 1.811 inches (46 mm) Service Limit . . . . . . . . . . . . . . 0.039 inch (1,0 mm)
Inclination
Free Length
Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Square
B08208
7B34
VALVES (Contd) Valve Spring (Contd) Check the valve spring tension [A]. New Preload . . . . . . . . . . . . . . . . 29 lbs. @ 1.469 inches (129 N @ 37 mm) Used Preload . . . . . . . . . . . . . . . 83 lbs. @ 1.106 inches (369 N @ 28 mm) Service Limit . . . . . . . . . . . . . . 76 lbs. @ 1.106 inches (338 N @ 28 mm)
B08209
The exhaust and intake valve springs are the same. When installing the spring the colored portion (red or green) is in the up position [B].
B
Identification Color:
NOTE: Install with colored portion up Check the valve seat insert depth [C]. If the depth exceed the service limit, replace the valve seat insert. Installed Height of Spring: Standard . . . . . . . . . . . . . . . . . . 1.469 inches (37,3 mm) Service Limit . . . . . . . . . . . . . . +0.039 inch (+1,0 mm)
B09775
B09737
7B35
PISTON AND CONNECTING ROD Removal Remove the cylinder head. (See Page 7B30.) Remove the oil pan. (See Page 7B51.) Remove the ridge and carbon deposits at the top of the cylinder bore with a ridge reamer. Make sure the piston has identification marks [A].
Notch
Notch
B09778
Rotate the crankshaft until a pair of connecting rods are at B.D.C. Make sure the connecting rod caps and the rods have identification marks [B]. Remove the nuts and remove the caps. NOTE: If the bearings are to be used again, they must be marked so they will be returned to their original location. Use a hammer handle, push the piston and rod assembly out of the engine block. After the pair has been removed, rotate the engine crankshaft and remove the other pair of pistons.
B09683
Disassembly Remove the rings from the pistons [C]. To remove the piston pin from the connecting rod, a special tool is needed (See Page 7B40 for the correct procedure for Disassembly And Assembly.)
B08194
7B36
PISTON AND CONNECTING ROD (Contd) Inspection Clean all the parts in clean solvent. Check the clearance of the new rings in the piston grooves [A]. No. 1 Ring Standard . . . . . . . 0.00120.0028 inch (0,030,06 mm) Service Limit . . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm) No. 2 Ring Standard . . . . . . . 0.00080.0024 inch (0,020,06 mm) Service Limit . . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm)
B09730
Check the ring gap in the cylinder bore [B]. No. 1 & 2 Ring End Gap: Standard . . . . . . . . . . . . 0.0080.016 inch (0,20,4 mm) Service Limit . . . . . . . . . . . . . . . . . 0.039 inch (1,0 mm) Oil Ring Side Rail: Standard . . . . . . . . . . . . 0.0080.020 inch (0,20,5 mm) Service Limit . . . . . . . . . . . . . . . . . . 0.39 inch (1,0 mm)
B09729
Check the connecting rod alignment [C]. Connecting Rod Bend: Standard . . 0.0020/3.937 inches or less (0,05/100 mm)
B08232
Assembly When assembling the piston and connecting rod, make sure to align the marks on the piston and rod [D]. See Page 7B41 for the correct procedure to press the piston pin into the connecting rod.
Front Mark
B09776
7B37
PISTON AND CONNECTING ROD (Contd) Assembly (Contd) Install the piston rings on the piston in the following sequence: Install the three piece oil ring [A].
Side Rail Gap
B09734
Install the No. 2 ring [B]. Install the No. 1 ring [B].
Chrome Plated No. 1 Piston Ring No. 2 Piston Ring
Oil Ring
Side Rail
Chrome Plated Spacer Expander Installation NOTE: Make sure the piston ring positioned as illustrated [C]. Put oil around the piston and piston rings. Using a ring compressor tool, compress the rings on the piston. Make sure the mark is toward the front of the engine block. No. 2 Ring Gap and Spacer Expander Gap Install the piston and connecting rod assembly [D]. Front of Engine gaps are
B09735
Gap of Lower Side Rail
No. 1 Ring Gap
Gap of Upper Side Rail
B09733
B0337
7B38
PISTON AND CONNECTING ROD (Contd) Assembly (Contd) Put oil on the bearings. Install the bearing cap [A].
B03208
Tighten the nuts to 2425 ft.lbs. (3334 Nm) torque [B]. Rotate the crankshaft to put the other pair of crankpins at the bottom dead center. Repeat the procedure and install the other pair of pistons.
2425 ft.lbs. (3334 Nm)
B03325
7B39
PISTON PIN Assembly Of The Tool The tool listed will be needed to do the following procedure: MEL1286 Piston Pin Tool Set Install the retaining ring (Item 1) [A] on the tube (Item 2) [A] (MEL1290). Drive or press the tube into the base (Item 3) [A] (MEL1291). Install the rear support (Item 4) [A] and wing nut (MEL1289). NOTE: The rear support will have to be adjusted so the piston and connecting rod assembly are level in the anvil. Install the anvil (Item 1) [B] on the tube (MEL1293). Install the insert (Item 2) [B] on the anvil (MEL12941).
A
2 1
B09695
1
B09696
Removal Of The Piston Pin Before pressing the old pin from the piston and connecting rod assembly do the following, this will correctly set up the tool: Install the stop plug (MEL1287) into the tube [C].
B09898
Install the spring (MEL1288) (Item 1) [D], spacer (MEL12943) (Item 2) [D] and pin guide (MEL1292) (Item 3) [D] into the tube.
B09677
7B40
PISTON PIN (Contd) Removal Of The Piston Pin (Contd) Install the old piston and connecting rod assembly on the insert in the anvil. Make sure the insert goes between the rod small end and piston. hold the piston down against spring pressure. Turn the stop plug inward until the pin guide (Item 1) [A] just begins to lift the piston from the insert. Now the stop plug is set for the correct distance when installing the new piston pins. Remove the pin guide, spacer and spring from the tube.
B09682
Install the piston and connecting rod assembly into the anvil, make sure the insert (MEL12941) goes between the rod small end and the piston [B].
B09697
Use the drive tool (MEL12942) (Item 1) [C] and press the pin from the rod and piston. Installation Of The Piston Pin Install the spring, spacer and pin guide into the tube. The pin guide, under spring pressure, will pas up through the rod and piston in line until the new pin is installed. Put oil on the piston pin before installing it into the piston and rod.
C
1
B09679
Use the driver tool (MEL12942) (Item 1) [D], press the pin (Item 2) [D] into the piston and connecting rod, until the spacer stops against the plug on the bottom of the tube. Check to see if the pin is centered in the connecting rod. Equal space at both sides of the piston pin. NOTE: The piston must be free to move while pressing the pin into position, check it several times during installation of the piston pin.
D
1 2
B09676
7B41
CYLINDER LINERS Checking Check the cylinder bore with an inside micrometer. the checks must be made at parallel and right angles to the center line of the bore [A]. Measuring points are done approximately 0.35 inch (9 mm), 3.5 inches (90 mm) and 5.4 inches (137 mm) below the top of the cylinder bore. Standard . . . . . . . . . . . . . . . . . 3.0276 inches (76,8 mm) OutOfRound and Taper: Standard . . . . . . . . . . . . . 0.0008 inch (0,02 mm) or less Piston to Cylinder Wall Clearance: Standard . . . . . . . 0.00080.0016 inch (0,020,04 mm) If the cylinder bores shown wear more than specified outofround or taper or if the bores are badly scoffed or scored, the cylinder block must be rebored and honed to oversize and O/S pistons fitted. Piston Service Size: 0.010 inch (0,25 mm) O.S. 0.020 inch (0,50 mm) O.S. 0.030 inch (0,75 mm) O.S. 0.039 inch (1,00 mm) O.S.
A
0.5 (90 mm) 0.35 (9 mm)
5.4 (137 mm)
B09736
7B42
CRANKSHAFT AND MAIN BEARINGS Description The crankshaft has five main bearings. The end play is controlled by a thrust bearing at the center main bearing. Each main bearing cap has identification marks in relation to the engine block [A]. The position of each cap can not be changed from the original location.
A
Arrow Mark (Front of Engine)
Cap No. View X Removal Remove the timing cover and timing belt. (See Page 7B47.) Remove the oil pan. (See Page 7B51.) Remove the crankshaft rear oil seal and case [B].
B09777
B09754
Remove the main bearing caps and bearings [C]. NOTE: If the main bearings are going to be used again, put a mark on them for correct installation. Remove the crankshaft.
B09740
Checking Check the crankshaft connect rod journals [D]: Standard . . . . . . . . . . . . . . . . . . . 1.7717 inches (45 mm) OutofRound and Taper . . . . . . . . . . . . . . . 0.0004 inch (0,01 mm) or less Oil Clearance . . . 0.00040.0024 inch (0,010,06 mm)
B08244
7B43
CRANKSHAFT AND MAIN BEARINGS (Contd) Checking (Contd) Check the crankshaft main bearing journals [A]: Standard . . . . . . . . . . . . . . . . . 2.244 inches (56,99 mm) OutofRound and Taper . . . . . 0.0004 inch (0,01 mm) or less Oil Clearance . . . 0.00080.0028 inch (0,020,07 mm)
B08246
Checking Oil Clearance (Plastic Gauge) Remove all the oil from the crankshaft bearing journals to be checked. Cut plastic gauge to the width of the bearing [B]. Install the bearing cap. Tighten the bolts to 3739 ft.lbs. (5053 Nm) torque. DO NOT turn the crankshaft. Remove the bearing cap. Measure the width of the plastic gauge [B]. If the clearance exceeds the limit, bearing must be replaced or undersize used. Installation Install the upper bearings in the engine block. Put oil on the crankshaft journal. Install the crankshaft. Install the main bearing caps and tighten to specified torque [C].
B09739
3739 ft.lbs. (5053 Nm)

B03345
Starting at the center bearing cap and moving toward each end of the crankshaft [D].
D
Cap No.
Arrow Mark
B09740
7B44
CRANKSHAFT AND MAIN BEARINGS (Contd) Crankshaft End Play The end play can be checked by either a feeler gauge [A] or a dial indicator [B]. End Play . . . . . . . . . . 0.0020.007 inch (0,050,18 mm) The fitting of oversize thrust bearing can be used to correct the end play if it is over specifications.
B09728
B03291
Rear Oil Seal The tool listed will be needed to do the following procedure: MEL1300 Seal Installation Tool Press the rear oil seal into the housing using the special tool [C]. Put oil on the seal lip. Install the housing and rear seal on the engine. Install the bolts and tighten.
Oil Seal
Press
B09738
7B45
TIMING BELT Adjustment It is not necessary to remove the timing belt covers for adjustment. Check and adjust the belt tension every 500 hours of loader operation, use the following procedure: Remove the shield from the engine. Remove the plugs (two) in the cover for the timing belt [A].
B09851
Loosen the top nut and bottom bolt [B].
B09850
Put a screwdriver into the top hole and push on the belt tensioner bracket to remove excessive slack from the timing belt [C]. Tighten the bottom bolt after the slack has been removed [C].
B09852
7B46
TIMING BELT (Contd) Removal Remove the crankshaft pulley (Item 1) [A]. Remove the upper timing belt cover (Item 2) [A]. Remove the lower timing belt cover (Item 3) [A]. Remove the crankshaft sprocket bolt (Item 4) [A].
1 3
B09759
Loosen the belt tensioner mounting nut [B]. Move the belt tensioner to loosen the timing belt [B]. Remove the timing belt from the sprockets. Nut
Water Pump
Tensioner Bolt Remove the crankshaft sprocket [C]. Timing Belt
B09758
B09691
7B47
TIMING BELT (Contd) Inspection Check the timing belt sprockets and tensioner for wear, cracks or damage. The surfaces of the oil pump sprocket and camshaft spacer which contact the oil seal must be checked for wear. Inspect the tensioner for easy and smooth rotation. Check for end play and noise. Check the belt for oil or dust deposits. The slight deposits must be cleaned with cloth or paper. DO NOT use solvent to clean the timing belt.
A
Flaw Conditions
Back surface glossy. Nonelastic and so hard that even if a fingernail is forced into it, no mark is produced. 1.
2. Check the timing belt in detail for the following conditions, replace as needed [A]. 1. 2. 3. 4. 5. 6. 7. 8. 9. Hardened back surface rubber. Cracked back surface rubber. Cracked or exposed canvas. Badly worn teeth (initial stage). Badly worn teeth (last stage). Cracked tooth bottom. Missing tooth. Side of belt badly worn. Side of belt cracked. Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced). 5. Separation 3. Separation Crack Crack
Canvas on load side tooth flank worn. Fluffy canvas fibers, rubber gone and color changed to white, and unclear canvas texture. 4.
6. Crack Tooth missing and canvas fiber exposed
7.
NOTE: Normal belt should have clearcut sides as if cut by a sharp knife. Round 8. Belt Side Abnormal wear (fluffy canvas fiber)
9.
B09751
7B48
TIMING BELT (Contd) Assembly Install the crankshaft sprocket [A]. Tighten the bolt to 4450 ft.lbs. (6068 Nm) torque.
B09691
Align timing mark on the crankshaft sprocket with the timing mark on the front case [B]. Put a small amount of oil on the outside of the camshaft spacer and install the spacer on the camshaft. Install the camshaft sprocket. Tighten the bolt to 4457 ft.lbs. (6077 Nm) torque.
Timing Mark
B09752
Align the camshaft timing mark with the mark on the upper cover [C].
Upper Under Cover
Timing Mark
Camshaft Sprocket
Dowel Pin
B09755
Install the spring and tensioner, and temporarily tighten the nut [D]. Push the flange, located under the tensioner, to make alignment of the holes (Items 1 & 2) [D]. Install the bolts into the holes. Install the front end of the spring (bent at right angle) on the projection of the tensioner. Install the other end (straight end) on the water pump body [D].
Spring Tensioner
Install the spring end at this position of the water pump body.
2
B09750
7B49
TIMING BELT (Contd)

Assembly (Contd) Install the timing belt, use the following procedure: Put the belt on the crankshaft sprocket. Install on the oil pump sprocket. Then on the camshaft sprocket. Make sure that all the timing marks are in alignment. Move the belt tensioner to apply pressure to the belt [A]. NOTE: Do not turn the crankshaft in a reverse direction. DO NOT push or twist the belt or try to test the tension. This will result incorrect belt tension. Push the tensioner, with your hand a small amount to make sure the belt comes in complete mesh with the sprockets. If this is neglected and the belt tension adjusted with the belt out of mesh with the sprocket (Item 1) [B], the belt tension will not be correct. Turn the engine through one revolution in normal direction, to remove all slack at the timing belt.
Water Pump
Nut
Tensioner Bolt Timing Belt
B09758
1
Tensioner
B09757
Tighten the tensioner mounting nut first and then the bolt [C]. Tighten the nut and bolt to 1621 ft.lbs. (2228 Nm) torque.
B09753
Check the tension side of the timing belt, the clearance between the belt and the seal line is 0.470 inch (12 mm) [D]. If specifications are not correct, readjust the belt.
D
0.470 (12 mm)
B09756
7B50
FRONT CASE AND OIL PAN Removal And Installation The front case contains the oil pump and relief valve and can be removed as an assembly. Remove the front cover and timing belt. (See Page 7B47.) Remove the engine oil. Remove the oil pan bolts (Item 1) [A]. Installation: Tighten the bolts to 5466 in.lbs. (6,17,5 Nm) torque. Remove the oil pan and oil screen. Installation: Tighten the oil screen nuts to 1318 ft.lbs. (1824 Nm) torque (Item 2) [A]. Remove the bolts from the front case [A]. The front case is held closely to the engine block, it may be hard to loosen. Insert a screwdriver into the groove and pry. Avoid prying on the thinner portion of the flange.
B09772
Installation: Install the front case bolts according to the correct length [B]. Tighten the bolts to 1113 ft.lbs. (1518 Nm) torque.
B
L=0.79 (20 mm)
L=0.98 (25 mm)
L=length of bolt L=1.57 (40 mm)
L=0.98 (25 mm) When installing the oil pan, apply sealant to the four areas shown [C]. NOTE: For inspection of the oil pump. (See Page 7B52 for the specifications.)
L=1.57 (40 mm)
B09773
Oil Seal Case
Front Case
Cylinder Block
B09747
7B51
OIL PUMP Removal Remove the timing cover and timing belt. (See Page 7B47.) Remove the oil pump sprocket, use the following procedure: Use an old timing belt and put it around the oil pump sprocket to hold it. DO NOT use a screwdriver. Loosen the nut at the sprocket. Remove the timing belt and sprocket. Remove the pump bolts at the oil pump. Slide the oil pump assembly away from the front case [A]. Remove the rotor from the oil pump cover. Inspection Use a feeler gauge to check the clearances as listed [B]: Tip Clearance . . . . 0.00160.0047 inch (0,40,12 mm) Body Clearance . 0.00390.0063 inch (0,100,16 mm) Side Clearance . 0.00080.0020 inch (0,020,05 mm) ShafttoCover Clearance . . . . . . . . 0.00080.002 inch (0,020,05 mm)
B09745
Body Clearance
Side Clearance
Tip Clearance
Shafttocover Clearance
B09742
Installation Install a new cover gasket in the front case [C]. Install the gasket with the round edge toward the oil pump cover.
C
Front Case
Gasket
Sectional Form of Gasket

B09746
Use a flat plate, install the oil seal using a press until it is flush with the front edge of the oil pump cover [D].
D
Oil Pump Cover
Flat Iron Plate
Oil Seal
B09741
7B52
OIL PUMP (Contd) Installation (Contd) Install the inner and outer rotor in the oil pump cover, after putting oil on the surface of the rotors. The inner rotor and outer rotor have a mark on them, install the rotors with the marks in the same direction [A].
Marks
B09743
Slide the oil pump assembly into the front cover [B].
B09745
Install the 0.24 inch (6 mm) diameter bolt (Item 1) [C]. Install the other bolts and tighten to 1113 ft.lbs. (1518 Nm) torque. Tighten the bolt (Item 1) [C] to 90102 in.lbs. (10,211,5 Nm) torque. Put a small amount of oil on the oil seal. Install the sprocket for the oil pump. Put an old timing belt around the sprocket to hold it and tighten the nut to 2528 ft.lbs. (3438 Nm) torque. Install the timing belt and front cover. (See Page 7B48.)
B09773
Relief Valve Remove the oil pressure relief valve [D]. Check the poppet for damage. Check the spring for free length and preload as listed below: Free Length . . . . . . . . . . . . . . . . . 1.850 inches (47 mm) Preload . . 16 lbs. @ 1.398 inches (71 N @ 35,5 mm) If spring is not within specifications, replace the spring.
B09699
7B53
FRONT CASE SEAL Removal And Installation The tool listed will be needed to do the following procedure: MEL1301 Front Crankshaft Seal Installation Tool Remove the crankshaft pulley, timing belt covers and timing belt. (See Page 7B47.) Remove the bolt at the crankshaft sprocket [A]. Installation: Tighten the bolt to 3643 ft.lbs. (4958 Nm) torque.
B09705
Remove the crankshaft sprocket. Drill a hole into the front seal [B]. Be careful not to damage the front case surface behind the seal with the drill.
B09690
Use a slide hammer puller, remove the front seal [C].
B09692
Use the installation tool, install the front seal [D]. Install guide over camshaft and key way (MEL13011). Install seal over the guide. Using the driver, install the seal into the front housing (MEL13012).
B09689
7B54
WATER PUMP Removal And Installation Drain the coolant from the cooling system. Remove the alternator belt. Remove the crankshaft pulley, timing belt covers, timing belt, camshaft sprocket and belt tensioner. (See page 7B47.) Remove the four water pump bolts [A].
B09687
Slide the water pump to the side and remove it from the engine block [B].
B09688
Installation: Make sure the correct length bolt is in the correct location [C]. Tighten the bolts to 1113 ft.lbs. (1518 Nm) torque. Inspection Check each part for cracks, damage or wear and replace the water pump assembly if necessary.
C
L=2.75 (70 mm)
L=Length of Bolt
L=2.10 (28 mm)
L=2.17 (55 mm)

B09779
Check the bearing for damage, noise and slow rotation [D]. Check the seal for leaks and replace the water pump assembly if necessary.
D
Pulley Bracket
From Radiator Cylinder Block
Impeller To Water Jacket Of Engine Shaft Assembly Seal Unit 7B55 Water Pump Body
B09744
THERMOSTAT
742B, 743B Service Manual #6720772 (S/N 18001 & Above) Engine System Section Part 5 of 5
Removal And Installation The thermostat is of the wax type, valve cracking temperature is not affected by pressure in the water jacket. The jiggle valve removes air from the system during filling the cooling system and to reduce the warmup time. Drain the cooling system. Remove the radiator hose at the thermostat housing. Remove the bolts from the housing [A].
B09702
Remove the housing and the thermostat [B]. Inspection Put the thermostat in a container filled with water. Heat the water. Measure the temperature at which the valve cracks and the valve lift is fully open. Cracking Temperature . . . . . . . . . . . . . . 179 F. (82 C.) 0.315 inch (8 mm) Lift Temperature . . . . . . . . . . . . . . . . . . . . 203 F. (95 C.) If the thermostat is not within specifications, replace the thermostat.
B09703
7B56
SPECIFICATIONS Page Number 743B LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A1 742B LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C1
SPECIFICATIONS
743B
742B TECHNICAL DATA
8A3
SPECIFICATIONS (743B) Page Number ENGINE SPECIFICATIONS Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER SPECIFICATIONS Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation And Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3 8A4 8A4 8A3 8A4 8A5 8A3 8A3 8A4 8A4 8A4 8A3 8A3 8A3 8A2 8A2 8A1 8A2 8A2 8A1 8A1 8A2
743B
8A1
743B LOADER SPECIFICATIONS

LOADER DIMENSIONS
Dimensions are given for loader equipped with standard tires and dirt bucket. Dimensions may vary with other types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Where applicable, specifications conform to SAE standards and are subject to change without notice.
100
139.6 (3546) 69.7 (1770)
55.1 (1400)
37 109 (2769)
44.2 (1123) 21.8 (554) 75.8 (1925) 35.7 (907)
86.3 (2192) 32.3 (820) 58.5 (1486)
28 7.5 (191) 94.5 (2423) 35.4 (899) 8.0 (203)
26
54.0 (1372)
47.0 (1194)
PI2206 120.4 (3058) This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.
OPERATIONS & PERFORMANCE Weights Operating Weight . . . . . . . . . . . . . . . . . . . Rated Operating Capacity . . . . . . . . . . . . Tipping Load . . . . . . . . . . . . . . . . . . . . . . . Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Function . . . . . . . . . . . . . . . . . . . . Engine Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horsepower . . . . . . . . . . . . . . . . . . . . . . . . Maximum Governed RPM . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of Cylinders . . . . . . . . . . . . . . . . . Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Ventilation . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . Revised Sept. 93 8A1
743B
4720 lbs. (2188 kg) 1300 lbs. (590 kg) 2600 lbs. (1180 kg) Infinitely variable 06.0 MPH (9,7 km/hr.)
Direction & speed controlled by two hand levers. Lift & Tilt Function: Controlled by separate foot pedals. Front Auxiliary Function: Controlled by the right steering lever. Hand lever throttle & keytype starter switch; Hydrostatic Mechanical disc, foot operated pedal
Kubota V1702BA Diesel 36 HP (27 kW) 2800 RPM 80 ft.lbs. (108 Nm) @ 1600 RPM Four 3.23/3.23 (82/82) 105.7 cu. in. (1732 cm ) Liquid Full pressure with full flow filter PCV Dry replaceable paper cartridge Compression Diesel 28603000 RPM 1150 RPM
LOADER SPECIFICATIONS (Contd) HYDRAULIC SYSTEM Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . Pump Capacity . . . . . . . . . . . . . . . . . . . . . System Main Relief . . . . . . . . . . . . . . . . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . Bore Diameter: Lift Cylinder (2) Tilt Cylinder (1) Rod Diameter: Lift Cylinder (2) Tilt Cylinder (1) Stroke: Lift Cylinder (2) Tilt Cylinder (1) .................... .................... .................... .................... .................... ....................
743B
Engine driven gear type 12.1 GPM (45,8 L/min.) @ 2500 RPM 22502400 PSI (1551316548 kPa) Replaceable #3 micron paper element in charge line Doubleacting
2.00 (51) 3.25 (83) 1.25 (32) 1.50 (32) 25.00 (635) 14.5 (368) 3spool, open center type, W/float detent on lift, detent on auxiliary SAE standard tubes, hoses & fittings
Control Valve . . . . . . . . . . . . . . . . . . . . . . . Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Function Time: Raise Lift Arms to Maximum Height . . . . Lower Lift Arms from Maximum Height . Move Bucket to Dump Position . . . . . . . . Move Bucket to Retracted Position . . . . Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Seconds 2.7 Seconds 2.7 Seconds 2.3 Seconds Bobcat Fluid (P/N 6563328). If fluid is not available use 10W30 or 10W40 Class SE Motor Oil for temperatures above 0_F (18_C) & 5W30 for temperatures below 0_F (18_C)
ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil W/Filter . . . . . . . . . . . . . . . . . . Hydraulic/Hydrostatic System . . . . . . . . . Chaincase Reservoir . . . . . . . . . . . . . . . . TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Belt drive, 55 amps. Open 12 volt, 625 cold crank amps. @ 0F (17.8C) 125 min. reserve capacity 12 volt
Tandem hydro. pumps driving 2 fully reversing hydro. motors #80 HS roller chain & sprockets in sealed chaincase with oil lubrication
13 qts. (12 L) 13 gals. (49 L) 9 qts. (8,5 L) 6 gals. (23 L) (Includes 3.5 gals [13,2 L] in reservoir) 8 gals. (30,3 L)
7:00 x 15, 6Ply Rating 4550 PSI (310345 kPa) 10 x 16.5, 6 Ply Rating 3035 PSI (207241 kPa)
8A2
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Fuel Injection Nozzles Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19902130 PSI (1372114686 kPa) Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 18481990 PSI (1274213721 kPa) Fuel Injection Pump Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 sec: initial pressure from 85327110 PSI (5882849023 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 seconds or less Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . 10 sec: initial pressure from 142271 PSI (9805490 kPa) Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 seconds or less Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2526 degrees before TDC High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28603000 RPM Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001000 RPM Cylinder Head Cylinder Head Surface Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.057 (1,45) Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 or 0.0079 (0,15 or 0,2) Top Clearance (Piston to Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02760.0354 (0,70,9) Head Bolt Torque Flange Head Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6568 ft.lbs. (8892 Nm) Bolt W/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5868 ft.lbs. (7983 Nm) Maximum Allowable Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1) Valves Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0827 (2,1) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees O.D. of the Valve Stem (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31340.3140 (7,9607,975) I.D. of the Valve Guides (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31560.3161 (8,0158,030) Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0028 (0,040,07) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 (0,1) Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04330.0512 (1,11,3) Valve Clearance (Cold) (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00710.0087 (0,180,22) Valve Springs Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64171.6614 (41,742,2) Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3839 (35,15) Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 lbs. (118 N) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (100 N) Rocker Arms O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55010.5506 (13,97313,985 ) I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55130.5529 (14,00314,043) Clearance Between Rocker Arm & Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00040.0028 (0,010,07) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15) Camshaft O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57221.5728 (39,934329,9 ) I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57481.5758 (40,040,025) Clearance Between Camshaft Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020.0036 (0,50,091) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15) Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,02) Cam Lobe Height (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3134 (33,31) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3114 (33,31) Gear Clearance (Backlash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0045 (0,0410,114) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 (0,3) 742B, 743B Loader Service Manual
8A3
ENGINE SPECIFICATIONS (Contd)

Cylinders I.D. of Cylinder Liner (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22833.2291 (82,082,019) Oversized Liner I.D. (After Reboring .020 O/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2483.2489 (82,49982,522) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15) Piston Rings Ring Gap (Top and 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01180.0177 (0,300,45) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0492 (1,25) Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009800.0157 (0,250,40) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0492 (1,25) Side Clearance of Ring in Groove Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Clearance 2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00370.0047 (0,0930,120) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0020 (0,0200,051) Pistons I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90550.9060 (2323,013) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9076 (23,053) O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90560.9059 (23,00223,011) I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90650.9071 (23,02523,04) Clearance Between Piston Pin & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0015 (0,0150,038) Service Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0026 (0,0150,07) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15) Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Connecting Rod Big End I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (W/O Bearing) 1.8501.851 (47,047,02) Crankshaft O.D. Main Bearing Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04412.0449 (51,9251,94) I.D. of Crankshaft Main Bearing (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04652.0488 (51,9852,039) I.D. of Crankshaft Main Bearing (No. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04652.0482 (51,9852,025) Clearance Between Crankshaft Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00130.0042 (0,030,11) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,2) O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73071.7313 (43,95943,975) I.D. of Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73271.7343 (44,0144,052) Clearance Between Connecting Rod Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00140.0037 (0,0350,093) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,2) End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00590.080 (0,150,21) Thrust Plate Thickness: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0910.093 (2,312,36) Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09350.0955 (2,372,43) 0.0960.098 (2,442,49) 0.09850.1005 (2,502,55) 0.1010.103 (2,572,62) Crankshaft Journal U/S (Dia.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.03632.037 (51,7251,74) 2.02842.0291 (51,5251,54) Oil Pump Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4256 PSI (290386 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PSI (248 kPa) Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.0063 (0,100,16) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,20) Clearance Between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00430.0075 (0,110,19) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 (0,25) Engine Oil Check oil level every 8 hours of operation. (Check oil every 4 hours on new engine during the first 50 hours of operation.) Oil level must be between the add and full marks on the dipstick. Use a good quality detergent motor oil that meets the correct API service classification. (See Chart of Page 8A5.) Use oil of the correct SAE viscosity for expected temperature conditions. 742B, 743B Loader Service Manual
8A4
ENGINE SPECIFICATIONS (Contd) RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)
C34 29 23 18 13 7 1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60 SAE 40 or 20W50
Never overfill the engine crankcase with oil.

SAE 10W30
I21250597
SAE 15W40
SAE 5W30
SAE 30W
SAE 20W20
SAE 10W
F30 20
10
+10
+20 +30
+40 +50 +60
+70
+80 +90 +100 +110 +120 +130 +140
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE or SF) (DIESEL: USE API CLASSIFICATION CC, CD or CE)
ENGINE BOLT TORQUES Bolt material grades are shown by numbers punched on the bolt heads. Before tightening, check the numbers shown below: NOTE: Special bolts are used where required. Please refer to Assembly Section for correct special bolt torque. Ft.Lbs. Fuel injector Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Pump Adapter Flange to Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump to Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Pump to Flywheel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel to Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulley to Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Cover Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Case Bolt (1) Through Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Case Halves 2 Bolts Each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1720 1517 6570 56 1315 2528 6570 2236 7280 101110 5057 1317 56 2630 4750 2125 1315 Nm 2327 2023 8895 6,88,1 1820 3438 8895 3049 98108 137149 6878 1720 6,88,1 3541 6468 2834 1820
8A5

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772SpecificationsSectionPart1of3
Engine Bolt Torques (Contd)
BOLT TORQUES MATERIAL GRADE NOMINAL DIAMETER M6 M8 M10 M12 M14 M16 M18 M20 STANDARD BOLT SS42, S20C 5.8 to 6.9 ft.lbs. (7.8 to 9.3 Nm) 13 to 15 ft.lbs. (18 to 20 Nm) 28 to 33 ft.lbs. (38 to 45 Nm) 46 to 53 ft.lbs. (62 to 72 Nm) 79 to 92 ft.lbs. (107 to 125 Nm) 123 to 141 ft.lbs. (167 to 191 Nm) 180 to 209 ft.lbs. (244 to 283 Nm) 245 to 289 ft.lbs. 332 to 392 Nm) SPECIAL BOLT S43C, S48C (Refined) 7.2 to 8.3 ft.lbs. (9.8 to 11.3 Nm) 17 to 20 ft.lbs. (23 to 27 Nm) 35 to 41 ft.lbs. (47 to 56 Nm) 57 to 66 ft.lbs. (77 to 89 Nm) 91 to 108 ft.lbs. (123 to 146 Nm) 144 to 166 ft.lbs. (195 to 225 Nm) 202 to 235 ft.lbs. (274 to 318 Nm) 271 to 318 ft.lbs. (367 to 431 Nm) SPECIAL BOLT SCR3, SCM3 (Refined) 9.0 to 10.5 ft.lbs. (12.3 to 14.2 Nm) 21 to 25 ft.lbs. (28 to 34 Nm) 44 to 52 ft.lbs. (60 to 71 Nm) 75 to 86 ft.lbs. (102 to 117 Nm) 123 to 144 ft.lbs. (167 to 195 Nm) 191 to 224 ft.lbs. (159 to 303 Nm) 153 to 196 ft.lbs. (343 to 401 Nm) 361 to 419 ft.lbs. (489 to 568 Nm)
8A6
SPECIFICATIONS (742B) Page Number ENGINE SPECIFICATIONS Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm & Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER SPECIFICATIONS Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation And Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B7 8B4 8B6 8B4 8B4 8B3 8B3 8B7 8B7 8B4 8B6 8B3 8B3 8B3 8B6 8B6 8B7 8B7 8B6 8B5 8B5 8B4 8B6 8B2 8B2 8B1 8B2 8B2 8B1 8B1 8B2
742B
8B1
742B BOBCAT LOADER

LOADER DIMENSIONS
Dimensions are given for loader equipped with standard tires and dirt bucket. Dimensions may vary with other types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Where applicable, specifications conform to SAE standards and are subject to change without notice.
100
139.6 (3546) 69.7 (1770)
55.1 (1400)
37
109 (2769)
44.2 (1123)
21.8 (554) 75.8 (1925) 35.7 (907)
86.3 (2192)
58.5 (1486)
28 7.5 (191) 94.5 (2423) 120.4 (3058) 35.4 (899) 8.0 (203)
32.3 (820) 26 47.0 (1194) 54.0 (1372)
B12596
This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts. OPERATIONS & PERFORMANCE Weights Operating Weight . . . . . . . . . . . . . . . . . . . Rated Operating Capacity . . . . . . . . . . . . Tipping Load . . . . . . . . . . . . . . . . . . . . . . . Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Function . . . . . . . . . . . . . . . . . . . . Engine Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horsepower . . . . . . . . . . . . . . . . . . . . . . . . Maximum Governed RPM . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of Cylinders . . . . . . . . . . . . . . . . . Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Ventilation . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . Revised Sept. 93 8B1
742B
4830 lbs. (2193 kg) 1300 lbs. (590 kg) 2600 lbs. (1180 kg) Infinitely variable 06.0 MPH (9,7 km/hr.)
Direction & speed controlled by two hand levers. Lift & Tilt Function: Controlled by separate foot pedals. Front Auxiliary Function: Controlled by the right steering lever. Hand lever throttle & keytype starter switch; Hydrostatic Mechanical disc, foot operated pedal
Mitsubishi 4G32 Gasoline, leaded or unleaded 36 HP (27 kW) 2800 RPM 73 ft.lbs. (99 Nm) @ 2000 RPM Four 3.03/3.38(76,9/85,8) 95.62 cu. in. (1567 cm3 ) Liquid Full pressure with full flow filter PCV Dry replaceable paper cartridge 12 volt, battery ignition W/breaker points & coil 29002975 RPM 850950 RPM
LOADER SPECIFICATIONS (Contd) HYDRAULIC SYSTEM Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . Pump Capacity . . . . . . . . . . . . . . . . . . . . . System Main Relief . . . . . . . . . . . . . . . . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . Bore Diameter: Lift Cylinder (2) Tilt Cylinder (1) Rod Diameter: Lift Cylinder (2) Tilt Cylinder (1) Stroke: Lift Cylinder (2) Tilt Cylinder (1) .................... .................... .................... .................... .................... ....................
742B
Engine driven gear type 12.1 GPM (45,8 L/min.) @ 2500 RPM 22502400 PSI (1551416548 kPa) @ Quick Couplers Replaceable #3 micron paper element in charge line Doubleacting
2.00 (51) 3.25 (83) 1.25 (32) 1.50 (32) 25.00 (635) 14.5 (368) 3spool, open center type, W/float detent on lift, detent on auxiliary SAE standard tubes, hoses & fittings
Control Valve . . . . . . . . . . . . . . . . . . . . . . . Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Function Time: Raise Lift Arms to Maximum Height . . . . Lower Lift Arms from Maximum Height . Move Bucket to Dump Position . . . . . . . . Move Bucket to Retracted Position . . . . Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Seconds 2.7 Seconds 2.7 Seconds 2.3 Seconds Bobcat Fluid (P/N 6563328). If fluid is not available use 10W30 or 10W40 Class SE Motor Oil for temperatures above 0_F (18_C) & 5W30 for temperatures below 0_F (18_C)
ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil W/Filter . . . . . . . . . . . . . . . . . . Hydraulic/Hydrostatic System . . . . . . . . . Chaincase Reservoir . . . . . . . . . . . . . . . . TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Belt drive, 55 amps. Open 12 volt, 435 cold crank amps. @ 0F (17.8C) 125 min. reserve capacity 12 volt
Tandem hydro. pumps driving 2 fully reversing hydro. motors #80 HS roller chain & sprockets in sealed chaincase with oil lubrication
11 qts. (10,4 L) 13 gals. (49 L) 4 qts. (3,8 L) 6 gals. (23 L) (Includes 3.5 gals [13,2 L] in reservoir) 8 gals. (30,3 L)
7:00 x 15,6 Ply Rating 4550 PSI (310345 kPa) 10 x 16.5, 6 Ply Rating 3035 PSI (207241 kPa)
8B2
ENGINE SPECIFICATIONS
General Compression PSI @ 250 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 PSI (1034 kPa) Difference between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Within 10% Ignition Timing (BTDCwith Vacuum Line Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 @ 700750 RPM
Cylinder Head Flatness of Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) or less Flatness of Manifold Mounting Surface Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3) Oversize Valve Seat Hole Intake 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5471.548 (39,2939,32) 0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5591.560 (39,6039,62) Exhaust 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3501.351 (34,3034,32) 0.24 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3621.363 (34,6034,62) Camshaft cap to Camshaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020.004 (0,050,10) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Valve Guide Hole Oversize (Both Intake & Exhaust) 0.002 (0,05) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51380.5145 (13,0513,068) 0.010 (0,25) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.52160.5224 (13,2513,268) 0.020 (0,50) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.53150.5322 (13,5013,518) Valve Seat Contact Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0350.051 (0,91,3) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder Block Flatness of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) or less Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.276 (76,90) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20) Service Limit (Maximum Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.047 (+1,2) Cylindrical Within Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 (0,01) or less Cylinder to Piston Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0016 (0,020,04)
Piston Piston O.D. @ Skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0276 (76,90) Piston Pin Hole I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.748 (19,0) Piston O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,75); 0.039 (1,0) Piston Ring to Groove Clearance Compression No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00110.0027 (0,30,07) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Compression No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0024 (0,020,06) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Compression Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00980.0177 (0,250,45) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 (1,0) Oil Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.028 (0,20,7) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 (1,0) Piston Ring O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,75); 0.039 (1,0)
Piston Pin Piston Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.748 (19,) Piston to Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.000040.0005 (0,0010,013) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011 (0,03) Interference to Connecting Rod: Press Fit Load (Normal Temp.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11013304 lbs. (5001500 kg)
8B3

Connecting Rod Bend or Twist of Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011 (0,03) or less End Play of Big End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.010 (0,10,25) Rod Bearing Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.000550.0025 (0,0140,064) Rod Bearing U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,75); 0.039 (1,0)
Crankshaft Crankshaft Journal Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0028 (0,0150,07) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Crank Pin Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00040.0025 (0,010,064) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10) Crankshaft Bearing U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,075) Crankshaft Journal O.D. (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.244 (57,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9) Journal Undersize Machining Size: 0.010 (0,25) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23372.2343 (56,73556,750) 0.020 (0,50) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22382.2244 (56,48556,500) 0.030 (0,75) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.211402.2146 (56,23556,250) Crank Pin O.D. (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.772 (45,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9) Pin Undersize Machining Size: 0.010 (0,25) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.76127.7618 (44,73444,750) 0.020 (0,50) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75141.7520 (44,48544,500) 0.030 (0,75) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74151.7421 (44,23444,250) Bend of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012 (0,03) or less Cylindrical Within Journal & Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0002 (0,005) or less Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00020.0069 (0,050,175) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Flywheel Flywheel RunOut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,13) or less Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009 (0,2)
Camshaft Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386 (34,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Cylindrical Within Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00004 (0,001) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02) or less Height of Cam Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4331 (36,4) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5) Fuel Pump Drive Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.575 (40,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5) Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00020.0069 (0,050,175) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Valve Train Valve Stem O.D.: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 (8,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 (8,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
8B4

Valve Train (Contd) Overall Length: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.071 (103,4) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.937 (100) Thickness of Head: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.059 (1,5) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.059 (1,5) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5) Clearance to Guide: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00100.0023 (0,0250,058) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00200.0034 (0,050,085) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Valve Clearance: Cold Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007 (0,18) Hot: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Valve Guide Valve Guide O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.512 (13,0) Valve Guide I.D.: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3150.317 (8,08,05) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3150.317 (8,08,05) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Valve Guide Installed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5390.563 (13,714,3) Valve Guide O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,05); 0.020 (0,25); 0.030 (0,50) Valve Seat Ring O.S.: Intake 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.547 (39,3) 0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.559 (39,6) Exhaust 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.350 (34,3) 0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.362 (34,6) Height of Ring: 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2910.299 (7,47,6) 0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3030.311 (7,77,9)
Valve Spring Color Code BLUE: New Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.811 (46,0) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 (1,0) New Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 lbs. @ 1.469 (365 N @ 37,3) Use Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 lbs. @ 1.106 (414 N @ 28,1) Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8B5

Rocker Arm And Shaft L.H. Rocker Shaft: O.D. x Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.744 x 14.035 (18,9 x 356,5) R.H. RockerShaft: O.D. x Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.744 x 14.035 (18,9 x 350,5) Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,05) or less Rocker Arm I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.744 (18,9) Arm to Shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00050.0017 (0,0120,043) Rocker Shaft Spring: Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.098 (53,3) Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 lbs. @ 1.396 (16 N @ 35,5)
Oil Pump Relief Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5771 lbs. (254316 N) Outer to Inner Rotor Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.004 (0,040,12) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25) Pump Body to Outer Rotor Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.006 (0,100,16) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3) Rotor Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00230.005 (0,060,12) Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Relief Spring: Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.850 (47,0) Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 lbs. @ 1.398 (71 N @ 35,5)
Fuel Pump Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 qts. (2 L) @ 5000 RPM Closed Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75 PSI (25,534,5 kPa)
Carburetor Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700750 RPM Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downdraft Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2832DIDSA Main Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.037 (0,94) Main Air Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9) Pilot Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 (0,55) Pilot Air Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.062 (1,6) Enrichment Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.023 (0,6) Needle Valve Seat Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.078 (2,0) Fast Idle Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Idle CompensatorFully Open Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131158F. (5570 C.)
Water Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal, Impeller Type Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2760.394 @ 22 lbs. (710 @ 98 N)
Thermostat Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wax Type Valve Cracking Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 F. (82 C.) Valve Lift & Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31 (8,0) @ 203 F. (95 C.)
8B6

Starter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise Alternator Output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Amps. @ 2600 RPM Distributor Timing (With Vacuum Line Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BTDC @ 700750 RPM Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise Ignition Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1342 Centrifugal Spark Advance: Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 @ 1000 RPM End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 @ 2500 RPM Vacuum Spark Advance: Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 @ 0.36 in. of mercury Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 @ 9.84 in. of mercury End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 @ 15.8 in. of mercury Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0180.021 (0,440,55) Dwell Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 + 3 Condenser Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 uF Spark Plugs Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0280.031 (0,70,8) Engine Torque Cylinder Head Bolts (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Hot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker cover Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake & Exhaust Manifold Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Cap Mounting Bolts (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Sprocket Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Main Bearing Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Sprocket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Support Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Brace Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Tensioner Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Screen Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor Holding Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ft.Lbs. 5154 5861 45 1114 1415 79 3643 3640 2325 8094 5560 46 3643 1116 89 2529 1822 79 79 1623 7.58.5 1621 1113 1318 1113 1521 Nm 6973 7983 5,46,8 1519 1920 9,512,2 4958 4954 3134 113122 7581 5,48,1 4958 1522 10,812,2 3440 2430 9,512,2 9,512,2 2231 10,211,5 2228 1518 1824 1518 2028
8B7
TECHNICAL DATA Page Number DICIMAL AND MILLIMETER EQUIVALENTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C2 HYDRAULIC AND HYDROSTATIC FLUID SPECIFICATIONS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C1 STANDARD TORQUE SPECIFICATIONS FOR BOLTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C4 TORQUE FOR GENERAL METRIC BOLTS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C3 U.S. TO METRIC CONVERSION Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C2
TECHNICAL DATA
8C1
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not available, use 10W30 or 10W40 SAE Motor Oil.
Use Class SE or SF motor oil (5W30 at temperatures below 10F (23C)).
DO NOT use automatic transmission fluids in this loader or permanent damage to the transmission will result. Where temperatures below zero are common, loaders 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) will cause transmission damage in less than 60 seconds time.
When the temperature is below 20F (30C), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0F (18C) if possible.
I20071285
8C1
DECIMAL AND MILLIMETER EQUIVALENTS

FRACTIONS 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 DECIMALS 0.015625 0.03125 0.046875 0.0625 0.078125 0.09375 0.109375 0.1250 0.140625 0.15625 0.171875 0.1876 0.203125 0.21875 0.234375 0.2500 0.265625 0.28125 0.296875 0.3125 0.328125 0.34375 0.359375 0.3750 0.390625 0.40625 0.421875 0.4375 0.453125 0.46875 0.484375 0.5000 MM 0.397 0.794 1.191 1.588 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700 FRACTIONS 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 DECIMALS 0.515625 0.53125 0.546875 0.5625 0.578125 0.59375 0.609375 0.6250 0.640625 0.65625 0.671875 0.6875 0.703125 0.71875 0.734375 0.7500 0.765625 0.78125 0.796875 0.8125 0.828125 0.84375 0.859375 0.8750 0.890625 0.90625 0.921875 0.9375 0.953125 0.96875 0.984375 1.000 MM 13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 25.400
1 mm = 0.03937
0.001 = 0.0254 mm
U.S. TO METRIC CONVERSION

TO CONVERT LINEAR MEASUREMENT Miles Yards Feet Feet Inches Inches Inches Square Miles Square Feet Square Inches Acre Cubic Yards Cubic Feet Cubic Inches Tons (Short) Pounds Ounces (Avdp.) Pounds/Sq. In. FootPounds Quarts Gallons Gallons/Minute Fahrenheit INTO Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Square Kilometers Square Meters Square Centimeters Hectare Cubic Meters Cubic Meters Cubic Centimeters Metric Tons Kilograms Grams Kilopascal NewtonMeter Liters Liters Liters/Minute Celsius MULTIPLY BY 1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4 2.59 0.0929 6.452 0.4047 0.7646 0.02832 16.39 0.9078 0.4536 28.3495 6.895 1.356 0.9463 3.785 3.785 1.Subtract 32 2. Multiply by 5/9 8C2 742B, 743B Loader Service Manual
AREA
VOLUME WEIGHT PRESSURE WORK LIQUID VOLUME LIQUID FLOW TEMPERATURE
TORQUE FOR GENERAL METRIC BOLTS
Thread Size (Dia. x Pitch) 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 66 ft.lbs. (812 Nm) 1318 ft.lbs. (1824 Nm) 2230 ft.lbs. (3041 Nm) 3650 ft.lbs. (4968 Nm) Head Mark 4
Material Head Mark 7 34 ft.lbs. (45 Nm) 67 ft.lbs. (89 Nm) 1116 ft.lbs. (1522 Nm) 2230 ft.lbs. (3041 Nm) 4054 ft.lbs. (5473 Nm) 5880 ft.lbs. (79108 Nm) 69 ft.lbs. (812 Nm) 1825 ft.lbs. (2434 Nm) 3650 ft.lbs. 4968 Nm) 6987 ft.lbs. (94118 Nm) 116137 ft.lbs. (157186 Nm) Head Mark 10
8C3
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

742B (S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772SpecificationsSectionPart3of3
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE INCH. LBS. (Nm) .250 .3125 .375 .4375 .500 .5625 .625 FOOT LBS. (Nm) .750 .875 1.000 1.125 1.250 1.375 1.500 1.625 1.750 1.875 2.000
SAE GRADE 5 8090 (9,010,2) 180200 (20,322,6) 2528 (3438) 4045 (5461) 6570 (8895) 90100 (122136) 125140 (170190) 220245 (300330) 330360 (450490) 475525 (645710) 650720 (880975) 9001000 (12001360) 12001350 (16301830) 15001650 (20402240) 20002800 (27202980) 25002750 (33903730) 31503500 (42704750) 38004200 (51505700)
SAE GRADE 8 110120 (12,413,6) 215240 24,227,1) 3540 (4754) 6065 (8188) 90100 (122136) 125140 (170190) 175190 (240260) 300330 (410450) 475525 (645710) 725800 (9851085) 10501175 (14251600) 14751625 (20002200) 20002200 (27202980) 26002850 (35303870) 34503800 (46805150) 43004800 (58306500) 55006100 (74508300) 65007200 (88009800)
8C4
742B, 743B001
Revision Number
28 January 1993
SERVICE MANUAL REVISION

AFFECTING: Product BOBCAT LOADER Model 742B & 743B (S/N 18001 & Above)
Date
ROUTE TO ATTENTION
PARTS MANAGER SERVICE MANAGER SALES MANAGER X
Manual No. 6720772 (792)
NOTICE
Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 742B & 743B (S/N 18001 & Above) Service Manual P/N 6720772 (792). Take out and put in the revised pages as listed below: TAKE OUT 11, 12 HYDRAULIC/HYDROSTATIC FLOW CHART For Model 742B & 743B (S/N 18001 & Above) Chart #6722239 (Printed July 1992) HYDRAULIC/HYDROSTATIC SYSTEM OPERATION To Be Used With Chart #6722239 (Printed July 1992) PUT IN 11 (Revised Jan. 93), 12 HYDRAULIC/HYDROSTATIC FLOW CHART For Model 742B & 743B (S/N 18001 & Above) Chart #6722239 (Printed January 1993) HYDRAULIC/HYDROSTATIC SYSTEM OPERATION To Be Used With Chart #6722239 (Printed January 1993)
742B, 743B002
Revision Number
22 September 1993

Date
ROUTE TO ATTENTION
Manual No. 6720772 (792)
NOTICE
The following pages are a revision to the 742B & 743B (S/N 18001 & Above) Service Manual P/N 6720772 (792). Take out and put in the revised pages as listed below: TAKE OUT Maintenance Safety Page 11, 12 113, 114 Section 4 Content Page 41 thru 418 Section 6 Content Page CAB WIRING DIAGRAM (P/N 6722266) Model 742B & 743B (S/N 18001 & Above) (Printed July 1992) ENINE WIRING DIAGRAM (P/N 6722240) Model 742B & 743B (S/N 18001 & Above) (Printed July 1992) 63 thru 615 7A1, 7A2 7A7, 7A8 7A9, 7A10 7A17, 7A18 7A19, 7A20 8A1, 8A2 8B1, 8B2 PUT IN Maintenance Safety Page 11 (Revised Sept. 93), 12 113 (Revised Sept. 93), 114 Section 4 Content Page (Revised Sept. 93) 41 thru 418 (Revised Sept. 93) 419 (Added Sept. 93) Section 6 Content Page (Revised Sept. 93) CAB WIRING DIAGRAM (P/N 6722266) Model 742B & 743B (S/N 18001 & Above) (Printed September 1993) ENGINE WIRING DIAGRAM (P/N 6722240) Model 742B & 743B (S/N 18001 & Above) (Printed September 1993) 63 thru 615 (Revised Sept. 93) 616 thru 620 (Added Sept. 93) 7A1, 7A2 (Revised Sept. 93) 7A7, 7A8 (Revised Sept. 93) 7A9 (Revised Sept. 93), 7A10 7A17, 7A18 (Revised Sept. 93) 7A19, 7A20 (Revised Sept. 93) 8A1 (Revised Sept. 93), 8A2 8B1 (Revised Sept. 93), 8B2
742B, 743B003
Revision Number
3 May 1996

Date
ROUTE TO ATTENTION
Manual No. 6720772 (792)
NOTICE
The following pages are a revision to the 742B & 743B (S/N 18001 & Above) Service Manual P/N 6720772 (792). Take out and put in the revised pages as listed below: TAKE OUT 15, 16 211, 212 213, 214 PUT IN 15 (Revised May 96), 16 (Revised May 96) 211, 212 (Revised May 96) 213 (Revised May 96), 214
742B, 743B004
Revision Number
12 July 1996

Date
ROUTE TO ATTENTION
Manual No. 6720772 (792)
NOTICE
The following pages are a revision to the 742B & 743B (S/N 18001 & Above) Service Manual P/N 6720772 (792). Take out and put in the revised pages as listed below: TAKE OUT 121, 122 HYDROSTATIC SYSTEM TAB PAGE 37, 38 317 ENGINE SERVICE TAB PAGE (Kubota 743B) 7A3, 7A4 7B11, 7B12 PUT IN 121 (Revised July 96), 122 HYDROSTATIC SYSTEM TAB PAGE (Revised July 96) 37 (Revised July 96), 38 (Revised July 96) 317 (Revised July 96), 318 (Added July 96) ENGINE SERVICE TAB PAGE (Revised July 96) (Kubota 743B) 7A3 (Revised July 96), 7A4 7B11, 7B12 (Revised July 96)

8530114-Bobcat 742b 743b Skid Steer Loader Service Repair Workshop Manual Instant Download

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7 4 2 B 7 4 3 B

Melroe Company 1992

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

DRIVE SYSTEM CALIFORNIA PROPOSITION 65 WARNING

742B, 743B Loader Service Manual

5. Machine signs must be legible and in the correct location.

6. Steering levers and foot pedals must return to neutral.

14. Inspect for fuel, oil or hydraulic fluid leaks.

7. Check for correct function of the work lights.

15. Lubricate the loader.

8. The parking brake function correctly.

16. Check the condition of the battery and cables.

742B, 743B Loader Service Manual

18. Check the electrical charging system.

19. Check tires for wear and pressure.

20. Inspect for loose or broken parts or connections.

21. Operate the loader and check all functions.

22. Check for any field modification not completed.

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

BOBCAT SKID STEER LOADER IDENTIFICATION

FRONT LIGHTS (OPT.) SEAT BAR GRAB HANDLES STEERING LEVER

QUICK COUPLERS TILT CYLINDER

BUCKET SEAT BAR

SAFETY TREAD BUCKET STEPS OPERATOR CAB (ROPS & FOPS)

REAR LIGHT (OPT.) UPRIGHTS

LIFT ARM SUPPORT DEVICE

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

SERVICE SCHEDULE ITEM

742B, 743B Loader Service Manual

AVOID INJURY OR DEATH

742B, 743B Loader Service Manual

LIFT ARM SUPPORT DEVICE

742B, 743B Loader Service Manual

Nut Washer Bolt

Plate Bushing Washer

742B, 743B Loader Service Manual

AVOID INJURY OR DEATH

742B, 743B Loader Service Manual

Remove the dust cover [C].

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

P0705 P00705 P0705

Remove the wing nut [C].

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

+40 +50 +60

+80 +90 +100 +110 +120 +130 +140

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

+40 +50 +60

+80 +90 +100 +110 +120 +130 +140

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual

742B, 743B Loader Service Manual