~

,
I

Service

Manual

 MAINTENANCE SAFETY
( Instructions are necessary before operating or servicing machine. Read
and understand the Operation & Maintenance Manuar, Handbook and
signs (decals) on machine. Follow warnings and instructions in the
manuals when making repairs, adjustmenfs or servicing. Check for
correct function after adjustmenfs, repairs or service. Untrained
operators and failure to foUow instructions can cause injury or death.
W-2003-0199

A Safety Alert Symbol: This symbol with a warning statement, means: "Warning, be alert! Your safety is
_----------in-v-o-lv--,ed!" Carefully read the message that follows. r------------"""'"I
CORRECT CORRECT
- ~ \\ \ I, / I 1/ /
/

EH0731 ~12365 ~7469

Never service the Bobcat® Skid Use the correct procedure to lift or A Cleaning and maintenance are
Steer Loader without lower operator cab. required daily.
Instructions.

G WRONG

~11799 ~1523 1 ~1 52 80

Have good ventilation when

A welding or grinding painted parts.
A Disconnecting or 100senln9. any
hydraulic tubeline, hose, fitting,
A Never work on loader with lift
arms up unless lift arms are held
...Wear dust mask when grinding component or a part failure can by an approved lift arm support
painted parts. Toxic dust and gas cause 11ft arms to drop. Do not go A device. Replace If damaged.
A can be produced. under lift arms when raised ...Never modify equipment or add
... Avoid exhaust fume leaks which unless supported by an approved attachments not approved by
can kill without warning. Exhaust lift arm support deVice. Replace if Melroe Company.
system must be tightly sealed. damaged.
WRONG

8-6590 ~65 89

A Stop, cool
flammable
and clean engine of
materials before
A Keep body, jewelry and clothing A Lead-acid batteries produce
away from moving parts, A flammable and explosive gases.
A checking fluids. electrical contacts, hot parts and ... Keep arcs, sparks, flames and
... Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless
A Instructed to do so In the manual.
A Wear eye protection to guard
from battery acid, compressed
A batteries.
... Batteries
contain acid which
... Avoid contact with leaking springs, fluids under pressure burns eyes or skin on contact.
hydraulic fluid or diesel fuel and flying debris when engines Wear protective clothing. If acid
under pressure. It can penetrate are running or tools are used. Use contacts body, flush well with
A the skin or eyes. eye protection approved for type water. For er.e contact flush well
... Never
fill fuel tank with engine of welding . and get mmedlate medical
running, while smoking or when A Keep rear door closed except for attention.
near open flame. service. Close and latch door
( before operating the loader.
Maintenance procedures which are ~iven in the Operation & Maintenance Manual can be performed by
the owner/operator without any speCific technical training. Maintenance procedures which are not in the
Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE
PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course
is available from your Bobcat dealer. MSW01-o299
 FORE WOR D
PREVENTIVE
MAINTENANCE
This manual gives instructions for:

1. Co rrect service and adjustme nt of the Bobcat Loader.

2. Overhaul instructions of the engine, loader hydraulic/hydrostatic system and HYDRAULIC

mainframe parts. SYSTEM

See the Owner's Manual for operating instructions (Starting Procedure, Regular Checks,
Basic Ma intenance, etc.).

Make a complete inspection of these items after completion of service or repair: HYDROSTATIC
SYSTEM _
1. Check the hydrau lic fluid level, engine oil level, fuel supply, and coolant level.

2. Look for any sign of fue l, oil or hydraulic fluid leaks.

3. Comp lete lubrication of the machine.

.
DRIVE
SYSTEM
4. Check the battery condition, electrolyte level and cables.

5. Check the ai r cleaner system for damage or leaks. Check the element and replace if
necessary.

6. Check the electrical system. MAIN FRAME

7. Check the warni ng lamps.

8. Check the tires for wear and correct pressure.

9. Check the Bob-Tach attachment for condition. Check the wedges for damage or
wear.
ELECTRICAL
SYSTEM
10. Che ck all safety items fo r condition (Operator Enclosure, Seat Belt, Safety Treads,
Lamps, Parking Brake, etc.).

11. Make a visual ins pection for loose or broken parts or connections.
ENGINE SERVICE
12. Operate the loader, and check operation of drive system and hydraulic system. (520, 530)
,.
Tell the owner if any of the above items are in need of repair.

ENGINE SERVICE
(533)
CONTENTS

ALPHABETICAL INDEX .10-1

TECHNICAL
ELECTRICAL SYSTEM 6....,.1 DATA
ENGINE SERVICE (520/530) 7-1
ENGINE SERVICE (533) 8-1
HYDRAULIC SYSTEM 2-1
HYDROSTATIC SYSTEM 3-1 ALPHABETICAL
MAIN FRAME 5-1 INDEX
DRIVE SYSTEM 4-1
PREVENTIVE MAINTENANCE 1-1
TECHNICAL DATA . . 9-1
 PREVENTIVE MAINTENANCE
PREVENTIVE
MAINTENANCE:
(
Paragraph Page
Number Number

AIR CLEA NER 1-5 1-4

BOBCAT SE RVIC E SCH EDULE 1-3 1-3
BOB-TACH 1-21 1-13
CHANGING ENGIN E OIL AND
F I LTE R (520/530) 1-10 1-6
CHANGING ENGINE OIL AN D FI LTER (533) 1-11 1-7
ELECTRICAL SYSTEM 1-14 1-9
ENGINE COOLING SYSTEM (520/530 ) 1-12 1- 8
ENG INE COOLING SYSTEM (533) 1-13 1-8
ENGINE LUB RICATION SYSTEM 1-9 1-6
ENGINE SERV ICE 1-4 1-4
FI ~A L DRIVE TRANSM ISSION (CHAINCASE) 1-18 1-11
FUEL FILTE R . 1-8 1-5
FUEL SYSTEM SERVICE 1-7 1-5
HYDRAULIC FILTER RE PLACEMENT 1-17 1-11
HYDRAULIC/ HYDROSTATIC FLUID 1- 16 1-10
HYDRAULIC SYSTEM 1-1 5 1-10
INTRODUCTION 1-1 1-1
LUBRICATION OF LOAD ER 1-20 1-12
PIVOT PINS 1- 22 1-13
PREVENTIV E MAINTENA NCE 1-2 1-3
TIRE MAINTENAN CE 1-19 1-12
 1-1 INTRODUCTION

1-1.1 Symbols

II
This symbol is on the machine and used
in t his manual for an ident ificat ion of
warning. When this symbo l is shown, look
for possible d anger to personnel. Carefully
read and follow the instructions on this
\ Serial

symbol.

Fig. 1-1 Loader Ser ial Numb er

This symbol is used as an ident ification
for possible damage to equipme nt when
you work o n a specific part of the
machine. Caref ull y read and follow the
instructions on t his symbol.

1-1.2 Serial Number Identification ~

~
It is im portant to make correct refere nce to the serial number of the loader when you / ~
I
( make repai rs o r are o rderi ng parts. Early or later models (identification made by " Lot")
sometimes use different pa rts, or it may be necessary to use a different procedure In CO) Serial Number
doing a specific job. Ma ke reference to the pa rts manua l for identification informat ion. (520tS30)

1-1 .3 Loader Serial Number

The plate for the se ri al number of the loader is ins ide the left uprlght (Fig. 1-1) .

The seria l number is made up as follows:

M 11001

I
I Production Sequence

Plant Location

Model , Eng ine Type Fig. 1-2 Engine Se rial Numbers

1-1.4 Engine Serial Number

( The Kohler (5201530 ) engi ne seri al number is located on the blower housing, at the right
side of t he engine (Fig. 1-2 ).

The ISUZU engine (533) engine serial number is o n 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
N.·........ ~r.:..:.":.:.:'~=.-----,

The pre-delivery inspection is used to make sure that the loader is in correct operating .. - . .- _ ...._ . _ .. 1 ....­

condition when delivery is made to the dealer. -. - - - -.:.-.:..~..:.:-.: 1 =.= :'.~~.."

i ,- . ~ . ..

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 comp leted according to
specifications in this manual. _... _-­
~ :~::- .::.:-- ..

1-1.6 30 Hour Inspection

Fig. 1-3 Pre·Delivery Inspection
The 30 hour inspection must be completed soon after the first 30 hours of loader
operation.
CUIII"

The purpose of the 30 hour inspection is as follCMIs:

(1) For adjustment and inspection after first work period.

_---- ---­
...--------
[ _ ..._-_.-- I
1:=
· '. . .-1
---- - - -.--­
~- =

(2) To correct wrong maintenance and operating methods.

r.. ---.· ·:----- 1
(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:

(1) The mechanic completing the inspection.

(2) Dealer person Fig. 1-4 30 Hour Inspection

(3) Owner or operator

520, 530, 533 Loade r

-1-2· Service Manual
 1 - 2 PREVENTIVE MAINTENANCE

Maintenance w ork must be done at regular intervals. Failure to do this will cause

dam age and f ai lure t o the m achine or its engine. The service schedule is a guide to

( maintenance of t he 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
1 - 3 BOBCAT SERVICE SCHEDULE ~
It) 0
0-
0
N
0
('I) ...
0

ITEM SERVICE REQUIRED

Eng ine Air Cleaner Clean dust cup . Inspect condition of system .

Engine Oil Check and add oil as necessary .

Engine Cooli ng System Check coolant level in coolant rec overy tank . Add
coolant when low. Remove any debris from radiator
gril l area.

Tires Inspect for damage and check tire pressure .

All Pivot Points Add lubricant to all fittings (1 2),

Indicators. etc. Check for correct operation of all indicators.

switches . lights .

Operator Guard Check condition and holding bolts .

Seat Belt Check condition of straps and buckle and replace if

defective .

Safety Decals Check for missing or damaged decals . Replace as

necessary .

Hyd raulic Fluid Check level and add recommended fl uid if needed.

Engine Oil & Filter Replace oi l and filter .

Battery Check cables .

Control Pedals & Steering Check operation. Make repairs and adjustments as
needed.

Bob-Tach Inspect locking levers and wedges for condition and

operation.

I
Governor Lubrication

Brakes
Check oil level and add as needed .

Check operation . Make adjustment as needed .

Chaincase Fluid Check level. Add fluid if needed .

Engin e Cy linder 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 .

I
Spark Arresto r M uffler Clean carbon from the muffler.

Hydraulic Filter Replace element .

Engine Air Housing (5201 Remove and clean housing and cooling fins .
530 )

Engine Fuel Filter Replace element or clean as necessary.

Injection Pump Oil (533) Replace oil in injection pump reservoir .

Engine Ignit ion Sy stem Check points and timing. Replace spark plu gs.
(52 0/530)

Chain case Replace fluid.

Hydraulic System Repla ce fluid and filter. Clean inlet screen and ven t .

520, 530, 533 Loader

Revised Mar 79 -1-3- Service Manual

1-4 ENGINE SERVICE

The rear door must be opened to

service the engine. Pull the door latch
to the left to open the door (Fig. 1 - 5) .
NOTE: The 530; SIN 12291 & up
and 533; SIN 12121 & up
loaders have a rear door stop
(Fig. 1-6a). The door stop
will hold the rear door open
while servicing the engine. Be
sure to disengage the door
stop before closing the rear
door. C·I024

Fig. 1-5 Air Cleaner

IMPORTANT

Fig. 1-5 Releasing the Rear Door

Door must be closed when
operating loader.

1-5 AIR CLEANER SYSTEM (Fig .

1-6)
Regular maintenance of the air cleaner
system is very important for good
engine performance and long service
life .
Service as follows : (Fig . 1 -7)
(1) Remove dust cup and clean
each day.
(2) Make replacement of element
only when necessary . To check for
need of replacement, hold an
illuminated flashlight inside the
element . If light can not be seen
through element or if element has

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 Re'm oving 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.
B-2215

Fig. 1--8 Checking Element with Flashlight Fig. 1-9 Checking Air Cleaner System

520. 530. 533 Loader

Revised Mar 79 -1-4­ Service Manual
 c . If t he engine does not stop, the system has a leak. Check the system
and make re pairs as necessary.

NOTE: Look for a leak in the air cleaner hose or t he crankcase breathe r hose. Filler
Cap
'r 1 - 6 FUEL SYSTEM

Use only re gular grade or lead-free gasoline in the 520/ 530 engine.
Use No.2 diesel fu el in 533 engine (#1 during cold weather [below + 20 0 F -6Cll .
. A visu al check will show the fuel level in the tank .

Never add fuel to the loader when the

AWARNING engine is runni ng or is hot!

1 - 7 FUEL SYSTEM SERVICE

Remove t he fi ller cap to service the fuel tank as follows : (Fig . 1 - 1 0 & 1 - 1 1 ) Fig. 1- 10 Fuel Fi lling (520)
( 1 ) Ignition must be in off position and engine must be cooled .

(2) Add fue l only in an area which has good air movement and is fre e from

sparks . (NO SMOKI NG.)

(3) Use a clean approved safety con tainer to add fuel to the fuel tank .

(4) Lower the spil l guard (Fig. 1 - 10) .

(5 ) Use on ly clean fuel to fill the tank .
(6 ) Be sure to tig hten t he cap on t he f iller pipe .

Be sure t he air inlet hose (Fig. 1 -1 1) is

IMPORTANT in place to prevent moisture (rain .

sno w . etc.) from entering t h e air
cleaner system.

1 - 8 FUEL FILTER

The 5 2 0 and 5 3 0 loader has a f uel fil ter installed next to the shut-off valve on the

fue l tank (Fig . 1 - 1 2 ).

T o check or replace t he f ilter element :

(1) Close shut-off v alv e ( 1 ) fo r f uel.
NOTE: Some of the 530 & 533
Fig. 1- 11 Fuel Tan k Cap (530 . 533 )

loaders did not have manual

shut-off valves installed . Be

sure to install the fuel shut-off

if it does not have one (See

Parts Manual or microfiche for

parts).
(2) Loosen the tubeline nut (2)

and disconnect the tubeline .

Tu rn the element to remove it from

the shut -off valve .
Put air pressure through th e

element in the direction of the

arro w . (Air must have free

~ .
passage .)

Whe n y ou install a new element,

make sure that the arrow point is in

direction of the carbur etor (Fig.

1 - 12 ).

1
Fuel Filter
(3) Tig ht en the t ubeline nut, open
8-2921
the f uel shu t -off v alve and ch eck

for leaks .
Fig. 1-13 Fue l Filter (533)

520. 530. 5 33 Loader

Revised Mar 79 -1-5 ­ Service Manual
The 533 fuel system uses a "turn on" filter element, installed on the left side of the
engine (Fig. 1 -13).

To replace the element:

Close the shut-off valve for fuel (Fig . 1 -1 2, Item 1). \

(2) Turn the filter element counterclockwise to remove it .

.(3) Clean the element contact area on the filter housing.

(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 .

(5) Open the shut-off valve for fuel.

(6) loosen the screw to let air out of the system (Fig . 1 -1 3, 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.
r/f

1 - 9 ENGINE LUBRICATION SYSTEM

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 -1 5), 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) .

1 -10 CHANGING ENGINE OIL & FILTER (520/530)

Fig. 1-15 Engine Oil Check (533)
The engine oil & filter should be
replaced after every 50 hours of
operation .

Remove the drain plug (Fig. 1 - 1 6)

when the engine is hot . let oil flow fully
out for several minutes .

Use a 1" size socket or box end wrench

to remove the oil filter (Fig . 1 -17). Put
an open reservoir or rags under filter
area to catch leaking oil.

Clean the filter contact area before

installing a new element.

Fig. 1-16 O il Drain Plug (520, 530) Remove Oil Filter Element (520, 530)

520, 530, 533 Loader

-1-6­ Service Manual
Put oil on the gasket before installing the element. Turn the element on until it is
hand ti ght and use the socket or box end wr ench to tighten the element an additional
1/4 to 1/2 t urn .

Install the drain plug and remove the oil f iller cap . Fill with 4 quarts (3,8 Ll of oil of
the corre ct specification (See ch art).

Start th e 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
th e d ipstick.

NOTE: Do not overfill the crankcase.

RECOMMENDED SA E VISCOSITY NUMBER

ILUBRICATION OILS FOR ENGINE CRANKCASE)

CO ·34 ·29 + 38
B-2633R

Fig. 1-18 Oil F ilter Location (533)

·30 ·20 · 10 0 + 10+ 20 + 30 +40+50+60 +70+80+90 + 100

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

(GASOLINE: USE A PI CLASSIFICATION SE)

(DIESEL: USE API CLASSIFICATION CD)

1 -11 CHANGING ENGINE OIL AND FILTER 1533)

O·1 379R

Change the engine oil and filter after ev ery 50 hours of operation . Fig. 1-18a Oil Drai n (533 )

Remove the drain plug when t he engine is hot . Let oil flow for several minutes.

Use a fi lter wrench to remove the oil filter (Fig . 1 -18) . Place an open reservoir or
rags under filte r area to catch leaking oi l.
Clean the f ilter contact area and put on the gasket before installing the element. Turn
t he element on unti l it is hand tight.

I
NOTE: Be sure to check the engine oil drain for a leak which is caused by engine
vibration (SIN 11339 & below). When t here is a leak , you can install a new
tubeline assembly (See Parts Manual or microfiche for parts).
Install t he drain plug and remove th e oil f iller cap (Fig. 1 -15). Fill with 3.4 quarts
(3,2 l) of oil of correct specification (See chart) .
Start th e engine and let it ru n for a few minutes . Then stop the engine and check for
leaks at t he 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 th e oi l level and add oil, if needed, to bring the level to the "F" mark on the
dipstick.
NOTE: Do not overfill the crankcase .

520, 530, 533 Loader

Revised Mar 79 ·1-7­ Service Manual
i-12 ENGINE COOLING SYSTEM
(5201530)

The oil cooler grill and engine cylinder

cooling fins must be kept clean and free
of foreign material or overheating of
engine will result.

A 'WARNING
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.

NOTE: Do not use a scraper on the oil cooler.

Be sure to replace all covers after deaning.

Never operate the engine with any part of

IMPORTANT the shrouding removed.

1-13 ENGINE COOLING SYSTEM (533)

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.

Check coolant level daily at the coolant

recovery tank (F ig. 1-22). Correct tank
level is 1/3 full when the engine is cold
and 2/3 full when the engine is warm.

Add coolant at the recovery tank only. Fig. 1 -21 Blower & Housing (533) Fig. 1-22 Coolant Recovery Tank (533)

520, 530, 533 Loader

-1-8­ Service Manual
 3/1 6" (5 mml

AWARNING

Do not remove t he radiator cap

to check coolant level unless
the engine is cold .

To protect against freezing in cold

clim ate, add anti·freeze as necessary . A·2626

The cooling syst em must be made Fig. 1-23 Alternator Belt Tension

empty and flushed cl ean once each

year. Fill with new , clea n coolant,

containing a rust inhibitor.

IMPORTANT Never operate the engine with any part

of the blower shrouding removed.

Check the w at er pump and altern at or belt tension and adjust when necessary . The
correct belt tension is 3 / 16" (5 mm ) with a little amount of finger pressure at t h e
center of the belt span (Fig . 1- 23 ).

1 - 14 ELECTRICAL SYSTEM

Th e 5 20/530 loader is equipped with a 12 volt, 15 amp, flyw heel generator charge
syst em . (See Section 6 for wirin g diagram .)
The 533 loader uses a 1 2 volt, 37 amp, belt driven alternator charge system. (See
Section 6 for wiri ng diagram. l
Service the electri cal system as foll ows:
( 1 ) Check the battery electrol yt e level and if it is low, fill to the mark with
distilled wa t er. (Not requ ired on "Maintenance Free" type battery . )
(2 ) Keep the bat tery cables and

term inals clean and tight . Remove

acid corrosion w ith a baking soda

and w ater solution. Coat the

terminals w ith grease to prevent

corrosion build up .

To remove the b attery, pull back and

lift up on the h olddo w n lever (Fig.

1 - 24 ). On later m odel loaders remove

nuts and c lamp. Use a carrystrap to lift

the b atte ry out o f the engi ne

com partme nt .

I
Be sure to fa sten the battery in place
w ith the holdd own lev er or clamp when
insta lling .
On the 520; a" 530; 11080 &
NOTE below and 533; 11165 &
below, the battery holddown
can bend. Insta" 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

wirin g.
Fig. 1-24 Banery Hold Down Fig. 1-24A Battery Ho ld Down

520, 530, 533 Loader

Revised Mar 79 -1- 9­ Service Manual
1 -15 HYDRAULIC SYSTEM
HYDRAULIC CIRCUITRY
The loader hydraulic and hydrostatic O Y(~ .. ()It.·c~".:.c!.:.o.P{~.
DJ!£o . ~~ !.!o<.P(
systems use fluid from the same D~&1.i: ' L()roIr~ ,>w-t
DGPE:l" 'CA>(~ .......
hydraulic fluid reservoir. o
o
IT 8\.(".(
ORIlK:£
'S~AOo<!.~ c.......v....l "PCs..,pc
' r~\A? II(")L~ 6...:1<)0.1)
~ l~[ Co-.',,,-< !,

The engine driven vane pump moves

fluid to the control valve to give power
to the lift and tilt cylinders (Fig . 1 - 25),

FI~id also goes from the control valve

to the hydrostatic transmission pumps
to be used to give power to the drive
system.

The 10 micron hydraulic filter is

installed at the right side of the engine
compartment (Fig. 1 -26). This filter
cleans the fluid for the hydrostatic .. ~ .........>c
',00
transmission. 'o"''-'P€
.. ~ ~ "'-
>t: "'"

of'
The oil cooler (Fig. 1 - 27) cools the

I
fluid before it returns to the inlet of the
vane pump.

Be sure the hydraulic hoses for

NOTE the oil cooler are in the
position as shown in figure
1-27 to prevent damage to
the hoses.
E-1l39

1 - 16 HYDRAULIC/HYDROSTATIC Fig. 1-25 Hydraulic Flow Diagram

FLUID

Use only 10W-40 SE motor oil in

Bobcat hydraulic reservoir. When the
0
starting temperature is below -10 F
1-23 0 C] use 5W-30 SE motor oil in the
hydraulic system.

IMPORTANT
_---:.~-:- Filter
Element

Never use automatic

transmission fluid in the Bobcat B-2657
hydraulic system.
Fig. 1-26 10 Micron Filter

1-16.1 Checking and Adding Fluid

To check the fluid level in the hydraulic

reservoir:

(1) Put the ' loader on a level

surface.

(2) Open the lower valve on the

side of the reservoir (Fig. 1 - 28,
B-2236R
Item 1). If no fluid flows, close the
valve, Fig. 1 -27 Hydraul ic Oil Cooler 1520.5301

520, 530, 533 Loader

Revised M ar 79 -1-10­ Service Manual
 (3) Open the upper valve (F ig.

1- 28, Item 2). Remove the reservoir

fil l c ap (Fig. 1-29) and add

recommended fluid. When the fluid

flow s from t he upper valve , close

the valve and install the fill cap.

1-16.2 Hydraulic/Hydrostatic Fl uid

Replacement

Remove the fluid from the hydraulic

reservoir and replace it with new approved
flu id afte r every 1000 hours of operation,
or sooner, if t he fluid is dirty.

To remove fluid from the reservoir :

(1) Remove the hose from the

out let el bow on the oil cooler (long

hose) and put the end into a clean

Fig. 1-28 Hydraulic Re servoi r Level Check

reservoir (Fig. 1-30).

(2) Aft er all fluid has been

remov ed, connect the hose to the cooler.

(3) Remove the spring dip and remove the screen from the reservoir filler pipe
(F ig. 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.

1-17 HYDRAULIC FI LTE R REPLACEMENT

Re place the hydraulic filter element after every 100 hours of operation, or sooner, if
necessary (indicated by illuminated "tran" light).

To rep lace the element :

(1) Remove the element (Fig. 1-32). (Use an open reservoir to catch leaking
f lu id.)

(2) C lean the element contact area

o f t he filter housing.

(3) Pu t o il on the rubbe r gasket

o n the new filter element.
Fig. 1-30 Draining Reservoir (520, 5301
(4 ) Inst all the element. Tighten it
until it is hand tight only.

(5) Start t he loader engine and

check for leaks.

1-18 FINAL DRIVE TRANSMISSION

(CHAINCASEI

The chaincase is the housing for the final

drive sprockets and cha in s. The chaincase
is filled with the same fluid as the
hydraulic/hydrostatic t ransmissi on.

To check the flu id level: 8-2235

(1) Put loader on a level surface. Fig. 1-31 Removing Filler Pipe Section Fig. 1-32 Remove Hydraul ic Oi l Fil ter

520, 530, 533 Loader

-1-1 1­ Service Manual
 (2) Remove the plug, located at
the front of the chaincase hou sing
(Fig. 1-33).

(3) Add recommended fluid into

the hole until the fluid is level with
the hole. Install the plug.

(4) To remove fluid from the

chaincase, put the rear end of the
loader on blocks and remove the
fluid through the opening in the
front end of the chain case. Fig. 1-33 Cha incase Check. Fill. Dra in Plug

1-19 TIRE MAINTENANCE C· 1965

Check the tires regularly for wear, damage Fig. 1-34 T ire Rotation

and correct pressure (See specification,

page 8-31.

1-19.1 Tire R01ation

Tires must be rotated (front to rear, rear

to front, Fig. 1-34) for even wear,

When tires are installed new, install them

two per each side of the loader.

Do not put fluid (ballast) in the tires on

this loader.

Check the wheel fastening bolts or nuts

often and make sure that they are tight GREASE
GASOLINE TANK
(Seee specifications, page 8-3).

1-20 LUBRICATION OF LOADER

For good performance, lubricate the

loader regularly as specified in the service
schedule on page 1-3.

Figure 1-35 shows the location of the

grease fittings on the Bobcat loader.

Use a good quality lithium based,

mUlti-purpose grease when servicing the
loader with lubricant. Add lubricant until
it comes out of the area being serviced.

Also, lubricate the seat rails (Fig. 1-36A)

to make easy movement for seat 6553967
ad justment. Fig. 1-35 Lubrication Point s

520, 530, 533 Loader

-1-12­ Service Manual
Add oi l t o the oil hole in the steering
control shaft (Fig . 1- 3 6) . Use regular Add Lubricant
motor oil for this purpose . Remove the
seat and seat pan to reach the steering
mechanism .

1 - 21 BOB-TACH

Check the Bob-Tach regularly (See

service schedule, page 1- 3) for
condition and wear.

When the levers are in the "locked"

position (Fig. 1 - 3 7). the w edges must
extend through the slots in the
attachment (Fig. 1 - 38).

NOTE: Some Bob-Tachs will not fit in­ B·2135

to mounting f rame of attach­
ments (Example: Pallet Fork Fig. 1-36 Lubrtcat ion Steering Shaft Fig. 1-36A Seat Rails
and Angle Broom). Grind 1'4"
(6.35 mm) of material from
each side of the Bob-Tach
(Fig. 1 -37).

1 - 22 PIVOT PINS To
Lock
All pivot points (lift arm , Bob-Tach and
cylinder) use pins w hich are held in Here
place by lock bolts (Fig . 1 - 39 ).

Check lockbolt nuts for tightness. (See

Remove

the "Service Schedule" for interval of Material

check. ) Here

D-1380

Fig. 1-37 Bob·Tach

Fig. 1-38 Locking Wedges Fig. 1-39 Pivot Pin Lockbolt

520. 5 30. 533 Loader

Revised Mar 79 ·1 -13­ Service Manual
1-23 FUEL INJECTION PUMP
RESERVOIR (533)

The oil reservoir level in the injection

pump muSt be checked every 100 hours.

To check level : (Fig. 1-40)

(1) Remove the check plug (Fig.

1-40, Item 11.

(2) If no oil can be seen at the

opening, remove the breather on top
of the pump (Item 2).

(3) Add oil of same specificat ion

as recommended for engine (See
chart). Add until oil flows out of
check opening.

(4) Install the breather and the

check plug.

Every 300 hours replace oil as follows :

(1) Remove the plug at the

bottom of the pump (Item 3) and
let out the oil.

(2) After all oil has been removed,

install plug. Remove the level check
plug (I tern 11.

(3) Remove the breather (Item 2)

and fill the reservoir to check plug
level with new oil, according to
engine oi I spec chart. Install the
breather and the plug.

InjeCtion Pump

520, 530. 533 Loader

-1-14- Service Manual
 HYD RAULI C SYSTEM

Paragraph Page
Number Number

CHECKING CONTROL VALVE AND CY LINDERS 2-8 2-6 HYDRAULIC

CHECKING OUTPUT OF VANE PUMP 2-6 2-4 SYSTEM
CHECKING RELIEF VA LVE 2-5 2-4
CONTROL VALVE REPA IR 2- 10 2-7
GENERAL INFOR MATIO N 2-2 2-1
HYDRAULIC CIRCUIT 2-1 2-1
HYDRAULIC CYLINDER REPAI R 2-9 2-6
PROBLEM AN ALYSIS CHARTS 2-4 2-3
TROUB LE SHOOTING HYDRAULIC SYSTE M 2- 3 2- 2
VANE PUMP REPA IR . 2-7 2-5

520, 530, 533 Loader

Senica Manual
2-1 HYDRAULIC CIRCUIT (Fig. 2-1)
520 HYDRAlJUC ORCUITRY
Cl YEW)Jw • CHot.AC£ ~ ~Y
Fluid is added to the Bobcat by removing Cl REO • t<iH PIA£~
Qc.lI.J.£ 'lOW~
the vented cap and fiffing through the c::::J QlE(H • CAS( CAot.N

a If 8u£ • S,lA011CEO OIAK£ PAESSotA:

screen installed in the tank. There are two o cswa. . F"l.l.Cl AE~
&..Cr.::HI
~.L.H: CCJ.ITN.£S
valves on the s ide of the reservoir for
checking the fluid level.

(1) A specific amount of fluid

f rom the hydrostatic motors, and
fl uid from the reservoir goes into
the port block to keep the hydraulic
system fuff of fluid.

(2) Fluid goes from the pump to

the control valve.

(3) When the controls are activated

the cylinders move until they reach
the end of their length, then the
hydraulic relief valve open s to
protect the system from too high
pressure.

(4) All oil from the control valve

goes to the hydraul ic filter, and
then to the hydrostatic drive system.

(5) A by-pass valve installed in the

port block will open whenever there
is an over limit of oil pressure. The
higher pressure can be caused by: Fig. 2-1 Hydraulic Circuit
(1) Cold fluid too thick to flow
through the filter element. (2) Dirty
filter. (3) Added flow of fluid (lowering lift arms or moving bucket back).

(6) A restrictor orifice is installed in the hydraulic filter tubeline to l imit oil flow
and protect the filter from too high oil pressure .

Restrictor orifice locations are shown in figure 2-1;

Location A . Machine SIN 12,300 & Up (520, All 530 & 533)

Location B - Machine SIN 12,299 & Below (520)

Mark a Lin e On Nut

and Adaptor Before To rquing

2-2 G ENERAL INFORMATION

2-2.1 Keep ing Part s and Wo rk Area Cle an

When mak ing repairs on the hydraulic system keep all parts completely clean. Use caps
and plugs to keep dirt out of tube lines and openings.
Misalignment of Ma rk s Show s
Amount to Tighten (See Chart )
Put only clean oil in reser\Joir. Be sure the screen for the reservoir filler tube is in the
correct location.

2-2.2 37 0 Flare Connections

To tighten flare fittings, use this method :

(1) Tighten the nut until the flame is in contact with the seat.
A-J897
(2) Make a line from the nut to the adapter (Fig. 2-2).
Fig . 2- 2 Tightening Flared Fitting

520. 530, 533 Loader

-2- 1b· Service Manual
 (3) Use this chart to find amount of tightening for fittings:

Fitting Thread Size Rotate Number of Hex Flats

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. rrhe 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.

2-2.3 Straight Thread O-ring Connections

These connections seal by compression of the O-ring. To tighten O-ring fittings, use this
method:

(1) Loosen the nut and slide the washer and O-ring against the thread (Fig. 2-3).

Put oil on the O-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 Sea! in Place

(3) Hold the fitting with a wrench. Use another wrench to tighten the jam nut

(Fig. 2-4). The O-ring must fit into the space as shown.

(4) If the fitting is not turned in correctly, the O-ring will have damage and the

fitting will leak (Fig. 2-5).

2-2.4 Tubelines and Hoses

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.

2-3 TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM

PROBLEM CHART CORRECTION

Fig. 2--5 Wrong Installation

Slow hydraulic or no hydraulic A Check control linkage and fluid

power on all ci rcu its_ level. Check release pressure and
pump output.

Slow hydraulics or no hydraulic B Check control linkage, cylinder

on one ci rcu it. condition . Check valve section for
leakage.

Cylinders move with controls in B Check cylinder condition. Check

neutral position (See Note Al. valve section for leakage. Check
for tubeline leakage.

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 bo Its evenly, a sma II amount at a time.

520, 530, 533 Loader

·2-2­ Service Manual
 2-4 PROBLEM ANALYSIS.

CHART A
SLOW HYDRAU LI C OR NO HYDRAULIC POWER TO ALL CIRCUITS

Check
Fluid
Level
-
If
Full
..... Check Control
Linkage Adiustment
Be Free Movement
If
f- Good
..... Check Release
Pressure
(Sec. 2-5)
- If
Good
---..
Check Output
Of Vane Pump
(Sec. 2-6)

I
If
I
If Not
I
If Not
I
If Not
Low Correct Correct Correct

•
Add
t
Make Corrections
t
Remove, Clean Be
Inspect Relief
t
Ma ke Repai rs
As Needed
Fluid As Needed
Valve (Sec. 2-5.1) (Sec. 2-7)

CHART B
SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ONE CIRCU IT

ONL Y. CYLIN DERS MOVE WITH CONTROLS IN NEUT RAL POSITION.

Check Control
Check Condition Remove, Clean Be
_ If If
Linkage Adiustment
~ Of Cylinders f--- ~ Inspect Control
Co rrect Good
Be Free Movement
(Sec. 2-8.1) Valve (Sec. 2-10)

I
If Not Correct
I
If Bad
I

If Bad

t
~ ~

Make Repairs

Make Repair
Make Repair

Or Replacement

Or Adiustment
Or Replacement

As Needed

As Needed
As Needed

(Sec. 2-9)

520, 530, 533 Loader

-2-3­
Service Manual
2-5 CHECKING RELIEF VALVE

NOTE : Hydraulic checks are made using

a hydraul ic tester. The tester
gives flow and pressure
measurements and has a flow
control valve. Release pressure
setting can also be checked with
a pressure gauge connected to
the hose which has presSUre. The
machine must be put on blocks
when making tests.

2-5.1 To Check Release Pressure

(1) Activate all controls to re lease

hydraulic pressure.

(2) Connect a tester or pressure

gauge to the aux il iary connections as

shown in figure 2-6 . The tester also

Fig. 2-6 Testing Hydraulic Sys t em

can be connected to the tilt cylinder

hoses.

NOTE : The flow control on the tester must be fully opened.

(3) Start the engine and ru n it at full throttle.

(4) Activate the hydraulic oontrol which will put pressure on the hose connected
to the te ster. Read the pressure (See Section 8 for correct pressure) .

2-5.2 Relief Valve Removal and Replacement

(1) Activate the controls to release pressu re from the hydrau lic systems.

(2) Remove the relief valve assembly from the contro l valve (Fig. 2-7).

(3) Remove the snap ring from the end of the valve and lift t he parts out (F ig.
2-8, Item 10). Clean and make an inspection of all parts.

Be sure to assemble the relief valve parts

correctly. Wrong assembly of these parts
can cause pump damage (Fig. 2-8). Relief Va lve Removal

(4) Insta ll the relief valve (Fig. 2-20, Item 16) with new O·rings (Items 13 & 15)
and back-up washer (Item 14).

(5) Check release pressure again. If

pressure is not correct after cleaning,
a new relief valve must be installed.
After insta lIing a new reli ef valve,
check the release pressure again.

2-6 CHECKING OUTPUT OF VANE

PUMP

(1) Lift the loader and put it on

jack stands. Remove the wheels and
the seat assembly.

(2) Connect the hydraulic tester to

the system as shown in figure 2-9.
Fully open the flow control valve
on the tester. Fig. 2-8 Relief Valve A ssembly Fig. 2~ Checking Output of Vane Pump

520, 530, 533 Loader

-2-4­ Service Manual
 Us e caution when tu rning the flow
control valve. There is no rei ief va lve in
( the hyd raulic circu it for protect ion to the
system when tester is connected this way .

(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.

2-7 VA NE PUMP R EPA IR

2-7.1 Removal Fig. 2 -10 Removing Port Block

(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 hold s 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

Put the pump in a vise (Fig . 2-11). Put a

long mark on the side of the pump to
Fig . 2 -1 1 Marking Pump
help in alignment of parts during
assembly. Remove the bolts which hold
the pump together and make a separation
of all the parts.
Body

2-7.3 Inspect ion

Clean all the parts thoroughly. Check the

areas shown for wear, scratches and other
damage (Fig. 2-121.

2-7.4 Assembly (Fig. 2 - 13)

t

Pressure
Ring
Plate Rotor
NOTE : Install new O-r ings and put oil 8-2104
on all the parts du ring assembly.
Fig . 2-12 Vane Pump Wear Areas

(1) Put the pump housing in vise.

Install a new O-ri ng in groove (F ig.
2-13, Item 1)
Vane CD'x .,
(2) Install the center ring (Item 21.
0 0 CD~ ~
Put pins (Item 3) through the ring
and into the pump body. Install the
\ \ \.J
\ \)~
vanes and rotor. Be sure the round
edge of each vane is toward the
outside of the pu mp. Arrow must
point in direction of pump rotation.
(3) I nstall the pressure plate (Item
4) and spring (Item 5) over the ring.
Put a new O-ring (Item 6) on the
-e -~ -
Rotor
t '0
pressure plate. Install the cover and A·1900
fasten it wi th bolts.
Fig. 2-13 Va ne Pump

520, 530, 533 Loader

-2-5­ Service Manual
2-7.5 Pump Installation

(1) Install a new a-ring on the pump and put the pump in position on the
hydrostatic pump assembly . Fasten the pump with bolts.

(2) Fasten th e hoses and port block to the pump. Fill the reservoir with clean,
recommended flu id.

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 th e
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~Z
are good, the defect is probably in the oontrol valve. LEFT SIDE
2-8.1 To Check Lift Cylinders Fig. 2-14 Disconnect Lift Cylinder Hose

(1) Lower the lift arms fully.

(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 (F if).
2-14 and 2-15). In stall 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.

2-8.1 To Check the Tilt Cylinder I

(1) Tilt the Bob·Tach all the way back. B·2852
RIGHT SIDE
Fig . 2-15 Disconnect Lift Cy linder Hose
(2) Put the machine on jackstands and remove the wheels .

(3) Di sconnect the hose which goes to the top (Base End) of the tile cylind er (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.

Be sure to support the lift arms or Bob·Tach

to prevent them from falling

AWARNING when a cylinder is removed .

B·2853

2-9.1 Removal and Installation Fig . 2-16 Disconnect T i lt Cylinder Hose

(1) Activate the oontrols to release pressure in the system.

Cylinder
(2) Disconnect the hoses from the cylinder.

(3) Remove the bolts and pins which hold the cyl inder in position.

Installation is the reverse of removal.

2-9.2 Disassembly and Repair

(1) Remove the cylinder head with a spa nner wrench (Fig. 2-17).
/'

(2) Pull the rod and piston assembly from the case. spann~
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 th e cylinder rod for scratch mark s or other damage. Remove small St one
defect s by grinding (Fig. 2-18).

(5) Check the c ylinder hou si ng and piston for damage.

I
(6) Put new seal parts on the cylinder rod , piston and cylinder head .

(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 p iston and t ighten
the nut to correct torque (See Section 9).

(8) Slide the piston and rod assembly into the housing and tighten the head w ith
a spanne r w rench . PI·1221b
2-10 CONTR O L VA LVE R EPA IR
Fig. 2 - 18 R em o ving Marks
Be sure that lift arms are fully down and Bo b·Tach
is fastened fully back before

AWARNING removing control valve tube lines.

2-10.1 Removal
(1) R emove the seat and shield above the transmi ss ion area .

(2) Disconnect the co ntrol linkage a nd hydraul ic tubelines from the contr o l va lve.

(3 ) Re mo ve the two bolts which hold the control valve and lift the valve out of the
Bobcat.
2 - 10.2 Disasse m bly and Inspection (All Sections) (F ig. 2-20)
Pl-l 22 l a
NOT E: Be sure to put the spools back in their or iginal bores.
Fig. 2-19 Beveli ng th e Shoulder

C·2012

F ig . 2 - 20 ContrOl Valve Assembl y

520 . 530. 533 Load e r

·2-7­ Service Manual
 (1) Remove the screws wh ich hold
the boot assembly on the valve
body (Fig. 2-21).

(2) Push the lift spool in until it is

In the detent position.

NOTE: This is necessary to prevent the

spring and bolts from falling out.

(3) Turn the caps off the end of

the valve bod y and sl ide the spoo Is
out (F ig. 2-22).
B·2855
B-2898
(4) Remove the spacers from the Fig. 2-21 Removing Rubber Boots. Fig. 2-22 Removing Spools
bores (Fig. 2-23).

(5) Remove the relief valve

assembly (Fig. 2-24, Item 1). (See
Paragraph 2-5.2 for relief valve
service.)

(6) Remove the load check valves

(Fig. 2-24, Item 2).

(7) Remove the O-rings (Fig.

2-25).

(8) Check the spools and bores for

wear or scratch marks.
B-2899
2-10.3 Assembly of Valve Fig. 2-23 Remove Spacers from Bores Fig. 2-24 Relief Valve Removal

Use all new O-rings and put hydraulic

fluid on all parts during assembly.

Lift Spool Repair

o
(1) Put a cloth around the spool
and cap to hold the spring and balls
in position. Pull the cap from the
spool.

(2) Assemble by installing the

spring with the balls on each end.
Slide the cap over the spool to hold
the parts in place (Fig. 2-26).
B·2904 B-2896

(3) Be sure the restriction washer

Fig. 2-25 Removing O-Rings Fig. 2-26 Float Detent Assembly
is installed correctly in the rear port
of the lift section (Fig. 2-27).

NOTE: Check the "Detent". It will

normally take 20 to 100 Ibs_ of oI
force to disengage the "Detent".

B·2903

Fig. 2-27 Install Flow Restriction Washer

520. 530. 533 Loader

-2-8­ Service Manual
ADJUSTMENT OF PEDAL LINKAG E
This Corner of Pedal
Must Align With Top Edge
Several problems are caused when the pedal support does not have the correct
adjustment. The lift arms or bucket may raise, lower or tilt too slow or the spool in
the control valve may not go to the centered position for neutral.

Ad just the linkage so the pedals will not touch the floor when you tilt them fully
bac k. Each valve must move the full length of it's stroke when you push the heel or
toe of the pedal.

To adjust the pedal supports :

( 1) Loosen the 2 bolts on the pedal support (Fig. 2-28).

6- 303 2
(2) Move the support and pedal to give correct adjustment. Fig. 2-28 Pedal Adjustment

(3) Tighten the locknuts on the pedal support.

2 - 11 HYDRAULIC HOSES

2 - 11 .1 Hydraulic Hose Protection

On some of the 53 0 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
up right at the location directly in front of the door hinge (Fig . 2-28) . Drill a 5/16"
(7, 93 7 mm) hole at the location as shown in figure 2-28 and install a 3 /8" (9 , 525
mm) ID x 2-3/ 4" (69,85 mm) long bushing, 5/16" x 3-1/2" bolt and locknut.

Bushing is Installed
Bet ween Door Hinge and
Hydraulic Hoses

~Bushing
_"""m,.m.~
. ""'
.....
_
/
/
/
/
/
..L

2- 1/2" (63,5 mm)

6- 3 1 66
Fig . 2 - 2 8 In stalling 6u shing for Hydraulic Hose Protect ion

520, 530, 533 loader

Added Mar 79 -2-9­ Service Manual
2-12 QUICK-COUPLERS

2-12.1 Restriction In The Quick-Couplers

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.

Fig. 2-29 Removing The Quick·Coupler

Remove
3/16"
(4,76 mm)
~
~J On This

I
~
End Only
,1­ - 1­
_ _ _ ..J
~~
-
r ~--- -?
'­

---­ A-2704

Fig. 2 - 30 Quick-Coupler Adaptor

520, 530, 533 Loader

A dded January 1980 -2-10- Service Manual
 HYDROSTATIC SYSTEM

r
:, Paragraph
Page
~~
Number
Number

BY-PASS V ALV E REPAI R 3-5 3-4

HYDROSTATIC CIRCUIT 3-1 3-1
HYDROSTATIC MOTOR RE NEWAL AND
INSTAL LAT ION 3-8 3-7
HYD ROSTATIC MOTOR REPAIR 3-9 3-7
RE MOVAL AN D INSTALLATION OF PUMP HYDROSTATIC
SYSTEM
ASSEM BLY 3-6 3-4
REPAIR OF HYD ROSTATIC PUMP ASSEMBLY 3-7 3-5
REPLENISHING VALV ES 3-4 3-4
STEE RING LINKAGES 3- 10 3-11
TROUBLESHOOTING CHART 3-2 3-1

520, 530, 533 Loader

Service Manual
3 HYDROSTATIC SYSTEM 520/530 6 533
HYDROSTATIC CIRCUITRY
3-1 HYDROSTATI C CIRCUIT (Fig. 3-1) FORWARD POSITION
D ~ 'C ~~SoIPI"'o-V
o ~o . H(,H PAE SSI...A(
Fluid fro m the hydraulic control valves 0 8..1.£ 'LO""~
o GAEE N • SlPPLV IRESER\ORl a. CASE ~I<I

goes to the hydrostatic filter and then to

the hydrostatic pumps. I f the pressu re to c:::::::==t ' LIt<E: CON TN.£ S

the filter is too high (oil too thick, as in

cold weather starti ng), the by·pass valve in
the port blo ck will open and let fluid
re turn to the inlet of the hydraulic pump.

Fluid which goes to the hydrostatic

pumps keeps the lines fro m the pumps to
the motors fu ll of fluid. Fluid enters the
system through the replenishing valves.
Fl uid which leaks (internally) from the
pumps returns to the hydraul ic vane
pum p, through an internal passage.
Fluid w hich leaks internally from the
hydrostatic motors goes to the oil cooler.
Fro m t he oil cooler, the flu id returns to
the inlet of the hydraulic (vane) pump.
If the pressure of the fluid supply to the
hyd rostatic pumps is too low (filter is
dirty or one of the pumps has wear), the
pressure switch at the filter wi II close and
illumi nate the "Trans" light on the dash
panel.
PI-2327
If the fl uid becomes too hot, the switch
at the port block will close and illuminate Fig. 3-1 Hydrostatic Circuitry
the "Trans" light.

There is a restrictor orifice (Fig. 3-2) which protects the filter from damage from sudden
increases in pressure. Th is orifice is in location at the control valve end of the filter
tube li ne (1) o n 520 SIN 12,299 and below. On 520 SIN 12,300 and above and all 530,
533's, t he o rifice is located at the inlet tubeline to the 10 micron filter (2).

3-2 TROUBLESHOOTING CHART

PROBLEM CHART NO CORRECT ION

No drive on one side in one None Check for hydraulic leaks. Check
direction. steering linkage, check
replenish ing valves (Sec. 3-4.1).

No dr ive on either side. A Check fluid level and steering

linkages, make replacement of
filter, inspect by-pass. Check vane
Restrictor
pump. Check restri ctor.
(Late Models)

No drive , one side, both B Check linkage. Check for pump

direct ions. or motor damage.

Machine does not move in a C Check dia. and size of tires

st ra ight line. steering linkage, see Chart B.

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. "-Restricto r
8-2286
(Early Modelsl
Fig. 3 - 2 Rest rictor At Filter Inlet

520, 530, 533 Loader

-3-1b­ Service Manual
 CHART A

NO DRIVE ON EITHER SIDE

Check
Fluid Level
If
Correct
..

~
Turn Ignition
Switch "On" ­ If "Trans"
Liltlt
Comes On
~
Start Engine &
Run At 1/2 Throttle

I
If Light Does
If Low
Not Come On

+
Add Make Repair To Install
Fluid Light System N_ Filter

If Light Is On

Remove, Clean &

Check Inspect By-Pass
Vane Pump Valve (Sec. 3-5).
If Light Goes Out

If Light Is On
If Good

J
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 & Is Off . . Hydrostatic Motor
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
If light

Stays On

j r
NOTE: If Either
Make Repairs The Pump or Motor
Repair Elect rical Hydrostatic Pump
As Needed Has Damage, Remove,
(Sec. 3-10) System Has A Defect
Clean & Inspect
Both Units.

520 Loader
-3-2 Service Manual

L.
 CH AR T C
BOBCAT DOES NOT MOVE IN A ST RAIG HT LINE

Check Size
& Pressure
If
Correct
., Check Steering
Linkage If ., Go To
(Sec. 3-10) Correct Chart B
Of Tires

I
If Not Corrlet
I
If Not Correct

t t
Change Tire Make

Or Pressure Repairs

As Needed As Needed

CHA RT D
BOBCAT OVERHEATS

Check If Hydraul ic
Check
Fluid Level
_ If . . .
Correct
Check & Clean
Oil Cleaner
I-- If -+­
Clean
Controls Are Being
Held Out of
- If
Not
~
Check
"Temp Sender"
(Sec. 1-11)
Neutral Position

I
If Low
I
If So

t t
Loader Is
Add Fluid Not Being
Operated Correctly

·3-3·
3-4 REPLENISHING VALVES

3-4.1 Checking the Replenishing

Valves (Fig. 3-3)

If there is a loss of drive in one direction

on one side, check as follows :
(1) Remove and exchange the
location of the two valves for the
side which has the drive problem .
The valves are located on each side
of the valve plate, near the pump,
for the drive on the same side. If
r
,
___ J
I
I
L___• I
•I •I
Seat Area
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 .
NOTE: Do not lose the small pin in the ~ I
0
end of each valve.
(2) If exchanging the valves does
not change which side loses power
or drive, remove all four valves and 0 I
6 I

wipe them dry.

(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. 6-1608
Fig. 3-3 Replen ishing 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.

3 - 5 BY-PASS VALVE REPAIR

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).

(2) Check the spring poppet and

its seat for damage or binding.

(3) Assembly is the reverse of

disassembly .

3-6 REMOVAL AND INSTALLATION

OF PUMP ASSEMBLY

(1) Activate the controls to

raelease the hydraulic pressure .

(2) Disconnect the hose from the

reservoir at the vane pump. Put

covers on the openings.

(3) Remove the two bolts which

ho ld the vane pump to the

hydrostatic pump assembly. Slide

8-3127
the vane pump, with hoses, away

from the hydrostatic pump .

Fig. 3-5 By-Pass Valve Removal

520, 530, 533 Loader

Revised M ar 79 -3-4­ Service Manual
 (4) Remove the engine (See
Section 7).

(5) Disconnect the steering linkage

at the steering levers. Disconnect all
other hoses to the hydrostatic pump
assembly . Put covers on all openi ngs,
to keep dirt out.

(6) Remove the two bolts which

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).

Insta Ilation is the reverse of removal. Be

sure to use a new Q·ring between the
vane pump and hydrostatic pump 8-2894
assembly.
Fig . 3-6 Remove Coupling Assembly

3-7 REPAI R OF HYDROSTATIC PUMP

ASSEMBLY

NOT E: Be careful to keep dirt out of

hydr ostat ic system. Dirt will
cause se rious damage.

Do not use parts from one pump for

repair of another pump.

3-7.1 Pump Disassembly

(1) Remove steering linkage and

head shield.

(2) Remove coupling assembly

(F ig. 3-6) from pump with puller. B·2902 B·2987

(3) Remove bolts holding the Fig. 3 -7 Remove Pump From Valve Plate Fig. 3~ 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).

NOTE: The disassembly and assembly

proced ure for both pumps is
similar but there is not a shaft
seal in t he front (right side
drive) pump.

(4) Remove the small snap ring

(Fig. 3-9) to remove the race.
Remove the rotating group from the
housing.

(5) Remove the large snap ring

(Fig. 3-10) which holds the shaft
and be aring in position. Use a soft 8-2895
ham mer to remove the shaft from
the housing. Fig. 3 -9 Remove Small Snap Ring Fig. 3 - 10 Remove Large Snap Ring

520, 530, 533 Loader

-3-5· Service Manual
 (6) Remove the pintle seal plate

(F ig. 3-11). Remove the two bolts

which hold the pintles in the yoke.

Remove the pintles, together with

O·rings and cloth seals (Fig. 3-12).

Lift the swashplate out of the

housing.

NOTE: A puller can be used to remove

the pintle bearings if necessary. B·2901 B·2886
There is a key between the
longer p intle shaft and the yoke. Fig. 3-11 Remove Pintle Seal Plate Fig. 3-12 Remove Pintles

Wear Area
(7) Use a hammer and punch to
remove the shaft seal (Fig. 3-13).

(8) Check all parts for wear,

scratch marks or other damage (Fig.
3-14, 3-15 & 3-16). If the
swashplate bearings need
replacement, use a puller to remove
them. Be careful not to cause
damage to the parts. B·2887 A-2304

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 O-rings.

This Dimension Must Be Maintained On All

Nine Shoes Within 0.001 Inch.

. - - - - Wear Areas-------,
L--
-
/--
Shoe Faces Slides
on Swash Plate
Shoe Must Swivel Smoothly on Ball.
End Play Must Not Exceed 0.003 Inch.
Piston

A-1850

Fig. 3-15 Rotating Group Fig . 3-16 Piston Shoe

520, 530, 533 Loader

-3-6­ Service Manual
 3- 8 HYD ROST A TIC MOTOR SHAFT SEAL INSTALLATI ON
REM OV AL A ND INSTA LLATION
NOTE: All
o
(1) Put the machine on jack­
stands. Remove the cover from Di mensi on s

( under the motor (Fig. 3-18). In Inches.

Driver·---..
(2) Let hydraulic fluid out of the
chain case. Remove the foot rests,
seat assembly, shield and
chaincase covers .

(3) Make a separation of the front

drive chain at the white connector
link. If chain does not have a ~Shaft 8·2985
connector link. Put paint on the J. Seal

t 1
new connector link for future
Fig. 3-18 Remove the Cover
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.
(5) Remove the bolts which hold
the motor to the chaincase. Tilt the
motor to one side to release the
o.375
t
...... a,;.=~ t--:'
-
0.500
+ 0.125.
+ 1'1/~l 45.: 1~1141}6IX t150
tension on the rear drive chain,
then remove the motor (Fig. R
3-19). 2.062 I.. .
3 - 8.1 Installation (,!}4{
1.375 ~~
/~+"
Installation is the reverse of removal.

I
~
Be sure to use a new a-ring between A·1851
2.437-
the motor and the chaincase. On the
520; SIN 13 24 6 & below and 533; Fig. 3-17 Seal Installation Tool Fig. 3-19 Remove Motor
SIN 1 1060 & below, use new twelve
point bolts if not installed .

3 - 9 HYDROSTATIC MOTOR REPAIR

3 - 9 . 1 Disassembly and Inspection "­

I '
I "
,,
(1) Remove the nut and use a ,,
puller to remove the sprocket from ,, 18
the motor shaft. ,,
,,
(2) Remove the bolts which hold
the end cover to the motor. Use a
soft hammer to make a separation
of the end cover and sleeve
protector (Fig. 3 - 20).

(3) Remove the internal parts

from the motor (Fig. 3-21).

30
.~
)

,,
,,
,,

8·2876 C·2013

Fig. 3 - 20 Remove End Cap Fig. 3-21 H ydrostatic Motor Brea kdo w n

520, 530, 533 Loader

Revised Mar 79 ·3-7­ Service Manual
 (4) Slide the coupling shaft from
the housing (Fig. 3-22).

(5) Remove the seal from the

housing (Fig. 3-23). Remove the
<r-.."".---'-''--­ ____ _ _ ~
snap ring and seal parts under the
outside seal (Fig. 3-24). ~

(6) Use a press to carefully push

against the th rust washer to remove
the needle bearings (Fig. 3-25).

NOTE: Remove these bearings only if B-2841 8 ·2877

t hey have wear or damage.
Install new bearings if the old Fig. 3-22 Remove Coupling Shaft Fig . 3-23 Remo ve Sea l
bearings are removed .

(7) Clean and check all parts for

scratch ma rks, wear and damage

(Fig. 3-26).

Be sure the inside ball is free. Move the

Press
motor housing to hear the inner ball. Do
not remove the larger, pre ss fit ball (F ig.
3-21, Item 1).

3-9.2 Assembly

(1) Clean all parts thoroughly and

8·2842 8-2872
install new seals and O·rings. Put

hydraulic fluid on the parts during

Fig . 3-24 Remove Snap Ring & Seal Pafts Fig. 3-25 R em o ve Needle Seal lngs
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 c hamfer toward the
hou sing (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 ~ Spacer
Ring ------II.. ~/ ~
Manifold I

Wear Plate
Installation
Sleeve ­
I I
I

~///
/
//
J~im
,/

~
Installation

Collar

Rubber Sealing
Ring

Manifold Plate 8·2875 A·2522

Geroter Section (Stator & Rolled

Fig. 3-26 Wear Areas Fig. 3-27 Install Sealing Ring

520, 530, 533 Loader

·3--8· Service Manual
 (5) Remove installation sleeve

and collar .

(6) Install shim on seal, then

install spacer and snap ring (Fig.

3-27).

NOTE: Be sure tapered edge of snap

the snap rin g is tow ards
the spacer .

(7) Install wiper seal (Fig.

3-27).
1>-2869

(8) Install thrust bearings and Fig. 3-28 Insta ll Thru st Bearings Fig. 3-29 Install Wide Shaft Bea ring
races (Fig . 3-28),

(9) Install wide shaft bearings

(Fig. 3-29). Push on numbered
side only . The distance from
machined surface of the housing to
the nu mbered side of the bearing
must be 2 . 4 - 2.42 inches
(60 ,96-61,47 mm) (Fig . 3-30).

(10) Install the narrow shaft

bearing by pushing on the
numbered side. Distance from the
machined surface of the housing to
the numbered side of the bearing
mus~ be . 150- . 2 10 inches
(3 ,81 -5,334 mm). Fig. 3-30 Check Bearing Location

(11) Put the housing in a vise . Put

tape over the key slot on the shaft
to prevent seal damage. Install the
shaft in the housing .

NOTE: Be sure to measure the length

of the shuttle pin (Fig. 3-3 2).
The co rr ec t leng th is,
minim um 1.455 inchs (3 6 ,9 5
mm) and maximum 1.495
inc hes (37, 97 mm). Replace
the shuttle pin when it is not
in th is specification range.

(12) Put the sealing ring in the

groove in the housing with the Install Ball and Pin Fig.
bevel side up (Fig . 3 - 31). Install
the ball and pin in the housing (Fig.
3-32).

(13) Install the drive link in the

coupling shaft (Fig. 3 - 33 ). Be
sure that the hole in the drive link is
in alignment with the hole in the
side of the coupling shaft.

(14) Install the thrust bearing over

the shaft (Fig. 3-34).

NOTE: Alignment bolts can be used

to aid in assembly.
: iZ865
(15) Inst all the wear plate over
the sha ft (Fig . 3-35).
Fig. 3-34 Install Thrust Bearing Install Wear Plate

5 20, 530 , 533 Loader

-3-9­ Service Manual
Revised Mar. 79
(16) Install the stator ring and the
rotor assembly (Fig. 3-36).

(17) Install the manifold plate (Fig.

3-37).

(18) Install the manifold (Fig.

3-38).

(19) Install commutator and special

sealing ring with flat side out (Fig.
3-39).

Fig. 3-36 Install Stator Ring & Rotor Fig. 3-37 Install Manifold Plate
(20) Install the commutator (F ig.
3-40).

(21) Put grease on the seal ing ring

and install the sleeve protector (Fig.
3-41).

(22) Install the sealing ring on the

end cover and put the cover on the
housing and protector sleeve. Fasten
the cover with bolts and tighten the
bolts evenly to 50 ft.-Ibs. (67,8 Nm)
torque.

Fig. 3-38 Install Manifold Fig. 3-39 Install Commutator Ring

Fig. 3--40 Install Commutator Fig. 3-41 Install Sleeve Protector

520, 530, 533 Loader

-3-10- Service Manual
 3 - 10 STEERING LINKAGE

3 - 1 O. 1 Adjustment (Old Style Linkage)

(1) Put the machine on jackstands .

Be sure that the tires are off the floor

AWARNING and are not hitting jackstands.

NOTE: Th e nuts that hold the steering linkage can become loose (Fig. 3 - 4 3,

I (2)
Item 1). Tighten the nut t o 2 5 - 2 8 ft.-Ibs. (33,8 - 37,9 Nm ) torque.

Disconnect the steering levers from the control rod .

Fig. 3-42 Loosen Pintle Arm Stops

(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) . 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

f orce to hold the pintle arms in the

neutral p osition. Adjustment to the

spring is made by turning the nut

(I tem 2).

NOT E: Current produ ction load ers

(5 30 ; SIN 1203 4 & above
and 5 3 3 ; SI N 12000 &
above) hav e improved steeri ng
li nkage and p edal control
p arts . You c an replace t hese
p a rt s with " i mproved "
parts. (See your Parts Manual
or microfich e for parts. ) J •
/
3 - 10.2 Adjus tm ent (N e w Style
Linkage)

To adj ust for neutral position (Fig .

0 - 1283
3- 45 ).
Fig . 3 - 4 3 S teering Controls
( 1) Put the machine on
jackstands.

AWARNING

Be sure t hat t he tires are off t he

fl oor an d are n ot hittin g
jackstands.

(2) M ove the left steering lever

until the tires do not turn (neutral).
Ad just rear pin tle bar so that the
bar is tight against both lobes of
8·2 828
pintle lev er and tighten the bolt
first to 28 ft.-Ibs . (38 Nml torque . Fig . 3-44 Centering Sprin g Assembly

520, 530, 533 Loader

Revised Mar 79 -3 ­ 11 - Service Manual
 (3) Move the steering lever
forward and backward and let the Left Steering Right Steering
pump return to neutral position . If Bar Bar

~
the pump does not return to
neutral, make adjustment again.
There must not be any space
between the bar and the lobes.

(4) Move right steering lever until

the tires do not turn (neutral).
Adjust the front pintle bar so that
the bar is tight against both lobes
of the pintle lever and the pump is Bar Centering
Lever Bar
still in neutral. Tighten both lobes Strip
to 28 ft .-Ibs . (38 Nm) torque .

(5) Move both steering levers

forward and backward and let C-2 431

them return to neutral. Fig. 3-45 Adjusting Neutral Position

(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 .

(10) Install the seat and seat plate .

(11) Remove jackstands and lift arm stop and lower lift arms .

520,530.533Loader
A dded M ar 79 -3-12- Service Manual
 DRIVE SYSTEM

Paragraph Page
Number Number

AXLES AND BEARINGS 4-2 4-1

BRAKE PAD REPLACEMENT 4-3 4-3

DRIVE CHAINS . . . . . 4-1 4-1

DRIVE

. SYSTEM

520, 530, 533 loader

Service Manual

4 FINAL DRIVE

4-1 DRIVE CHAINS

The drive chai ns are endless. (Do not have Front Cover

I
con nector 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.

4-1 .1 Chain Replacement

(1) Put mach ine on jackstands.

(2) Remove seat assembly and

transmission shield.

(3) Remo ve the covers f rom the

chai ncase (F ig. 4-1).

(4) Check the chain for connector

link. If there is no connector li nk,

sepa ration of the chain can be made

at any link.

E-1138R
(5) Install the new chain over the

sprockets. Use a new connector link

Fig. 4-1 Remove Chainease Covers

when oonnecting th e chain together.

\ ----­
(6 ) Install the chaincase covers,

transmission shie ld and seat

assembly. Add hydraulic f luid to the

chaincase reservoi r if fluid level is

low.

4-2 AXLES & BEARINGS

Axle
4-2.1 Removal Procedure For All Four
B-2814
Axles Is Similar
Fig. 4-2 Remove Bolt & Washe r Fig _ 4-3 Remove Axle

NOTE: Chain separation is not necessary

for axle removal.

(1) Put the machine on jackstands.

(2) Remove the bolt and washer

from the end of the axle (F ig. 4-2).
Remove the wheel.

(3) Use a slide hammer to pull the

axle from the machine (F ig. 4-3).

(4) Remove the inside bearing cone

with a long punch. if bearing B-2840
replacement is necessary (F ig. 4-4) . Fig. 4-4 Remove Bea ri ng Cone

520. 530, 533 Loader

-4-1- Service Manual
 (5) Use a puller to remove the
outer bearing cone (Fig. 4-5).

(6) Use a pu Iler to remove the

bearing from the axle shah if either
the bearing or seal have defects (Fig.
4-6).

(7) Clean and check all parts

thoroughly for wear or damage .

4-2.2 Assembly and Installation

(1) Install a new seal on the shah

with the open side toward the
chaincase. Lubricate the seal with
grease.
(2) Use a press to push the bearing
onto the shah (Fig. 4-7). B·2889 B·2 885

Fig. 4-5 Remo ve 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.

(4) Put the sprocket into the

chaincase and put the chain in
position on the sprocket.
Press
NOTE: The wide sprocket hub mu st be
toward the inside in the fro nt of
Beari ng
th e load er and toward the
outsid e at rea r of the load e r.

(5) Install the axle in the housing

and insta II the bearing and sprocket.

(6) Install the inner halves of the

installation tool (Fig. 4-8).

(7) Install the outer halves of the

installation tool (F ig. 4-9). 8·2810

Fig. 4-7 Install OUler Beari~g

(8) I nstall the spring on the
installation tool (Fig. 4-10).

(9) Use a hammer to hit the axle

until the installation tool is In
contact with both the axle flange
Fig. 4--8 InSTall Inner Halve s o f T oo l
and axle hou sing.

(10) Remove the installation tool.

(11) Tighten the axle bolt to pull

the seal and inner bearing into
position (F ig. 4-2) (See Section 8
Technical Data for torque
speci ficat ions).

(12) If the chain was separated

during axle removal, install the chain
and connector li nk.

(13) I nstall the covers on the

B·2774
chai ncase and install the transmi ssion
shield and seat assembly. Fig. 4-9 Install Outer Hal v es of T ool Fig. 4-10 InSla11 Sprrng o n To Ol

520, 530, 533 Loader

·4-2· Ser vice Manual
 . 4-3 BRAKE PAD REPLACEMENT (Fig .
4-11)

(1) Remove the seat assembly,

transmission shield and
transmission covers. Disconnect
the linkage from the brake lever. Front panel~_~
(2) Install the pucks into the
block (Fig . 4- 11, Item 1). Install
Wey---p'da,
the last puck into puck retainer and
put into the block.
(3) Put oil on the o-ring and put
~y ;;4 CD ...
the o -ring on the cam. Install the
cam in the block from the top (Fig . Brake Lever ... ~/r···---·-··-·~~
4-11 , ltem2) . ~ : ,' , ~· ··ld r

(4) Install the brake/puck block

on the transm ission cover . Install
Rear Cover V \ l·~
~~~~
; ~

~ ~. , 7 )
bolts and tighten &Fig . 4 - 11 ,
Item 3).
Puck ~. --- .. - ,' ront Cover

(5) Put the brake/puck assembly Retai\ner G}::::~ ;;am

and transmission cover over the
brake d iscs.
L Caliper Assembly

~G.I:-~i
(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·'328R

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 i
far clockwise as possible (against the right pump mount). I
(10) Install front cover and angle bracket and tighten bolts to 20 ft .-Ibs . (27 r

Nm) torque (Fig. 4-11 , ltem 4). I

(11) Install bar and bolt on the cam (Fig. 4-11, Item 5) and tighten bolt to 70 . ~.

ft. -I bs. (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).

(12) Assemble brake pedal and

rod (Fig . 4-11, Item 6).

(13) Install brake pedal on front

cover.

(14) Install brake rod into hole in

brake lever.

(1 5) Install nut (big nut) and lock

---,
nut onto brake rod (Fig . 4-11,

Item 7).

I
:©
(16) Connect one end of the
I
I
spring to bar on the cam. Connect

I
other end to angle bracket on front
I
cover .
___ J I©
(1 7) Adjust the brake rod nut (big

nut) for 1/4" freeplay between nut

and brake lever and turn lock nut

-../. against the nut (big nut).

(18) Check pedal operation in

locked and unlocked position.

(19) Install front plate , seat and

Fig. 4-12 Brake Pad Adjustment
seat plate.
520, 530, 53 3 Loader
Revised Mar 79 -4-3· Service M anual
 MAIN FRAME

Paragraph Page
Number Number

BOB-TACH 5-3 5-2

REMOVAL OF FUEL TANK AND

HYDRAULIC RESERVOIR 5-4 5-:4

REMOVAL OF ROPS 5-1 5-1

REPLACEMENT OF PIVOT PINS 5-2 5-1

MAIN
FRAME

520, 530, 533 Loader

Service Manual

 5 MAIN FRAME

5-1 REMOVAL OF ROPS (Operator

Guard) (Fig. 5-1)

(1) Stop the engine and activate

the hydraul ic contro Is to release
hydraulic pressure in the system.

(2) Fasten a chain hoist to the

ROPS .

(3) Remove the two (2) bolts from

the front corners of the ROPS .

(4) Remove the two (2) bolts from

the rear corners of the ROPS.
Fig. 5-1 Rem ove The ROPS

(5) Disconnect the wiring harness.

(6) Lift the ROPS from the

Bobcat.

,
,
CSl

{
AWARNING ~ " I
J

'--/-..J

Be sure to install hold down bolts

and washers when installing the
ROPS (F ig. 5-2).

D-l369R

Fig. 5-2 Install Holddow n Bolts

5-2 REPLACEMENT OF PIVOT PINS

(Fig. 5-3)

(1) Stop the engine and activate

the hydraulic controls to release

hydraulic pressure in the system.

( 2) Fasten a chain hoist to the lift

arms.

(3) Remove the bolt in the pivot

pin.

B-280 1
(4) Use a punch and hammer to

remove the pivot pins.

Fig. 5-3 Liftarm Removal

520, 530, 533 Loader

-5-1­ Service Manual
 r--(] ......._ - - - - Bushing

This Sleeve used on

early 520 models only
, (Kit #6555534)
p,
.
:-; /
- --(]

D-1467

Fig. 5-4 Bushing Replacement

5 - 2 . 1 Bushing Replacement

T here are bushing s i n the lift arm pivots

on ly (Fi g . 5-4 ).

The bu sh ings must be removed and

installed with a bu shing driver of the
correct size. Be sure that the grease
hole in the lower pivot bushing is
alig n ed with the grease f itting. Push the
upper pi v ot bushing in until it is even Weld Both
with t he outside of the collar. LH and RH
Sides of Lift Arms

AWARNING

Release the hydraulic pressure Fill in W ith

and use a good support to hold W eld On
the cylinders and lift arms Corner Openings
before removing any pivot pin. (Both Sides)

Weld On Four Sides

Th ere m ay be a failure of w elds on the Edge Along The (2 On the Inside)
lift arm crossbar on t h e early 520 Crossbar (2 On the Outside)
Bob c at s. Remove the lift arms and
make a continuous wel d as shown in
figure 5-4a . Corner Opening

Fill With Weld

NOTE: W eld the crossbar at each

junction and fill in the corner
0 · 146 7
openings with weld so it be­
comes a solid piece. Fig. 5 - 4 a Li ft Arm W eld (520)

520, 530, 533 Loader

Revised Mar 79 -5-2- Service Manual
5-3 BOB-TACH

5- 3.1 To Check the Wedges (Fig.

5-51

(1) Install an attachment on the

Bobcat.

(21 Engage the locking levers.

(31 Replace the wedges if they do

not extend at least 1/4 inch (6,5

mml through the notches in the

attachment (Fig. 5 - 5).

(4) Check that the locknut is tight

(Fig. 5-6).

NOTE: There is no adjustment for the

Bob-Tach wedges.
Fig.5-5 Checking Bob-Tach Wedges Fig. 5 - 6 Check Locknut

520, 530, 533 Loader

Revised M ar 79 -5-Za- Service Manual
5-3.2 Removal of Bob-Tach (Fig.
5-7)

(1) Lower the lift arms and Bob­

Tach to the ground.

(2) Stop the engine and activate

hydraulic controls to release
hydraulic pressure from the
system.

(3) Remove the pivot pin from the

rod end of the tilt cylinder.

8-2791 8-3062

(4) Remove the bolts and Fig. 5 - 7 Removal of Bob-Tach Fig. 5 - 8 Remove Bob-Tach Pin

washers from the Bob-Tach pivot

pins.

NOTE: Early 520 loader used a

straight (not tapered) pin, kit
#6555534 should be installed
on these loaders.

(5) Use a hammer and punch to

push the pivot pins into the Bob­
Tach frame (Fig. 5-8).

(6) Remove the Bob-Tach.

Installing 80b-Tach Pins

To install Bob-Tach, remove the grease
fittings and use a thin punch to push
the pivot pins out of Bob-Tach frame
(Fig. 5-9).

5-3.2a Bob-Tach Over-Center Stop

Install mechanical stops on the Bob­

Tach and lift arms when the Bob-Tach
goes over-center when tilted fully
forward.

Install the kit (PIN 6560898) to

prevent damage to the tilt cylinder
parts (Fig. 5-9a). 0-1488
Fig. 5-9a Bob·Tach Over-Center Stops
520, 530, 533 Loader
Revised A pril 79 -5-3­ Service Manual
 5-4 REMOVAL OF FU EL TANK AND
HYDRAULIC RESERVOIR

(1) Remove th e seat assembly. \.

\.

(2) Remove the cover (Fig. 5-10).

(3) L et fluid out of the tank or

reservoir. (See Section for
remov ing hydraul ic f lu id .)

.'
'. /

(4) 0 isconnect the tubel i ne or hose .­

.
to the tank or rese rvoir. Put covers
on all openi ngs to keep dirt out. :~
~
' - - '
, - - OJ
l " -", ;,'
- . ". • • • ¥ /'

'~0

(5) R emove the tank or reservoir .

~-
, "­
~ :------ - ----, p -­
, . °

(6) When installing tank or I

~ ,'
'

~J
reservoir. be sure the cushions are in
correct position.

~~-.....J.(1
,o.p.,........... --to'!

Hydraulic
Reservoir Tank

Fuel Tank
____----------------~~
Reservoir

(533)

Sy st em

Fig . 5-10 Removal of Fuel and Hydraulic Reservoir Tanks

520, 530, 533 Loader

·5-4· Service Manual

-
 ELECTRICAL SYSTEM

/ /r "
Paragraph Page
d
\:~ Number Number

CHECKS & REPAIRS OF THE ELECTRICAL

SYSTEM (520/530) 6-3 6-8
CHECKS & REPAIRS OF THE ELECTRICAL
SYSTEM (533) , 6-5 6-9
ELECTRICAL CI RCUITRY 6-1 6-1
GENERATOR SERVICE 6-6 6-10
PROBLEM ANALYSIS CHARTS 6-2 6-1
REPAIR OF THE STARTER 6-7 6-12
STARTER 6-4 6-8

ELECTRICAL
SYSTEM

520, 530, 533 Loader

Service Manual
 6 ELECTRICAL SYSTEM
Solenoid
6-1 ELECTRICAL CIRCUITRY

There are three basic electrical ci rcuits

in the loader electrical system. They
are:

(1) The sta rting circuit (switch,

solenoid, battery and starter) (Fig.

6-1).

(2) The ignition circuit (points,

spark plugs, coil and attached

wiring). (See Section 7, "520 and

5 30 Loaders ".)

Switch
B·2275

Fig. 6-1 Starting Circ uit (Simplified)

Battery

AWARNING
Before making repairs on the

electrical circuits, disconnect

the battery ground cable.

Generator
Rectifier IRegulator
The 520 and 530 loader has a 12 volt,
15 amp . flywheel alternator charge
system. (See figure 6 - 3 and 6 - 4 for
wiring diagrams.) B-2274

Fig. 6-2 Charging Circuit (Simplified)

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.)

6 - 2 PROBLEM ANALYSIS CHARTS

See the charts for diagno sis of electrical problems (Page 6 - 7).

Chart A: Battery does not keep charge.

( Chart B: Starter will not turn engine.

The charts give the correct order for finding problem s and making repairs.
520,530,533loader
Revised Mar 79 -6-1- Service Manual
 AMP
Gauge
Inst r ument
11 /
Box
-1!J / '
~ EngineOil

Hydraulic P ressure
Ignition Sw it ch
Switch /
~/
"--D- - Q- - ~ --c:8 ~I
.-'~-- --e
,>-

...............
Transm ISSIon
' ,
Oil

Hour Meter

\, ,I
I

-w.,;t
'

• I

.. I "
'

--,'
I

- I

I
I
I
I
I

Battery
\;u. Spark

~
-;:1r- '.
Engin e "
Oil
__, .... Press u
E r ----~e
ng. Temp -
~ .
"wi tch

..,
~
I
r_
Stator I I
I
- _ I
D,128 7

Fig. 6 - 3 Ele ctrical System 15 20 loader )

520, 530, 533 Loader

Revised Feb ruary 80 6-2­ Service Ma nual
 Front
. -C) ~
(

Rear
Light

1 "
J '

~ . / ~~I(ij· ,j
~~ ligh' Switch
0"

/
Instrument Box

Meter
Spa rk Plug
Wire
Ammeter

Stator
1 E-1 183

- - . 1
E- 1 18 8

Fig, 6-4 --;;;;~-----~

Ele CHical S ystem (5 30 Loaded

520, 530 , 53 3 Loader

Revised February 80 -6-3· Se rvice Manual

 Front Lights

~\

Rear
L ight

AMP Gauge
\
Hour Meter

I
i
Hydro Pressure
Switch

Batte~ ___________ ~

E·1166
E·1188

Fig. 6-5 Electrical System (533 Loaded

520. 530. 533 Loader

.6-4­ Service Manual
 ------,
I

,t'
I

;:
.-n-l ,
~~
I

Fig. 6--6 Electrical Sc h ematic {530 Loaded

520" 530 533 LoaderI

·6-5· Service Manua
 ELECTRICAL SCHEMATIC

"'''
~LlIoOto

_-_"_' _ __ - ' - - _ - - ._ _ _r ll~fS.l.o()O"

SCHEMAT IC

Fig. 6 - 7 Electrical Schematic (533 Loaderl

520, 530, 533 Loader

-6-6­ Service Manual
 CHART A
BATTERY WILL NOT HOLD A CHARGE
/

Charge Battery
Check Condition

Completely & Check

_
Condition With

If ...
Good
Of Battery

Terminals & Wiring

Check A.C.
Voltage

(See Sec. 6-3)

- If
Good
... Install New
Rectifier/
Regulator
A Hydrometer
And Fuse

If Bad If Bad If Not Correct

t t
•

Install New
Make Repairs

Install New

Battery
As

Stator

Needed

CHART B

STARTER IfI'ILL NOT TURI\I EI\IGII\!E

II
Check Condition

Of Battery With

A Hydrometer

- If
Good
... Check Wires
For Damage - If
Good
.. Connect Jumper
Wire Across
Solenoid (Sec. 6-5)
If
_Engine....
Does Not
Turn
R .
M.:ke epalrs
To Starter
(Sec. 6-4.3)

I 1
If Bad If Bad
If Engine
Turns
I

If Starter Turns

t But Engine

Does Not Turn

Put Charge

In Battery
Make Repairs Install New
Check Charging
As Needed Solenoid
System

Install New
(See Chart A)

Starter Drive
(Sec. 6-6)

520, 530, 533 Loader

-6-7­ Service Manual
6 -3 CH ECKS AND REPAIRS OF T HE
EL ECTRICAL SYST EM (520 & 530)

6- 3.1 Ch ec ki ng A. C. Voltage

( 1) Put the machi ne on ;acks ta nds

and remove th e wheels.

(2) Disconnect the stator wires

f rom th e re ctifier and connect them

t o t he A.C. vo ltm et er (F ig. 6-8).

(3) Start the engine and let it run

at max imum RPM. The voltage must

be 28 or more vo Its. If the voltage

Fig. 6~ Check AC Voltage Fig. 6-9 R emove Flywheel Nut

is less than 28 volts. replace t he

stat er. If th e voltage is over 28 volts. the stator is good .

6-3 .2 Alternator Re pair

The alternator is located behind the engine flywheel.

6-3 .3 Replaceme nt of the Stator

(1) R emove the blower hou sing.

(2) Hold th e flywhee l wi th a piece of wood and rem ove the nut (Fig . 6-9) .

(3) U se a pu ller (Fig. 6 -10) t o remove the flywhee l.

(4) Remove the screws that hold the st ator (F ig. 6-11).

(5) I nstall the new stator. Install the flywhee l and blower housing. (See Section 8
for correct torque for the flyw heel nut .

6-4 STARTER

6-4. 1 To Check the Star ter

NOTE : Before ch ec ki ng the starter. be sure th e batte ry has full charge and all electrical
connections are good. C·2334

(1) Pu t the mach ine on ;ackstand s. Remove the wheel s. Fig . 6 - 10 Remove Fl ywhee l

(2) Con nect a large wire between the two large t e rm ina ls on th e so len oid (Fig .

6 -12).

(3) If the starter turns rapidl y. it

has no defect but the solenoid can

h ave a defect.

6 -4.2 Removal of Starter

(1) Disconnect the ground cable

from the batte ry .

(2) Disconnect the wi re from the

sta rter.

(3 ) Remove the so lenoid from the

sta rter.

(4) R emov e the bolts which hold

B·2907
the starter and remove the starter.
Fig. 6-11 Remove Stato r Fig. 6 -12 Checking Starter
520. 530. 533 Loader
·6~· Servic e Manual
 (5) When installing the starter,
connect the battery ground wire
last.

6-4.3 Disassembly and Repair

(1) Pull the rubber cap off the end

of the starter shaft . Use two
wrenches to remove the nut on the
end of the shaft (Fig. 6-13) .

(21 Remove the starter drive B-2862

parts as shown (Fig . 6-14) .
Fig. 6-13 Remove Shaft Nut Fig. 6-14 Remove Starter Drive Parts

(31 Put a mark on the side of the

starter housing and end plates for
an aid in assembly .

(4) Remove the long bolts and

make a separation of the housing
and end plates .

(5) Check the condition of the

brushes . If the brushes are less
than 5/16" (8 mm1 in length,
install new brushes (Fig . 6-15) .

B-2878 B-2860
(61 Check the commutator (Fig .
6-16) and check the armature in Fig. 6-15 Check Brushes Fig. 6-16 Check Commutator
a growler.

(71 Check all the parts of the

starter for damage. Add lubricant No.2
to the bushings and assemble the
parts in reverse order of
disassembly .

NOTE: Do not put lubricant on the

starter drive splines.

6-5 CHECKS AND REPAIRS OF THE

ELECTRICAL SYSTEM (533)

6-5.1 To Check the Wiring

(1) Turn the switch key to "on" .

Connect a voltmeter from the
chassis to : (Fig . 6 -17)

No . 1 generator connection

No.2 generator connection

"Bat" connection

(2) If any of these connections

show zero voltage, the wiring has
defect . Find the defect and make 8-2113
repair. Then check the voltage
again. Fig. 6 ­ 17 Alternator

520, 530, 533 Loader

Re vised Mar 79 -6-9­ Service Manual
6 - 5.2 To Check t he Generator Out put Test Hole

(1) Put the machine on jack­

stands.

(2) Disconnect the negative

battery cable . Connect an ammeter
in line with the "Bat." terminal of
the generator , and connect the
battery cable.

(3) Lower the electric charge in

battery. (Turn the engine with the A-2211
8-2113 B· 2655
starter, connect lights, etc.)
Fig. 6-18 Che ck ing Regulator Fig .6- 18a " Pre-Heat" Position
(4) Start the engine and run at full
throttle. The indication on the
ammeter must be within 10
amperes of the rating mark on the
generator.

(5) If the indication is correct, the

gene rator is good . If the indication
is high or low, check the regulator .

6 - 5.3 To Check the Regulator Diode ~/~

(1) Leave the ammeter I

/~-- -­6- - - ...
connected as in Paragraph 6 -14. ~ /

(2) Lower the electric ch arge in

battery. (Turn the engine with the
starter, connect lights, etc .)
~S ~r-" .
(3) with the engine running at full
pre He~
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 B-3140R
amperes of the rating mark on the
generator. If the indication is Fig . 6-18b Pre-Heat Indicator Installation & Wiring Circuitry

correct, the regulator probably has

a defect. If t he indication is not
c orrect, the problem is in the diode Pre-Heat Indicator
trio, the rectifier, the stator or the Connecting Bar
rotor.

6 - 5.4 To Check the Engine Pre-Heat Lt. Blue/Black

(1) Turn the starter switch to the

"pre-heat" position (Fig. 6 -18 a).
_ - - - - - Diode
(2 ) If the indicator is "ON" White Wire
(glows), the circuit is good.

(3) The pre-heat indicator must

be installed as shown in figure
6 - 1 8b and 6 - 1 8c . Starter Switch

(4) The diode must be installed as

shown for the glow plug t o operate 4" Jump Wire
6-2943
wh en the starter switch is in the
"start" position. Fig. 6 ­ 18c Pre-Heat Wir ing Circuitry

520. 530. 533 Loader

Revised Mar 79 -6- 10­ Service Manual
 6":"'6 GENERATOR SERVICE

6-6.1 Removal of the Generator

t ' (1) Disconnect the negative battery cable.

'i'.
(2) Disconnect the wires from the generator.

(3) Remove the two bolts that hold the generator in place and remove the

generator.

(4) Installation is the reverse of removal.

C·1959

6-6.2 Disassembly Fig. 6-19 Separate Housing

(1) Put a mark across each housing half for correct alignment during assembly.

(2) Remove the pulley from the shaft.

(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.

(6) Disconnect the diode trio.

I .'
520. 530. 533 Loader
A dded Mar 79 -6-10a- Service Manual
 6-7.2 Checking the Starter

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.

Standard outside diameter 1.73" (41 mm)

Minimum allowable diameter 1.61" (41 mm)

B-3009

Fig. 6-27 Aramture Undercut

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.

Value ind ication for need of

servici ng above .016" (0.44 mm)

Finishing accuracy .002" (0.05 mm)

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.

Value indication for need of

servicing above .OOS" (0.2 mm)

Standard depth .020" ..031" (0.5 - O.S mm)

(3) Armature coil insulation test:

Test for insulation between the commutator segments using a growler tester (Fig. B-2990
6-2S). If the light of the growler illuminates, the coils are poorly insulated and the
arm atu re needs replacement. Fig. 6-29 Armature Coil Short Test

(4) Testing of the armature coi Is for shorts:

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.

(5) Armature coil continuity test:

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

Fig. 6-30 Armature Coil Continuity Test

520, 530, 533 Loader
-6-13­ Service Manual
Field Coils

(1) Measure the insulation resistance between the field coils and yoke , using a
megger meter (Fig . 6-31).

Standard insulation resistan ce 1M or higher

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 f ield coils using a tester (Fig. 6-32) .

If the indication between the coil leads show resistance, replace the fiel d coils. 8-2995

Brushes and Brush Holder Fig . 6 - 31 Fi eld Coil In su lati o n Te s t

(1) Check the brushes for wear, damage and broken wires and replace the
parts if defect is found .

Brush information

Standard Brush Length Limit for use

.710" (18 mm) .472" (12 mm)

Check the brushes for broken springs , corrosion, distortion or weak tension .
Replace parts with defects, as necessary .

Standard spring tension .031" (0.8 kg)

8·2994
(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 Fie ld Coi l Con ti n Uity Te st

Solenoid O perating 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 mou nting frame. Also be sure the
connections on the solenoid have insulation covers.

6 - 8 CHECKING ELECTRICAL WIRING

(1) Check all wires for broken insulation and replace any bad wires.

(2) The electrical connector (between the ROPS and the mainframe) can get
corrosion. Put a sealant (water resistant) on the connector before installing.
Fig. 6 - 33 Check Bru sh Holders

(See the Parts Manual (or microfiche) for the part number of the sealant).

6 - 9 STARTER SUPPORT BRACKET

Install a support bracket (Fig. 6-34) at the lower through bolt of the starter and the

1right front engine mount if there is a failure of the starter mount. (See Parts Book or
Microfiche for correct PIN).

Revised February 80 -6 -14­

 ENGINE SERVICE (520/530)

Paragraph Page
..f'
Number Number

CARBURETOR REPAIR 7-3 7-3

CHECKS AI\ID ADJUSTMENTS 7-2 7-2
ENGINE 7-5 7-5
OIL PUMP AND RELIEF VALVE 7-8 7-7
PISTONS, RODS, CRANKSHAFT 7-9 7-7
REPAIR OF THE ENGINE 7-6 7-5
REPAIR OF THE GOVERNOR 7-4 7-4
TIMING COVER, TIMING GEARS, CAMSHAFT 7-7 7-6
TROUBLESHOOTING THE ENGINE 7-1 7-1

ENGINE SERVICE
(520, 530)

520, 530, 533 Loader

Service Manu<ll
7-1 TROUBLESHOOTING THE ENGINE (520/530)

PROBLEM CAUSE CORRECTION PAGE

Engine will not turn with starter. Battery charge low. Increase charge in 'battery, find 6-2
cause for charge loss.

Cables loose or d irty. Clean and tighten cables. 6-2

Starter defect, solenoid or wiring. Check starting circuit. Make 6-3

repairs as needed .

Engine turns with starter, but is Wrong starting procedure. See Owner's Manual for correct -
difficult to start. procedure.

No fuel in tank. Add fuel , if needed. -

Vent in fuel fi lier cap has Clean as needed. -
rest rictio n.

Dirt or water in fuel system. Make repairs as needed. -

Defect in carburetor. Make repairs as needed. 7-3

Hole in fuel line. Make repa irs as needed. -

Choke not closing completely. Make adjustment of linkage. -

Ign iti on system has defect. Check and make repairs as 7-3
needed.

Wrong oil in engine. See Oil Specifications. 9-1

Engine has lost compression. Overhaul the engine. 7-5

Engine has overheated . Clean cool ing system. check 1-6

ignition.

Engine has little power or runs Defect in ignition system. Make repairs as needed. 7-3
rough.

Dirt or water in fuel system . Clean and make repairs as -

needed.

Choke not open . Check choke linkage. -

Governor adjustment is wrong. Check and make adjustment if 7-2

needed .

Dirty air cleaner. Check air cleaner. 1-4

Engine has lost compression. Overhaul the engine. 7-5

Engine overheats. Cooling system is dirty. Clean coo ling system. 1-6

Engine air housing cover damaged Check air housing covers. -

or miss ing.

Ignition system set wrong. Engine Check ignition timing. Operate 7-3
is overloaded. 10 a d e r with engine at full
th rottle.

520, 530, 533 Loader

Revised Mar 79 -7-1­ Service Manual
7 - 2 CH ECKS AND ADJUSTMENTS

NOTE : All engine specificat ions can be found in Section 9.

7-2 . 1 Oil Pressure

(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).

Fig. 7-1 Checking Oil Pressu re

(4) Make adjustment of pressure
by loosening the jam nut under No.
1 cylinder (Next to the Flywheel)
and turning the screw in or out
(Fig. 7-2).
ACORN SELF LOCKING NUT
LOCK NUT
7-2.2 Valve Clearance "'-..
NOTE: Ma ke adjustment of tappets with ~ :~
engi ne cold.

(1) Remove the covers from the

-Ii 1(
I ADJUSTING
valve chambers. I SCREW
£a rl 4 mot12ls have aco l"T1 nut .

(2) Turn the crankshaft until there

PI-1908
is a ma x imum amount of clearance
between the valve and tappet. Check Fig. 7-2 Oil Pressure Adjustment
the clearance wi th a feeler gauge
(Fig . 7-3)
Valve-Tappet Clearance
(3) If the clearance is wrong, turn

the screw on the end of the tappet

unt iii t is correct. (See Section 9 for

correct clearance.)

7 - 2.3 Compression

NOT E : Check compress ion with the

engine hot .

( 1) Remove both spark plugs.

(2) Open the throttle and choke

PI-1911
fully. Remove the coil high voltage
Fig . 7 -3 Val ve Clearance Adju stment
wires.

(3) Install the compression gauge in the cylinder to be checked. Throt tle
l inkage
(4) Turn the engine several times with the starter. Check the gauge. (See
Specifications, Section 9).
7-2.4 Ad just ment of the Ca rb uretor

NO T E:Adjustm ent to the carburetor is to be made only when the ignitjon system is
cor rect.
7-2.5 Thrott le and Governor Link age (F ig. 7-4)

(1) Put the machine on jackstand s . Screw

(2) Disconnect the throttle linkage between the carburetor and go vernor arm. Hold
the throttle on the carburetor fully open , and hold the governor arms against the Bracket B-2282
stop (Fig. 7-4) . Adjust the length of the throttle linkage so it will fit.
Fig. 7 -4 Throttle & Governor Linkage

520, 530, 533 loader

-7-2· Service Manual
 (3) Push the throttle control fully ahead . The speed stop screw must be against
the stop. If not, make adjustment of the stop screw at the throttle control lever
(Fig. 7-5).

(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 cont ro l 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 auxiliary control and check the high .idle RPM . Turn the speed
RPM stop screw to get correct RPM. Fig . 7 -5 Throttle Leve r 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.

7-2.6 Ignition System Adjustment

Main Fuel
(1) Install new ignition points and turn the engine until maximum point gap is Adjustment
reached. PI·] 905

Fig. 7-6 CarburetOr Adju stment

(2) Make an adjustment of the gap to .020" (.51 mm) (Fig. 7-7).

(3) Put Bobcat on jackstands.

(4) Remove the cover for the timing si ght 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. U se 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 bolt s.

(7) Check adjustment of the idle RPM. Fig. 7 -7 Adjust Po;nts

7-3 CARBURETOR REPAIR

7-3.1 Removal

(1) Disconnect the hoses and linkage from the carburetor.

(2) Remove the bolt and two nuts which hold the carburetor te 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.

520, 530, 533 Loader

-7-3­ Service Manual
7 - 3 .2 Disassembly and Inspection
(Fig . 7- 9)

(1) Remove both mixture screws

and springs .

(2) Remove the plug from the

float bowl. Remove the bowl from
the carburetor body . CARBURETOR
BODY
(3) Remove the float pin, float
and needle from the carburetor
body.

~ FUEL INLET
(4) Remove the seat from the
carburetor body.
~7NEEDLE & SEAT

®
(5) Clean all parts thoroughly. Do
not remove the throttle or choke
shafts. BAFFLE

(6) Check the float for bends and

damage .

(7) Check the end of the needle

valve for wear or damage.

7 - 3 .3 Assembly
PI-1912

NOTE: Use all new gaskets during Fig. 7-9 Carburetor Assembly

assembly.

(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) Tu rn 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 bo wl with a new gasket installed on the plug.

NOTE: When gravity flow of fuel to the carburetor continues w hen the ignition
B-2883
switch is off (All 520 & 530. SIN 12138 & Below) install the parts for the
fuel shut-off (Solenoid Activated ). When the engine continues to run after Fig. 7 - 10 Remove Paints
the switch is turned off (Dieseling). install the carburetor w ith the "Anti­
Dieseling" solenoid. (The choke linkage must be replaced with a choke
cable kit) (See Parts Manual or Microfiche for Parts).

7 - 4 REPAIR OF THE GOVERNOR

7 - 4 . 1 Removal

(1) Disconnect the hoses and linkage from the governor.

(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.

(3) Remove th e crankcase breather .

Rem ove the ignition point cover, ignition points and push rod (Fig. 7 -10).

520. 5 30 . 533 Loader

Revised Oct. 80 -7-4­ Service Manual
7 -4.2 Installation

Remove the plug from the top of the

governor adapter and ignition timing
sight hole cover . Turn the flywheel so
the D.C. mark can be seen. Insta[[ the
governor so the bevel on the gear is in
alignment with the hole in the governor
adapter (Fig. 7-11) . Check the
adjustment of the timing, governor
linkage and carburetor

NOTE: On the 530 loader with engine

SIN 9224060 & up there may
be too much oil consumption
when engine has a small
amount of hours. Remove the
oil tube, elbow and adapter
that goes from the engine
block to the governor. Install
1/8" NPT plugs in the holes
which will prevent oil from
going into the carburetor
through the breather hose.

7-5 ENGINE

7 - 5.1 Removal and Installation of the

Engine

NOTE: If the engine is to be tested

out of the machine, a plate
must be installed on the pump
drive end to keep the oil in
the engine. 8·2293

(1 ) Remove the battery. Fig. 7 -11 Timing Marks

(2) Remove the muffler.

(3) Disconnect the throttle and choke linkage .

(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 .

Fig. 7 - 12 Transmis sion Support

Use a chain or other support to hold the end of the pump for correct alignment during
engine installation (Fig . 7 -12).

7 -6 REPAIR OF THE ENGINE

7 - 6. 1 Flywheel

NOTE: It is not necessary to remove the engine for flywheel replacement.

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.

00 not try to replace the ring gear. If the ring gear teeth are damaged, replace the

1complete flywheel. The side with the bevel on the teeth must be toward the engine
(Fig. 7 -13). Fig. 7 -13 Ring Gear Installation

520, 530, 533 Loader

-7-5­
Revised July 79 Service Manual
7-6.2 Repair of the Valves and Guides

(1) Remove the engine.

(2) Remove the shrouding, cylinder

heads, manifold and valve chamber

covers. Turn the crankshaft and

check the amount of valve lift. If

not enough, the cam is worn and

needs replacement. (See Section 8

for Speci ficationsl.

(3) Use a valve spring compreSSOr

to remove the valve springs (Fig.

7-14).

NOTE: There are valve rotators under

the exhau st valve spri ngs. T he
exhau st valve springs are shorter.
The close coils on the spri ngs
must be toward s the cyli nder
heads.

(4) Check the clearance between

the valves and guides. If over

maximum, push the guides out and

install new guides. Use a reamer in

the new guide to make it the

correct size.

(5) Check the exhaust valve seats PI· 1910

for wear, distortion or cracks. Use a
Fig. 7-1 4 Remove Valve Springs & Locks
valve seat tool to remove old seats,

if necessary.

NOT E : Only exhaust seats can be

removed.

(6) Grind the valves and seats. Use grinding compound to check that valves are
fitted correctly and seat has correct width .

7-7 TI MIN G COVER, T IM ING G EA RS, CAMS HAFT

7-7. 1 T iming Cove r

(1) Remove the air housing for the flywheel.

(2) Remove the bolts which hold the timing cover in position and slide it off the
cran kshaft.

(3) When installing the timing cover, note the two special bolts. Install and tighten
these two bo Its first (F ig. 7 -15).

7-7.2 Timing G ears

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
off.

If the oil pump gear is bad, make a replacement of the complete pump.

NOT E: Be sure that t he crank and cam gea r marks are in al ignment (Fig. 7-161. F ig. 7-15 T iming Gear Cover Installation

520, 530, 533 Loader

·7-6­ Service Manual
 7 -7.3 Camshaft and Tappets

The gear cover must be removed to

remove the camshaft gear. Remove all
oJ the bolts which hold the gear cover
plate in place. Remove the cylinder
heads and valves . Turn the camshaft to
push the tappets out of the way and
slide the shaft out of the engine .

NOTE: If the camshaft is worn, also

replace the tappets. To replace
the tappets, the oil pan must
be removed .

7 - 8 OIL PUMP AND RELIEF VALVE

The relief valve for oil pressure is under Fig . 7 - 16 Alignment of the Crank a nd Cam Ge ar Mark s
the No . 1 cylinder (Fig . 7 - 17). The oil
pressure is adjusted by loosening the
jam nut and turning the sc rew 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.

If oil pump has a defect, a replacement

must be made. To remove the pump,
( remove the oil pan and take off the
strainer . Then, remove the flywheel
and gear cover . Remove 2 bolts which
hold the pump in place and lift out the
pump (Fig . 7 -18).

7-8.1 Adjust Gear Clearance for

Engine Oil Pump
Fig. 7 -16a Adju st ing Oil Pump Ge ar With Feeler Gauge

When installing the oil pump on the

520 and 530 engine, it is important to
adjust the clearance between the oil
pump gear and the crankshaft gear .
The clearance between the gears is
.005" to .009" (0,127 to 0,228 mm) .
A feeler gauge or a dial indicator can be
used.

To Set Clearance With Feeler Gauge :

(1) After oil pump is installed, do

not tighten the mounting bolts .

(2) Use a .007" (0,177 mm)

feeler gauge and adjust the
clearance between the oil pump
and crankshaft gear (Fig. 7 - 16al. A· 2 64 2
Tighten the mounting bolts . Fig. 7 -16b Adjusting Oil Pump Gear With Dial Indicator

520,530,533 Loader
Revised Mar 79 -7-7­ Service Manual
 (3) Check the clearance at two other locations (1 20 0 from each other) to be
sure the clearance is correct.

(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.

To Set Clearance With Dial Ind icator:

(1) After oil pump is installed, do not tighten the mounting bolts.
Fig . 7 - 17 Relief Va lv e

(2) Mount a dial indicator on the engine (Fig. 7 -1 6b) . 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.

Fig . 7 -18 Remove Oi l Pum p

(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 .

7 - 9 PISTONS, RODS, CRANKSHAFT

(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 -191.

(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
beari ng in the engine block.
Fig . 7 - 19 Remove Piston & Connecting Rod

520, 530, 53 3 Loader

Revised Mar 79 -7-8­ Service Manual
 (6) Check the following:

a. Crankshaft: keyway, diameters, round condition.

b. Rods : condition of bearing surfaces.

c. Pistons: scratch marks, ring groove clearance, cracks or damage.

d. Cylinder Block : condition of bearings, cylinder walls .

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.

If new bearing inserts are installed in block, push the bearing even with outside
Fig. 7 - 20 U si ng Hon e 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 t ightened 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 -10 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 Chec king Ring Gap
shown in figure 7-23 .

7 - 11 INTAKE AND EXHAUST M A NIFOLD Bevel Up

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 .

7 -12 ENG INE HEAT SHIELD .

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

1
Bulletin· #530-005 or current Parts Manual for kit part no . for new corrective heat
shield. 2284

Fig . 7 - 22 Pis ton & Ri ngs

Never use loader models 520 and 530

with S.N 4981-M-11001 to SIN
4994-M-141 98· with enclosed cabs
unless corrected with shield kit PIN
6561963 .

The corrective shield must be used to

deflect poisonous engine exhaust
gases with carbon monoxide away
from enclosed operator cabs .

Exhau st gases can kill. Always use

with adequate ventilation and keep
exhaust system tight with no leaks.
Fig.7-23 Hea d Torq ue Seq ue nce

520, 530, 533 Loader

Revised December 1 9 79 -7-9­ Service Manual
 ENGIN E SERVICE (533)

-- ~

Paragraph Page
Number Number

ASSEMB LY OF ENGINE 8- 13 8-11

CAMS HA FT 8-10 8-11
CLEANING AND INSPECTIO N 8-3 8-3
CRANKS HAFT BEAR INGS 8-8 8-10
CYLIN DER BLOCK 8-6 8-7
DI SASSEMB LY A ND ASSEMBLY OF
RO CKE R SHAFT 8-4 8-3
DISASS EM BLY, INSP ECTION AND ASSEMBLY
OF TH E OIL FILTER 8-15 8-15
DISASSEM BLY, INSPECT ION A ND ASSEMBLY
OF THE 01 L PU MP 8-14 8-15
DISASSEMBLY OF ENGINE 8-2 8-1
DISASS EMBLY OF TH E CYLI NDER HEAD 8-5 8-4
ENGI NE OV ERHAUL 8-1 8-1
FLYWHEEL AND RING GEAR 8-9 8-11
INJ ECTION NOZZLES 8-17 8-17
INJ ECTIO N PUMP 8-18 8- 18
MAN IFO L D A SSEMBLY 8-12 8- 11
PISTON A ND PISTON RING ASSEMBLIES 8- 7 8-8
) T IM IN G GEAR 8-11 8-11
--- WATER PUMP 8-16 8-16

ENGINE SERVICE
(533)

520, 530, 533 Loader

Service Manual
8 DIESEL ENGINE (533)

8-1 ENGIN E OVERHAUL

Check the following to see if the engine

needs an overhaul.

(1) Check the compression pressure

in the cylinders:

Run the engine until the cool ant

0
reaches 75 C. Remove the injector

nozzles . To check compression

pressure in cylinders, engage the

starter to turn the engine at a

minimum of 250 RPM. The throttle

valve must be fully open.

If the compression pressure is lower

than 300 PSI (2068 kPa) the engine

needs an overhau I.

(2) Check oil consumption

Hi g hail 00 nsum pation ind icates

worn piston rings and valve guides.

(3) Check fuel consumption

High fuel consumption is an

indication of defect in the valves.

(4) Engine makes noise.

Noise in engine is an indication of

loose parts becau se of wear or other

damage.

8-2 DISASSEMB LY OF ENGINE

Rem a v e t he ai I fro m t he eng i ne

crankcase, and remove coolant from the

cooling system.

Fig. 8-1 Fuel Injection Pump

(1) Disconnect the fuel pipe at the
connections on the fuel fi Iter and

on the injection pump (Fig. 8-1 ,

Item 1).

(2) Remove the bolts which hold the fuel filter and remove the fuel filter

assembly.

(3) Disconnect and remove the injection tubelines.

(4) Disconnect and remove the leak-{)ff tubeline from the injectors.

(5) Remove the oil filter assembly and disconnect the tubeline that gives oil

pressure for the shaft of the rocker anm.

(6) Remove the bolts which hold the timing gear cover and remove the injection

pump (Fig. 8-2).

(7) Remove the fuel injectors.

(8) Remove the indicator switch for oil pressure.

(9) Remove the bolts from the adjustment plate for the generator and the bolt for

lower mounting and remove the generator.

Fig. 8- 2 Rem o ve Iniection Pump

520, 530, 533 Loader

·8-1· Service Manual
 (10) Remove the blower, sheave and
belt.

( 11) Remove the bolts that hold the

starter and remove the starter.

( 12 ) Remove the dipstick and

remove the muffler and manifold
assembly.

(13) Remove the bolts which hold

the water pump and remove the
water pump.

(14) Bend the washer on the bolt

Fig. 8-3 Remove Crankshaft Sheave Fig. 8-4 Remove Rocker A ssembly
for the cran kshaft sheave. Take out
the bolt and use a puller to remove
the sheave (F ig. 8-3).

(15) Remove the timing gear cover.

(16) Remove the idle gear.

(17) Remove the Cover for the rocker arms. Remove the rocker assembly (Fig.

8-4).

NOTE: Tum each bolt in the ro cker assembly 1/4 turn at a time until all of the bolts
are loose.

(18) Pullout the push rods and remove the cylinder head and gasket

NOTE: Turn each bolt in the cyli nder 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 t he crankcase will not come away from th e cylinder body, put a screwdriver
into the grooves in the cran kcase 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 (F ig. 8-6).

NOT E: Be careful not to make a sc ratch on the camshaft bearings.

(22 ) Remove the front plate from the engine.

Fig. 8-B Remove Camsha ft
(2 3) Use a magnetic tool to remove the tappets from the bottom of the engine

(Fig. 8-7).

(24) Remove the connecting·rod

caps and push out the piston and

rod assemblies through the top of

the engine (Fig. 8-8).

NOTE : 1. Remove carbon from the

upper part of the cylinder wall
before remov ing the piston and
rod assembly.

NOTE: 2. Make a note of the cylinder

number of each rod and bearing
ca p t hat is removed, so that B·2835
each will be installed in the Fig. 8 -7 Remove Valve Tapp ets Fig. 8-8 Remove the Piston
correct order.
520, 530, 5 33 Loader
·8-2­ S ervice Manual
 (3) Check the wear of the faces of
the rocker arms that are in contact
with the valve stem. Replace the
rocker arms if the amount of wear
is over maximum. Remove small
scratch marks on the curved face of
the rocker arms, by grinding (Fig.
8-14).

8-5 DISASSEMB LY OF THE CYLIND ER

HE AD
A·2524 B-2 849
(1 ) D is connect the glow plug
Fig. 8-14 Grinding Rocker A rm Fig. 8-15 Remove the Valve Spri ngs
wiring at the connectors and remove

the glow plugs .

NOTE : Put the cylinde r numb er mark on the valves so that each will be installed in the
correct locat ion.

(2) Use a valve spring compressor to remove valve spri ngs and remove the split
collar. valve springs and valve (Fig. 8-15).

(3) Remove the valve seals from the valve guides.

(4) Use a tool to force the valve guides out toward the bottom of the cylinder
head (Fig. 8-16).

NOT E: If the hot plugs are to be removed, follow Steps 5 through 7.

(5) Put a cylinder number mark on each of the hot plugs.

Fig_ 8-16 Remove Valve Guides

(6) Put a rod, 1/4" (5-7 mm) diameter, into the nozzle hole in the cylinder head .
Use a hammer to fo rce out the hot plug (F ig. 8-17).

NOTE: 1. Hol d rod so that it is against the upper edge of the hole with threads. as
show n 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) Carefu Ily remove carbon from the bottom of the cyl inder head. Check the
cylinder head for cracks and damage. (Use a magnetic process for crack detection or
red color check).

B-3003
NO TE : When removing ca rbon f rom the lower face of the cylinder head. be careful to
prevent scratch mar ks of the valve seat areaS. Fig. 8 - 17 R emove 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 mml. 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
mo re than .016" (OA mm), correct by grinding so that maximum amount of
distortion is within .0012" (0.05 mm).

8-5.2 Inspection of the Comb usti on Chambers

(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

520, 530, 533 Loader

·8--4· Service Manual
 (2) Check the hot plug fitting areas for cracks and damage and make replacement

of the cylinder head assembly if there is any damage condition to the cylinder head.

High spots or pieces on the hot plug seat area can cause poor fitting of the hot

plug.

Clearance
8-5.3 Inspection of the Valves and Valve Guide s

(1) Check for amount of wear of the valve stems in the valve guides (Fig. 8-19).

(2) Use a m ic rometer to measure the ou ts ide diameter of the valve stems at

locations A , Band C (Fig . 8-20) .

PI-2096

Fig. 8 - 19 Check Valve Stem Wear

8-5.4 Inspection and Corre ction o f t he

Valve Seats

(1) Check the valve seats for Valve stem end

w ro ng co n tact or damage and

I
co rrect or replace as necessary.
/
Before co rrecting the valve seat,

check the valve gu ide and install a

new guide, when necessary.

(2) Cut the valve seat using seat

cutters of correct specification so

c B
that the contact width is correct

(Fig . 8-21 & 8-22).

PI·2077

NOTE : When cutting the valve seat u se Fig. 8-20 Measure Outside Diameter of Valve Stem~

a guide rod of co rrect diameter.

(3) If t he amount of valve seat

depth is over the va lu e indication
for need of servicing, replace the
valve seat in sert (Fig. 8-23).

(4) Procedure fo r replacement of

the va Ive seat insert.

a. Use an oxy·acetylene Valve gu ide must be

cutting and weld ing torch to free from wear,
heat the opposed 2 portions of
the inner face of the valve seat
inclination and
out-ol·round. \
insert until red hot (700 -
BOOoe). Let the inse rt cool for \ PI-2095 PI·2 098

3 to 5 minutes. Use a Fig. 8-21 Using Vawe Seat Cutters Fig. 8-22 CUlling to Correc t Contac t Width
screwdriver to remove the
va Ive seat i nse rt .

b. Remove carbon and metal

deposit from the insert bores
in the cylinder head. Measure
the d iameters of the insert
bores and select the inserts
according to the specifications
section.

(5) Press the insert all the way

into the bottom of the insert bore.
Then grind the seat face.

Fig. 8 - 23 Ch eck for Co rrect Valve Seat Depth

520, 530, 5 33 Loader

-8-5 · Servic e Manual
 (6) C heck the head and stem of

t he in take and exhaust valves for

wear, pointed pieces and distortion

and replace as necessary. Also check

and install a new valve if the

thickness of the valve head is less

than the limit (F ig. 8-24 ).

(7) Use a valve grinder to correct

the seat face of the va Ives to an

angle of 450. Correct the valve stem

end as necessary.
Thickness of VIlli/a heed

(8) Put valve grinding compound

B·2101 B-2851
on the seat face of the valve and
Fig. 8-24 Check Nevv V alve F ig. 8 -25 Grinding the V alve Seat
use a grinding tool to grind the

valve seat (Fig. 8-25).

(9) When va Ive grinding is complete, check th at valve contact width is within the

specif ications 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 co ntact width will increase the wear of the pa rts.

8-5.5 Inspection of th e Valve Springs

Deviation of valve springs from vertica l
(1) Make a vi sual check of the valve springs for damage. Put the valve spring on a
Limit for use (mm) 1.04" (1,0 m
surface plate and check the amount of deviation of the valve spring from vertical,

usi ng a square. Install a new spring if the amount of deviation from vertical is over

the limit (Fig. 8-26).

(2) Check the ten sion of the valve springs with a spring tester. I nstall new valve

springs if the measured value is over the limit (Fig. 8-27).

8-5.6 Inspection of the Push-Rods and Ta ppets

Free
length
(1) C heck the push·rods for wear or bending. Replace worn or bent push-rods.

(2) Check the face of the tappets in contact w ith the push-rod s for wear. Replace

any tappets which have a defect.

Measure the outside diameter of the tappets w ith a micrometer. Install new tappets
PI-2119
if the amount of reduction in the outside diameter is over the limit (Fig. 8-28).
F ig. 8- 26 Check V alve Springs

8-5.7 Installation o f the Ho t Plugs

(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 circumference of the hot

plug, ca refully, with a brass hammer.

(2) Hold a soft metal plate with

smooth surface on the hot plug to

protect the face of the hot plug

from damage.

(3) Use a hydraulic press to press

the hot plug fully into position,

slowly. Use a maximum pressure of

4 tons.

NOTE: Avoid the use of over-maximum

pressure .

A-2525

Fig. 8-27 Check Valve Spring Tension Fig. 8- 28 Check V alve Tappet

520. 530. 533 Loader

-8-6­ Service Man ual
 (4) After the new hot plug has been insta lled , grind the end of the hot plug until

it is even with the cylinder head face (Fig. 8-29).

8-5.8 Assemb ly of the Valve System

(1) Pu sh the valve gu ide into pos ition from the upper face of the cylinder head

(F ig. 8-30 & 8-31).

(2) Install the oil seal on the valve guide.

NOTE : Insta ll the oil seal carefull y, to prevent distortion.

Flush
(3) Install the valve springs and valve spring seat.
8 ·3004

(4) Compress the valve springs with the valve spring compressor and install the Fig. 8-29 G r ind New Ho t Plug to F it
locks for the valve stem .

(5) In stall the manifold gasket and manifold assembl y.

8-6 CYLI NDER BLOCK

8 - 6.1 Inspection of the Cyl inde r Blo ck

for Cracks

(1) Check the cylinder block for

cracks by the magnetic or red color
method (Fig . 8-32).

8-6.2 Distortion of the Cylinder Block

Upper Surface

Standard value for

as~mbl y . Below .002" (0,05 mm)
Value for need of
servicing . . . Be low .008" (0 ,2 mm)

Fig. 8-30 Valve Guide Location ICross Sec ti on I

8-6.3 Correction of Cylinde r Bores

(1) Use a cylinder bore gauge to

measure the cy linder bore at the
upper , middle and lower locations of
th e cylinder in two directions : (1)
In line with the crankshaft. (2 ) At a
right angle to the cran kshaft.

Cut the cylinders to oversize if the

amount of wear is over the standard
value, or if the cylinder wall is
damaged.

(2) When measurements are taken,

find the piston oversize according to
larg est bore diameter. Use a
micrometer to measure the outside
diameter of p istons at the base, in
the d irection ' of side thru st, at
normal room tempe rature (20°C).
B·2846 C·2340

Fig. 8-31 I nstall Oil Seal Valve Guide Fig. 8-;-32 Check the Cylinde r Bl oc k

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-8-7­ Service Manual
 To find the bore diameter needed for hone operation, use the following formula:

Cylinder bore diameter after hone operation = P + C - H + E

P: Piston outside diameter

c: Piston clearance

H: Amount for hone operation

E: Error in bore finish

(3l 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 Pist o n Snapring
mm) of each other .

8 - 7 PISTONS AND PISTON RIN G AS SEMBLIES

8 - 7. 1 Disassembly

(l l Use a piston ring expander tool to remove the piston rings from the piston,

NOTE: Keep the piston rings separate , in t he 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 c o nnect ing-rod from each cylinder in
separate gro ups in the sequence of t he 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 , c ompare the measured values to find the piston clearance, The standard

clearan c e is ,004" - .005" (0 . 104 - 0.124 mm) at 68 0 F (20 0 C),

NOTE: When installing new piston ri ngs on the pistons without c utting new
cylinder sizes, measure the pist on ring gaps with the piston rings held
at the lower point of the cylin der (Fig . 8 - 35l. Fig. 8-35 Check Piston Ring Gap

8 - 7 .3 Inspection of Pist on Ring Clearance

( 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 of the piston (Fig , 8 - 36). (See Specif ications Section.)

8 - 7 .4 Assembly of Piston and Connecting -Rods

(1) Heat the piston to about 190 - 250 0 F (70 - 120 0 C), Align the small-end
hole of the conne c ting-rod with the piston pin hole and install the piston pin.

NOTE : Assemble the connecting-rod with th e piston so that the side of the
connecting -rod with the cylinde r num ber mark is tow ard t he c amshaft side
of the engine.

(2l Install the snap rings,

Fig. 8-36 Check Piston Ring Clearance

520. 530. 533 Loader

Revised Mar 79 -8-8­ Service Manual
 (3) Use a ring expanding tool to
assemble the piston rings on the
piston (Fig. 8-36Al.

NOTE: 1. The 1st comp ression ring is

chamfered.

NOTE: 2. Install the 3rd compression

ring with unde rcut side down.

NOT E : 3. Assemble the 1 st o il ri ng to

the piston with the expander
ring. A·2507

Fig. 8-36A Piston Ring Arrangement Fig. 8-37 Check Connecting Rod AI ignm ent
8-7.5 Connecting- Rods

(1) Chec k the connecting·rods for

bending , distortion and damage.

Check for alignment between the big·end and small-end.

If the amount of wrong alignment or distortion is over the value limit for servicing,
correct or replace the connecting-rod (F ig. 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.

8-7.6 Clearance Between the Small· End Bushing and Piston Pin
Fig. 8-38 Check Sideplay
Standard Clearanc e Limit for use

below .0005" (0,013 mm) below .002" (0,05 mm)

(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).

8-7.7 Clea rance Between the Big- End Bearing and Crankpin

Sta ndard cl earance Limit for use

.008-.010" (0 ,2-0, 25 mm) above .014" (0,35 mm)

(4) When a new bushing is fitted into the connecting-rod .small·end, make the inner A-2S09
face smooth with a reaming tool according to the piston pin diameter.
Fig. 8-39 Check Weight 01 Pi ston 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).

8-7.8 Connect ing·R od Bearings

(1) Check the connecting·rod bearings for wear, poor contact, sign of seizure or
loss of tension and replace if defect is found.

I nstall the con necting-rod bearing and bearing cap and tighten the bearing cap bolts
to a torque of 58 ft.·lbs. (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 Beari ng
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-8-9­ Service Manual
8- 7.9 Co nn ect ing·Rod Bearing Oil Clearance

To measure oil clearance:

(1) Wipe and clean the bearings and crankpins to remove dust and oil.

(2) Install a piece of plasti~auge over the crankpin or bearing in the direction of

the axis of the crankshaft.

(3) Inst all the connecting·rod bearing cap and tighte n the bearing cap bolts to the

correct torque.

NOTE: Do not move the crankshaft or connecting-rods when making this chec k.

(4) Remove the bearing cap bolts and bearing cap.

Fig. 8 -41 Check Width of Plastic-G auge

Remove flattened plasti-gauge and check width of plasti ·gauge against the scale

print ed o n the instruction s (Fig. 8-41).

NOTE: 1. Never try to file the bearings or install shims to ad ju st the oil clearance.

NOTE: 2. Check that the oil cleara nce is w ithin specifications before installing the
piston and connecting-rod.

NOTE: 3. Have the crankpins cut to size indicated in the specifications sectio n when
insta lling smaller size bearings.

8-8 CRANKS HA FT BEAR INGS

(1) Check the crankshaft bear ings and install them using the same method as u sed

for installing connecting-rod bearings.

(2) Have the crank journals ground to size indicated in specifications se ction when

installing smaller size bearings.

8-8 .1 Crankshaft

(1) Visually check th e crank journals, c rankpin s and oil seal fitti ng face s for

damage or wear and check the oil pa ssages for restriction.

(2) Use a micrometer to mea sure th e out si de diameter of the crank journa ls and

crankpins. Take measu rement s at severa l locat ions on the crank journals a nd

crankpins to find the amount of wear (Fig. 8-42).

Fig. 8-42 Chec k Crank Jo urn als

If the amount of wear is more than .002 " (0,05 mm), have th e cran k jou rnal sa nd

cran kp ins cut to size ind icated in the specifi ca tion s section and in stall smaller s ize

bearings .

(3) Che ck the crankshaft for ax ial alignment and correct if the amou nt me asu red is

beyond th e amou nt indic ating a need for servicing (Fig. 8-43). (See Specifications

Section.!

NOTE: To check the cranks haft for axial alignment :

1) Put the crankshaft on V blocks at each end and hold the point of a dial

indicator in co ntact with the center journal.

2) Slowly turn t h e cran kshaft one full turn and read the dial indicat or.

(1/2 of the indication correspo nd s to actual crankshaft alignment).

(4) Use a feeler gauge to check the cr ankshaft thrust cl earance at the cente r

bea ring. If the measured valu e is ov er the limit, install oversize thrust bearing. (See

Specifications Section.)

NOTE: Install the thrust bearing so that the side with t he oil groove is toward the

crankshaft thrust face. Fig. 8 -43 Check for A xi al Alignmen t

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. -8-10- Service Manual
8-9 F LYWHEEL AN D RIN G GEAR

(1) Check the ring gear for wear or damage. If wear to the ring gear teeth is in
0
one area, the ring gear may be removed, turn 180 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 CA MSHA FT

(1) Check the camshaft journals, cam lobes and oil pump drive gear for wear or
damage.

(2) Use a micrometer to measure the height of the cam lobes.

8·2996

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 (Fig. 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).

To measure the camshaft end play: (Fig. 8-45)

8·3001
Install the gear on the camshaft and push the thrust plate against the cam gear. Use
a feeler gauge to measure the clearance between the thrust plate and journal. Fig. 8-45 Check Camshaft Endplay

8-11 TIMING GEA R

(1) Check the timi ng 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.

8-12 MANI FOLD ASS EMBLY

(1) Check the intake manifold for cracks. corrosion or damage . Correct or replace
the mani fold 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.)

8- 13 ASSEMBLY OF ENGINE

8-13.1 Special Cautions

(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.

(5) Tighten the bolts and studs to the correct specifications.

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-8-11· Service Manual
8-13.2 Assembly

(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 wit h the oil groove is away fro m 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 evenly 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.

(6) Put a thin layer of silicone

rubber-base sealant on the outer
Cylinder body
circumference of the rear oil seal. Oil seal
Fill the clearance between the lips Crankshaft
of the oil seal with grease. Install
the oil seal. Setting tool
(7) Install the rear plate.

(8) Fasten the flywheel to the ... Ha mmer

crankshaft and tighten the bolts in
di agonal sequence to the specified
Grease
torque. Bend the lock plates over
the bolt heads (Fig. 8-48).

(9) Set the piston ring gaps so that

their gaps are 180 degrees apart
from each other. PI-2097

NOT E: Put engine oil on the cylinder Fig. 8-47 Install Gasket on Bearing Caps

walls and around t he pistons and

piston ring s.

(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 (o n 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 co nnecting-rod bea rings are tightened, check that the
crankshaft turns smoot hly.

(1 2) Install the engine front plate .

NOTE: Before installing, put cement on the surface of t he 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

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·8-12· Service Manual
NOT E: Put engine oil on the tappets
and install them befure installing
th e camshaft.

(14) Install the camshaft. Then,

install the thrust plate on the
cylinder block.

(15) Install the oil pump assembly

and connect the oil pipes (F ig.
8-49).

NOT E: F ully tighten the oil pipe

connections.
Fig. 8-49 Install Oil Pump Fig. 8-50 Inst all Timing Gears
(1 6) Install the oil pan on the
crankcase and fasten the crankcase
to the cylinder b lock.

NOTE : 1. Put cement on the upper

an d lower surfaces of t he
cra nkcase, bot h sides of the oil "Y" Marks
pan gasket and No. 1 and No . 3
bea ring cap gaskets for t he
cra nkshaft.

NOT E: 2. Let cement d ry for 10 . 30

minutes.

Tighten the 4 b olts around the

b e arin g caps. Tighten the
remainder of t he bolts evenly in
sequence, then fini sh tighteni ng
the 4 bolts.

(17 ) Install the timing gears (Fig.

8-501.

NOTE: Install the idler gea r th rust collar

"Z" Marks
on the idler shaft and install the
timing gears so that t he "X" and
"Y" marks are in alignment (Fig.
8 -50A).
(18) Install the cylinder head.
"X" Marks
(19) First tighten the cylinder head
bolts to 20 . 35 h .·lbs. (25 . 45
Nm) torque, in sequence, starting
wi th those at the center. Then,
Fig. 8 -50A Timing Gear Alignment
tighten them further, to a torque of
45 h.·lbs. (60 Nml. Then tighten
them to the Iast torque of 60
ft.·lbs. (80 N m) (F ig. 8-51).

NOTE: Put engine oil on the cylinder head bolts befor e installation.

(20) Connect the oil tubeline for the rocker shah.

(21) Install the push·rods.

(22) Install the rocker shaft assembly.

(23 ) Adjust the valves for correct clearance.

NOTE: Valve clearance adjustment is made with the engine cold. (See Specif ications
Section). Fig . 8-51 Install Cylinder Head

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-8-13­ Service Manual
Method of Adjustme nt

[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 [TDC] 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) T urn t he crankshaft one complete revolution so that the piston of the No.2 cylinde r
is at the bottom center on the intake stroke. [6J Hold the engine stationary and adju st
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 t he lips of oil seal with gre ase before installing the oil
seal.

(25) Install the injection pump and fasten it with the long bolts fo r the timing gear
cover. Fig. 8 -52 Timing In jectio n Pump

NOTE: Align the mark "z" on the inject ion pump gear with the mark "z" on the
ca mshaft gea r and install t he 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 oi l o n the co unterbore for the oil seal on the sheave, before
installing the sheave.

(27) I nstall 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 injectio n pipe connection is down. Nozzle assy
- Nozzle washer
.. Corrugate washer
(28) Install the rocker arm ccver. Heat shield
Hot J'!l ug

(29) Install the manifold gasket and muffler/manifold. Install the lifting hook at the
J­
rear end of engi ne.

(30) Install the thermostat and thermostat housing. Fasten the thermostat housing
and lifting hook with the bolts.

PI·2082
(31) I nstall the water pump assembly.
Fig. 8-53 In;tall Inje ctio n Nozzles
(32) Install the blower.

(33) Install the generator fastening bracket and the coolant temperature switch.
Ins tall th e ge nerato rand bol ts. 3/16" (5 mm )

(34) I nstall 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 fa sten the oil filter as se mbly to the
cyl inder block.

(36) Connect the injection tubelines and tighten the fastening bolts for the injection
nozzles to the correct torque. (See "Specifications", Section 9.)

(37) Connect the le ak-o ff tubelines to the injector nozzles.

A·2626
(38 ) Install the starter. Fig. 8 -54 Adjust Belt Ten sion

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-8-14­ Service Manual
8-14 DISASSEMBLY, INSPECTION AND
ASSEMBLY OF THE OIL PUMP (Fig.
8- 55)

(1) Disconnect the oil

8-55A).
pipe

(2) Remove the strainer case and

pump cover. Then, remove the vane.
(Fig.

./
j
(3) Remove the pin which holds
the pinion .

(4) Pullout the pin and remove

the rotor.
Fig. 8-55A Disconnect the Oil Pipe

(5) Remove the rotor shaft.

(6) Assemble the parts in the

reverse order of disassembly .

(7) When assembling operation is

completed, check that the rotor
shaft turns smoothly.

8-14. 1 Inspect ion

( 1) Make a visual check of the

vane , rotor and pinion gear for
wear . Install new parts if the
amount of wear is over C·2344
speci fications.
Fig. 8-55 Oil Pump Assembly

(2) Measure the cI earance between

the rotor, vane and cover. (See
Specifications Section.) Make
replacement of either the rotor or
the vane if the measured amount is
over the limit for servicing (Fig.
8-56).

(3) Use a feeler gauge to measure C-2337

the tip clearance between the rotor
and vane. Make replacement of the Fig. 8-56 Check tor Oil Pump Wear

rotor assembly if the measured

clearance is over the standard limit
(F ig . 8-57).

(4) Measure the clearan ce between

the rotor shaft and pump body. Fig. 8-57 Check Rotor & Vane Clearance

Replace the parts if the clearance is

over the limit for servicing (Fig.
8-58L

8- 15 DISASSEMBLY, INSPECTION AND

ASSE M BLY OF THE OIL FI LTER
ASSEMBLY

8- 15.1 Disassembly and Assembly (F ig.

8- 59)

(1) Remove the oil filter assembly

and remove the fi Iter element by
turning it counterclockwise.

(2) Remove the relief valve and

overflow valve. Fig. 8 -58 Che ck Oil Pump & Rotor C learance Fig. 8-59 Oil Filter A ssembly

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·8-15· Service Manual
 (3) Assemble the parts In the

reverse order of disassembly. Install

the element by turning it on hand

t ight.

NOTE: Replace the filter elem ent and

gasket afte r every 50 hours of
ope rati on (Each oil change !.

8- 15.2 Inspect ion

(1) The relief valve and overflow

valve cannot be disassembled. Make

a visual check of these valves for

damage or other defect condition

B ·30 10
and replace the valve if defect is
Fig. 8-60 Water Pump Assemb ly
found.

(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 runn ing.

8- 16 WATE R PUMP (Fig. 8-60)

Name of Parts

Ref. Name Ref . Name

1. Pulley center 7. Seal unit

2. Pump body 8. Impeller B·2997
3. Setscrew , spring washer 9. Gasket
4. Screw p lug 10. Cover Fig. 8--61 Loosen Bearing Setscrew
5. Bearing unit 11 . Screw
6. Thrower

8- 16.1 Disassembly of the Water Pump (Fig. 8-60)

(1) Remove the rear cover from the body and loosen the bearing set screw (F ig.

8-61) .

(2) Remove the pulley center using a puller (Fig. 8-62).

(3) Remove the shaft and impeller from the body using a bench press (Fig. 8--63).

NOTE: The impeller is mad e of cast iron. Do not use hammer to remove it.

8 - 16.2 Inspection

(1) C heck t he disassemb led parts for wear, cracks or other damage and replace the Fig. 8--62 Remove Pul le y Center
pu mp if defect is fou nd .

(2) Check the shaft for straight condition.

(3) Check for loose bearing unit. Replace the bearing unit if the bearing un it is

loose by more tha>1 .008" {O,2 mml.

8-16.3 Assembly (Fig. 8-GO )

(1) Install the thrower (Item 6) and seal unit (Item 7) on the bearing seat location

on the shaft.

NOT E: Install the seal uni t so that the side with the spring is tow ard the impell er.

(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 (F ig. 8 - 64).

Fig. 8 --63 Remove Shaft and Impell er

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-8-16­ Serv ic e Manual
 (3) Use a bench press to install the

impeller on the shaft.

a. There must be a clearance

of about .040" (1 mm)

( between the rear face of the

impeller and the inner face of
the pump body.

b. Standard clearance

between outer circumference

of the impeller and pump

body is .047 . .051" (1,2·1,3

A·2523
mm) (Fig. 8-65). 8·2999

Fig. 8-64 Install Pump Impeller Shaft Fig. 8 -65 Impelle r & Pump Body Clearance
(4) Use a bench press to install the
pulley center (Fig. 8-66).

(5) Tighten the setscrew and install

the rear cover.

(6) When assembly operation is

completed, check that fan center
turns smoothly.

8- 17 INJECTION NOZZLES

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).

To remove the nozzles:

(1) Remove the high and low pressure tubelines.

(2) Use a wrench to remove the nozzle holder and nozzle assembly.

Diese l fu el under pressure can go through

the ski n and cause injury. Keep your
hands away from the nozzle spray area .

(1) Install the nozzle on a nozzle tester and put pressure of 1435 PSI (9880 kPa)
continuously and check for sign of leakage (Fig. 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

520, 530, 533 Loader

-8-17- Service Manual
8- 17.2 Disassembly of the Nozzle Holder
Assembly (Fig. 8-68)

(1) Fasten the body of the nozzle 8 910 11 12 13

holder (Item 4) in a vise and I II I / / /14 15 16 }7
remove the cap nut, (Item 14) being ·@OO~ / /
careful not to put a scratch on the ~
nozzle holder.

(2) Remove the nut and

adjustment s crew (Item 11 & 12) and
take out the washers, nozzle spring
and the push rod (I tem 7, 8, 9 &
C.Z345
101.
Fig. 8-68 Nozzle and Halder Assembly
(3 ) Remove the nozzle nut (Item

1) and take out the nozzle

assembly (Item 2), then remove ~he

bushing (Item 3). Keep the nozzle

assembly in clean kerosene or diesel

fuel.

(4) Remove the inlet connector assembly together with the gasket (Item 10) and

take OUt the edge fi Iter (Item 6).

8- 17.3 Inspection of t he Nozzle and Nozzle Holder Assemblies

(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 needle valve slides

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 needle valve for wear. Replace the

nozzle if it is worn.
F ig. 8-69 Remove Injector Fuel Lines

(2) Nozzle holders.

a. Check the thread areas of the nozzle holders for wear or damage . Replace the

nozzle assembly if a defect is found.

b. Check the nozzle springs for weak condition, corrosion or damage.

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.

8-17.4 Assembling the Nozzle

Assemble the nozzle in the reverse order 0 f d isassemb Iy 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.

Install NEW gaskets at the time of assembly.

8-18 INJECTI O N PUMP

8 - 18.1 R emoval o f Pump

(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) .

(3) Remove the injection pump (Fig. 8-70).

520, 530, 533 Loader

·8-18­ Service Manua l
 8-18.2 To Remove the Pump Drive Gear

(1) Remove the nut and lockwasher from the injection pump shaft (Fig. 8-71).

(2) Use a gear puller to remove the gear.

(
8-18.3 To Install t he Pump Drive Gear

(1) Insert the key and al ign the key groove on the gear with the key groove on

the pump shaft when installing the gear.

(2) I nstall the lockwasher and nut. Tighten the nut to 40 ft.·lbs. (54 Nm) torque.
B-2979
8-18.4 Installation and T im ing 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.·lbs. (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

Fig. 8 - 72 Timing Injection Pump Gear

Fig. 8-73 Timing the Injection Pump

!
I

\
'~

520, 530, 533 loader

·8-19- Service Manual
 TE CHNICAL DATA

Paragraph Page

\. DEISEL ENGIN E TORQUE SPEC IF ICATIONS (533)

Number

9-7
Number

9-4
ITS, CLE A RANCES, ADJUSTMENTS (520/530) 9-12 9-5
FITS, CLEAR AN CES, ADJ USTMENTS (533) 9-13 9-6
FUE L SPECIFICAT IO NS 9-1 9-1
GASOLINE ENGIN E TORQUE SPECIF ICATION
(520/530) 9-6 9-4
GE NER AL TORQUE SPECIFICATIO N 9-14 9-9
HYDRAULIC/H YDROSTAT IC SYSTEM 9-10 9--4
HYDRAULIC MOTO R TORQU E SPE CIFICATIONS 9-9 9-4
HYDROSTATIC PUMP T ORQUE SPECI FICATION 9-8 9-4
LOAD ER SP ECIF ICATIONS (520/530) 9-3 9-2
LOADER SP ECIFICATIO NS (533) 9--4 9-3
LOADER TORQUE SPECIFICATIONS 9-5 9--4
LUBRICANTS 9-2 9-1
SE AL INSTAL LING TOOL 9-11 9-5

(~
\

TECHNICAL
DATA

520, 530, 533 Loader

Service Manual
9 SPECIFICATIONS

9-1 FUEL SPECIFICATIONS

Jasoline 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

9-2_1 Gasoline Engine (520(530)

RECOMME ND ED SAE V ISCOSITY NUMBER

-34 -29 -23 -18 -13 -7 -1 +4 +10 +15 +21 +27 +32 +38

-30 -20 -10 o +10 +20 +30 +40 +50 +60 +70 +80 +90 +100

(API SE RV ICE CLASSIF ICATION SC)

TEMPER AT UE R RAN GE ANTICI PATED BEFOR E NEXT OIL CHANGE

AWARNING Do not overfill engine crankcase!

9-2_2 Diesel Engine (5 33)

RECOMME NDED SAE VISCOSIT Y NUMBER

-34 -29 -23 -18 -13 -7 -1 +4 +10 +15 +21 +27 +32 +38

-30 -20 -10 o +10 +20 +30 +40 +50 +60 +70 +80 +90 +100

(API SERVIC E CLASSIFICATI ON CC)

TEMPERAT URE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

9- 2_3 Hydraulic System

If the system oil level is low or the oil is being changed, use 10W-30 or lOW-40 engine
o il (Classification SE) oil when filling the reservoir

System Capacity A pprox imately 5 .5 gallons (21 Liters)

Reservoir Capacity : 3.5 gallons (13 Liters)

9-2_4 Chaincase

Fill with IOW-30 or 10W-40 engine oil.

Capacity : Approximately 4 gallons (15 Liters)

520, 530, 533 Loader

-9-1­ Service Manual
9-3 LOADE R SPECI F ICATIONS (520 /530)

/~ "\
,,/: 97° 127.5
, ""...... I ,,'~ .. ... ,
(3238)
~ ::~:·:..:: ,7
" ' ~'1-,_-_-
, -,'-'-,,':"';
, -;­ -r---,
,

72.5
(1841)

PI-1857

PI·l8S7

Dimensions are given for loader equipped with dirt Wh ere app l i cable ,

bucket and may vary with other bucket types. A ll specificatio ns confo rm to

dimensions are shown in i nches, Respectiv e metric ICED & SAE sta ndards

dimensions are given in millimeters enclosed by and are subject to change

parent heses. without notice.

9-3.1 Opera ting Specifications Bore and Stroke 3.5 x 3" Cyl inders . Daub leacti ng
(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)5)

Lower . . · 3.0 sec.

Tilt . · 2.5 sec. 9-3.3 EL ECTRICAL 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 vo It gear drive with remote primary drive. Single chain reduction
controlled by two hand levers. R .H . lever solenoid final drive.
moves sideways to control aux il iary Fuses .. 2, 30 ampere, on the dash panel

hydraulic circuit. & at coil 9-3.6 CAPACITIES

Loader . . . .. . Hydraulic lift and tilt Battery. 12 volt

controlled by left and right foot Circuit Breaker On indicator :amps and Fuel Tank . .10 gal. (38 l)

pedals. hr . meter Chaincase . .4 gal. (15 L)

9-3.4 H YDR AULIC SYSTEM Hydraulic Reservoir .3 .5 gal. (System: 5.5

gal [21 L1 )
Pump . Engine driven vane·type Engine Oil .4 qt. (3,8 l)
9-3.2 ENGINE System Design . Series· open center valve
System Re lease Pressure . . . . . 1500 psi 9-3.7 TI RES
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 11m in .) 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.

Max imum Torque .40.8 ft.·lbs. (55,3 Nm) Filter screen in reservoir fill for

at 2200 RPM hydraulic system.

520, 530, 533 Loader

,9-2, Service M anual
9-4 LOAD ER SPECIFICATIONS (533)

,,
, , ,~,
I
--------r-~

127.5
49
(1245) I
//~:F'~::~:::~(_~___
,___.,,_______-r(3238)
11"-""

, '
','

1
18-1N 0
(457):; / ' ~ 36 ~
85
I

72.5 I

(2159)
(1841)

38
(965)

PI-22 18

Dimensions are given for loader eq uipped with dirt Wher e applicable,
bucket. And may vary with other bucket types. All specifications confor m to
di mensions are shown in inches. Respecti ve metric ICED & SAE standards
dimensions are given in m illi mete~ enclosed by and are subject to change
parentheses. without notice.

9-4.1 Operating Specifica t ions 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 POW ER T RAIN
Rollback .
. . 2.0 sec.
Travel Speed .0 - 5.5 MPH (8,9 Km/hr) 9-4.3 ELECTR ICAL Transmission . . . Both sides independent.

Controls: Infinitely 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 fina I drive.

moves sideways to control auxiliary Banery 12 volt

hydraulic circuit. Fuse . . . . . . . .. . . .. _On dash panel 9-4.6 CAPAC ITIES
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 Ll)
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 1/ min.)
Make and Model . . . . . . ISUZU 2AA1 Hydrostatic Charge Pressure .. 55 - 75 psi Standard . .. . 5.70 x 15,55 psi (379 kPa)
Type 2 cylinder diesei en9ine (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 hydraul ic system_

520, 530, 533 Loader

-9-3­ Service Manual
The following special torque specs must be used on the 520, 530 & 533 load ers:

W heel Bolts . . . . ... . . . ... 70 - 85ft.-lbs . (95 - 120Nm)

A x le-to -Sp rocketBolts . . . . . . 240-300ft.-lbs. (325.4 - 406 ,8Nm )

Bolts th rough Rubber Pu mp, Engine Mounts and

Operator Enclosure . . . . . . .. . . . .. ... . .. .. . 35ft. -l bs. {47,5Nml

Upright Frame-to-Axl e Housing . . . . . . . .. . . . 95- 1 20ft .-lbs . (1 28 ,8 -162 , 7 Nm)

Steering Linkage Spring . .. . .. Tighten boltuntil spring is 2.5" - 2.75" (63,5 - 70 mm)

long with levers in neutral position .

Hydraulic Cylinder Piston Nuts : . . Lift 11 0-1 20ft.-lbs. (149 - 163 Nm )

Tilt 2 10 - 260 ft .-Ibs . (285 - 38 2 Nm )

Motorto Sprocket Nut. . . . . . .. 300-400ft .-lbs. (407 - 542 Nmi

SplineAdapterScrew .. . . .. . . . 20-25ft. -lbs.(27,l-33 , 9Nml

Motor-to- Transmission Fastening Nuts ... . .. . 70 - 85 ft. -Ibs . (9 5 - 120 Nm )

A lternatorSheaveNut. . . . . .. .... . .. . . . . . . . . .. . 40- 60ft .-lbs . (54-81 Nm l

Pu mp to Engine Fasteni n g Nuts. . . _ . ... . .. . . 65 - 70ft.-lbs. {81 -95 Nml

Pump High Pressure " Banjo" FittinQ S

I (HollowScrew) . ... . . .... . . ... .. . . . . . ... .. .... 150ft.-lbs . (203Nm)

9 - 6 GASOLINE ENGINE TORQUE SPECIFICATIONS (5 2 0 1530)

Pum pCouplertoSh aft . .. . . . .... . . 30 - 35 ft.-Ibs . (40 , 7 - 47.5Nm )

Flywheel Retaining Nut . . . . . . . .. . . 115 ft.-Ibs . {155 , 9Nml

Ca mshaft Retaining Nut . . .. . . . . 40 ft .-Ibs . (54 ,2 Nm )

OilPan Sc rews . . . . . . . . . . . .. . . . . 3 0 ft .-Ibs . (40 , 7 Nm)

Manifold Screws 2 5 ft.-Ibs. (33 , 9 Nm)

Closure Rlate Screws . . . . . . . . . 30 ft.-Ibs. (40 ,7 Nm )

Connec t ing Rod" .. with 3 18" bolts . . 300 in .-Ibs . (34Nm)

Connecting Ro d" .. with 5116" bolts .. 2 00 in.·lbs. (23 Nm)

Spark Plug .. . .. . . 20 ft.-Ibs . (27,1 Nm)

Cylind er Head Bolts . .. . . . .. ... . .

I
35 ft .-Ibs . (47,5Nm )
* .. Lightly oi led treads
9 - 7 DIESEL ENGINE TORQUE SPECIFICATIONS (53 3)

Crankshaft Bearing Cap Bolts 1 2 0 ft.-Ibs . (163Nm)

FlywheeltoCrankshaft Bolts ... .. . . . 58 ft -Ibs . (79 Nm)

Connecting Rod Bearing Cap Bolts 58 ft.-Ibs . (79 Nm)

Camshaft Thrust Plate Bolts 50 ft .-Ibs . (68Nm)

Crankshaft to Block Bolts ... 15 ft. -Ibs . (20Nm)

Oil Pan Bol ts 6 ft. -Ibs . (8Nml

Cyl inder Head Bolts ... . 60 ft .-Ibs . (80Nm )

Ro cker Arm Ass embly Bolts 20 ft .-Ibs . (27 Nm)

Cr ankshaft Pulley Bolt . . 108 ft. -Ibs . (146 Nm )

Injection Nozzle Holding Bolts 54 ft.-Ibs. (73 Nm)

9 - 8 HYDROSTATIC PUMP TORQU E SPECIFICATIONS

AII 31 8 Ass embly Bolts . 42 ft.-Ibs . (57 Nm)

Couplerto Shaft . 20 - 25 ft.-Ibs . (27 - 34 Nm)

9 - 9 HYDRAULIC MOTOR TORQUE SPECIFICATIONS

Moto r Assembly Bolts .. 45 - 55 ft.-Ibs. {61 -75 Nml

Sprocket to Motor Nuts 300 - 400 ft.-Ibs. (407 - 542 Nm)

9 - 10 HYDRAULlCIHYDROST ATIC SYSTEM

Vane Pump Flow at 2500 RPM

and 1 000 PSI (689 5kPa) . . .. ... .. .... 8 . 1 gpm 1 I min . (30,66 UMin .1

Hydraulic Release Pressure . . . 1500-1600PSI ( 10340-11030kPa)

Hydrauli c Filt er Element . . . . 1 Omnominal, without bypas s v alve

Rel ease Pressure at Byp ass Valve at Full

EngineRPM . ... . . . ... 67-83PSI(460 - 570kPa )

Ross MotorShaft End Play . 005 - 025 in . !G , 127 -O ,635mm )

520, 530. 5 33 Loader

Revised July 79 -9-4- Service Manual
9-11 SE AL INSTAL LI NG TOOLS

Axle Seal Installing Tool · . . . . P/N 6558009

Pump Seal Installing Tool · Manufacture Locally
Motor Seal I nstalling Tool · . . . . P/N 6558458
Motor Sprocket Tool . . . . . . . . ... . . P/N 6559551

9-12 FITS, CLEARAN CES, ADJUSTMENTS (520/530)

9- 12.1 Engine

Ignition Point Gap . .018· .022 (,46 . ,56)

Spark Plug Gap . ' . . . .025" (,6)
Compression at Cranking Speed 100 - 120 PSI (689 . 827 kPa)
High Idle at no Load . . . . . . . . 2700 RPM
Low Idle at no Load . . . . . . . . . . . . . .. . 1000 RPM
Oil Pressure ((0 Idl e RPM) . .. . . . . . . . . . .. . . . . 40 . 50 PSI (276 - 345 kPa)
9-12.2 Cyli nder Bore

INCHES MILLIMETE RS

New Diameter . . . . .. . 3.500 88,9

Wear Diameter (Ma ximum ) 3.503 88,976
Taper (Maxim um) 0.0015 0,038
Out-ai-Round (Maximum) 0.005 0,127

9-12.3 Cranks haft

End Play .. .. 0.004·0.010 0.102-1,254

Crankpin - New Diameter. 1.625 41 ,275
Crankpin - Maximum Out-of-Round 0.0005 0,013
Crankpin - Ma xim um Taper 0.001 0,025
Crankshaft Sleeve Bearing·Running Clearance 0 .0015-0.005 0,038·0,127

9 - 12.4 Camshaft

End Play 0 .017 -0 .038 0,432-0,965

Shaft to Bearing Clearance . 0.0005-D.0035 0,013-0,089

9 - 12.5 Co nnecting Rod

Big End· Maximum Wear Diameter 1.627 41,326

Rod to Crankpin - Maximum Clearance 0.0035 0,089
Small End· New Diameter 0.87585 22,246
Rod to Piston Pin - Clearance .0.0003-D0008 0,008-0,020
Side Play on Crankpin 0 .005-0.014 0,127-0,356

9-12.6 Piston, Pin & Rings

Thrust Face * - Maximum Wear Diameter 3.4945 88,760

Thru st Face* to Bore· Maximum Clearance 0 .007 -0.010 0,178·0,254
Ring· Maximum Side Clearance 0.006 0,152
Ring - End Gap in Used Bore 0.030 0,762
Pin to Boss Clearance (Loose) 0.0005 0,013
Pin to Rod Clearance . . .0.0003·0.0008 0,008·0,020

9- 12.7 Valves, Gu ides, Tappets

Intake Valve to Tappet · Cold Clearance 0.008-0.010 0,203·0,254

Exhaust Valve to Tappet - Cold Clearance 0.017 -0020 0,432·0,508
Valve Lift - Zero Lash 0.324 8,230
Intake Valve Stem to Guide - Max. Clearance 0.0045 0,114
Ex haust Valve Stem to Guide-Max. Clearance . 0.0065 0,165
Tappet Clearance in Guide .. .0.0012-0.0023 0,030-0,058
Guide Interference F it in Block . 0 .0005·0.002 0,013·0,051
Guide Ream Diameter .. . 0.312-0 .313 7,9248-7,950
0
Valve Seat Angle (Degrees) 45
Valve Seat Width . . . .030" ,762

*Measured just below oil ring at right angles to pin.

520, 530, 533 Loader

-9-5­ Service Manual
9 - 13 FITS, CLEARANCES, ADJUSTMEN TS (533)

9- 13.1 Cylinder Compression (@ 250 RPM) . . . . . . . . (Minimum) 284 PSI (1945 kPa)

9-13.2 Valves

0
Intake va Ives open <:t (B .T .D.C. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
0
Intake valves close at (A.B.D .C. ) . . . . .. . .. . . . . . . . . . . . . .. . . . . . • . . . . 49
0
Exhaust valves open at (B .T. D.C. ) .. . . . . . . . . .. .. . . ... . . . . . . . . . .. . . 51
0
Exhaust valves close at (A.B .D.C .) .. . ... . . . . . . . . . . . ... . . . .. ... .. . .. 9
Valve clearances (int ake valves) (mm) . . . . . . . . . . . . . . . . . . . . .. .018" (,45 mm)
Valve clearances (exhaust valves) (mm) . . . . . . . . . . . . . . .018" (,45 mm)

9- 13.3 Fuel Injection Tim ing . . .. . . .. 180 B.T.D .C.

9-13.4 Injection Pressure . . . . . . . . . . . . . . . .. . . . . . . . . . 1706 PSI (11762 kPa)

9-13.5 Glow Plugs

Voltage (V) Current (A) . .. 10.5V, 5.5A

9-13.6 Starting Motor:

Voltage (V) Output (KW) . 12V, 1.2KW

9-13.7 Generator:

Voltage (V) Ca pac ity (A) . . . . . . . . . . . . . . . 12VAC, 37A

9-13.8 Oil Pump

Lubricating Method Pre ssurized Circulation

Oil pump type Trochoid type

Oi l pump delivery

Pump speed: 1400 rpm

Pressure of de livery : 57 PSI (393 kPa)

Oi l temperature : 50 0 C

Oil f ilte r t ype Full·flow type with paper element

Relief valve opening pressure 64 PSI (441 kPa)

9-13.9 DIMENSIONAL SPECIFICATIONS

9-13.10 Cylinder Head

Distortion of Cylinder Head Face, standard . . . . . . . . .122" (3,1 mm)

Limit for use above .142" (3,6 mm)

Rocker Arm Shah Diameter, normal .748" (19 mm)

Limit for use .742" (18,85 mm)

Clearance between Rocker Arm

Shah and Bushing, standard' . . . .. . . . . . . . . . . . . . . . . . . . . . .0016" (,04 mm)

Limit for use .008" (,2 mm)

Valve Stem Diameter, normal .. . . . . .. ... .. .. . . . . . . . . .315" (8 mm)

Limit for use .310" (7,88 mm)

Clearance between Valve Stem and Valve Guide Intake Exhaust

(Standaro V alve) .002 " (,05 mm) .003" (,08 mm )

(Limit for use) .008" (,02 mm) .010" (,25 mm)
520, 530, 533 Loader
·9~· Service Manual
Valve Contact with Seat (Intake & Exhaust)
Standard contact width . .047" . .059" (1,2 . 1,5 mm)
Limit for use . . above .079 (2 mm)

Valve Seat Depth, normal .1 22 (3,1 mm)

Li mit for use . .142 (3,6 mm)

Valve Clearances
Intake and Exhaust (Cold) . .. . . . . . . .. . . . . . . .. . .. . . . . . .018" (,45 mm)

Va Ive Seat Inserts

Insert Bore Insert Outside

Diameter Diameter

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)

Thickness of Valve Head, standard .05" (1 ,3 mm)

Limit for use . .. . .039" (1 mm)

Valve Spring Deviation (From Vertical) .039" (1 mm)

Valve Spring Tens ion

Free Length Tension (Length· 1.30" [33 mmJ)

Standard 1.535" (39 mm) 29.3· 33.7 Ibs. (13,3 - 15,3 kg)
Limit for use 1.48" (37,7 mm) 24.9 Ibs. (13,3 kg)

9-13.11 Cylinder Block

Distortion of Upper Surface, standard .002" (,05 mm)

Limit for use . . . . . . .008" (,2 mm)

Cylinder Bore Diameter 3.386" (86 mm)

Limit for use . . . .. . .016" (,4 mm)

9-13.12 Piston Rings

Gap Clearance, 1st, 2nd & 3rd Compression Rings

Standard . .. .008" . .016" (,2 - ,4 mm)
Limit for use . . .079" (, 2 mm)

1st & 2nd Oil Rings

Standard . . . . . .004" - .012" (,1 - ,3 mm)

Ring Groov e Clearance, 1st Compression Ring

Standard . .. .002" - .003" (,045 - ,075 mm)
Limit for use . . . . . .. . _ . . - . . . .. . .012" L3 mm)

2nd & 3rd Compre ssion Rings

Stand ard . .001" - .002" (,030 - ,060 mm)
Limit for use . . . . _ . . . _ . . _ .012" (,3 mm)

1st & 2nd Oil Rings

Standard . . . .0008 " - .002" (,020 - ,054 mm)
Limit for use . _ .. _ . . . , .006" (,15 mm)

9-13.13 Connecting Rods

Al ignment b etween big end and small end (per 3.94" [100 mmJ )
Sta ndard . . below .002" (,05 mm)
Limit for use . . . above .006" (,15 mm)

520. 530. 533 loader

·9-7· SerVice Manual
Pi:iton Pi n Clearance
Standard . . . .0003" - .0001" (,008 - ,020)
Limit for use . . . . . . . . . · . . . . . .002" (,05 mm)

Big End & Crankpin S ide Clearance

,Stand ard .. .. .. . . . . . . .008" - .010" (,18 - ,30 mm)
,L imit for use · . . . . above .014" (,35 mm)

Connecting Rod Bearing & Crankpin Clearance

Standa rd . . . . . . . .. . .0016" (,04 mm)
. Limit for use . . . . . .005" (,12 mm)
9-13.14 Cra nkshaft

Cra nkpin Outside Diameters

Bearing Si ze Crankpin Size

Standard
2.087" (53 mm)
Undersize .010" (,25 mm)
2.077" (52,75 mm)
U/S .020" (,50 mm)
2.067" (52,50 mm)
U/S .030" (,75 mm)
2.057" (52,25 mm)
U/S .040" (1 mm)
2.047" (52 mm)

Crankshaft Bearing Clearance

Sta ndard . . . .001" - .003" (,029 . ,085 mm)
Limit for use . . . . . . . . · . . . . above .005" (,12 m r:1)

Crankshaft Journal Outside Diameters

Bearing Size Journal Size

Standard
2.756" (70 mm)
U/S .0 10" (,25 mm)
2.746" (69,75 mm)
U/S .020" (,50 mm)
2.736" (69,50 mm)
U/S .030" (,75 mm)
2.726" (69,25 mm)
U/S .040" (1 m m)
2.7 16 " (69 mm)

Cra nkshaft Run-Out

Standard . . . . .below .001" (,03 mm)
Limit for use . . . .. . . . . above .002" (,06 m m)

Crankshaft Thrust (End Play) Clearance

Stand ard . . . .004" (,10 mm)
Limit for use . .019" (,30 mm)

9-13.15 Camshaft

Height of Cam Lobes

Standard .. 1.319" (33,5 mm)
Limit for use . . . . 1.303" (33,1 mm)

Camshaft Journal Diameter

Stand ard . . . . 1.890" (48 mm)
Lim it for use .. 1.B74" (47,6 mm)

Camshaft End Play

Stand ard . .. . . . .. .003" (,OB mm)
Limit for use .. . .above .OOB" (,2 mm)

9- 13.16 Timing Gears

Standard Backl ash .

.004" (,1 mm)
Limit for use .. . . .. .
.above .012" (,3 mm)

520, 530, 533 Loader

-9-8· Service Manual
9-13.17 Manifolds

Face 0 istortion
Standard . . . .002" (,05 mm)
Limit for use . .008" (.2 mm)

9-13.18 Oil Pump

Clearance between Rotor, Vane & Cover

Standard .. . .0008" . .003" C02· ,07 mm)
Limit for u se . . . . . . . . . . . . . . . . .. .006" (,15 mm)

Rotor and Van e Tip Clearance

Standard (Maximum ) . .. . .0009" . .005" (,02 . ,13 mm)

9-13.19 GeneratorlWater Pump Belt Tension 3/8" (15 mm) deflection

9-13.20 Injection Nozzle Breaking Pressure .. 1720 PSI (11860 kPa)

9-13.21 Injection Nozzle Spra y A ngle . .. . . . . . . . . . . 4 degrees

9-14 GENERAL TORQU E SPECI FICATIONS

For st andard fasteners on th e loader use the following chart of general torque specs (Page
9-10).

NOTE: Weld·on stud s use grad e 2 lubricated specifications.

520, 530, 533 Loader

·9--9­ Service Manual
 STANDARD TORQUE SPECIFICATIONS FOR BOLTS

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 SA E GRADE 8

INCH. .250 80-90 110-120

LBS . (9 - 10) (13-14)
(Nm)
.3125 180- 200 215-240
(21 - 23) (24- 27)
.375 25 - 28 35-40
(34- 38) (48-54)

.4375 40 - 45 60-65
(54 - 61) (82-881
.500 65- 70 90-100
(88 -95) (125-135)
.5625 90 - 100 125-140
(125 - 135) (170-190)
.625 125-140 175-190
(170- 190) (240-260)
FOOT .750 220 - 245 300-330
LBS. (300 - 330) (410-450)
(Nm )
.875 330 - 360 475-525
(450 - 490) (645-710)
1.000 475 - 525 725-800
(645-71 0) (985-1085)
1.125 650 - 720 1050-1175
(880- 975) (1425-1600)
1.250 900 - 1000 1475-1625
(1200 - 1360) (2000 - 22(0)

1.375 1200 - 1350 2000 - 2200

(1 630 - 1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530 -3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680-5150)
1.750 2500-2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150- 3500 5500-6100
(4270 -4750) (7450 -8300)
2.000 3800- 4200 6500 - 7200
(5150 - 5700) (8800 -9800)

520 . 530. 5 3 3 Loader

Added Mar 79 -9- 10- Se rvice Manual
 DECIMAL AND MILLIME TER EQUIVALENTS

FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 - 0.015625- 0.397 33/64- 0 .515625-13.097
1/32 .03125 - 0.794 17/32 .53125 -13.494
~. - , "
3/64 - .046875- 1.191 35/64- .546875-13.891
1/16 .0625 - 1.588 9116 .5625 -14.288
5/64 - .078125- 1.984 37/64- .578125-14.684
3/32 .09375 - 2.381 19/32 .59375 -15.081

.8 5/32
7164 -

9/64 -

11/64 -
.109375-
.1 250 -
.1 40625-
.1 5625 -
.1 71875-
2.778
3.1 75
3.572
3.969
4.366
e
21 /32
39/64- .609375-1 5.4 78
.6250
41/64- .640625-16.272
-15.875

.65625 -16.669
43 /64- .671875--' 17.066 ':";
3/1 6 .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
15164 - .234375-
.2500 -
17/64- .26 5625- 6.747
5.953
6.350

.28 125 - 7.144

e
25/32
47 /64- .734375- 18.653
.7500 -19.050
49/64- .765625- 19.447
.78125 -1 9.844
19/64- .296875- 7.541 51/64- .796875-20 .24 1
5/16 .31 25 - 7.938 13/16 .8125 -20.638
21/64 - .328125- 8.334 53/64 - .828125-21.034
11 /32 .34375 - 8.731 27/32 .84375 -21.431

e 13/32
23/64 -

25/64 -
.359375- 9.128
.3750 - 9.525
.390625- 9.922
.40625 - 10.319
e
29/32
55/64 - .859375-21.828
.8750 -22.225
57/64 - .890625-22.622
.90625 -23.01 9
27/64 - .421875-10.7 16 59/64 - .921875-23.41 6
7/18 .4375 - 11.112 15/16 .9375 -23.81 2
29/64 - .453125-11.509 61/64 - .953125-24.209
15/32 .46875 - 11 .906 31/32 .9687 5 -24.606

'-.-/
J e 1 mm =
31/64 -

.03937"
.484375- 12.303
.5000 - 12.700
0
.001" =
63/64- .984375-25.003

.0254 mm
1.000 -25.400

U.S. TO METRIC CONVERSION

TO CONVERT IN TO MU LTIPLY BY
LIN EAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Milimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Squ are Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0 .7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp .) Grams 28.3495
PRESSU RE Pounds/ Sq. In . Kilopascal 6.895
WORK Foot -pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LI QUID FLOW Gallons / Minute Liters / Minute 3.785
'-../1. TEMPERATURE Fahrenhe it Celsius 1. Subtract 32 0
2. Multiply by 5/9

520, 530, 533 Loader

Added Mar 79 -9 -11­ Service Manual
 A LPHABETICAL INDEX

Page
Number
ALPHABETICALINDEX ..... .. .... ...... . 10-1 , 10- 2

ALPHABETICAL
INDEX

520, 530. 533 Loader

Service Manual
 10 ALPHABETICAL INDEX

Subject Page Subject Page

A .C . Voltage, check (520 / 530) .6-2

Hydraulic Circuit
.2-1

( Air Cleaner . .. .. . . . . . . 1-4

Hydraulic Cylinder, repair . . .
.2-6

Alternator, repair (520/530) .6-2

Hydraulic Filter Replacement
1-11

Axles and Bearings ..... . 4-1

Hydraulic / Hydrostatic Fluid .
1-10

Hydraulic Reservoir, remo va l

.5-4

Block, caution . , .1-1

Hydraulic System . . . . . . .
1-10

Block , warning . ,.1-1

Hydraulic System, troubleshooting
.2-2

Bob-Tach .. " . ,1-13, 5-2

Hydrostatic Circuit .....
.3-1

Brake Pad, replacement. ,4-3

Hydrostatic Motor, removal
.3-7

Bushing, replacement ,5-2

Hydrostatic Motor, repair .
.3-7

By,Pass Valve, repair ., .3-4

Hydrostatic Pump, removal
,3-4

Hydrostatic Pump, repair ..

.3-5

Camshaft (533) . . . . . 8-11

Hydrostatic System, troubleshooting
.3-1

Camshaft & Tappets (520 / 530) , .. .. .. . . . .. . . .

, .. 7-7

Ca rburetor, adjustment (520 /530) " " " ..

.7-2
Ignition, adjustment (520/530)
,7-3

Carburetor, repair (520/530) .. . ' . . . . .

. 7-3
Injection Nozzles (533 ) .
8-17

Combustion Chambers (533) .. . . . . .

,8-4
Injection Pu mp , . . . .
8-18

Compression, check (520/530)

,7-2

Connections, straight thread

.2-2
Lift Cylinder, checking
, 2-6

Connecting Rods (533) .. .

, 8--8
Lubricants .. , . , , ..
. 9- 1

Co ntrol Valve , repair . .. .

,2-7
Lubrication of Loader
1-12

Crankshaft (520/530) . ' ,

.7-7

Crankshaft Bearings (533) .

8-10
Maintenance, preventive
,1-3

Cylinder Block (533) .. ' ,

.8-7
Manifold Assembly (533)
8-11

Cylinder Head, disassembly (533)

.8-4

Oil Filter (533) ' . ' , ..

8-15

Dimen sional Specifications

, 9-6
Oil Filter, changing (533)
,1-7

Drive Chains ."

,4-1 Oil Filter, changing (520/530)
.1-6

Oil Pressure, check (5201530) .

.7-2

Electrical System
, 1-9
Oil Pump (520/530)
, 7'-7

Electrical System (520/530)

,6-1
Oil Pump (533 )
8- 15

E lectrica I System (533)

.6-9
Operator Guard , removal
. 5-1

Engine (520 /530) ' . ..

.7-5

Engine (533) . . . , , , .
.8-1
Pistons (5201530) ,
. 7-7

Engine, assembly (533) .

8-11
Pistons (533) .. , ,
. 8-7

Engine, disassembly (533)

, 8-1
Piston Rings (533)
,8-7

Engine Cooling System (520/530)

1--8
Pivot Pins . . . . , .
1-1 3

Engine Cooling System (533) .

. 1--8
Pivot Pin, replacement '"
, 5-1

Engine Lubrication System

. 1-6
Pre-Delivery Inspection . ' .
. 1-2

Engine Oi l, changing (520/530)

,1-6
Problem Analysis, hydraulic
, 2-3

Engine Oil , changing (533)

. 1-7
Problem Analysis, electrical
.6-1

Engine Service .. , . . ' . '

1-4

Engine, troubleshooting (520 /530)

. 7-1
Regulator, check (533) ..
6-10

Release Pressure, checking

.2-4

Final Drive Transmission , . . . , .

1-11
Relief Valve (520/530) . ,
. 7-7

F its. Clearance s, adjustments (520/530)

,9-5
Relief Valve, checking .. '
.2 -4

F its, Clearances. adjustments (533)

,9-6
Relief Valve, removal & replacement
.2-4

Flare Connections .. ' , , . ' ,

.2-1
Replenishing Valves . . . . . . .. .
. 3-2

Flywheel (520/530) , . . . . , .
, ,7-5
Rocker Shaft, disassembly (533)
.8-3

Flywheel and Ring Gear (533)

. 8-11
Rods (520 /530) ..
.7-7

Fuel Filter
,1-5

Fuel Injection Pump Reservoir (533)

1-14
Seal Installing Tool
,9-5

Fuel Specifications
,9-1
Serial Number, engine '"
.1-1

Fuel System .. " .

. 1-5
Serial Number, identification .
.1-1

Fuel System Service,

,1-5
Serial Number, lo ader ..
.1-1

Fuel Tank, removal ,

.5-4
Service Schedule ,
,1-3

Starter (520 /530)

, 6-2

Generator, check output (533)

6-10
Starter, repa ir
6-12

Generator Service (533)

6-10
Stator, replacement (520/530)
.6-2

Governor Linkage (520/530)

.7-2
Steering Linkage , , , , , ' . ' .
3-11

Governor Repair (520/530) ,

.7-4
Specifications, capacities (520/530)
.9-2

Specifications, capacities (533) ..

,9-3

Hot Plugs (533) .8-6

Specifications, electrical (520/530) .
, .9-2

520, 530, 533 Loader

-10-1­ Service Manual

10-1 ALPHABETICAL INDEX (Cont'd)

Subject Page Subject Page

Specifications, electrical (533) . . . . . . . . . . .. .. . .9-3

Specifications, engine (5201530) . . . . . .. . . . 9-2

Specifications, engine (533) . ' .9-3

Specifications, engine torque (520/530) .9-4

Specifications, engine torque (533) .. .. . . •. .9-4

Specifications, general torque . . . . . . . . . .9-9

Specifications, hydrauli c (520/530) .. .

.9-2

Specifications, hydraulic (533) . . .. .

.9-3

Specifications, hydraulic/ hydrostatic . .

.9-4

Specifications, hydraulic motor torque

. 9-4

Specifications, hydrostatic pump torque

. . . . . . 9-4

Specifications, loader torque . .. .. .

.9-4

Spe cifications, operating (520/530) . .

. 9-2

Specifications, operating (533)

. 9-3

Specifications, power train (520/530)

.9-2

Specifications, power train (533) . .

.9-3

Specification s, tires (520/ 530)

. 9-2

Specifications, tires (533) .. .

. 9- 3

Thirty Hour Inspection . . .

.1-2

Throttle Linkage {520/530}

.7-2

Tilt Cylinder, checking .

.2-5

Timing Cover (520/530)

. 7--{j

Timing Gears (520/530)

. 7-6

Timing Gears (533) ..

8-11

T ire Maintenance . . .
1-12

T ubelines and Hoses

. 2-2

V alve Clearances (520/530)

.7-2

V alve Guides (533) ..

· . .. 8-5

Valve Seats (533) . . .

· . . . 8-5

Valve Springs (533)

· . .. 8--{j

Valve System (533) ..

. .. . .. . . 8-7

V alves (533) .. . .. . .. .
.8-5

V alves & Guides, repair (520 /530)

. 7--{j

V ane Pump, checking ..

. 2-4

Vane Pump, repair . . . ..

. 2-5

Water Pu mp (533) .. . . . . 8-16

520, 530, 533 Loader

-10- 2- Service Manual

CIJARK Division Melroe
U- bobcat 530 - 001

Bull etin Num ber

20 MARCH 79
Date

-SERVICE BULLETIN­
AFFECTING:
ROUTE TO
Product BOBCAT LOADER ATTENTION

Model 520 AND 530 SERIES PARTS MANAGER

SERVICE MANAGER
Serial No. 520, 530 & 5 33 ALL SALES M A NAGER o

Manual No. 6556407 (10-78)

o

SUBJECT: SHUTTLE PIN ON THE MOTOR (ROSS MOTOR PIN

12012, 12021 OR 12024)

PROBLEM:

Loss of drive on one side of the loader.

CAUSE:

The shuttle pin (PIN 651 2304) is too short and the edge of the case drain port can
hold it in an open or closed position.

CORRECTION:

Remove the motor f rom 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 (36,9 5 m m ) and th e maximum length is 1 .495 inches (37,97 mm ).
Replace the shuttle pin when it is not in this specification range.

Put the rev ised pages in your 520 , 530 and 533 Service Manual (PIN 65564 07
(10-78]).

REMOVE PUT IN

3 -9,3- 10 Revised Mar . 79 - 3-9, 3-1 0

POLICY:

Melroe w ill 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 shut tle
pin .

EXPIRATION DATE:

31 Dec. 79

Refer To
Bulletin No.(s)
BULLETIN STATUS
NON CURRENT o
 W
• bobcat

530 - 002
Bu lletin Number

24 APRIL 79
Date

--SERVICE BULLETIN­
AFFECTING:

ROUTE TO

Product
BOBCAT LOADER
ATTENTION

Model 530 & 533

PARTS MANAGER fJJ
SERVICE MANAGER L!1
Serial N o.
5 30 - 12348 & Below 533 - 12121 & Below SALES MANAGER D
Manual No. ~6~5~5~6~4
~~7
0 ~_____________________________

o
SUBJECT: BOB - TACH OVER- CENTER STOP KIT

PROBLEM:

The tilt cylinder is damaged when using t ilt hydraulics .

CAUSE:

The Bob-Tach goes over-center when tilted fully forward.

CORRECTION:

Install the stops from the kit (P/N 65 60898 ).

Order the kit from Chicago Central Parts.

This Service Bulletin includes one page which is to be put in the 520, 530 & 5~3
Service Manual (65 56407 [1 0 -781l".

REMOVE PUT IN

5- 3,5 -4 Revised 5-3, 5-4

POLICY:

This kit is available as a Dealer/Customer option only. Melroe will not give warranty
com pensation for parts or labor.

Refer To
Bulletin No.(s) Printed in U.S.A.
BULLETIN STATUS
NON CURRENT o
 J&
"bobcat
530 - 003
Bulletin Number

15 MAY 79
Date

-SERVICE BULLETIN­
AFFECTING:
ROUTE TO
Product BOBCAT LOADER ATTENTION

~
Model 520, 530 AND 533 PARTS MANAGER
SERVICE MANAGER
Serial No. SALES MANAGER D
o
M anual No. 5 5 6 40 7_______________________________
~6~~~~~~

SUBJECT: REVISION TO THE SERVICE MANUAL

The attac hed pages are a revision t o the 52 0, 530 and 533 Service Manual (PIN
6556407 [1 0 -78) ). There are 24 pages to this bulletin, be sure you have them all.

The list of the f ollowing Service Bulletins have been added or are in the Service
Manual.

Bltn. No. Date Bltn. No. Date Bltn. No. Date

.... ~ - .-/'

76-20 Aug 76 0 39 Dec 77 074 Oct 78

76-20 Sept 7 6 04 1 Jan 78 075 Oct 78
009 Mar7 7 044 Mar 78 077 Oct 78
014 May 77 0 45 Apr 78 080 Nov 78
016 Aug 77 0 46 Apr78 082 Nov 78
018 Au g 77 054 May 78 089 Dec 78
020 Sept 77 060 Oct 78 091 Nov 78
022 Oct 77 064 . Aug 78 092 Nov 79
026 Sept 77 0 68 Sept 78 097 Jan 79
028 Oct 77 0 70 Sept. 78
032 Nov77 07 3 Oct 78

Remove t he fo llowing pages in the Service Manual and put in the revised or added
pages, on the back of this page:

Refer To
Bulletin No.ls)
BULLETIN STATUS
NON CURRENT o
 Melroe

Division ~

- bobcat
530 - 004
Bulletin Nu mber
( 31 JULY 79
Date

CIiiI SERVICE BULLETIN Iiiiii) ----~

AFFECTING:
.ROUTE TO
BOBCAT LOADER
Product ATTENTION

~
Model 520, 530 and 533 PARTS MANAGER
SERVICE MANAGER
Serial No. SALES M ANAGER D
D
Manual No. 6 5 56407
~~~~---------------------------------

SUBJECT: REVISION TO THE SERVICE MANUAL

The attached pages are a revision to the 5 20 , 530 and 533 Service Manual (PIN
655 640 7 [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

Revised Mar 79 7 - 5, 7 - 6 Revised June 79 7-5, 7-6

Added 7- 9 Revised June 79 7 - 9
9-3, Revised Mar 7 -9,9-4 9-3, Revised June 79,9-4

Refer To

Bulletin No.(s) Printed in U.S.A.

BULLETIN STATUS
NON CURRENT o
 It( 530 - 00 5

• bobcat Bulletin Numb er

8 JANUARY 1980

Date

.. SERVICE BULLETIN =­

SAFETY N OTICE

AFFECTING:
ROUTE TO

BOBCAT LOADER

Product

ATTENTION

Model

520, 530
PARTS MAN AGER
SERVICE MANAGER ~
520's (ALL) 530's (SIN 14119 & Below)
SALES MANAGER o
Serial No.
o
65564 07 [10-78] (520, 530, 533 Service Manual)
Manual No.
HEAT SHIELD FOR ENGINE

SUBJECT:

PROBLEM:

Poisonous eng ine exhaust gases with carbon monoxide accumulate in operator com·
partm ent 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 ventilate d if operator compartment is enclosed.

CORRECTION:

Never use loader with encl osed operator enclosure unless corrective shield kit (PIN
65619 63) is installed . Ord er kit from Chicago Central Parts. Install warning dec al
(PIN 65619 60). which is supplied wit h kit , on upper left side of loader panel behind
seat. A fte r correcti ve shield is instali ed put correction notice decal (PI N 6561961).
supplied w ith kit, on the warning decal.

POLICY:

M elroe will give warranty compensation for cost of parts and 4 hours labor for in­
stallat ion of t he new heat shield on machine serial numbers listed above with any
type of wea th er enclos ure installed .

EXPIRATION DATE: Indefinite

The attached page is a revision to the 520, 530, 533 Service Manual (PIN
6556407 [10-78)).

REMOVE PUT IN

7-9 Revised 7-9

Refer To
Bulletin No.(s)
Printed in U.S.A.
BULLETIN STATUS
NON CURRENT o
CURRK Melroe
Division ~t( 530-006

* bobcat Bulletin Number

29 JANUA RY 80
Date

-SERVICE BULLETIN­
AFFECTING:

ROUTE TO
Produ ct BOBCAT LOADER
ATTENTION

Model 520 A ND 53 0 SERIES PARTS M ANAGER

SERVICE MANAGER
Serial No. SA LES MANAGER o

o
M anual No. 6556407

SUBJECT: THE RESTRICTION OF OIL THROUGH THE QUICK-CO UPLERS

PROBLEM:

Not enough oil flow t hrough the quick-couplers (high back pressure, slow operation

of the attachment).

CAUSE:

The adapter which connects the quick-coupler has a restriction.

CORRECTION:

Rem ov e the male quick-c o upler and adaptor and cut the "taper" from the end of the

adaptor (See Page 2 - 1 0, Fig. 2 - 3 0).

This Service Bu lletin includes one page which is to be put in the 520, 5 3 0 & 5 33
Serv ice Manua l (6 5 5 6 704 [ 10-78))'.

REMOVE PUT IN

2-9 2-9, Added 2- 1 0

POLICY:

Mel ro e will give warranty compensation for 1Ii hour labor to remove th e "taper"
from th e adaptor.

EXPIRATION DATE:

31 May 1980

Refer To

Bulletin No.ls) Printed in U.S.A.

BULLETIN STATUS
NON CURRENT o
 Melroe

Division ~

- bobcat
530-00 7
Bu ll etin N umber

26 FEBRUA RY 80
Date

Ciii SERVICE BUL L ET IN~

AFFECTING:

ROUTE TO
Product
BOB CAT LOADER
ATTENTION
Model
520 & 530
PARTS M AN AGER CJ
SERVI CE MANAGER ~
Serial No.
SALES M A NAGER D
D
M anual No.
6556407

SUBJECT: SUPPORT BRAC KET FOR THE STARTER

PROBLEM:

Failure at the starter mounting.

CAUS E:

Not enough support for the starter.

) CORRECTION :

Install the suppo rt brac k et (PI N 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).

Order the bracket from Chicago Central Parts.

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

Revised Mar. 6-1, 6-2 Revised Mar. 6-1, Revised Jan. 6-2
6-3, 6 -4 Revised Jan . 6-3, 6-4
6-13, Revised Mar. 6-14 6-13, Revised Jan. 6-14

POLICY:

Melroe will give warranty compensation for the part (PI N 6561936) and flat rate
- - - - _ . -- -­ --_._----_.
labor fo r Bobcats which have starter failure within 1 year from date of delivery to the
origin al owner .

~.
I EXPIRATION DATE:

31 DECEMBE R 80

Refer To

Bulletin No.(s) Printed in U.S.A.

BULLETIN STAT US
NON CURRENT o
-
 C 1 ~RRK Melrae
LI Division ~ 530 - 0 0 8
·r * bobcat Bulletin Number

t. ' :" '.

2 8 OCTOBER 8 0
Date
---­
-SERVICE BULLETIN=­ - -- -- - ~--- ....... - ~ --- - --~ ..

AFFECTING:
ROUTE TO
Product
BOBCAT LOADER ATTENTION

~
Model 520, 530
PARTS MANAGER
SERVICE M ANAGER
Serial No.
SALES MANAGER o
o
M anual No.

SUBJECT: ENGINE CARBURETOR AND CHOKE CONTROL

PROBLEM:

Eng ine continu es t o run after the key switch is turned off.

CAUSE:

/ Carburetor does no t have a fu el shut off solenoid.

~~
CORRECTION:

Replace carburetor 6 51 2225 with carburetor 6514854 which has a fuel shut off
so len oid .

Replace the ro d c ontrolled choke linkage with a cable controlled choke (Kit PIN
6561996).

The fuel solenoid carburetor has the choke lever on the left side and cannot be
connected to the rod controlled c hoke linkage .

The cable controlled c h oke will fully open and close the choke and give better
assistance in c old weather starting.

The c able cont rolled c hoke cannot be installed on machines with carburetor part
number 651 2 225 installed because th e choke lever is on the right side of the
carburetor, and w ill result in interference with the governor control.

The atta ched pages are a revisio n t o the 520 , 530 & 533 Service Manual (P/N
6556407 [ 10-78 ]).

Remove the following pages in t he Service Manual and put in the revised pages .

REMOVE PUT IN

7- 3 , Revised Apr . 7-4 7 - 3, Revised Oct. 7 - 4

POLICY:

Melroe offers this for installatio n at the dealer/customer option and will not give
warranty com pensatio n for parts or labor .

Refer To

Bulletin No.(s) Printed in U.S.A.

BULLETIN STATUS
NON CURRENT o