2 3
0 3
Service
Manual
5
3
0
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
See the Owner's Manual for operating instructions (Starting Procedure, Regular Checks,
Basic Maintenance, etc.).
Make a complete inspection of these items after completion of service or repair: HYDROSTATIC
SYSTEM
1. Check the hydraulic fluid level, engine oil level, fuel supply, and coolant level.
5. Check the air cleaner system for damage or leaks. Check the element and replace if
necessary.
9. Check the Bob·Tach attachment for condition. Check the wedges for damage or
ELECTRICAL
wear.
SYSTEM
10. Check all safety items for condition (Operator Enclosure, Seat Belt, Safety Treads,
Lamps, Parking Brake, etc.).
Tell the owner if any of the above items are in need of repair.
ENGINE SERVICE
(533)
CONTENTS
AWARNING
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.
W-2003-1289
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete in structions 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 wel l as rou ti ne mainte·
nance 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.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator's Handbook fastened to the operator cab. Its brief instructions are conven ient to the
operator. The handbook is available from your dealer in English edition or a combination English, French, German , Italian,
Dutch & Spanish edition.
• The EMI Safety Manual delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from you r dealer for use by mechanics to do shop-type service and
repair work.
• The Skid-Steer 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.
AWARNING IMPORTANT
Warnings on the machine and In the This notice identifies procedures
manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause Injury or damage to the machine.
death. 1- 2019-0284
W-2044-1285
A Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this
symbol follow the safety message to avoid personal injury or death.
• Wear tight fitting cloth ing. 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 extinguishers and first aid kits 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 eng ine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.
• Check all electrical wirfng and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.
• Check fuel and hydraulic tubes, hoses and fittings fo r damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti-freeze.
• Do not use ether or starting fluids on thi s engine. It has glow plugs. These starting aids can cause explosion and injure
you or bystanders.
• Always clean the loader and disconnect the battery before doing any welding . Cover rubber hoses, battery and all other
fl ammable parts. Keep a fire extinguisher near the loader when weld ing. 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 (>moking!
• Use the procedu re in the Operation & Maintenance or Service Man uals for connecting the battery.
• Use the procedure in the Operation & Maintenance or Service Manuals for cleaning the spark arrestor muffler.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
Paragraph Page
Number Number
1-1.1 Symbols
The plate for the serial number of the loader is inside the left upr[ght (Fig. 1-1).
M 11001
I Production Sequence
I Plant Location
The Kohler (520/530) engine serial number is located on the blower housing, at the right
side of the engine (Fig. 1-2).
The ISUZU engine (533) engine serial number is on the left side of the engine, above the
injection pump (Fig. 1-2).
520, 530, 533 Loader
·1-1· Service Manual
1-1.5 Pre-Delivery Inspection ClARK
The pre-delivery inspection is used to make sure that the loader is in correct operating
condition when delivery is made to the dealer.
.
The pre-delivery inspection also helps to let the factory know when something is wrong
with the loader.
All items on the inspection form (Fig. 1-3) must be completed according to
specifications in this manual.
..
~ :::~":.~:: ..:..-;::.::~:'" ". .- I
(3) To show correct service procedures to customers.
All items on the 30 hour inspection form (Fig. 1-4) must be completed by the mechanic
according to specifications in this manual.
When the 30 hour inspection is completed, the form must be signed by:
Maintenance work must be done at regular intervals. Failure to do this will cause
damage and failure to the machine or its engine. The service schedule is a guide to
maintenance of the Bobcat loader. Do not change this schedule unless to shorten the
intervals during very hot, cold, dirty conditions that can cause corrosion.
HOURS
0 0
..... 0 0 0
0
0 0
eX;, It) 0 0 0
1 - 3 BOBCAT SERVICE SCHEDULE ..... N M .....
ITEM SERVICE REQUIRED
Engine Air Cleaner Clean dust cup. Inspect condition of system.
Engine Cooling System Check coolant level in coolant recovery tank. Add
coolant when low. R"emove any debris from radiator
grill area.
Control Pedals & Steering Check operation. Make repairs and adjustments as
needed.
I Governor Lubrication
Brakes
Check oil level and add as needed.
Engine Cylinder Head Tighten to correct torque after first 100 hours. Also
Bolts (533) adjust valve tappets.
Engine Air Filter System Inspect system for leaks. Replace element, if
needed.
Engine Air Housing (5201 Remove and clean housing and cooling fins.
530)
Engine Ignition System Check points and timing. Replace spark plugs.
(520/530)
Hydraulic System Replace fluid and filter. Clean inlet screen and vent.
IMPORTANT
Fig. 1-5 Releasing the Rear Door
Door must be closed when
operating loader.
I
holes in it, replacement is
necessary (Fig. 1 - 8).
Be sure the inlet of the air Fig. 1-6a Rear Door Stop Fig. 1-7 Removing Air Cleaner Elemen+
NOTE cleaner has the rubber elbow
installed. It helps prevent
water from getting into the air
cleaner.
Be sure to clean the inside of the
housing before installing a new
element. Make sure that the gasket
(Fig. 1 - 6, Item 1) is correctly in place
and the arrow on the end of the cover is
pointing up.
(3) Check complete air inlet
system and replace any parts
which have a defect.
(4) Check the operating condition
of the system, as follows:
a. Run the engine at idle.
Remove the rubber elbow, if
installed.
b. Hold a piece of wood over
©):)
the inlet pipe of the air cleaner
(Fig. 1 -9). The engine must
slow down then stop.
Fig. 1-8 Checking Element with Flashlight Fig. 1 - 9 Checking Air Cleaner System
NOTE: Look for a leak in the air cleaner hose or the crankcase breather hose.
Remove the filler cap to service the fuel tank as follows: (Fig. 1 -10 & 1 -11) Fig. 1-10 Fuel Filling (520)
(1) Ignition must be in off position and engine must be cooled.
(2) Add fuel only in an area which has good air movement and is free from
sparks. (NO SMOKING.)
(3) Use a clean approved safety container to add fuel to the fuel tank.
(4) Lower the spill guard (Fig. 1 -10).
(5) Use only clean fuel to fill the tank.
(6) Be sure to tighten the cap on the filler pipe.
Close the shut-off valve for fuel (Fig. 1 -12, Item 1).
(4) Put oil on the rubber gasket and turn the new element clockwise to install
it. Use your hand to tighten the element until it is hand tight.
(6) Loosen the screw to let air out of the system (Fig. 1 -13, Item 1).
(7) Engage the starter and turn the engine until fuel flows freely from the
loosened screw, then tighten the screw. Fig. 1-14 Checking Engine Oil (520. 530)
Start the engine and let it run for several minutes. Then check for leaks.
Check the oil level every 4 hours during the first 50 hours of operation. Check the oil
level daily after the first 50 hours of operation.
To check the oil level, stop the engine and remove the dipstick at the left side of the
engine on the model 520/530 loader (Fig. 1 -14). The dipstick on the 533 loader is
at the right side of the engine (Fig. 1 -15), early models (left side on current
models).
Oil level must be kept between the "L" (Low) and "F" (Full) marks on the dipstick.
Do not overfill - - - oil level must not exceed the "F" mark. Use good quality
detergent motor oil which meets recommended API Service Classifications (See
chart).
Use oil of proper SAE viscosity for expected temperature conditions at the time of
starting, not for the highest temperature expected during the working day (See chart
on page 1 - 7).
Fig. 1-16 Oil Drain Plug (520, 530) Remove Oil Filter Element (520, 530)
Install the drain plug and remove the oil filler cap. Fill with 4 quarts (3,8 U of oil of
the correct specification (See chart).
Start the engine and let it run for a few minutes and check for leaks at the filter.
Check the oil level again and add oil, if needed, to bring the level to the "F" mark on
the dipstick.
Change the engine oil and filter after every 50 hours of operation. Fig. 1 -18a Oil Drain (533)
Remove the drain plug when the engine is hot. Let oil flow for several minutes.
Use a filter wrench to remove the oil filter (Fig. 1 -18). Place an open reservoir or
rags under filter area to catch leaking oil.
Clean the filter contact area and put on the gasket before installing the element. Turn
I
the element on until it is hand tight.
NOTE: Be sure to check the engine oil drain for a leak which is caused by engine
vibration (SIN 11339 & below). When there is a leak, you can install a new
tubeline assembly (See Parts Manual or microfiche for parts).
Install the drain plug and remove the oil filler cap (Fig. 1 -1 5). Fill with 3.4 quarts
(3,2 U of oil of correct specification (See chart).
Start the engine and let it run for a few minutes. Then stop the engine and check for
leaks at the filter.
NOTE: To check engine oil. the dipstick cap must touch the dipstick tube. To get
the proper oil level. DO NOT tighten the dipstick in the tube.
Check the oil level and add oil, if needed, to bring the level to the "F" mark on the
dipstick.
NOTE: Do not overfill the crankcase.
AWARNING
Wear safety goggles when cleaning
with air hose.
Use air pressure or water spray to clean Fig. 1-19 Cleaning Oil Cooler Grill (520,530)
oil cooler grill area (Fig. 1-19).
Remove the shrouding on the engine to clean the cooling fins. Be sure to wear safety
goggles when using water spray or air pressure to clean cooling fins.
Use a hard brush and scraper tool to remove hard deposits on the cooling fins (Fig.
1-20). The oil cooler can be removed for better cleaning.
The radiator grill area must be kept clean and free of foreign material or the engine will Fig. 1-20 Cleaning Cooling Fins (520, 530)
become too hot.
Keep the blower fan clean and free from debris (Fig. 1-21).
AWARNING
Use safety goggles when cleaning
the grill area with air pressure.
Add coolant at the recovery tank only. Fig. 1-21 Blower & Housing (533) Fig. 1-22 Coolant Recovery Tank (533)
AWARNING
Do not remove the radiator cap
to check coolant level unless
the engine is cold.
The cooling system must be made Fig. 1-23 Alternator Belt Tension
empty and flushed clean once each
year. Fill with new, clean coolant,
containing a rust inhibitor.
,
IMPORTANT Never operate the engine with any part
of the blower shrouding removed.
Check the water pump and alternator belt tension and adjust when necessary. The
correct belt tension is 3/16" (5 mm) with a little amount of finger pressure at the
center of the belt span (Fig. 1-23).
1 - 14 ELECTRICAL SYSTEM
The 520/530 loader is equipped with a 12 volt, 15 amp, flywheel generator charge
system. (See Section 6 for wiring diagram.)
The 533 loader uses a 12 volt, 37 amp, belt driven alternator charge system. (See
Section 6 for wiring diagram.)
Service the electrical system as follows:
(1 ) Check the battery electrolyte level and if it is low, fill to the mark with
distilled water. (Not required on "Maintenance Free" type battery.)
(2) Keep the battery cables and
terminals clean and tight. Remove
acid corrosion with a baking soda
and water solution. Coat the
terminals with grease to prevent
corrosion build up.
To remove the battery, pull back and
lift up on the holddown lever (Fig.
1-24). On later model loaders remove
nuts and clamp. Use a carrystrap to lift
the battery out of the engine
compartment.
Be sure to fasten the battery in place
with the holddown lever or clamp when
installing.
NOTE: On the 520; all 530; 11080 &
below and 533; 11165 &
below. the battery hold down
can bend. Install a new hold-
down rod which has been heat
treated. (See Parts Manual or
microfiche for parts) (PIN has
not been changed).
(3) Check for worn or loose
wiring. Fig. 1-24 Battery Hold Down Fig. 1-24A Battery Hold Down
I
fluid before it returns to the inlet of the
vane pump.
(3) Remove the spring cI ip and remove the screen from the reservoir filler pipe
(Fig. 1-31). Wash the screen in clean solvent and install it in the filler pipe. (Clean
the reservoir screen only when necessary.)
(4) Open the upper valve at the side of the reservoir (Fig. 1-28, Item 2). Add
recommended fluid (about 4 gallons [15 Ltrs.l) to the reservoir. When fluid flows
at the open valve, close the valve and install the filler cap.
Replace the hydraulic filter element after every 100 hours of operation, or sooner, if
necessary (indicated by illuminated "tran" light).
(1) Remove the element (Fig. 1-32). (Use an open reservoir to catch leaking
fluid.)
Fig. 1-31 Removing Filler Pipe Section Fig. 1-32 Remove Hydraulic Oil Filter
(1) Put loader on a level surface.
520, 530, 533 Loader
·1-11- Service Manual
(2) Remove the plug, located at
the front of the chaincase housing
(Fig. 1-33).
Check the tires regularly for wear, damage Fig. 1-34 Tire Rotation
1-21 BOB-TACH
1 - 22 PIVOT PINS
D-1380
Injection Pump
Paragraph Page
Number Number
',~-
goes to the hydraul ic filter, and
then to the hydrostatic drive system.
(6) A restrictor orifice is installed in the hydraulic filter tubeline to limit oil flow
and protect the filter from too high oil pressure.
Location A . Machine SIN 12,300 & Up (520, All 530 & 533)
When making repairs on the hydraulic system keep all parts completely clean. Use caps
and plugs to keep dirt out of tubelines and openings.
Misalignment of Marks Shows
Amount to Tighten (See Chart)
Put only clean oil in reservoir. Be sure the screen for the reservoir filler tube is in the
correct location.
(1) Tighten the nut u nti I the flame is in contact with the seat.
A·1897
(2) Make a line from the nut to the adapter (Fig. 2-2).
Fig. 2-2 Tightening Flared Fitting
9/16 - 18 2
3/4 - 16 2
7/8 - 14 1-1/2 - 2
1-1/16 - 12 1
1-5/16 - 12 3/4 - 1
(4) Use a wrench to turn the fittings to the correct number of flats shown in chart Fig. 2-3 Straight Tread Seal
above. Loosen the fitting and tighten again. (The first tightening action is for
alignment and the second is for correct torque).
(5) Check the fitting for leakage. If there is leakage, remove the fitting and look
for damage.
These connections seal by compression of the D-ring. To tighten D-ring fittings, use this
method:
(1) Loosen the nut and slide the washer and D-ring against the thread (Fig. 2-3).
Put oil on the D-ring.
(2) Tighten the fitting in place by hand. If the fitting is an elbow turn the elbow
until it is in alignment with the tubeline or hose.
Fig. 2-4 Seal in Place
(3) Hold the fitting with a wrench. Use another wrench to tighten the jam nut
(Fig. 2-4). The D-ring must fit into the space as shown.
(4) If the fitting is not turned in correctly, the D-ring will have damage and the
fitting will leak (Fig. 2-5).
Make replacement of any tubelines which has damage, or the restriction to size can cause
heat and slow hydraulic action. A replacement of hoses must be made when they have
wear or damage. Use correct clamps to hold the hoses and tubelines in position.
A_ If the spool is not free, turn the spool 180 0 in its location or loosen the control
valve from the frame and tighten the bolts evenly, a small amount at a time.
A WARNING
Put jackstands under the front axles and rear
corners of the frame before running the engine 8-5257
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W-2017-0286 B
This test will determine the acceptable flow of the
hydraulic pump. A hydraulic tester is required that will
measure flow, temperature and pressure.
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.
520,430,533 Loader
Service Manual
2-4 PROBLEM ANALYSIS.
CHART A
SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ALL CIRCUITS
I
If
low
f
I
If Not
Correct
t ,I
If Not
Correct
I
If Not
Correct
t
Make Repairs
Make Corrections Remove, Clean &
Add
Inspect Relief As Needed
Fluid As Needed
Valve (Sec. 2-5.1) (Sec. 2-7)
CHART B
SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ONE CIRCUIT
ONL Y. CYLINDERS MOVE WITH CONTROLS IN NEUTRAL POSITION.
I
If Not Correct
I
If Bad
I
If Bad
~ + ~
Make Repairs
Make Repair Make Repair
Or Replacement
Or Adjustment Or Replacement
As Needed
As Needed As Needed
(Sec. 2-9)
(4) Activate the hydraulic control which will put pressure on the hose connected
to the tester. Read the pressure (See Section 8 for correct pressure).
(1) Activate the controls to release pressure from the hydrau lie systems.
(2) Remove the relief valve assembly from the control valve (Fig. 2-7).
(3) Remove the snap ring from the end of the valve and lift the parts out (Fig.
2-8, Item 10). Clean and make an inspection of all parts.
(4) Install the relief valve (Fig. 2-20, Item 16) with new a-rings (Items 13 & 15)
and back-up washer (Item 14).
(3) Start the engine and run it at full throttle. Close the flow control valve slowly.
Read the flow on the gauge (See Section 8 for correct flow), If the flow is less
than specifications, hydraulic pump repairs are needed.
(1) Remove the seat and the shield above the transmission area.
(2) Disconnect the hose from the reservoir and the vane pump at the port block.
Put a cap on the hose to keep the fluid in the system.
(3) Remove the hex plug from the top of the port block and use a long link socket to
remove the large screw which holds the port block in place (Fig. 2-10).
(4) Remove the two screws which hold the vane pump and lift the pump out of
the Bobcat.
2-7.2 Disassembly
2-7.3 Inspection
(1) Install a new O-ring on the pump and put the pump in position on the
hydrostatic pump assembly. Fasten the pump with bolts.
(2) Fasten the hoses and port block to the pump. Fill the reservoir with clean,
recommended fluid.
NOTE: No special "start-up" procedure is needed when installing only the vane pump.
2-8 CHECKING CONTROL VALVE AND CYLINDERS
Wear in the control valve or spools will cause: (1) Hydraulic cylinders to move when the
controls are in neutral position. (2) Loss of hydraulic power. Check condition of the
hydraulic cylinders by following the procedures given on the next page. If the cylinders ~ B.28~?
are good, the defect is probably in the control valve. LEFT SIDE
2-8.1 To Check Lift Cylinders Fig. 2-14 Disconnect Lift Cylinder Hose
(2) Put the machine on blocks and remove the wheels. Activate the controls to
release hydraulic pressure.
(3) Open the rear door. Disconnect the hoses which go to the lift cylinders (Fig.
2-14 and 2-15). Install plugs in the tubelines.
(4) Start the Bobcat and push the toe of the lift pedal.
(5) If hydraulic fluid leaks from the open hoses, (continuous floW) remove the cylinder
from the side with the leak, for repair.
(3) Disconnect the hose which goes to the top (Base End) of the tile cylinder (Fig.
2-16). Put a plug in the hose.
(4) Start the engine. Push the heel of the tilt pedal. If a continuous flow of fluid
leaks from the open connection on the cylinder, the cylinder needs repair.
2-9 HYDRAULIC CYLINDER REPAIR
NOTE: Repair procedure for the tilt and lift cylinder is similar.
B·2853
2-9.1 Removal and Installation Fig. 2-16 Disconnect Tilt Cylinder Hose
(3) Remove the bolts and pins which hold the cylinder in position.
(1) Remove the cylinder head with a spanner wrench (Fig. 2-17).
(2) Pull the rod and piston assembly from the case. ·Spanner
Wrench A-1896
(3) Remove the nut from the end of the rod. Slide the piston and O-ring off the
Fig. 2-17 Cylinder Head Removal
rod.
520, 530, 533 Loader
-2-6- Service Manual
(4) Check the cylinder rod for scratch marks or other damage. Remove small Stone
defects by grinding (Fig. 2-18).
(7) If there is a sharp edge on the end of the rod, remove the edge with a file
and slide the cylinder head over the rod (Fig. 2-19). Install the piston and tighten
the nut to correct torque (See Section 9).
(8) Slide the piston and rod assembly into the housing and tighten the head with
a spanner wrench. PI·1221b
2-10 CONTROL VALVE REPAIR
Fig. 2-18 Removing Marks
Be sure that lift arms are fully down and Bob-Tach
is fastened fully back before
2-10.1 Removal
(1) Remove the seat and shield above the transmission area.
(2) Disconnect the control linkage and hydraulic tubelines from the control valve.
(3) Remove the two bolts which hold the control valve and lift the valve out of the
Bobcat.
2-10.2 Disassembly and Inspection (All Sections) (Fig. 2-20)
PI·1221a
NOTE: Be sure to put the spools back in their original bores.
Fig. 2-19 Beveling the Shoulder
12
/
6~.r--------- // ,/'
17~' 6')1' L-------:)O\
29 -;rf P' ll-d ~
):::Y ,<::::1/, 6
27-A 28-@ @
23 26}~ 27~' (:{' \ 17
--~ -, 23- 26 }iT " 18
24_~~' 2 I ~ @~ 30
I / -""18 4__ ~ jf / \ 19
'~--25 K --18 /0'\ 18
~ ~--23 ~\ 20
°--
#l 25
')2 \
22
23 21 C·2012
2-10.3 Assembly of Valve Fig. 2-23 Remove Spacers from Bores Fig. 2-24 Relief Valve Removal
B·2903
Adjust the linkage so the pedals will not touch the floor when you tilt them fully
back. Each valve must move the full length of it's stroke when you push the heel or
toe of the pedal.
2 - 11 HYDRAULIC HOSES
On some of the 530 and 533 loaders, the hydraulic hoses come in contact with the
rear door hinge when the door is opened. Install a bolt and a bushing in the right hand
upright at the location directly in front of the door hinge (Fig. 2 - 28). Drill a 5/16"
(7,937 mm) hole at the location as shown in figure 2- 28 and install a 3/8" (9,525
mm) 10 x 2-3/4" (69,85 mm) long bushing, 5/16" x 3-1/2" bolt and locknut.
Bushing is Installed
Between Door Hinge and
Hydraulic Hoses
/
/
/
-
/
/
~Bushing
Bolt
~
...L
I
2-1/2" (63,5 mm)
,
B-3166
If there is not enough oil flow through the quick-couplers there will be high back
pressure, on the hydraulic system, and slow attachment operation.
The adaptor on the male quick-coupler has a "taper" end which can cause the
restriction in the hydraulic oil flow and over-heating. Remove the quick-coupler (Fig.
2-29) and the adaptor and cut away the "taper" about 3/16" (4.76 mm) (Fig.
2 - 30). Do not cut the threads on the adaptor.
Remove
3/16"
14,76 mm)
,------..,
----.- I ~j On This
End Only
'"
/ - - - ----I ~
-
~ - - ~--- f- -p
\.-J
A-2704
• hydraulic pump 0
The hydraulic control valve
valve
through the control valve
to the hydraulic control valve
e
e
49 .
has a pilot operated main relief
4D . When all three spools are in neutral position, the oil goes
and out to the "Tee" fitting. If one of
the spools is activated, the oil goes out the respective port and to
either the base end, or the rod end of.the hydraulic cylinder(s). As the
oil goes into one end of the cylinder(s), return oil comes from the
- opposite end of the cylinder(s) and back into the control valve
When the cylinder reaches the end of the stroke, the oil flow stops and
e.
causes hydraulic pressure to increase. When the pressure reaches the
setting of the relief valve G it opens and lets the oil bypass the
hydraulic circuit (internally) and goes out the "Tee" fitting. When this
happens, there, is no oil going to the down-stream sections of the
control valve e. If you let the spool go back to the neutral position,
then there is oil available for the other sections. Two sections of the
control valve e can be used at the same time if the main relief
valve G is not open.
• The oil which goes to the "Tee" fitting on the control valve
two places, one is to the hydraulic filter «Ii) and
CD will go
to the bypass
When the oil gets to the hydrostatic pumps e, it activates the high
pressure replenishing valves 8. As the pressure increases the
replenishing valves 8 open and let oil into the hydrostatic
pumps e, for replenishing, lubrication and cooling. This oil is called
"charge oil". The hydrostatic pumps e do not need the full volume
of the charge oil so there is extra oil. This extra oil goes through the
other side of the "Tee" fitting to the charge bypass valve e. When
the pressure reaches the setting of the charge bypass valve e and if
opens and lets this extra oil go back to the inlet of the hydraulic
pump O.
There are two hydrostatic pumps e and two hydrostatic
motors e. One pump and one motor work together as a pair to drive
one side of the machine. The other pump and motor work as a pair to
drive the opposite side of the machine.
When the replenishing valves 8 open and charge oil goes into the
hydrostatic pumps e, the flow becomes "drive loop oil". When the
steering levers are in neutral, the hydrostatic pumps e and the
hydrostatic motors e are not working but do have charge pressure.
When the steering levers are moved; the swashplates in the
hydrostatic pumps e are angled and oil is pumped out of the
pressure side of the hydrostatic pumps 0 to the hydrostatic
motors e.
This flow of oil is called "drive pressure". Drive pressure is much
higher than charge pressure causing the high pressure replenishing
valves8 to close 'allowing the flow of oil to go to the hydrostatic
motors 8.
When the machine is driven with the bucket down, into a pile of dirt,
there is resistance causing high pressure oil in the drive loop. There is a
relief valve built into the high pressure replenishing valves 8. This
relief valve releases the high pressure in the drive loop. When the relief
valve opens the extra oil goes from the drive loop to the charge loop to
-2-
be used again. If the oil pressure gets above the setting of the relief
valves, the pressure could break tubelines, damage the hydrostatic
pumps e or the hydrostatic motors O. There are four high
pressure replenishing valves 8 ' two for each side of the hydrostatic
pumps e. One is forward travel and one is for reverse travel.
-3-
HYDRAULIC FLOW CHART
520 (All) (
•
OIL COOLER • TEMPERATURE SWITCH, 230°F [110°C]
• •
•
G
TILT CYLINDER
PRESSURE SWITCH, 23-27 PSI [158-186 kPa]
FILTER, 10 Micron
(
o G) RESTRICTOR
BY-PASS VALVE
G MAIN RELIEF, 1500-1600 PSI [10342-11032 kPa]
SWITCH.
•
TEMPERATURE
SWITCH o
Lin
48
At Valve (1575-1675 PSI [10859-11549 kPa]
Measured at Aux. Quick Couplers)
HYDRAULIC CONTROL VALVE
G) ORIFICE
TERG «0 FILTER BY-PASS, 30 PSI [206 kPa] (530 & 533 Only)
G) OIL COOLER
RESTRICTOR G)
o HYDROSTATIC PUMP
G CONTROL
HYDRAULIC
VALVE
•
_
RED - - - - - - - High Pressure
BLUE - - - - - - Low Pressure
• GREEN - - - - - Case Drain & Reservoir
G
.............
MAIN RELlEF-
•
TILT
CYLINDER
ORANGE - - - -Charge Pressure
PI-2499
HYDROSTATIC FLOW CHART
Neutral Position (Open Center System)
520 (All)
530 (SIN 13,999 & Below)
533 (SIN 12,999 & Below)
HYDROSTATIC FLOW CHART HYDROSTATIC.
Neutral Position (Open Center System)
520 (All)
o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
FILTER
G!) AHYDROSTA
• •
e
_
OIL COOLER
HYDROSTATIC PUMP
RED - - - - - - - High Pressure
V MOTOR
_ BLUE - - - - - - Low Pressure
ORIFICEG) _ GREEN - - - - - Case Drain & Reservoir
ORANGE - - - -Charge Pressure
FILTER.
BY-PASSW
•
HYDRAULIC
CONTROL V~
MAIN RELIEF.
PI· 2500
HYDROSTATIC FLOW CHART
Forward Position (Open Center System)
520 (All)
530 (SIN 13,999 & Below)
533 (SIN 12,999 & Below)
HYDROSTATIC FLOW CHART
Forward Position (Open Center System)
520 (All)
•
HYDROSTATIC
MOTOR o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
G)
533 (SIN 12,999 & Below)
..
OIL RESERVOIR
. . HIGH PRESS. RELIEF VALVES, 3000 PSI [20685 kPa]
.•
e
PORT BLOCK
BY·PASS VALVE. 55·75 PSI [379·517 kPa]
OIL COOLER
49 o HYDRAULIC OIL PUMP, 8 GPM [30,3 LIm] at 2500 RPM
HYDROSTATIC
PUMP o TEMPERATURE SWITCH, 230°F [110°C]
e PRESSURE SWITCH, 23 • 27 PSI [158 ',186 kPa]
• HYDROSTATIC MOTOR
G) FILlER, 10 Micron
( G MAIN RELIEF, 1500 • 1600 PSI [10342 • 11032 kPa]
At Valve (1575 • 1675 PSI [10859 • 11549 kPa]
BY·PASSA
VALVE V Measured at Aux. Quick Couplers)
L1CO
OIL PUMP ,
o HYDRAULIC CONTROL VALVE
G) ORIFICE
TEMPERATURE
SWITCH e FILTER BY·PASS, 30 PSI [206,9 kPa] [530 & 533 Only]
o G) OIL COOLER
49 HYDROSTATIC PUMP
HYDROSTATIC RED· •••••• High Pressure
MOTOR
•
IiiIiI BLUE· ••••• Low Pressure
~- ORIFICE G) _ GREEN· •••• Case Drain & Reservoir
CJ ORANGE· •• ·Charge Pressure
HYDRAULIC
CONT;L~LF::::::::;
MAIN RELIEF
G PI·2501
SYSTEM OPERATIONS
)
hydraulic pump 0 to the hydraulic control valve 49 .
The hydraulic control valve 49 has a pilot operated main relief
valve CD . When all three spools are in neutral position, the oil goes
out the respective port and to either the base end, or the rod end of the
hydraulic cylinder(s). As the oil goes into one end of the cylinder(s),
return oil comes from the opposite end of the cylinder(s) and back into
the control valve 49. When the cylinder reaches the end of the
stroke, the oil flow stops and causes hydraulic pressure to increase.
When the pressure reaches the setting of the relief valve CD it opens
and lets the oil bypass the hydraulic circuit (internally) and goes out
the "Tee" fitting. When this happens, there is no oil going to the
down-stream sections of the control valve 49 .If you let the spool go
back to the neutral position, then there is oil available for the other
sections. Two sections of the control valve 49 can be used at the
same time if the main relief valve CD is not open.
The oil which goes to the "Tee" fitting on the control valve 49 will go
) two places, one is through the protective orifice CD) into the oil
cooler 0 and to the bypass valve • in the port block • . The
hydraulic filter CD has a bypass valve e to allow oil flow when it
6566162 (2 ·811· 21C -1- Printed in U.S.A .
cannot go through the filter element (plugged).
When the oil gets to the hydrostatic pumps 41), it activates the
replenishing function of the high pressure relief valves • . As the
pressure increases the replenishing valves. open and let oil into the
hydrostatic pumps 41) , for replenishing, lubrication and cooling . This
oil is called" charge oil" . The hydrostatic pumps 41) do not need the
full volume of the charge oil so there is extra oil. This extra oil goes to
the charge relief valve 8 and through the other side of the "Tee"
fitting to the charge bypass valve • . When the pressure reaches the
setting of the charge bypass valve. it opens and lets this extra oil
go back to the inlet of the hydraulic pump O.
There are two hydrostatic pumps ell) and two hydrostatic
motors • . One pump and one motor work together as a pair to drive
one side of the machine. The other pump and motor work as a pair to
drive the opposite side of the machine.
When the replenishing valves. open and charge oil goes into the
hydrostatic pumps ell) , the flow becomes "drive loop oil". When the
steering levers are in neutral, the hydrostatic pumps ell) and the )
hydrostatic motors. are not working but do have charge pressure .
When the steering levers are moved, the swash plates in the
hydrostatic pu~ps 41) are angled and oil is pumped out of the
pressure side of the hydrostatic pumps ell) to the hydrostatic
motors • . This flow of oil is called ."drive pressure". Drive pressure
is much higher than charge pressure causing the high pressure
replenishing valves. to close allowing the flow of oil to go to the
hydrostatic motors • .
When the machine is driven with the bucket down, into a pile of dirt,
there is resistance causing high pressure oil in the drive loop. There is a
relief valve built into the high pressure replenishing valves • . This
relief valve releases the high pres~ure in the drive loop. When the relief
valve opens the extra oil goes from the drive loop to the charge loop to
be used again . If the oil pressure gets above the setting of the relief
valves, the pressure could break tubelines, damage the hydrostatic
pumps ell) or the hydrostatic motors. . There are four high
pressure replenishing valves • ' two for each side of the hydrostatic
)
pumps ell) . One is forward travel and one is for reverse travel.
·2·
The hydrostatic motors 0 are a "geroller type" and have a built in
shuttle that meters oil to the port block 0 .The oi l flows to the port
block 0 located on top of the hydraulic pump 0 . The shuttle
operates when the steering levers are moved. When the hydrostatic
pumps e. forces drive pressure oil to the hydrostatic motors 0 .
the shuttle is forced in one direction. Low pressure oil is then metered
out through case drain to the port block 0 . When the direction of
the steering levers are changed. the shuttle moves toward the
opposite side and low pressure oi l continues to be metered out to the
port block O. There is an orifice 0 in the case drain line to help
dampen the shuttle movement.
-3-
HYDRAULIC FLOW CHART (
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above)
HYDRAULIC FLOW CHART
530 (SIN 14,001 & Above)
533 (SIN 13,001 & Above) o
OIL RESERVOIR---..I
o OIL RESERVOIR, System Cap.: 5 Gal. [19 L]
• PORT BLOCK
• BY-PASS VALVE. 78-97 PSI [537-668 kPa]
G)
HYlllROliTATIC PUMP
o HYDRAULIC OIL PUMP, 8 GPM [30,3 LIm] at 2500 RPM
G
FILTER BY-PASS
•
PORT DLu•.,n
•
o
o
TEMPERATURE SWITCH, 230°F [110°C]
LIFT CYLINDERS
TILT CYLINDER
49
o PRESSURE SWITCH, 23 - 27 PSI [158 - 186 kPa]
OIL COOLER
.-...!..!.---- BY-PASS VALVE.
o RESTRICTOR
~~------ HYDRAULICO G) MAIN RELIEF, 1500 - 1600 PSI [10342 - 11032 kPa]
TEMPERATURE OIL PUMP , At Valve (1575 - 167~ PSI [10859 - 11549 kPa]
SWITCH Measured at Aux. QUick Couplers)
PRESSURE SWITCH • 0 G HYDRAULIC CONTROL VALVE
o ~--- LIFT CYLINDERS ~
W OIL COOLER
•
FILTER
BY-I"A:!Io~
e
I!!!I!!!!!!!!~"- HIGH PRESSURE
CHARGEaRELIEF VALVES
GTEMPERATURE SWITCH, 230°F [110°C]
• PRESSURE SWITCH, 23-27 PSI [158-186 kPa]
/
RELIEF V
,
o HYDROSTATIC MOTOR
- , ,,
\
G)ORIFICE
OIL COOLER G MAIN RELIEF, 1500-1600 PSI [10342-11032 kPa]
At Valve (1575-1675 PSI [10859-11549 kPa]
Measured at Aux. Quick Couplers)
_
OIL COOLER
PORT
r--''''--, BLOCK
0
HYDRAULIC 0
o
o
PRESSURE SWITCH, 23 - 27 PSI [158 - 186 kPa)
HYDROSTATIC MOTOR
HYDRAULIC
CONTROL VALVE
o HYDROSTATIC PUMP
Paragraph Page
Number Number
There is a restrictor orifice (Fig. 3-2) which protects the filter from damage from sudden
increases in pressure. This orifice is in location at the control valve end of the filter
tubeline (1) on 520 SIN 12,299 and below. On 520 SIN 12,300 and above and all 530,
533's, the orifice is located at the inlet tubeline to the 10 micron filter (2).
No drive on one side in one None Check for hydraulic leaks. Check
direction. steering linkage, check
replenishing valves (Sec. 3-4.11.
NOTE: If the "Trans" light is illuminated, check which sender is actuating the light by
removing the wire at the pressure sender switch. If the light is still illuminated,
the temperature sender is actuating the light because fluid is too hot. If the light
goes out when the pressure sender wire is removed it is an indication of loss of
hydrostatic charge pressure.
" Restrictor
(Early Modelsl B-2286
Fig. 3-2 Restrictor At Filter Inlet
If "Trans"
Check Turn Ignition Start Engine &
Fluid Level
If
Correct Switch "On"
Light
Comes On
• Run At 1/2 Throttle
If Light Does
If Low
Not Come On
+
Add Make Repair To Install
Fluid Light System New Filter
If Light Is On
If Light Is On
If Good
iF
t
Hydrostatic Pump
Has Defect. Remove,
Make Repairs Check Clean & Inspect
If Good
To Controls Pump Drive Pump And Motor
(Sec. 3-6 & 3-8).
CHART B
NO DRIVE: 1 SIDE, BOTH DIRECTIONS
If Light
Check Steering If Turn Ignition If Light.. Start Engine & I-Is Off.- Hydrostatic Motor
r--
Linkage Good Switch "On" Is On Run At 1/2 Throttle 'But No Has Defect
Drive
I
If Not
Correct
t ,
If Light
Is Not On
,I
If Light
Stays On
,It
NOTE: If Either
Make Repairs The Pump or Motor
Repair Electrical Hydrostatic Pump
As Needed Has Damage, Remove,
(Sec. 3-10) System Has A Defect
Clean & Inspect
Both Units.
520 Loader
-3-2 Service Manual
CHART C
BOBCAT DOES NOT MOVE IN A STRAIGHT LINE
Check Size
& Pressure
Of Tires
If
Correct
.. Check Steering
Linkage
(Sec_ 3-101
If
Correct
... Go To
Chart B
I
If Not Correct
I
If Not Correct
t t
Change Tire Make
Or Pressure Repairs
As Needed As Needed
CHART D
BOBCAT OVERHEATS
Check If Hydraulic
Check
Check
Fluid Level
_ If
Correct
~ Check & Clean
Oil Cleaner
_If~
Clean
Controls Are Being
Held Out of
- If
Not
~ "Temp Sender"
(Sec. 1-111
Neutral Position
I I
If Low If So
t
Loader Is
Add Fluid Not Being
Operated Correctly
-3-3-
3-4 REPLENISHING VALVES
t
there is no loss of drive in the A·2380
opposite direction, one of the
Fig. 3-4 Valve Seating Area
valves has a defect and needs ,,
replacement.
Q
NOTE: Do not lose the small pin in the ,
end of each valve.
(2) If exchanging the valves does I
not change which side loses power
or drive, remove all four valves and
wipe them dry.
cD
(3) Put a coloring fluid on the
valves and let them dry (Fig. 3-4).
Replenishing
(4) Use a needle nosed pliers to High Pressure
install the valve into the hole. Relief Valves
Install the valve lightly in the seat
and turn it very little. 8·1608
Fig. 3-3 Replenishing Valves
(5) Remove the valve and check the contact area of valve. If the contact area
of valve does not show sign of full contact around the seat area, the seat in the
valve plate has defect. The valve plate must be replaced.
If the "TRANS" indicator light continues to goON or OFF, and you do not notice any
poor hydrostatic performance, the by-pass valve can be the problem. The poppet
does not fit correct against seat and must be replaced. (See Parts Manual or
microfiche for parts.)
(1) Disconnect the hose from the control valve to the port block. Slide the
spring and poppet out of the port block (Fig. 3-5).
.. ,
hold the pump assembly to the
frame and lift the pump assembly
out of the Bobcat. Weight of the
pump assembly is about 90 Ibs. (41
kg).
.".
. .,.,.-- "",-
-
Installation is the reverse of removal. Be
-- ,
". ..~.
(3) Remove bolts hold ing the Fig. 3-7 Remove Pump From Valve Plate Fig. 3-8 Remove Coupling from Valve Plate
pump housing to the valve plate.
Remove the pumps from the valve
plate (Fig. 3-7). Remove the spline
coupling from the valve plate (F ig.
3-8).
Wear Area
(7) Use a hammer and punch to
remove the shaft seal (F ig. 3-13).
Fig. 3-13 Remove Shaft Seal Fig. 3-14 Valve Plate Wear
3-7.2 Assembly
Use a seal installation tool (Fig. 3-17) to install the new seal (See Section 8, "Special
Tools"). Put hydraulic fluid on parts during assembly. Install new seals and a-rings.
L--
/-~
Shoe Faces Slides
Shoe Must Swivel Smoothly on Ball.
on Swash Plate
End Play Must Not Exceed 0.003 Inch. A-1850
1!
new connector link for future
identification. Do not use the old
connector link again.
(4) Disconnect the hoses to the 4.000
!
hydrostatic motor and put covers
on the hoses to keep dirt out. , 0.500
(5) Remove the bolts which hold o.375 ~ 0.125
the motor to the chain case. Tilt the
motor to one side to release the
t
e=a,;.= F==?,
+
tension on the rear drive chain,
R
t
then remove the motor (Fig.
3-19).
3-8.1 Installation
I
Installation is the reverse of removal.
Be sure to use a new o-ring between
the motor and the chaincase. On the
520; SIN 13246 & belo.w and 533;
SIN 11060 & below, use new twelve
point bolts if not installed.
Fig. 3-17 Seal Installation Tool
A-1851
30
.~
)
B·2876 C-2013
Fig. 3-20 Remove End Cap Fig. 3-21 Hydrostatic Motor Breakdown
3-9.2 Assembly
(2) Use a seal installation tool. Install the rubber sealing ring inside the collar of
the tool, with numbered side toward the chamfer (Fig. 3-27).
(3) Put the installation collar into the housing with the chamfer toward the
housing (Fig. 3-27).
(4) Put the installation sleeve into the collar and push the seal into the housing Wiper
(F ig. 3-27). Seal
\
Snap Q Spacer
Ring ------.,~ • _ /
..l..,
Manifold
In~~~::on _I 1
~
,
I
I
<C>
),
Shim
I
Wear Plate
~
Installation
Collar
Rubber Sealing
Ring
(8) Install thrust bearings and Fig. 3-28 Install Thrust Bearings Fig. 3-29 Install Wide Shaft Bearing
races (Fig. 3-28).
Fig. 3-36 Install Stator Ring & Rotor Fig. 3-37 Install Manifold Plate
(20) Install the commutator (Fig.
3-40).
I NOTE: The nuts that hold the steering linkage can become loose (Fig. 3-43,
Item 1). Tighten the nut to 25 - 28 ft.-Ibs. (33,8 - 37,9 Nm) torque. Fig. 3-42 Loosen Pintle Arm Stops
(2) Disconnect the steering levers from the control rod.
(3) Start the engine and run it at idle RPM. Adjust the rear pintle arm first.
Loosen the pintle arm stops (Fig. 3-42, Item 1 I. Adjust the pintle arms (Item 2)
so that the axles do not turn. Slide the stops against the pintle arms and tighten
the bolts.
(4) The centering spring (Fig.
3-44, Item 1) must have enough
force to hold the pintle arms in the
neutral position. Adjustment to the
spring is made by turning the nut
(Item 21.
AWARNING
Be sure that the tires are off the
floor and are not hitting
jackstands.
(6) Check to see that there is no clearance between the bars and the lobes.
Make adjustment if necessary.
(7) Tighten the bolts that hold the steering linkages to the pintle levers to 12
ft.-Ibs. (16 Nm) torque. Install new locknuts on each bolt and tighten to 23 ft.-
Ibs. (31 Nm) torque.
NOTE: The nuts at the front end of steering linkages go toward the center of
machine.
(8) Tighten two bolts at the front end of the steering linkages to 12 ft.-Ibs. (16
Nm) torque.
(9) Install new locknuts on these bolts and tighten to 23 ft.-Ibs. (31 Nm)
torque.
(11) Remove jackstands and lift arm stop and lower lift arms.
Paragraph Page
Number Number
DRIVE
. SYSTEM
The drive chains are endless. (Do not have Front Cover
I
connector links.) A separation of the
cha ins can be made if needed. If chain
separation is necessary, use a new press-on
connector link when installing again. Put
paint on the connector link for future
identification.
Fig. 4-5 Remove Outer Bearing Cone Fig. 4-6 Remove Axle Bearing
(3) The outer and inner bearing
races can be pulled into position by
using a long bolt and washers.
~
(8) Install the spring on the Fig. 4-7 Install Outer Beari!1g
f~i
installation tool (Fig. 4-10).
if pu!.s @~ @
(6) Turn the cam counterclock-
wise with a vice-grip pliers to force
the pucks against the discs.
(7) While holding the pucks
against the discs, align the
transmission cover so that the
discs are centered between the
sprocket teeth.
(8) Align the gasket and install
V
Discs D-1328R
cover bolts and tighten to 20 ft.- Fig. 4-11 Brake Pad Replacement
Ibs. (27 Nm) torque.
(9) Be sure pucks are tight
against discs; then install brake
lever on the cam with the lever as
far clockwise as possible (against the right pump mount).
(10) Install front cover and angle bracket and tighten bolts to 20 ft.-Ibs. (27
Nm) torque (Fig. 4-11, Item 4).
(11) Install bar and bolt on the cam (Fig. 4-11, Item 5) and tighten bolt to 70
ft.-Ibs. (95 Nm) torque.
NOTE: Be sure that the lever and bar are at right angle from each other and that the
bar is parallel with transmission wall (Fig. 4-12).
Paragraph Page
Number Number
MAIN
FRAME
AWARNING '*
~
I
I
I
~
n
Be sure to install holddown bolts
and washers when installing the
ROPS (Fig. 5-21.
D·1369R
8-2801
(4) Use a punch and hammer to
remove the pivot pins. Fig. 5-3 Liftarm Removal
\7
I
-'ClI-D-~ Bushing
./
D-1467
AWARNING
Release the hydraulic pressure Fill in With
and use a good support to hold Weld On
the cylinders and lift arms Corner Openings
before removing any pivot pin. (Both Sides)
B-2791 B·3062
(4) Remove the bolts and Fig. 5-7 Removal of Bob-Tach Fig. 5 - 8 Remove Bob-Tach Pin
c:'~
Hydraulic
Reservoir Tank
Fuel Tank
Reservoir
(533)
System
Paragraph Page
Number Number
ELECTRICAL
SYSTEM
Switch
B·2275
Battery
AWARNING
Before making repairs on the
electrical circuits, disconnect
the battery ground cable.
Generator
Rectifier /Regulator
The 520 and 530 loader has a 12 volt,
1 5 amp. flywheel alternator charge
system. (See figure 6 - 3 and 6 - 4 for
wiring diagrams.) B-2274
The 533 loader has a 12 volt, 37 amp, belt driven alternator charge system. (See
figure 6- 5 for wiring diagram.)
NOTE: If the fuses on your 530 or 533 Bobcat are not in the dash panel, there are
I parts available to put the fuses in the dash panel for better access.
(See your Parts Manual or microfiche for the parts.)
The charts give the correct order for finding problems and making repairs.
520,530,533 Loader
Revised Mar 79 -6-1- Service Manual
Circuit
Breaker
/ AMP
Gauge
Ignition
Hydraulic Pressure
Switch
Switch
/'
-Cr""'- - ~- -')-~1
Transmission
Oil
Hour Meter
Spark
\;"
~ ...
\
\
Engine
Oil
__ ,,,-"pressure
f -----
Eng. Temp.
0-1287
E-1159R
---~
Rear
Light
1
Switch
/
Instru ment Box
Spark Plug
Wire
Ammeter
I
,, I
c_ I
Stator I
I E·1183
- - _1
E·1188
--.~\
Rear
Light
l "
"
"
\). . ~ . J)
"
,/ 0"
Hour Meter
I
i
Hydro Pressure
Switch
Batte~ __________ ~
E-1l66
E-1l88
f!! '. i
! I
I ~!,l
'" m .,
t - , ""'- 80J ~l _
!r~lj[1 J~ ~ ~
-----~:-l
~g
I ,,
,,1 ;"."
~l: 2:
'i
~
' __
o 9i:_Jme 11
~
'Vll-31IHM---'/
r'--:--c;;;'39N't1!lO'i31IH .....
/ ~
~.h
r=--=='="=-=~gt: =~~
:::E
w
l:
o
en
...J
«
o
Ii:
t;
W
...J
W
~"
HAIlNES'.
CONNECTOR
~A~_~~_O" ~'~_"="CCO"-'
I
o _ _ _ __ -~
"'~,
GROUIC)
ENGINE
WATER
TEMPERATURE
" Jrr---r---
I
" -------/.....F()
I rr~----"'::S=':"-;;-~4FJ ALTERNATOR
~,:":,"_ _ _ _ _L
R f f i - - I -_ _ _ _ __
LIGHT
SWITCH
FEEOFOR
FU!;EO ..cCESSORIES
IHORNI
SCHEMATIC
Charge Battery
Completely & Check
Condition With
A Hydrometer
If
-Good·
Check Condition
Of Battery
Terminals & Wiring
And Fuse
- If
Good . Check A.C.
Voltage
(See Sec. 6-3)
- If
Good
.. Install New
Rectifier/
Regulator
If Bad If Bad
I
If Not Correct
t ~
Install New Make Repairs
Install New
Battery As
Stator
Needed
CHART B
STARTER WILL NOT TURN EI\1GII'JE
Check Condition
Of Battery With - If
Good
... Check Wires
For Damage - If
Good
. Connect Jumper
Wire Across
If
- Engine......
r-::, .
Make Repairs
To Starter
A Hydrometer Solenoid (Sec. 6-5) Does Not (Sec. 6-4.3)
Turn
If Bad If Bad
I
If Engine
I
I
Turns If Starter Turns
t t t But Engine
Does Not Turn
Put Charge
In Battery Make Repairs Install New T
Check Charging As Needed Solenoid
System Install New
(See Chart A)
Starter Drive
(Sec. 6-6)
(2) Hold the flywheel with a piece of wood and remove the nut (Fig. 6-9).
(4) Remove the screws that hold the stator (Fig. 6-11).
(5) Install the new stator. Install the flywheel and blower housing. (See Section 8
for correct torque for the flywheel nut.
6-4 STARTER
NOTE: Before checking the starter, be sure the battery has full charge and all electrical
C-2334
connections are good.
(1) Put the machine on iackstands. Remove the wheels. Fig. 6-10 Remove Flywheel
(2) Connect a large wire between the two large terminals on the solenoid (Fig.
6-12).
B-2878 B-2860
(6) Check the commutator (Fig.
6 -16) and check the armature in Fig_ 6-15 Check Brushes Fig_ 6-16 Check Commutator
a growler.
"Bat" connection
"'~H.at 'nd;ca'o,
battery. (Turn th·e engine with the
starter, connect lights, etc.)
ft'
throttle, connect the generator
field to the chassis with a small
screwdriver or wire (Fig. 6-18). Fuse
(4) Check the ammeter. The Starter Switch
indication must be within 10 6-3140R
amperes of the rating mark on the
generator. If the indication is Fig. 6-1Sb Pre-Heat Indicator Installation & Wiring Circuitry
(3) Remove the two bolts that hold the generator in place and remove the
generator.
(1) Put a mark across each housing half for correct alignment during assembly.
(3) Remove the four bolts which hold the case together.
(4) Use a screwdriver to separate each half of the housing (Fig. 6-19). Slide
the rotor out of the housing.
(5) Remove the nuts which hold the three stator wires to the housing. Remove
the stator.
Armature
CORRECT
(1) Make a visual check of the commutator for rough or burned surface and if
necessary, polish with a fine sand paper. Turn the commutator in a lathe if it is
rough or taper wear is over maximum.
Measure the outside diameter of the commutator at several locations with an outside
micrometer and compare the highest micrometer indication with lowest indication to
find the amount of wear. Correction is necessary if the amount of wear is beyond
the value indication for need of servicing.
B-2988
(2) Measure the depth of the undercut mica on the commutator (Fig. 6-27). Fig. 6-28 Armature Insulation Test
Correction is necessary, if the measured values are beyond the value indication for
need of servicing.
Test for insulation between the commutator segments using a growler tester (Fig. B-2990
6-28). If the light of the growler illuminates, the coils are poorly insulated and the
armatu re needs replacement. Fig. 6-29 Armature Coil Short Test
Put the armature on the growler and turn the armature on the growler slowly while
holding a hacksaw blade or a strip of steel over the sections of the armature core
(Fig. 6-29). If there is vibration of the hacksaw blade or a strip of steel, or if it is
pulled, the armature coils are shorted and the armature needs replacement.
Make a continuity test between the commutator sections using a growler (Fig.
6-30). If the light of the growler does not illuminate when the tester wires are
connected across the commutator sections, the coil circuit is open and armature
needs replacement.
B-2989
(1) Measure the insulation resistance between the field coils and yoke, using a
megger meter (Fig. 6-31).
If the test indication shows poor insulation, find the cause for por insulation or
grounding by making the test with the cores removed one at a time.
(2) Make a conductor test on the four field coils using a tester (Fig. 6-32).
If the indication between the coil leads show resistance, replace the field coils. B·2995
(1 ) Check the brushes for wear, damage and broken wires and replace the
parts if defect is found.
Brush information
Check the brushes for broken springs, corrosion, distortion or weak tension.
Replace parts with defects, as necessary .
B·2994
(2) Clean the brush holders to remove carbon and check for insulation
between the brush holders and the mounting plate (Fig. 6-33). Fig. 6 - 32 Field Coil Continuity Test
(1) The magnetic switch is normal if the plunger is pulled hard when 12V
power is applied between the C and M terminals and returns smoothly when the
power is removed.
NOTE: When the starter solenoid is fastened to the engine. vibration can cause
failure. Move the solenoid to the engine mounting frame. Also be sure the
connections on the solenoid have insulation covers.
(1) Check all wires for broken insulation and replace any bad wires.
(2) The electrical connector (between the ROPS and the mainframe) can get
Fig. 6 - 33 Check Brush Holders
corrosion. Put a sealant (water resistant) on the connector before installing.
(See the Parts Manual (or microfiche) for the part number of the sealant).
1Install a support bracket (Fig. 6-34) at the lower through bolt of the starter and the
right front engine mount if there is a failure of the starter mount. (See Parts Book or
Microfiche for correct PIN).
Paragraph Page
Number Number
ENGINE SERVICE
(520, 530)
Engine will not turn with starter. Battery charge low. Increase charge in 'battery, find 6-2
cause for charge loss.
Engine turns with starter, but is Wrong starting procedu reo See Owner's Manual for correct -
difficult to start. procedure.
Ign ition system has defect. Check and make repairs as 7-3
needed.
Engine has little power or runs Defect in ignition system. Make repairs as needed. 7-3
rough.
Ignition system set wrong. Engine Check ignition timing. Operate 7-3
is overloaded. loader with engine at full
throttle.
(1) Remove the sender from the engine and install a pressure gauge in the opening
(Fig. 7-1).
(2) Put the machine on jackstands. Start and run the engine until it is at operating
temperature.
(3) Check the oil pressure at idle RPM. (See Specifications, Section 9, For Correct
Pressure).
(1)
Make adjustment of tappets with
engine cold.
Eart~
-i-i (
modets have acorn nut.
I ADJUSTING
I SCREW
7-2.3 Compression
(4) Turn the engine several times with the starter. Check the gauge. (See
Specifications, Section 9).
7-2.4 Adjustment of the Carburetor
NOTE: Adjustment to the carburetor is to be made only when the ignition system is
correct.
7-2.5 Throttle and Governor Linkage (Fig. 7-4)
Speed Stop
(1) Put the machi ne on jackstands. Screw
(2) Disconnect the throttle linkage between the carburetor and governor arm. Hold
the throttle on the carburetor fully open, and hold the governor arms against the B-2282
stop (F ig. 7 -4). Adjust the length of the throttle linkage so it will fit.
Fig. 7-4 Throttle & Governor Linkage
(4) Start the engine and let it run at idle RPM. Turn the screw for idle adjustment
to get the fastest idle RPM (Fig. 7-6). Then make adjustment of the idle RPM
screw for correct low idle RPM.
(5) Run the engine at full throttle and engage the auxiliary control or move the
Bob·Tach fully back to put a load on the engine. Turn the main fuel adjustment in
or out for smooth engine operation.
(6) Disengage the aux il iary control and check the high ·id Ie RPM. Turn the speed
RPM stop screw to get correct RPM. Fig. 7-5 Throttle Lever Stops
(7) Engage and release the auxiliary control at full engine RPM. If governor action
for engine RPM changes is not smooth, connect the governor spring to a lower hole
on the governor arm. If the engine RPM rapidly becomes slower, move the spring to
a higher hole in governor arm.
(8) If the location of the spring was changed, check the high idle RPM again.
(4) Remove the cover for the timing sight hole (Fig. 7-8) and turn the flywheel
until the "SP" mark is in the timing sight hole. Put a chalk mark on the "SP" mark
on the flywheel.
(5) Start the engine and run it at minimum of 1200 RPM. Use a timing light to
check the alignment of the "SP" mark with the sight hole.
(6) If alignment is not correct, loosen the 2 bolts on the governor and turn the
governor until timing is correct. Stop the engine and tighten the 2 bolts.
(7) Check adjustment of the idle RPM. Fig. 7-7 Adjust Points
7-3.1 Removal
(2) Remove the bolt and two nuts which hold the carburetor to the engine.
Installation is the reverse of removal. Be sure to check adjustment of the linkage and
mixture screws after installation. Use a new gasket. Fig. 7-8 Timing Engine
~ FUEL INLET
~7NEEDLE
(4) Remove the seat from the
& SEAT
carburetor body.
BOWL GASKET
~
(5) Clean all parts thoroughly. Do
not remove the throttle or choke
shafts. BAFFLE
7-3.3 Assembly
PI·1912
(1) Install a new needle and seat assembly in the carburetor body.
(2) Put a new bowl gasket and baffle gasket in position. Put the float in
position to install the float pin.
(3) Turn the carburetor so the bottom is up. The float must be parallel to the
gasket surface of the carburetor body. If it is not, bend the tab on the float to
adjust the float position.
(4) Install the bowl with a new gasket installed on the plug.
NOTE: When gravity flow of fuel to the carburetor continues when the ignition
B-2883
switch is off (All 520 &. 530, SIN 12138 &. 8elow) install the parts for the
fuel shut-off (Solenoid Activated). When the engine continues to run after Fig. 7-10 Remove Points
the switch is turned off (Dieseling), install the carburetor with the "Anti-
Dieseling" solenoid. (The choke linkage must be replaced with a choke
cable kit) (See Parts Manual or Microfiche for Parts).
7-4.1 Removal
(2) Remove screws which hold the governor in position and lift it off the
engine. Remove the shrouding from the right cylinder to reach the lower bolt.
Remove the ignition point cover, ignition points and push rod (Fig. 7 -10).
7-5 ENGINE
(4) Disconnect the fuel line, air filter hose and wire harness.
(5) Fasten a chain or other support to hold the pump assembly and remove the
bolts which hold the pump to the engine adapter.
(6) Remove the bolts which hold the engine block to the engine adapter.
(7) Slide the engine out of the rear of the Bobcat (Weight is approximately 200
Ibs. [100 kgl]).
Installation is the reverse of removal. Be sure to install a new gasket between the
pump and pump drive housing.
7-6.1 Flywheel
Remove the shrourding and the nut from the end of the flywheel. Attach a puller on
the four bolt holes to remove the flywheel from the craankshaft (See Paragraph
6-3.3, Section 6(.
Check the flywheel for broken cooling fins, loose magnets, cracks or keyway
damage. Also check the keyway in the crankshaft for damage.
1 00 not try to replace the ring gear. If the ring gear teeth are damaged, .replace the
complete flywheel. The side with the bevel on the teeth must be toward the engine
(Fig. 7 -13).
Fig. 7 -13 Ring Gear Installation
(6) Grind the valves and seats. Use grinding compound to check that valves are
fitted correctly and seat has correct width.
(2) Remove the bolts which hold the timing cover in position and slide it off the
crankshaft.
(3) When installing the timing cover, note the two special bolts. Install and tighten
these two bolts first (Fig. 7-15).
While the timing cover is off the engine, the gears can be removed. The camshaft gear is
removed by putting a block of wood between the gear teeth and removing the nut from
the camshaft. Then the gear will slide off.
THIRD
Remove the snap ring from the end of the crankshaft and the crankshaft gear will slide HOLE UP
off.
If the oil pump gear is bad, make a replacement of the complete pump.
NOTE: Be sure that the crank and cam gear marks are in alignment (Fig. 7-16). Fig. 7-15 Timing Gear Cover Installation
The relief valve for oil pressure is under Fig. 7 -16 Alignment of the Crank and Cam Gear Marks
the No.1 cylinder (Fig. 7 -17). The oil
pressure is adjusted by loosening the
jam nut and turning the screw with an
allen wrench. Oil pressure is checked
with engine idling and oil at operating
temperature. If the oil pressure can not
be adjusted, either the bearings or the
pump has a defect.
(4) If one or more locations do not have the same clearance, loosen the bolts
and adjust the clearance until all three locations have the same clearance.
(1) After oil pump is installed, do not tighten the mounting bolts.
(2) Mount a dial indicator on the engine (Fig. 7 ~ 16b). Be sure the dial
indicator arm is against one of the gear teeth. Zero the dial indicator.
(3) Adjust the clearance by moving the oil pump backward and forward until
the clearance is between .005" to .009" (0,127 to 0,228 mm), tighten the
mounting bolts.
(4) Check the clearance at two other locations (120 0 from each other) to be
sure the clearance is correct.
(5) If one or more locations do not have the same clearance, loosen the bolts
and adjust the clearance until all three locations have the same clearance.
(1) Remove the engine, flywheel, oilpan, strainer and oil pump.
(2) Put marks on the rods and caps. The caps, rods and pistons must be
installed in the original bores.
NOTE: The notch on the cap and notch on the rod must be together.
(3) Remove the rod bolts and caps and slide the pistons out of the engine (Fig.
7~ 19).
(4) Remove the adapter and bearing plate and the snap ring from the end of the
crankshaft. Slide the bearing plate, with bearing, off the engine.
(5) Slide the crankshaft out of the engine. Be careful to prevent damage to the C-2339
bearing in the engine block.
Fig. 7 ~ 19 Remove Piston & Connecting Rod
520,530,533 Loader
Revised Mar 79 -7~8-
Service Manual
(6) Check the following:
Use a cylinder hone to correct surface on the cylinder walls (Fig. 7-20). Check the
clearance between the piston and cylinder wall. If it is over maximum, check the
book for available sizes.
"" PI1907
If new bearing inserts are installed in block, push the bearing even with outside
Fig. 7 - 20 Using Hone on Cylinder
surface of the block. Be sure oil holes in bearings are in alignment with holes in
block.
Install the new rings on the pistons (Fig. 7-22) (See instructions on ring package.).
The early Kohler engines use connecting rods with 3/8" rod bolts. The later Kohler
engines now use 5/16" rod bolts. The old style connecting rod with the 3/8" bolt
must be tightened to 300 in.-Ibs. (34 Nm( torque. The new style connecting rod
with 5/16" bolt must be tightened to 200 in.-Ibs. (23 Nm) torque.
NOTE: Too much torque on the new style connecting rod bolts will cause seizure
of the connecting rod cap to the crankshaft.
7 - 1 0 CYLINDERHEADS
PI 1904
Use new gaskets, Put the head in position and install the bolts, make sure washers
are used. Tighten bolts to 35 ft.-Ibs. (47.5 Nm) torque in the correct sequence as Fig. 7 - 21 Checking Ring Gap
shown in figure 7-23.
Put heavy flat washerslor spacers on the manifold where the bolts are used to fasten
the manifold and side baffles to engine. Put on the intake and exhaust manifold,
install the bolts and tighten to 25 ft.-Ibs. (33.9 Nm) torque.
1
On all 520 loaders and 530 with (SIN 14119 & Below), a new corrective heat shield
must be installed before any weather enclosure is installed on the RaPS. See Service
Bulletin·#530-005 or current Parts Manual for kit part no. for new corrective heat
shield.
Paragraph Page
Number Number
ENGINE SERVICE
(533)
(4) Disconnect and remove the leak-off tubeline from the injectors.
(5) Remove the oil filter assembly and disconnect the tubeline that gives oil
pressure for the shaft of the rocker arm.
(6) Remove the bolts which hold the timing gear cover and remove the injection
pump (Fig. 8-2).
(9) Remove the bolts from the adjustment plate for the generator and the bolt for
lower mounting and remove the generator.
Remove Injection Pump
(17) Remove the Cover for the rocker arms. Remove the rocker assembly (Fig.
8-4).
NOTE: Turn each bolt in the rocker assembly 1/4 turn at a time until all of the bolts
are loose.
(18) Pull out the push rods and remove the cylinder head and gasket.
NOTE: Turn each bolt in the cylinder head 1/4 turn at a time until all the bolts are
Fig. 8-5 Remove Oil Pan
loose.
(19) Remove the crankcase and the oil pan together (Fig. 8-5).
NOTE: If the crankcase will not come away from the cylinder body, put a screwdriver
into the grooves in the crankcase to remove.
(20) Disconnect the pipe at the connection on the cylinder body side. Remove the
bolts and remove the oil pump assembly from the cylinder body.
(21) Remove the bolts from the thrust plate of the camshaft and remove the
camshaft (Fig. 8-6).
NOTE: 1. When removing the bolts from the bearing caps on the crankshaft, loosen
them evenly, a little amount at a time.
NOTE: 2. Do not cause damage to the oil seal in the cap for the rear bearing.
NOTE: 3. Keep the bearings and bearing caps in order so that each will be installed in
correct location.
Fig. 8-9 Remove the Flywheel
(27) Remove the crankshaft pilot bearing.
(1) Wash and clean all parts to remove dirt, carbon, oil, grease or rust.
(2) Inspect the cylinder body and cylinder head for damage.
(3) Clean all oil openings in the parts with compressed air and check that each
opening is free from restriction.
B-2834
(4) Remove carbon from the pistons, cylinder head and valves carefully, to prevent Fig. 8-10 Remove the Crankshaft
scratches.
(5) Put a cylinder number mark on the valves, bearings, pistons, connecting rods so
that each will be installed in correct location.
8-4.1 Disassembly
(1) Remove the snap ring from each end of the rocker shaft. Remove the springs,
rocker arms, rocker shaft brackets and rocker shaft (F ig. 8-11).
NOTE: Keep the rocker arms from each cylinder separate so that they will be installed
in correct location.
A-2512
(2) Assemble the parts in the Fig. 8-11 Remave the Rocker Arm & Shaft
reverse order of disassembly.
Inspection
NOTE: Put the cylinder number mark on the valves so that each will be installed in the
correct location.
(2) Use a valve spring compressor to remove valve springs and remove the split
collar, valve springs and valve (Fig. 8-15).
(4) Use a tool to force the valve guides out toward the bottom of the cylinder
head (Fig. 8-16).
(6) Put a rod, 1/4" (5-7 mm) diameter, into the nozzle hole in the cylinder head.
Use a hammer to force out the hot plug (Fig. 8-17).
NOTE: 1. Hold rod so that it is against the upper edge of the hole with threads, as
shown in figure 8-17.
(7) Do not hit the hot plug with the rod, or damage to the heat shield can result.
8-5.1 Inspection
(1) Carefully remove carbon from the bottom of the cylinder head. Check the
cylinder head for cracks and damage. (Use a magnetic process for crack detection or
red color check)'
B-3003
NOTE: When removing carbon from the lower face of the cylinder head, be careful to
prevent scratch marks of the valve seat areas. Fig. 8-17 Remove the Hot Plug
(2) Check the lower surface of the cylinder head for distortion, in six directions,
using a straight edge and a feeler gauge. If the amount of distortion is more than
.008" (0.2 mm), correct by grinding so that maximum amount of distortion is
within .0012" (0.05 mm).
(3) Check the joining face of the intake and exhaust manifolds for distortion, in
the same manner as for checking the cylinder head. If the amount of distortion is
more than .016" (0.4 mm), correct by grinding so that maximum amount of
distortion is with in .0012" (0.05 mm).
(1) Remove all carbon from the combustion chambers (Fig. 8-18). Check the heat
A-2521
shield and hot plug holes in the combustion chambers, for damage.
Fig. 8-18 Remove Carbon
L Clearance
8-5.3 Inspection of the Valves and Valve Guides
(1) Check for amount of wear of the valve stems in the valve guides (Fig. 8-19).
(2) Use a micrometer to measure the outside diameter of the valve stems at
locations A, Band C (Fig. 8-20).
PI·2096
NOTE: When cutting the valve seat use Fig. 8-20 Measure Outside Diameter of Valve Stem;
a guide rod of correct diameter.
(9) When valve grinding is complete, check that valve contact width is within the
specifications and that the contact is correctly centered on the valve seat.
NOTE: Too wide contact width will cause carbon deposits between valve and seat. Too
narrow contact width will increase the wear of the parts.
8-5.5 Inspection of the Valve Springs Deviation of valve springs from vertical
(1) Make a visual check of the valve springs for damage. Put the valve spring on a Limit for use (mm) 1.04" (1,0 mm
surface plate and check the amount of deviation of the valve spring from vertical,
using a square. Install a new spring if the amount of deviation from vertical is over
the limit (Fig. 8-26).
(2) Check the tension of the valve springs with a spring tester. Install new valve
springs if the measured value is over the limit (Fig. 8-27).
(2) Check the face of the tappets in contact with the push-rods for wear. Replace
any tappets which have a defect.
Measure the outside diameter of the tappets with a micrometer. Install new tappets P[·2119
if the amount of reduction in the outside diameter is over the limit (Fig. 8-28). Fig. 8-26 Check Valve Springs
(1) Align the round part of the hot plug with the groove in the cylinder head and
install the hot plug into position by
hitting the ci rcumference of the hot
plug, carefully, with a brass hammer.
A·2525
Fig. 8-27 Check Valve Spring Tension Fig. 8-28 Check Valve Tappet
(1) Push the valve guide into position from the upper face of the cylinder head
(Fig. 8-30 & 8-31).
(3) Install the valve springs and valve spring seat. Flush
B-3004
(4) Compress the va Ive springs with the valve spri ng compressor and install the Fig. 8-29 Grind New Hot Plug to Fit
locks for the valve stem.
Fig. 8-31 Install Oil Seal Valve Guide Fig_ 8:-32 Check the Cylinder Block
C: Piston clearance
(3) Measure the cylinder bore diameter after hone operation is complete.
B-3012
NOTE: Cylinder bores, after hone operation, must be held within .0008" (0,02
Fig. 8-33 Remove Piston Snapring
mm) of each other.
8 - 7 . 1 Disassembly
(1) Use a piston ring expander tool to remove the piston rings from the piston.
NOTE: Keep the piston rings separate, in the sequence of the cylinder numbers.
(2) Use a snap ring pliers to remove the piston pin snap rings (Fig. 8 - 33).
(3) Heat the piston to 120 - 140 0 F (50 - 60 0 C) and remove the piston pin (Fig.
8-34).
NOTE: Keep the piston, piston pin and connecting-rod from each cylinder in
separate groups in the sequence of the cylinder numbers, to be sure of Fig. 8-34 Remove Piston Pin
assembly into their original positions.
8 - 7 . 2 Inspection of Pistons
(1) Make a visual check of the pistons for scratch marks, cracks or seizure and
replace any found to have defect.
(2) Use an outside micrometer to measure the outside diameter of the piston at
the base, at a right angle to the piston pin hole. Measure the cylinder bore
diameter at the base of the piston, with a cylinder bore gauge.
Then, compare the measured values to find the piston clearance. The standard
clearance is .004" - .005" (0,104 - 0, 124 mm) at 68 0 F (20 0 C).
NOTE: When installing new piston rings on the pistons without cutting new
cylinder sizes, measure the piston ring gaps with the piston rings held
at the lower point of the cylinder (Fig. 8- 35). Fig. 8-35 Check Piston Ring Gap
(1) Use a feeler gauge to measure the clearance between the piston ring and
ring groove in the piston. Take measurements at several locations around the
circumference ofthe piston (Fig. 8 - 36). (See Specifications Section.)
(1) Heat the piston to about 190 - 250 0 F (70 - 1 20 0 C). Align the small-end
hole of the connecting-rod with the piston pin hole and install the piston pin.
NOTE: Assemble the connecting-rod with the piston so that the side of the
connecting-rod with the cylinder number mark is toward the camshaft side
of the engine.
(2) Install the snap rings. Fig. 8-36 Check Piston Ring Clearance
Fig. 8-36A Piston Ring Arrangement Fig. 8-37 Check Connecting Rod AI ignment
8-7.5 Connecting-Rods
If the amount of wrong alignment or distortion is over the value limit for servicing,
correct or replace the connecting-rod (Fig. 8-37). (See Specifications Section.)
(2) The normal clearance between the piston pin and the small-end bushing is such
that the lubricated piston pin can be pushed into the bushing with finger pressure.
Replace either the piston pin or bushing if the pin fits too loose into the bushing.
(3) Assemble the connecting-rod on the crankshaft and use a feeler gauge to
measure the side clearance between the connecting-rod big-end and the crankpin.
Replace the connecting-rod if the clearance is over the limit (Fig. 8-38).
(4) When a new bushing is fitted into the connecting-rod small-end, make the inner A-2509
face smooth with a reaming tool according to the piston pin diameter.
Fig. 8-39 Check Weight of Piston Assemblies
(5) When installing a new connecting-rod, piston or piston pin, measure the weight
of the replacement parts. Make necessary adjustment by grinding or selection of
parts, so that weight of each piston and connecting-rod assemblies is held within 15
grams of each other (Fig. 8-39).
(1) Check the connecting-rod bearings for wear, poor contact, sign of seizure or
loss of tension and replace if defect is found.
Install the connecting-rod bearing and bearing cap and tighten the bearing cap bolts
to a torque of 58 ft.-Ibs. (79 Nm). Then, measure the inside diameter of the bearing
with a cylinder bore gauge (Fig. 8-40).
B-2991
(2) If the oil clearance has increased because of wear in the crank pins, have the
crankpins cut to a smaller size and install smaller size connecting-rod bearings. Fig. 8-40 Measure Rod Bearing
(1) Wipe and clean the bearings and crankpins to remove dust and oil.
(2) Install a piece of plasti-gauge over the crankpin or bearing in the direction of
the axis of the crankshaft.
(3) Install the connecting-rod bearing cap and tighten the bearing cap bolts to the
correct torque.
NOTE: Do not move the crankshaft or connecting-rods when making this check.
Remove flattened plasti-gauge and check width of plasti-gauge against the scale
printed on the instructions (Fig. 8-41 I.
NOTE: 1. Never try to file the bearings or install shims to adjust the oil clearance.
NOTE: 2. Check that the oil clearance is within specifications before installing the
piston and connecting-rod.
NOTE: 3. Have the crankpins cut to size indicated in the specifications section when
installing smaller size bearings.
(1) Check the crankshaft bearings and install them using the same method as used
for installing connecting-rod bearings.
(2) Have the crank journals ground to size indicated in specifications section when
installing smaller size bearings.
8-8.1 Crankshaft
(1) Visually check the crank journals, crankpins and oil seal fitting faces for
damage or wear and check the oil passages for restriction.
(2) Use a micrometer to measure the outside diameter of the crank journals and
crankpins. Take measurements at several locations on the crank journals and
crankpins to find the amount of wear (Fig. 8-421. Fig. 8-42 Check Crank Journals
If the amount of wear is more than .002" (0,05 mm), have the crank journals and
crankpins cut to size indicated in the specifications section and· install smaller size
bearings.
(3) Check the crankshaft for axial alignment and correct if the amount measured is
beyond the amount indicating a need for servicing (Fig. 8-431. (See Specifications
Section.)
2) Slowly turn the crankshaft one full turn and read the dial indicator.
(4) Use a feeler gauge to check the crankshaft thrust clearance at the center
bearing. If the measured value is over the limit, install oversize thrust bearing. (See
Specifications Section.)
NOTE: Install the thrust bearing so that the side with the oil groove is toward the
crankshaft thrust face. Fig. 8-43 Check for Axial Alignment
(1) Check the ring gear for wear or damage. If wear to the ring gear teeth is in
one area, the ring gear may be removed, turn 180 0 degrees and installed again. Heat
is used to fit the ring gear to the flywheel, and it can be removed or installed again
by heating.
8-10 CAMSHAFT
(1) Check the camshaft journals, cam lobes and oil pump drive gear for wear or
damage.
Replace the camshaft if the amount of reduction in the height of cam lobes is over Fig. 8-44 Check Camshaft Journal
the limit or if cam surfaces are found to have bad damage. Small scratch marked on
the cam surfaces can be removed with polishing stone.
(3) Use a micrometer to measure the diameter of the camshaft journals (See
Specifications Section.)
Replace the camshaft if the amount of wear is over the value indicating need for
servicing (F ig. 8-44).
(4) Measure the camshaft end play with a feeler gauge. Install a new thrust plate if
the measured value is over the value indicating need for servicing (See Specifications
Section).
(1) Check the timing gears for wear and damage. Replace the timing gears if any
defect is found.
(2) Measure the clearance between the timing gears, using a feeler gauge or dial
indicator. Replace the timing gears if the amount of clearance is over maximum
specifications.
(1) Check the intake manifold for cracks, corrosion or damage. Correct or replace
the manifold as necessary.
(2) Check contact surfaces of the intake and exhaust manifolds for distortion.
Replace the part or correct by grinding if the amount of distortion is over the limit
for servicing. (See Specifications.)
(1) Wash and clean disassembled parts, such as, the oil ports, bearings, pistons,
cylinders, etc.
(2) Put engine oil on the cylinder walls and the bearings and pistons.
(3) Install new gaskets at the time of assembly. Use a liquid gasket where it is
necessary to prevent oil leakage.
(4) Check the oil clearances and other clearances when assembling the parts.
(1) Install the upper half of the crankshaft bearing and thrust bearings on the
cylinder block (Fig. 8-46).
NOTE: Install the thrust bearings so that the side with the oil groove is away from the
crankshaft bearing.
(2) Put a thin layer of sealant on the connecting areas of the No. 1 and No. 3
bearing caps. Install the bearing caps.
(3) Install and tighten the bolts in the bearing caps to the specified torque.
(4) When the crankshaft is correctly installed, check the crankshaft for correct end
clearance (See Specifications). Fig. 8-46 Install Crankshaft Bearings
(5) Install the gasket on the No. 1 and No. 3 bearing caps. Put sealant on the
inner surface of the gasket and install the gasket ev~nly into the groove in the
bearing cap. Hold it with fingers for about 5 minutes (Fig. 8-47). Be sure the
gasket is 0 . 0.002 inch (0-0,05
mm) beyond the end of the bearing
cap.
(10) Use a piston ring compressor tool to install the piston and connecting-rod
assembly. The front mark on top of the piston must be toward the water pump end
of the engine.
NOTE: The piston and connecting-rod assemblies must be installed so that the cylinder
number mark (on the connecting-rod) is toward the camshaft side.
(11) Install and tighten the connecting-rod bearing cap bolts to specifications, Then,
check connecting-rod end clearance. (See Specifications Section.)
NOTE: When the cap bolts for the connecting-rod bearings are tightened, check that the
crankshaft turns smoothly.
NOTE: Before installing, put cement on the surface of the engine front plate in contact
with the cylinder body and injection pump and put the gasket in place.
(13) Install the tappets into position from the oil pan side, Fig. 8-48 Install the Flywheel
520, 530, 533 Loader
-8-12- Service Manual
NOTE: Put engine oil on the tappets
and install them before installing
the camshaft.
NOTE: Put engine oil on the cylinder head bolts before installation.
(20) Connect the oil tube line for the rocker shaft.
NOTE: Valve clearance adjustment is made with the engine cold. (See Specifications
Section). Fig. 8-51 Install Cylinder Head
[1] Turn the engine and stop it when the exhaust valve on the No.2 cylinder is ready
to open. [2] Align the Top-mark on the crank sheave with the pointer on the timing gear
cover. (Piston in the No. 1 cylinder is now at the top center [TOC] on the compression
stroke.)
[3] Hold the engine stationary and adjust the intake and exhaust valve clearances on the
No.1 cylinder. [4] Adjust the intake valve on the No.2 cylinder.
[5] Turn the crankshaft one complete revolution so that the piston of the No.2 cylinder
is at the bottom center on the intake stroke. [6] Hold the engine stationary and adjust
the exhaust valve clearance on the No.2 cylinder.
(24) Install the crankshaft front oil seal on the timing gear cover and fasten the
cover with screws.
NOTE: Fill the space between the lips of oil seal with grease before installing the oil
seal.
(25) Install the injection pump and fasten it with the long bolts for the timing gear
cover. Fig. 8-52 Timing Injection Pump
NOTE: Align the mark "z" on the injection pump gear with the mark "z" on the
camshaft gear and install the cover (Fig. 8-52).
(26) Install the crankshaft sheave on the crankshaft and tighten the bolt. Bend part
of the washer over the head of the bolt.
NOTE: Put a thin layer of oil on the counterbore for the oil seal on the sheave, before
install ing the sheave.
(27) Install the injection nozzles and tighten the bolts to one-half the specified
torque.
NOTE: 1. Use corrugated washer and nozzle washer when installing the injection
nozzles. Corrugated washer must be so installed that the side of the washer with
the groove is up (Toward Nozzle) (Fig. 8-53).
2. Turn the nozzles so that the injection pipe connection is down. Nozzle assy
- Nozzle washer
. Corrugate washer
(28) Install the rocker arm cover. Heat shield
Hot J>lug
(29) Install the manifold gasket and muffler/manifold. Install the lifting hook at the
J-
rear end of engine.
(30) Install the thermostat and thermostat housing. Fasten the thermostat housing
and lifting hook with the bolts.
PI-2082
(31) Install the water pump assembly.
Fig. 8-53 Install Injection Nozzles
(32) Install the blower.
(33) Install the generator fastening bracket and the coolant temperature switch.
Install the generator and bolts. 3/16" (5 mm)
(34) Install the belt for the generator and water pump. Adjust the belt tension for
1/4" (5 mm) movement and tighten the generator bolts (Fig. 8-54).
(35) Install "0" ring on the oil filter and fasten the oil filter assembly to the
cylinder block.
(36) Connect the Injection tubelines and tighten the fastening bolts for the injection
nozzles to the correct torque. (See "Specifications", Section 9.)
J
(1) Disconnect the oil pipe (Fig.
8-55A).
8-14.1 Inspection
8-15.2 Inspection
(2) To check the relief valve opening pressure, proceed as follows: Connect a
pressure gauge to the oil gallery at a point closest to the oil filter and check valve
opening pressure with engine running.
Narne of Parts
(1) Remove the rear cover from the body and loosen the bearing setscrew (Fig.
8-61).
(3) Remove the shaft and impeller from the body using a bench press (Fig. 8-63).
NOTE: The impeller is made of cast iron. Do not use hammer to remove it.
8-16.2 Inspection
(1) Check the disassembled parts for wear, cracks or other damage and replace the Fig. 8-62 Remove Pulley Center
pump if defect is found.
(3) Check for loose bearing unit. Replace the bearing unit if the bearing unit is
loose by more than .008" (0,2 mm).
(1) Install the thrower (Item 6) and seal unit (Item 7) on the bearing seat location
on the shaft.
NOTE: Install the seal unit so that the side with the spring is toward the impeller.
(2) Install the shaft in the water pump body from the pulley side. Use a bench
A·2528
press and align the screw hole in the water pump body with screw hole for the
outer bearing race (Fig. 8-64). Fig. 8-63 Remove Shaft and Impeller
520, 530, 533 Loader
-8-16- Service Manual
(3) Use a be nch press to install the
impeller on the shaft.
b. St a nd ard clearance
between outer circumference
of the impeller and pump
body is .047 - .051" 0,2-1,3
A-2523
mm) (Fig. 8-65). B-2999
Fig. 8-64 Install Pump Impeller Shaft Fig. 8-65 Impeller & Pump Body Clearance
(4) Use a bench press to install the
pulley center (Fig. 8-66).
The nozzles have an injection orifice size Fig. 8-66 Install Pulley Center
of .039" (1 mm) in diameter and have
the spray angle of 4 0 degrees. Fuel
injection pressure (breaking pressure) is set to 1720 PSI (11860 kPa) by an adjustment
screw (Fig. 8-68, Item 5).
(2) Use a wrench to remove the nozzle holder and nozzle assembly.
(1) Install the nozzle on a nozzle tester and put pressure of 1435 PSI (9880 kPa)
continuously and check for sign of leakage (F ig. 8-67).
(2) Increase the testing pressure to 4300 PSI (29640 kPa) by turning the
adjustment screw in and check the time taken for pressure to decrease from 3580
PSI (24700 kPa) to 2860 PSI (19760 kPa).
A-2513
If the time is less than 5 seconds, install new nozzle assembly. Fig. 8-67 Testing Nozzle
(1) Wash the needle valve and nozzle body in kerosene or diesel fuel. Tilt the
nozzle body to an angle of 60 0 from vertical and check that the need Ie valve sl ides
out smoothly. If the needle valve is not free or if its sliding movement is very
loose, replace the nozzle assembly.
a. Check the seat area and the tip on the need Ie valve for wear. Replace the
nozzle if it is worn. Fig. 8-69 Remove Injector Fuel Lines
a. Check the thread areas of the nozzle holders for wear or damage. Replace the
nozzle assembly if a defect is found.
c. Check the push·rods for bending and the surface in contact with the needle
valve for wear and magnet effect.
d. Check the upper surface and needle valve seat area on the nozzle body for
wear or scratch marks.
Assemble the nozzle in the reverse order of disassembly and note the following: Fig. 8-70 Remove Injection Pump
(1) Wipe and clean the contact areas of the nozzle and body of the nozzle holder
to remove any oil. Install the nozzle into the body of the nozzle holder and tighten
the nozzle nut.
(1) Remove the fuel supply line and high pressure tubelines to the injectors (Fig. 8-69).
(2) Remove the six bolts which hold the injection pump to the engine. (These bolts
are on the timing gear cover).
(1) Remove the nut and lockwasher from the injection pump shaft (F ig. 8-71).
(1) Insert the key and align the key groove on the gear with the key groove on
the pump shaft when installing the gear.
(2) Install the lockwasher and nut. Tighten the nut to 40 ft.·lbs. (54 Nm) torque.
B·2979
8-18.4 Installation and Timing of Injection Pump
Fig. 8-71 Remove Pump Drive Gear
(1) Remove the cover from the hole for visual timing of the injection pump gear
(Fig. 8-72).
(2) Install the injection pump and gear so that the "Z" marked tooth on the
pump gear is between the two "Z" marked teeth on the camshaft gear.
(3) Tighten the fastening bolts for the injection pump to 12 ft.-Ibs. (16 Nm)
torque.
(4) Check to see that the timing mark on the pump flange (Fig. 8-73) is in
alignment with the mark on the pump mounting bracket. If the marks are not in
alignment, loosen the three fastening nuts and turn the pump to adjust until marks
are in correct alignment.
A·2506
Paragraph Page
Number Number
TECHNICAL
DATA
Gasoline Engine - Regular or low-lead gasoline with minimum octane rating of 85.
Diesel Engine - #2 Diesel fuel. Use No. 1 Diesel fuel in temp. below + 20F (-6C).
9-2 LUBRICANTS
-34 -29 -23 -18 -13 -7 -1 +4 +10 +15 +21 +27 +32 +38
FO -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
-34 -29 -23 -18 -13 -7 -1 +4 +10 +15 +21 +27 +32 +38
FO -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
If the system oil level is low or the oil is being changed, use 10W-30 or 10W-40 engine
oil (Classification SE) oil when filling the reservoir.
9-2.4 Chaincase
/
/
,/,-~I
I
'"
970
t
127.5
,'" ~:/:Z~t;.~.,r--' ", (3238)
'~'1-_-_-__-_-_-_'-';_;-=...-_7---,
, I
, I
72.5
(1841)
(1199)
PI·1BS7
PI·1857
Dimensions are given for loader equipped with dirt Where applicable,
bucket and may vary with other bucket types. All specifications conform to
dimensions are shown in inches. Respective metric ICED & SAE standards
dimensions are given in millimeters enclosed by and are subject to change
parentheses. without notice.
9-3.1 Operating Specifications Bore and Stroke . . . . . . . . 3.5 x 3" Cylinders . Doubleacting
(88,0 x 76,2 mm)
Operating Weight . 3075 Ibs. (1396 kg) Displacement .. . 57.7 in. 3 (946 cm 3 ) Function Tilt Lift
Rated Capacity. .. 800 Ibs. (363 kg) Cooling System . . . . . . . Forced Air Bore 3.0 (76,20) 2.G (50,80)
Cycle Times: Air Filter . . . . . Replaceable dry type Stroke 12.4 (314,96) 22.2 (563,88)
Lift ... .4.0 sec. Crankcase Ventilation .. Internal Breathing Rod 1.50 (38,10) 1.25 (31,75)
Lower .. . 3.0 sec.
Tilt ... .2.5 sec. 9-3.3 ELECTRICAL 9-3.5 POWER TRAIN
Rollback .. 2.0 sec.
Travel Speed .0 - 5.5 MPH (8,9 Km/hr) Generator ... 15 amp. flywheel generator Transmission ... Both sides independent.
Controls: with external rectifier Infinitely variable hydrostatic
Vehicle .. . Steering, direction, speed Starter ... 12 volt gear drive with remote primary drive. Single chain reduction
controlled by two hand levers. R.H. lever solenoid fi nal drive.
moves sideways to control auxiliary Fuses. . 2, 30 ampere, on the dash panel
hydraulic circuit. & at coil 9-3.6 CAPACITIES
Loader . . . . . . Hydraulic lift and tilt Battery. . . . . . . . . . . . . . . . . 12 vo It
controlled by left and right foot Circuit Breaker .. On indicator lamps and Fuel Tank . . . . . . · . . . . 10 gal. (38 L)
pedals. hr. meter Chaincase · . . . . .4 gal. (15 L)
9-3.4 HYDRAULIC SYSTEM Hydraulic Reservoir .3.5 gal. (System: 5.5
gal. [21L])
Pump . . . . . . . Engine driven vane-type Engine Oil · .... .4 qt. (3,8 L)
9-3.2 ENGINE System Design . Series - open center valve
System Release Pressure . . . . . 1500 psi 9-3.7 TIRES
Make and Model . . . . . . . . Kohler K582 (10343 kPa)
Type . . . . . . . . . . .2 cylinder, opposed Pump Volume, @ 2500 RPM .. 8.33 gpm Standard.. .5.70 x 15,55 psi (379 kPa)
Fuel . Leaded or non-leaded gasoline with (32 l/min.) Flotation.. . . . . . 8.50 x 15,33 . 37 psi
minimum octane rating of 85 Hydrostatic Charge Pressure .. 55 - 75 psi (240 kPa)
Horsepower . . . . . . . 19 Bhp (14,3 Kw) (379 - 517 kPa)
at 2500 RPM Filters .. 10 micron for hydrostatic drive.
Maximum Torque .40.8 ft.-Ibs. (55,3 Nm) Filter screen in reservoir fill for
at 2200 RPM hydraulic system.
~1------~4
/ / 1
/ 1
_ 1,'-_,
1
127.5
~'::r:-o.~/! " (3238)
"~I '
' ..- - - - - I - - J
" , \
\
"~)-:------r~~
1
72.5
85
(2159)
(1841)
PI·2218
Dimensions are given for loader equipped with dirt Where applicable,
bucket. And may vary with other bucket types. All specifications conform to
dimensions are shown in inches. Respective metric ICED & SAE standards
dimensions are given in millimeters enclosed by and are subject to change
parent heses. without notice.
9-4.1 Operating Specifications Maximum Torque ... 40 ft.-Ibs. (54 Nm) Cylinders ... Doubleacting
at 2000 RPM
Operating Weight .. 3300 Ibs. (1500 kg) Bore and Stroke . . . . . . . 3.38 x 3.30" Function Tilt Lift
Rated Capacity . . . . . . 800 Ibs. (363 kg) (86 x 83 mm) Bore 3.0 (76,20) 2.0 (50,80)
Cycle Time: Displacement . . . . . . . . . 60 in. 3 (1 L) Stroke 12.4 (314,96) 22.2 (563,88)
Lift . . . . . . . . . . . . . . . . . 4.0 sec. Cooling System . . . . . . . . . . . . Liquid Rod 1.50 (38,10) 1.25 (31,75)
Lower . . . . . . . . . . . . . . . . 3.0 sec. Air Filter . . . . . . . Replaceable dry type
Tilt . . . . . . . . . . . . . . . . . 2.5 sec. Crankcase Ventilation . External Breathing 9-4.5 POWER TRAIN
Rollback . . . . . . . . . . . . . . 2.0 sec.
Travel Speed .. 0 - 5.5 MPH (8,9 Km/hr) 9-4.3 ELECTRICAL Transmission ... Both sides independent.
Controls: I nfinitely variable hydrostatic
Vehicle . . . . Steering, direction, speed Generator . . . . . . . . . 37 ampere, open primary drive. Single chain reduction
controlled by two hand levers. R.H. lever Starter . . . . . . . . . . . 12 volt gear drive final drive.
moves sideways to control auxiliary Battery . . . . . . . . . . . . . . . . 12 volt
hydraulic circuit. Fuse . . . . . . . . . . . . . . On dash panel 9-4.6 CAPACITIES
Loader . . . . . . Hydraulic lift and tilt
controlled by left and right foot Fuel Tank . . . . . . . . . . 11 gal. (41,6 L)
pedals. 9-4.4 HYDRAULIC SYSTEM Chaincase . . . . . . . . . . . .4 gal. (15 L)
Hydraulic Reservoir . . . . . . . 3.5 (13 L)
Pump . . . . . . . Engine driven vane-type (System: 5.5 gal. [21 LJ)
System Design . Series - open center valve Engine 0 il . . . . . . . . . . 4 qts. (3,8 L)
System Release Pressure . . . . 1500 psi Cooling System . . . . . . 10 qts. (94,6 L)
(10343 kPa)
9-4.2 ENGINE Pump Volume, @ 2500 RPM .. 8.33 gpm 9-4.7 TIRES
(32 l/min.)
Make and Model . . . . . . . ISUZU 2AA 1 Hydrostatic Charge Pressure .. 55 - 75 psi Standard . . . . 5.70 x 15,55 psi (379 kPa)
Type . . . . . . . . 2 cylinder diesei engine (379 - 517 kPa) Flotation . . . . . . . . 8.50 x 15,33-37 psi
Fuel . . . . . . . . . . . . . . . . #2 Diesel Filters .. 10 micron for hydrostatic drive. (240 kPa)
Horsepower . . . . . . . . 19 Bhp (14 Kw) Filter screen in reservoir fill for
at 2500 RPM hydraulic system.
The following special torque specs must be used on the 520, 530 & 533 loaders:
I
Pum p High Pressure "Banjo" Fittinqs
(HollowScrew) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150ft.-lbs. (203Nm)
I
Cylinder Head Bolts . . . . . . . . . . . . .
* * Lightly oiled treads
35 ft.-Ibs. (47,5 Nm)
520,530,533 Loader
Revised July 79 -9-4- Service Manual
9-11 SEAL INSTALLING TOOLS
9-12.1 Engine
INCHES MILLIMETERS
9-12.3 Crankshaft
9-12.4 Camshaft
9-13.1 Cylinder Compression (@ 250 RPM) . . . . (Minimum) 284 PSI (1945 kPa)
9-13.2 Valves
9-13.7 Generator:
Valve Clearances
Intake and Exhaust (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . .018" (,45 mm)
Intake 1.575" - 1.576" (40 - 40,03 mm) 1.579" - 1.580" (40,11 - 40,13 mm)
Exhaust 1.339" - 1.340" (34 - 34,03 mm) 1.343" - 1.344" (34,11 - 34,13 mm)
Alignment between big end and small end (Per 3.94" [100 mml)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below .002" (,05 mm)
Limit for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . above .006" (,15 mm)
Crankshaft Run-Out
Standard . . . . . . . . . . . . . . . . . . . · . . . . . . below .001" (,03 mm)
Limit for use . . . . . . . . . . . . . . . . · . . . . . . above .002" (,06 mm)
9-13.15 Camshaft
Face Distortion
Standard ... .002" (.05 mm)
Limit for use . .008" (.2 mm)
For standard fasteners on the loader use the following chart of general torque specs (Page
9-10).
The following table shows standard torque specifications for bolts with zinc phosphate
coating. Bolts purchased from Clark that have zinc phosphate coating are specified by the
letter "H" following the part number.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
e 5/32
7/64 - .109375- 2.778
.1250 - 3.175
9/64 - .140625- 3.572
.15625 - 3.969
e 21/32
39/64- .609375-15.478
41/64 -
.6250 -15.875
.640625-16.272
.65625 -16.669
11/64- .171875- 4.366 43/64- .671875-17.066
3/16 .1875 - 4.762 11/16 .6875 -17.462
13/64- .203125- 5.159 45/64- .703125-17.859
7/32 .21875 - 5.556 23/32 .71875 -18.256
e 9/32
15/64 - .234375- 5.953
.2500 - 6.350
17164 - .265625- 6.747
.28125 - 7.144
19/64- .296875- 7.541
e 25/32
47/64- .734375-18.653
.7500 -19.050
49/64- .765625-19.447
.78125 -19.844
51/64- .796875-20.241
5/16 .3125 - 7.938 13/16 .8125 -20.638
21/64 - .328125- 8.334 53/64 - .828125-21.034
11/32 .34375 - 8.731
e
27/32 .84375 -21.431
13/32
23/64 - .359375- 9.128
.3750 - 9.525
25/64 - .390625- 9.922
.40625 -10.319
27/64- .421875-10.716
e 29/32
55/64- .859375-21.828
.8750 -22.225
57/64 - .890625-22.622
.90625 -23.019
59/64 - .921875-23.416
7/18 .4375 -11.112 15/16 .9375 -23.812
29/64 - .453125-11.509 61/64 - .953125-24.209
15/32 .46875 -11.906 31/32 .96875 -24.606
e 1 mm =
31/64 - .484375-12.303
.03937"
.5000 -12.700
0 .001" =
63/64- .984375-25.003
.0254 mm
1.000 -25.400
Page
Number
ALPHABETICAL INDEX 10-1,10-2
ALPHABETICAL
INDEX
20 MARCH 79
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER
Product ATTENTION
520 AND 530 SERIES
6556407 (10-78)
PROBLEM:
CAUSE:
The shuttle pin (PIN 6512304) is too short and the edge of the case drain port can
hold it in an open or closed position.
CORRECTION:
Remove the motor from the loader (Make reference to the Service Manual). Remove
the shuttle pin from the motor housing. Measure the pin length. The minimum length
is 1.455 inches (36,95 mm) and the maximum length is 1.495 inches (37,97 mm).
Replace the shuttle pin when it is not in this specification range.
Put the revised pages in your 520, 530 and 533 Service Manual (PIN 6556407
[10-78]).
REMOVE PUT IN
POLICY:
Melroe will give compensation for the part (PIN 6512304) and labor which is
needed to repair the loaders in warranty which have had a failure due to the shuttle
pin.
EXPIRATION DATE:
31 Dec. 79
BUL~TUS
Refer To
Bulletin No.ls) Printed in U.S.A. NON CURRENT D-
W
• bobcat
__.... _ .. _!;i;30~.J)Q~
Buil€ltln
24 APRIL 79
Di:lte
-SERVICE BULLETIN-
ROUTE TO
Product BOBCAT LOADER
...................• -.~-~~.~. ATTENTION
Mode! 530 & 533
----
..- - -.•.
6556407
PROBLEM:
CAUSE:
CORRECTION:
This Service Bulletin includes one page which is to be put in the 520, 530 & 5S3
Service Manual (6556407 [10-78]).
REMOVE PUT IN
POLICY:
This kit is available ,as a DealerlCustomer option only. Melroe will not give warranty
compensation for parts or labor.
-SERVICE BULLETIN-
ROUTE TO
. BOBCAT LOADER ATTENTION
6556407
The attached pages are a revision to the 520, 530 and 533 Service Manual (PIN
6556407 [10-78)). There are 24 pages to this bulletin, be sure you have them all.
The list of the following Service Bulletins have been added or are in the Service
Manual.
Remove the following pages in the Service Manual and put in the revised or added
pages, on the back of this page:
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER
ATTENTION
520, 530 and 533
SALES MANAGER
The attached pages are a revision to the 520, 530 and 533 Service Manual (PIN
6556407 [10-78). There are three pages to this Service Bulletin.
Remove the following pages in the Service Manual and put in the revised pages.
Remove Put In
.. SERVICE BULLETIN"
SAFETY NOTICE
ROUTE TO
BOBCAT LOADER
ATTENTION
520, 530
PROBLEM:
Poisonous engine exhaust gases with carbon monoxide accumulate in operator com-
partment if the operator compartment is enclosed. This problem was identified by a
Warning Notice of 19 Oct. 79 mailed to owners.
CAUSE:
Original heat shield allows excess exhaust gases to blow towards operator space
which is not adequately ventilated if operator compartment is enclosed.
CORRECTION:
Never use loader with enclosed operator enclosure unless corrective shield kit (PIN
6561963) is installed. Order kit from Chicago Central Parts. Install warning decal
(PIN 6561960), which is supplied with kit, on upper left side of loader panel behind
seat. After corrective shield is installed put correction notice decal (PIN 6561961),
supplied with kit, on the warning decal.
POLICY:
Melroe will give warranty compensation for cost of parts and 4 hours labor for in-
stallation of the new heat shield on machine serial numbers listed above with any
type of weather enclosure installed.
The attached page is a revision to the 520, 530, 533 Service Manual (PIN
6556407 [10-78)).
REMOVE PUT IN
Refer To
Bulletin No.ls)
Printed in U.S.A.
BULLETIN STATUS
NON CURRENT o
CUARK Melroe
Division ~( 530-006
"bobcat
29 JANUARY 80
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER ATTENTION
520 AND 530 SERIES
........................................................
6556407
PROBLEM:
Not enough oil flow through the quick-couplers (high back pressure, slow operation
of the attachment).
CAUSE:
CORRECTION:
Remove the male quick-coupler and adaptor and cut the "taper" from the end of the
adaptor (See Page 2-10, Fig. 2-30),
This Service Bulletin includes one page which is to be put in the 520, 530 & 533
Service Manual (6556704 [10-78]).
REMOVE PUT IN
2-9 2 - 9, Added 2 - 1 0
POLICY:
Melroe will give warranty compensation for 112 hour labor to remove the "taper"
from the adaptor.
EXPIRATION DATE:
31 May 1980
26 FEBRUARY 80
-SERVICE BULLETIN-
AFFECT!
ROUTE TO
BOBCAT LOADER ATTENTION
Mode! 520 & 530
'ocl
6556407
o
su SUPPORT BRACKET FOR THE STARTER
PROBLEM:
CAUSE:
CORRECTION:
Install the support bracket (PIN 6561936). Fasten the support bracket to the lower
through bolt on the starter and the right front engine mounting bolt. (See Page
6~ 14, Fig. 6~34).
The attached pages are a revision to the 520, 530 & 533 Service Manual
(6556407 [10-78]).
Remove the following pages in the Service Manual and put in the revised or added
pages.
REMOVE PUT IN
POLICY:
Melroe will give warranty compensation for the part (PIN 6561936) and flat rate
labor for Bobcats which have starter failure within 1 year from date of delivery to the
original owner.
EXPIRATION DATE:
31 DECEMBER 80
BULLETIN STATUS
Refer To
Bulletin No.ls) Printed in U.S.A. NON CURRENT D
Melroe
Division ~(
"bobcat
28 OCTOBER 80
-SERVICE BULLETIN-
ROUTE TO
BOBCAT LOADER ATTENTION
520, 530
PROBLEM:
CAUSE:
CORRECTION:
Replace carburetor 6512225 with carburetor 6514854 which has a fuel shut off
solenoid.
Replace the rod controlled choke linkage with a cable controlled choke (Kit PIN
65619961.
The fuel solenoid carburetor has the choke lever on the left side and cannot be
connected to the rod controlled choke linkage.
The cable controlled choke will fully open and close the choke and give better
assistance in cold weather starting.
The cable controlled choke cannot be installed on machines with carburetor part
number 6512225 installed because the choke lever is on the right side of the
carburetor, and will result in interference with the governor control.
The attached pages are a revision to the 520, 530 & 533 Service Manual (P/N
6556407 [10-7811.
Remove the following pages in the Service Manual and put in the revised pages.
REMOVE PUT IN
POLICY:
Melroe offers this for installation at the dealer/customer option and will not give
warranty compensation for parts or labor.
BULLETIN STATUS
Refer To
Bulletin No.(s) Printed in U.S.A. NON CURRENT D
MELROE
INGERSOLL-RAND
SERVICE MANUAL
-- r ., bobcat ®
530-9
Revision Number
10 September 1996
Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER 0
SERVICE MANAGER 00
Model __~5=2=W~53~0~/5~3~3~________________________ SALES MANAGER 0
Manual No. 6556407 (10-78)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 520,530,533 Service Manual PIN 6556407.
Take out the pages shown and put in the revised pages as follows:
TAKEOUT PUTIN
Prinh>rt in I I !'-.