Complete official service manual for Bobcat Loaders 1213, 1600, 2000, 2000 RTF, 2100, 2100S, 2200, 2200S, 2300, 2400, 2410, AL275, AL350, AL440, WL350, WL350S, WL440, WL440S, with all the shop information to maintain, diagnose, and repair like professional mechanics.

Bobcat Loaders 1213, 1600, 2000, 2000 RTF, 2100, 2100S, 2200, 2200S, 2300, 2400, 2410, AL275, AL350, AL440, WL350, WL350S, WL440, WL440S official workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

22856454 (6-12) - WL350 - WL350 S WL440 - WL440 S Wheel Loader Service Manual.pdf
22582639 (6-12) for WL350 - Deutz Engine Manual (2011 de Operation Manual).pdf
6987392 (4-09) - 2100 Operation & Maintenance Manual.pdf
6904895 (5-09) - 2200, 2200S Operation & Maintenance Manual.pdf
6904893 (12-09) - 2200, 2200S, 2300 Service Manual.pdf
6904892 (5-09) - 2300 Operation & Maintenance Manual.pdf
6903129 (12-09) - 2200 Service Manual.pdf
6903128 (5-09) - 2200 Operation & Maintenance Manual.pdf
6901987 (5-09) - 2100, 2100S Service Manual.pdf
6901986 (5-09) - 2100, 2100S Operation & Maintenance Manual.pdf
6722327 (3-93) - 2410 Service Manual.pdf
6722326 (11-92) - 2410 Operation & Maintenance Manual.pdf
6720455 (6-12) - 2400 Series Loader Service Manual.pdf
6720455 (5-90) - 2400 Service Manual.pdf
6720276 (2-90) - 2410 Operation & Maintenance Manual.pdf
6570571 (8-89) - 2400 Operation & Maintenance Manual.pdf
6570468 (5-87) - 1600 Operation & Maintenance Manual.pdf
6570156 (6-85) - 1213 Service Manual.pdf
6570063 (6-85) - 1213 Operation & Maintenance Manual.pdf
6566906 (8-87) - 1600 Service Manual.pdf
6566906 (6-12) - 1600 Service Manual.pdf
6566672 (7-84) - 2000 RTF Operation & Maintenance Manual.pdf
6566671 (9-96) - 2000 Operation & Maintenance Manual.pdf
6566667 (2-86) - 1600 Operator's Manual.pdf
6566662 (11-88) - 2000 RTF Service Manual.pdf
6566662 (4-83) - 2000 RTF Service Manual.pdf
6566459 (2-83) - 2000 Operation & Maintenance Manual.pdf
6566396 (7-82) - 2000 RTF Operator's Manual.pdf
6566182 (7-82) - 2000 Operator's Manual.pdf
6566180 (06-12) - 2000 Service Manual.pdf
6566180 (4-85) - 2000 Service Manual.pdf
4950152 (9-08) - AL275, AL350, AL440 Service Manual.pdf

Total Pages: 6,221 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
22582639 (6-12) for WL350 - Deutz Engine Manual (2011 De Operation Manual)...1
  OPERATION MANUAL...3
    SAFETY GUIDELINES / ACCIDENT PREVENTION...4
    FOREWORD...6
    CONTENTS...7
    GENERAL...10
    ENGINE DESCRIPTION...12
      MODEL...14
        Rating Plate...13
        Position Of The Rating Plate...13
        Engine Serial NumberCylinder Numbering...13
        Fuel delivery Lock...14
      ENGINE ILLUSTRATION...15
      OIL CIRCUIT...23
      FUEL SYSTEM SCHEMATIC...24
    ENGINE OPERATION...27
      COMMISSIONING...27
      STARTING...31
      MONITORING OPERATION...33
      SHUTTING OFF...35
      OPERATING CONDITIONS...36
    OPERATING MEDIA...38
      LUBE OIL...39
      FUEL...40
    SERVICE...42
      SERVICE PLAN...43
      SCHEDULED MAINTENANCE PLAN...45
      MAINTENANCE CHART...46
      MAINTENANCE WORK COMPLETED...47
    SERVICE AND MAINTENANCE...51
      LUBRICATION SYSTEM...52
      FUEL SYSTEM...56
      COOLING SYSTEM...59
      COMBUSTION AIR FILTER...60
      BELT DRIVES...62
      ADJUSTMENTS...64
      ACCESSORIES...66
      ENGINE CLEANING...69
    FAULTS, CAUSES AND REMEDIES...71
      FAULT TABLE...72
    ENGINE PRESERVATION...75
      PRESERVATION...76
    TECHNICAL SPECIFICATION...77
      ENGINE SPECIFICATIONS AND SETTINGS...78
      TORQUE WRENCH SETTINGS...82
      TOOLS...83
      NOTES...85
    SERVICE...87
22856454 (6-12) - WL350 - WL350 S WL440 - WL440 S Wheel Loader Service Manual...88
  CONTENTS...90
  WHEEL LOADER WL350...92
    DIESEL ENGINE...93
    ELECTRICAL SYSTEM...93
    TRANSMISSION...93
    TRAVEL RANGE...94
    PRESSURE AND SETTING VALVES (TRAVEL)...94
    STEERING...95
    WORKING HYDRAULICS...95
    PRESSURE AND SETTING VALVES (WORKING)...95
    WORKING CYCLES...95
    AXLES...96
    BRAKE SYSTEM...96
    LUBRICANTS...96
    MAINTENANCE PARTS...96
    CAPACITIES...96
    DECSCRIPTION A 6 VM DA 5 WITH SWITCHING SOLENOIDS...97
    TRAVEL PUMPS...111
    LOCATION OF HYDRAULIC COMPONENTS...119
    FUSE BOX - ASSIGNMENT DIAGRAM...121
    START UP...122
    WASH / WIPE SYSTEM...123
    MONITORING...124
    TRAVEL FUSE...126
    TRAVEL SPEED...127
    LIGHTING & SIGNALLING...128
    ROTATING BEACON...129
    POWER SUPPLY MODULE...130
    OPERATOR CONTROL AND DISPLAY ELEMENTS...134
    Untitled...138
  WHEEL LOADER WL440...142
    DIESEL ENGINE...143
    ELECTRICAL SYSTEM...143
    TRANSMISSION...143
    TRAVEL RANGE...144
    PRESSURE AND SETTINGS VALUES (TRAVEL)...144
    STEERING...145
    WORKING HYDRAULICS...145
    PRESSURE AND SETTING VALUES (WORKING)...145
    WORKING CYCLES...145
    AXLES...146
    BRAKE SYSTEM...146
    LUBRICANTS...146
    MAINTENANCE PARTS...146
    CAPACITIES...146
    TRAVEL PUMPS...147
    LOCATION OF HYDRAULIC COMPONENTS...150
    FUSE BOX - ASSIGNMENT DIAGRAM...152
    START-UP...153
    WASH / WIPE SYSTEM...154
    MONITORING...155
    TRAVEL FUSE...157
    TRAVEL SPEED...158
    LIGHTING AND SIGNALLING...159
    ROTATING BEACON...160
    POWER SUPPLY MODULE...161
    INSPECTION PLAN...165
    Untitled...168
4950152 (9-08) - AL275, AL350, AL440 Service Manual...173
  ALPHABETICAL INDEX...175
  CONTENTS...177
    FOREWORD...178
    SAFETY INSTRUCTIONS...178
      Emergency exit...183
      Other dangers...183
      Pictogram...184
  SAFETY AND MAINTENANCE...189
    General Notes...191
    Intervals...193
    Warranty...195
    Inspection parts and aids...197
    Care and cleaning...199
    Notes for winter operation...201
      Hydraulic oil...201
      Engine oil...201
      Battery charge...201
      Fuel...201
    Checking, maintenance and inspection plans...203
      Initial inspection (delivery / handing-over inspection)...203
      Daily and weekly tasks...204
    Overview of lubricating points...207
    Inspection and maintenance work...209
      Inspection plan...209
      Engine oil...213
      Engine oil cooler (AL275)...215
      Fuel system...218
      Fuel system (Cont’d)...219
      Fuel system (Cont’d)...220
      Fuel system (Cont’d)...221
      Fuel system (Cont’d)...222
      Air filter, air intake...223
      Fan belt...226
      Brakes...227
      Hydraulic oil...228
      Hydraulic oil cooler...228
      Hydraulic oil (Cont’d)...229
      Hydraulic oil (Cont’d)...230
      Breather...230
      Axles...231
      Wheels...232
      Injection valves...232
      Toothed belt for engine...232
      Electrical equipment...233
      Cab ventilation dust filter...234
      Wind shield washer system...234
    Shutdown...235
      Preservation (temporary shutdown)...235
      During shutdown...235
      After shutdown...235
    Troubleshooting...237
      General...237
      Engine...237
    Regular oil analyses...241
      Advantages of an oil analysis...241
      Oil analysis intervals...241
  HYDRAULIC SYSTEM...243
    Travel drive...245
    Travel drive (coNT’D)...246
    Setting instructions travel hydraulics...247
      Check and adjustment of the charge pressure...247
      Check and adjustment of the travel pump neutral position...247
      Check and adjustment of the start-up speed...247
      Check and adjustment of the engine stall rpm...247
      Check and adjustment of the pressure cut-off...248
      Check and replacement of the travel high pressure valves...248
      Check and adjustment of the regulation start...248
    AL350 until S/N A01M / AL440 until S/N A01M...249
      Method 1: Test at slope...249
      Method 2: Test on even ground...249
      Check and adjustment of the regulation start against mechanical stop...250
      Check and adjustment of the inching...252
      Check of pressure switch (hydrostatic brake S26)...252
  Electrical System...253
    Fuse box - Assignment diagram AL275...255
    Fuse box - Assignment diagram AL350...260
    Fuse box - Assignment diagram AL440...265
    Cable colours...270
    Cable connections...272
    Flow diagram...272
    Joystick...273
      Relay Device Type PCL 401...273
      Functional description...274
  Technical data...275
    Test Ports...277
      Measuring hoses...277
    Drift values...278
      Test conditions:...278
    Emissions for AL275/Al350/AL440...279
    Technical specifications AL275...281
      Diesel engine...281
      Electrical system...281
      Transmission...281
      Brakes...281
      Hydraulic system...282
      Axles...282
      Tires...283
      Consumables...284
      Consumable specifications...285
      Alternative recommendation for other temperature ranges...286
      Permissible loads in compliance with German Road Traffic Regulations (StVZO)...286
      Sound level values, vibration...286
      Dimensions and weights...286
      Front loader installation...287
      Bucket...287
      Fork lift attachment...287
    Technical specifications AL350...289
      Diesel engine...289
      Electrical system...289
      Transmission...289
      Brakes...289
      Hydraulic system...290
      Axles...290
      Tires...291
      Consumables...292
      Consumable specifications...293
      Alternative recommendation for other temperature ranges...294
      Permissible loads in compliance with German Road Traffic Regulations (StVZO)...294
      Sound level values, vibration...294
      Dimensions and weights...294
      Front loader installation...295
      Bucket...295
      Fork lift attachment...295
    Technical specifications AL440...297
      Diesel engine...297
      Electrical system...297
      Transmission...297
      Brakes...297
      Hydraulic system...298
      Axles...298
      Tires...299
      Consumables...300
      Consumable specifications...301
      Alternative recommendation for other temperature ranges...302
      Permissible loads in compliance with German Road Traffic Regulations (StVZO)...302
      Sound level values, vibration...302
      Dimensions and weights...302
      Front loader installation...303
      Bucket...303
      Fork lift attachment...303
  Appendix...305
    Hydraulic diagram AL275...307
    Hydraulic diagram AL350...313
    Hydraulic diagram AL440...319
    Wheel loader Software V0.40...325
      Programing Description...325
      There are 3 different screens that you can choose from by selecting: “Operation Data”; Exceeded Limits” and “Programming”...327
      Procedure to transfer the operation data out of a defective T|S CU into a new unit and program the up to date machine specific file (*.hex-File)...327
  SPECIFICATIONS AL275...345
    Contents...345
  SPECIFICATIONS AL350...353
    Contents...353
  SPECIFICATIONS AL440...361
    Contents...361
6566180 (06-12) - 2000 Service Manual...369
  MAINTENANCE SAFETY...371
  CONTENTS...373
    FOREWORD...373
    SAFETY INSTRUCTIONS...375
      Safety Is your Responsibility...375
      Before You Operate The Bobcat Loader...375
      Safe Operation needs A Qualified Operator...376
    FIRE PREVENTION...376
    SERIAL NUMBER LOCATIONS...377
      Loader Serial Number...377
      Engine Serial Number Locations...377
    ARRIVAL CONDITION REPORT...377
    DELIVERY REPORT...377
    BOBCAT LOADER IDENTIFICATION...378
  PREVENTIVE MAINTENANCE...379
    SERVICE SCHEDULE...381
    LIFT ARM STOP...382
    FRAME LOCK...382
    LIFTING AND BLOCKING THE LOADER...382
    REAR DOOR...383
      Door Latch Adjustment...383
    AIR CLEANER...383
    FUEL SYSTEM...384
      Filling The Fuel Tank...384
      Fuel Filter...385
      Removing Air From The Fuel System...386
    ENGINE LUBRICATION SYSTEM...386
      Engine Oil And Filter Replacement...387
    ENGINE COOLING SYSTEM...388
      Coolant Level...388
      Coolant Replacement...388
    ALTERNATOR BELT ADJUSTMENT...388
    ELECTRICAL SYSTEM...388
      Electrical System Service...389
      Using An Extra Battery (Jump Starting)...389
      Battery Replacement...391
    HYDRAULIC / HYDROSTATIC SYSTEM...391
      Hydraulic/Hydrostatic Fluid Reservoir...391
      Checking And Adding Fluid...391
      Hydraulic Fluid Replacement...392
      Hydraulic / Hydrostatic Filter Replacement...392
    SPARK ARRESTOR MUFFLER...393
    FRONT & REAR AXLES...394
    U-JOINTS...395
    TIRE MAINTENANCE...395
      Wheel Nuts...395
    LOADER LUBRICATION...396
    BACK-UP ALARM...397
    OPERATOR CAB...397
  HYDRAULIC SYSTEM...399
    HYDRAULIC / HYDROSTATIC SCHEMATICS...402
    TROUBLESHOOTING...423
    HYDRAULIC SYSTEM INFORMATION...424
      37° Flare Connections...424
      Straight Thread O-Ring Fitting...424
      Tubelines And Hoses...424
    PORT BLOCK SERVICE...425
      Bronze (40 Micron) Filter Replacement...425
      Neutral By-Pass Valve Replacement...426
      Cold Oil By-Pass Valve Replacement...426
    OIL RESERVOIR...426
      Oil Reservoir Removal...426
      Oil Reservoir Installation...427
    HYDRAULIC CONTROL VALVE (S/N 12999 & BELOW)...427
      Hydraulic Control Valve Removal...427
      Hydraulic Control Valve Disassembly...428
      Inlet Section...429
      Tilt Section...429
      Lift Section...431
      Auxiliary Section (For Older Style Control Valves)...434
      Auxiliary Section (For Control Valves Equipped With Adjustable Detent)...436
      Auxiliary Detent Adjustment...438
      Hydraulic Control Valve Assembling...439
      Hydraulic Control Valve Installation...439
    HYDRAULIC CONTROL VALVE (S/N 13001 & ABOVE - MELROE VALVE)...440
      Hydraulic Control Valve Removal...440
      Hydraulic Control Valve Disassembly...441
      Hydraulic Control Valve Inspection...444
      Hydraulic Control Valve Assembling...444
      Hydraulic Control Valve Installation...446
    HYDRAULIC MAIN RELIEF VALVE...446
      Hydraulic Main Relief Valve Testing...446
      Hydraulic Main Relief Valve Replacement...447
      Hydraulic Main Relief Valve Adjustment (S/N 12999 & Below)...448
      Hydraulic Main Relief Valve Cleaning (S/N 13001 & Above)...448
      Hydraulic Main Relief Valve Adjustment (S/N 13001 & Above)...448
    HYDRAULIC PUMP...449
      Checking Hydraulic Pump Pressure...449
      Hydraulic Pump Removal...450
      Hydraulic Pump Disassembly...450
      Hydraulic Pump Inspection...451
      Hydraulic Pump Assembling...451
      Hydraulic Pump Installation...452
      Checking Steering Relief Pressure...452
    HYDRAULIC CYLINDERS...453
      Checking Lift And Tilt Cylinder Seals...453
      Checking Steering Cylinder Seals...454
      Lift Cylinder Removal...454
      Lift Cylinder Installation...455
      Tilt Cylinder Removal...455
      Tilt Cylinder Installation...456
      Steering Cylinder Removal...456
      Steering Cylinder Installation...457
      Hydraulic Cylinder Disassembly...457
      Hydraulic Cylinder Assembly...460
    STEERING CONTROL VALVE...462
      Steering Control Valve Removal...462
      Steering Control Valve Disassembly...463
      Steering Control Valve Inspection...465
      Steering Control Valve Assembling...466
      Steering Control Valve Installation...470
  HYDROSTATIC SYSTEM...471
    TROUBLESHOOTING...473
    SERVO CONTROL...475
      Servo Control Neutral Adjustment...475
      Servo Control Removal...476
      Servo Control Disassembly...477
      Servo Control Assembling...478
      Servo Control Installation (S/N 13033 & Below)...478
      Servo Control Installation (S/N 13034 & Above)...479
    FOOT PEDAL, PEDAL LOCK SYSTEM AND CENTERING MECHANISM...480
      Foot Pedal Angle Adjustment...480
      Seat Bar Assembly (S/N 13092 & Above)...481
      Pedal Lock Cable...481
      Centering Mechanism Removal...482
      Centering Mechanism Spring Adjustment...483
        S/N 13091 & Below...483
        S/N 13092 & Above...483
      Centering Mechanism Spring Replacement...484
        S/N 13091 & Below...484
        S/N 13092 & Above...485
      Centering Mechanism Installation...486
      Checking The Neutral Safety Switch...486
      Neutral Safety Switch Adjustment...487
      Micro Switch Adjustment...488
    CHARGE PRESSURE AND REPLENISHING VALVES...490
      Checking Charge Pressure...490
      Checking Orifice In Charge Tubeline...490
      Replenishing Valves...491
    HYDROSTATIC PUMP...492
      Hydrostatic Pump Removal...492
      Hydrostatic Pump Disassembly...494
      Hydrostatic Pump Inspection...497
      Hydrostatic Pump Assembling...499
      Hydrostatic Pump Installation On The Manifold Block...504
      Hydrostatic Pump Installation...505
      Hydrostatic Pump Start-Up Procedure...507
    HYDROSTATIC MOTOR...508
      Hydrostatic Motor Removal...508
      Hydrostatic Motor Disassembly...509
      Hydrostatic Motor Inspection...512
      Hydrostatic Motor Assembly...513
      Manifold block Disassembly...516
      Manifold Block Assembling...516
      Hydrostatic Motor Installation...516
      Hydrostatic Motor Start-Up...517
      Emergency Tow Valve...518
  DRIVE SYSTEM...519
    TROUBLESHOOTING THE DRIVE SYSTEM...521
    DRIVE SHAFT...521
      Drive Shaft Removal...521
      Drive Shaft Installation...522
    REAR AXLE...522
      Rear Axle Removal...522
      Rear Axle Installation...522
    FRONT AXLE...523
      Front Axle Removal...523
      Front Axle Installation...523
    AXLE AND DIFFERENTIAL DISASSEMBLY AND ASSEMBLY...524
      Hub Removal...524
      Hub Installation...525
      Differential Assembly Removal...528
      Ring Gear Removal...529
      Ring Gear Installation...531
      Clutch Plate Removal...531
      Clutch Plate Installation...532
      Drop Gear And Pinion Shaft Removal...533
      Assembling Procedure Explanation...534
      Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)...535
      Pinion Shaft Bearing Installation...536
      Pinion Shaft Installation...537
      Setting Pinion Shaft Position (Using Tool - Pinion Shaft NOT Installaed)...538
      Setting Pinion Bearing Pre-Load...539
      Differential Assembly Installation & Checking End Play (Pinion Shaft Installed)...541
        Checking Gear Backlash...544
    PARKING BRAKE (S/N 13060 & BELOW)...545
      Description...545
      Parking Brake Adjustment...545
      Parking Brake Cable Removal...546
      Parking Brake Cale Installation...546
      Parking Brake Removal Fromm The Hydrostatic Motor...546
      Parking Brake Installation On The Hydrostatic Motor...547
    HYDRAULIC BRAKE (DUSCO) (S/N 13061 & ABOVE)...547
      Description...547
      Brake Removal (Dusco)...547
      Brake Servicing (Dusco)...547
      Brake Installation (Dusco)...549
      Removing Air From The Brake System (Dusco)...550
      Brake Valve Removal...550
      Brake Valve Service...550
      Brake Valve Installation...551
    BRAKE (SY*TEC)...551
      Removal And Installation...551
      Disassembly And Assembly...551
  MAIN FRAME...555
    OPERATOR CAB...557
      Operator Cab Removal...557
      Operator Cab Installation...558
    BOB-TACH...558
      Checking Bob-Tach Wedges...559
      Bob-Tach Removal...559
      Bob-Tach Installation...560
    FLOORPANEL...561
      Floorpanel Removal...561
      Floorpanel Installation...561
    SEAT AND SEAT PLATE...561
      Seat And Seat Plate Removal...561
      Seat And Seat Plate Installation...562
    FUEL TANK...562
      Fuel Tank Removal...562
      Fuel Tank Installation...563
    DOORS...563
      Rear Door Removal...563
      Rear Door Installation...563
      Side Door Removal...563
      Side Door Installation...563
    LOADER DISASSEMBLY AND ASSEMBLY...564
      Seperating The Sections...564
      Connecting The Sections...566
    LIFT ARMS...567
      Lift Arm Removal...567
      Lift Arm Installation...567
  ELECTRICAL SYSTEM...569
    ELECTRICAL SCHEMATICS...571
    ELECTRICAL SYSTEM...579
      Description...579
    TROUBLESHOOTING...579
    BATTERIES...580
      Checking The Batteries...580
      Battery Safety Procedures...580
    DIODES...581
      Checking The Diodes...581
      Diode Replacement...582
    ALTERNATOR...582
      Checking The Alternator...582
      Alternator Removal...583
      Alternator Service...584
      Alternator Installation...585
    STARTER...585
      Checking The Starter...585
      Starter Removal...586
      Starter Service...586
      Starter Installation...588
  ENGINE SERVICE...589
    ENGINE SERVICE (S/N 12999 & BELOW)...591
      TROUBLESHOOTING...593
      CHECKS AND ADJUSTMENTS...594
        Oil Pressure...594
        Valve Clearance...595
        Engine Compression...595
        Servicing The Air Cleaner...595
        Throttle Linkage Adjustment...596
      FUEL SYSTEM AND TIMING...596
      FUEL FILTERS...597
        Replacing The Final Fuel Filter Element...597
        Cleaning The Water Filter Trap...597
      REMOVING AIR FROM THE FUEL SYSTEM...597
      FUEL LIFT PUMP...598
        Checking The Lift Pump...598
        Removing The Lift Pump...598
        Installing The Lift Pump...598
      FUEL INJECTION PUMP...598
        Removing The Fuel Injection Pump...599
        Installing The Fuel Injection Pump...599
        Timing The Fuel Injection Pump (Using Dial Indicator)...599
        Timing The Fuel Injection Pump (Using The Timing Tool)...600
        Checking The Timing Mark On The Flange Injection Pump...601
      FUEL INJECTOR NOZZLES...602
        Removing Fuel Injector Nozzles...602
        Checking Fuel Injector Nozzles...602
        Installing Fuel Injector Nozzles...603
      ENGINE...604
        Removing The Engine...604
        Installing The Engine...605
      BLOWER HOUSING SHIELD...606
        Removing The Blower Housing Shield...606
        Installing The Blower Housing Shield...606
      RADIATOR AND OIL COOLER ASSEMBLY...606
        Cleaning Radiator And Oil Cooler Assembly...606
        Removing Radiator And Oil Cooler Assembly...606
        Installing Radiator And Oil Cooler Assembly...606
      ENGINE BLOWER HOUSING...607
        Installing The Engine Blower Housing...607
      SPARK ARRESTOR MUFFLER...607
        Cleaning The Muffler...607
        Removing The Muffler...608
        Installing The Muffler...608
      CYLINDER HEAD...608
        Removing The Cylinder Head...608
        Removing Valves...609
        Reconditioning The Valves And Valve SEATS...609
        Installing Valve Guides...609
        Checking Valve Springs...610
        Combustion Chamber Inserts...611
        Aligning Cylinder Head Surfaces...611
        Installing Valves...611
        Disassembling The Rocker Arms...612
        Checking The Rocker Arms...613
        Assembling The Rocker Arms...613
        Installing The Cylinder Head...613
      RECONDITIONING THE ENGINE...614
      PISTONS AND CONNECTING RODS...614
        Removing Pistons...614
        Disassembling Pistons...615
        Inspecting The Pistons...615
        Installing Pistons To Connecting Rod...616
        Installing Piston Assembly In The Engine Block...617
        Installing New Pistons...617
      CYLINDER LINERS...618
        Checking Liners...618
        Installing Liners...618
      MAIN BEARINGS...619
        Removing The Main Bearings...619
        Installing The Main Bearings...619
        Crankshaft End Play...620
      CRANKSHAFT...620
        Removing The Crankshaft...620
        Checking The Crankshaft...621
        Installing The Crankshaft...621
      REAR MAIN BEARING OIL SEAL...622
        Installing The Oil Seal...622
      TIMING CASE AND GEARS...623
        Removing The Timing Case Cover...623
        Installing The Timing Case Cover...623
        Removing The Front Seal...623
        Installing The Front Seal...623
        Removing The Idler Gear and Hub...624
        Inspecting The Idler Gear And Hub...624
        Installing The Idler Gear And Hub...624
        Removing The Camshaft Gear...625
        Installing The Camshaft Gear...625
        Removing The Fuel Injection Pump...626
        Installing The Fuel Injection Pump...626
        Removing The Crankshaft Gear...626
        Removing The Timing Case...626
        Installing The Timing Case...626
        Removing Camshaft And Tappets...627
        Inspecting Camshaft And Tappets...627
        Installing Camshaft And Tappets...628
      LUBRICATION SYSTEM...628
        Description Of The Lubrication System...628
        Checking Engine Oil...629
        Replacing Engine Oil And Filter...629
      OIL PAN...629
        Removing The Oil Pan...630
        Installing The Oil Pan...630
      OIL PUMP...630
        Removing The Oil Pump...630
        Disassembling The Oil Pump...630
        Checking The Oil Pump...631
        Assembling The Oil Pump...631
        Installing The Oil Pump...631
      OIL FILTER...632
        Removing The Oil Filter...632
        Disassembling The Oil Filter...632
      COOLING SYSTEM...632
        Belt For The Alternator And Water Pump...632
        Coolant Level...632
        Removing Coolant From The Cooling System...632
      WATER PUMP...633
        Removing The Water Pump...633
        Disassembling The Water Pump...633
        Checking The Water Pump...633
        Assembling The Water Pump...633
        Installing The Water Pump...634
      THERMOSTAT...634
        Removing The Thermostat...634
        Checking The Thermostat...634
        Installing The Thermostat...634
      FLYWHEEL...635
        Removing The Flywheel...635
        Replacing The Flywheel Ring Gear...635
        Installing The Flywheel...635
    ENGINE SERVICE (S/N 13001 & ABOVE)...637
      TROUBLSHOOTING...639
      CHECKS AND ADJUSTMENTS...641
        Serial Number...641
        Oil Pressure...641
        Valve Clearance...641
        Check Engine Compression...641
      FUEL SYSTEM AND TIMING...642
        Fuel Filter...642
        Removing Air From The Fuel System...642
        Fuel Injection Pump...643
        Removing The Fuel Injection Pump...643
        Installing The Fuel Injection Pump...644
        Timing The Fuel Injection Pump...645
        Fuel Injector Nozzles...646
        Removing The Fuel Injector Nozzles...647
        Checking The Fuel Injector Nozzles...647
        Installing The Fuel Injector Nozzles...648
        High Pressure Fuel Lines...648
        Glow Plugs...649
      ENGINE AND ATTACHING PARTS...650
        Removing The Engine...650
        Installing The Engine...651
        Blower Housing Shield...652
          Removal...652
          Installation...652
        Engine Coolant Radiator ...652
          Removal...652
          Installation...653
        Engine Blower Housing...653
          Removal...653
          Installation...653
        Engine Muffler...654
          Removal...654
          Installation...654
        Oil Cooler...654
          Removing The Oil Cooler...654
          Installing The Oil cooler...654
      CYLINDER HEAD...655
        Removing The Cylinder Head...655
        Removal Of The Valves...655
        Reconditioning The Valves And Valve Seats...656
        Installing The Valve Guides...656
        Checking Valve Springs...657
        Combustion Chamber Inserts...658
        Cylinder Head Inspection...658
        Installation Of The Valves...659
        Reconditioning The Rocker Arms...659
          Disassembly...659
          Checking...660
          Assembly...660
        Installing The Cylinder Head...660
      RECONDITIONING THE ENGINE...662
        Pistons And Connecting Rods...662
          Removal...662
          Disassembly...663
          Inspection...663
        Installation Of Piston To Connecting Rod...664
        Installation Of Rings On The Piston...664
        Installing Piston Assembly In The Engine Block...665
        Cylinder Liners...665
          Checking...665
          Installation...666
        Main Bearings...667
          Removal...667
          Installation...668
        Crankshaft End Play...668
        Crankshaft...668
          Removal...668
          Checking...669
          Installation...670
        Rear Main Bearing Oil Seal...670
      TIMING CASE AND GEARS...671
        Timing Case Cover...671
          Removal...671
          Installation...671
        Front Seal...672
          Removal...672
          Installation...672
        Idler Gear And Hub...672
          Removal...672
          Inspection...673
          Installation...673
        Camshaft Gear...673
          Removal...674
          Installation...674
        Fuel Injection Pump Gear...674
          Removal...674
          Installation...674
        Crankshaft Gear...675
        Timing Case...675
          Removal...675
          Installation...675
        Camshaft And Tappets...676
          Removal...676
          Inspection...677
          Installation...677
      LUBRICATION SYSTEM...677
        Description Of The Lubrication System...677
        Oil Pan...678
          Removal...678
          Installation...678
        Oil Pump...679
          Removal...679
          Disassembly...679
          Checking...680
          Assembly...681
          Installation...681
        Oil Filter And Adapter Housing...682
        Removal...682
        Installation...682
      COOLING SYSTEM...682
        Alternator And Water Pump Belt...682
        Water Pump...682
          Removal...682
          Installation...683
        Thermostat...683
          Removal...683
          Testing The Thermostat...683
          Installation...683
      FLYWHEEL...684
        Removal Of The Flywheel...684
        Replacement Of The Flywheel Ring Gear...684
        Installation Of The Flywheel...684
  TECHNICAL DATA (S/N 12999 & BELOW)...685
    LOADER SPECIFICATIONS...687
      Specifications...687
      Engine...687
      Loader Hydraulics...688
      Electrical...688
      Drive System...688
      Capacities...688
      Tires...688
    ENGINE SPECIFICATIONS...689
      Cylinder Head Dimensions...689
      pistons And Connecting Rod Dimensions...690
      Cylinder Block And Liners Dimensions...691
      Crankshaft And Main Bearings Dimesions...691
      Timing Cse, Camshaft And Drive Dimensions...692
      Oil Pump Dimensions...693
      Cooling System And Water Pump Dimensions...694
      Fuel System Specifications...694
      De-Rating For Altitude...695
      Engine Bolt Torque...695
      Grinding Specifications For Crankshaft...696
      Crankshaft Regrinding Data...696
    HYDRAULIC SYSTEM...697
    HYDROSTATIC SYSTEM...697
    DECIMAL AND MILLIMETER EQUIVALENTS...698
    U.S. TO METRIC CONVERSION...698
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...699
  TECHNICAL DATA (S/N 13001 & ABOVE)...701
    LOADER SPECIFICATIONS...703
      Specifications...703
      Engine...703
      Loader Hydraulics...704
      Electrical...704
      Drive System...704
      Capacities...704
      Tires...704
    ENGINE SPECIFICATIONS...705
      Cylinder Head Dimensions...705
      Pistons And Connecting Rod Dimensions...705
      Cylinder Block And Liner Dimensions...706
      Crankshaft And Main Bearing Dimensions...707
      Timing Case, Camshaft And Drive Dimensions...707
      Oil Pump Dimensions...707
      Cooling System And Water Pump Dimensions...708
      Fuel System Specifications...708
      De-Rating For Altitude...708
      Engine Torque...709
      Grinding Specifications For Crankshaft...710
      Crankshaft Regrind Data...710
  ALPHABETICAL INDEX...711
  SERVICE MANUAL REVISIONS...715
    2000-1...715
    2000-2...717
    2000-3...719
    2000-4...721
6566180 (4-85) - 2000 Service Manual...723
  MAINTENANCE SAFETY...725
  CONTENTS...727
    FOREWORD...727
    SAFETY INSTRUCTIONS...729
      Safety Is your Responsibility...729
      Before You Operate The Bobcat Loader...729
      Safe Operation needs A Qualified Operator...730
    FIRE PREVENTION...730
    SERIAL NUMBER LOCATIONS...731
      Loader Serial Number...731
      Engine Serial Number Locations...731
    ARRIVAL CONDITION REPORT...731
    DELIVERY REPORT...731
    BOBCAT LOADER IDENTIFICATION...732
  PREVENTIVE MAINTENANCE...733
    SERVICE SCHEDULE...735
    LIFT ARM STOP...736
    FRAME LOCK...736
    LIFTING AND BLOCKING THE LOADER...736
    REAR DOOR...737
      Door Latch Adjustment...737
    AIR CLEANER...737
    FUEL SYSTEM...738
      Filling The Fuel Tank...738
      Fuel Filter...739
      Removing Air From The Fuel System...740
    ENGINE LUBRICATION SYSTEM...740
      Engine Oil And Filter Replacement...741
    ENGINE COOLING SYSTEM...742
      Coolant Level...742
      Coolant Replacement...742
    ALTERNATOR BELT ADJUSTMENT...742
    ELECTRICAL SYSTEM...742
      Electrical System Service...743
      Using An Extra Battery (Jump Starting)...743
      Battery Replacement...745
    HYDRAULIC / HYDROSTATIC SYSTEM...745
      Hydraulic/Hydrostatic Fluid Reservoir...745
      Checking And Adding Fluid...745
      Hydraulic Fluid Replacement...746
      Hydraulic / Hydrostatic Filter Replacement...746
    SPARK ARRESTOR MUFFLER...747
    FRONT & REAR AXLES...748
    U-JOINTS...749
    TIRE MAINTENANCE...749
      Wheel Nuts...749
    LOADER LUBRICATION...750
    BACK-UP ALARM...751
    OPERATOR CAB...751
  HYDRAULIC SYSTEM...753
    HYDRAULIC / HYDROSTATIC SCHEMATICS...756
    TROUBLESHOOTING...777
    HYDRAULIC SYSTEM INFORMATION...778
      37° Flare Connections...778
      Straight Thread O-Ring Fitting...778
      Tubelines And Hoses...778
    PORT BLOCK SERVICE...779
      Bronze (40 Micron) Filter Replacement...779
      Neutral By-Pass Valve Replacement...780
      Cold Oil By-Pass Valve Replacement...780
    OIL RESERVOIR...780
      Oil Reservoir Removal...780
      Oil Reservoir Installation...781
    HYDRAULIC CONTROL VALVE (S/N 12999 & BELOW)...781
      Hydraulic Control Valve Removal...781
      Hydraulic Control Valve Disassembly...782
      Inlet Section...783
      Tilt Section...783
      Lift Section...785
      Auxiliary Section (For Older Style Control Valves)...788
      Auxiliary Section (For Control Valves Equipped With Adjustable Detent)...790
      Auxiliary Detent Adjustment...792
      Hydraulic Control Valve Assembling...793
      Hydraulic Control Valve Installation...793
    HYDRAULIC CONTROL VALVE (S/N 13001 & ABOVE - MELROE VALVE)...794
      Hydraulic Control Valve Removal...794
      Hydraulic Control Valve Disassembly...795
      Hydraulic Control Valve Inspection...798
      Hydraulic Control Valve Assembling...798
      Hydraulic Control Valve Installation...800
    HYDRAULIC MAIN RELIEF VALVE...800
      Hydraulic Main Relief Valve Testing...800
      Hydraulic Main Relief Valve Replacement...801
      Hydraulic Main Relief Valve Adjustment (S/N 12999 & Below)...802
      Hydraulic Main Relief Valve Cleaning (S/N 13001 & Above)...802
      Hydraulic Main Relief Valve Adjustment (S/N 13001 & Above)...802
    HYDRAULIC PUMP...803
      Checking Hydraulic Pump Pressure...803
      Hydraulic Pump Removal...804
      Hydraulic Pump Disassembly...804
      Hydraulic Pump Inspection...805
      Hydraulic Pump Assembling...805
      Hydraulic Pump Installation...806
      Checking Steering Relief Pressure...806
    HYDRAULIC CYLINDERS...807
      Checking Lift And Tilt Cylinder Seals...807
      Checking Steering Cylinder Seals...808
      Lift Cylinder Removal...808
      Lift Cylinder Installation...809
      Tilt Cylinder Removal...809
      Tilt Cylinder Installation...810
      Steering Cylinder Removal...810
      Steering Cylinder Installation...811
      Hydraulic Cylinder Disassembly...811
      Hydraulic Cylinder Assembly...814
    STEERING CONTROL VALVE...816
      Steering Control Valve Removal...816
      Steering Control Valve Disassembly...817
      Steering Control Valve Inspection...819
      Steering Control Valve Assembling...820
      Steering Control Valve Installation...824
  HYDROSTATIC SYSTEM...825
    TROUBLESHOOTING...827
    SERVO CONTROL...829
      Servo Control Neutral Adjustment...829
      Servo Control Removal...830
      Servo Control Disassembly...831
      Servo Control Assembling...832
      Servo Control Installation (S/N 13033 & Below)...832
      Servo Control Installation (S/N 13034 & Above)...833
    FOOT PEDAL, PEDAL LOCK SYSTEM AND CENTERING MECHANISM...834
      Foot Pedal Angle Adjustment...834
      Seat Bar Assembly (S/N 13092 & Above)...835
      Pedal Lock Cable...835
      Centering Mechanism Removal...836
      Centering Mechanism Spring Adjustment...837
        S/N 13091 & Below...837
        S/N 13092 & Above...837
      Centering Mechanism Spring Replacement...838
        S/N 13091 & Below...838
        S/N 13092 & Above...839
      Centering Mechanism Installation...840
      Checking The Neutral Safety Switch...840
      Neutral Safety Switch Adjustment...841
      Micro Switch Adjustment...842
    CHARGE PRESSURE AND REPLENISHING VALVES...844
      Checking Charge Pressure...844
      Checking Orifice In Charge Tubeline...844
      Replenishing Valves...845
    HYDROSTATIC PUMP...846
      Hydrostatic Pump Removal...846
      Hydrostatic Pump Disassembly...848
      Hydrostatic Pump Inspection...851
      Hydrostatic Pump Assembling...853
      Hydrostatic Pump Installation On The Manifold Block...858
      Hydrostatic Pump Installation...859
      Hydrostatic Pump Start-Up Procedure...861
    HYDROSTATIC MOTOR...862
      Hydrostatic Motor Removal...862
      Hydrostatic Motor Disassembly...863
      Hydrostatic Motor Inspection...866
      Hydrostatic Motor Assembly...867
      Manifold block Disassembly...870
      Manifold Block Assembling...870
      Hydrostatic Motor Installation...870
      Hydrostatic Motor Start-Up...871
      Emergency Tow Valve...872
  DRIVE SYSTEM...873
    TROUBLESHOOTING THE DRIVE SYSTEM...875
    DRIVE SHAFT...875
      Drive Shaft Removal...875
      Drive Shaft Installation...876
    REAR AXLE...876
      Rear Axle Removal...876
      Rear Axle Installation...876
    FRONT AXLE...877
      Front Axle Removal...877
      Front Axle Installation...877
    AXLE AND DIFFERENTIAL DISASSEMBLY AND ASSEMBLY...878
      Hub Removal...878
      Hub Installation...879
      Differential Assembly Removal...882
      Ring Gear Removal...883
      Ring Gear Installation...885
      Clutch Plate Removal...885
      Clutch Plate Installation...886
      Drop Gear And Pinion Shaft Removal...887
      Assembling Procedure Explanation...888
      Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)...889
      Pinion Shaft Bearing Installation...890
      Pinion Shaft Installation...891
      Setting Pinion Shaft Position (Using Tool - Pinion Shaft NOT Installaed)...892
      Setting Pinion Bearing Pre-Load...893
      Differential Assembly Installation & Checking End Play (Pinion Shaft Installed)...895
        Checking Gear Backlash...898
    PARKING BRAKE (S/N 13060 & BELOW)...899
      Description...899
      Parking Brake Adjustment...899
      Parking Brake Cable Removal...900
      Parking Brake Cale Installation...900
      Parking Brake Removal Fromm The Hydrostatic Motor...900
      Parking Brake Installation On The Hydrostatic Motor...901
    HYDRAULIC BRAKE (DUSCO) (S/N 13061 & ABOVE)...901
      Description...901
      Brake Removal (Dusco)...901
      Brake Servicing (Dusco)...901
      Brake Installation (Dusco)...903
      Removing Air From The Brake System (Dusco)...904
      Brake Valve Removal...904
      Brake Valve Service...904
      Brake Valve Installation...905
    BRAKE (SY*TEC)...905
      Removal And Installation...905
      Disassembly And Assembly...905
  MAIN FRAME...909
    OPERATOR CAB...911
      Operator Cab Removal...911
      Operator Cab Installation...912
    BOB-TACH...912
      Checking Bob-Tach Wedges...913
      Bob-Tach Removal...913
      Bob-Tach Installation...914
    FLOORPANEL...915
      Floorpanel Removal...915
      Floorpanel Installation...915
    SEAT AND SEAT PLATE...915
      Seat And Seat Plate Removal...915
      Seat And Seat Plate Installation...916
    FUEL TANK...916
      Fuel Tank Removal...916
      Fuel Tank Installation...917
    DOORS...917
      Rear Door Removal...917
      Rear Door Installation...917
      Side Door Removal...917
      Side Door Installation...917
    LOADER DISASSEMBLY AND ASSEMBLY...918
      Seperating The Sections...918
      Connecting The Sections...920
    LIFT ARMS...921
      Lift Arm Removal...921
      Lift Arm Installation...921
  ELECTRICAL SYSTEM...923
    ELECTRICAL SCHEMATICS...925
    ELECTRICAL SYSTEM...933
      Description...933
    TROUBLESHOOTING...933
    BATTERIES...934
      Checking The Batteries...934
      Battery Safety Procedures...934
    DIODES...935
      Checking The Diodes...935
      Diode Replacement...936
    ALTERNATOR...936
      Checking The Alternator...936
      Alternator Removal...937
      Alternator Service...938
      Alternator Installation...939
    STARTER...939
      Checking The Starter...939
      Starter Removal...940
      Starter Service...940
      Starter Installation...942
  ENGINE SERVICE...943
    ENGINE SERVICE (S/N 12999 & BELOW)...945
      TROUBLESHOOTING...947
      CHECKS AND ADJUSTMENTS...948
        Oil Pressure...948
        Valve Clearance...949
        Engine Compression...949
        Servicing The Air Cleaner...949
        Throttle Linkage Adjustment...950
      FUEL SYSTEM AND TIMING...950
      FUEL FILTERS...951
        Replacing The Final Fuel Filter Element...951
        Cleaning The Water Filter Trap...951
      REMOVING AIR FROM THE FUEL SYSTEM...951
      FUEL LIFT PUMP...952
        Checking The Lift Pump...952
        Removing The Lift Pump...952
        Installing The Lift Pump...952
      FUEL INJECTION PUMP...952
        Removing The Fuel Injection Pump...953
        Installing The Fuel Injection Pump...953
        Timing The Fuel Injection Pump (Using Dial Indicator)...953
        Timing The Fuel Injection Pump (Using The Timing Tool)...954
        Checking The Timing Mark On The Flange Injection Pump...955
      FUEL INJECTOR NOZZLES...956
        Removing Fuel Injector Nozzles...956
        Checking Fuel Injector Nozzles...956
        Installing Fuel Injector Nozzles...957
      ENGINE...958
        Removing The Engine...958
        Installing The Engine...959
      BLOWER HOUSING SHIELD...960
        Removing The Blower Housing Shield...960
        Installing The Blower Housing Shield...960
      RADIATOR AND OIL COOLER ASSEMBLY...960
        Cleaning Radiator And Oil Cooler Assembly...960
        Removing Radiator And Oil Cooler Assembly...960
        Installing Radiator And Oil Cooler Assembly...960
      ENGINE BLOWER HOUSING...961
        Installing The Engine Blower Housing...961
      SPARK ARRESTOR MUFFLER...961
        Cleaning The Muffler...961
        Removing The Muffler...962
        Installing The Muffler...962
      CYLINDER HEAD...962
        Removing The Cylinder Head...962
        Removing Valves...963
        Reconditioning The Valves And Valve SEATS...963
        Installing Valve Guides...963
        Checking Valve Springs...964
        Combustion Chamber Inserts...965
        Aligning Cylinder Head Surfaces...965
        Installing Valves...965
        Disassembling The Rocker Arms...966
        Checking The Rocker Arms...967
        Assembling The Rocker Arms...967
        Installing The Cylinder Head...967
      RECONDITIONING THE ENGINE...968
      PISTONS AND CONNECTING RODS...968
        Removing Pistons...968
        Disassembling Pistons...969
        Inspecting The Pistons...969
        Installing Pistons To Connecting Rod...970
        Installing Piston Assembly In The Engine Block...971
        Installing New Pistons...971
      CYLINDER LINERS...972
        Checking Liners...972
        Installing Liners...972
      MAIN BEARINGS...973
        Removing The Main Bearings...973
        Installing The Main Bearings...973
        Crankshaft End Play...974
      CRANKSHAFT...974
        Removing The Crankshaft...974
        Checking The Crankshaft...975
        Installing The Crankshaft...975
      REAR MAIN BEARING OIL SEAL...976
        Installing The Oil Seal...976
      TIMING CASE AND GEARS...977
        Removing The Timing Case Cover...977
        Installing The Timing Case Cover...977
        Removing The Front Seal...977
        Installing The Front Seal...977
        Removing The Idler Gear and Hub...978
        Inspecting The Idler Gear And Hub...978
        Installing The Idler Gear And Hub...978
        Removing The Camshaft Gear...979
        Installing The Camshaft Gear...979
        Removing The Fuel Injection Pump...980
        Installing The Fuel Injection Pump...980
        Removing The Crankshaft Gear...980
        Removing The Timing Case...980
        Installing The Timing Case...980
        Removing Camshaft And Tappets...981
        Inspecting Camshaft And Tappets...981
        Installing Camshaft And Tappets...982
      LUBRICATION SYSTEM...982
        Description Of The Lubrication System...982
        Checking Engine Oil...983
        Replacing Engine Oil And Filter...983
      OIL PAN...983
        Removing The Oil Pan...984
        Installing The Oil Pan...984
      OIL PUMP...984
        Removing The Oil Pump...984
        Disassembling The Oil Pump...984
        Checking The Oil Pump...985
        Assembling The Oil Pump...985
        Installing The Oil Pump...985
      OIL FILTER...986
        Removing The Oil Filter...986
        Disassembling The Oil Filter...986
      COOLING SYSTEM...986
        Belt For The Alternator And Water Pump...986
        Coolant Level...986
        Removing Coolant From The Cooling System...986
      WATER PUMP...987
        Removing The Water Pump...987
        Disassembling The Water Pump...987
        Checking The Water Pump...987
        Assembling The Water Pump...987
        Installing The Water Pump...988
      THERMOSTAT...988
        Removing The Thermostat...988
        Checking The Thermostat...988
        Installing The Thermostat...988
      FLYWHEEL...989
        Removing The Flywheel...989
        Replacing The Flywheel Ring Gear...989
        Installing The Flywheel...989
    ENGINE SERVICE (S/N 13001 & ABOVE)...991
      TROUBLSHOOTING...993
      CHECKS AND ADJUSTMENTS...995
        Serial Number...995
        Oil Pressure...995
        Valve Clearance...995
        Check Engine Compression...995
      FUEL SYSTEM AND TIMING...996
        Fuel Filter...996
        Removing Air From The Fuel System...996
        Fuel Injection Pump...997
        Removing The Fuel Injection Pump...997
        Installing The Fuel Injection Pump...998
        Timing The Fuel Injection Pump...999
        Fuel Injector Nozzles...1000
        Removing The Fuel Injector Nozzles...1001
        Checking The Fuel Injector Nozzles...1001
        Installing The Fuel Injector Nozzles...1002
        High Pressure Fuel Lines...1002
        Glow Plugs...1003
      ENGINE AND ATTACHING PARTS...1004
        Removing The Engine...1004
        Installing The Engine...1005
        Blower Housing Shield...1006
          Removal...1006
          Installation...1006
        Engine Coolant Radiator ...1006
          Removal...1006
          Installation...1007
        Engine Blower Housing...1007
          Removal...1007
          Installation...1007
        Engine Muffler...1008
          Removal...1008
          Installation...1008
        Oil Cooler...1008
          Removing The Oil Cooler...1008
          Installing The Oil cooler...1008
      CYLINDER HEAD...1009
        Removing The Cylinder Head...1009
        Removal Of The Valves...1009
        Reconditioning The Valves And Valve Seats...1010
        Installing The Valve Guides...1010
        Checking Valve Springs...1011
        Combustion Chamber Inserts...1012
        Cylinder Head Inspection...1012
        Installation Of The Valves...1013
        Reconditioning The Rocker Arms...1013
          Disassembly...1013
          Checking...1014
          Assembly...1014
        Installing The Cylinder Head...1014
      RECONDITIONING THE ENGINE...1016
        Pistons And Connecting Rods...1016
          Removal...1016
          Disassembly...1017
          Inspection...1017
        Installation Of Piston To Connecting Rod...1018
        Installation Of Rings On The Piston...1018
        Installing Piston Assembly In The Engine Block...1019
        Cylinder Liners...1019
          Checking...1019
          Installation...1020
        Main Bearings...1021
          Removal...1021
          Installation...1022
        Crankshaft End Play...1022
        Crankshaft...1022
          Removal...1022
          Checking...1023
          Installation...1024
        Rear Main Bearing Oil Seal...1024
      TIMING CASE AND GEARS...1025
        Timing Case Cover...1025
          Removal...1025
          Installation...1025
        Front Seal...1026
          Removal...1026
          Installation...1026
        Idler Gear And Hub...1026
          Removal...1026
          Inspection...1027
          Installation...1027
        Camshaft Gear...1027
          Removal...1028
          Installation...1028
        Fuel Injection Pump Gear...1028
          Removal...1028
          Installation...1028
        Crankshaft Gear...1029
        Timing Case...1029
          Removal...1029
          Installation...1029
        Camshaft And Tappets...1030
          Removal...1030
          Inspection...1031
          Installation...1031
      LUBRICATION SYSTEM...1031
        Description Of The Lubrication System...1031
        Oil Pan...1032
          Removal...1032
          Installation...1032
        Oil Pump...1033
          Removal...1033
          Disassembly...1033
          Checking...1034
          Assembly...1035
          Installation...1035
        Oil Filter And Adapter Housing...1036
        Removal...1036
        Installation...1036
      COOLING SYSTEM...1036
        Alternator And Water Pump Belt...1036
        Water Pump...1036
          Removal...1036
          Installation...1037
        Thermostat...1037
          Removal...1037
          Testing The Thermostat...1037
          Installation...1037
      FLYWHEEL...1038
        Removal Of The Flywheel...1038
        Replacement Of The Flywheel Ring Gear...1038
        Installation Of The Flywheel...1038
  TECHNICAL DATA (S/N 12999 & BELOW)...1039
    LOADER SPECIFICATIONS...1041
      Specifications...1041
      Engine...1041
      Loader Hydraulics...1042
      Electrical...1042
      Drive System...1042
      Capacities...1042
      Tires...1042
    ENGINE SPECIFICATIONS...1043
      Cylinder Head Dimensions...1043
      pistons And Connecting Rod Dimensions...1044
      Cylinder Block And Liners Dimensions...1045
      Crankshaft And Main Bearings Dimesions...1045
      Timing Cse, Camshaft And Drive Dimensions...1046
      Oil Pump Dimensions...1047
      Cooling System And Water Pump Dimensions...1048
      Fuel System Specifications...1048
      De-Rating For Altitude...1049
      Engine Bolt Torque...1049
      Grinding Specifications For Crankshaft...1050
      Crankshaft Regrinding Data...1050
    HYDRAULIC SYSTEM...1051
    HYDROSTATIC SYSTEM...1051
    DECIMAL AND MILLIMETER EQUIVALENTS...1052
    U.S. TO METRIC CONVERSION...1052
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1053
  TECHNICAL DATA (S/N 13001 & ABOVE)...1055
    LOADER SPECIFICATIONS...1057
      Specifications...1057
      Engine...1057
      Loader Hydraulics...1058
      Electrical...1058
      Drive System...1058
      Capacities...1058
      Tires...1058
    ENGINE SPECIFICATIONS...1059
      Cylinder Head Dimensions...1059
      Pistons And Connecting Rod Dimensions...1059
      Cylinder Block And Liner Dimensions...1060
      Crankshaft And Main Bearing Dimensions...1061
      Timing Case, Camshaft And Drive Dimensions...1061
      Oil Pump Dimensions...1061
      Cooling System And Water Pump Dimensions...1062
      Fuel System Specifications...1062
      De-Rating For Altitude...1062
      Engine Torque...1063
      Grinding Specifications For Crankshaft...1064
      Crankshaft Regrind Data...1064
  ALPHABETICAL INDEX...1065
  SERVICE MANUAL REVISIONS...1069
    2000-1...1069
    2000-2...1071
    2000-3...1073
6566182 (7-82) - 2000 Operator's Manual...1075
  OPERATOR SAFETY WARNINGS...1076
  DAFETY INSTRUCTIONS...1077
  FOREWORD...1079
    CONTENTS...1079
    2000 BOBCAT LOADER IDENTIFICATION...1080
  OPERATING INSTRUCTIONS...1081
    OPERATING INSTRUCTIONS...1083
    SAFETY SIGNS (DECALS)...1084
    CONTROLS...1085
    DASH PANEL...1085
    THROTTLE CONTROL...1086
    STOPPING THE ENGINE...1086
    PARKING BRAKE...1086
    STEERING AND SPEED CONTROLS...1087
    HYDRAULIC CONTROLS...1088
    LIFT ARM OPERATION...1088
    TILT OPERATION...1088
    AUXILIARY OPERATION...1089
    BEFORE YOU START THE ENGINE...1089
    STARTING THE ENGINE...1090
      Normal Starting Condition...1091
      Cold Temperature Starting Condition...1091
      Cold Weather Starting Procedure...1092
    BOBCAT LOADER OPERATION...1092
      Bucket Size...1093
      Installation Of Attachments...1093
      Removal Of Attachments...1094
    OPERATION OF THE BOBCAT LOADER...1094
    OPERATING PROCEDURE...1094
      Filling The Bucket...1097
      Emptying The Bucket...1097
      Digging Into The Ground...1097
      Making The Ground Level...1097
      Filling A Hole...1098
    STOPPING THE BOBCAT LOADER...1098
    TRANSPORTING THE BOBCAT LOADER...1098
    EMERGENCY (TOW) VALVE...1100
    FRONT WINDOW...1100
  PREVENTIVE MAINTENANCE...1101
    WARNINGS...1103
    SERVICE SCHEDULE...1105
    FRAME LOCK...1106
    ENGINE SERVICE...1106
    AIR CLEANER SERVICE...1106
    FUEL SYSTEM...1107
    FUEL SYSTEM SERVICE...1108
    FUEL FILTERS...1108
    REMOVING AIR FROM THE FUEL SYSTEM...1109
    ENGINE LUBRICATION SYSTEM...1110
    REPLACEMENT OF THE ENGINE OIL AND FILTER...1110
    ENGINE COOLING SYSTEM...1111
      Coolant Level...1111
      Removing Coolant From The Cooling System...1111
    ALTERNATOR...1111
      Adjusting The Alternator Belt Tension...1111
    ELECTRICAL SYSTEM...1112
    USING AN EXTRA BATTERY (BOOSTER STARTING)...1114
    TO INSTALL NEW BATTERIES...1115
    HYDRAULIC/HYDROSTATIC SYSTEM...1116
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1116
      Checking And Adding Hydraulic / Hydrostatic Fluid...1118
      Removing The Hydraulic / Hydrostatic Fluid...1118
    REPLACEMENT OF THE HYDRAULIC / HYDROSTATIC FILTER...1118
    FRONT & REAR AXLE...1119
    U-JOINTS...1119
    TIRE MAINTENANCE...1119
    LUBRICATION OF THE BOBCAT LOADER...1120
    SPARK ARRESTOR MUFFLER...1121
    BOB-TACH...1121
    LOADER SERIAL NUMBER...1121
    OPERATOR GUARD...1122
    DELIVERY REPORT...1122
    THIRTY HOUR INSPECTION...1122
  TROUBLESHOOTING...1123
    TROUBLESHOOTING THE ENGINE...1125
    TROUBLESHOOTING THE DRIVE SYSTEM...1126
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1126
  MAJOR PARTS...1127
    MAIN FRAME...1129
    FUEL TANK, SEAT & STEERING CONTROL...1130
    DRIVE SYSTEM...1131
    LIFT & TILT HYDRAULICS...1132
    HYDROSTATIC CIRCUITRY...1133
    OPERATOR GUARD ELECTRICAL...1135
    ENGINE ELECTRICAL...1136
    ENGINE & ATTACHING PARTS...1137
  GENERAL INFORMATION...1139
    SPECIFICATIONS...1141
    ENGINE...1141
    LOADER HYDRAULICS...1142
    ELECTRICAL...1142
    DRIVE SYSTEM...1142
    CAPACITIES...1142
    TIRES...1142
    ADDITIONAL PUBLICATIONS...1143
  WARRANTY...1145
6566396 (7-82) - 2000 RTF Operator's Manual...1147
  WARNINGS...1148
  SAFETY INSTRUCTIONS...1149
    SAFETY IS YOUR RESPONSIBILITY...1149
    BEFORE YOU OPERATE THE BOBCAT LOADER...1149
  FOREWORD...1151
    CONTENTS...1151
    2000 BOBCAT ROUGH TERRAIN FORKLIFT IDENTIFICATION...1152
  OPERATING INSTRUCTIONS...1153
    OPERATING INSTRUCTIONS...1155
    SAFETY SIGNS (DECALS) LOCATIONS...1156
    DASH PANEL...1157
    THROTTLE CONTROL...1158
    STOPPING HTE ENGINE...1158
    PARKING BRAKE...1158
    STEERING AND SPEED CONTROLS...1159
    HYDRAULIC CONTROLS...1160
    VERTICAL LIFT OPERATION...1160
    HYDRAULIC OPERATION...1160
    BEFORE YOU START THE ENGINE...1160
    STARTING THE ENGINE...1160
      Normal Starting Condition...1162
      Cold Temperature Starting Condition...1162
      Cold Weather Starting Procedure...1163
    ATTACHMENTS...1164
      Pallet Forks...1164
      Vertical Mast...1164
    BOBCAT ROUGH TERRAIN FORKLIFT OPERATION...1165
    OPERATING PROCEDURE...1165
      Loading The Vertical Mast...1168
      Unloading The Vertical Mast...1168
    STOPPING THE BOBCAT ROUGH TERRAIN FORKLIFT...1168
    TRANSPORTING THE BOBCAT ROUGH TERRAIN FORKLIFT...1169
    EMERGENCY (TOW) VALVE...1170
    FRONT WINDOW...1171
  PREVENTIVE MAINTENANCE...1173
    WARNINGS...1174
    SERVICE SCHEDULE...1175
    FRAME LOCK...1176
    JACKING AND BLOCKING THE BOBCAT FORKLIFT...1176
    ENGINE SERVICE...1177
    ADJUSTING THE DOOR LATCH...1177
    AIR CLEANER SERVICE...1177
    FUEL SYSTEM...1178
    FUEL SYSTEM SERVICE...1178
    FUEL FILTERS...1179
    REMOVING AIR FROM THE FUEL SYSTEM...1179
    ENGINE LUBRICATION SYSTEM...1180
    REPLACEMENT OF ENGINE OIL AND FILTER...1181
    ENGINE COOLING SYSTEM...1182
      Coolant Level...1182
    REMOVING COOLANT FROM THE COOLING SYSTEM...1182
    ALTERNATOR BELT...1182
    ELECTRICAL SYSTEM...1182
    USING AN EXTRA BATTERY (BOOSTER STARTING)...1185
    INSTALLING NEW BATTERIES...1186
    HYDRAULIC / HYDROSTATIC SYSTEM...1187
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1187
      Checking And Adding Hydraulic / Hydrostatic Fluid...1189
      Removing Hydraulic / Hydrostatic Fluid...1189
    REPLACEMENT OF THE HYDRAULIC / HYDROSTATIC FILTER...1189
    FRONT AND REAR AXLES...1190
    U-JOINTS...1190
    TIRE MAINTENANCE...1190
    LUBRICATION OF THE BOBCAT ROUGH TERRAIN FORKLIFT...1191
    SPARK ARRESTOR MUFFLER...1192
    BACK-UP ALARM...1193
    VERTICAL MAST...1193
    SERIAL NUMBER LOCATIONS...1193
    OPERATOR CAB...1193
    DELIVERY REPORT...1193
  TROUBLESHOOTING...1195
    TROUBLESHOOTING THE ENGINE...1197
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1199
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1198
    TROUBLESHOOTING THE VERTICAL MAST...1200
  MAJOR PARTS...1201
    MAIN FRAME...1203
    FUEL TANK, SEAT & STEERING CONTROL...1204
    DRIVE SYSTEM...1205
    BRAKE SYSTEM...1206
    HYDROSTATIC SYSTEM...1207
    OPERATOR GUARD ELECTRICAL...1209
    ENGINE ELECTRICAL...1210
    ENGINE & ATTACHING PARTS...1211
  GENERAL INFORMATION...1213
    SPECIFICATIONS...1215
    VERTICAL MAST...1215
    ENGINE...1215
    LOADER HYDRAULICS...1216
    ELECTRICAL...1216
    DRIVE SYSTEM...1216
    CAPACITIES...1216
    TIRES...1216
  WARRANTY...1217
6566459 (2-83) - 2000 Operation & Maintenance Manual...1219
  WARNINGS...1220
  SAFETY INSTRUCTIONS...1221
    SAFETY IS YOUR RESPONSIBILITY...1221
    BEFORE YOU OPERATE THE BOBCAT LOADER...1221
    SERIAL NUMBER LOCATIONS...1222
      Loader Serial Number...1222
      Engine Serial Number...1222
  FOREWORD...1223
    CONTENTS...1223
    2000 BOBCAT LOADER IDENTIFICATION...1224
  OPERATING INSTRUCTIONS...1225
    OPERATING INSTRUCTIONS...1227
    MACHINE SIGNS (DECALS)...1228
    OPERATING CONDITIONS...1230
    CONTROLS...1230
    DASH PANEL...1230
    THROTTLE CONTROL...1231
    STOPPING THE ENGINE...1231
    PARKING BRAKE...1231
    STEERING AND SPEED CONTROLS...1232
    HYDRAULIC CONTROLS...1233
    LIFT ARM OPERATION...1233
    TILT OPERATION...1233
    AUXILIARY OPERATION...1234
    BEFORE YOU START THE ENGINE...1234
    STARTING THE ENGINE...1235
      Normal Starting Condition...1236
      Cold Temperature Starting Condition...1236
      Cold Weather Starting Procedure...1237
    ATTACHMENTS & BUCKETS ...1237
      Installation Of Attachments...1238
      Removal Of Attachments...1239
    OPERATION OF THE BOBCAT LOADER...1239
    OPERATING PROCEDURE...1239
      Filling The Bucket...1242
      Emptying The Bucket...1242
      Digging Into The Ground...1242
      Making The Ground Level...1242
      Filling A Hole...1243
    STOPPING THE BOBCAT LOADER...1243
    TRANSPORTING THE BOBCAT LOADER...1243
    EMERGENCY (TOW) VALVE...1245
    FRONT WINDOW...1245
  PREVENTIVE MAINTENANCE...1247
    WARNINGS...1248
    SERVICE SCHEDULE...1249
    FRAME LOCK...1250
    LIFTING AND BLOCKING THE BOBCAT LOADER...1250
    ENGINE SERVICE...1251
    ADJUSTING THE DOOR LATCH...1251
    AIR CLEANER SERVICE...1251
    FUEL SYSTEM...1252
    FUEL SYSTEM SERVICE...1252
    FUEL FILTER...1253
    REMOVING AIR FROM THE FUEL SYSTEM...1253
    ENGINE LUBRICATION SYSTEM...1254
    REPLACEMENT OF ENGINE OIL AND FILTER...1255
    ENGINE COOLING SYSTEM...1256
      Coolant level...1256
    REMOVING COOLANT FROM THE COOLING SYSTEM...1256
    ALTERNATOR BELT...1256
    ELECTRICAL SYSTEM...1256
    USING AN EXTRA BATTERY (BOOSTER STARTING)...1259
    INSTALLING A NEW BATTERY...1260
    HYDRAULIC / HYDROSTTATIC SYSTEM...1261
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1261
      Checking And Adding Hydraulic / Hydrostatic Fluid...1263
      Removing The Hydraulic/Hydrostatic Fluid...1263
    REPLACEMENT OF THE HYDRAULIC / HYDROSTATIC FILTER...1263
    FRONT & REAR AXLES...1264
    U-JOINTS...1264
    TIRE MAINTENANCE...1264
      Tire Rotation...1265
      Wheel Nuts...1265
    LUBRICATION OF THE BOBCAT LOADER...1266
    SPARK ARRESTOR MUFFLER...1267
    BOB-TACH...1268
    BACK-UP ALARM...1268
    OPERATOR CAB (ROPS & FOPS)...1268
    DELIVERY REPORT...1268
  TROUBLESHOOTING...1269
    TROUBLESHOOTING THE ENGINE...1271
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1272
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1273
  MAJOR PARTS...1275
    MAIN FRAME...1277
    FUEL TANK, SEAT & STEERING CONTROL...1278
    DRIVE SYSTEM...1279
    BRAKE SYSTEM...1280
    HYDROSTATIC CIRCUITRY...1281
    OPERATOR GUARD ELECTRICAL...1283
    ENGINE ELECTRICAL...1284
    ENGINE & ATTACHING PARTS...1285
  WARNING SIGNS...1287
    WARNING - 6563484...1289
    SERVICE SCHEDULE - 6585084...1290
    WARNING - 6584333...1292
    WARNING - 6584243...1293
    IMPORTANT - 6560573...1294
  GENERAL INFORMATION...1295
    OPERATION AND PERFORMANCE...1297
    ENGINE...1297
    HYDRAULICS...1298
    ELECTRICAL...1298
    DRIVE SYSTEM...1298
    CAPACITIES...1298
    TIRES...1298
    ADDITIONAL PUBLICATIONS...1299
  WARRANTY...1301
6566662 (11-88) - 2000 RTF Service Manual...1303
  WARNINGS...1304
  SAFETY NSTRUCTIONS...1305
    Safety Is Your Responsibility...1305
    Safe Operation Needs A Qualified Operator...1306
  CONTENTS...1307
    FOREWORD...1307
  PREVENTIVE MAINTENANCE...1309
    FRAME LOCK...1311
    LIFTING AND BLOCKING THE BOBCAT FORKLIFT...1311
    SERIAL NUMBER LOCATIONS...1312
      Machine Serial Number...1312
      Engine Serial Number...1312
      Vertical Mast Serial Number...1312
      Axle Serial Numbers...1312
    DELIVERY REPORT...1312
    SERVICE SCHEDULE...1313
    ENGINE SERICE...1314
    ADJUSTING THE DOOR LATCH...1314
    AIR CLEANER SERVICE...1314
    FUEL SYSTEM...1315
      Removing Air From The Fuel System...1316
      Fuel System Service...1315
      Fuel Filter...1316
    ENGINE LUBRICATION SYSTEM...1317
      Replacement Of Engine Oil And Filter...1318
    ENGINE COOLING SYSTEM...1319
      Coolant Level...1319
      Removing Coolant From The Cooling System...1319
    ALTERNATOR BELT...1319
    ELECTRICAL SYSTEM...1319
      Operator Guard Electrical Circuitry...1320
      Engine Electrical Circuitry...1321
      Using An Extra Battery (Booster Starting)...1322
      New Battery Installation...1323
    HYDRAULIC/HYDROSTATIC SYSTEM...1324
      Hydraulic/Hydrostatic Fluid Reservoir...1324
      Checking And Adding Hydraulic/Hydrostatic Fluid...1326
      Replacement Of The Hydraulic/Hydrostatic Filter...1326
    FRONT & REAR AXLE...1327
    U-JOINTS...1327
    TIRE MAINTENANCE...1328
      Tire Rotation...1328
      Wheel Nuts...1328
    LUBRICATION OF THE BOBCAT ROUGH TERRAING FORKLIFT...1329
    SPARK ARRESTOR MUFFLER...1330
    BACK-UP ALARM...1331
    VERTICAL MAST...1331
    OPERATOR CAB...1331
  HYDRAULIC SYSTEM...1333
    HYDRAULIC/HYDROSTATIC SCHEMATICS...1335
    HYDRAULIC SYSTEM OPERATIONS...1343
      Description...1343
      Flow Chart...1343
    TROUBLESHOOTING...1344
    HYDRAULIC SYSTEM OPERATION...1345
      37° Flare Connections...1345
      Straight Thread O-Ring Fitting...1345
      Tubelines And Hoses...1345
    HYDRAULIC SYSTEM SERVICE...1346
      Checking And Adding Hydraulic Fluid...1346
      Replacing The Hydraulic Fluid...1346
      Replacing The Hydraulic Fluid Filters...1347
      Replacing The Bronze (40 Micron) Filter...1347
      Replacing The Neutral By-Pass Valve...1348
      Replacing The Cold Weather By-Pass Valve...1349
    OIL RESERVOIR...1349
      Removing The Oil Reservoir...1349
      Installing The Oil Reservoir...1349
    HYDRAULIC CONTROL VALVE...1350
      Description Of The Control Valve...1350
      Removing The Hydraulic Control Valve...1351
      Disassembly Of The Control Valve...1352
      Inspection Of The Control Valve...1354
      Reassembly Of The Control Valve...1354
      Installing The Control Valve...1355
    HYDRAULIC MAIN RELIEF VALVE...1355
      Checking The Hydraulic Main Relief Valve...1355
      Replacing The Hydraulic Main Relief Valve...1357
    HYDRAULIC PUMP...1357
      Checking The Hydraulic Pump Pressure...1357
      Removing The Hydraulic Pump...1358
      Disassembly Of The Hydraulic Pump...1359
      Inspection Of The Hydraulic Pump...1360
      Assembly Of The Hydraulic Pump...1360
      Installing The Hydraulic Pump...1361
      Checking Steering Relief Pressure...1361
    COUNTERBALANCE VALVE...1362
    HYDRAULIC CYLINDERS...1362
      Checking The Lift Cylinder Seals...1362
      Checking The Tilt Cylinder Seals...1363
      Checking The Steering Cylinder Seals...1364
      Removing The Lift Cylinder...1364
      Inspecting The Lift Cylinder...1366
      Installing The Lift Cylinder...1366
      Removing The Tilt Cylinders...1366
      Installing The Tilt Cylinders...1367
      Removing The Steering Cylinder...1368
      Installing The Steering Cylinder...1368
      Disassembly Of The Hydrailic Cylinder...1368
      Assembly Of The Hydraulic Cylinder...1371
    STEERING CONTROL VALVE...1372
      Removing The Steering Control Valve...1373
      Disassembly Of The Steering Control Valve...1373
      Inspection Of The Steering Control Valve...1376
      Assembly Of The Steering Control Valve...1377
      Installing The Steering Control Valve...1381
  HYDROSTATIC SYSTEM...1383
    SYSTEM OPERATIONS DESCRIPTION...1385
    TROUBLESHOOTING...1386
    SERVO CONTROL...1388
      Neutral Adjustment For Servo Control...1388
      Removing The Servo Control...1389
      Disassembly Of The Servo Control...1389
      Assembly Of The Servo Control...1390
      Installing The Servo Control...1390
    FOOT PEDAL AND CENTERING MECHANISM...1391
      Removing The Centering Mechanism...1391
      Adjusting The Springs In The Centering Mechanism...1391
      Replacing The Springs On The Centering Mechanism...1392
      Installing The Centering Mechanism...1393
      Adjusting The Neutral Safety Start Switch...1393
    CHARGE PRESSURE AND REPLENISHING VALVES...1394
      Checking The Charge Pressure...1394
      Checking Orifice In Charge Tubeline...1394
      Replenishing Valves...1395
    HYDROSTATIC PUMP...1396
      Removing The Hydrostatic Pump...1396
      Disassembly Of The Hydrostaic Pumps...1398
      Hydrostatic Pump Inspection...1401
      Assembly Of The Hydrostatic Pump...1403
      Installing Pumps To The Manifold Block...1407
      Hydrostatic Pump Installation...1408
      Hydrostatic Pump Start-Up Procedure...1410
    HYDROSTATIC MOTOR...1410
      Hydrostatic Motor Removal...1411
      Hydrostatic Motor Disassembly...1411
      Inspection Of The Hydrostatic Motor...1414
      Assembling The The Hydrostatic Motor...1415
      Manifold Block Disassembly...1419
      Manifold Block Assembly...1419
      Hydrostatic Motor Installation...1419
      Hydrostatic Motor Start-Up...1420
      Tow Valves...1420
  DRIVE SYSTEM...1421
    DESCRIPTION...1423
    DIFFERENTIAL OIL LEVEL...1423
    LUBRICATING THE U-JOINTS...1423
    DRIVE SHAFT...1423
      Removing The Drive Shaft...1423
      Installing The Drive Shaft...1424
    REAR AXLE...1424
      Description...1424
      Removing The Rear Axle...1424
      Installing The Rear Axle...1425
    FRONT AXLE...1425
      Description...1425
      Removing The Front Axle...1425
      Installing The Front Axle...1425
    DISASSEMBLING AND ASSEMBLING AXLES...1426
      Removing Hubs...1426
      Installing Hubs...1427
      Removing The Differential Assembly...1429
      Removing The Ring Gear...1430
      Installing The Ring Gear...1431
      Removing Clutch Plates...1432
      Installing Clutch Plates...1433
      Explanation Of Assembly Procedure...1434
      Removing The Drop Gear And Pinion Shaft...1433
      Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)...1435
      Installing The Pinion Shaft Bearings...1436
      Installing The Pinion Shaft ...1436
      Setting Pinion Shaft position (Using Tool - Pinion Shaft NOT Installed)...1437
      Setting Pinion Bearing Pre-Load...1438
      Installing Differential Assembly & Checking end Play (Pinion Shaft Installed)...1440
      Checking Gear Backlash...1443
    PARKING BRAKE...1444
      Description...1444
      Adjusting The Parking Brake...1444
      Removing The Parking Brake Cable...1445
      Installing The Parking Brake Cable...1445
      Removing The Parking Brake Assembly From The Hydrostatic Motor...1445
      Installing The Parking Brake Assembly On The Hydrostatic Motor Housing...1446
  MAIN FRAME...1447
    OPERATOR CAB...1449
    REAR GRILL...1449
      Removing The Rear Grill...1449
      Installing The Rear Grill...1449
    FLOORPANELS...1449
      Removing The Floorpanels...1449
      Installing The Floorpanels...1449
    SEAT AND SEAT PLATE...1450
      Removing The Seat And Seat Plate...1450
      Installing The Seat And Seat Plate...1450
    FUEL TANK...1451
      Removing The Fuel Tank...1451
      Installing The Fuel Tank...1451
    DOORS...1451
      Removing The Rear door...1451
      Installing The Rear Door...1451
      Removing The Side Doors...1452
      Installing The Side Doors...1452
    DISASSEMBLING THE BOBCAT FORKLIFT...1452
      Seperating The Sections...1452
      Ball Stud & Race Assembly...1453
      Removing The Oscillating Link...1453
    ASSEMBLING THE BOBCAT FORKLIFT...1454
  VERTICAL MAST...1455
    TROUBLESHOOTING THE VERTICAL MAST...1457
    REMOVING THE VERTICAL MAST...1457
    INSTALLING THE VERTICAL MAST...1458
    INSPECTING THE VERTICAL MAST...1459
    REPLACING THE BRONZE BUSHING...1460
    REMOVING THE MOUNTING FRAME...1460
    INSTALLING THE MOUNTING FRAME...1461
    REMOVING THE CARRIAGE CHAINS...1461
    INSTALLING THE CARRIAGE CHAINS...1461
    ADJUSTING THE LIFT CARRIAGE...1462
    REMOVING THE LIFT CARRIAGE...1462
    INSTALLING THE LIFT CARRIAGE...1463
    ADJUSTING THE CARRIAGE ROLLERS...1463
    PALLET FORKS...1466
      Installing The Pallet Forks...1466
      Removing The Pallet Forks...1466
      Adjusting The Pallet Forks...1466
  ELECTRICAL SYSTEM...1467
    ELECTRICAL SCHEMATICS...1469
    DESCRIPTION...1477
      Dash Panel...1477
      Wiring Diagrams...1477
    SERVICING THE ELECTRICAL SYSTEM...1478
      Cautions To Be Taken In Use Of The Alternator...1478
      General Servicing...1478
      Charging The Batteries...1478
    TROUBLESHOOTING THE ELECTRICAL SYSTEM...1479
    CHECKING THE BATTERIES...1479
    REPLACING THE BATTERIES...1479
    WIRING HARNESS DIODES...1480
      Description...1480
      Checking The Diodes...1480
      Replacing The Diodes...1480
    NEUTRAL START SAFETY SWITCH...1480
      Checking The Neutral Start Safety Switch...1480
    ALTERNATOR...1481
      Description...1481
      Adjusting Or Replacing The Alternator Belt...1481
      Checking Alternator Wiring...1481
      Checking Alternator Output...1482
      Checking The Regulator...1482
      Removing The Alternator...1482
      Disassembling The Alternator...1482
      Checking The Rotor...1483
      Checking The Stator...1483
      Checking Diode Trio...1484
      Checking Rectifier...1484
      Assembling And Installing The Alternator...1484
    STARTER...1484
      Description...1484
      Checking Starter...1485
      Removing Starter...1485
      Disassembling The Starter...1485
      Cleaning And Inspecting The Starter...1486
      Replacing The Brushes...1486
      Assembling The Starter...1486
    BACK-UP ALARM...1487
  ENGINE SERVICE...1489
    TROUBLESHOOTING...1491
    CHECKS & ADJUSTMENTS...1493
      Oil Pressure...1493
      Valve Clearance...1493
      Check Engine Compression...1493
    FUEL SYSTEM AND TIMING...1494
      Fuel Injection Pump...1494
      Removing The Fuel Injection Pump...1494
      Installing The Fuel Injection Pump...1495
      Timing The Fuel Injection Pump...1496
      Fuel Injector Nozzles...1497
      Removing Fuel Injector Nozzles...1498
      Checking The Fuel Injector Nozzles...1498
      Installing The Fuel Injector Nozzles...1499
      High Pressure Fuel Lines...1499
      Glow Plugs...1500
    ENGINE AND ATTACHING PARTS...1501
      Removing The Engine...1501
      Installing The Engine...1502
      Blower Housing Shield...1503
        Removal...1503
        Installation...1503
      Engine Coolant Radiator...1503
        Removal...1503
        Installation...1504
      Engine Blower Housing...1504
        Removal...1504
        Installation...1504
      Engine Muffler...1505
        Removal...1505
        Installation...1505
      Oil Cooler...1505
      Installing The Oil Cooler...1505
      Removing The Oil Cooler...1505
    CYLINDER HEAD...1506
      Removing The Cylinder Head...1506
      Removal Of The Valves...1506
      Reconditioning The Valves And Valve Seats...1507
      Installing Valve Guides...1507
      Checking Valve Springs...1508
      Combustion Chamber Inserts...1509
      Cylinder Head Inspection...1509
      Installation Of The Valves...1510
      Reconditioning The Rocker Arms...1510
        Disassembly...1510
        Checking...1511
        Assembly...1511
      Installing The Cylinder Head...1511
    RECONDITIONING THE ENGINE...1513
      Pistons And Connecting Rods...1513
        Removal...1513
        Disassembly...1514
        Inspection...1514
      Installation Of Piston To Connecting Rod...1515
      Installation Of Rings On The Piston...1515
      Installing Piston Assembly In The Engine Block...1516
      Cylinder Liners...1516
        Checking...1516
        Installation...1517
      Main Bearings...1518
        Removal...1518
        Installation...1519
      Crankshaft End Play...1519
      Crankshaft...1519
        Removal...1519
        Checking...1520
        Installation...1521
      Rear Main Bearing Oil Seal...1521
    TIMING CASE AND GEARS...1522
      Timing Case Cover...1522
        Removal...1522
        Installation...1522
      Front Seal...1523
        Removal...1523
        Installation...1523
      Idler Gear And Hub...1523
        Removal...1523
        Inspection...1524
        Installation...1524
      Camshaft Gear...1524
        Removal...1525
        Installation...1525
      Fuel Injection Pump Gear...1525
        Removal...1525
        Installation...1525
      Crankshaft Gear...1526
      Timing Case...1526
        Removal...1526
        Installation...1526
      Camshaft And Tappets...1527
        Removal...1527
        Inspection...1528
        Installation...1528
    LUBRICATION SYSTEM...1528
      Description Of The Lubrication System...1528
      Oil Pan...1529
        Removal...1529
        Installation...1529
      Oil Pump...1530
        Removal...1530
        Disassembly...1530
        Checking...1531
        Assembly...1532
        Installation...1532
      Oil Filter And Adapter Housing...1533
        Removal...1533
        Installation...1533
    COOLING SYSTEM...1533
      Alternator And Water Pump Belt...1533
      Water Pump...1533
        Removal...1533
        Installation...1534
      Thermostat...1534
        Removal...1534
        Testing The Thermostat...1534
        Installation...1534
    FLYWHEEL...1535
      Removal Of The Flywheel...1535
      Replace The Flywheel Ring Gear...1535
      Installation Of The Flywheel...1535
  TECHNICAL DATA...1537
    FORKLIFT SPECIFICATIONS...1539
      Specifications...1539
      Vertical Mast...1539
      Engine...1539
      Hydraulics...1540
      Electrical...1540
      Drive System...1540
      Capacities...1540
      Tires...1540
    ENGINE SPECIFICATIONS...1541
      Cylinder Head Dimensions...1541
      Pistons And Connecting Rod Dimensions...1541
      Cylinder Block And Liner Dimensions...1542
      Crankshaft And Main Bearing Dimensions...1542
      Timing Case, Camshaft And Drive Dimensions...1543
      Oil Pump Dimensions...1543
      Cooling System And Water Pump Dimensions...1543
      Fuel System Specifications...1544
      De-Rating For Altitude...1544
      Engine Torque...1544
      Grinding Specifications For Crankshaft...1545
      Crankshaft Regrind Data...1545
    HYDRAULIC SYSTEM...1546
    HYDROSTATIC SYSTEM...1546
    DECIMAL AND MILLIMETER EQUIVALENTS...1547
    U.S. TO METRIC CONVERSION...1547
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1548
  ALPHABETICAL INDEX...1549
6566662 (4-83) - 2000 RTF Service Manual...1555
6566667 (2-86) - 1600 Operator's Manual...1804
  WARNINGS...1806
  SAFETY INSTRUCTIONS...1808
    SAFETY IS YOUR RESPONSIBILITY...1808
    BEFORE YOU OPERATE THE BOBCAT LOADER...1808
    SAFE OPERATION NEEDS A QUALIFIED OPERATOR...1809
    SERIAL NUMBER LOCATIONS...1809
      Loader Serial Number...1809
      Engine Serial Number...1809
    DELIVERY REPORT...1809
  FOREWORD...1810
    CONTENTS...1810
    REFERENCE INFORMATION...1810
    1600 BOBCAT LOADER IDENTIFICATION...1811
  OPERATING INSTRUCTIONS...1812
    OPERATING INSTRUCTIONS...1814
    MACHINE SIGNS (DECALS) LOCATIONS...1815
    OPERATING CONDITIONS...1815
    CONTROLS...1818
    DASH PANEL...1818
    THROTTLE CONTROL...1819
    STOPPING THE ENGINE...1819
    PARKING BRAKE...1819
    STEERING AND SPEED CONTROLS...1820
    HYDRAULIC CONTROLS...1821
    LIFT ARM OPERATION...1821
    TILT OPERATION...1821
    AUXILIARY HYDRAULICS OPERATION...1821
    BEFORE YOU START THE ENGINE...1822
    STARTING THE ENGINE...1823
      Normal Starting Conditions...1823
      Cold Temperature Starting Condition...1824
      Cold Weather Starting Procedure...1825
    ATTACHMENTS AND BUCKETS FOR THE BOBCAT LOADER...1826
      Installaing Attachments...1826
      Removing Attachments...1827
    OPERATING PROCEDURE...1827
      Emptying The Bucket...1830
      Digging Into The Ground...1830
      Leveling The Ground...1830
      Filling A Hole...1831
    PARKING THE LOADER...1831
    TOWING THE LOADER...1831
      Tow Valve...1831
      Brake Release...1831
    TRANSPORTING THE BOBCAT LOADER...1832
    LIFT ARM STOP...1833
    FRONT & REAR WINDOWS...1833
  PREVENTIVE MAINTENANCE...1834
    WARNINGS...1835
    SERVICE SCHEDULE...1836
    FRAME LOCK...1837
    ENGINE SERVICE...1837
    ADJUSTING THE DOOR LATCH...1838
    AIR CLEANER SERVICE...1838
    FUEL SYSTEM...1839
    FUEL SYSTEM SERVICE...1839
    FUEL FILTER...1840
    REMOVING AIR FROM THE FUEL SYSTEM...1840
    ENGINE LUBRICATION SYSTEM...1841
    ENGINE OIL AND FILTER REPLACEMENT...1841
    ENGINE COOLING SYSTEM...1842
      Coolant Level...1842
    REMOVING COOLANT FROM THE COOLING SYSTEM...1842
    ADJUSTING THE ALTERNATOR BELT...1843
    OPERATOR CAB ELECTRICAL...1844
    ENGINE ELECTRICAL...1845
    ELECTRICAL SYSTEM...1846
    USING AN EXTRA BATTERY TO START ENGINE...1846
    INSTALLING A NEW BATTERY...1848
    HYDRAULIC/HYDROSTATIC SYSTEM...1849
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1850
      Checking And Adding Hydraulic / Hydrostatic Fluid...1850
      Removing The Hydraulic / Hydrostatic Fluid...1850
    HYDRAULIC / HYDROSTATIC FILTER REPLACEMENT...1850
    FRONT & REAR AXLES...1851
    U-JOINTS...1851
    TIRE MAINTENANCE...1851
      Tire Rotation...1852
      Wheel nuts...1852
    BOBCAT LOADER LUBRICATION...1853
    SPARK ARRESTOR MUFFLER...1854
    BOB-TACH...1855
    BACK-UP ALARM...1855
    OPERATOR CAB (ROPS)...1855
  GENERAL INFORMATION...1856
    LOADER SPECIFICATIONS...1858
    OPERATION & PERFORMANCE...1858
    ENGINE...1858
    HYDRAULICS...1859
    ELECTRICAL...1859
    DRIVE SYSTEM...1859
    CAPACITIES...1859
    TIRES...1859
  WARRANTY...1860
6566671 (9-96) - 2000 Operation & Maintenance Manual...1862
  OPERATOR SAFETY WARNINGS...1864
  FOREWORD...1866
    CONTENTS...1866
    SAFETY INSTRUCTIONS...1868
      SAFETY IS YOUR RESPONSIBILITY...1868
      BEFORE YOU OPERATE THE BOBCAT LOADER...1868
      SAFE OPERATION NEED A QUALIFIED OPERATOR...1869
    FIRE PREVENTION...1869
    SERIAL NUMBER LOCATIONS...1870
    DELIVERY REPORT...1870
    BOBCAT LOADER IDENTIFICATION...1871
  OPERATING INSTRUCTIONS...1872
    OPERATING INSTRUCTIONS...1874
    GETTING ON AND OFF THE LOADER...1874
    MACHINE SIGNS (DECALS)...1875
    LEARNING THE CONTROLS...1875
    DASH PANEL...1878
    THROTTLE CONTROL...1878
    PARKING BRAKE...1878
    STEERING AND SPEED CONTROLS...1879
    HYDRAULIC CONTROLS...1880
      Lift Arm Operation...1880
      Tilt Operation...1880
      Hydraulic Operation...1880
      Auxiliary Operation...1880
    BEFORE STARTING THE ENGINE...1881
    STARTING THE ENGINE...1882
      Cold Temperature Starting...1884
    ATTACHMENTS AND BUCKETS...1884
      Bucket Or Fork Installation...1885
      Bucket Or Fork Removal...1886
    OPERATING PROCEDURES...1886
      Filling The Bucket...1888
      Emptying The Bucket...1888
      Digging Into The Ground...1888
      Leveling The Ground (Using Float Position For The Lift Arms)...1889
      Backfilling...1890
    STOPPING THE ENGINE AND PARKING THE LOADER...1890
    TRANSPORTING THE BOBCAT LOADER...1890
    EMERGENCY (TOW) VALVE...1891
    FRONT AND REAR WINDOWS...1892
    OPERATOR RESTRAINT SYSTEM...1893
      Inspection Of The Operator Restraint System...1893
      Service Of The Operator Restraint System...1893
  PREVENTIVE MAINTENANCE...1894
    MAINTENANCE SAFETY...1895
    SERVICE SCHEDULE...1896
    LIFT ARM STOP...1897
    FRAME LOCK...1897
    REAR DOOR...1897
      Door Latch Adjustment...1898
    AIR CLEANER SERVICE...1898
    FUEL SYSTEM...1899
      Fuel System Service...1899
      Fuel Filter...1899
      Removing Air From The Fuel System...1900
    ENGINE LUBRICATION SYSTEM...1901
      Engine Oil And Filter Replacement...1901
    ENGINE COOLING SYSTEM...1902
      Coolant Level...1902
      Coolant Replacement...1902
    ALTERNATOR BELT ADJUSTMENT...1902
    ELECTRICAL SYSTEM...1902
      Electrical System Service...1905
      Using An Extra Battery (Jump Starting)...1905
      Battery Replacement...1907
    SPARK ARRESTOR MUFFLER...1907
    HYDRAULIC/HYDROSTATIC SYSTEM...1908
      Hydraulic / Hydrostatic Fluid Reservoir...1908
      Checking And Adding Hydraulic/Hydrostatic Fluid...1910
      Hydraulic / Hydrostatic Fluid Removal...1910
      Hydraulic/Hydrostatic Filter Replacement...1910
    FRONT AND REAR AXLES...1911
    U-JOINTS...1912
    TIRE MAINTENANCE...1912
      Wheel Nuts...1912
    BOBCAT LOADER LUBRICATION...1913
    BACK-UP ALARM...1914
    OPERATOR CAB...1914
  TROUBLESHOOTING...1916
    TROUBLESHOOTING THE ENGINE...1918
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1919
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1920
  MAJOR PARTS...1922
    MAIN FRAME...1924
    FUEL TANK, SEAT & STEERING CONTROLS...1925
    DRIVE SYSTEM...1926
    BRAKE SYSTEM...1927
    HYDRAULIC SYSTEM...1928
    HYDROSTATIC CIRCUITRY...1930
    OPERATOR CAB ELECTRICAL...1932
    ENGINE ELECTRICAL...1933
    ENGINE & ATTACHING PARTS...1934
  WARNING SIGNS...1936
    WARNING - 6565980...1938
    SERVICE SCHEDULE - 6584441...1939
    WARNING - 6584333...1941
    WARNING - 6595483...1942
    IMPORTANT - 6560573...1943
  SPECIFICATIONS...1944
    OPERATION & PERFORMANCE...1946
    ENGINE...1946
    HYDRAULICS...1947
    ELECTRICAL...1947
    DRIVE SYSTEM...1947
    CAPACITIES...1947
    TIRES...1947
    ADDITIONAL PUBLICATIONS...1948
  WARRANTY...1950
6566672 (7-84) - 2000 RTF Operation & Maintenance Manual...1951
  WARNINGS...1952
  FOREWORD...1953
    CONTENTS...1953
    SAFETY INSTRUCTIONS...1955
      SAFETY IS YOUR RESPONSIBILITY...1955
      BEFORE YOU OPERATE THE BOBCAT FORKLIFT...1955
    FIRE PREVENTION...1956
    SERIAL NUMBER LOCATIONS...1957
      FORKLIFT SERIAL NUMBER...1957
      ENGINE SERIAL NUMBER...1957
      VERTICAL MAST SERIAL NUMBER...1957
    DELIVERY REPORT...1957
    BOBCAT FORKLIFT IDENTIFICATION...1958
  OPERATING INSTRUCTIONS...1959
    OPERATING INSTRUCTIONS...1961
    GETTING ON AND OFF THE FORKLIFT...1961
    MACHINE SIGNS (DECALS)...1962
    LEARNING THE CONTROLS...1962
    DASH PANEL...1965
    THROTTLE CONTROL...1965
    PARKING BRAKE...1965
    STEERING AND SPEED CONTROLS...1966
    HYDRAULIC CONTROL...1967
      Vertical Lift Operation...1967
      Tilt Operation...1967
      Hydraulic Operation...1967
    BEFORE STARTING THE ENGINE...1967
    STARTING THE ENGINE...1969
      Cold Temperature Starting...1971
    ATTACHMENTS...1971
      Pallet Fork Installation...1972
      Pallet Fork Removal...1972
      Pallet Fork Adjustment...1972
      Vertical Mast...1973
    OPERATING PROCEDURES...1973
      Loading The Vertical Mast...1974
      Unloading The Vertical Mast...1975
    STOPPING THE ENGINE AND PARKING THE FORKLIFT...1975
    TRANSPORTING THE BOBCAT FORKLIFT...1976
    EMERGENCY (TOW) VALVE...1976
    FRONT AND REAR WINDOWS...1977
  PREVENTIVE MAINTENANCE...1979
    WARNINGS...1980
    SERVICE SCHEDULE...1981
    FRAME LOCK...1982
    REAR DOOR...1982
      Door Latch Adjustment...1982
    AIR CLEANER SERVICE...1983
    FUEL SYSTEM...1984
      Fuel System Service...1984
      Fuel Filter...1984
      Removing Air From The Fuel System...1985
    ENGINE LUBRICATION SYSTEM...1985
      Engine Oil And Filter Replacement...1986
    ENGINE COOLING SYSTEM...1987
      Coolant Level...1987
      Coolant Replacement...1987
    ALTERNATOR BELT ADJUSTMENT...1987
    ELECTRICAL SYSTEM...1987
      Electrical System Service...1990
      Using And Extra Battery (Jump Starting)...1990
      Battery Replacement...1992
    SPARK ARRESTOR MUFFLER...1992
    HYDRAULIC / HYDROSTATIC SYSTEM...1994
      Hydraulic/Hydrostatic Fluid Reservoir...1994
      Checking And Adding Hydraulic/Hydrostatic Fluid...1994
      Hydraulic / Hydrostatic Fluid Removal...1995
      Hydraulic / Hydrostatic Filter Replacement...1995
    FRONT AND REAR AXLES...1996
    U-JOINTS...1996
    TIRE MAINTENANCE...1996
      Wheel Nuts...1997
    FORKLIFT LUBRICATION...1998
    BACK-UP ALARM...1999
    VERTICAL MAST...1999
    OPERATOR CAB...1999
  TROUBLESHOOTING...2001
    TROUBLESHOOTING THE ENGINE...2003
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...2004
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...2005
    TROUBLESHOOTING THE VERTICAL MAST...2006
  MAJOR PARTS...2007
    MAIN FRAME...2009
    FUEL TANK, SEAT & STEERING CONTROL...2010
    DRIVE SYSTEM...2011
    BRAKE SYSTEM...2012
    HYDRAULIC SYSTEM...2013
    HYDROSTATIC SYSTEM...2015
    OPERATOR CAB ELECTRICAL...2017
    ENGINE ELECTRICAL...2018
    ENGINE & ATTACHING PARTS...2019
  WARNING SIGNS...2021
    WARNING - 6584442...2023
    SERVICE SCHEDULE - 6584443...2025
    IMPORTANT - 6560573...2028
  SPECIFICATIONS...2029
    FORKLIFT SPECIFICATIONS...2031
    OPERATION & PERFORMANCE...2031
    VERTICAL MAST...2031
    ENGINE...2031
    FORKLIFT HYDRAULICS...2032
    ELECTRICAL...2032
    DRIVE SYSTEM...2032
    CAPACITIES...2032
    TIRES...2032
    ADDITIONAL PUBLICATIONS...2035
  WARRANTY...2037
6566906 (6-12) - 1600 Service Manual...2039
  MAINTENANCE SAFETY...2041
  CONTENTS...2043
    FOREWORD...2045
    SAFETY INSTRUCTIONS...2047
    SERIAL NUMBER LOCATIONS...2048
    LOADER SERIAL NUMBER...2048
    ENGINE SERIAL NUMBER...2048
    DELIVERY REPORT...2048
    BOBCAT LOADER IDENTIFICATION...2049
  PREVENTIVE MAINTENANCE...2051
    SERVICE SCHEDULE...2053
    LIFTING AND BLOCKING THE LOADER...2054
      Procedure...2054
    LIFT ARM SUPPORT DEVICE...2055
      Procedure...2055
    FRAME LOCK...2055
      Procedure...2055
    TRANSPORTING THE BOBCAT LOADER...2056
      Procedure...2056
    OPERATOR RESTRAINT SYSTEM...2057
      Description...2057
      Inspection Of The Operator Restraint System...2057
      Serviceing The Operator Restraint System...2057
    USING AND EXTRA BATTERY (JUMP STARTING)...2058
      Procedure...2058
  HYDRAULIC SYSTEM...2059
    HYDRAULIC/HYDROSTATIC SCHEMATICS...2061
    HYDRAULIC SYSTEM (S/N 12001 & ABOVE)...2085
      TROUBLESHOOTING...2087
      HYDRAULIC SYSTEM INFORMATION...2088
        Flare Connections...2088
        O-Ring Face Seal Connection...2088
        Straight Thread O-Ring Fitting...2088
        Tubelines And Hoses...2088
      LIFT CYLINDER...2089
        Checking The Lift Cylinder...2089
        Removal And Installation...2089
      TILT CYLINDER...2090
        Checking The Tilt Cylinder...2090
        Removal And Installation...2090
      STEERING CYLINDER...2091
        Checking The Steering Cylinder...2091
        Removal And Installation...2091
      HYDRAULIC CONTROL VALVE...2092
        Check The Main Relief Valve...2092
        Main Relief Valve Removal And Installation...2092
        Removal And Installation...2093
      HYDRAULIC PUMP...2094
        Checking Output Of The Hydraulic Pump...2094
        Removal And Installation...2095
      BUCKET POSITION VALVE (S/N 12026 & BELOW)...2096
        Removal And Installation...2096
        Disassembly And Assembly...2096
      BUCKET POSITION VALVE (S/N 12027 & ABOVE)...2098
        Removal And Installation...2098
      STEERING CONTROL VALVE...2100
        Checking Steering Relief Valve...2100
        Removal And Installation...2101
        Disassembly...2102
        Inspection...2104
        Assembly...2105
      PORT BLOCK...2109
        Removal And Installation...2109
        Disassembly And Assembly...2109
      PRIORITY VALVE...2110
        Removal And Installation...2110
        Disassembly And Assembly...2110
        Adjustment Of Steering Relief Valve...2110
      HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...2111
        Removal And Installation...2111
    HYDRAULIC SYSTEM (S/N 11999 & BELOW)...2113
      HYDRAULIC CONTROL VALVE...2115
        Checking The Main Relief Valve...2115
        Mian relief Valve Removal And Installation...2116
        Checking Output Of The Hydraulic Pump...2117
        Removal And Installation...2118
      STEERING CONTROL VALVE...2119
        Checking Steering Relief Valve...2119
      PORT BLOCK...2120
        Removal And Installation...2120
        Cold Weather By-Pass Valve...2120
        Servo Relief Valve...2120
        Charge Relief Valve...2120
      OIL COOLER...2121
        Removal And Installation...2121
        Oil Cooler Service...2121
  HYDROSTATIC SYSTEM...2123
    HYDROSTATIC SYSTEM (S/N 12001 & ABOVE)...2125
      TROUBLESHOOTING...2127
      HYDROSTATIC SYSTEM INFORMATION...2128
        High Pressure Relief Replenishing Valves Function...2128
      CENTERING MECHANISM...2129
        Foot Pedal Angle Adjustment...2129
        Removal And Installation...2129
        Centering Mechanism Spring Replacement...2129
        Adjusting The Springs In The Centering Mechanism...2131
        Micro Switch Adjustment...2132
      HYDROSTATIC MOTOR...2133
        Removal And Installation...2133
      TWO SPEED VALVE...2134
        Removal And Installation...2134
        Disassembly And Assembly...2135
      HYDROSTATIC PUMP...2136
        Checking Charge Pressure...2136
        Checking The High Pressure Relief Replenishing Valve...2136
        Neutral Adjustment...2137
        Removal And Installation...2138
    HYDROSTATIC SYSTEM (S/N 11999 & BELOW)...2141
      TROUBLESHOOTING...2143
      SERVO CONTROL...2144
        Neutral Adjustment...2144
        Removal And Installation...2145
        Disassembly And Assembly...2146
        Servo Control Pressure...2147
      CENTERING MECHANISM...2148
        Removal And Installation...2148
        Centering Mechanism Spring Replacement...2149
        Adjusting The Springs in The  Centering Mechanism...2150
        Neutral Safety Switch Adjustment...2151
      HYDROSTATIC MOTOR...2152
        Removal And Installation...2152
        Manifold Block...2152
      HYDROSTATIC PUMP...2154
        Checking Charge Pressure...2154
        Replenishing Valves...2154
        Removal And Installation...2155
  DRIVE SYSTEM...2157
    TROUBLESHOOTING...2159
    DRIVE SHAFT...2160
      Removal And Installation...2160
    AXLE AND DIFFERENTIAL...2161
      Rear Axle Removal And Installation...2161
      Front Axle Removal And Installation...2162
      Wheel RPM...2163
      Hub Removal...2164
      Hub Installation...2167
      Differential Disassembly...2169
      Ring Gear Removal...2170
      Ring Gear Installation...2172
      Pinion Shaft And Drop Gear Removal...2172
      Assembly Procedure Explanation...2174
      Checking Differential Assembly End Play (Without Pinion Shaft Installed)...2175
      Pinion Shaft Installation...2176
      Differential Assembly Installation...2180
    BRAKE (S/N 12001 & ABOVE)...2185
      Removal And Installation...2185
      Disassembly And Assembly...2185
    BRAKE VALVE...2191
      Removal And Installation...2191
      Disassembly And Assembly...2191
    BRAKE (S/N 11242 - 11999)...2192
      Removal And Installation...2192
      Disassembly And Assembly...2192
      Moving The Loader...2194
    BRAKE (S/N 11241 & bELOW)...2195
      Removal And Installation...2195
      Disassembly And Assembly...2195
      Removing Air From The Brake System...2196
  MAIN FRAME...2197
    OPERATOR CAB...2199
      Removal And Installation...2199
    REAR DOOR...2200
      Door Latch Adjustment...2200
      Removal And Installation...2200
    LIFT ARMS...2201
      Removal And Installation...2201
    BOB-TACH...2202
      Removal And Installation...2202
    FLOOR PANEL...2203
      Removal And Installation...2203
    SEAT AND SEAT PAN...2204
      Removal And Installation...2204
    STEERING COLUMN COVER...2205
      Removal And Installation...2205
    TUBELINE COVER...2206
      Removal And Installation...2206
    FUEL TANK...2206
      Removal And Installation...2206
    LOADER FRAME DISASSEMBLY AND ASSEMBLY...2207
      Description...2207
      Seperating The Front Section From The Center Section...2207
      Connecting The Front Section To The Center Section...2209
      Seperating The Rear Section From The Center Section (S/N 11999 & Below Only)...2209
      Rear Section Service Procedures (S/N 11999 & Below Only)...2213
      Connecting The Rear Section To The Center Section (S/N 11999 & Below Only)...2214
  ELECTRICAL SYSTEM...2215
    ELECTRICAL SCHEMATICS...2218
    ELECTRICAL SYSTEM INFORMATION...2235
      Description...2235
    TROUBLESHOOTING...2235
    BATTERY...2236
      Checking The Battery...2236
      Removal And Installation...2236
    DIODES...2236
      Checking The Diodes...2236
    ALTERNATOR (DELCO)...2237
      Alternator Belt Adjustment...2237
      Checking Alternator Wiring Harness...2237
      Checking Alternator Output...2238
      Checking Alternator Regulator...2238
      Removal And Installation...2238
      Disassembly And Assembly...2239
    MELROE ALTERNATOR...2242
      Checking The Alternator Output...2242
      Checking The Alternator Regulator...2242
      Removal And Installation...2243
      Disassembly And Assembly...2244
    STARTER...2247
      Checking The Starter...2247
      Removal And Installation...2247
      Disassembly And Assembly...2248
      Inspection...2249
      Replacing The Brushes...2249
  ENGINE SERVICE...2251
    TROUBLESHOOTING...2253
    VALVE CLEARANCE...2254
      Adjustment...2254
    ENGINE COMPRESSION...2255
      Checking...2255
    FUEL FILTER...2256
      Water Trap...2256
      Fuel Filter Element...2256
    REMOVING AIR FROM THE FUEL SYSTEM...2257
      Procedure...2257
    ENGINE SHUT-OFF SOLENOID...2257
      Removal And Installation...2257
    THROTTLE TENSION ADJUSTMENT...2257
      Procedure...2257
    FUEL INJECTION PUMP...2258
      Removal And Installation...2258
      Checking The Injection Pump...2259
      Timing The Injection Pump...2259
    FUEL INJECTOR NOZZLES...2260
      Removal And Installation...2260
      Checking The Injector Nozzles...2261
    GLOW PLUGS...2262
      Removal And Installation...2262
      Checking The Glow Plug...2262
    ENGINE...2263
      Removal And Installation...2263
    RADIATOR AND OIL COOLER...2266
      Removal And Installation...2266
      Oil Cooler Removal And Installation...2267
    MUFFLER...2268
      Removal And Installation...2268
    BLOWER HOUSING...2268
      Removal And Installation...2268
    ENGINE FLYWHEEL AND U-JOINT...2269
      Removal And Installation...2269
      Flywheel Ring Gear...2269
    CYLINDER HEAD...2270
      Removal Of The Cylinder Head...2270
      Disassembly Of The Cylinder Head...2271
      Servicing The Cylinder Head...2271
      Assembly Of The Cylinder Head...2273
      Installing The Cylinder Head...2273
    TIMING GEAR COVER...2274
      Removal And Installation...2274
    TIMING GEAR, CAMSHAFT AND OIL PUMP...2276
      Removal And Installation...2276
      Oil Pump Service...2277
      Servicing The Camshaft...2278
    CRANKSHAFT AND PISTONS...2279
      Piston And Crankshaft Removal And Installation...2279
      Crankshaft Service...2281
      Service The Connecting Rods And Pistons...2282
    CYLINDER LINERS...2285
      Checking The Cylinder Liners...2285
    WATER PUMP...2286
      Disassembly And Assembly...2286
  TECHNICAL DATA...2287
    LOADER SPECIFICATIONS (S/N 11999 & BELOW)...2289
      Operation And Performance...2289
      Engine...2289
      Loader Hydraulics...2290
      Electrical...2290
      Drive System...2290
      Capactities...2290
      Tires...2290
    LOADER SPECIFICATIONS (S/N 12001 & ABOVE)...2291
      Operation And Performance...2291
      Engine...2291
      Loader Hydraulics...2292
      Electrical...2292
      Drive System...2292
      Capacities...2292
      Tires...2292
    ENGINE SPECIFICATIONS...2293
      Fuel Injection Nozzles...2293
      Fuel Injection Pump...2293
      Cylinder Head...2293
      Valves...2293
      Valve Springs...2293
      Rocker Arms...2293
      Camshaft...2294
      Cylinders...2294
      Piston Rings...2294
      Pistons...2294
      Crankshaft...2294
      Oil Pump...2295
      Engine Bolt Torque...2295
    TORQUE SPECIFICATIONS...2296
      Engine Group...2296
      Hydrostatic Controls (S/N 11999 & Below)...2298
      Hydrostatic System (S/N 12001 & Above)...2299
      Hydrostatic System (S/N 11999 & Below)...2301
      Hydraulic Controls...2302
      Steering Controls And Rear Door...2303
      Drive System...2304
      Lift Arm & Bob-Tach Group...2305
      Frame & Articulation Unit Group...2306
    DECIMAL AND MILLIMETER EQUILAVENTS...2307
    U.S. TO METRIC CONVERSION...2307
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2308
  SERVICE MANUAL REVISIONS...2309
    1600-1...2309
    1600-2...2311
    1600-3...2313
    1600-4...2315
    1600-5...2317
    1600-6...2319
6566906 (8-87) - 1600 Service Manual...2321
  MAINTENANCE SAFETY...2323
  CONTENTS...2325
    FOREWORD...2327
    SAFETY INSTRUCTIONS...2329
    SERIAL NUMBER LOCATIONS...2330
    LOADER SERIAL NUMBER...2330
    ENGINE SERIAL NUMBER...2330
    DELIVERY REPORT...2330
    BOBCAT LOADER IDENTIFICATION...2331
  PREVENTIVE MAINTENANCE...2333
    SERVICE SCHEDULE...2335
    LIFTING AND BLOCKING THE LOADER...2336
      Procedure...2336
    LIFT ARM SUPPORT DEVICE...2337
      Procedure...2337
    FRAME LOCK...2337
      Procedure...2337
    TRANSPORTING THE BOBCAT LOADER...2338
      Procedure...2338
    OPERATOR RESTRAINT SYSTEM...2339
      Description...2339
      Inspection Of The Operator Restraint System...2339
      Serviceing The Operator Restraint System...2339
    USING AND EXTRA BATTERY (JUMP STARTING)...2340
      Procedure...2340
  HYDRAULIC SYSTEM...2341
    HYDRAULIC/HYDROSTATIC SCHEMATICS...2343
    HYDRAULIC SYSTEM (S/N 12001 & ABOVE)...2367
      TROUBLESHOOTING...2369
      HYDRAULIC SYSTEM INFORMATION...2370
        Flare Connections...2370
        O-Ring Face Seal Connection...2370
        Straight Thread O-Ring Fitting...2370
        Tubelines And Hoses...2370
      LIFT CYLINDER...2371
        Checking The Lift Cylinder...2371
        Removal And Installation...2371
      TILT CYLINDER...2372
        Checking The Tilt Cylinder...2372
        Removal And Installation...2372
      STEERING CYLINDER...2373
        Checking The Steering Cylinder...2373
        Removal And Installation...2373
      HYDRAULIC CONTROL VALVE...2374
        Check The Main Relief Valve...2374
        Main Relief Valve Removal And Installation...2374
        Removal And Installation...2375
      HYDRAULIC PUMP...2376
        Checking Output Of The Hydraulic Pump...2376
        Removal And Installation...2377
      BUCKET POSITION VALVE (S/N 12026 & BELOW)...2378
        Removal And Installation...2378
        Disassembly And Assembly...2378
      BUCKET POSITION VALVE (S/N 12027 & ABOVE)...2380
        Removal And Installation...2380
      STEERING CONTROL VALVE...2382
        Checking Steering Relief Valve...2382
        Removal And Installation...2383
        Disassembly...2384
        Inspection...2386
        Assembly...2387
      PORT BLOCK...2391
        Removal And Installation...2391
        Disassembly And Assembly...2391
      PRIORITY VALVE...2392
        Removal And Installation...2392
        Disassembly And Assembly...2392
        Adjustment Of Steering Relief Valve...2392
      HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...2393
        Removal And Installation...2393
    HYDRAULIC SYSTEM (S/N 11999 & BELOW)...2395
      HYDRAULIC CONTROL VALVE...2397
        Checking The Main Relief Valve...2397
        Mian relief Valve Removal And Installation...2398
        Checking Output Of The Hydraulic Pump...2399
        Removal And Installation...2400
      STEERING CONTROL VALVE...2401
        Checking Steering Relief Valve...2401
      PORT BLOCK...2402
        Removal And Installation...2402
        Cold Weather By-Pass Valve...2402
        Servo Relief Valve...2402
        Charge Relief Valve...2402
      OIL COOLER...2403
        Removal And Installation...2403
        Oil Cooler Service...2403
  HYDROSTATIC SYSTEM...2405
    HYDROSTATIC SYSTEM (S/N 12001 & ABOVE)...2407
      TROUBLESHOOTING...2409
      HYDROSTATIC SYSTEM INFORMATION...2410
        High Pressure Relief Replenishing Valves Function...2410
      CENTERING MECHANISM...2411
        Foot Pedal Angle Adjustment...2411
        Removal And Installation...2411
        Centering Mechanism Spring Replacement...2411
        Adjusting The Springs In The Centering Mechanism...2413
        Micro Switch Adjustment...2414
      HYDROSTATIC MOTOR...2415
        Removal And Installation...2415
      TWO SPEED VALVE...2416
        Removal And Installation...2416
        Disassembly And Assembly...2417
      HYDROSTATIC PUMP...2418
        Checking Charge Pressure...2418
        Checking The High Pressure Relief Replenishing Valve...2418
        Neutral Adjustment...2419
        Removal And Installation...2420
    HYDROSTATIC SYSTEM (S/N 11999 & BELOW)...2423
      TROUBLESHOOTING...2425
      SERVO CONTROL...2426
        Neutral Adjustment...2426
        Removal And Installation...2427
        Disassembly And Assembly...2428
        Servo Control Pressure...2429
      CENTERING MECHANISM...2430
        Removal And Installation...2430
        Centering Mechanism Spring Replacement...2431
        Adjusting The Springs in The  Centering Mechanism...2432
        Neutral Safety Switch Adjustment...2433
      HYDROSTATIC MOTOR...2434
        Removal And Installation...2434
        Manifold Block...2434
      HYDROSTATIC PUMP...2436
        Checking Charge Pressure...2436
        Replenishing Valves...2436
        Removal And Installation...2437
  DRIVE SYSTEM...2439
    TROUBLESHOOTING...2441
    DRIVE SHAFT...2442
      Removal And Installation...2442
    AXLE AND DIFFERENTIAL...2443
      Rear Axle Removal And Installation...2443
      Front Axle Removal And Installation...2444
      Wheel RPM...2445
      Hub Removal...2446
      Hub Installation...2449
      Differential Disassembly...2451
      Ring Gear Removal...2452
      Ring Gear Installation...2454
      Pinion Shaft And Drop Gear Removal...2454
      Assembly Procedure Explanation...2456
      Checking Differential Assembly End Play (Without Pinion Shaft Installed)...2457
      Pinion Shaft Installation...2458
      Differential Assembly Installation...2462
    BRAKE (S/N 12001 & ABOVE)...2467
      Removal And Installation...2467
      Disassembly And Assembly...2467
    BRAKE VALVE...2473
      Removal And Installation...2473
      Disassembly And Assembly...2473
    BRAKE (S/N 11242 - 11999)...2474
      Removal And Installation...2474
      Disassembly And Assembly...2474
      Moving The Loader...2476
    BRAKE (S/N 11241 & bELOW)...2477
      Removal And Installation...2477
      Disassembly And Assembly...2477
      Removing Air From The Brake System...2478
  MAIN FRAME...2479
    OPERATOR CAB...2481
      Removal And Installation...2481
    REAR DOOR...2482
      Door Latch Adjustment...2482
      Removal And Installation...2482
    LIFT ARMS...2483
      Removal And Installation...2483
    BOB-TACH...2484
      Removal And Installation...2484
    FLOOR PANEL...2485
      Removal And Installation...2485
    SEAT AND SEAT PAN...2486
      Removal And Installation...2486
    STEERING COLUMN COVER...2487
      Removal And Installation...2487
    TUBELINE COVER...2488
      Removal And Installation...2488
    FUEL TANK...2488
      Removal And Installation...2488
    LOADER FRAME DISASSEMBLY AND ASSEMBLY...2489
      Description...2489
      Seperating The Front Section From The Center Section...2489
      Connecting The Front Section To The Center Section...2491
      Seperating The Rear Section From The Center Section (S/N 11999 & Below Only)...2491
      Rear Section Service Procedures (S/N 11999 & Below Only)...2495
      Connecting The Rear Section To The Center Section (S/N 11999 & Below Only)...2496
  ELECTRICAL SYSTEM...2497
    ELECTRICAL SCHEMATICS...2500
    ELECTRICAL SYSTEM INFORMATION...2517
      Description...2517
    TROUBLESHOOTING...2517
    BATTERY...2518
      Checking The Battery...2518
      Removal And Installation...2518
    DIODES...2518
      Checking The Diodes...2518
    ALTERNATOR (DELCO)...2519
      Alternator Belt Adjustment...2519
      Checking Alternator Wiring Harness...2519
      Checking Alternator Output...2520
      Checking Alternator Regulator...2520
      Removal And Installation...2520
      Disassembly And Assembly...2521
    MELROE ALTERNATOR...2524
      Checking The Alternator Output...2524
      Checking The Alternator Regulator...2524
      Removal And Installation...2525
      Disassembly And Assembly...2526
    STARTER...2529
      Checking The Starter...2529
      Removal And Installation...2529
      Disassembly And Assembly...2530
      Inspection...2531
      Replacing The Brushes...2531
  ENGINE SERVICE...2533
    TROUBLESHOOTING...2535
    VALVE CLEARANCE...2536
      Adjustment...2536
    ENGINE COMPRESSION...2537
      Checking...2537
    FUEL FILTER...2538
      Water Trap...2538
      Fuel Filter Element...2538
    REMOVING AIR FROM THE FUEL SYSTEM...2539
      Procedure...2539
    ENGINE SHUT-OFF SOLENOID...2539
      Removal And Installation...2539
    THROTTLE TENSION ADJUSTMENT...2539
      Procedure...2539
    FUEL INJECTION PUMP...2540
      Removal And Installation...2540
      Checking The Injection Pump...2541
      Timing The Injection Pump...2541
    FUEL INJECTOR NOZZLES...2542
      Removal And Installation...2542
      Checking The Injector Nozzles...2543
    GLOW PLUGS...2544
      Removal And Installation...2544
      Checking The Glow Plug...2544
    ENGINE...2545
      Removal And Installation...2545
    RADIATOR AND OIL COOLER...2548
      Removal And Installation...2548
      Oil Cooler Removal And Installation...2549
    MUFFLER...2550
      Removal And Installation...2550
    BLOWER HOUSING...2550
      Removal And Installation...2550
    ENGINE FLYWHEEL AND U-JOINT...2551
      Removal And Installation...2551
      Flywheel Ring Gear...2551
    CYLINDER HEAD...2552
      Removal Of The Cylinder Head...2552
      Disassembly Of The Cylinder Head...2553
      Servicing The Cylinder Head...2553
      Assembly Of The Cylinder Head...2555
      Installing The Cylinder Head...2555
    TIMING GEAR COVER...2556
      Removal And Installation...2556
    TIMING GEAR, CAMSHAFT AND OIL PUMP...2558
      Removal And Installation...2558
      Oil Pump Service...2559
      Servicing The Camshaft...2560
    CRANKSHAFT AND PISTONS...2561
      Piston And Crankshaft Removal And Installation...2561
      Crankshaft Service...2563
      Service The Connecting Rods And Pistons...2564
    CYLINDER LINERS...2567
      Checking The Cylinder Liners...2567
    WATER PUMP...2568
      Disassembly And Assembly...2568
  TECHNICAL DATA...2569
    LOADER SPECIFICATIONS (S/N 11999 & BELOW)...2571
      Operation And Performance...2571
      Engine...2571
      Loader Hydraulics...2572
      Electrical...2572
      Drive System...2572
      Capactities...2572
      Tires...2572
    LOADER SPECIFICATIONS (S/N 12001 & ABOVE)...2573
      Operation And Performance...2573
      Engine...2573
      Loader Hydraulics...2574
      Electrical...2574
      Drive System...2574
      Capacities...2574
      Tires...2574
    ENGINE SPECIFICATIONS...2575
      Fuel Injection Nozzles...2575
      Fuel Injection Pump...2575
      Cylinder Head...2575
      Valves...2575
      Valve Springs...2575
      Rocker Arms...2575
      Camshaft...2576
      Cylinders...2576
      Piston Rings...2576
      Pistons...2576
      Crankshaft...2576
      Oil Pump...2577
      Engine Bolt Torque...2577
    TORQUE SPECIFICATIONS...2578
      Engine Group...2578
      Hydrostatic Controls (S/N 11999 & Below)...2580
      Hydrostatic System (S/N 12001 & Above)...2581
      Hydrostatic System (S/N 11999 & Below)...2583
      Hydraulic Controls...2584
      Steering Controls And Rear Door...2585
      Drive System...2586
      Lift Arm & Bob-Tach Group...2587
      Frame & Articulation Unit Group...2588
    DECIMAL AND MILLIMETER EQUILAVENTS...2589
    U.S. TO METRIC CONVERSION...2589
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2590
  SERVICE MANUAL REVISIONS...2591
    1600-1...2591
    1600-2...2593
    1600-3...2595
    1600-4...2597
    1600-5...2599
6570063 (6-85) - 1213 Operation & Maintenance Manual...2601
  OPERATOR SAFETY...2602
  FOREWORD...2603
    CONTENTS...2603
    REFERNCE INFORMATION...2603
    SAFETY INSTRUCTIONS...2605
      Safety Is Your Responsibility...2605
      Before You Operate The Bobcat Feller Buncher...2605
    FIRE PREVENTION...2606
    SERIAL NUMBER LOCATIONS...2607
      Feller Buncher Serial Number...2607
      Engine Serial Number Location...2607
    DELIVERY REPORT...2607
    FELLER BUNCHER IDENTIFICATION...2608
  OPERATING INSTRUCTIONS...2609
    OPERATING INSTRUCTIONS...2611
    GETTING ON AND OFF THE FELLER BUNCHER...2611
    GETTING READY FOR OPERATION...2611
    SAFETY SIGNS (DECALS)...2612
    LEARNING THE CONTROLS...2615
    INSTRUMENT PANEL...2615
    THROTTLE CONTROL...2616
    PARKING BRAKE...2616
    STEERING LEVERS...2617
    HYDRAULIC CONTROLS...2618
      Hydraulic Leveling Control...2618
      Foot Pedal Controls...2618
      Shear Operation Controls...2619
    BEFORE STARTING THE ENGINE...2620
    STARTING THE ENGINE...2621
      Cold Temperature Starting...2622
      Warming The Hydrostatic Transmission...2622
    OPERATING THE FELLER BUNCHER...2623
    OPERATING PROCEDURE...2623
      Slope Cutting Operation...2623
    OPERATING THE TREE SHEAR...2624
      Fastening And Cutting...2625
      Moving The Tree...2625
      Using The Accumulator Arm...2625
      Making A Group of Cut Trees (Bunching)...2625
      To Deposit A Tree...2626
      Tree Cutting...2626
      Tree Sizes...2626
    DIFFERENT CUTTING APPLICATIONS...2626
      Plantation Tree Cutting (6 ft Rows)...2626
      Plantation Tree Cutting (12 ft Rows)...2627
      Clear Cutting...2627
      Thinning (Random Cutting)...2627
    PARKING THE FELLER BUNCHER...2628
    TRANSPORTING THE FELLER BUNCHER...2628
  FIRE PREVENTIVE MAINTENANCE...2629
    FIRE PREVENTION...2631
    MAINTENANCE FOR FIRE PREVENTION...2631
    FIRE EQUIPMENT...2633
    FIRE FIGHTING...2633
    EMERGENCY EXIT...2634
    PROCEDURES FOR PREVENTING FIRE...2634
  PREVENTIVE MAINTENANCE...2635
    WARNINGS...2636
    SERVICE SCHEDULE...2637
    LIDT ARM STOP...2638
    OPERATOR CAB...2638
      Seat Bar System...2638
      Seat Bar Inspection...2639
      Seat Bar Maintenance...2639
      Raising The Operator Cab...2640
      Lowering The Operator Cab...2640
    REAR DOOR...2641
      Door Latch Adjustment...2641
    AIR CLEANER SERVICE...2642
    FUEL SYSTEM...2643
      Filling The Fuel Tank...2643
      Fuel Filter (Water Trap)...2643
      Fuel Filter (Element)...2644
      Removing Air From The Fuel System...2644
    ENGINE LUBRICATION SYSTEM...2645
      Engine Oil And Filter Replacement...2645
    COOLING SYSTEM...2647
      Coolant Level...2647
      Cooling System Maintenance...2647
      Coolant Replacement...2649
    ALTERNATOR BELT ADJUSTMENT...2650
    ELECTRICAL SYSTEM...2653
      Battery Disconnect Switch...2653
      Battery Replacement...2653
      Electrical System Service...2653
      Using An Extra Battery (Jump Starting)...2654
    HYDRAULIC / HYDROSTATIC SYSTEM...2656
      Checking \ Adding Fluid To Reservoir...2656
      Hydraulic / Hydrostatic Fluid Replacement...2656
      Hydraulic / Hydrostatic Filter Replacement...2657
    SPARK ARRESTOR MUFFLER...2657
      Cleaning Spark Arrestor Muffler...2657
    FINAL DRIVE TRANSMISSION...2658
      Chaincase Fluid Level...2658
      Wheel End Clearance...2658
    TIRE MAINTENANCE...2658
      Tire Rotation...2658
      Tire Pressure...2659
      Tire Installation On Rim...2659
      Wheel Nuts...2659
    FELLER BUNCHER LUBRICATION...2660
    PARKING BRAKE ADJUSTMENT...2661
    FOOT PEDAL AREA...2661
    PIVOT PINS...2661
  TROUBLESHOOTING...2663
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...2665
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...2666
    TROUBLESHOOTING THE ENGINE...2667
  MAJOR PARTS...2669
    MAIN FRAME...2671
    FUEL TANK...2672
    CHAINCASE & BRAKE...2673
    FINAL DRIVE CHAINCASE...2674
    FRONT & REAR DOOR...2675
    HYDROSTATIC SYSTEM...2676
    LIFT ARM HYDRAULICS...2677
    ELECTRICAL SYSTEM...2678
    STEERING & FOOT PEDAL CONTROLS...2679
    ENGINE & ATTACHING PARTS...2680
    TREE SHEAR...2681
  SPECIFICATIONS...2683
    SPECIFICATIONS...2685
    ENGINE...2686
    FELLER BUNCHER HYDRAULICS...2686
    ELECTRICAL...2687
    DRIVE SYSTEM...2687
    CAPACITIES...2687
    TIRES...2687
  WARRANTY...2689
6570156 (6-85) - 1213 Service Manual...2691
  MAINTENANCE SAFETY...2693
  CONTENTS...2695
    FOREWORD...2695
    SAFETY INSTRUCTIONS...2697
      Safety Is Your Responsibility...2697
      Before You Operate The Bobcat Loader...2697
      Safe Operation Needs A Qualified Operator...2698
    FIRE PREVENTION...2698
    SERIAL NUMBER LOCATIONS...2699
      Feller Buncher Serial Number...2699
      Engine Serial Number...2699
    DELIVERY REPORT...2699
    FELLER BUNCHER IDENTIFICATION...2700
  PREVENTIVE MAINTENANCE...2701
    SERVICE SCHEDULE...2703
    LIFTING AND BLOCKING THE FELLER BUNCHER...2704
      Procedure...2704
    TRANSPORTING THE FELLER BUNCHER...2705
      Procedure...2705
    LIFT ARM STOP...2706
      Procedure...2706
    OPERATOR CAB...2707
      Raising The Operator Cab...2707
      Lowering The Operator Cab...2707
    REAR DOOR...2708
      Door Latch Adjustment...2708
    AIR CLEANER SERVICE...2709
      Filter Element Replacement...2709
    FUEL SYSTEM...2710
      Filling The Fuel Tank...2710
      Removing Water From Fuel Filter...2710
    ENGINE OIL AND FILTER...2711
      Procedure...2711
    COOLING SYSTEM...2713
      Coolant Level...2713
      Cooling System Maintenance...2713
      Coolant Replacement...2715
    ELECTRICAL SYSTEM...2716
      Description...2716
      Battery Disconnect Switch...2716
      Electrical System Maintenance...2716
      Using An Extra Battery (Jump Starting)...2717
    COLD TEMPERATURE STARTING...2718
      Procedure...2718
      Warming The Hydrostatic Transmission...2718
    HYDRAULIC / HYDROSTATIC SYSTEM...2719
      Checking And Adding Fluid...2719
      Hydraulic Filter Replacement...2720
      Hydrostatic Filter Replacement...2720
    SPARK SRRESTOR MUFFLER...2721
      Cleaning Spark Arrestor Muffler...2721
    FINAL DRIVE TRANSMISSION...2722
      Chaincase Fluid Level...2722
      Wheel End Chaincases...2722
    TIRE MAINTENANCE...2722
      Tire Rotation...2722
      Tire Pressure...2723
      Tire Installation On Rims...2723
      Wheel Nuts...2723
    FELLER BUNCHER LUBRICATION...2724
      Procedure...2724
      Pump Drive Coupler...2725
    PARKING BRAKE ADJUSTMENT...2725
      Procedure...2725
    FOOT PEDAL AREA...2725
      Cleaning...2725
    PIVOT PINS...2725
      Procedure...2725
    REMOTE START SWITCH...2726
      Procedure...2726
    TRACKS...2727
      Installation And Removal...2727
      Adjustments...2728
  HYDRAULIC SYSTEM...2729
    HYDRAULIC / HYDROSTATIC SCHEMATICS...2731
    TROUBLESHOOTING...2737
    HYDRAULIC SYSTEM INFORMATION...2738
      Flare Connections...2738
      Straight Thread O-Ring Fitting...2738
      Tubelines And Hoses...2738
    LIFT CYLINDER...2739
      Checking The Lift Cylinder(s)...2739
      Removal And Installation...2739
    TILT CYLINDER...2741
      Checking The Tilt Cylinder(s)...2741
      Removal And Installation...2741
    REAR LEVELING CYLINDER...2743
      Checking The Rear Leveling Cylinder(s)...2743
      Removal And Installation...2743
    HYDRAULIC CYLINDER REPAIR...2745
      Disassembly...2745
      Assembly...2747
    HYDRAULIC VALVE MAIN RELIEF...2750
      Checking The Main Relief Valve (Front Control Valve)...2750
      Checking The Main Relief Valve (Rear Control Valve)...2751
    FRONT HYDRAULIC VALVE...2752
      Removal And Installation...2752
      240 PSI By-Pass Valve...2753
      Shear Spool Electric Solenoid...2754
      Disassembly And Assembly...2755
      Lift Section Anti-Cavitation Valve...2758
      Lift Section Port Relief...2758
      Tilt Section Anti-Cavitation Valve...2758
      Lift Section Orifice...2759
      Load Check Valves...2759
    REAR HYDRAULIC VALVE...2760
      Removal And Installation...2760
      Disassembly And Assembly...2762
    HYDRAULIC PUMP...2763
      Checking The Output Of The Hydraulic Pump...2763
      Removal And Installation...2764
      Disassembly And Assembly...2765
      Inspection...2767
    HYDRAULIC FLUID FILTER HOUSING...2768
      Removal And Installation...2768
      180 PSI By-Pass Valve...2769
      72 PSI By-Pass Valve...2769
    REAR CYLINDER LOCK VALVE...2770
      Removal And Installation...2770
      Disassembly And Assembly...2770
    HYDRAULIC RESERVOIR & PORT BLOCK...2771
      Removal And Installation...2771
    HYDRAULIC CONTROL PEDALS...2774
      Removal And Installation...2774
      Adjustment...2774
    PEDAL LOCK LINKAGE...2775
      Adjustment...2775
  HYDROSTATIC SYSTEM...2777
    TROUBLESHOOTING...2779
    HYDROSTATIC SYSTEM INFORMATION...2780
      High Pressure Relief Replenishing Valves Function...2780
    FRONT & SIDE PANELS...2781
      Removal And Installation...2781
    STEERING LEVERS...2784
      Removal And Installation...2784
      Centering Mechanism...2785
      Neutral Adjustment...2786
    SERVO CONTROL...2787
      Removal And Installation...2787
      Disassembly And Assembly...2788
    PINTLE LEVER ARMS...2789
      Removal And Installation...2789
    HYDROSTATIC MOTOR...2790
      Removal And Installation...2790
      Disassembly And Assembly...2791
      Inspection...2795
      Timing The Hydrostatic Motor...2796
    HYDROSTATIC PUMPS...2797
      Checking The High Pressure Relief Replenishing Valve...2797
      Checking Charge Pressure...2798
      Removal And Installation...2798
      Disassembly And Assembly...2799
      Rear Pump...2801
      Front Pump...2801
      Inspection...2804
      Tow Valves...2805
    HYDROSTATIC FLUID FILTER...2807
      Removal And Installation...2807
      Filter By-Pass Valve...2808
  DRIVE SYSTEM...2809
    PARKING BRAKE...2811
      Adjustment...2811
      Removal And Installation...2811
      Blocks And Pucks...2812
    FINAL DRIVE AXLE SEAL & WEAR RING...2814
      Removal And Installation...2814
    CHAINCASE AXLE SEAL & WEAR RING...2817
      Removal And Installation...2817
    FRONT AND REAR FINAL DRIVE CHAINS...2819
      Front Final Drive Chains Removal And Installation...2819
      Rear Final Drive Chains Removal And Installation...2821
    FINAL DRIVE AXLES...2822
      Removal And Installation...2822
      Front Final Drive Chaincase Only...2825
      Rear Final Drive Axle Installation...2826
      Front Final Drive Axles Installation...2826
    FINAL DRIVE CHAINCASE...2827
      Front Final Drive Chaincase Removal And Installation...2827
      Rear Final Drive Chaincase Removal And Installation...2828
      Pivot Bearing Sleeve Removal And Installation...2830
    MAIN FRAME CHAINCASE...2832
      Axles And Bearings Removal And Installation...2832
      Drive Chain(s) Removal And Installation...2835
    REDUCTION GEARCASE...2837
      Removal And Installation...2837
      Checking Reduction Gearcase...2837
      Disassembly And Assembly...2838
      Installation...2842
      Reduction Gearcase Seal...2843
  MAIN FRAME...2845
    OPERATOR CAB...2847
      Removal And Installation...2847
    OPERATOR CAB GAS CYLINDERS...2850
      Removal And Installation...2850
    FRONT DOOR GAS CYLINDER...2851
      Removal And Installation...2851
    SEAT BAR...2852
      Removal And Installation...2852
    SEAT BAR SYSTEM...2852
      Seat Bar Inspection...2852
      Seat Bar Maintenance...2852
    REAR DOOR...2853
      Removal And Installation...2853
    LIFT ARMS...2855
      Removal And Installation...2855
    TREE SHEAR...2857
      Removal And Installation...2857
    TREE SHEAR HYDRAULIC CYLINDERS...2857
      Gathering & Accumulator Arm Cylinders Removal And Installation...2857
      Shear Blade Hydraulic Cylinder Removal And Installation...2858
    SHEAR BLADES...2859
      Removal And Installation...2859
    FUEL TANK...2860
      Removal And Installation...2860
      Fuel Tank Sender Switch...2861
  ELECTRICAL SYSTEM...2863
    ELECTRICAL SCHEMATICS...2866
    ELECTRICAL SYSTEM INFORMATION...2871
      Description...2871
    TROUBLESHOOTING...2871
    SEALED ELECTRICAL TERMINAL...2872
      Removal And Installation...2872
    BATTERY...2873
      Checking The Battery...2873
      Removal And Installation...2873
    STEERING LEVERS ELECTRICAL SWITCHES...2874
      Removal And Installation...2874
    ALTERNATOR...2876
      Alternator Belt Adjustment...2876
      Checking Alternator Wire Harness...2877
      Checking Alternator Output...2877
      Checking Alternator Regulator...2877
      Removal And Installation...2878
      Disassembly And Assembly...2879
    STARTER...2881
      Checking The Starter...2881
      Removal And Installation...2881
      Disassembly And Assembly...2883
      Cleaning And Inspection...2883
      Replacing The Brushes...2884
    OPERATOR CAB HARNESS...2885
      Removal And Installation...2885
    CHASSIS HARNESS...2887
      Removal And Installation...2887
    ENGINE HARNESS...2889
      Removal And Installation...2889
  ENGINE SERVICE...2893
    TROUBLESHOOTING...2895
    VALVE CLEARANCE...2896
      Adjustment...2896
    ENGINE COMPRESSION...2897
      Checking...2897
    FUEL FILTER...2898
      Water Trap...2898
      Fuel Filter Element...2898
    REMOVING AIR FROM FUEL SYSTEM...2899
      Procedure...2899
    FUEL INJECTION PUMP...2900
      Removal And Installation...2900
    ENGINE TIMING TO INJECTION PUMP...2903
      Procedure...2903
    FUEL INJECTOR NOZZLES...2905
      Removal And Installation...2905
      Checking...2906
    GLOW PLUGS...2908
      Removal And Installation...2908
    ENGINE...2909
      Removal And Installation...2909
    RADIATOR...2914
      Removal And Installation...2914
    OIL COOLER...2916
      Removal And Installation...2916
    ENGINE MUFFLER...2917
      Removal And Installation...2917
    ENGINE FLYWHEEL & U-JOINT...2918
      Removal And Installation...2918
      Flywheel Ring Gear...2918
    ENGINE BLOWER HOUSING...2919
      Removal And Installation...2919
    ENGINE MOUNTS...2920
      Removal And Installation...2920
    CYLINDER HEAD...2921
      Removal And Installation...2921
      Cylinder Head Surface Alignment...2922
      Exhaust Manifold...2922
    VALVES...2923
      Removal And Installation...2923
      Reconditioning The Valve And Valve Seats...2923
      Valve Seat Insert...2924
      Valve Springs...2925
      Valve Guides...2924
    ROCKER ARMS...2926
      Disassembly And Assembly...2926
      Push Rods...2926
    PISTON AND CONNECTING ROD...2927
      Removal...2927
      Disassembly...2927
      Inspection...2928
      Assembly...2931
      Installation...2932
    CYLINDER LINERS...2933
      Removal...2933
      Installation...2933
    MAIN BEARINGS...2934
      Removal...2934
      Installation...2935
      Crankshaft End Play...2936
    CRANKSHAFT...2937
      Removal...2937
      Checking Tuffriding (Soft Nitriding) Coating...2937
      Checking...2937
      Crankshaft Ger...2939
      Removal And Installation...2939
      Installation...2939
    TIMING CASE COVER SEAL...2940
      Removal And Installation...2940
    TIMING CASE COVER...2941
      Removal And Installation...2941
    IDLER GEAR AND HUB...2943
      Removal And Installation...2943
      Checking...2943
    FUEL INJECTION PUMP IDLER GEAR...2945
      Removal And Installation...2945
      Bearing Installation...2945
    CAMSHAFT GEAR...2946
      Removal And Installation...2946
    TIMING CASE...2947
      Removal And Installation...2947
    CAMSHAFT...2948
      Removal And Installation...2948
      Checking...2948
      Camshaft Bearings...2949
      Tappets...2949
      Installation...2950
    OIL PAN...2951
      Removal...2951
      Installation...2951
    OIL PUMP...2952
      Removal And Installation...2952
      Checking...2952
      Gear Replacement...2953
      Oil Pump Relief Valve...2954
      Rotor Replacement...2954
    WATER PUMP...2955
      Removal And Installation...2955
      Disassembly...2955
      Assembly...2956
    THERMOSTAT...2958
      Removal And Installation...2958
      Inspection...2958
    WATER JACKET TUBE...2959
      Removal And Installation...2959
  TECHNICAL DATA...2961
    SPECIFICATIONS...2963
      ENGINE...2964
      FELLER BUNCHER HYDRAULICS...2964
      ELECTRICAL...2965
      DRIVE SYSTEM...2965
      CAPACITIES...2965
      TIRES...2965
    ENGINE SPECIFICATIONS...2966
      Cylinder Head...2966
      Valve, Valve Guide & Seat Inserts...2966
      Valve Springs...2966
      Rocker Arm...2966
      Tappets...2967
      Piston, Pin & Rings...2967
      Connecting Rod & Bearing...2967
      Cylinder Liners...2967
      Camshaft...2967
      Crankshaft...2968
      Idler Gear...2968
      Oil Pump...2968
      Engine Torque...2969
    HYDRAULIC / HYDROSTATIC FLUID...2970
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2971
    DECIMAL AND MILLIMETER EQUIVALENTS...2972
    U.S. TO METRIC CONVERSION...2972
6570468 (5-87) - 1600 Operation & Maintenance Manual...2973
  WARNINGS...2975
  FOREWORD...2977
    CONTENTS...2977
    REFERENCE INFORMATION...2977
    SAFETY INSTRUCTIONS...2979
      Safey Is Your Responsibility...2979
      Before You Operate The Bobcat Loader...2979
      Safe Operation Needs A Qualified Operator...2980
    FIRE PREVENTION...2980
    SERIAL NUMBER LOCATIONS...2981
      Loader Serial Number...2981
      Engine Serial Number...2981
    DELIVERY REPORT...2981
    BOBCAT LOADER IDENTIFICATION...2982
  OPERATING INSTRUCTIONS...2983
    OPERATOR'S INSTRUCTIONS...2985
    GETTING ON AND OFF THE LOADER...2985
    GETTING READY FOR OPERATION...2985
    SAFETY SIGNS (DECALS)...2986
    INSTRUMENT PANEL...2989
    THROTTLE CONTROL...2989
      To Stop The Engine...2989
    PARKING BRAKE...2990
    STEERING AND SPEED CONTROLS...2990
      Transmission Range Selector...2990
      Foot Pedal Control...2990
      Steering Wheel...2991
    HYDRAULIC CONTROLS...2992
      Lift Arm Operation...2992
      Tilt Operation...2992
      Auxiliary Hydraulic Operation (Optional)...2992
    BEFORE STARTING THE ENGINE...2993
    STARTING THE ENGINE...2994
      Normal Starting Condition...2994
      Cold Temperature Starting...2995
      Warming The Hydrostatic Transmission...2995
    ATTACHMENTS & BUCKETS...2996
      Installation Of Attachment...2997
      Removing The Attachment...2997
    OPERATING PROCEDURE...2998
      Filling The Bucket...2998
      Emptying The Bucket...2999
      Digging Into The Ground...2999
      Leveling The Ground...3000
      Backfilling...3000
    PARKING THE LOADER...3000
    TRANSPORTING THE BOBCAT LOADER...3001
    FRONT AND REAR WINDOWS...3002
  PREVENTIVE MAINTENANCE...3003
    WARNINGS...3004
    SERVICE SCHEDULE...3005
    LIFT ARM STOP...3006
    FRAME LOCK...3006
    OPERATOR RESTRAINT SYSTEM...3007
      Inspection Of The Operator Restraint System...3007
      Service Of The Operator Restraint System...3007
    REAR DOOR...3008
      Adjusting The Rear Door Latch...3008
    AIR CLEANER...3009
    FUEL SYSTEM...3010
      Fuel Specifications...3010
      Fuel System Service...3010
      Fuel Filter...3010
      Removing Air From The Fuel System...3011
    ENGINE LUBRICATION SYSTEM...3012
      Engine Oil And Filter Replacement...3012
    ENGINE COOLANT SYSTEM...3013
      Coolant Level...3013
      Removing Coolant From The Cooling System...3013
    ALTERNATOR BELT...3013
    OPERATOR CAB ELECTRICAL DIAGRAM...3014
    ENGINE ELECTRICAL DIAGRAM...3015
    ELECTRICAL SYSTEM...3016
      Electrical System Service...3016
      Using An Extra Battery (Jump Starting)...3016
      New Battery Installation...3017
    HYDRAULIC / HYDROSTATIC FLOW CHART...3018
    HYDRAULIC / HYDROSTATIC SYSTEM...3019
      Checking And Adding Fluid...3019
      Replacement Of The Hydraulic Filter...3019
      Hydraulic / Hydrostatic Fluid Replacement...3020
    SPARK ARRESTOR MUFFLER...3020
      Cleaning The Spark Arrestor Muffler...3020
    FRONT AND REAR AXLE DIFFERENTIAL...3021
      Checking Differential Oil Level...3021
    U-JOINT...3021
    TIRE MAINTENANCE...3022
      Tire Rotation...3022
      Wheel Nuts...3022
    BOB-TACH...3022
    LUBRICATION OF THE BOBCAT LOADER...3023
  TROUBLESHOOTING...3025
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...3027
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...3028
    TROUBLESHOOTING THE DRIVE SYSTEM...3029
    TROUBLESHOOTING THE ELECTRICAL SYSTEM...3030
    TROUBLESHOOTING THE ENGINE...3031
  SPECIFICATIONS...3033
    LOADER SPECIFICATIONS...3035
    OPERATION AND PERFORMANCE...3035
    ENGINE...3035
    LOADER HYDRAULICS...3036
    ELECTRICAL...3036
    DRIVE SYSTEM...3036
    CAPACITIES...3036
    TIRES...3036
  WARRANTY...3038
6570571 (8-89) - 2400 Operation & Maintenance Manual...3039
  WARNINGS FOR BACKHOE OPERATION...3041
  FOREWORD...3043
    CONTENTS...3043
    SAFETY INSTRUCTIONS...3045
    FIRE PREVENTION...3046
    SERIAL NUMBER LOCATIONS...3047
    DELIVERY REPORT...3047
    BOBCAT LOADER IDENTIFICATIONS...3048
    SAFETY SIGNS (DECALS)...3049
  OPERATING INSTRUCTIONS...3051
    LOADER OPERATING INSTRUCTIONS...3053
      OPERATING INSTRUCTIONS...3055
      COUNTERWEIGHT...3055
      GETTING ON AND OFF THE LOADER...3055
      SEAT BELT...3056
      TILT STEERING WHEEL AND RESTRAINT ARM...3056
      INSTRUMENT PANEL...3057
      THROTTLE CONTROL...3058
      PARKING BRAKE...3058
      STEERING AND SPEED CONTROLS...3059
        Foot Pedal Control...3060
        Steering Wheel...3060
      HYDRAULIC CONTROLS...3061
        Lift Arm Operation...3061
        Tilt Operation...3061
        Auxiliary Hydraulic Operation (Optional)...3061
        Constant Flow Operation...3061
      DAILY INSPECTION...3062
      STARTING THE ENGINE...3063
        Normal Starting Condition...3063
        Cold Temperature Starting...3064
        Warming The Hydrostatic Transmission...3065
      ATTACHMENTS & BUCKETS...3065
        Rated Operating Capacity...3065
        Installation Of Bucket (Attachment)...3066
        Removing The Bucket (Attachment)...3066
        Bucket Anti-Roll Back Linkage Adjustment...3067
      OPERATING PROCEDURE...3068
        Operating On Slopes...3068
        Filling The Bucket...3069
        Emptying The Bucket...3069
        Digging Into The Ground...3070
        Leveling The Ground...3070
        Backfilling...3071
      PARKING THE LOADER...3071
      TRANSPORTING THE LOADER...3072
      TOWING THE LOADER...3072
    BACKHOE OPERATING INSTRUCTIONS...3073
      911B & 914B BACKHOE OPERATING INSTRUCTIONS...3075
        914B BACKHOE IDENTIFICATION...3077
        911B BACKHOE IDENTIFICATION...3078
        SAFETY SIGNS (DECALS)...3079
        BACKHOE INSTALLATION...3081
        REMOVING THE BACKHOE...3084
        OPERATOR'S INSTRUCTIONS...3087
        SEAT...3087
        SEAT BELT...3087
        OPERATING THE BACKHOE...3088
          Operation Of Rear Auxiliary Control Lever...3088
          Operation Of The Control Levers...3089
          Operation Of The Stabilizers...3090
        BOOM LOCKING PIN...3090
        OPERATING PROCEDURE...3091
          Digging With The Dipperstick...3093
          Digging With The Bucket...3093
        MOVING THE BACKHOE...3094
        LIFTING AND MOVING OBJECTS...3094
        TRANSPORTING THE LOADER/BACKHOE...3095
      937S BACKHOE OPERATING INSTRUCTIONS...3097
        937S BACKHOE IDENTIFICATION...3099
        SAFETY SIGNS (DECALS)...3100
        BACKHOE INSTALLATION...3101
        REMOVING THE BACKHOE...3103
        OPERATING INSTRUCTIONS...3105
        GETTING ON AND OFF THE LOADER/BACKHOE...3105
        SEAT...3105
        SEAT BELT...3105
        OPERATING THE BACKHOE...3106
          Operatation Of The Control Levers (ISO Controls)...3106
          Operation Of The Stabilizers...3107
        SWING LOCK PIN...3107
        BOOM LOCKING PIN...3108
        SIDE SHIFT OPERATION...3109
          Moving The Swing/Side Shift Frame...3109
        OPERATING PROCEDURE...3110
          Digging With The Dipperstick...3113
          Digging With The Bucket...3113
        MOVING THE LOADER/BACKHOE...3114
        LIFTING AND MOVING OBJECTS...3114
        TRANSPORTING THE LOADER/BACKHOE...3115
      THREE-POINT HITCH OPERATING INSTRUCTIONS...3117
        THREE-POINT HITCH IDENTIFICATION...3119
        THREE-POINT HITCH...3121
        Mounting The Three-Point Hitch...3121
        Removal...3122
  PREVENTIVE MAINTENANCE...3123
    LOADER...3125
      MAINTENANCE SAFETY...3127
      SERVICE SCHEDULE...3129
      LIFT ARM STOP...3130
      STEERING FRAME LOCK...3130
      ENGINE HOOD...3131
      ENGINE REAR DOORS...3131
      AIR CLEANER...3132
      FUEL SYSTEM...3133
        Fuel Specifications...3133
        Filling The Fuel Tank...3133
        Fuel Filter (Final)...3134
        In-Line Fuel Filter (S/N 11277 & Below)...3135
        Removing Air From The Fuel System...3135
      ENGINE LUBRICATION SYSTEM...3136
        Checking Engine Oil...3136
        Engine Oil & Filter Replacement...3136
      ENGINE COOLANT SYSTEM...3137
        Coolant Level...3137
        Removing Coolant From The Cooling System...3137
        Radiator Side Screen...3138
        Cooling System Maintenance...3138
      ALTERNATOR BELT...3139
      ELECTRICAL SYSTEM...3139
        Electrical Breaker...3139
        Fuses...3140
        Electrical System Service...3140
        Using An Extra Battery (Jump Starting)...3141
        Battery Removal And Installation...3142
      HYDRAULIC / HYDROSTATIC SYSTEM...3143
        Checking And Adding Fluid...3143
        Replacement Of The Hydraulic Filter...3143
        Hydraulic / Hydrostatic Fluid Replacement...3144
      SPARK ARRESTOR MUFFLER...3144
        Cleaning The Spark Arrestor Muffler...3144
      TIRE MAINTENANCE...3145
        Tire Rotation...3145
        Tire Inflation...3145
        Wheel Nuts...3145
      BOB-TACH...3145
      FRONT AND REAR DIFFERENTIAL...3146
        Checking Differential Oil Level...3146
        Checking Gear-Drop Box Oil Level...3146
        Checking Wheel Ends Oil Level...3146
      LUBRICATION OF THE LOADER...3147
      DRIVE BELT ADJUSTMENT...3149
      OPERATOR CAB BLOWER FILTER...3150
    BACKHOE...3151
      TROUBLESHOOTING...3153
      LUBRICATION OF THE BACKHOE...3154
  SPECIFICATIONS...3155
    LOADER...3157
      LOADER DIMEMSIONS...3159
      OPERATION AND PERFORMANCE...3159
      ENGINE...3159
      HYDRAULIC SYSTEM...3160
      ELECTRICAL...3160
      DRIVE SYSTEM...3160
      CAPACITIES...3160
      TIRES...3160
    2400/914B BACKHOE...3161
      BACKHOE DIMEMSIONS...3163
      OPERATION AND PERFORMANCE...3164
      ENGINE...3164
      HYDRAULIC SYSTEM...3164
      TRANSPORT...3165
      OPERATIONAL...3165
    2400/914B EXTENDABLE BACKHOE ...3166
      BACKHOE DIMEMSIONS...3166
      OPERATION AND PERFORMANCE...3167
      ENGINE...3167
      HYDRAULIC SYSTEM...3167
      TRANSPORT...3168
      OPERATIONAL...3168
    2400/911B BACKHOE...3169
      BACKHOE DIMENSIONS...3171
      OPERATION AND PERFORMANCE...3172
      ENGINE...3172
      HYDRAULIC SYSTEM...3172
      TRANSPORT...3173
      OPERATIONAL...3173
    2400/937S BACKHOE...3175
      SPECIFICATIONS...3177
      OPERATION AND PERFORMANCE...3178
      ENGINE...3178
      HYDRAULIC SYSTEM...3178
      TRANSPORT...3179
      OPERATIONAL...3179
    2400/THREE-POINT HITCH...3181
      SPECIFICATIONS...3183
      OPERATION & PERFORMANCE...3183
      ENGINE...3183
      HYDRAULIC SYSTEM...3184
      ELECTRICAL...3184
      DRIVE SYSTEM...3184
      CAPACITIES...3184
      TIRES...3184
  WARRANTY...3185
6720276 (2-90) - 2410 Operation & Maintenance Manual...3187
  OPERATOR SAFETY WARNINGS...3189
  FOREWORD...3191
    CONTENTS...3191
    REFERENCE INFORMATION...3191
    SAFETY INSTRUCTIONS...3193
      Safety Is The Operator's Responsibility...3193
      Before Operating The Bobcat Loader...3193
      Safe Operation Needs A Qualified Operator...3194
    FIRE PREVENTION...3194
    SERIAL NUMBER LOCATIONS...3195
    LOADER SERIAL NUMBER...3195
    ENGINE SERIAL NUMBER...3195
    DELIVERY REPORT...3195
    BOBCAT LOADER IDENTIFICATION...3196
    SAFETY SIGNS (DECALS)...3197
  OPERATING INSTRUCTIONS...3199
    INSTRUMENT PANEL...3201
    THROTTLE CONTROL...3202
    PARKING BARKE...3202
    TRANSMISSION RANGE SELECTOR...3203
    STEERING AND FOOT PEDAL...3204
      Foot Pedal Control...3204
      Steering wheel...3204
    HYDRAULIC CONTROLS...3205
      Lift Arm Operation...3205
      Tilt Operation (Bucket)...3205
      Auxiliary Hydraulic Operation...3206
      Constant Flow Operation...3206
      Release Hydraulic Pressure At Couplers...3206
    DAILY INSPECTION...3207
    COUNTERWEIGHT...3208
    GETTING READY FOR OPERATION...3208
    STARTING THE ENGINE...3210
      Normal Starting Condition...3210
      Cold Temperature Starting...3211
      Warming The Hydrostatic Transmission...3211
    ATTACHMENTS & BUCKETS...3212
      Rated Operating Capacity...3212
      Installation Of Bucket (Attachment)...3213
      Removing The Bucket (Attachment)...3213
      Bucker Indicator Linkage Adjustment...3214
    OPERATING PROCEDURE...3215
      Operating On Slopes...3215
      Filling The Bucket...3216
      Emptying The Bucket...3216
      Digging Into The Ground...3217
      Leveling The Ground...3217
      Backfilling...3218
    PARKING THE LOADER...3218
    TRANSPORTING THE LOADER...3219
    TOWING THE LOADER...3220
  PREVENTIVE MAINTENANCE...3221
    MAINTENANCE SAFETY...3222
    SERVICE SCHEDULE...3225
    LIFT ARM STOP...3226
    STEERING FRAME LOCK...3226
    ENGINE HOOD...3227
    ENGINE REAR DOORS...3227
    AIR CLEANER...3228
    FUEL SYSTEM...3230
      Filling The Fuel Tank...3230
      Fule Filter...3230
      Removing Air From The Fuel System...3232
    ENGINE LUBRICATION SYSTEM...3233
      Engine Oil And Filter Replacement...3233
    COOLING SYSTEM...3234
      Radiator Side Screen...3234
      Cooling Syatem Maintenance...3234
      Checking Coolant Level...3235
      Removing Coolant From The Cooling System...3235
    ALTERNATOR BELT...3236
      Adjusting The Alternator Belt...3236
    ELECTRICAL SYSTEM...3237
      Description...3237
      Electrical System Service...3237
      Fuses...3237
      Using A Booster Battery (Jump Starting)...3238
      Battery Removal And Installation...3239
    HYDRAULIC / HYDROSTATIC SYSTEM...3240
      Checking And Adding Fluid...3240
      Hydraulic / Hydrostatic Filter Replacement...3240
      Hydraulic Fluid Replacememnt...3241
    SPARK ARRESTOR MUFFLER...3242
    TIRE MAINTENANCE...3243
      Wheel Nuts...3243
      Tire Rotation...3243
      Tire Inflation...3243
    FRONT AND REAR DIFFERENTIAL...3244
      Checking Differential Oil Level...3244
      Checking Gear-Drop Box Oil Level...3244
      Checking Wheel End Oil Level...3244
    DRIVE BELT...3245
      Adjustment...3245
      Removal And Installation...3245
    LUBRICATION OF THE LOADER...3247
    BOB-TACH...3250
    BLOWER FILTER (OPERATOR CAB)...3250
  SPECIFICATIONS...3251
    LOADER DIMEMSIONS...3253
    OPERATION AND PERFORMANCE...3253
    ENGINE...3253
    HYDRAULIC SYSTEM...3254
    ELECTRICAL...3254
    DRIVE SYSTEM...3254
    CAPACITIES...3254
    TIRES...3254
  WARRANTY...3255
6720455 (5-90) - 2400 Service Manual...3257
  MAINTENANCE SAFETY...3259
  FOREWORD...3261
    CONTENTS...3263
    SAFETY INSTRUCTIONS...3265
    SERIAL NUMBER LOCATIONS...3266
    LOADER SERIAL NUMBER...3266
    ENGINE SERIAL NUMBER...3266
    DELIVERY REPORT...3266
    BOBCAT ARTICULATED LOADER IDENTIFICATION...3267
  PREVENTIVE MAINTENANCE...3269
    SERVICE SCHEDULE...3271
    LIFTING AND BLOCKING THE LOADER...3272
      Procedure...3272
    TRANSPORTING THE LOADER...3273
      Procedure...3273
    LIFT ARM STOP...3274
      Procedure...3274
    STEERING FRAME LOCK...3274
      Procedure...3274
    AIR CLEANER...3275
      Replacement Of Filter Element...3275
    FUEL SYSTEM...3277
      Fuel Specifications...3277
      Filling The Fuel Tank...3277
    ENGINE LUBRICATION SYSTEM...3278
      Checking Engine Oil...3278
      Replacement Of Oil And Filter...3278
    ENGINE COOLANT SYSTEM...3279
      Checking Coolant Level...3279
      Removing Coolant From The Cooling System...3279
      Radiator Side Screen...3280
      Cooling System Maintenance...3280
    USING A BOOSTER BATTERY (JUMP STARTING)...3281
      Procedure...3281
    HYDRAULIC/HYDROSTATIC SYSTEM...3282
      Checking And Adding Fluid...3282
      Hydraulic/Hydrostatic Filter Replacement...3282
      Hydraulic Fluid Replacement...3283
    SPARK ARRESTOR MUFFLER...3284
      Cleaning Procedure...3284
    TIRE MAINTENANCE...3285
      Wheel Nuts...3285
      Tire Rotation...3285
      Tire Inflation...3285
    FRONT AND REAR DIFFERENTIAL...3286
      Checking Differential Oil Level...3286
      Checking Gear–Drop Box Oil Level...3286
      Checking Wheel End Oil Level...3286
    LUBRICATION OF THE LOADER...3287
      Procedure...3287
    BLOWER FILTER (OPERATOR CAB)...3290
      Cleaning The Filter...3290
  HYDRAULIC SYSTEM...3291
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3293
    TROUBLESHOOTING...3323
    HYDRAULIC SYSTEM INFORMATION...3324
      Flare Connections...3324
      O–Ring Face Seal Connection...3324
      Straight Thread O–Ring Fitting...3324
      Tubelines And Hoses...3324
    TILT CYLINDER...3325
      Checking The Tilt Cylinder...3325
      Removal And Installation...3325
      Pivot Pin Seals...3327
      Bucket Anti–Roll Back Linkage Adjustment (11000 Series)...3328
      Bucket Indicator Linkage Adjustment (12000 Series)...3329
    LIFT CYLINDER...3330
      Checking The Lift Cylinder...3330
      Removal And Installation...3331
    STEERING CYLINDER...3333
      Checking The Steering Cylinder...3333
      Removal And Installation...3333
      Rod End Bearing...3334
    HYDRAULIC CONTROL VALVE (11000 Series)...3335
      Checking The Main Relief Valve...3335
      Main Relief Valve...3335
      Removal And Installation...3336
    HYDRAULIC CONTROL VALVE (12000 Series)...3340
      Checking The Main Relief Valve...3340
      Main Relief Valve...3340
      Removal And Installation...3341
    BUCKET POSITION VALVE...3344
      Removal And Installation...3344
    HYDRAULIC PUMP (11000 Series)...3346
      Checking Hydraulic Pump Output (Small Section)...3346
      Checking Hydraulic Pump Output (Large Section)...3347
      Removal And Installation...3349
    HYDRAULIC PUMP (12000 Series)...3351
      Checking Hydraulic Pump Output (Small Section)...3351
      Checking Hydraulic Pump Output (Large Section)...3352
      Removal And Installation...3353
    PORT BLOCK (11000 Series)...3355
      Removal And Installation...3355
      Normally–Open Switch...3358
      Charge Pressure Switch...3359
      Temperature Sender...3359
      Oil Cooler By–Pass Valve...3360
      Two–Speed Solenoid...3360
    PORT BLOCK (12000 Series)...3362
      Removal And Installation...3362
      Two–Speed Solenoid...3364
      Normally–Open Switch...3365
      Temperature Sender...3366
      Oil Cooler By–Pass Valve...3367
    HYDRAULIC VALVE CONTROL HANDLE (11000 Series)...3368
      Removal And Installation...3368
      Disassembly And Assembly...3369
      Control Handle Electrical Harness...3371
    HYDRAULIC VALVE CONTROL HANDLE (12000Series)...3373
      Removal And Installation...3373
      Disassembly And Assembly...3374
    STEERING CONTROL VALVE...3376
      Removal And Installation...3376
      Disassembly...3378
      Inspection...3381
      Assembly...3381
      Checking Steering Relief Valve...3385
    HYDRAULIC RESERVOIR...3386
      Removal And Installation...3386
    PRIORITY VALVE...3388
      Removal And Installation...3388
      Disassembly And Assembly...3388
      Adjustment Of Steering Relief Valve...3388
  HYDROSTATIC SYSTEM...3389
    TROUBLESHOOTING...3391
    HYDROSTATIC SYSTEM INFORMATION...3392
      High Pressure Relief/Replenishing Valve Function...3392
    HYDROSTATIC MOTOR...3393
      Removal And Installation...3393
    MULTI–DISC BRAKE...3396
      Removal And Installation...3396
      Disassembly And Assembly...3396
    HYDROSTATIC PUMP (11000 Series)...3400
      Checking Charge Pressure...3400
      Checking The High Pressure Relief/Replenishing Valve...3400
      Removal And Installation...3401
    HYDROSTATIC PUMP (12000 Series)...3406
      Checking Charge Pressure...3406
      Checking The High Pressure Relief/Replenishing Valve...3406
      Removal And Installation...3407
    DRIVE BELT...3411
      Adjustment...3411
      Removal And Installation...3411
    DRIVE BELT TENSION PULLEY...3413
      Removal And Installation...3413
    FOOT PEDAL CONTROL (11000 Series)...3415
      Removal And Installation...3415
    FOOT PEDAL CONTROL (12000 Series)...3417
      Removal And Installation...3417
    TOWING THE LOADER...3419
      Procedure...3419
  DRIVE SYSTEM...3421
    TROUBLESHOOTING...3423
    DRIVE SHAFT...3424
      Removal And Installation...3424
    AXLE AND DIFFERENTIAL...3425
      Front Axle Removal And Installation...3425
      Rear Axle Removal And Installation...3426
      Oscillation Blocks And Bushings...3427
      Oscillation Frame Removal And Installation...3429
      Axle Hub Housing Removal And Installation...3430
      Axle Hub Housing Disassembly...3430
      Axle Hub Housing Assembly...3434
      Axle Hub Removal And Installation...3437
      Axle Seal Removal And Installation...3438
      Axle End Housing Removal And Installation...3438
      Axle End Housing Disassembly And Assembly...3439
      Axle Housing End Clearance...3443
      Axle End Cover Removal And Installation...3445
      Differential Axle And Seal...3446
      Brake And Drum...3449
      Disassembly Of Differential...3451
      Assembly Of The Differential ...3460
    DROP–BOX GEARCASE...3469
      Removal And Installation...3469
      Disassembly And Assembly...3469
    BRAKE PEDAL MECHANISM...3474
      Removal And Installation...3474
      Disassembly And Assembly...3475
      Brake Pedal Adjustment...3477
  MAIN FRAME...3479
    FLOOR PANEL...3481
      Removal And Installation...3481
    THROTTLE COVER...3483
      Removal And Installation...3483
    SEAT AND SEAT MOUNTING FRAME...3484
      Removal And Installation...3484
    REAR FLOOR PANEL...3485
      Removal And Installation...3485
    ENGINE HOOD...3486
      Removal And Installation...3486
      Hood Adjustment (12000 Series)...3487
    BOB–TACH TILT ROD (11000 Series)...3488
      Removal And Installation...3488
    BOB–TACH TILT ROD (12000 Series)...3490
      Removal And Installation...3490
    TILT TRANSFER ARM (11000 Series)...3492
      Removal And Installation...3492
    TILT TRANSFER ARM (12000 Series)...3493
      Removal And Installation...3493
    BOB–TACH...3494
      Removal And Installation...3494
      Bob–Tach Wedges...3495
    STEERING WHEEL (11000 Series)...3496
      Removal And Installation...3496
    STEERING WHEEL (12000 Series)...3499
      Removal And Installation...3499
    STEERING COLUMN...3502
      Removal And Installation...3502
      Tilt Lock Mechanism...3502
    FUEL TANK...3504
      Removal And Installation...3504
      Fuel Sender...3505
    REAR DOOR (12000 Series)...3506
      Removal And Installation...3506
      Adjustment...3506
    LOADER MAIN FRAME...3507
      Separating The Front And Rear Main Frame...3507
      Bottom Pivot Pin Bearing...3510
      Top Pivot Pin Bearing...3512
  ELECTRICAL SYSTEM...3513
    ELECTRICAL SCHEMATICS...3516
    TROUBLESHOOTING...3541
    ELECTRICAL SYSTEM...3541
      Description...3541
      Electrical Breaker (11000 Series)...3542
      Fuses (11000 Series)...3542
      Fuses (12000 Series)...3543
      80 Amp. Fuse (12000 Series)...3543
      Electrical System Service...3545
    SEALED ELECTRICAL TERMINAL...3545
      Removal And Installation...3545
    DIODES...3545
      Checking The Diodes...3545
    BATTERY...3546
      Checking The Battery...3546
      Removal And Installation (11000 Series)...3546
      Removal And Installation (12000 Series)...3547
    ALTERNATOR...3548
      Belt Tension...3548
      Troubleshooting The Alternator...3548
      Checking The Alternator Output...3549
      Removal And Installation...3550
      Disassembly And Assembly...3550
      Brush Inspection...3554
      Testing Diode–Trio & Rectifier Assembly...3554
      Checking The Stator...3554
      Rotor Testing And Inspection...3555
      Replacing The Rear Rotor Bearing...3555
      Inspection Of Rear Housing...3556
    STARTER (11000 Series)...3557
      Checking The Starter...3557
      Removal And Installation...3557
      Disassembly And Assembly...3558
      Cleaning And Inspection...3558
      Replacing The Brushes...3559
    STARTER (12000 Series)...3560
      Checking The Starter...3560
      Removal And Installation...3560
      Disassembly And Assembly...3561
      Cleaning And Inspection...3563
    INSTRUMENT PANEL (11000 Series)...3564
      Removal And Installation...3564
    INSTRUMENT PANEL (12000 Series)...3565
      Removal And Installation...3565
    SIGNAL LIGHT CONTROL...3567
      Removal And Installation...3567
  ENGINE SERVICE...3569
    TROUBLESHOOTING...3571
    VALVE CLEARANCE...3572
      Adjustment...3572
    AIR CLEANER HOUSING...3572
      Removal And Installation...3572
    FUEL FILTERS...3573
      Water Trap...3573
      Removal And Installation...3573
      Removing Air From The Fuel System...3574
    FUEL LIFT PUMP...3575
      Checking...3575
      Removal And Installation...3575
    FUEL INJECTION PUMP...3576
      Removal And Installation...3576
    TIMING...3579
      Engine Timing To Injection Pump...3579
      Checking Timing Mark On Injection Pump Flange...3580
    FUEL INJECTOR NOZZLES...3581
      Removal And Installation...3581
      Checking...3582
    ENGINE COMPRESSION...3583
      Checking...3583
    COOLANT RECOVERY TANK...3584
      Removal And Installation...3584
    RADIATOR AND OIL COOLER...3585
      Removal And Installation...3585
    RADIATOR FAN...3589
      Removal And Installation...3589
    ENGINE...3590
      Removal And Installation...3590
    ENGINE FLYWHEEL...3591
      Removal And Installation...3591
      Flywheel Ring Gear...3591
    ENGINE MUFFLER...3592
      Removal And Installation...3592
    CYLINDER HEAD...3593
      Removing The Cylinder Head...3593
      Cylinder Head Surface Alignment...3593
      Installing The Cylinder Head...3593
    VALVES...3595
      Removal Of The Valves...3595
      Installing The Valves...3595
      Reconditioning The Valve And Valve Seats...3595
      Installing Valve Guides...3596
      Installing The Valve Seats...3597
      Checking The Valve Springs...3597
    ROCKER ARMS...3598
      Disassembly...3598
      Assembly...3598
    PISTON AND CONNECTING RODS...3599
      Removal...3599
      Disassembly...3600
      Inspection...3600
      Installation...3601
    CYLINDER LINERS...3602
      Inspection...3602
      Removal...3602
      Installation...3602
    MAIN BEARINGS...3603
      Removal...3603
      Installation...3604
      Crankshaft End Play...3604
    CRANKSHAFT...3605
      Removal...3605
      Checking...3605
      Installation...3606
    REAR MAIN OIL SEAL...3606
      Removal And Installation...3606
    TIMING CASE COVER...3607
      Removal And Installation...3607
    IDLER GEAR AND HUB...3608
      Removal And Installation...3608
    CAMSHAFT GEAR...3609
      Removal And Installation...3609
    FUEL INJECTION PUMP GEAR...3609
      Removal...3609
      Installation...3609
    CRANKSHAFT GEAR...3609
      Removal...3609
    TIMING CASE...3610
      Removal And Installation...3610
    CAMSHAFT...3610
      Removal And Installation...3610
    BALANCER UNIT AND OIL PUMP...3612
      Balancer Removal And Installation...3612
      Engine Timing To Balancer Unit...3612
      Oil Pump Removal And Installation...3612
      Oil Pump Inspection...3613
      Oil Pump Relief Valve...3613
      Balancer Disassembly And Assembly...3614
      Inspection...3615
  SPECIFICATIONS...3617
    LOADER SPECIFICATIONS – 2400...3619
      LOADER DIMENSIONS...3619
      OPERATION & PERFORMANCE...3619
      ENGINE...3619
      HYDRAULIC SYSTEM...3620
      ELECTRICAL...3620
      DRIVE SYSTEM...3620
      CAPACITIES...3620
      TIRES...3620
    LOADER SPECIFICATIONS – 2410...3621
      LOADER DIMENSIONS...3621
      OPERATION & PERFORMANCE...3621
      ENGINE...3621
      HYDRAULIC SYSTEM...3622
      ELECTRICAL...3622
      DRIVE SYSTEM...3622
      CAPACITIES...3622
      TIRES...3622
    ENGINE SPECIFICATIONS...3623
      Cylinder Head...3623
      Valve Guides...3623
      Exhaust Valve...3623
      Intake Valve...3623
      Valve Springs...3623
      Rocker Arms & Tappets...3623
      Piston & Piston Rings...3624
      Piston Pin & Bushing...3624
      Cylinder Block & Liners...3624
      Crankshaft, Main Bearings & Thrust Washer...3625
      Connecting Rod and Bearings...3625
      Camshaft & Thrust Washer...3626
      Timing Case & Timing Gears...3626
      Oil Pump, Gear & Relief Valve...3626
      Cooling System & Water Pump...3627
      Fuel Lift Pump...3627
      Fuel Injection Pump & Injectors...3627
      De–Rating for Altitude...3628
      Balancer Unit...3628
      Engine Bolt Torques...3629
      Service Wear Limits...3629
      Crankshaft Re–Grind Data...3630
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...3631
      Specifications...3631
    DECIMAL AND MILLIMETER EQUIVALENTS...3632
    U.S. TO METRIC CONVERSION...3632
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...3633
  SERVICE MANUAL REVISIONS...3635
    2400-1...3635
    2400-2...3637
    2400-3...3639
    2400-4...3641
    2400-5...3643
    2400-6...3645
6720455 (6-12) - 2400 Series Loader Service Manual...3647
  MAINTENANCE SAFETY...3649
  FOREWORD...3651
    CONTENTS...3653
    SAFETY INSTRUCTIONS...3655
    SERIAL NUMBER LOCATIONS...3656
    LOADER SERIAL NUMBER...3656
    ENGINE SERIAL NUMBER...3656
    DELIVERY REPORT...3656
    BOBCAT ARTICULATED LOADER IDENTIFICATION...3657
  PREVENTIVE MAINTENANCE...3659
    SERVICE SCHEDULE...3661
    LIFTING AND BLOCKING THE LOADER...3662
      Procedure...3662
    TRANSPORTING THE LOADER...3663
      Procedure...3663
    LIFT ARM STOP...3664
      Procedure...3664
    STEERING FRAME LOCK...3664
      Procedure...3664
    AIR CLEANER...3665
      Replacement Of Filter Element...3665
    FUEL SYSTEM...3667
      Fuel Specifications...3667
      Filling The Fuel Tank...3667
    ENGINE LUBRICATION SYSTEM...3668
      Checking Engine Oil...3668
      Replacement Of Oil And Filter...3668
    ENGINE COOLANT SYSTEM...3669
      Checking Coolant Level...3669
      Removing Coolant From The Cooling System...3669
      Radiator Side Screen...3670
      Cooling System Maintenance...3670
    USING A BOOSTER BATTERY (JUMP STARTING)...3671
      Procedure...3671
    HYDRAULIC/HYDROSTATIC SYSTEM...3672
      Checking And Adding Fluid...3672
      Hydraulic/Hydrostatic Filter Replacement...3672
      Hydraulic Fluid Replacement...3673
    SPARK ARRESTOR MUFFLER...3674
      Cleaning Procedure...3674
    TIRE MAINTENANCE...3675
      Wheel Nuts...3675
      Tire Rotation...3675
      Tire Inflation...3675
    FRONT AND REAR DIFFERENTIAL...3676
      Checking Differential Oil Level...3676
      Checking Gear–Drop Box Oil Level...3676
      Checking Wheel End Oil Level...3676
    LUBRICATION OF THE LOADER...3677
      Procedure...3677
    BLOWER FILTER (OPERATOR CAB)...3680
      Cleaning The Filter...3680
  HYDRAULIC SYSTEM...3681
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3683
    TROUBLESHOOTING...3713
    HYDRAULIC SYSTEM INFORMATION...3714
      Flare Connections...3714
      O–Ring Face Seal Connection...3714
      Straight Thread O–Ring Fitting...3714
      Tubelines And Hoses...3714
    TILT CYLINDER...3715
      Checking The Tilt Cylinder...3715
      Removal And Installation...3715
      Pivot Pin Seals...3717
      Bucket Anti–Roll Back Linkage Adjustment (11000 Series)...3718
      Bucket Indicator Linkage Adjustment (12000 Series)...3719
    LIFT CYLINDER...3720
      Checking The Lift Cylinder...3720
      Removal And Installation...3721
    STEERING CYLINDER...3723
      Checking The Steering Cylinder...3723
      Removal And Installation...3723
      Rod End Bearing...3724
    HYDRAULIC CONTROL VALVE (11000 Series)...3725
      Checking The Main Relief Valve...3725
      Main Relief Valve...3725
      Removal And Installation...3726
    HYDRAULIC CONTROL VALVE (12000 Series)...3730
      Checking The Main Relief Valve...3730
      Main Relief Valve...3730
      Removal And Installation...3731
    BUCKET POSITION VALVE...3734
      Removal And Installation...3734
    HYDRAULIC PUMP (11000 Series)...3736
      Checking Hydraulic Pump Output (Small Section)...3736
      Checking Hydraulic Pump Output (Large Section)...3737
      Removal And Installation...3739
    HYDRAULIC PUMP (12000 Series)...3741
      Checking Hydraulic Pump Output (Small Section)...3741
      Checking Hydraulic Pump Output (Large Section)...3742
      Removal And Installation...3743
    PORT BLOCK (11000 Series)...3745
      Removal And Installation...3745
      Normally–Open Switch...3748
      Charge Pressure Switch...3749
      Temperature Sender...3749
      Oil Cooler By–Pass Valve...3750
      Two–Speed Solenoid...3750
    PORT BLOCK (12000 Series)...3752
      Removal And Installation...3752
      Two–Speed Solenoid...3754
      Normally–Open Switch...3755
      Temperature Sender...3756
      Oil Cooler By–Pass Valve...3757
    HYDRAULIC VALVE CONTROL HANDLE (11000 Series)...3758
      Removal And Installation...3758
      Disassembly And Assembly...3759
      Control Handle Electrical Harness...3761
    HYDRAULIC VALVE CONTROL HANDLE (12000Series)...3763
      Removal And Installation...3763
      Disassembly And Assembly...3764
    STEERING CONTROL VALVE...3766
      Removal And Installation...3766
      Disassembly...3768
      Inspection...3771
      Assembly...3771
      Checking Steering Relief Valve...3775
    HYDRAULIC RESERVOIR...3776
      Removal And Installation...3776
    PRIORITY VALVE...3778
      Removal And Installation...3778
      Disassembly And Assembly...3778
      Adjustment Of Steering Relief Valve...3778
  HYDROSTATIC SYSTEM...3779
    TROUBLESHOOTING...3781
    HYDROSTATIC SYSTEM INFORMATION...3782
      High Pressure Relief/Replenishing Valve Function...3782
    HYDROSTATIC MOTOR...3783
      Removal And Installation...3783
    MULTI–DISC BRAKE...3786
      Removal And Installation...3786
      Disassembly And Assembly...3786
    HYDROSTATIC PUMP (11000 Series)...3790
      Checking Charge Pressure...3790
      Checking The High Pressure Relief/Replenishing Valve...3790
      Removal And Installation...3791
    HYDROSTATIC PUMP (12000 Series)...3796
      Checking Charge Pressure...3796
      Checking The High Pressure Relief/Replenishing Valve...3796
      Removal And Installation...3797
    DRIVE BELT...3801
      Adjustment...3801
      Removal And Installation...3801
    DRIVE BELT TENSION PULLEY...3803
      Removal And Installation...3803
    FOOT PEDAL CONTROL (11000 Series)...3805
      Removal And Installation...3805
    FOOT PEDAL CONTROL (12000 Series)...3807
      Removal And Installation...3807
    TOWING THE LOADER...3809
      Procedure...3809
  DRIVE SYSTEM...3811
    TROUBLESHOOTING...3813
    DRIVE SHAFT...3814
      Removal And Installation...3814
    AXLE AND DIFFERENTIAL...3815
      Front Axle Removal And Installation...3815
      Rear Axle Removal And Installation...3816
      Oscillation Blocks And Bushings...3817
      Oscillation Frame Removal And Installation...3819
      Axle Hub Housing Removal And Installation...3820
      Axle Hub Housing Disassembly...3820
      Axle Hub Housing Assembly...3824
      Axle Hub Removal And Installation...3827
      Axle Seal Removal And Installation...3828
      Axle End Housing Removal And Installation...3828
      Axle End Housing Disassembly And Assembly...3829
      Axle Housing End Clearance...3833
      Axle End Cover Removal And Installation...3835
      Differential Axle And Seal...3836
      Brake And Drum...3839
      Disassembly Of Differential...3841
      Assembly Of The Differential ...3850
    DROP–BOX GEARCASE...3859
      Removal And Installation...3859
      Disassembly And Assembly...3859
    BRAKE PEDAL MECHANISM...3864
      Removal And Installation...3864
      Disassembly And Assembly...3865
      Brake Pedal Adjustment...3867
  MAIN FRAME...3869
    FLOOR PANEL...3871
      Removal And Installation...3871
    THROTTLE COVER...3873
      Removal And Installation...3873
    SEAT AND SEAT MOUNTING FRAME...3874
      Removal And Installation...3874
    REAR FLOOR PANEL...3875
      Removal And Installation...3875
    ENGINE HOOD...3876
      Removal And Installation...3876
      Hood Adjustment (12000 Series)...3877
    BOB–TACH TILT ROD (11000 Series)...3878
      Removal And Installation...3878
    BOB–TACH TILT ROD (12000 Series)...3880
      Removal And Installation...3880
    TILT TRANSFER ARM (11000 Series)...3882
      Removal And Installation...3882
    TILT TRANSFER ARM (12000 Series)...3883
      Removal And Installation...3883
    BOB–TACH...3884
      Removal And Installation...3884
      Bob–Tach Wedges...3885
    STEERING WHEEL (11000 Series)...3886
      Removal And Installation...3886
    STEERING WHEEL (12000 Series)...3889
      Removal And Installation...3889
    STEERING COLUMN...3892
      Removal And Installation...3892
      Tilt Lock Mechanism...3892
    FUEL TANK...3894
      Removal And Installation...3894
      Fuel Sender...3895
    REAR DOOR (12000 Series)...3896
      Removal And Installation...3896
      Adjustment...3896
    LOADER MAIN FRAME...3897
      Separating The Front And Rear Main Frame...3897
      Bottom Pivot Pin Bearing...3900
      Top Pivot Pin Bearing...3902
  ELECTRICAL SYSTEM...3903
    ELECTRICAL SCHEMATICS...3906
    TROUBLESHOOTING...3931
    ELECTRICAL SYSTEM...3931
      Description...3931
      Electrical Breaker (11000 Series)...3932
      Fuses (11000 Series)...3932
      Fuses (12000 Series)...3933
      80 Amp. Fuse (12000 Series)...3933
      Electrical System Service...3935
    SEALED ELECTRICAL TERMINAL...3935
      Removal And Installation...3935
    DIODES...3935
      Checking The Diodes...3935
    BATTERY...3936
      Checking The Battery...3936
      Removal And Installation (11000 Series)...3936
      Removal And Installation (12000 Series)...3937
    ALTERNATOR...3938
      Belt Tension...3938
      Troubleshooting The Alternator...3938
      Checking The Alternator Output...3939
      Removal And Installation...3940
      Disassembly And Assembly...3940
      Brush Inspection...3944
      Testing Diode–Trio & Rectifier Assembly...3944
      Checking The Stator...3944
      Rotor Testing And Inspection...3945
      Replacing The Rear Rotor Bearing...3945
      Inspection Of Rear Housing...3946
    STARTER (11000 Series)...3947
      Checking The Starter...3947
      Removal And Installation...3947
      Disassembly And Assembly...3948
      Cleaning And Inspection...3948
      Replacing The Brushes...3949
    STARTER (12000 Series)...3950
      Checking The Starter...3950
      Removal And Installation...3950
      Disassembly And Assembly...3951
      Cleaning And Inspection...3953
    INSTRUMENT PANEL (11000 Series)...3954
      Removal And Installation...3954
    INSTRUMENT PANEL (12000 Series)...3955
      Removal And Installation...3955
    SIGNAL LIGHT CONTROL...3957
      Removal And Installation...3957
  ENGINE SERVICE...3959
    TROUBLESHOOTING...3961
    VALVE CLEARANCE...3962
      Adjustment...3962
    AIR CLEANER HOUSING...3962
      Removal And Installation...3962
    FUEL FILTERS...3963
      Water Trap...3963
      Removal And Installation...3963
      Removing Air From The Fuel System...3964
    FUEL LIFT PUMP...3965
      Checking...3965
      Removal And Installation...3965
    FUEL INJECTION PUMP...3966
      Removal And Installation...3966
    TIMING...3969
      Engine Timing To Injection Pump...3969
      Checking Timing Mark On Injection Pump Flange...3970
    FUEL INJECTOR NOZZLES...3971
      Removal And Installation...3971
      Checking...3972
    ENGINE COMPRESSION...3973
      Checking...3973
    COOLANT RECOVERY TANK...3974
      Removal And Installation...3974
    RADIATOR AND OIL COOLER...3975
      Removal And Installation...3975
    RADIATOR FAN...3979
      Removal And Installation...3979
    ENGINE...3980
      Removal And Installation...3980
    ENGINE FLYWHEEL...3981
      Removal And Installation...3981
      Flywheel Ring Gear...3981
    ENGINE MUFFLER...3982
      Removal And Installation...3982
    CYLINDER HEAD...3983
      Removing The Cylinder Head...3983
      Cylinder Head Surface Alignment...3983
      Installing The Cylinder Head...3983
    VALVES...3985
      Removal Of The Valves...3985
      Installing The Valves...3985
      Reconditioning The Valve And Valve Seats...3985
      Installing Valve Guides...3986
      Installing The Valve Seats...3987
      Checking The Valve Springs...3987
    ROCKER ARMS...3988
      Disassembly...3988
      Assembly...3988
    PISTON AND CONNECTING RODS...3989
      Removal...3989
      Disassembly...3990
      Inspection...3990
      Installation...3991
    CYLINDER LINERS...3992
      Inspection...3992
      Removal...3992
      Installation...3992
    MAIN BEARINGS...3993
      Removal...3993
      Installation...3994
      Crankshaft End Play...3994
    CRANKSHAFT...3995
      Removal...3995
      Checking...3995
      Installation...3996
    REAR MAIN OIL SEAL...3996
      Removal And Installation...3996
    TIMING CASE COVER...3997
      Removal And Installation...3997
    IDLER GEAR AND HUB...3998
      Removal And Installation...3998
    CAMSHAFT GEAR...3999
      Removal And Installation...3999
    FUEL INJECTION PUMP GEAR...3999
      Removal...3999
      Installation...3999
    CRANKSHAFT GEAR...3999
      Removal...3999
    TIMING CASE...4000
      Removal And Installation...4000
    CAMSHAFT...4000
      Removal And Installation...4000
    BALANCER UNIT AND OIL PUMP...4002
      Balancer Removal And Installation...4002
      Engine Timing To Balancer Unit...4002
      Oil Pump Removal And Installation...4002
      Oil Pump Inspection...4003
      Oil Pump Relief Valve...4003
      Balancer Disassembly And Assembly...4004
      Inspection...4005
  SPECIFICATIONS...4007
    LOADER SPECIFICATIONS – 2400...4009
      LOADER DIMENSIONS...4009
      OPERATION & PERFORMANCE...4009
      ENGINE...4009
      HYDRAULIC SYSTEM...4010
      ELECTRICAL...4010
      DRIVE SYSTEM...4010
      CAPACITIES...4010
      TIRES...4010
    LOADER SPECIFICATIONS – 2410...4011
      LOADER DIMENSIONS...4011
      OPERATION & PERFORMANCE...4011
      ENGINE...4011
      HYDRAULIC SYSTEM...4012
      ELECTRICAL...4012
      DRIVE SYSTEM...4012
      CAPACITIES...4012
      TIRES...4012
    ENGINE SPECIFICATIONS...4013
      Cylinder Head...4013
      Valve Guides...4013
      Exhaust Valve...4013
      Intake Valve...4013
      Valve Springs...4013
      Rocker Arms & Tappets...4013
      Piston & Piston Rings...4014
      Piston Pin & Bushing...4014
      Cylinder Block & Liners...4014
      Crankshaft, Main Bearings & Thrust Washer...4015
      Connecting Rod and Bearings...4015
      Camshaft & Thrust Washer...4016
      Timing Case & Timing Gears...4016
      Oil Pump, Gear & Relief Valve...4016
      Cooling System & Water Pump...4017
      Fuel Lift Pump...4017
      Fuel Injection Pump & Injectors...4017
      De–Rating for Altitude...4018
      Balancer Unit...4018
      Engine Bolt Torques...4019
      Service Wear Limits...4019
      Crankshaft Re–Grind Data...4020
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...4021
      Specifications...4021
    DECIMAL AND MILLIMETER EQUIVALENTS...4022
    U.S. TO METRIC CONVERSION...4022
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...4023
  SERVICE MANUAL REVISIONS...4025
    2400-1...4025
    2400-2...4027
    2400-3...4029
    2400-4...4031
    2400-5...4033
    2400-6...4035
    2400-7...4037
6722326 (11-92) - 2410 Operation & Maintenance Manual...4039
  OPERATOR SAFETY WARNINGS...4041
  CONTENTS...4043
    REFERENCE INFORMATION...4043
  FOREWORD...4045
    SERIAL NUMBER LOCATIONS...4047
      LOADER SERIAL NUMBER...4047
      ENGINE SERIAL  NUMBER...4047
    DELIVERY REPORT...4047
    BOBCAT LOADER IDENTIFICATION...4048
  SAFETY...4049
    SAFETY INSTRUCTIONS...4051
    FIRE PREVENTION...4053
    SAFETY SIGNS (DECALS)...4054
  OPERATING INSTRUCTIONS...4057
    INSTRUMENT PANEL...4059
    THROTTLE CONTROL...4060
    PARKING BRAKE...4060
    TRANSMISSION RANGE SELECTOR...4061
    STEERING AND FOOT PEDAL...4062
      Foot Pedal Control...4062
      Steering Wheel...4062
    HYDRAULIC CONTROLS...4063
      Lift Arm Operation...4063
      Bucket Position Valve Operation...4063
      Auxiliary Hydraulic Operation...4064
      Constant Flow Operation...4064
      Release Hydraulic Pressure At Couplers...4064
    DAILY INSPECTION...4065
    COUNTERWEIGHT...4066
    GETTING READY FOR OPERATION...4066
      Standard Seat...4067
      Deluxe Seat (W/Enclosed *Cab)...4068
      Restraint Arm & Steering Wheel...4069
    STARTING THE ENGINE...4069
      Normal Starting Condition...4070
      Cold Temperature Starting...4071
      Warming The Hydrostatic Transmission...4071
    ATTACHMENTS & BUCKETS...4072
      Rated Operating Capacity...4072
      Installation Of Bucket (Attachment)...4073
      Removing The Bucket (Attachment)...4073
      Bucket Indicator Linkage Adjustment...4074
    OPERATING PROCEDURE...4075
      Operating On Slopes...4075
      Filling The Bucket...4076
      Emptying The Bucket...4076
      Digging Into The Ground...4077
      Leveling The Ground...4077
      Backfilling...4078
    PARKING THE LOADER...4078
    TRANSPORTING THE LOADER...4079
  PREVENTIVE MAINTENANCE...4081
    MAINTENANCE SAFETY...4082
    SERVICE SCHEDULE...4083
    LIFT ARM SUPPORT DEVICE...4084
    STEERING FRAME LOCK...4084
    ENGINE HOOD...4085
    ENGINE REAR DOORS...4085
    AIR CLEANER...4086
    FUEL SYSTEM...4088
      Fuel Specifications...4088
      Filling The Fuel Tank...4088
      Fuel Filter...4088
      Removing Air From The Fuel System...4090
    ENGINE LUBRICATION SYSTEM...4091
      Oil & Filter Replacement...4091
    COOLING SYSTEM...4092
      Radiator Side Screen...4092
      Cooling System Maintenance...4092
      Checking Coolant Level...4093
      Removing Coolant From The Cooling System...4093
    ALTERNATOR BELT...4094
      Adjusting The Alternator Belt...4094
    ELECTRICAL SYSTEM...4095
      Description...4095
      Electrical System Service...4095
      Fuses...4095
      Using A Booster Battery (Jump Starting)...4096
      Battery Removal And Installation...4097
    HYDRAULIC / HYDROSTATIC SYSTEM...4099
      Checking And Adding Fluid...4099
      Hydraulic / Hydrostatic Filter Replacement...4099
      Hydraulic Fluid Replacement...4100
    SPARK ARRESTOR MUFFLER...4101
    TIRE MAINTENANCE...4102
      Wheel Nuts...4102
      Tire Rotation...4102
      Tire Inflation...4102
    FRONT AND REAR DIFFERENTIAL...4103
      Checking Differential Oil Level...4103
      Checking Gear-Drop Box Oil Level...4103
      Checking Wheel End Oil Level...4103
    LUBRICATION OF THE LOADER...4104
    BOB-TACH...4107
    BLOWER FILTER (OPERATOR CAB)...4107
  TROUBLESHOOTING...4109
    TROUBLESHOOTING THE ENGINE...4111
    TROUBLESHOOTING THE DRIVE SYSTEM...4112
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...4113
  SPECIFICATIONS...4115
    LOADER DIMENSIONS...4117
    OPERATION AND PERFORMANCE...4117
    ENGINE...4117
    HYDRAULIC SYSTEM...4118
    ELECTRICAL...4118
    DRIVE SYSTEM...4118
    CAPACITIES...4118
    TIRES...4118
  WARRANTY...4119
6722327 (3-93) - 2410 Service Manual...4121
  MAINTENANCE SAFETY...4123
  CONTENTS...4125
    FOREWORD...4127
    SAFETY INSTRUCTIONS...4129
    SERIAL NUMBER LOCATIONS...4130
    LOADER SERIAL NUMBER...4130
    ENGINE SERIAL NUMBER...4130
    DELIVERY REPORT...4130
    BOBCAT ARTICLATED LOADER IDENTIFICATION...4131
  PREVENTIVE MAINTENANCE...4133
    SERVICE SCHEDULE...4135
    LIFTING AND BLOCKING THE LOADER...4136
      Procedure...4136
    TRANSPORTING THE LOADER...4137
      Procedure...4137
    LIFT ARM SUPPORT DEVICE...4138
      Procedure...4138
    STEERING FRAME LOCK...4138
      Procedure...4138
    AIR CLEANER...4139
      Replacement Of Filter Element...4139
    FUEL SYSTEM...4141
      Fuel Specifications...4141
      Filling The Fuel Tank...4141
    ENGINE LUBRICATION SYSTEM...4142
      Checking Engine Oil...4142
      Replacement Of Oil And Filter...4142
    ENGINE COOLANT SYSTEM...4143
      Checking Coolant Level...4143
      Removing Coolant From The Cooling System...4143
      Radiator Side Screen...4144
      Cooling System Maintenance...4144
    USING A BOOSTER BATTERY (JUMP STARTING)...4145
      Procedure...4145
    HYDRAULIC / HYDROSTATIC SYSTEM...4146
      Checking And Adding Fluid...4146
      Hydraulic/Hydrostatic Filter Replacement...4146
      Hydraulic Fluid Replacement...4147
    SPARK ARRESTOR MUFFLER...4148
      Cleaning Procedure...4148
    TIRE MAINTENANCE...4149
      Wheel Nuts...4149
      Tire Rotation...4149
      Tire Inflation...4149
    FRONT AND REAR DIFFERENTIAL...4150
      Checking Differential Oil Level...4150
      Checking Gear-Drop Box Oil Level...4150
      Checking Wheel End Oil Level...4150
    LUBRICATION OF THE LOADER...4151
      Procedure...4151
    BLOWER FILTER (OPERATOR CAB)...4154
      Cleaning The Filter...4154
  HYDRAULIC SYSTEM...4155
    HYDRAULIC / HYDROSTATIC SCHEMATICS...4157
    TROUBLESHOOTING...4169
    HYDRAULIC SYSTEM INFORMATION...4170
      Flare Connections...4170
      O-Ring Face Seal Connectin...4170
      Straight Thread O-Ring Fitting...4170
      Tubelines And Hoses...4170
    TILT CYLINDER...4171
      Checking The Tilt Cylinder...4171
      Removal And Installation...4171
      Tilt Cylinder Base End Pivot Pin...4172
      Pivot Pin Seals...4173
      Bucket Indicator Linkage Adjustment...4173
    LIFT CYLINDER...4174
      Checking The Lift Cylinder...4174
      Removal And Installation...4175
    STEERING CYLINDER...4177
      Checking The Steering Cylinder...4177
      Removal And Installation...4177
      Rod End Bearing...4178
    HYDRAULIC CONTROL VALVE...4179
      Checking The Main Relief Valve...4179
      Main Relief Valve...4179
      Removal And Installation...4180
    BUCKET POSITION VALVE...4184
      Removal And Installation...4184
    HYDRAULIC PUMP...4186
      Checking Hydraulic Pump Output (Small Section)...4186
      Checking Hydraulic Pump Output (Large Section)...4187
      Removal And Installation...4188
    HYDRAULIC CONTROL LEVER...4190
      Removal And Installation...4190
      Disassembly And Assembly...4191
    STEERING CONTROL VALVE...4193
      Removal And Installation...4193
      Disassembly...4195
      Checking Steering Relief Valve...4202
      Assembly...4197
    PRIORITY VALVE...4203
      Removal And Installation...4203
      Disassembly And Assembly...4204
      Adjustment Of Steering Relief Valve...4204
    HYDRAULIC RESERVOIR...4205
      Removal And Installation...4205
    HYDRAULIC FILTER HOUSING...4207
      Oil Cooler By-Pass...4207
      Removal And Installation...4207
  HYDROSTATIC SYSTEM...4209
    TROUBLESHOOTING...4211
    HYDROSTATIC SYSTEM INFORMATION...4212
      High Pressure Relief/Replenishing Valve Function...4212
    HYDROSTATIC MOTOR...4213
      Removal And Installation...4213
    MULTI-DISC BRAKE...4216
      Removal And Installation...4216
      Disassembly And Assembly...4216
    HYDROSTATIC PUMP...4220
      Checking Charge Pressure...4220
      Removal And Installation...4221
    DRIVE BELT...4225
      Removal And Installation...4225
    TENSION ARM & PULLEY...4228
      Disassembly And Assembly...4228
    FOOT PEDAL CONTROL...4231
      Removal And Installation...4231
  DRIVE SYSTEM...4233
    TROUBLESHOOTING...4235
    DRIVE SHAFT...4236
      Removal And Installation...4236
    AXLE AND DIFFERENTIAL...4237
      Front Axle Removal And Installation...4237
      Rear Axle Removal And Installation...4238
      Oscillation Blocks And Bushings...4239
      Oscillation Frame Removal And Installation...4240
      Axle Hub Removal And Installation...4241
      Axle Seal Removal And Installation...4242
      Axle End Housing Removal And Installation...4243
      Axle End Housing Disassembly And Assembly...4243
      Axle Housing End Clearance...4247
      Axle Hub Shaft End Play...4249
      Differential Axle Removal And Installation...4249
      Differential Axle And Seal...4250
      Brake And Drum...4253
      Disassembly Of Differential...4254
      Assembly Of Differential...4263
    DROP-BOX GEARCASE...4271
      Removal And Installation...4271
      Disassembly And Assembly...4272
    BRAKE PEDAL MECHANISM...4276
      Removal And Installation...4276
      Disassembly And Assenbly...4277
      Brake Pedal Adjustment...4279
  MAIN FRAME...4281
    FLOOR PANEL...4283
      Removal And Installation...4283
    THROTTLE COVER...4285
      Removal And Installation...4285
    SEAT AND SEAT MOUNTING FRAME...4286
      Removal And Installation...4286
    REAR FLOOR PANEL...4287
      Removal And Installation...4287
    ENGINE HOOD...4288
      Removal And Installation...4288
      Hood Adjustment...4289
    FRONT BUMPER...4289
      Removal And Installation...4289
    BOB-TACH TILT ROD...4290
      Removal And Installation...4290
    TILT TRANSFER ARM...4292
      Removal And Installation...4292
    BOB-TACH...4293
      Removal And Installation...4293
      Bob-Tach Lever And Wedge...4294
    STEERING WHEEL...4296
      Removal And Installation...4296
    STEERING COLUMN...4299
      Removal And Installation...4299
      Tilt Lock Mechanism...4299
    FUEL TANK...4301
      Removal And Installation...4301
      Fuel Sender...4302
    REAR DOOR...4303
      Removal And Installation...4303
      Adjustment...4303
    LOADER MAIN FRAME...4304
      Seperating The Front And Rear Main Frame...4304
      Bottom Pivot Pin Bearing...4307
      Top Pivot Pin Bearing...4308
  ELECTRICAL SYSTEM...4309
    ELECTRICAL SCHEMATICS...4312
    TROUBLESHOOTING...4321
    ELECTRICAL SYSTEM...4321
      Description...4321
      Fuses...4322
      In-Line Master Fuse...4322
      Electrical System Service...4324
    SEALED ELECTRICAL TERMINAL...4324
      Removal And Installation...4324
    DIODES...4324
      Checking The Diodes...4324
    BATTERY...4325
      Checking The Battery...4325
      Removal And Installation...4325
    ALTERNATOR...4326
      Belt Tension...4326
      Troubleshooting The Alternator...4327
      Checking The Alternator Output...4328
      Removal And Installation...4329
      Disassembly And Assembly...4329
      Brush Inspection...4333
      Testing Diode-Trio & Rectifier Assemble...4333
      Checking The Stator...4333
      Rotor Testing And Inspection...4334
      Replacing The Rear Rotor Bearing...4334
      Inspection Of Rear Housing...4335
    STARTER...4336
      Checking The Starter...4336
      Removal And Installation...4336
      Disassembly And Assembly...4337
      Cleaning And Inspection...4339
    INSRTUMENT PANEL...4340
      Removal And Installation...4340
    SIGNAL LIGHT CONTROL...4342
      Removal And Installation...4342
  ENGINE SERVICE...4343
    TROUBLESHOOTING...4345
    VALVE CLEARANCE...4346
      Adjustment...4346
    AIR CLEANER HOUSING...4346
      Removal And Installation...4346
    FUEL FILTER...4347
      Water Trap...4347
      Removal And Installation...4347
      Removing Air From The Fuel System...4348
    FUEL LIFT PUMP...4349
      Checking...4349
      Removal And Installation...4349
    FUEL INJECTION PUMP...4350
      Removal And Installation...4350
    TIMING...4353
      Engine Timing To Injection Pump...4353
      Checking Timing Mark On Injection Pump Flange...4354
    FUEL INJECTOR NOZZLES...4355
      Removal And Installation...4355
      Checking...4356
    ENGINE COMPRESSION...4357
      Checking...4357
    COOLANT RECOVERY TANK...4358
      Removal And Installation...4358
    RADIATOR AND OIL COOLER...4359
      Removal And Installation...4359
    RADIATOR FAN...4363
      Removal And Installation...4363
    ENGINE...4364
      Removal And Installation...4364
    ENGINE FLYWHEEL...4366
      Removal And Installation...4366
      Flywheel Ring Gear...4366
    ENGINE MUFFLER...4367
      Removal And Installation...4367
    CYLINDER HEAD...4369
      Removing The Cylinder Head...4369
      Cylinder Head Surface Alignment...4369
      Installing The Cylinder Head...4369
    VALVES...4371
      Removal Of The Valves...4371
      Installing The Valves...4371
      Reconditioning The Valve And Valve Seats...4371
      Installing Valve Guides...4372
      Installing The Valve Seats...4373
      Checking The Valve Springs...4373
    ROCKER ARMS...4374
      Disassembly...4374
      Assembly...4374
    PISTON AND CONNECTING RODS...4375
      Removal...4375
      Disassembly...4376
      Inspection...4376
      Installation...4377
    CYLINDER LINERS...4378
      Inspection...4378
      Removal...4378
      Installation...4378
    MAIN BEARINGS...4379
      Removal...4379
      Installation...4380
      Crankshaft End Play...4380
    CRANKSHAFT...4381
      Removal...4381
      Checking...4381
      Installation...4382
    REAR MAIN OIL SEAL...4382
      Removal And Installation...4382
    TIMING CASE COVER...4383
      Removal And Installation...4383
    IDLER GEAR AND HUB...4384
      Removal And Installation...4384
    CAMSHAFT GEAR...4385
      Removal And Installation...4385
    FUEL INJECTION PUMP GEAR...4385
      Removal...4385
      Installation...4385
    CRANKSHAFT GEAR...4385
      Removal...4385
    TIMING CASE...4386
      Removal And Installation...4386
    CAMSHAFT...4386
      Removal And Installation...4386
    WATER PUMP...4387
      Disassembly Of The Water Pump...4387
      Inspection Of The Water Pump...4387
      Assembly Of The Water Pump...4388
    BALANCER UNIT AND OIL PUMP...4390
      Balancer Removal And Installation...4390
      Engine Timing To Balancer Unit...4390
      Oil Pump Removal And Installation...4390
      Oil Pump Inspection...4391
      Oil Pump Relief Valve...4391
      Balancer Disassembly And Assembly...4392
      Inspection...4393
      Installing Balancer Bushings...4393
  SPECIFICATIONS...4395
    LOADER SPECIFICATIONS...4397
      Loader Dimensions...4397
      Operation & Performance...4397
      Engine...4397
      Hydraulic System...4398
      Electrical...4398
      Drive System...4398
      Capacities...4398
      Tires...4398
    ENGINE SPECIFICATIONS...4399
      Cylinder Head...4399
      Valve Guides...4399
      Exhaust Valve...4399
      Intake Valve...4399
      Valve Springs...4399
      Rocker Arms & Tappets...4399
      Piston & Piston Rings...4400
      Piston Pin & Bushing...4400
      Cylinder Block & Liners...4400
      Crankshaft, Main Bearings & Thrust Washer...4401
      Connecting Rod And Bearings...4401
      Camshaft & Thrust Washer...4402
      Timing Case & Timing Gears...4402
      Oil Pump, Gear & Relief Valve...4402
      Cooling System & Water Pump...4403
      Fuel Lift Pump...4403
      Fuel Injection Pump & Injectors...4403
      De-Rating For Altitude...4404
      Balancer Unit...4404
      Engine Bolt Torques...4405
      Service Wear Limits...4405
      Crankshaft Re-Grind Data...4406
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4407
    DECIMAL AND MILLIMETER EQUIVALENTS...4408
    U.S. TO METRIC CONVERSION...4408
    STANDARD TORQUE SPECIFICATION FOR BOLTS...4409
  SERVICE MANUAL REVISIONS...4411
    2410-1...4411
    2410-2...4413
    2410-3...4415
6901986 (5-09) - 2100, 2100S Operation & Maintenance Manual...4417
  Safety Decal and Feature Identification...4422
    2100...4423
    2100...4424
    2100S...4425
    2100S...4426
  Practice Safety...4427
  Proposition 65 - State of California...4427
  Safety Details...4428
  General Warnings...4429
  General Information...4430
  Model Identification...4430
  Controls and Indicators...4431
    KEY SWITCH...4431
    FORWARD/REVERSE CONTROL...4432
    Accelerator Pedal...4432
    Brake Pedal...4433
    Park Brake...4433
    CHOKE...4433
    Differential Lock...4434
    Low Oil Warning Light...4434
    Fuel Gauge/Hour Meter...4434
    Headlight control...4435
  Seat Latch and Adjustment...4435
  Pre-Operation and Daily Safety Checklist...4435
  Performance Inspection...4436
  Driving Instructions...4437
    Starting the vehicle...4438
    Stopping the vehicle...4439
    Parking and leaving the vehicle...4439
  Bed Latch and Prop Rod...4439
  Front Shock Absorbers...4440
  Loading and Unloading...4441
  Towing with the Vehicle...4442
  Transporting on a Trailer...4442
  Storage...4443
    Preparing the Vehicle for Extended Storage...4443
    Returning the Stored Vehicle to Service...4445
  Maintenance...4446
  Periodic Service Schedule...4447
  Periodic Lubrication Schedule...4449
  Master Cylinder...4450
    Brake Fluid...4450
  Engine Oil...4451
    Engine Oil Level Check...4451
    Engine Oil And Filter Change...4451
    Oil Viscosity...4455
  Fueling Instructions...4455
  Battery...4456
  Cleaning the Vehicle...4458
  Accessories...4459
    Electric Winch Accessory...4459
  Subsequent Owner Registration...4459
  Vehicle Specifications...4460
    Bobcat Utility Vehicles...4462
6901987 (5-09) - 2100, 2100S Service Manual...4469
  Section 1 - Safety...4483
  General Warning...4483
  Section 2 - Vehicle Specifications...4487
  Section 3 - General Information...4489
  General Information...4489
  Serial Number Identification...4489
  Storage...4490
    Preparing the Vehicle for Extended Storage...4490
    To Return Vehicle to Service...4490
  Section 4 - Body and Trim...4493
  Cleaning the Vehicle...4493
  Front Body Repair...4493
    Abrasions and Haze...4493
    Light Scratches...4494
    Large Scratches and Abrasions...4494
  Front Body Components...4494
    Dashboard Removal...4494
    Dashboard Installation...4494
    Front Body Removal...4495
    Front Fender Removal...4495
    Front Fender Installation...4496
    Front Body Installation...4496
  Seat...4496
    Seat Adjustment...4496
  Front Seat Support...4498
    Front Seat Support Removal...4498
    Front Seat Support Installation...4499
  Rear Seat Support...4499
    Rear Seat Support Removal...4499
    Rear Seat Support Installation...4499
  Cargo Bed...4501
    Cargo Bed Removal...4501
    Cargo Bed Installation...4501
    Bed Stop Bumper Adjustment...4503
  Rear Fender...4504
    Rear Fender Removal...4504
    Rear Fender Installation...4504
  Tailskirt...4504
    Tailskirt Removal...4504
    Tailskirt Installation...4504
  Receiver Hitch...4504
    Receiver Hitch Removal...4504
    Receiver Hitch Installation...4505
  Floor Mat...4506
    Floor Mat Removal...4506
    Floor Mat Installation...4506
  Section 5 - Accelerator and Brake Pedal Assemblies...4507
  Brake Pedal...4507
    Brake Pedal Removal...4507
    Brake Pedal Installation...4507
  Brake Pedal Adjustment...4508
  Accelerator Pedal...4510
    Accelerator Pedal Removal...4510
    Accelerator Pedal Installation...4511
  Accelerator Pedal Adjustment...4511
  Section 6 - MC012C-AS00 Transaxle: Hydraulic and Park Brake Systems...4515
  Brake System Inspection...4515
  Brake System Troubleshooting...4517
  Brake Drum Removal...4520
    Front Wheel Brake Drum Removal...4520
    Rear Wheel Brake Drum Removal...4522
  Brake Shoe Removal...4522
    Front Brake Shoe Removal...4522
    Rear Brake Shoe Removal...4523
  Brake Cluster Inspection and Cleaning...4524
  Brake Shoe Installation...4525
    Front Brake Shoe Installation...4526
    Rear Brake Shoe Installation...4526
  Brake Drum Installation...4528
    Front Wheel Brake Drum Installation...4528
    Rear Wheel Brake Drum Installation...4530
  Brake Cluster Assembly Replacement...4531
    Front Brake Cluster Assembly Removal...4531
    Front Brake Cluster Assembly Installation...4531
    Rear Brake Cluster Assembly Removal...4532
    Rear Brake Cluster Assembly Installation...4533
  Wheel Cylinder Replacement...4533
    Front Wheel Cylinder Removal...4533
    Front Wheel Cylinder Installation...4534
    Rear Wheel Cylinder Removal...4534
    Rear Wheel Cylinder Installation...4534
  Brake Shoe Adjuster Replacement...4535
    Front Brake Shoe Adjuster Removal...4536
    Front Brake Shoe Adjuster Installation...4536
    Rear Brake Shoe Adjuster Removal...4536
    Rear Brake Shoe Adjuster Installation...4536
  Hydraulic Line and Hose Replacement...4537
    Front Brake Line Removal...4537
    Front Brake Line Installation...4537
    Front Brake Hose Assembly Removal...4538
    Front Brake Hose Assembly Installation...4538
    Rear Brake Line Removal...4538
    Rear Brake Line Installation...4540
    Rear Brake Hose Removal...4540
    Rear Brake Hose Installation...4541
  Master Cylinder And Bell Crank Replacement...4541
    Bell Crank Removal...4541
    Bell Crank Installation...4541
    Master Cylinder Removal...4543
    Master Cylinder Installation...4543
  Bleeding the Hydraulic Brake System...4545
    Purging the Hydraulic System...4546
    Filling the Hydraulic System...4546
  Park Brake System...4547
    Park Brake Cable Removal...4547
    Park Brake Cable Installation...4548
    Park Brake Handle Removal...4549
    Park Brake Handle Installation...4549
    Park Brake Adjustment...4549
  Section 7 - Steering and Front Suspension...4553
  Steering Wheel...4553
    Steering Wheel Removal...4553
    Steering Wheel Installation...4555
  Steering Column...4555
    Steering Column Removal...4555
    Steering Column Disassembly...4555
    Steering Column Assembly...4556
    Steering Column Installation...4556
  Rack and Pinion...4557
    Rack and Pinion Removal...4557
    Rack and Pinion Disassembly...4558
    Rack and Pinion Assembly...4561
    Rack and Pinion Installation...4562
  Front Suspension...4564
    Lubrication...4564
    Wheel Alignment...4564
  Front Suspension Components...4566
    Kingpin and Steering Spindle Removal...4566
    Kingpin and Steering Spindle Installation...4566
    A-Arm Removal...4567
    A-Arm Installation...4569
    Shock Absorber Removal...4569
    Shock Absorber Installation...4570
  Front Wheel Bearings and Hubs...4570
    Front Wheel Free Play Inspection...4570
    Front Wheel Bearings and Hub Removal...4571
    Front Wheel Bearings and Hub Installation...4571
  Section 8 - Wheels and Tires...4573
  General Information...4573
  Section 9 - Rear Suspension...4575
  Shock Absorbers...4575
    Shock Absorber Removal and Inspection...4575
    Shock Absorber Installation...4575
  Multi-Leaf Springs...4575
    Multi-Leaf Spring Removal...4575
    Multi-Leaf Spring Installation...4577
  Snubber...4578
    Snubber Removal...4578
    Snubber Installation...4578
  Section 10 - Periodic Maintenance...4579
  Periodic Service Schedule...4579
  Periodic Lubrication Schedule...4580
  Master Cylinder...4581
    Brake Fluid...4582
  Engine Oil...4582
    Engine Oil Level Check...4582
    Engine Oil and Filter Change...4583
    Oil Viscosity...4585
  Fueling Instructions...4585
  Battery...4586
  Section 11 - Troubleshooting and Electrical System: FE400 Engine...4589
  Troubleshooting Guide...4589
  Electrical System...4593
  Wiring Diagram...4594
  Electrical Circuits...4596
    Starter Circuit...4596
    Generator Circuit...4596
    Engine Ignition Circuit...4597
    Engine Kill Circuit...4597
    Reverse Buzzer Circuit...4598
    Low Oil Warning Circuit...4598
    Lockout Cam Circuit...4600
    Fuel Gauge and Sending Unit Circuit...4601
    Hour Meter Circuit...4602
    Lighting Circuit...4602
  Circuit Testing...4602
    Testing the Starter Circuit and Generator Circuit...4603
    Testing the Engine Ignition Circuit...4604
    Testing the Engine Kill Circuit...4604
    Testing the Reverse Buzzer Circuit...4605
    Testing the Low Oil Warning Circuit...4606
    Testing the Lockout Cam Circuit...4607
    Testing the Fuel Gauge and Sending Unit Circuit...4607
    Testing the Lighting Circuit...4608
  Test Procedures...4608
    Index of Test Procedures...4608
  Section 12 - Electrical Components: FE400 Engine...4637
  Starter/Generator...4637
  Voltage Regulator...4647
  Diode...4648
  Key Switch...4650
  Solenoid...4651
  Fuse...4651
  Lockout Cam Limit Switch...4653
  Lockout Cam...4653
  Reverse Warning Buzzer...4654
  Reverse Buzzer Limit Switch...4655
  Low Oil Warning Light...4656
  Fuel Gauge/Hour Meter...4657
  Fuel Level Sending Unit...4658
  RPM Limiter...4658
  Ignition Coil...4659
  Oil Level Sensor...4662
  Headlights...4662
  Headlight Diode...4663
  Light Switch...4664
    Testing the Light Switch...4664
  Battery...4664
    General Information...4665
  Ground Straps...4669
  Section 13 - FE400 Engine...4671
  General Information...4671
    Before Servicing...4671
    Lubrication System...4671
    Spark Plug...4671
  Cylinder...4673
    Breather Valve (Reed Valve)...4673
    Valve Clearance Check and Adjustment...4673
  Crankcase...4673
    Engine Removal...4673
    Crankcase Cover Removal...4674
    Oil Level Sensor...4675
  Ignition Coil and Flywheel...4676
    Crankcase Cover Installation...4677
  Flywheel Installation...4677
  Engine Installation...4678
    Torque Specifications...4679
    Adjustment and Settings...4679
  Section 14 - Fuel System...4681
  General Information...4681
  Carburetor...4681
    Main Jet Elevation/Size Chart...4681
    Changing the Main Jet...4682
  Engine Control Linkage...4685
    General Information...4685
    Accelerator Rod...4686
    Governor Cable...4687
    Accelerator Cable...4688
    Closed Throttle or Idle Adjustment...4690
    Engine RPM Adjustment...4690
  Choke and Air Intake System...4691
    Choke Cable Removal...4691
    Choke Cable Installation...4691
    Air Box Removal...4691
    Air Box Installation...4692
    Intake Duct Repair...4693
    Intake Duct Removal...4693
    Intake Duct Installation...4695
    Air Filter...4696
  Fuel Filters...4697
    Fuel Filter Removal...4697
    Fuel Filter Installation...4697
  Fuel Pump...4697
    General Information...4697
    Fuel Pump Removal...4700
    Fuel Pump Disassembly...4700
    Fuel Pump Cleaning and Inspection...4700
    Fuel Pump Assembly...4701
    Fuel Pump Installation...4701
  Fuel Tank...4702
    Fuel Tank Removal...4702
    Fuel Tank Storage or Disposal...4706
    Fuel Tank Installation...4706
  Fuel Lines...4707
  Fuel Shut-Off Valve...4708
  Section 15 - Exhaust System...4711
  Muffler...4711
    Muffler Removal...4711
    Muffler Installation...4711
  Section 16 - MC012C-AS00 Unitized Transaxle with Differential Lock...4713
  General Information...4713
    Lubrication...4714
  Axle Shaft...4715
    Axle Shaft, Bearing, and Oil Seal Removal...4715
    Axle Bearing Removal...4717
    Axle Shaft, Bearing, and Oil Seal Installation...4717
  Unitized Transaxle Removal...4718
  Unitized Transaxle Installation...4728
  Forward/Reverse Shifter Cable...4736
    Forward/Reverse Shifter Cable Removal...4736
    Forward/Reverse Shifter Cable Installation...4736
    Forward/Reverse Shifter Cable Adjustment...4737
  Differential Lock System...4738
    Differential Lock System Inspection...4738
    Differential Lock Cable Removal...4738
    Differential Lock Cable Installation...4739
  Section 17 - Torque Converter...4741
  General Information...4741
  Troubleshooting...4743
  Drive Belt...4743
    Drive Belt Removal...4743
    Drive Belt Installation...4744
  Drive Clutch...4744
    Drive Clutch Removal...4744
    Drive Clutch Cleaning and Inspection...4745
    Drive Clutch Disassembly...4746
    Inspection of Drive Clutch Parts...4747
    Drive Clutch Assembly...4749
    Drive Clutch Installation...4752
  Driven Clutch...4753
    Driven Clutch Removal...4753
    Driven Clutch Disassembly...4753
    Driven Clutch Inspection...4753
    Driven Clutch Assembly...4755
    Driven Clutch Installation...4757
  Section 18 - Reconditioning the FE400 Engine...4759
  General Information...4759
  Special Engine Service Tools Available...4759
    Recommended Replacement Parts For Engine Teardown...4760
    Before Servicing...4760
    Mechanical Systems...4760
  Cylinder Components...4762
    Cylinder Head...4762
    General Information...4762
    Cylinder Shroud Removal...4763
    Rocker Arm and Push Rod Removal...4765
    Cylinder Head Removal...4766
    Valve Removal...4766
    Breather Valve (Reed Valve)...4767
    Cylinder Head Cleaning and Inspection...4767
    Valve Guides...4768
    Valve Seats...4769
    Valves...4771
    Rocker Arm and Rocker Shaft inspection...4773
    Push Rod Inspection...4774
    Cylinder Head Installation...4774
    Valve Clearance Check and Adjustment...4775
    Breather Valve (Reed Valve)...4775
    Installation of Remaining Engine Components...4776
  Crankcase Components...4778
    Crankcase Cover Removal...4778
    Camshaft and Hydraulic Lifters...4780
  Piston and Connecting Rod...4782
  Cylinder Block...4784
  Ignition Coil and Flywheel...4786
  Oil Pump...4787
    Oil Pressure Relief Valve...4789
  Crankshaft and Counterbalance...4790
    Counterbalance Weight...4793
    Oil Screen...4796
    Ball Bearing...4796
    Oil Seals...4797
  Crankshaft Axial Play Adjustment...4800
    Crankcase Cover Installation...4802
  Engine Assembly...4803
  Engine Installation...4804
  Service Specifications...4805
    Specifications for Resizing Cylinder Bore...4806
    Torque Specifications...4806
    Adjustment and Settings...4807
  Section 19 - Reconditioning the MC012C- AS00 Unitized Transaxle with Differential Lock...4809
  General Information...4809
  Transaxle Model and Identification...4809
    Lubrication...4810
  Axle Shaft...4811
  Unitized Transaxle Removal...4811
  Unitized Transaxle Disassembly...4813
  Component Disassembly...4815
    Differential Gear Lock Housing Disassembly...4815
    Governor Gear Disassembly...4817
    Differential Gear Case Disassembly...4817
    Shifter Fork Disassembly...4820
    Synchronizer Gear Disassembly...4820
    Intermediate Gear Disassembly...4821
    Idler Shaft Disassembly...4822
  Unitized Transaxle Component Inspection...4823
  Component Assembly...4823
    Idler Shaft Assembly...4823
    Intermediate Gear Assembly...4824
    Synchronizer Gear Assembly...4824
    Shifter Fork Assembly...4826
    Differential Gear Case Assembly...4827
    Governor Gear Assembly...4829
    Differential Gear Lock Housing Assembly...4829
  Unitized Transaxle Assembly...4830
  Unitized Transaxle Installation...4837
    A...4839
      accelerator...4839
      air box...4839
      air filter 14-1...4839
      armature...4839
      axle...4839
    B...4839
      ball bearing...4839
      battery 12-28...4839
      bed, cargo...4839
      belt, drive...4839
      body, front...4839
      brakes...4839
      breather valve (reed valve) 18-9...4840
    C...4840
      camshaft...4840
      camshaft and hydraulic lifter...4840
      carburetor...4840
      cargo bed...4840
      CAUTION...4840
      choke 14-1...4840
      cleaning...4840
      clutch (torque converter) troubleshooting 17-3...4840
      clutch, drive...4840
      clutch, driven...4840
      column, steering...4840
      commutator...4840
      connecting rod...4840
      counterbalance...4840
      counterbalance guide shaft...4840
      counterbalance weight...4840
      crankcase 18-20...4840
      crankshaft...4840
      cylinder block 18-26...4840
      cylinder head 18-4...4840
      cylinder shroud...4840
    D...4840
      DANGER...4840
      dashboard...4840
      differential gear case...4840
      differential lock...4841
      differential lock housing...4841
      diode...4841
      diode, headlight...4841
      drive belt...4841
      drive clutch...4841
      driven clutch...4841
    E...4841
      electrical system...4841
      engine...4841
      engine oil 10-4...4841
      exhaust system 14-1...4841
    F...4841
      fender, front...4841
      fender, rear...4841
      field coil...4841
      fluid, brake 10-4...4841
      flywheel...4841
      forward/reverse...4841
      front body...4841
      fuel filter 14-1...4841
      fuel gauge...4841
      fuel gauge sending unit circuit...4841
      fuel gauge/hour meter...4841
      fuel level sending unit 12-22...4842
      fuel lines 14-1...4842
      fuel pump 14-1, 14-17...4842
      fuel shut-off valve 14-28...4842
      fuel tank...4842
      fueling instructions 10-7...4842
      fuse...4842
    G...4842
      generator circuit...4842
      governor cable...4842
      governor gear...4842
      governor system 16-3, 19-3...4842
      ground straps...4842
    H...4842
      headlight bulb...4842
      headlight diode...4842
      headlight switch...4842
      headlights...4842
      hour meter...4842
      hydraulic lifter...4842
      hydrometer test 11-21...4842
    I...4842
      idler shaft...4842
      ignition...4842
      ignition coil...4842
      inspection...4842
      intake duct...4843
      intermediate gear...4843
    K...4843
      key switch...4843
      kill circuit, engine...4843
      kill wire, engine...4843
    L...4843
      leaf springs, multi 9-1...4843
      lighting circuit...4843
      link rod...4843
      lockout cam...4843
      lockout cam circuit...4843
      low oil warning circuit...4843
      low oil warning light...4843
      lubrication...4843
    M...4843
      maintenance...4843
      master cylinder...4843
      muffler...4843
    N...4843
      neutral lockout 16-3...4843
    O...4843
      oil level sensor...4843
      oil light...4843
      oil pressure relief valve...4843
      oil pump...4843
      oil screen...4843
      oil seal...4843
      oil viscosity 10-7...4843
      oil, engine 10-4...4843
    P...4843
      park brake...4843
      pedal, accelerator...4844
      pedal, brake...4844
      periodic lubrication schedule 10-2...4844
      periodic service schedule 10-1...4844
      piston...4844
      piston and connecting rod...4844
      piston pin...4844
      piston ring...4844
      push rod...4844
    R...4844
      rack and pinion...4844
      receiver hitch...4844
      reed valve...4844
      reverse buzzer...4844
      reverse buzzer circuit...4844
      rocker arm...4844
      rocker arm and push rod...4844
      rocker shaft...4844
      RPM adjustment 14-10...4844
      RPM limiter...4844
    S...4844
      safety...4844
      seat...4844
      serial number, vehicle 3-1...4844
      service schedule...4844
      shifter fork...4844
      shock absorber...4844
      snubber...4844
      solenoid...4844
      spark plug 13-1, 14-1...4844
      specifications...4844
      starter/generator...4844
      starter/generator circuit...4845
      steering...4845
      steering column...4845
      steering wheel...4845
      storage...4845
      suspension, front...4845
      suspension, rear...4845
      synchronizer gear...4845
    T...4845
      test procedure...4845
      test procedures, index of 11-19...4845
      testing...4845
      tire...4846
      torque converter...4846
      torque specifications 18-48...4846
      trailer hitch...4846
      transaxle...4846
      troubleshooting...4846
    U...4846
      unitized transaxle 19-1...4846
    V...4846
      valve (cylinder)...4846
      valve guide...4846
      valve seat...4846
      valves (engine)...4846
      voltage limiter...4846
      voltage regulator...4846
    W...4847
      WARNING...4847
      wheel...4847
      wheel cylinder...4847
      wire continuity testing 11-29...4847
      wiring diagram 11-5...4847
6903128 (5-09) - 2200 Operation & Maintenance Manual...4851
  Notice...4853
  Foreword...4854
  Table of Contents...4855
  Safety Details...4861
    Key Switch - Gasoline Vehicles...4865
    Key Switch - Diesel Vehicles...4865
    Forward/Reverse Control...4865
    Accelerator Pedal...4867
    Brake Pedal...4867
    Park Brake...4867
    Low Oil Warning Light...4867
    Fuel Gauge/Hour Meter...4868
    Headlight control...4868
    Steering Adjustment Lock...4868
    Electric Bed Lift...4868
    Vehicles with Electric Bed Lift Option...4868
    Choke...4868
    Gasoline Vehicles Only...4868
    High-Temperature Warning LIght...4868
    Diesel Vehicles Only...4868
    Performance Inspection...4872
    Starting The Vehicle...4873
    All-Wheel Drive (AWD) Operation...4874
    Stopping The Vehicle...4875
    Parking And Leaving The Vehicle...4875
    Preparing the Vehicle for Extended Storage...4880
    Returning the Stored Vehicle to Service...4880
  Periodic Lubrication Schedule...4885
    Brake Fluid...4887
    Oil Pressure - Gasoline Engine...4887
    Engine Oil Level Check...4887
    Engine Oil and Filter Change...4888
    Engine Oil Draining...4888
    Engine Oil Filter Change...4889
    Engine Oil Filling...4891
    Oil Viscosity...4891
    Lubrication Level Check for Front Differential, Transmission, and Rear Differential...4892
    Lubrication Change for Front Differential, Transmission, and Rear Differential...4892
    Engine Coolant Level Check...4893
  Air Intake...4894
    Air Filter Replacement...4894
    Air Filter Removal...4894
    Air Filter Installation...4894
  Fueling Instructions...4895
    Draining Water from Fuel Filter...4896
    Diesel Vehicles Only...4896
  Battery...4897
    Electric Winch Accessory...4899
    Mud Tire OPtion...4900
  Warranty...4903
    Bobcat Utility Vehicles...4903
    Manual No. 102397422...4906
    Edition Code 0304J0707H...4906
6903129 (12-09) - 2200 Service Manual...4907
  Section 1 - Safety...4923
    General Warning...4923
  Section 2 - Vehicle Specifications...4927
  Section 3 - General Information...4929
    General Information...4929
    Model Identification...4929
    Storage...4930
      Preparing the Vehicle for Extended Storage...4930
        1. Unload the vehicle so that the tires are supporting only the weight of the vehicle...4930
        2. Store the vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it...4930
        3. Make sure the key switch is in the OFF position and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels...4930
        4. Prepare the fuel tank...4930
        5. Remove both spark plugs and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil through each of the two spark plug holes. Rotate the engine crankshaft by hand several times, then install both spark plugs...4930
        6. Prepare the fuel tank...4930
        7. Disconnect the battery cables, negative (-) cable first. See WARNING “To avoid unintentionally starting...” in Section 1 - Safety on page 1-2...4931
        8. Change engine oil. See Engine Oil and Filter Change on page 10-7...4931
        9. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and wate...4931
        10. Adjust the tires to the recommended tire pressure. See Section 8 - Wheels and Tires...4931
        11. Perform semiannual periodic lubrication. See Periodic Lubrication Schedule on page 10-4...4931
        12. Thoroughly clean the front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle...4931
        13. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling...4931
      Returning the Stored Vehicle to Service...4931
        1. Make sure the key switch is in the OFF position and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels...4931
        2. Restore the fuel system to operation (Figure 3-2, Page 3-3 or Figure 3-3, Page 3-3)...4931
        3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...4931
        4. Gasoline vehicles only: Completely open the fuel shut-off valve (Figure 3-4, Page 3-4). Ensure that the valve is fully open. ...4931
        5. Place the Forward/Reverse handle in the NEUTRAL position. Crank the engine until fuel is pumped into the carburetor (gasoline vehicles) and the fuel lines and the engine starts. Turn the engine off. See following NOTE...4932
        6. Perform the Pre-Operation and Daily Safety Checklist. See the Pre-Operation and Daily Safety Checklist in the vehicle owner’s manual...4932
  Section 4 - Body and Trim...4933
    Cleaning the Vehicle...4933
      Seat Cleaning...4933
    Front Body Repair...4934
      Abrasions and Haze...4934
      Light Scratches...4934
      Large Scratches and Abrasions...4934
    Front Body Components...4934
      Instrument Panel Removal...4934
        1. Loosen and remove the seven Tuflok® screws from the instrument panel...4934
        2. Pull the top of the instrument panel forward to access the panel rear...4934
        3. Disconnect the wiring from components mounted on the instrument panel...4934
        4. Gasoline vehicles: Remove the choke cable from the choke on the engine...4935
        5. Remove the instrument panel...4935
      Instrument Panel Installation...4936
        1. Connect the wiring to the electrical components mounted on the instrument panel. See Wiring Diagram on page 11a-6 (gasoline vehicles) or Wiring Diagram on page 11b-6 (diesel vehicles)...4936
        2. Gasoline vehicles: Connect the choke cable to the engine choke lever...4936
        3. Secure the instrument panel to the dashboard with the seven Tuflok screws...4936
      Dashboard Removal...4936
        1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels...4936
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...4936
        3. Remove the steering wheel. See Steering Wheel Removal, Section 7, Page 7-1...4936
        4. Remove the instrument panel. See Instrument Panel Removal on page 4-2...4936
        5. Remove the five plastic caps from the point where dashboard and front body meet...4936
        6. Remove the five Torx-head screws with special plastic washers from the top of the dashboard...4936
        7. Remove the park brake release handle and jam nut from the park brake cable assembly...4936
        8. Remove the knob from the Forward/Reverse shift handle...4936
        9. Remove the seven Tuflok screws from the underside of the dashboard, and gently slide the dashboard away from the floor mat trim plate and frame...4936
        10. Remove the 12-volt power plug wire harness...4936
        11. Remove the dashboard from the vehicle...4936
      Dashboard Installation...4936
        1. Position the dashboard over steering column and park brake cable assembly and locate attachment points. See following NOTE...4936
        2. Install and tighten the five Torx-head screws with special plastic washers on the top side of the dashboard to 45 in-lb (5.1 N·m)...4936
        3. Install five plastic caps onto the screw heads...4936
        4. Secure the underside of the dashboard with seven Tuflok screws...4936
        5. Advance the park brake release handle to the jam nut, and tighten the nut to 50 in-lb (5.6 N·m)...4936
        6. Install the instrument panel. See Instrument Panel Installation on page 4-4...4936
        7. Install the knob onto the Forward/Reverse shifter handle...4937
        8. Install the steering wheel. See Steering Wheel Installation, Section 7, Page 7-2...4937
      Front Body Removal...4937
        1. Remove the five plastic caps from the point where dashboard and body meet...4937
        2. Remove the five Torx-head screws with special plastic washers from the top of the dashboard...4937
        3. Remove the seven Tuflok fasteners from underneath the dashboard...4937
        4. Remove the six Tuflok fasteners: two from each side and two from the front of the body...4937
        5. Disconnect the headlight wire harness from each headlight at each connector...4937
        6. Lift the front edge of the body up, and pull forward to remove the body from the vehicle...4937
      Front Body Installation...4937
        1. Position the front body on the vehicle frame, and locate the attachment points...4937
        2. Connect the headlight wire harness to each headlight connector...4937
        3. Secure the front body to the dashboard and frame with Torx screws that have special plastic washers, and tighten the hardware to 45 in-lb (5.1 N·m)...4937
        4. Install five plastic caps...4937
        5. Secure the front body with six Tuflok fasteners...4937
      Front Fender Removal...4937
        1. Remove the front body. See Front Body Removal on page 4-5...4937
        2. Pull back the floor mat, and remove the two Torx-head screws securing the front fender to the floor...4937
        3. Remove the screws from the fender support, and remove the fender...4937
      Front Fender Installation...4937
        1. Position the fender on the body, and locate the attachment points...4937
        2. Tighten the Torx screws at the upper frame support to 55 in-lb (6.2 N·m)...4937
        3. Tighten the Torx screws at the floorboard to 55 in-lb (6.2 N·m)...4937
        4. Install the front body. See Front Body Installation on page 4-5...4937
    Roll-Over Protective Structure (ROPS)...4937
      ROPS Removal...4938
        1. Remove the lower four bolts (4), four washers (6), and four locknuts (5) that secure the top structure (1, 2, and 3) to the vehicle, and remove the top structure (Figure 4-4, Page 4-6)...4938
        2. Remove the two bolts (4), two washers (6), and two locknuts (5) that secure the two vertical front bars, (3) and remove the front bars (3) from the top structure (1)...4938
        3. Remove the two bolts (4), two washers (6), and two locknuts (5) that secure the two vertical rear bars (2), and remove the rear bars (2) from the top structure (1)...4938
      ROPS Installation...4938
        1. Install two rear vertical bars (2) on the top structure (1), and secure the bars with two bolts (4), two washers (6), and two locknuts (5). Tighten the hardware to 33 ft-lb (45 N·m)...4938
        2. Install the two front vertical bars (3) on the top structure (1), and secure the bars with two bolts (4), two washers (6), and two locknuts (5). Tighten the hardware to 33 ft-lb (45 N·m)...4938
        3. Install the top structure (1, 2, and 3) to the frame seat bars and front frame bars. Install four bolts (4), four washers (6), and four locknuts, and tighten the hardware to 33 ft-lb (45 N·m). See following WARNING...4938
    Seat...4939
      Seat Removal...4939
        1. Lift the seat back up and forward to raise it...4939
        2. Remove the seat by lifting the front edge hinges from the vehicle frame hinge slots...4939
      Seat Adjustment...4939
        1. Passenger Seat...4939
        2. Driver Seat...4939
      Seat Installation...4939
        1. Align the hinges on the underside of the seat front edge with the hinge slots on the frame...4939
        2. Push back and down on the seat back to secure the seat latch to the frame. See preceding WARNING...4939
      Seat Frame Removal...4939
        1. Remove the bolts, washers, and flanged locknuts from the seat frame (7), seat side plates, and engine cover plate (Figure 4-4, Page 4-6)...4939
        2. Remove the seat frame...4939
      Seat Frame Installation...4939
        1. Install the seat frame (7) (Figure 4-4, Page 4-6)...4939
        2. Secure the seat frame to the seat side plates with bolts, washers, and flanged locknuts. Tighten the hardware to 37 ft-lb (50 N·m)...4939
    Safety Belts...4940
      Safety Belt Removal...4940
        1. Remove the bolt from the base of the coiled safety belt assembly (outside location) (Figure 4-5, Page 4-8)...4940
        2. Remove the coiled safety belt assembly...4940
        3. Remove the bolt from the center safety belt latch base assembly (center location) (Figure 4-6, Page 4-8)...4940
        4. Remove the safety belt latch base assembly...4940
      Safety Belt Installation...4940
        1. Install the center safety belt latch base assembly to the center of the ROPS seat frame with a new thread- forming bolt. Orient the assembly with the latch end pointed up slightly, and tighten the hardware to 55 ft- lb (75 N·m)...4940
        2. Install the coiled safety belt assembly on the outside of the ROPS seat frame with a new thread-forming bolt. Orient the assembly with the tang end pointed up slightly, and tighten the hardware to 55 ft-lb (75 N·m)...4941
    Cargo Bed With Electric Lift...4941
      Testing the Bed Lift Motor...4941
      Bed Lift Motor Removal...4941
        1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels...4941
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...4941
        3. With the bed in the down position, working from under the vehicle, disconnect the two wires from the connectors at the electric bed lift motor...4941
        4. Remove the locknut, bolt, sleeve, spacers and washers from the rod end of the bed lift motor and bed frame...4941
        5. Remove the locknut, bolt, sleeve, spacers and washers from the base of the bed lift motor and vehicle frame and remove the bed lift motor...4941
      Bed Lift Motor Installation...4941
        1. Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels...4941
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...4941
        3. With the bed in the down position, working from under the vehicle, mount the base of the bed lift motor to the frame bracket...4941
        4. Attach the rod end of the bed lift motor to the bed frame bracket...4941
        5. Tighten the locknut on the bed lift motor base to 30 ft-lb (41 N·m)...4942
        6. Attach the two electric wire connectors, red to red and yellow to yellow...4942
      Cargo Bed Removal...4942
        1. Remove the electric actuator. See Bed Lift Motor Removal on page 4-9...4942
        2. With the bed in a down position, working from under the rear of the vehicle, remove the two nylon locknuts from the cargo bed hinge and bolts...4942
        3. Apply slight upward pressure on the rear of the bed to relieve pressure from the hinges. Remove the hinge bolts...4942
        4. With the help from an additional person, or an overhead lift hoist, remove the bed from the vehicle...4942
      Cargo Bed Installation...4942
        1. With the help from an additional person, or an overhead lift hoist, place the bed onto the vehicle frame and align the bed hinge brackets with the frame brackets...4942
        2. Start the bolts into both hinges with the bolt heads to the outside. Use an alignment tool if necessary...4942
        3. Use a small hammer, and lightly tap the bolts through the hinges...4942
        4. Install a nylon locknut on each bolt, and tighten the hardware to 15 ft-lb (21 N·m)...4942
        5. Install the electric actuator. See Bed Lift Motor Installation on page 4-9...4942
    Rear Fender...4942
      Rear Fender Removal...4942
        1. Remove the top Torx-head, self-tapping screw and washer...4942
        2. Remove the three phillips-head side screws and washers from the rubber well nuts...4942
        3. Remove the fender...4942
        4. Repeat steps 1 through 3 to remove the remaining fender if necessary...4942
      Rear Fender Installation...4942
        1. Loosely install the three phillips-head side screws and washers into the rubber well nuts...4942
        2. Install the top Torx-head, self-tapping screw and washer. Tighten the hardware to 50 in-lb (5.6 N·m)...4942
        3. Tighten the phillips-head side screws and washers to 13 in-oz (91.8 N·mm)...4942
        4. Repeat steps 1 through 3 to install the remaining fender if necessary...4942
    Floor Mat...4943
      Floor Mat Removal...4943
        1. Lift the back edge of the floor mat, and slide the front edge down and away from the aluminum mat shield...4943
      Floor Mat Installation...4943
        1. Slide the mat up and under the aluminum mat shield, and tuck the rear edge down against the seat panel...4943
  Section 5 - Accelerator and Brake Pedal Assemblies...4945
    Accelerator Pedal...4945
      Accelerator Pedal Removal...4945
        1. Turn the key switch OFF, and place the Forward/Reverse handle in the NEUTRAL position. Remove the key. Chock the rear wheels...4945
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...4945
        3. Remove the dashboard. See Dashboard Removal on page 4-4...4945
        4. Disconnect the cable strain relief from the pedal bracket...4945
        5. Disconnect the Z-shaped end (1) of the accelerator cable from the pedal (Figure 5-1, Page 5-1)...4945
        6. Remove the pedal assembly bolts and locknuts that secure the pedal assembly to the frame...4945
        7. Slide out and twist the pedal to remove the pedal assembly from the frame...4945
        8. Inspect the pedal bushings for wear and replace pedal assembly if worn...4945
        9. Inspect the pedal and return spring hub bushings for excessive side-to-side movement. Replace the pedal assembly if either or both show signs of excessive wear...4945
      Accelerator Pedal Installation...4946
        1. Twist the accelerator pedal assembly to return the pedal assembly into the frame location...4946
        2. Position pedal between the frame members...4946
        3. Secure the pedal assembly to the upper and lower frame member with bolts and locknuts...4946
        4. Tighten hardware to 15 ft-lb (20.3 N·m)...4946
        5. Attach accelerator cable Z-shaped end to hole in pedal...4946
        6. Adjust the accelerator pedal. See Accelerator Pedal and RPM Adjustment on page 5-2...4946
      Accelerator Pedal and RPM Adjustment...4946
        1. Turn the key switch OFF, and place the Forward/Reverse handle in the NEUTRAL position. Chock the front and rear wheels...4946
        2. Adjust the ground speed set screw to 3/4 inches (19 mm) as shown (Figure 5-3, Page 5-2)...4946
        3. Turn the key switch to start the engine. See following DANGER...4946
        4. Press the accelerator pedal and allow the engine to achieve full, steady level RPM. See following NOTE...4946
        5. Measure the engine RPM with a tachometer approved for this engine (CCI P/N AM 10753)...4946
        6. Release the accelerator pedal, turn the key switch to the OFF position, and remove the key...4946
        7. Adjust the ground speed set screw against the spring to achieve proper RPM...4946
        8. Adjust the screw until the RPM range is 3800-3850...4947
        9. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...4947
    Brake Pedal...4947
      Brake Pedal Removal...4947
        1. Turn the key switch OFF, and place the Forward/Reverse handle in NEUTRAL. Remove the key, and chock the rear wheels...4947
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...4947
        3. Remove the dashboard. See Dashboard Removal on page 4-4...4947
        4. Remove the rue pin and the clevis pin. Separate the clevis from the brake pedal (Figure 5-4, Page 5-3)...4947
        5. Remove the allen-head shoulder bolt and locknut from the pedal and frame brackets...4947
        6. Remove the brake pedal...4947
        7. Inspect the brake pedal bushing for wear and replace if necessary...4947
      Brake Pedal Installation...4947
        1. Position the brake pedal between the frame brackets...4947
        2. Install the allen-head shoulder bolt and locknut. Tighten the hardware to 4.8 ft-lb (6.5 N·m)...4947
        3. Install the master cylinder rod and threaded clevis pin assembly...4947
        4. Install the clevis pin and the rue pin...4947
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...4947
      Brake Pedal Adjustment...4948
        1. Loosen the master cylinder rod and clevis jam nut (Figure 5-4, Page 5-3)...4948
        2. Rotate the master cylinder rod to extend or retract the clevis and brake pedal to the desired position...4948
        3. Tighten the jam nut to 14 ft-lb (19 N·m)...4948
        4. Perform all brake system inspections to ensure that the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspection, Section 6, Page 6-1...4948
    Park Brake Pedal...4948
      Park Brake Pedal Removal...4948
        1. Turn the key switch OFF, and place the Forward/Reverse handle in NEUTRAL. Remove the key, and chock the rear wheels...4948
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...4948
        3. Remove the instrument panel. See Instrument Panel Removal on page 4-2...4948
        4. Remove the dashboard. See Dashboard Removal on page 4-4...4948
        5. Remove the retaining clip and washer from the brake cable. Remove the brake cable from the pedal bracket stud...4948
        6. Remove the three hex drive washer-head bolts and locknuts that secure the park brake pedal assembly to the frame. Remove the park brake...4948
      Park Brake Pedal Installation...4948
        1. Secure the park brake pedal assembly at three places with hex drive washer-head bolts and locknuts. Tighten the hardware to 15 ft-lb (20 N·m)...4948
        2. Install the cable end on the pedal bracket stud...4948
        3. Install a washer and the brake cable C-clip on the pedal bracket stud...4948
        4. Secure the park brake cable release handle to the dashboard, and loosely install a jam nut...4949
        5. Install the instrument panel. See Instrument Panel Installation on page 4-4...4949
        6. Install the dashboard. See Dashboard Installation on page 4-4...4949
        7. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...4949
      Park Brake Cable Installation...4949
        1. Use a small, stiff brush to remove all dirt and debris from the ratchet teeth (1) (Figure 5-5, Page 5-4)...4949
        2. Feed the eye end of the cable through the pedal bracket until the cable sheath ferrule is secure in the pedal bracket and the tines secure the cable (Figure 5-5, Page 5-4)...4949
        3. Install the eye of the cable on the park brake assembly pin, and install the C-clip...4949
        4. Secure the pedal return spring from the bracket frame to the park brake assembly pin...4949
      Park Brake Cable Adjustment...4949
        1. Release the park brake, and advance the conical nut until slack is removed from all cables...4949
        2. Push the park brake pedal until the pedal is firm and the brakes are locked...4949
        3. With the vehicle on flat ground and the Forward/Reverse handle in the NEUTRAL position, push the vehicle by hand. If the wheels move, tighten the conical nut until the vehicle does not move and the brake pedal locks the brakes at two to three clicks...4949
        4. If the pedal travels more than three clicks to a brake lock position, complete steps 4.1 and 4.2...4949
  Section 6 - Hydraulic and Park Brake Systems...4951
    Brake System Inspection...4951
    Brake System Troubleshooting...4953
    Brake Pads and Caliper...4955
      Front Brake Pad and Caliper Removal...4955
        1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4956
        2. Place jack stands under the front frame beams and lower onto stand (Figure 6-2, Page 6-6)...4956
        3. Remove the lug nuts and front wheel...4956
        1. Remove the two socket-head slide-pin bolts securing the top and bottom of the two brake pads (Figure 6-3, Page 6-7)...4956
        2. Remove the brake pads...4956
        1. Remove the banjo bolt and copper washers holding the brake line to the caliper body (Figure 6-4, Page 6-7). See following NOTE...4956
        2. Place a plastic bag over the hose fitting to prevent dirt and debris from entering the hydraulic brake system...4956
        3. Remove and discard the two hex-head bolts that secure the caliper assembly to the upright and remove the caliper...4956
        4. Repeat steps 1 through 3 for the opposite front wheel if necessary...4956
      Front Brake Pad and Caliper Installation...4957
        1. Secure the caliper body to the upright with two new lock-patch bolts tightened to 36 ft-lb (49 N·m)...4957
        2. Secure the brake line to the caliper with a new banjo bolt and new copper washers. Tighten to 13 ft-lb (18 N·m). See following CAUTION...4957
        3. Bleed the brake line at the top bleed port on the caliper body. Tighten the port fitting to 27 in-lb (3 N·m). See following NOTE...4957
        4. Repeat steps 1 through 3 for the opposite front wheel if necessary...4957
        1. Install the brake pads and install the socket-head slide-pin bolts through top and bottom holes of pads. Tighten the hardware to 32 ft-lb (43 N·m)...4957
        2. Install the tire and wheel. Finger-tighten the lug nuts...4957
        3. Lower the vehicle, and use a crisscross pattern to tighten the lug nuts to 85 ft-lb (115 N·m)...4957
        4. Repeat steps 1 through 3 for the opposite front wheel...4957
        5. Inspect the brake system. See Brake System Inspection on page 6-1...4958
      Rear Brake Pad and Caliper Removal...4958
        1. Chock the front wheels, release the park brake, loosen the rear wheel lug nuts, and lift the rear of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4958
        2. Place jack stands under the rear axle and lower onto stands...4958
        3. Remove lug nuts and rear wheel...4958
        1. Remove the two socket-head slide-pin bolts securing the top and bottom of the two brake pads...4958
        2. Remove the brake pads...4958
        1. Remove the banjo bolt and copper washers that secure the brake line to the caliper body (Figure 6-6, Page 6-9). See following NOTE...4958
        2. Place a plastic bag over the hose fitting to prevent dirt and debris from entering the hydraulic brake system...4958
        3. Remove and discard the two hex-head bolts that secure the caliper assembly to the axle tube, and remove the caliper (Figure 6-5, Page 6-9)...4958
        4. Repeat steps 1 through 3 for the opposite rear wheel if necessary...4958
      Rear Brake Pad and Caliper Installation...4959
        1. Secure the caliper body to the axle tube with two new lock-patch bolts tightened to 36 ft-lb (49 N·m)...4959
        2. Secure the brake line to the caliper with a new banjo bolt and new copper washers. Tighten the hardware to 13 ft-lb (18 N·m). See following NOTE and CAUTION...4959
        3. Bleed the brake line at the bleed port on the caliper body. See following NOTE...4959
        4. Repeat steps 1 through 3 for the opposite rear wheel if necessary...4959
        1. Install the brake pads, and install the socket-head slide-pin bolts through the top and bottom holes of the pads. Tighten the hardware to 32 ft-lb (43 N·m). See following NOTE...4959
        2. Install the tire and wheel, and finger-tighten the lug nuts...4959
        3. Lower the vehicle, and use a crisscross pattern to tighten the lug nuts to 85 ft-lb (115 N·m)...4960
        4. Repeat steps 1 through 3 for the opposite rear wheel if necessary...4960
        5. Inspect the brake system. See Brake System Inspection on page 6-1...4960
        6. Adjust the parking brake. See Park Brake Adjustment on page 6-23...4960
    Brake Disc and Hub...4960
      Front Wheel Disc and Hub Removal...4960
        1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-1...4960
        2. Place jack stands under the front frame beam and lower onto stand (Figure 6-2, Page 6-6)...4960
        3. Remove the lug nuts and front wheel...4960
        4. Remove the axle spindle nut and washer (Figure 6-7, Page 6-10). See following NOTE...4960
        5. Remove and discard the two hex-head bolts that secure the caliper assembly to the upright (Figure 6-8, Page 6-10). See following CAUTION...4960
        6. Remove the outer tie rod end from the upright...4961
        7. Remove the lower ball joint from the upright (Figure 6-9, Page 6-11)...4961
        8. Remove the upper ball joint from the upright (Figure 6-10, Page 6-11). See following NOTE and CAUTION...4961
        9. Remove the wheel hub, disc, and bearing assembly from the splined spindle and CV joint half shaft...4961
        10. Remove the wheel hub and disc from the bearing and upright. See following CAUTION and NOTE...4961
        11. Remove the snap ring (9) from the bearing cavity (7) in the upright (5) (Figure 6-12, Page 6-12)...4962
        12. Press the bearing out of the upright...4962
        13. Install a new bearing on the disc and hub...4963
        14. Install the snap ring (9) into the upright bearing cavity above the bearing (Figure 6-12, Page 6-12)...4963
        15. Press the shaft on the disc and hub into the bearing (Figure 6-15, Page 6-13)...4963
        16. The disc and hub shaft should be approximately 1/16 inch below the bearing inner race surface (Figure 6-16, Page 6-14)...4963
      Front Wheel Disc and Hub Installation...4964
        1. Inspect the ball joint boots for damage. Replace the ball joint and boot assemblies if necessary...4964
        2. Apply anti-seize compound to the half-shaft and CV joint spindle spline area...4964
        3. Slip the upright, wheel, and bearing assembly onto the CV joint spindle. See following CAUTION...4964
        4. Apply anti-seize compound to the upper and lower ball joint stud studs...4964
        5. Secure the upright, wheel, and bearing assembly to the upper ball joint. Use a new nylon locknut and tighten the hardware to 18 ft-lb (24 N·m)...4964
        6. Secure the upright, wheel, and bearing assembly to the lower ball joint. Use a new nylon locknut and tighten the hardware to 18 ft-lb (24 N·m)...4964
        7. Secure the outer tie rod end to the upright arm. Use a new nylon locknut and tighten the hardware to 70 ft-lb (95 N·m)...4964
        8. Inspect the brake pads for wear and replace if necessary. See Brake Disc and Pad Inspection on page 6-3. See Front Brake Pad Removal on page 6-6...4964
        9. Install the brake caliper on the upright. See Front Brake Caliper Installation on page 6-7...4964
        10. Install the brake pads. See Front Brake Pad Installation on page 6-7...4965
        11. Install the hardened washer and new flanged spindle nut. Tighten, but do not torque the hardware to its finished value...4965
        12. Install the tire and wheel, and finger-tighten the lug nuts...4965
        13. Remove the jack stand. With the tires on the ground, use a crisscross pattern to tighten the lug nuts to 85 ft-lb (115 N·m)...4965
        14. Tighten the flanged spindle nut to 150 ft-lb (203 N·m)...4965
        15. Inspect the brake systems. See Brake System Inspection on page 6-1...4965
      Rear Wheel Disc Removal...4965
        1. Chock the front wheels, release the park brake, and loosen the rear wheel lug nuts...4965
        2. Remove the rubber dust cap...4965
        3. Remove and discard the cotter pin...4965
        4. Loosen and discard the castle nut on the axle spindle...4965
        5. Lift the rear of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4965
        6. Place jack stands under the frame, and lower it onto the stands (Figure 6-17, Page 6-15)...4965
        7. Remove the lug nuts and wheel...4965
        8. Remove the rear caliper from the axle tube. Secure the rear caliper to the respective swing arm assembly with wire ties to remove pressure from the fittings and brake line...4965
        9. Slide the splined wheel disc and hub from the axle spindle (Figure 6-18, Page 6-15). See following NOTE...4966
        10. Repeat steps 2 through 9 for the opposite rear wheel if necessary...4966
      Rear Wheel Disc Installation...4966
        1. Clean the spline and threaded portion of the axle...4966
        2. Apply anti-seize compound to both the axle and wheel hub splined area. See following CAUTION...4966
        3. Apply a light coat of lubrication grease to the outside surface of the splined hub...4966
        4. Slide the wheel hub onto the splined portion of the axle end. See following NOTE...4966
        5. Install the large flat washer onto the threaded portion of the axle...4966
        6. Install a new axle nut, and advance the nut to the large flat washer...4966
        7. Install the rear caliper. See Rear Brake Caliper Installation on page 6-9. See following NOTE...4966
        8. Install the rubber dust cap...4966
        9. Install the tire and wheel, and loosely attach the lug nuts...4966
        10. Raise the vehicle, remove the jack stands, and lower the vehicle...4966
        11. Tighten the axle nut to 80 ft-lb (108 N·m). Position the locking cap and attach a new cotter pin...4966
        12. Tighten the lug nuts to 85 ft-lb (115 N·m)...4966
        13. Repeat steps 1 through 12 for the opposite rear wheel if necessary...4966
    Hydraulic Line Replacement...4967
      Front Brake Line Removal...4967
        1. Chock the rear wheels and set the park brake...4967
        2. Remove the top screw caps and screws from the dashboard and front body...4967
        3. Remove the front body from the vehicle. See Front Body Removal, Section 4, Page 4-5...4967
        4. Use a flare-nut wrench to remove the front brake line at the master cylinder. See following NOTE...4967
        5. Remove the front brake lines, banjo bolts, and copper washers at each front wheel caliper assembly...4967
        6. Remove the two brake line support brackets and T-bracket from the frame...4967
        7. Slide the front brake lines toward the front of the vehicle, away from the master cylinder...4967
      Front Brake Line Installation...4967
        1. Feed the new front brake line under the front of the vehicle and up to the master cylinder...4967
        2. Carefully insert the flared end of the brake line end into the master cylinder, and tighten the hardware to 132 in-lb (15 N·m)...4967
        3. Install the T-bracket on the frame, and tighten the hardware to 50 in-lb (5.6 N·m) (Figure 6-19, Page 6-18)...4967
        4. Install the two support brackets, and tighten the hardware to 50 in-lb (5.6 N·m) (Figure 6-20, Page 6-18)...4967
        5. Secure the hydraulic lines to the frame above the steering column shaft with wire ties...4967
        6. Install brake lines, new banjo bolts, and new copper washers on each front wheel caliper. Position the lines between the nearest top bleeder port and the wheel upright. Tighten the hardware to 13 ft-lb (18 N·m). See following CAUTION...4968
        7. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic Brake System on page 6-22...4968
        8. Inspect the brake system. See Brake System Inspection on page 6-1. See following WARNING...4968
        9. Install the front body. See Front Body Installation, Section 4, Page 4-5...4968
        10. Secure the dashboard and front body to the frame. See Dashboard Installation, Section 4, Page 4-4...4968
      Rear Brake Line Removal...4968
        1. Chock the front wheels and set the park brake...4968
        2. Remove the top screw caps and screws from the dashboard and front body...4968
        3. Remove the front body. See Front Body Removal, Section 4, Page 4-5...4968
        4. Use a flare-nut wrench to remove the rear brake line at the master cylinder. See following NOTE...4968
        5. Remove the brake lines, banjo bolts and copper washers from each rear caliper assembly. See following NOTE...4969
        6. Remove each brake line from the grommet and clamp locations...4969
        7. Remove the T-bracket from the passenger side on the rear receiver hitch frame...4969
        8. Remove the brake line from the clamp locations under the vehicle frame and floorboard...4969
        9. Remove the brake lines that are toward the rear of the vehicle on the passenger side. See following NOTE...4969
      Rear Brake Line Installation...4969
        1. Feed a new brake line from the rear of the vehicle, and position it in line with the frame clamps and up to the master cylinder. See following NOTE...4969
        2. Carefully install the flared end of the brake line into the master cylinder, and tighten to 11 in-lb (15 N·m)...4969
        3. Secure the brake lines to the clamp and grommet locations...4969
        4. Secure the brake lines, banjo bolts, and new copper washers to each rear wheel caliper. Tighten the hardware to 13 ft-lb (18 N·m). See following NOTE...4969
        5. Fill the reservoir of the master cylinder, and bleed the hydraulic system. See Bleeding the Hydraulic Brake System on page 6-22...4969
        6. Perform all of the brake system inspections. See Brake System Inspection on page 6-1...4969
    Master Cylinder and Reservoir...4970
      Filling the Hydraulic System...4970
      Reservoir Removal...4970
        1. Chock the wheels and set the park brake...4970
        2. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-2...4970
        3. Remove dashboard. See Dashboard Removal, Section 4, Page 4-4...4970
        4. Remove front body. See Front Body Removal, Section 4, Page 4-5...4970
        5. Remove the hoses at the master cylinder. See following NOTE...4970
        6. Remove the hoses at the reservoir...4970
        7. Remove the bolt, washer and locknut that secure the reservoir container to the steering column frame plate, and remove the container...4970
      Reservoir Installation...4970
        1. Secure the reservoir container to the steering column frame plate with a bolt, washer and locknut and tighten the hardware to 20 in-lb (2.2 N·m)...4970
        2. Install the hoses on the barbed fittings of the reservoir container...4970
        3. Install the remaining loose hose ends on the barbed ports of the master cylinder. See following NOTE...4970
        4. Fill the reservoir with brake fluid specified for this vehicle, and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-22...4970
        5. Inspect the brake system. See Brake System Inspection on page 6-1...4970
      Master Cylinder Removal...4971
        1. Chock the wheels and set the park brake...4971
        2. Remove the top screw caps and screws from the dashboard and front body...4971
        3. Remove the front body. See Front Body Removal, Section 4, Page 4-5...4971
        4. Remove the hoses from the master cylinder. See following NOTE...4971
        5. Use a flare-nut wrench to remove the front and rear brake lines from the master cylinder. See following NOTE...4971
        6. Remove the rue pin and clevis pin from the brake pedal and push rod clevis (Figure 6-21, Page 6-21)...4971
        7. Remove the two bolts and locknuts that secure the master cylinder to the frame...4971
        8. Remove the master cylinder from the vehicle...4971
      Master Cylinder Installation...4972
        1. Secure the master cylinder to the master cylinder bracket with two bolts and locknuts. Tighten the hardware to 16 ft-lb (22 N·m)...4972
        2. Loosen the jam nut on the push rod clevis, and secure the clevis to the brake pedal with a clevis pin and rue pin (Figure 6-21, Page 6-21)...4972
        3. Carefully secure the front and rear brake line flare fittings to the master cylinder. Finger-tighten the hardware...4972
        4. Use a flare-nut wrench to tighten the brake line fittings to 11 ft-lb (15 N·m)...4972
        5. Secure the reservoir hoses to the master cylinder barbed connectors. See following NOTE...4972
        6. Fill the reservoir with brake fluid specified for this vehicle, and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-22...4972
        7. Adjust the brake pedal stroke with the clevis and master cylinder push rod threaded connection. Tighten the jam nut to 14 ft-lb (19 N·m). See Brake Pedal Adjustment, Section 5, Page 5-4...4972
        8. Inspect the brake system. See Brake System Inspection on page 6-1...4972
    Bleeding the Hydraulic Brake System...4972
      1. Check the brake pedal and master cylinder push rod for proper adjustment before the brake system is bled. See Brake Pedal Adjustment, Section 5, Page 5-4...4972
      2. Chock the front or rear wheels, release the park brake, and lift the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning on page 1-1...4972
      3. Place jack stands under the outer front frame or under the rear axle tubes, and lower onto stands (Figure 6-2, Page 6-6)...4972
      4. Remove the cap from the master cylinder reservoir, and fill the reservoir with DOT 5 brake fluid...4972
      5. Place, but do not tighten, the cap on the master cylinder reservoir...4972
      6. Connect the vacuum-type brake bleeder (CCI P/N S0010702)...4972
      7. Tighten the cap on the master cylinder reservoir...4973
      8. Properly dispose of the brake fluid in the vacuum type brake bleeder tool...4973
      9. Inspect the brake system. See Brake System Inspection on page 6-1...4973
      Purging the Hydraulic System...4973
        1. Perform steps 2 through 6.5 of Bleeding the Hydraulic Brake System, Section 6, Page 6-22...4973
        2. Draw 1 qt. (0.9464 L) of the brake fluid into the vacuum-type brake bleeder tool...4973
        3. With the vacuum running, tighten the two top bleeder valves...4973
        4. Allow the handle on the brake bleeder tool to open, turning the vacuum system off...4973
        5. Repeat steps 1 through 4 for the two remaining wheels...4973
    Park Brake System...4973
      Park Brake Adjustment...4973
        1. Chock the wheels, release the park brake, and place the Forward/Reverse handle in the NEUTRAL position...4973
        2. Loosen, but do not remove the jam nut on the caliper park brake lever...4973
        3. Thread in and finger-tighten the adjustment bolt...4973
        4. Tighten the jam nut on the caliper lever to hold the adjustment bolt in place...4973
        5. Repeat steps 2 through 4 for the opposite park brake assembly...4973
        6. Inspect the brake system to ensure that both the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspection on page 6-1...4973
      Park Brake Cable Adjustment...4974
        1. Chock the wheels, release the park brake, and place the Forward/Reverse handle in the NEUTRAL position...4974
        2. With the park brake released, tighten the conical nut (23) until significant resistance is observed in the park brake cable (Figure 6-23, Page 6-25)...4974
        3. With the vehicle on flat ground and the Forward/Reverse handle in the NEUTRAL position, push the park brake pedal seven clicks...4974
        4. Push the vehicle by hand. If the wheels move easily when the vehicle is pushed, continue tightening the conical nut until the vehicle resists rolling easy and firm resistance is achieved...4974
        5. Release the park brake pedal, and push it again to eight clicks. The vehicle should not be movable with one person pushing...4974
        6. Tighten the equalizer jam nut against the conical nut and tighten to 55 in-lb (6.3 N·m)...4974
        7. Inspect the brake system to ensure that both the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspection on page 6-1...4974
      Park Brake Wheel Cables...4974
        1. Chock the rear wheels and release the park brake...4974
        2. Remove the cable bracket from the air cleaner mounting bolt...4974
        3. Remove the wire tie securing the cable to the frame...4974
        4. Remove the C-clip from the right rear cable sheath adjacent to the caliper...4974
        5. Slide the cable forward to release the sheath ferrule from the caliper bracket...4974
        6. Move the cable up and toward the rear of the vehicle, and remove the cable from the caliper arm (Figure 6-22, Page 6-25)...4974
        7. Disconnect the threaded end of the cable from the frame bracket, and remove the cable (Figure 6-23, Page 6-25)...4974
        1. Chock the rear wheels and release the park brake...4975
        2. Remove the cable from the plastic frame clip...4975
        3. Remove the C-clip from the right rear cable sheath adjacent to the caliper...4975
        4. Slide the cable forward to release the sheath ferrule from the caliper bracket...4975
        5. Move the cable up and toward the rear of the vehicle to remove the cable end from the caliper arm (Figure 6-22, Page 6-25)...4975
        6. Squeeze the ferrule tines together on the cable end at the frame bracket, and remove the cable from the vehicle (Figure 6-23, Page 6-25)...4975
        1. Install the caliper end of the cable into the brake caliper arm (Figure 6-22, Page 6-25)...4975
        2. Slide the sheath ferrule through the hole in the caliper mounting bracket...4975
        3. Install a C-clip to hold the cable ferrule in place...4975
        4. Route the cable up and across the air filter box, and secure the cable bracket to the top bolt on the filter mounting bracket (Figure 6-24, Page 6-26)...4975
        5. Route the cable end to the outside of the air intake hose...4975
        6. Secure the cable to the frame bracket at the outside hole (Figure 6-23, Page 6-25)...4975
        7. Insert the threaded end of the cable through the frame bracket. Use the nuts to adjust the cable end. Both cables should be equal in length. Tighten the nuts to 40 ft-lb (54 N·m)...4975
        8. Secure the cable to the frame with a wire tie...4975
        9. Secure cable end to the equalizer bracket...4975
        1. Install the caliper end of the cable into the brake caliper arm (Figure 6-22, Page 6-25)...4976
        2. Slide the sheath ferrule through the hole in the caliper mounting bracket...4976
        3. Install a C-clip to hold the cable ferrule in place...4976
        4. Route the cable to the inside of the air intake hose...4976
        5. Secure the cable end to the equalizer bracket. See Equalizer Installation on page 6-27...4976
      Front Park Brake Cable Removal...4976
        1. Chock the rear wheels and release the park brake...4976
        2. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...4976
        3. Remove the spring from the driver side equalizer adjustment rod (Figure 6-23, Page 6-25)...4976
        4. Remove the nuts from the threaded adjustment rod on the cable end...4976
        5. Remove the cotter pin and disconnect the front park brake cable end from the lower-most park brake bell crank (Figure 6-26, Page 6-27)...4976
        6. Release the tines securing the cable ferrule to the frame bracket and remove the cable from the vehicle...4976
        1. Chock the wheels and release the park brake...4976
        2. Remove the spring from the driver side equalizer adjustment rod (Figure 6-25, Page 6-27)...4976
        3. Remove the nuts from the threaded adjustment rod on the cable end...4976
        4. Remove the rear park brake cables from the equalizer, and remove the equalizer...4976
        1. Secure the equalizer to the ends of the rear park brake cables (Figure 6-25, Page 6-27)...4977
        2. Insert the threaded adjustment rod through the equalizer bracket...4977
        3. Secure the conical nut to the cable with the cone oriented toward the equalizer. Tighten the nut until the cable is drawn snugly through the equalizer bracket...4977
        4. Thread the jam nut onto the threaded portion of the equalizer rod so that it is beyond the spring retaining hole...4977
        5. Secure the extension spring to the end of the threaded end of the cable and the vehicle frame...4977
        6. Adjust the brake cable equalizer. See Park Brake Cable Adjustment on page 6-24...4977
      Front Park Brake Cable Installation...4977
        1. Route the cable end up to the lower-most park brake bell crank and secure the cable ferrule to the frame bracket. See Front Park Brake Cable Removal on page 6-26...4977
        2. Use a cotter pin to secure the front park brake cable end to the lower-most park brake bell crank...4977
        3. Insert the threaded adjustment rod through the equalizer bracket (Figure 6-25, Page 6-27)...4977
        4. Install the conical nut with the cone oriented toward the equalizer, and then install a jam nut onto the threaded portion of the cable end. Advance both nuts a few turns...4977
        5. Install the eye end of the cable onto the park brake assembly pin, and install the C-clip and washer...4977
        6. Secure the spring from the end of the adjustment rod to the brake cable frame bracket...4977
        7. Adjust the brake cable equalizer. See Park Brake Cable Adjustment on page 6-24...4977
        8. Inspect all of the brake systems to ensure that both the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspection on page 6-1...4977
        9. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...4977
  Section 7 - Steering and Front Suspension...4979
    Steering Wheel...4979
      Steering Wheel Removal...4979
        1. Turn the key switch OFF, and place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels...4979
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning on page 1-2...4979
        3. Gasoline vehicles: Disconnect the spark plug wires...4979
        4. Rotate steering wheel to a straight ahead position...4979
        5. Gently pry the center cap from the steering wheel center...4979
        6. Loosen the steering wheel bolt (18) approximately 1/4 inch (6mm). Do not remove the bolt (Figure 7-1, Page 7-2)...4979
        7. Remove the steering wheel. See following NOTE...4979
      Steering Wheel Installation...4980
        1. Install the steering wheel on the hex portion of the steering shaft. Align the hex fitting of the wheel with the steering column shaft (Figure 7-1, Page 7-2)...4980
        2. Install the steering wheel bolt, and tighten the bolt to 13 ft-lb (17.6 N·m)...4980
        3. Install the steering wheel center cap, and align the snap tabs on the cap with provisions in the wheel...4980
        4. Gasoline vehicles: Connect the spark plug wire...4980
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...4980
    Steering Column...4980
      Steering Column Removal...4980
        1. Turn the key switch OFF, and place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels...4980
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...4980
        3. Remove the steering wheel. See Steering Wheel Removal on page 7-1...4980
        4. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...4980
        5. Remove the front body. See Front Body Removal, Section 4, Page 4-5...4980
        6. Loosen the top bolt from the steering column shaft at the universal joint (Figure 7-4, Page 7-3)...4980
        7. Remove the bottom bolt from the rack and pinion shaft at the universal joint...4980
        8. Remove the three nuts from the steering column mount bolts...4980
        9. Remove the steering column, and pull the shaft up through the hole in the splash guard...4980
      Steering Column Installation...4981
        1. Slide the steering column through the frame opening and down through the hole in the splash guard...4981
        2. Position the steering column against the dash mounting plate, and install new locknuts. Tighten the hardware to 22 ft-lb (30 N·m)...4981
        3. Align the flat portion of the shaft with the bolt side of the universal joint. See following NOTES...4981
        4. Install the universal joint coupling bolt at the pinion shaft, and tighten the hardware to 18 ft-lb (24 N·m)...4981
        5. Tighten the steering column coupling bolt to 18 ft-lb (24 N·m)...4981
        6. Install the front body. See Front Body Installation, Section 4, Page 4-5...4981
        7. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...4981
        8. Install the steering wheel. See Steering Wheel Installation on page 7-2...4981
        9. Gasoline vehicles: Connect the spark plug...4981
        10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...4981
    Rack and Pinion...4981
      Rack and Pinion Removal...4981
        1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4981
        2. Place jack stands under the outer front frame beams, and lower the vehicle onto the stands. See Figure 6-2, Section 6, Page 6-6...4981
        3. Remove the front wheels...4982
        4. Remove the outer drag link ball joints from the upright assemblies and inspect for excessive wear and seal damage (Figure 7-5, Page 7-4)...4982
        5. Loosen the bolts on the steering universal joint that secure the steering column shaft and the rack and pinion shaft...4982
        6. Remove the rack and pinion spline bolt, and slide the universal joint up on the steering column shaft away from the rack and pinion splined shaft...4982
        7. Remove the four bolts from the rack and pinion steering assembly mounting bracket. Remove the rack and pinion assembly and the tie-rod assembly (Figure 7-6, Page 7-4)...4982
      Rack and Pinion Installation...4982
        1. Apply a light coat of anti-seize lubricant to the splined portion of the pinion shaft to minimize corrosion...4982
        2. Position the rack and pinion base next to the mounting bracket, and install the four bolts. Tighten the hardware to 23 ft-lb (31 N·m) (Figure 7-6, Page 7-4)...4982
        3. Slide the universal joint down over the pinion. Align the flat-way on the pinion with the bolt path on the universal joint...4982
        4. Install the universal bolt on the pinion shaft and tighten to 18 ft-lb (24 N·m)...4982
        5. Tighten the universal joint bolt on the steering column to 18 ft-lb (24 N·m)...4982
        6. Install both outer drag link ball joints, and advance the bolt approximately 6 threads. Do not tighten the jam nuts. Jam nuts will be tightened during alignment...4982
        7. Install the outer drag link ball joints on each upright, and tighten the hardware to 70 ft-lb (95 N·m) (Figure 7-5, Page 7-4)...4982
        8. Align the front wheels, and adjust the toe-in and camber. See Wheel Alignment on page 7-11...4982
        9. Adjust the outer drag link jam nuts, and tighten the hardware to 21 ft-lb (28.4 N·m)...4982
        10. Adjust the inner drag link jam nuts, and tighten the hardware to 21 ft-lb (28.4 N·m)...4982
        11. Remove the vehicle jack stands, and lower the vehicle to the ground...4982
      Rack and Pinion Disassembly...4983
        1. Remove the rack and pinion and drag link assembly. See Rack and Pinion Removal on page 7-3...4983
        2. Remove the two outer ball joints from the drag links (Figure 7-7, Page 7-5)...4983
        3. Remove both drag links (19) (Figure 7-8, Page 7-5)...4983
        4. Remove both bellows clamps (metal clamps or plastic wire ties) (Figure 7-9, Page 7-5). See following NOTE...4983
        5. Remove the two hex nuts from the inner ball-joint ends, and remove both of the dust seal bellows...4983
        6. Remove the rack screw nut (8), rack guide screw (7), rack guide pressure spring (6), and the rack guide (5) (Figure 7-16, Page 7-8)...4983
        7. Remove the dust seal (Figure 7-10, Page 7-6)...4983
        8. Remove the snap ring (4) (Figure 7-11, Page 7-6)...4983
        9. Install the universal joint on the pinion, and place a fork or a large open-end wrench under the universal joint (Figure 7-12, Page 7-6). Gently pry the pinion from the housing...4984
        10. Remove the U-joint from the pinion...4984
        11. If the pinion ball bearing has been damaged, remove the C-type stop ring (16) (Figure 7-11, Page 7-6), and use a press to remove the bearing (Figure 7-13, Page 7-6)...4984
        12. Inspect the bushing (17) and needle bearing (14) for excessive wear. If wear is excessive, replace the complete rack and pinion steering assembly (Figure 7-16, Page 7-8)...4984
        13. Inspect the inner ball joints for wear (Figure 7-16, Page 7-8). If either is excessively worn, replace both ball joints...4984
        14. Remove the rack (2) from the housing (1) (Figure 7-16, Page 7-8)...4985
      Rack and Pinion Assembly...4987
        1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17) and housing (1) (Figure 7-16, Page 7-8)...4987
        2. If the pinion bearing (15) was removed, grease a new bearing before installation. Press the new bearing onto the pinion shaft, and exert all pressure on the inner race. Then install the C-type stop ring (16). See preceding CAUTION...4987
        3. Install the pinion (3) and bearing (15) assembly into the housing (1). Ensure the gear teeth in the rack (2) will mesh with t...4987
        4. Install the snap ring (4)...4987
        5. Use a socket to apply pressure evenly, and press in a new dust seal (Figure 7-17, Page 7-9)...4987
        6. Apply a small amount of grease to the rack guide (5) where it contacts the rack (2) (Figure 7-16, Page 7-8)...4987
        7. Install the ball joints (9) onto the rack (2). Secure the rack in a vise with wood blocks between the rack and the jaws of the vise to protect the rack from damage, and tighten the ball joints to 60 ft-lb (81 N·m) (Figure 7-20, Page 7-10)...4987
        8. Tap a flange into the notch on the rack...4987
        9. Place a few drops of Loctite 222 on the threads of the screw (7) (Figure 7-18, Page 7-9)...4987
        10. Install the rack guide (5), pressure spring (6), and screw (7). Thread-in the screw until it bottoms out, and then unscrew it 1/4 turn (Figure 7-16, Page 7-8)...4988
        11. Insert a 3/8-inch, 1/4-drive deep-well socket into the steering column end of the universal joint (2), and tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-19, Page 7-10)...4988
        12. Connect a torque wrench to the 3/8-inch deep-well socket, and measure the resistance of the rack and pinion. Rotational resistance should measure 7 to 15 in-lb (0.8 to 1.7 N·m)...4988
        13. If the measured resistance is not 7 to 15 in-lb (0.8 to 1.7 N·m), adjust the screw (7) until the setting is correct. Tighten the nut (8) to 28 ft-lb (38 N·m) (Figure 7-18, Page 7-9). See following NOTE...4988
        14. Install the two dust seal bellows (10) (Figure 7-9, Page 7-5)...4988
        15. Secure the bellows with new bellows clamps or wire ties...4988
        16. Apply a light coat of anti-seize lubricating compound to the inner ball joint threads to minimize corrosion...4988
        17. Loosely install and advance the two nuts and drag links to the inner ball joint (Figure 7-8, Page 7-5). Nuts will be tightened during the toe-in adjustment procedure. See Toe-in Measurement on page 7-12...4988
        18. Apply a light coat of anti-seize lubricating compound to the drag link threads...4988
        19. Loosely install the two nuts and drag link ball joints. Advance the ball joints and nuts onto the drag link ends (Figure 7-7, Page 7-5). Nuts will be tightened during the toe-in adjustment procedure. See Toe-in Measurement on page 7-12...4988
        20. Install the rack and pinion assembly. See Rack and Pinion Installation on page 7-4...4988
    Front Suspension...4989
      Wheel Alignment...4989
        1. On a level, hard, and smooth surface roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. See following NOTE...4989
        2. Use a large carpenter’s square and position it a few inches (cm) away from the center of one wheel (Figure 7-21, Page 7-12)...4989
        3. Measure distance (A) between the edge of the square and a top location on the inside bead of the wheel rim. Record that measurement. See following NOTE...4989
        4. Measure distance (B) in the same method as distance (A), using the same reference on a bottom location on the inside bead of the wheel. Record that measurement. See following NOTE...4989
        5. The camber for this vehicle should be from 0.166 inch (4.2 mm) minimum to 0.275 inch (7.0 mm) maximum. See following NOTE...4989
        1. Locate the bolts that secure the flat camber adjustment bar in position at the underside of the lower A- arm. Loosen the bolts just enough to allow the bar to move with some resistance (Figure 7-22, Page 7-12)...4989
        2. Insert the cam tool (CCI P/N 102447101) into the adjustment slot on the lower A-arm assembly...4989
        3. Rotate the cam tool to adjust the bar until the desired dimension is achieved and the camber position is positive...4989
        4. Tighten the camber adjustment bar bolts to 53 ft-lb (72 N·m)...4989
        5. Check the measurement on the camber, and repeat steps 1 through 4 if necessary...4989
        6. Repeat steps 1 through 5 for the remaining front wheel...4989
        1. On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. See following NOTE...4990
        2. Mark each front tire at the center of the tread face that is facing the rear of the vehicle. The marks should be at the same height as the center of each hub. Measure the distance between the marks...4990
        3. Roll the vehicle forward one-half wheel revolution until the marks appear on the forward facing surfaces of the tires at the same height as the center of each hub. Measure the distance between the marks (Figure 7-23, Page 7-12). See following NOTE...4990
        4. Subtract the front face tire measurement from the rear face tire measurement. Proper toe-in is 3/8-inch (9.5 mm) ± 3/8-inch (9.5 mm)...4990
        1. Loosen the jam nuts on both ends of each drag link (Figure 7-24, Page 7-12)...4990
        2. Rotate both of the drag links equally. To increase the toe-in, rotate both drag links counterclockwise. To decrease the toe-i...4991
        3. Tighten the jam nuts to 21 ft-lb (28 N·m)...4991
        4. Check the toe-in, and repeat the adjustment procedure if necessary...4991
        5. After the toe-in adjustment is complete, the steering wheel should be at the center of its travel. If not, remove and correct the position so it is as close to center as possible. See Steering Wheel Installation on page 7-2...4991
    Front Suspension Components...4991
      Steering Upright Removal...4991
        1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4991
        2. Loosen the front wheel spindle nut...4991
        3. Place jack stands under the outer front frame beams, and lower the vehicle onto the stands. See Figure 6-2, Section 6, Page 6-6...4991
        4. Remove the front tire and wheel...4991
        5. Remove the front brake caliper. See Front Brake Pad and Caliper Removal, Section 6, Page 6-5...4991
        6. Rest the brake caliper on the A-arm. Ensure that there is no strain on the brake hose. See following WARNING...4991
        7. Remove the shock absorber...4992
        8. Remove the drag link ball joint from the upright assembly (Figure 7-26, Page 7-14)...4992
        9. Remove the axle spindle locknut that secures the wheel hub, disc, and upright...4992
        10. Remove the lower and upper ball joint locknut...4992
        11. Swing the lower A-arm down, and separate the brake rotor and upright from the half-shaft and the upper ball joint...4992
        12. Repeat steps 5 through 11 for the remaining front wheel if necessary...4993
      Upper A-Arm Removal...4993
        1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4993
        2. Loosen the front wheel spindle nut...4993
        3. Place jack stands under the outer front frame beams, and lower the vehicle onto the stands. See Figure 6-2, Section 6, Page 6-6...4993
        4. Remove the front tire and wheel...4993
        5. Remove the brake line bracket from the A-arm...4993
        6. Remove the two bolts and locknuts from the bottom mount of the shock absorber, and remove the shock absorber...4993
        7. Remove the nut from the ball joint (Figure 7-28, Page 7-14)...4993
        8. Remove the front and rear bolts, washers, and flanged locknuts from the A-arm and frame...4993
        9. Remove the A-arm from the frame and bushings...4993
        1. Inspect the ball joint. Replace the ball joint if it is worn, loose, or the rubber boot has been damaged...4993
        2. Repeat step 1 for the remaining side if necessary...4993
        1. Apply a 1/8 inch (3.2 mm) wide bead of Loctite 641 all the way around the face of the ball joint. Once the Loctite is applied...4994
        2. Install the C-clip. Verify that the C-clip is seated in the groove of the ball joint...4994
        3. Allow the Loctite to set up for at least 20 minutes before assembling the front suspension. See following NOTE...4994
      Upper A-Arm Installation...4994
        1. Install a new A-arm if necessary...4994
        2. Install new A-arm frame bushings. See following NOTE...4994
        3. Slide the A-arm over the frame bushings, and locate the bolt alignment...4994
        4. Install new bolts, washers, and new flanged locknuts in both the front and rear frame attachments. Tighten the hardware to 40 ft-lb (54 N·m)...4994
        5. Secure the brake line bracket to the A-arm, and tighten the hardware to 11 ft-lb (15 N·m)...4994
        6. Repeat steps 1 through 5 for the remaining side if necessary...4994
        7. Align the front wheels, and adjust the toe-in and the camber. See Wheel Alignment on page 7-11...4994
      Lower A-Arm Removal...4994
        1. Chock the rear wheels, set the park brake, loosen the front wheel lug nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4994
        2. Loosen the front wheel spindle nut...4994
        3. Place jack stands under the outer front frame beams, and lower the vehicle onto the stands. See Figure 6-2, Section 6, Page 6-6...4995
        4. Remove the front tire and wheel...4995
        5. Remove the bolt, washer, and flanged locknut from the lower A-arm and frame...4995
        6. Remove the A-arm from the frame and the bushings...4995
        1. Inspect the ball joint. Replace the ball joint if it is worn, loose, or if the rubber boot is damaged...4995
        2. Repeat step 1 for the remaining side if necessary...4995
        1. Apply a 1/8 inch (3.2 mm) wide bead of Loctite 641 all the way around the face of the ball joint. Once the Loctite is applied...4995
        2. Install the C-clip. Verify that the C-clip is seated in the groove of the ball joint...4995
        3. Allow the Loctite to set up for at least 20 minutes before assembling the front suspension. See following NOTE...4995
        4. Repeat steps 1 through 3 for the remaining side if necessary...4995
      Lower A-Arm Installation...4996
        1. Install a new A-arm if required...4996
        2. Install a new ball joint onto the A-arm. Be sure that the C-clip is seated in the groove of the A-arm (Figure 7-31, Page 7-16)...4996
        3. Install new A-arm frame bushings (Figure 7-33, Page 7-17). See following NOTE...4996
        4. Slide the A-arm over the frame bushings, and locate the bolt alignment...4996
        5. Install a new bolt, washer, and new flanged locknut. Tighten the hardware to 53 ft-lb (72 N·m)...4996
        6. Repeat steps 1 through 5 for the remaining side if necessary...4996
        7. Align the front wheels, and adjust the toe-in and the camber. See Wheel Alignment on page 7-11...4996
      Front Coil-Over Shock Absorber Removal...4996
        1. Chock the rear wheels, and set the park brake. Loosen the lug nuts on both front wheels, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...4996
        2. Place jack stands under the lower A-frame plate, and lower the vehicle onto the jack stands (Figure 7-34, Page 7-19)...4996
        3. Remove the lug nuts, and remove the tires and wheels...4996
        4. Place a floor jack under the lower A-arm at the lower ball joint, and raise the jack just enough to allow the A-arm assembly to rest on the jack...4996
        5. Remove the flange-head bolts and flanged locknuts from the bottom of the shock mount. Separate the bottom of the shock absorber from the top A-arm assembly (Figure 7-35, Page 7-19)...4996
        6. Remove the bolt, flat washer, and flanged locknut from the top of the shock mount. Remove the shock absorber. See following NOTE...4996
        7. Repeat steps 3 through 6 for the remaining shock absorber...4997
      Front Coil-Over Shock Absorber Installation...4997
        1. Install the top of the shock mount on the vehicle frame with a bolt, flat washer, and flange-head locknut. Tighten the hardware to 73 ft-lb (99 N·m) (Figure 7-36, Page 7-19)...4997
        2. Install the bottom of the shock mount on the upper A-arm with two new flange-head bolts and flange- head locknuts. Tighten the hardware to 22 ft-lb (30 N·m) (Figure 7-35, Page 7-19)...4998
        3. Remove the floor jack...4998
        4. Install the front tire and wheel. Finger-tighten the lug nuts...4998
        5. Raise the vehicle, and remove the jack stands...4998
        6. Tighten the lug nuts to 87 ft-lb (118 N·m)...4998
        7. Repeat steps 1 through 6 for the remaining shock absorber...4998
      Steering Upright Installation...4998
        1. Slide the upright and wheel hub assembly onto the splined half shaft spindle. See following NOTE...4998
        2. Loosely secure a large flat washer and new locknut to the spindle...4998
        3. Install the lower ball joint onto the upright lower tab (Figure 7-27, Page 7-14)...4998
        4. Install a new locknut, and tighten the hardware to 18 ft-lb (24 N·m)...4998
        5. Install the upper ball joint on the upright upper tab (Figure 7-28, Page 7-14)...4998
        6. Install a new locknut, and tighten the hardware to 18 ft-lb (24 N·m)...4998
        7. Install the drag link ball joint on the tab (Figure 7-26, Page 7-14)...4998
        8. Secure the top end of the shock absorber to the frame with a new flanged bolt and a new locknut. Tighten the bolt to 73 ft-lb (99 N·m)...4998
        9. Secure the bottom end of the shock absorber to the A-arm with new flanged bolts and new flanged locknuts. Tighten the hardware to 22 ft-lb (30 N·m)...4998
        10. Install the caliper assembly on the upright with lock-patch hex head bolts, and tighten the hardware to 16 ft-lb (22 N·m)...4998
        11. Install the tire and wheel, and finger-tighten the lug nuts...4998
        12. Lower the vehicle...4998
        13. Tighten the lug nuts to 85 ft-lb (115 N·m)...4998
        14. Tighten the spindle nut and washer to 150 ft-lb (203 N·m)...4998
        15. Align the front wheels, and adjust the toe-in and the camber. See Wheel Alignment on page 7-11...4998
  Section 8 - Wheels and Tires...4999
    General Information...4999
    Wheels...5000
      Wheel Removal...5000
        1. Slightly loosen the lug nuts on the wheel to be removed...5000
        2. Raise the end of the vehicle from which the wheel is to be removed. Make sure the wheels are off the ground. See WARNING “Lift only one end of the vehicle...” in General Warning, Section 1, Page 1-1...5000
        3. Remove the lug nuts and remove the wheel...5000
      Wheel Installation...5000
        1. Install the wheel(s), and use a crisscross pattern to tighten the lug nuts until they are snug. See following NOTE...5000
        2. Lower the vehicle, and use a crisscross pattern to finish tightening the lug nuts to 85 ft-lb (115 N·m)...5000
        3. Inspect the brake hoses at the front wheels. When the steering wheel is turned all the way from left to right and back again, the hoses should not come in contact with any component, especially the wheels or tires...5000
        4. Check the park brake cables. The cables should not come in contact with either of the rear wheels or tires...5000
    Tires...5000
      Tire Removal...5000
        1. Remove the tire and wheel assembly from the vehicle. See Wheel Removal on page 8-2...5000
        2. Remove the valve cap and valve core, and allow air to escape from the tire...5000
        3. Use a tire machine to remove the tire from the rim...5000
      Tire Installation...5000
        1. Use a tire machine to install the new tire on the rim...5000
        2. Install the valve core...5001
        3. Adjust the air pressure in the tire to the recommended pressure, and immerse the wheel and tire assembly in water to make sure there are no leaks. See General Information on page 8-1...5001
        4. Install the valve cap...5001
        5. Install the wheel. See Wheel Installation on page 8-2...5001
  Section 9 - Rear Suspension...5003
    Rear Coil-Over Shock Absorber...5003
      1. Chock the front wheels, and loosen both rear wheel lug nuts. Lift the rear of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5003
      2. Place jack stands under the rear portion of the frame tubes, and lower the vehicle onto the stands (Figure 9-1, Page 9-2)...5003
      3. Remove the lug nuts from the wheels, and remove the tires and wheels...5003
      4. Position the floor jack under the center of the hitch frame, and raise the jack arm until the pad touches the hitch frame...5003
      5. Remove the hydraulic line rubber grommet from the brake line bracket (Figure 9-2, Page 9-2)...5003
      6. Remove the bottom bolt, flat washer, and flanged locknut...5003
      7. Remove the top bolt, flat washer, and flanged locknut...5003
      8. Remove the coil-over shock absorber. See following NOTE...5003
      9. Repeat steps 5 through 8 for the remaining shock absorber...5003
      1. Install the top bolt, flat washer, and a new locknut. Tighten the hardware to 73 ft-lb (99 N·m)...5004
      2. Secure the bottom of the shock mount to the driver side axle frame bracket with a bolt, flat washer, rubber grommet bracket, and a new locknut. Tighten the hardware to 73 ft-lb (99 N·m)...5004
      3. Install the hydraulic line rubber grommet in the shock bracket...5004
      4. Install the rear tire and wheel. Finger-tighten the lug nuts...5004
      5. Repeat steps 1 through 4 for the remaining rear coil spring and shock...5004
      6. Raise the vehicle, and remove the jack stands...5004
      7. Lower the floor jack from the hitch frame...5004
      8. Tighten the lug nuts on both wheels to 85 ft-lb (115 N·m)...5004
    Swing Arms...5004
      Swing Arm Removal...5004
        1. Remove the rear axle. See Rear Axle Removal, Section 14, Page 14-8...5004
        2. Remove the rue pin, locknut and washer from the swing arm pivot bolt (Figure 9-3, Page 9-3)...5004
        3. Remove the swing arm bolt and grease fitting (Figure 9-4, Page 9-3). See following NOTE...5004
        4. Remove the swing arm...5004
        5. Remove the urethane bushings and teflon impregnated steel sleeves from the swing arms...5005
        6. Remove the urethane bushings from the swing arm brackets on the frame...5005
      Swing Arm Installation...5005
        1. Replace the urethane bushings in the swing arm brackets on the frame...5005
        2. Install new teflon impregnated steel sleeves into new swing arm urethane bushings...5005
        3. Install the urethane bushings and teflon impregnated sleeves (as an assembly) into the swing arms...5005
        4. Position the swing arm between the frame brackets and bracket bushings with the axle pad face down. Slide the swing arm pivot...5005
        5. Install the washer and locknut on the pivot bolt and tighten to 14 ft-lb (18 N·m) (Figure 9-3, Page 9-3)...5005
        6. Attach a new rue pin to the pivot bolt...5005
        7. Install the rear axle. See Rear Axle Installation, Section 14, Page 14-10...5005
  Section 10 - Periodic Maintenance...5007
    Periodic Service Schedule...5007
    Periodic Lubrication Schedule...5010
    Brake Fluid Reservoir...5012
      Brake Fluid...5012
    Engine Oil...5012
      Oil Pressure - Gasoline Engine...5012
      Engine Oil Level Check...5013
        1. Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick (Figure 10-5, Page 10-7 or Figure 10-6, Page 10-7). See following CAUTION...5013
        2. Check oil level by fully inserting the dipstick into the tube and immediately removing it...5013
        3. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level)...5013
      Engine Oil and Filter Change...5013
        1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the front wheels...5013
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in Section 1 - Safety on page 1-2...5013
        3. Remove the oil filler cap to allow the oil to drain properly...5013
        4. Position a pan designed for oil changes under the drain plug (1) (Figure 10-7, Page 10-8 or Figure 10-9, Page 10-8)...5013
        5. From the underside of the vehicle, use a 14mm socket or wrench to remove the drain plug (1). Turn the plug counterclockwise and drain the engine oil into the pan. See following WARNING...5013
        6. Clean the oil drain plug threads with solvent to remove oil and oil residue. Make sure that the compression washer remains on the drain plug. Inspect the compression washer and replace if necessary...5014
        7. Use a 14mm socket or wrench to replace the oil drain plug. Turn the plug clockwise and tighten to 29 ft- lb (40 N·m) for gasoline vehicles, 31 ft-lb (42 N·m) for diesel vehicles...5014
        1. Drain the engine oil. See Engine Oil Draining on page 10-7...5015
        2. Place the oil drain pan under the engine oil filter (2) (Figure 10-8, Page 10-8 or Figure 10-9, Page 10-8)...5015
        3. Remove the engine oil filter. Turn it counterclockwise and drain the residual oil in the filter port and filter into the oil drain pan. See following NOTE...5015
        4. Use a clean, lint-free rag to wipe the oil filter port flange surface clean where the oil filter gasket seats...5016
        5. To help seal the new oil filter to the engine oil filter port flange, apply a light coat of white lithium NLGI Number 2 greas...5016
        6. Tighten the oil filter by hand 2/3 turn after gasket contact. Do not use a band wrench or channel lock pliers...5016
        1. Add engine oil; use a funnel or pour spout to direct the oil into the opening (Figure 10-12, Page 10-10 or Figure 10-13, Page...5016
        2. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5016
        3. With the Forward/Reverse handle in the NEUTRAL position, start and run the engine for a few minutes. Observe both the drain p...5016
        4. Remove the dipstick and check the engine oil as a final step. Replace the dipstick...5016
      Oil Viscosity...5017
    Gearcase Lubrication...5017
      Lubrication Level Check for Front Differential, Transmission, and Rear Differential...5017
      Lubrication Change for Front Differential, Transmission, and Rear Differential...5017
    Engine Coolant - Diesel Vehicles...5019
      Engine Coolant Level Check...5019
        1. Check the coolant level of the reserve tank (2). If the coolant is at or below the LOW mark, add water until level reaches the FULL mark. If a leak is detected, have it checked by a trained technician. See following WARNING...5019
    Fueling Instructions...5019
      1. Remove the fuel cap and fill the tank with fuel. Gasoline vehicles have a black fuel cap; diesel vehicles have a green fuel cap. See preceding DANGER and following NOTE...5019
      2. Replace the fuel cap. Ensure that the cap is tightened securely...5020
      3. Clean any spilled fuel from the cap or around the fuel cap area...5020
      Draining Water from Fuel Filter...5021
        1. Position a pan under the fuel filter...5021
        2. Lift the passenger-side seat...5021
        3. Locate the valve (1) on the underside of the filter. Turn the valve clockwise until water begins to stream from the filter...5021
        4. Drain the water until it changes color (to fuel). See following WARNING...5021
        5. Close the valve by rotating it counterclockwise until the valve is firmly sealed...5021
        6. To resupply the filter with fuel, turn the key switch to the ON position for 10 seconds. See following NOTE...5021
    Battery...5021
  Section 11a - Troubleshooting and Electrical System: Gasoline Vehicles...5023
    Troubleshooting Guide...5023
    Wiring Diagram...5028
    Test Procedures...5030
      Index of Test Procedures...5030
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5031
        2. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary...5031
        3. Be sure that the battery has sufficient water to cover the plates by approximately 1/2-inch (13 mm) and is fully charged before the test. If water must be added, recharge the battery before performing the hydrometer test (Figure 11a-4, Page 11a-10)...5031
        4. Remove the vent cap...5031
        5. Use a battery thermometer (CCI P/N 1011767) to record the electrolyte temperature of a center cell...5031
        6. Use a hydrometer, and slowly draw an electrolyte sample (Figure 11a-3)...5031
        7. Ensure the float rises off the bottom. Adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release pressure from the bulb...5031
        8. Hold the hydrometer vertically, and ensure that the float does not contact the sides of the glass tube. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 11a-3, Page 11a-10)...5031
        9. Record the reading...5032
        10. Return the electrolyte to the cell from which it was taken. Replace vent cap...5032
        11. Repeat steps 4 through 10 on all cells...5032
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5032
        2. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary...5032
        3. Set the multimeter to the 20 VDC setting...5032
        4. Measure the voltage across the battery terminals. If the reading is less than 12.4 volts, or if the lowest specific gravity r...5033
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5033
        2. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary...5033
        3. Connect a 160-ampere load tester to the battery posts. See following NOTE...5033
        4. Turn the load tester switch to the ON position...5033
        5. Read the battery voltage after the load tester has been turned ON for 15 seconds. The minimum acceptable battery voltage for proper engine starting is approximately 9.6 VDC...5033
        6. If the battery voltage is acceptable, or if the electrical problem continues after the battery has been replaced, test the electrical circuits...5033
        7. If the voltage reading exceeds 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the starter. See Section 20. See also the following NOTE...5033
        8. If the reading is less than 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the battery electrolyte in each cell. See Test Procedure 1A - Hydrometer Test on page 11a-9...5033
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5033
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5033
        3. Remove the electrical component cover...5034
        4. Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary...5034
        5. Remove the fuse to be tested from the fuse block...5034
        6. Set a multimeter to 200 ohms, and connect the probes to the fuse terminals. The reading should indicate continuity. If there ...5034
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5034
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5034
        3. Check the frame ground connection for loose connections and damaged terminals (Figure 11a-6, Page 11a-13). Repair or replace as required...5034
        4. Check the negative (-) battery terminal and 6-gauge black wire (w81) for damage. Repair or replace as required...5034
        5. Check the engine ground for a loose connection and damaged terminals where the two 6-gauge black wires (w81 and w82) are connected to the engine block (under the starter) (Figure 11a-7, Page 11a-13). Repair or replace as required...5035
        6. Set the multimeter to 200 ohms...5035
        7. Check for continuity between the 6-gauge wire (w81) terminal that was disconnected from the negative (-) battery terminal, and the frame...5035
        8. Check for continuity between the 6-gauge wire (w81) terminal that was disconnected from the negative (-) battery terminal, and the engine...5035
        9. The readings obtained in the previous steps should indicate continuity. If any of the readings are incorrect, clean and tighten wire connections. If the connections are good and the reading is incorrect, repair or replace the wire...5035
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5035
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5035
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5035
        4. Ensure that the key switch connector is connected correctly and is tight. If it is not, repair or replace as necessary...5035
        5. Turn the key switch ON. Place the red (+) probe of the multimeter on the (B) terminal and the black (-) probe on the (L) term...5035
        6. With the key switch still in the ON position, place the red (+) probe of the multimeter on the (B) terminal and the black (-)...5036
        7. Turn and hold the key switch in the START position. The reading should indicate continuity. If the reading does not indicate ...5036
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5036
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5036
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5036
        4. Ensure that the key switch connector is connected correctly and is tight. If it is not, repair or replace as necessary...5036
        5. Turn the key switch to the ON position. With the multimeter set to 200 ohms, place the red (+) probe on the (B) terminal and ...5036
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5036
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11a-10, Page 11a-15). See following WARNING...5036
        3. Set the multimeter to 20 VDC...5037
        4. Place the probes to measure the voltage between the 16-gauge green wire (w58) terminal and the frame ground (Figure 11a-11, Page 11a-15)...5037
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF and ON positions. The reading should indicate approximately 12 VDC when the key is in the START position...5037
        6. If the readings differ from those described in step 5, perform the following test procedures:...5037
        7. If none of the previous steps resolves the problem, the starter solenoid and/or starter motor has failed. See Section 20...5037
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5037
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11a-10, Page 11a-15). See following WARNING...5037
        3. Set the multimeter to 20 VDC...5038
        4. Place the probes to measure the voltage between the 16-gauge green start relay wire (w44) terminal and the frame ground (Figure 11a-12, Page 11a-16)...5038
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF and ON positions. The reading should indicate approximately 12 VDC when the key is in the START position, and the relay should click. See following NOTE...5038
        6. If the reading is 12 VDC and the relay does not click when the key switch is turned to the START position, replace the relay...5038
        7. If the reading is 12 VDC and the relay clicks when the key is in the START position, check the relay contacts...5038
        8. If the reading obtained in step 5 is not 12 VDC with the key in the START position, perform the following test procedures:...5038
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5039
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11a-10, Page 11a-15). See following WARNING...5039
        3. Set the multimeter to 20 VDC...5039
        4. Place the probes to measure the voltage between the 18-gauge purple differential relay wire (w50) terminal and the frame ground...5039
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF position and the Forward/Reverse handle i...5039
        6. If the reading indicates 12 VDC and the relay does not click when the key switch is in the ON position and the Forward/Reverse handle is in the NEUTRAL position, replace the relay...5039
        7. If the reading indicates 12 VDC and the relay clicks when the key is in the ON position, check the relay contacts...5040
        8. If the reading obtained in step 5 is not 12 VDC with the key in the ON position, perform the following test procedures:...5040
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5041
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5041
        3. Disconnect the two-pin connector between the front gearcase and the wire harness...5041
        4. Set the multimeter to the diode test function (ç)...5041
        5. Connect the black (-) probe of the multimeter to the frame (ground)...5041
        6. Connect the red (+) probe of the multimeter to the 18-gauge gray wire (w34) on the two-pin connector (wire harness side)...5041
        7. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5042
        8. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5042
        9. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5042
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5042
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5042
        3. Remove the start relay from the multi-pin connector located on the electrical component mounting plate...5042
        4. Disconnect the 18-gauge yellow wire (w39) from the carburetor solenoid bullet connector (Figure 11a-16, Page 11a-20)...5042
        5. Set the multimeter to the diode test function (ç)...5042
        6. Connect the black (-) probe of the multimeter to the 18-gauge light-green wire (w44) at the start relay multi-pin connector...5042
        7. Connect the red (+) probe of the multimeter to the 18-gauge yellow wire (w39) at the bullet connector (wire harness side)...5042
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5042
        9. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5042
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5042
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5043
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5043
        3. Remove the instrument panel, and disconnect the multi-pin connector from the key switch. See Instrument Panel Removal, Section 12a, Page 12a-4...5043
        4. Disconnect the 18-gauge purple wire (w49) from the oil light...5043
        5. Disconnect the 18-gauge blue wire (w53) from the fuel gauge/hour meter...5043
        6. Remove the differential relay and the accessory relay from the multi-pin connector located on the electrical component mounting plate...5043
        7. Set the multimeter to the diode test function (ç)...5043
        8. Connect the black (-) probe of the multimeter to the 18-gauge purple wire (w47) at the key switch multi- pin connector...5043
        9. Connect the red (+) probe of the multimeter to the 18-gauge yellow wire (w39) at the bullet connector (wire harness side)...5043
        10. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter p...5043
        11. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5043
        12. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5043
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5043
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5043
        3. Remove the start relay, differential relay, and accessory relay from the multi-pin connector located on the electrical component mounting plate...5043
        4. Disconnect the two-pin connector between the neutral switch and the wire harness (Figure 11a-17, Page 11a-22)...5043
        5. Set the multimeter to the diode test function (ç)...5043
        6. Connect the black (-) probe of the multimeter to the 18-gauge black/white wire (w02) at the neutral switch two-pin connector...5043
        7. Connect the red (+) probe of the multimeter to the 18-gauge black wire (w61) on the multi-pin differential relay connector located on the electrical component mounting plate...5043
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5043
        9. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5044
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5044
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5044
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5044
        3. Remove the start relay, differential relay, and accessory relay from the multi-pin connector located on the electrical component mounting plate...5044
        4. Disconnect the two-pin connector between the neutral switch and the wire harness (Figure 11a-17, Page 11a-22)...5044
        5. Set the multimeter to the diode test function (ç)...5044
        6. Connect the black (-) probe of the multimeter to the 18-gauge black/white wire (w02) at the neutral switch two-pin connector...5044
        7. Connect the red (+) probe of the multimeter to the 18-gauge black wire (w60) on the multi-pin start relay connector located on the electrical component mounting plate...5044
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5044
        9. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5044
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5044
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5045
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5045
        3. Remove the instrument panel, and disconnect the multi-pin connector from the key switch. See Instrument Panel Removal, Section 12a, Page 12a-4...5045
        4. Disconnect the multi-pin connector between the voltage regulator and the wire harness...5045
        5. Set the multimeter to the diode test function (ç)...5045
        6. Connect the black (-) probe of the multimeter to the frame (ground)...5045
        7. Connect the red (+) probe of the multimeter to the 18-gauge yellow wire (w39) at the bullet connector (wire harness side)...5045
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5045
        9. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5045
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5045
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5045
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5045
        3. Remove the instrument panel, and disconnect the multi-pin connector from the key switch. See Instrument Panel Removal, Section 12a, Page 12a-4...5045
        4. Disconnect the multi-pin connector between the voltage regulator and the wire harness...5045
        5. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil (Figure 11a-10, Page 11a-15)...5045
        6. Set the multimeter to the diode test function (ç)...5045
        7. Connect the black (-) probe of the multimeter to the frame (ground)...5045
        8. Connect the red (+) probe of the multimeter to the 16-gauge green wire (w58) at the bullet connector...5045
        9. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5045
        10. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5045
        11. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12a, Page 12a-13...5045
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5046
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5046
        3. Disconnect the two-pin connector between the neutral switch and the wire harness (w02, and w56) (Figure 11a-17, Page 11a-22)...5046
        4. Check for continuity on the switch contacts with the Forward/Reverse handle in the FORWARD position (Figure 11a-18, Page 11a-24). The multimeter should indicate no continuity...5046
        5. Check for continuity on the switch contacts with the Forward/Reverse handle in the NEUTRAL position (Figure 11a-19, Page 11a-24). The multimeter should indicate continuity...5047
        6. Check for continuity on the switch contacts with the Forward/Reverse handle in the REVERSE position (Figure 11a-20, Page 11a-24). The multimeter should indicate no continuity...5047
        7. If any of the continuity readings are incorrect, replace the neutral switch. See Neutral Switch Removal on page 12a-2...5047
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5047
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5047
        3. To test a wire for continuity, disconnect either end from the electrical component to which it is attached...5047
        4. Set the multimeter to 200 ohms and place the red (+) probe on the terminal at one end of the wire. Place the black (-) probe ...5047
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5047
        2. Disconnect the battery as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5047
        3. Disconnect the two-pin connector between the wire harness and the front drive gearcase located under the front floorboard...5047
        4. Set the multimeter to 200 ohms...5047
        5. Measure the resistance between the two wires at the two-pin connector (front drive gearcase side)...5047
        6. The resistance should be 24.7 to 27.3 ohms...5047
        7. If the resistance is not within the stated range, replace the large output cover sub-assembly. See Section 18...5047
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5047
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5047
        3. Disconnect the multi-pin connector between the voltage regulator and the wire harness...5047
        4. Measure the resistance of the charge coil on the two blue wires at the voltage regulator multi-pin connector (harness side) (Figure 11a-21, Page 11a-26). The resistance should be small (less than 1 ohm)...5047
        5. If the resistance is high, or the multimeter indicates an over limit (no continuity), check the resistance at the two bullet connectors (engine side) close to the starter (Figure 11a-22, Page 11a-26)...5048
        6. If the resistance reading at the bullet connectors is less than 1 ohm, check for wire harness continuity on the blue wires (w...5048
        7. If the resistance is high, or the multimeter indicates an over limit (no continuity), the coil has failed. See Section 20...5048
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5048
        2. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary...5048
        3. Check the engine RPM setting to ensure that it is adjusted correctly. See Engine RPM Adjustment, Section 13a, Page 13a-25...5048
        4. With the battery in good condition and fully charged, run the engine for several minutes to bring the voltage regulator to operating temperature...5048
        5. Set the multimeter for 20 VDC...5048
        6. With the engine running at full-governed RPM, measure the battery voltage at the battery posts. If the reading is between 14...5048
        7. If the reading is less than 14.0 volts and not rising, check the charge coil. See Test Procedure 13 - Charge Coil on page 11a...5049
        8. If the reading is more than 15.0 volts and continues to rise, replace voltage regulator. See Voltage Regulator Removal, Section 12a, Page 12a-3...5049
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5049
        2. Remove the spark plug wire from one of the spark plugs...5049
        3. Use an ignition spark gap test tool (Thexton 404 or equivalent) to check for correct spark...5049
        4. Adjust the tester probes to approximately 18,000 volts (18 Kv), setting (SE - Small Engine Setting on the Thexton 404 tool). Connect the tester to the spark plug wire, and connect the alligator clip to a solid engine ground...5049
        5. If there is a strong blue spark between the probes of the spark gap tester, stop the engine, and perform the test on the remaining spark plug...5049
        6. There should be a strong blue spark between the probes of the spark gap tester when both spark plug circuits are tested. If t...5049
        7. If the spark gap tester tool indicates a strong blue spark, it is possible the spark plug has failed internally. Install a new spark plug set to the proper gap setting, and test the engine for proper operation. See Section 20...5049
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5049
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5049
        3. Disconnect white/black wire bullet connector located near the starter (Figure 11a-23, Page 11a-28)...5049
        4. Connect the red (+) probe of the multimeter to the male bullet terminal on the white/black wire, and connect the black (-) probe to the vehicle frame (ground). The multimeter should indicate continuity with the key switch in the OFF position...5049
        5. With the Forward/Reverse handle in the NEUTRAL position, insert the key and turn the key switch to the ON position. Note the multimeter reading. Turn the key and hold it in the START position. Note the multimeter reading...5049
        6. There should be no continuity when the key switch is in the ON or START position. If continuity is indicated, check for worn ...5050
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5050
        2. Disconnect the engine kill white/black wire (w38) at the bullet connector located near the starter (Figure 11a-23, Page 11a-28). See following NOTE...5050
        3. Turn the key switch to the START position, and release it after the engine starts. If the engine starts and continues to idle, check the kill wire for grounding. See Test Procedure 16 - Engine Kill Wire on page 11a-27. See following WARNING...5050
        4. Also check the key switch for proper operation. See Test Procedure 18 - Key Switch (Engine Kill Circuit) on page 11a-29. See preceding WARNING...5050
        5. If the engine does not run, connect the white/black wire at the bullet connector located near the starter and proceed to Test Procedure 15 - Ignition Spark on page 11a-27...5050
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5051
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5051
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5051
        4. Remove the connector from the key switch...5051
        5. Place the red (+) probe on the (M) terminal and the black (-) probe on the (G) terminal. With the key switch OFF, the reading...5051
        6. Reconnect the key switch to the wire harness. Ensure that the connector is connected correctly and is tight. If it is not, repair or replace as necessary...5051
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5051
        2. Check for proper wiring and tight connections at the reverse warning buzzer and the reverse warning buzzer limit switch (Figure 11a-25, Page 11a-30)...5051
        3. Move the Forward/Reverse handle to REVERSE and listen for an audible click from the limit switch. If there is no click, check the switch for proper alignment and switch arm movement...5051
        4. If the switch is being activated but the buzzer does not function, place the red (+) probe of the multimeter on one terminal ...5052
        5. Place the Forward/Reverse handle in the REVERSE position to activate the limit switch. The multimeter should indicate continu...5052
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5052
        2. Disconnect the battery as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5052
        3. Check for proper wiring and tight connections. Use a multimeter to check for continuity through each individual wire that con...5052
        1. Check the carburetor solenoid coil circuit...5052
        2. Check the carburetor solenoid coil...5053
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5054
        2. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5054
        3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary...5054
        4. Disconnect the 18-gauge black/white wire (w17) from the low oil warning light terminal...5054
        5. Leave the 18-gauge purple wire (w49) connected to the low oil warning light...5054
        6. Place a jumper wire on the terminal of the low oil warning light where the black/white wire was removed...5054
        7. Touch the frame (ground) with the remaining end of the jumper wire...5054
        8. Turn the key switch to the ON position. The low oil warning light should illuminate...5054
        9. If the low oil warning light does not illuminate when the key switch is in the ON position, check the 18- gauge purple wire (...5054
        10. If there is continuity between the 18-gauge purple wire (w49) at the low oil warning light and the 18-gauge purple wire (w47) at the key switch, replace the low oil warning light...5054
        11. If the problem is not corrected by performing the previous steps, test the oil pressure switch. See Section 20...5054
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5054
        2. Set the multimeter to 20 VDC...5054
        3. Measure the voltage between the center contact and the outer contact of the power point receptacle. The voltage should be approximately 12 VDC...5054
        4. If the voltage is not approximately 12 VDC, check the 10-amp fuse on wire 46 (w46) located on the electrical component mounting plate. See Test Procedure 2 - Fuse on page 11a-11...5054
        5. If the fuse is good, check the continuity of the wires connected to the power point receptacle...5054
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5055
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5055
        3. Disconnect the orange wire from the center post of the fuel level sending unit...5055
        4. With a multimeter set to 2k ohms, place the red (+) probe on the center post of the sending unit. Place the black (-) probe on the ground connection of the sending unit (Figure 11a-27, Page 11a-33)...5055
        5. The following resistance readings (in ohms) should be indicated, depending on the position of the float inside the fuel tank...5055
        6. If the readings are within the specifications listed in the preceding table, the fuel level sending unit is working properly...5055
        7. If the readings are correct and the fuel gauge does not function correctly, leave the battery disconnected and check the continuity of the following:...5056
        8. If the readings are correct according to the position of the float, but the reading on the fuel gauge/hour meter is incorrect, test the fuel gauge/hour meter. See Test Procedure 25 - Fuel Gauge on page 11a-34...5056
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5056
        2. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5056
        3. Disconnect the orange wire from the fuel gauge/hour meter...5056
        4. Set a multimeter to 20 volts DC, and place the red (+) probe on the positive (+) post of the battery. Place the black (-) probe on the negative (-) post of the battery. Record the voltage reading...5056
        5. Set a multimeter to 20 volts DC, and place the red (+) probe on the (2) terminal of the fuel gauge/hour meter where the blue ...5056
        6. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m)...5056
        7. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 11a-28, Page 11a-34)...5056
        8. The orange wire should remain disconnected for this step. Place the black probe of the multimeter on the (3) terminal of the ...5056
        1. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5057
        2. Turn the key switch ON, and record the current hour meter reading...5057
        3. Turn the key switch to the START position, and hold it until the engine is running smoothly. Release the key and it will return to the ON position. The engine should idle...5057
        4. Allow the engine to idle for at least 6 minutes (the meter records in 6-minute increments). See following DANGER...5057
        5. If the reading does not change after six minutes, check the low oil warning light and the oil pressure switch. See following NOTE. See also Test Procedure 22 - Low Oil Warning Light Circuit on page 11a-31...5057
        6. If the hour meter still does not function after the low oil warning light, oil pressure switch, and all of the appropriate wires have been checked for continuity, replace the fuel gauge/hour meter...5057
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5057
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5057
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5057
        4. Use a multimeter set to 20 volts DC, and place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal where the blue wire (w03) is connected (Figure 11a-30, Page 11a-36)...5057
        5. Connect the battery cables, positive (+) cable first...5058
        6. Connect the black (-) probe of the multimeter to the negative (-) post of the battery...5058
        7. With the light switch in the OFF position, the reading should indicate 0 volts. With the light in the ON position, the readin...5058
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5058
        2. Inspect the wires at the light bulb socket. Make sure the wires are securely fastened to the contacts inside the socket...5058
        3. Remove the wire harness from the headlight (Figure 11a-31, Page 11a-37)...5058
        4. Use a multimeter set to 20 volts DC, and place the black (-) probe into the black wire terminal of the wire harness. Place the red (+) probe into the blue wire terminal...5058
        5. Pull the light switch to the ON position. If the multimeter indicates approximately 12 volts, replace the headlight bulb...5058
        6. If there is no voltage reading at the wire harness, check the continuity of the 16-gauge blue wire from the headlight to the light switch...5059
        7. Check the continuity of the 16-gauge black wire from the headlight to the ground terminal...5059
        8. If the readings are correct in all of the previous steps, replace the headlamp...5059
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5060
        2. Disconnect the red and yellow wires from the bed lift motor (Figure 11a-32, Page 11a-37)...5060
        3. Set a multimeter for 20 VDC...5060
        4. Place the red probe in the bullet connector on the red wire (wire harness side), and place the black probe in the bullet connector on the black wire (wire harness side) (Figure 11a-33, Page 11a-38)...5060
        5. Have an assistant press the bed lift switch on the instrument panel in the UP position and monitor the multimeter:...5060
        6. Place the red probe in the bullet connector on the red wire (wire harness side), and place the black probe in the bullet connector on the black wire (wire harness side) (Figure 11a-34, Page 11a-38)...5060
        7. Have an assistant press the bed lift switch on the instrument panel in the DOWN position and monitor the multimeter:...5060
        8. If the bed lift motor does not function and the readings obtained in the previous steps are correct, the bed lift motor has failed and must be replaced. See Bed Lift Motor Removal, Section 4, Page 4-9...5061
        1. Remove the bed lift switch. See Bed Lift Switch Removal, Section 12a, Page 12a-14...5061
        2. Check continuity between the terminals (Figure 11a-35, Page 11a-39) of the toggle switch and compare the readings with the To...5061
        1. Remove the bed lift circuit breaker. See Bed Lift Circuit Breaker Removal, Section 12a, Page 12a-15...5062
        2. Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation, Section 12a, Page 12a-15...5062
  Section 11b - Troubleshooting and Electrical System: Diesel Vehicles...5063
    Troubleshooting Guide...5063
    Wiring Diagram...5068
    Test Procedures...5070
      Index of Test Procedures...5070
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5071
        2. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary...5071
        3. Be sure that the battery has sufficient water to cover the plates by approximately 1/2-inch (13 mm) and is fully charged before the test. If water must be added, recharge the battery before performing the hydrometer test (Figure 11b-4, Page 11b-10)...5071
        4. Remove the vent cap...5071
        5. Use a battery thermometer (CCI P/N 1011767), to record the electrolyte temperature of a center cell...5071
        6. Squeeze the rubber bulb of the hydrometer and insert it into the cell. Slowly release the bulb, drawing electrolyte up into the glass tube of the hydrometer...5071
        7. Ensure the float rises off the bottom. Adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release pressure from the bulb...5071
        8. Hold the hydrometer vertically, and ensure that the float does not contact the sides of the glass tube. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 11b-3, Page 11b-10)...5071
        9. Record the reading...5072
        10. Return the electrolyte to the cell from which it was taken. Replace vent cap...5072
        11. Repeat steps 4 through 10 on all cells...5072
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5072
        2. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary...5072
        3. Set the multimeter to the 20 VDC setting...5072
        4. Measure the voltage across the battery terminals. If the reading is less than 12.4 volts, or if the lowest specific gravity r...5073
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5073
        2. Check for loose or corroded battery terminal connections. Clean, tighten and replace connections as necessary...5073
        3. Connect a 160-ampere load tester to the battery posts. See following NOTE...5073
        4. Turn the load tester switch to the ON position...5073
        5. Read the battery voltage after the load tester has been turned ON for 15 seconds. The minimum acceptable battery voltage for proper engine starting is approximately 9.6 VDC...5073
        6. If the battery voltage is acceptable, or if the electrical problem continues after the battery has been replaced, test the electrical circuits...5073
        7. If the voltage reading exceeds 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the starter. See Section 19. See also the following NOTE...5073
        8. If the reading is less than 9.6 volts at 70 °F (21 °C) (electrolyte temperature), check the battery electrolyte in each cell. See Test Procedure 1A - Hydrometer Test on page 11b-9...5073
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5073
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5073
        3. Remove the electrical component cover...5073
        4. Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary...5073
        5. Remove the fuse to be tested from the fuse block...5073
        6. Connect the probes of a multimeter set to 200 ohms to the fuse terminals. The reading should be continuity. If there is no co...5074
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5074
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5074
        3. Check the frame ground connection for loose connections and damaged terminals (Figure 11b-6, Page 11b-13). Repair or replace as required...5074
        4. Check the negative (-) battery terminal and 6-gauge black wire (w92) for damage. Repair or replace as required...5074
        5. Check the engine ground for a loose connection and damaged terminals where the two 6-gauge black wires (w92 and w93) are connected to the engine block (under the starter) (Figure 11b-7, Page 11b-13). Repair or replace as required...5074
        6. Set the multimeter to 200 ohms...5074
        7. Check for continuity between the 6-gauge wire (w92) terminal that was disconnected from the negative battery terminal, and the frame...5074
        8. Check for continuity between the 6-gauge wire (w92) terminal that was disconnected from the negative battery terminal, and the engine...5074
        9. The readings obtained in the previous steps should indicate continuity. If any of the readings are incorrect, clean and tighten wire connections. If the connections are good and the reading is incorrect, repair or replace the wire...5075
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5075
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5075
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5075
        4. Ensure that the key switch connectors are connected correctly and are tight. If they are not, repair or replace as necessary...5075
        5. Set the multimeter to 200 ohms...5075
        6. Check the PR and GR key switch terminals...5075
        7. Check the BATT and ST terminals...5075
        8. Check the BATT and IGN terminals...5076
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5076
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5076
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5076
        4. Ensure that the key switch connectors are connected correctly and are tight. If they are not, repair or replace as necessary...5076
        5. Set the multimeter to 200 ohms...5076
        6. Check the BATT and IGN terminals...5076
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5077
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5077
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5077
        4. Ensure that the key switch connectors are connected correctly and are tight. If they are not, repair or replace as necessary...5077
        5. Set the multimeter to 200 ohms...5077
        6. Check the BATT and ACC terminals...5077
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5077
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11b-9, Page 11b-16). See following WARNING...5077
        3. Set the multimeter to 20 VDC...5077
        4. Place the probes to measure the voltage between the 16-gauge green wire (w58) terminal and the frame ground (Figure 11b-10, Page 11b-16)...5077
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF and ON positions. The reading should indicate approximately 12 VDC when the key is in the START position...5077
        6. If the readings differ from those described in step 5, perform the following test procedures:...5078
        7. If none of the previous steps resolves the problem, the starter solenoid and/or starter motor has failed. See Section 19...5078
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5079
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11b-9, Page 11b-16). See following WARNING...5079
        3. Set the multimeter to 20 VDC...5079
        4. Place the probes to measure the voltage between the 16-gauge green start relay wire (w44) terminal and the frame ground (Figure 11b-11, Page 11b-16)...5079
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF and ON positions. The reading should indicate approximately 12 VDC when the key is in the START position and the relay should click. See following NOTE...5079
        6. If the reading is 12 VDC and the relay does not click when the key switch is turned to the START position, replace the relay...5079
        7. If the reading is 12 VDC and the relay clicks when the key is in the START position, check the relay contacts...5079
        8. If the reading obtained in step 5 is not 12 VDC with the key in the START position, perform the following test procedures:...5079
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5080
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11b-9, Page 11b-16). See following WARNING...5080
        3. Set the multimeter to 20 VDC...5080
        4. Place the probes to measure the voltage between the 18-gauge purple differential relay wire (w50) terminal and the frame ground...5080
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF position and the Forward/Reverse handle i...5080
        6. If the reading is 12 VDC and the relay does not click with the key switch in the ON position and the Forward/Reverse handle in the NEUTRAL position, replace the relay...5080
        7. If the reading is 12 VDC and the relay clicks when the key is in the ON position, check the relay contacts...5080
        8. If the reading obtained in step 5 is not 12 VDC with the key in the ON position, perform the following test procedures:...5081
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5081
        2. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 11b-9, Page 11b-16). See following WARNING...5081
        3. Set the multimeter to 20 VDC...5081
        4. Place the probes to measure the voltage between the 18-gauge yellow fan relay wire (w81) terminal and the frame ground...5081
        5. Monitor the multimeter. The reading should indicate 0 volts with the key in the OFF position. The reading should indicate approximately 12 VDC when the key is in the ON position and the fan relay should click. See following NOTE...5081
        6. If the reading is 12 VDC and the relay does not click when the key switch is in the ON position, replace the relay...5081
        7. If the reading is 12 VDC and the relay clicks when the key is in the ON position, check the relay contacts...5082
        8. If the reading obtained in step 5 is not 12 VDC with the key in the ON position, perform the following test procedures:...5082
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5083
        2. Disconnect the two-pin connector between the thermostat switch and the wire harness (Figure 11b-17, Page 11b-21). See following WARNING...5083
        3. Unscrew the thermostat switch from the engine block. See preceding WARNING...5083
        4. Test for failed switches in closed condition...5083
        5. Test the fan control thermostat switch...5084
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5085
        2. Remove the front body. See Front Body Removal on page 4-5...5085
        3. Disconnect the two-pin connector from the fan motor (Figure 11b-19, Page 11b-23)...5085
        4. Disconnect the two-pin connector from the thermostat switch (Figure 11b-20, Page 11b-23)...5085
        5. Place a jumper wire between the frame and the 18-gauge yellow/black wire at the two-pin connector disconnected from the thermostat switch...5085
        6. Set a multimeter to measure 20 VDC...5085
        7. Place the multimeter probes into each terminal of the two-pin connector disconnected from the fan motor (wire harness side)...5085
        8. Connect the battery cables, positive (+) cable first...5085
        9. Leave the Forward/Reverse handle in the NEUTRAL position...5085
        10. Monitor the multimeter while turning the key switch to the ON position. The multimeter should indicate 0 (zero) VDC with the key in the OFF position, and approximately 12 VDC with the key switch in the ON position...5085
        11. If the voltage reading is approximately 12 VDC with the key switch in the OFF position, check the fan relay for proper wiring and function. See Test Procedure 10 - Fan Relay on page 11b-19...5086
        12. If the voltage reading is not approximately 12 VDC with the key switch in the ON position, check the following:...5086
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5087
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5087
        3. Disconnect the two-pin connector between the front gearcase and the wire harness...5087
        4. Set the multimeter to the diode test function (ç)...5087
        5. Connect the black (-) probe of the multimeter to the frame (ground)...5087
        6. Connect the red (+) probe of the multimeter to the 18-gauge gray wire (w34) on the two-pin connector (wire harness side)...5087
        7. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5087
        8. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5087
        9. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12b, Page 12b-18...5087
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5087
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5087
        3. Remove the front body. See Front Body Removal on page 4-5...5088
        4. Disconnect the two-pin connector between the fan and the wire harness (Figure 11b-19, Page 11b-23)...5088
        5. Set the multimeter to the diode test function (ç)...5088
        6. Connect the black (-) probe of the multimeter to the frame (ground)...5088
        7. Connect the red (+) probe of the multimeter to the 14-gauge blue wire (w66) on the two-pin connector (wire harness side)...5088
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5088
        9. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5088
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12b, Page 12b-18...5088
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5088
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5088
        3. Remove the start relay, differential relay, fan relay, and accessory relay from the multi-pin connector located on the electrical component mounting plate...5088
        4. Disconnect the two-pin connector between the neutral switch and the wire harness (Figure 11b-21, Page 11b-26)...5088
        5. Set the multimeter to the diode test function (ç)...5088
        6. Connect the black (-) probe of the multimeter to the 18-gauge black/white wire (w79) at the neutral switch two-pin connector...5088
        7. Connect the red (+) probe of the multimeter to the 18-gauge black wire (w61) on the multi-pin differential relay connector located on the electrical component mounting plate...5089
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5089
        9. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5089
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12b, Page 12b-18...5089
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5089
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5089
        3. Remove the start relay, differential relay, fan relay, and accessory relay from the multi-pin connector located on the electrical component mounting plate...5089
        4. Disconnect the two-pin connector between the neutral switch and the wire harness (Figure 11b-21, Page 11b-26)...5089
        5. Set the multimeter to the diode test function (ç)...5089
        6. Connect the black (-) probe of the multimeter to the 18-gauge black/white wire (w79) at the neutral switch two-pin connector...5089
        7. Connect the red (+) probe of the multimeter to the 18-gauge black wire (w60) on the multi-pin start relay connector located on the electrical component mounting plate...5089
        8. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5089
        9. Reverse the multimeter probes and note the reading. The multimeter should read approximately 540 mV, however, a range of 400-700 mV is acceptable...5089
        10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12b, Page 12b-18...5089
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5089
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5089
        3. Open the dashboard access door (Figure 11b-22, Page 11b-28)...5089
        4. Disconnect the multi-pin connector from the key switch (Figure 11b-23, Page 11b-28). See following NOTE...5090
        5. Remove the differential relay from the socket on the electrical component mounting plate (Figure 11b-24, Page 11b-28)...5090
        6. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 11b-25, Page 11b-28)...5090
        7. Disconnect the bullet connector between the fuel pump and the wire harness (Figure 11b-26, Page 11b-29)...5090
        8. Set the multimeter to the diode test function (ç)...5091
        9. Connect the black (-) probe of the multimeter to the frame (ground)...5091
        10. Connect the red (+) probe of the multimeter to the 18-gauge gray wire (w40) at the bullet connector (wire harness side)...5091
        11. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter p...5091
        12. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5091
        13. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12b, Page 12b-18...5091
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5091
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5091
        3. Disconnect the 16-gauge green wire (w58) from the starter solenoid coil (Figure 11b-9, Page 11b-16)...5091
        4. Set the multimeter to the diode test function (ç)...5091
        5. Connect the black (-) probe to the frame (ground)...5091
        6. Connect the red (+) probe to the 16-gauge green wire (w58) at the connector...5091
        7. The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter pr...5091
        8. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400-700 mV is acceptable...5092
        9. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal, Section 12b, Page 12b-18...5092
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5092
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5092
        3. Disconnect the two-pin connector between the neutral switch and the wire harness (w78, and w79) (Figure 11b-21, Page 11b-26)...5092
        4. Check for continuity on the switch contacts with the Forward/Reverse handle in the FORWARD position (Figure 11b-27, Page 11b-30). The multimeter should indicate no continuity...5092
        5. Check for continuity on the switch contacts with the Forward/Reverse handle in the NEUTRAL position (Figure 11b-28, Page 11b-31). The multimeter should indicate continuity...5092
        6. Check for continuity on the switch contacts with the Forward/Reverse handle in the REVERSE position (Figure 11b-28, Page 11b-31). The multimeter should indicate no continuity...5092
        7. If any of the continuity readings are incorrect, replace the neutral switch. See Neutral Switch Removal, Section 12b, Page 12b-2...5092
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5093
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5093
        3. To test a wire for continuity, disconnect either end from the electrical component to which it is attached...5093
        4. Set the multimeter to 200 ohms and place the red (+) probe on the terminal at one end of the wire. Place the black (-) probe ...5093
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5093
        2. Disconnect the battery as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5093
        3. Disconnect the two-pin connector between the wire harness and the front drive gearcase located under the front floorboard...5093
        4. Set the multimeter to 200 ohms...5093
        5. Measure the resistance between the two wires at the two-pin connector (front drive gearcase side)...5093
        6. The resistance should be 24.7 to 27.3 ohms...5093
        7. If the resistance is not within the stated range, replace the large output cover sub-assembly. See Section 18...5093
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5094
        2. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary...5094
        3. Check the engine RPM setting to ensure that it is adjusted correctly. See Engine RPM Adjustment, Section 13b, Page 13b-22...5094
        4. With the battery in good condition and fully charged, run the engine for several minutes to bring the voltage regulator to operating temperature...5094
        5. Set the multimeter for 20 VDC...5094
        6. With the engine running at full-governed RPM, measure the battery voltage at the battery posts. If the reading is between 14...5094
        7. If the reading is less than 14.2 volts and not rising or higher than 14.8 volts, replace the alternator...5094
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5094
        2. Remove the electrical component cover, and locate the 50-amp circuit breaker on the electrical component mounting plate (Figure 11b-30, Page 11b-32)...5094
        3. Ensure that the wires at the 50-amp circuit breaker and the large post of the starter solenoid are connected correctly and are tight. If they are not, rewire or tighten as necessary...5094
        4. Set the multimeter to 20 VDC...5094
        5. Place the black (-) probe on the frame (ground)...5094
        6. Place the red (+) probe on one of the studs of the 50-amp circuit breaker. The reading should indicate approximately 12 VDC (or full battery voltage)...5095
        7. Place the red (+) probe on the remaining stud of the 50-amp circuit breaker. The reading should indicate approximately 12 VDC (or full battery voltage)...5095
        8. If the multimeter indicated voltage on only one of the circuit breaker studs, the circuit breaker has failed and must be replaced. See 50-Amp Circuit Breaker Removal, Section 12b, Page 12b-3...5095
        9. If the multimeter did not indicate voltage on either of the circuit breaker studs, check the following:...5095
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5095
        2. Disconnect the two-pin connector from the thermostat switch (Figure 11b-20, Page 11b-23)...5095
        3. Place a jumper wire between the frame and the 18-gauge Green/White wire at the two-pin connector disconnected from the thermostat switch...5095
        4. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5095
        5. Disconnect the two wires connected to the engine coolant high-temperature light...5095
        6. Set a multimeter to 20 VDC...5096
        7. Place the multimeter probes into each terminal disconnected from the engine coolant high-temperature light...5096
        8. Connect the battery cables, positive (+) cable first...5096
        9. Leave the Forward/Reverse handle in the NEUTRAL position...5096
        10. Monitor the multimeter while turning the key switch to the ON position. The multimeter should indicate 0 (zero) VDC with the key in the OFF position and approximately 12 VDC with the key switch in the ON position...5096
        11. If the voltage reading is approximately 12 VDC with the key switch in the OFF position, check the key switch for proper wiring and function. See Test Procedure 5 - Key Switch (ON Position) on page 11b-14...5096
        12. If the voltage reading obtained in step 10 is correct, check the filament of the engine coolant high-temperature light...5096
        13. If the voltage reading obtained in step 10 is not approximately 12 VDC with the key switch in the ON position, check the following:...5096
        1. Turn the key switch OFF. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5096
        2. Set a multimeter to 20 VDC...5096
        3. Place the red (+) probe on the wire terminal where the 12-gauge blue wire (w28) connects to the glow plug and glow plug buss bar (Figure 11b-32, Page 11b-35)...5096
        4. Place the black (-) probe on the frame or engine block (ground)...5096
        5. The multimeter should indicate 0 VDC with the key in the OFF position...5096
        6. Monitor the multimeter, and turn the key to the PREHEAT position. Hold it for 5 seconds. The multimeter should indicate 11 to 12 VDC...5096
        7. If the readings in the previous two steps are incorrect, check the following:...5097
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5097
        2. Check for proper wiring and tight connections at the reverse warning buzzer and the reverse warning buzzer limit switch (Figure 11b-33, Page 11b-36)...5097
        3. Move the Forward/Reverse handle to REVERSE and listen for an audible click from the limit switch. If there is no click, check the switch for proper alignment and switch arm movement...5097
        4. If the switch is being activated but the buzzer does not function, place the red (+) probe of the multimeter on one terminal ...5097
        5. Place the Forward/Reverse handle in the REVERSE position to activate the limit switch. The multimeter should indicate continu...5097
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5098
        2. Disconnect the battery as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5098
        3. Check for proper wiring and tight connections. Use a multimeter, and check for continuity through each wire that connects to ...5098
        1. Turn the key switch OFF. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5098
        2. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 11b-25, Page 11b-28)...5098
        3. Set a multimeter to 20 VDC...5098
        4. Place the red (+) probe on the 14-gauge blue wire (w43) of the three-pin connector at the fuel solenoid (wire harness side)...5098
        5. Place the black (-) probe on the frame or engine block (ground)...5098
        6. The multimeter should indicate 0 VDC with the key in the OFF position...5098
        7. Monitor the multimeter, and turn the key switch to the ON position. The multimeter should indicate 0 VDC...5098
        8. Monitor the multimeter, and turn the key switch to the START position. The multimeter should indicate between 10 and 11.5 VDC...5098
        9. If the reading obtained in the previous step is correct, and the fuel solenoid does not operate correctly, replace the fuel solenoid. See Section 19...5099
        10. If any of the above readings is incorrect, check the following items:...5099
        1. Turn the key switch OFF. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5099
        2. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 11b-25, Page 11b-28)...5099
        3. Set a multimeter to 20 VDC...5099
        4. Place the red (+) probe on the 18-gauge gray wire (w41) of the three-pin connector at the fuel solenoid (wire harness side)...5099
        5. Place the black (-) probe on the frame or engine block (ground)...5099
        6. The multimeter should indicate 0 VDC with the key switch in the OFF position...5099
        7. Monitor the multimeter, and turn the key switch to the ON position. The multimeter should indicate approximately 12 VDC...5099
        8. If the reading obtained in the previous step is correct, and the fuel solenoid does not operate correctly, replace the fuel solenoid. See Section 19...5099
        9. If any of the above readings is incorrect, check the following items:...5099
        1. Turn the key switch OFF. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5099
        2. Disconnect the bullet connector between the fuel pump and the wire harness (Figure 11b-26, Page 11b-29)...5099
        3. Set a multimeter to 20 VDC...5099
        4. Place the red (+) probe on the 18-gauge gray wire (w40) disconnected from the fuel pump (wire harness side)...5099
        5. Place the black (-) probe on the frame or engine block (ground)...5100
        6. The multimeter should indicate 0 (zero) VDC with the key switch in the OFF position...5100
        7. Monitor the multimeter, and turn the key switch to the ON position. The multimeter should indicate approximately 12 VDC with the key in the ON position...5100
        8. If the reading obtained in the previous step is correct and the fuel pump does not operate correctly, replace the fuel pump. See Fuel Pump Removal, Section 13b, Page 13b-12...5100
        9. If any of the above readings is incorrect, check the following items:...5100
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5100
        2. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5100
        3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary...5100
        4. Disconnect the 18-gauge black/white wire (w17) from the low oil warning light terminal...5100
        5. Leave the 18-gauge purple wire (w49) connected to the low oil warning light...5100
        6. Place a jumper wire on the terminal of the low oil warning light where the black/white wire was removed...5100
        7. Touch the frame (ground) with the remaining end of the jumper wire...5100
        8. Turn the key switch to the ON position. The low oil warning light should illuminate...5100
        9. If the low oil warning light does not illuminate when the key switch is in the ON position, check the 18- gauge purple wire (...5100
        10. If there is continuity between the 18-gauge purple wire (w49) at the low oil warning light and the 18-gauge purple wire (w29) at the key switch, replace the low oil warning light...5100
        11. If the problem is not corrected by performing the previous steps, test the oil pressure switch. See Section 19...5100
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5101
        2. Set the multimeter to 20 VDC...5101
        3. Measure the voltage between the center contact and the outer contact of the power point receptacle. The voltage should be approximately 12 VDC...5101
        4. If the voltage is not approximately 12 VDC, check the 10-amp fuse on wire 46 (w46) located on the electrical component mounting plate. See Test Procedure 2 - Fuse on page 11b-11...5101
        5. If the fuse is good, check the continuity of the wires connected to the power point receptacle...5101
        1. Turn the key switch OFF, and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5101
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5101
        3. Disconnect the orange wire from the center post of the fuel level sending unit...5101
        4. With a multimeter set to 2k ohms, place the red (+) probe on the center post of the sending unit. Place the black (-) probe on the ground connection of the sending unit (Figure 11b-34, Page 11b-39)...5101
        5. The following resistance readings (in ohms) should be indicated, depending on the position of the float inside the fuel tank...5102
        6. If the readings are within the specifications listed in the preceding chart, the fuel level sending unit is working properly...5102
        7. If the readings are correct and the fuel gauge does not function correctly, leave the battery disconnected and check the continuity of the following:...5102
        8. If the readings are correct according to the position of the float, but the reading on the fuel gauge/hour meter is incorrect, test the fuel gauge/hour meter. See Test Procedure 29 - Fuel Gauge on page 11b-40...5102
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5102
        2. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5102
        3. Disconnect the orange wire from the fuel gauge/hour meter...5102
        4. Set a multimeter to 20 volts DC, and place the red (+) probe on the positive (+) post of the battery. Place the black (-) probe on the negative (-) post of the battery. Record the voltage reading...5102
        5. Set a multimeter to 20 volts DC, and place the red (+) probe on the (2) terminal of the fuel gauge/hour meter where the blue ...5102
        6. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m)...5102
        7. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 11b-35, Page 11b-41)...5102
        8. The orange wire should remain disconnected for this step. Place the black probe of the multimeter on the (3) terminal of the ...5102
        1. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5103
        2. Turn the key switch ON, and record the current hour meter reading...5103
        3. Turn the key switch to the START position, and hold it until the engine is running smoothly. Release the key and it will return to the ON position. The engine should idle...5103
        4. Allow the engine to idle for at least 6 minutes (the meter records in 6-minute increments). See following DANGER...5103
        5. If the reading does not change after six minutes, check the low oil warning light and the oil pressure switch. See following NOTE. See also Test Procedure 26 - Low Oil Warning Light Circuit on page 11b-38...5103
        6. If the hour meter still does not function after the low oil warning light, oil pressure switch, and all of the appropriate wires have been checked for continuity, replace the fuel gauge/hour meter...5103
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5103
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5103
        3. Remove the instrument panel. See Instrument Panel Removal, Section 12b, Page 12b-4...5104
        4. Use a multimeter set to 20 volts DC, and place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal where the blue wire (w03) is connected (Figure 11b-37, Page 11b-42)...5104
        5. Connect the battery cables, positive (+) cable first...5104
        6. Connect the black (-) probe of the multimeter to the negative (-) post of the battery...5104
        7. With the light switch in the OFF position, the reading should indicate 0 volts. With the light in the ON position, the readin...5104
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5104
        2. Inspect the wires at the light bulb socket. Make sure the wires are securely fastened to the contacts inside the socket...5104
        3. Remove the wire harness from the headlight (Figure 11b-38, Page 11b-43)...5104
        4. Use a multimeter set to 20 volts DC, and place the black (-) probe into the black wire terminal of the wire harness. Place the red (+) probe into the blue wire terminal...5104
        5. Pull the light switch to the ON position. If the multimeter reading indicates approximately 12 volts, replace the headlight bulb...5104
        6. If there is no voltage reading at the wire harness, check the continuity of the 16-gauge blue wire from the headlight to the light switch...5105
        7. Check the continuity of the 16-gauge black wire from the headlight to the ground terminal...5105
        8. If the readings are correct in all of the previous steps, replace the headlamp...5105
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5106
        2. Disconnect the red and yellow wires from the bed lift motor (Figure 11b-39, Page 11b-43)...5106
        3. Set a multimeter for 20 VDC...5106
        4. Place the red probe in the bullet connector on the red wire (wire harness side), and place the black probe in the bullet connector on the black wire (wire harness side) (Figure 11b-40, Page 11b-44)...5106
        5. Have an assistant press the bed lift switch on the instrument panel in the UP position and monitor the multimeter:...5106
        6. Place the red probe in the bullet connector on the red wire (wire harness side), and place the black probe in the bullet connector on the black wire (wire harness side) (Figure 11b-41, Page 11b-44)...5106
        7. Have an assistant press the bed lift switch on the instrument panel in the DOWN position and monitor the multimeter:...5106
        8. If the bed lift motor does not function and the readings obtained in the previous steps are correct, the bed lift motor has failed and must be replaced. See Bed Lift Motor Removal, Section 4, Page 4-9...5107
        1. Remove the bed lift switch. See Bed Lift Switch Removal, Section 12a, Page 12a-14...5107
        2. Check continuity between the terminals (Figure 11b-42, Page 11b-45) of the toggle switch and compare the readings with the To...5107
        1. Remove the bed lift circuit breaker. See Bed Lift Circuit Breaker Removal, Section 12b, Page 12b-19...5108
        2. Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation, Section 12b, Page 12b-19...5108
  Section 12a - Electrical Components: Gasoline Vehicles...5109
    Starter and Starter Solenoid...5109
    Relays...5109
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5110
      2. Remove the electrical component cover...5110
      3. Remove the relay from the multi-pin connector...5110
      1. Insert the relay into the multi-pin connector. See following NOTE...5110
    Neutral Switch...5110
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5110
      2. Disconnect the two-pin connector between the neutral switch and the wire harness...5110
      3. Use a wrench to loosen and remove the neutral switch from the transmission housing...5110
      1. Install the neutral switch to the transmission housing. Tighten the hardware to 20.5 ft-lb (27.8 N·m)...5110
      2. Connect the two-pin connector between the neutral switch and the wire harness...5110
      3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5110
    Carburetor Solenoid...5110
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5110
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2...5110
      3. Remove the intake hose from the carburetor intake adapter and remove the carburetor...5110
      4. Disconnect the 18-gauge yellow wire (w39) from the carburetor solenoid bullet connector (Figure 12a-3, Page 12a-3)...5111
      5. Remove the solenoid from the carburetor. See Section 20...5111
      1. Install the carburetor solenoid on the carburetor and install the carburetor. See Section 20...5111
      2. Install the intake hose on the carburetor intake adapter...5111
      3. Connect the 18-gauge yellow wire (w39) from the carburetor solenoid to the wire harness (Figure 12a-3, Page 12a-3)...5111
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5111
    Voltage Regulator...5111
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5111
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2...5111
      3. Disconnect the multi-pin connector between the voltage regulator and the wire harness (Figure 12a-4, Page 12a-4)...5111
      4. Remove the voltage regulator mounting screws and remove the voltage regulator...5111
      1. Position the voltage regulator on the mounting plate and install the mounting screws. Tighten screws to 9.0 ft-lb (12.2 N·m) (Figure 12a-4, Page 12a-4)...5111
      2. Connect the multi-pin connector from the voltage regulator to the wire harness...5112
      3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5112
      4. With the Forward/Reverse handle in NEUTRAL, start the engine and check the regulator for proper functioning as described in the voltage regulator test procedure. See Test Procedure 14, Section 11a, Page 11a-26...5112
    Instrument Panel...5112
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5112
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5112
      3. Loosen the Tuflok screws, but do not remove screws completely, as shown in Detail A (Figure 12a-5, Page 12a-5)...5112
      4. Remove Tuflok screws from instrument panel as shown in Detail B...5112
      5. Pull forward on top of the instrument panel...5112
      6. If required, disconnect the electrical components...5112
      7. If required, remove the choke cable. See Choke Cable Removal on page 13a-27...5112
      1. Reverse removal procedures to install the instrument panel...5113
      2. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5113
    Key Switch...5113
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5114
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5114
      3. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5114
      4. Remove the multi-pin connector from the key switch...5114
      5. Remove the key switch nut, and remove the key switch from the back side of the instrument panel...5114
      1. Reverse the removal procedure to install key switch in the instrument panel. Tighten the key switch nut firmly...5114
      2. Connect the multi-pin connector to the key switch...5114
      3. Install the instrument panel in reverse order of removal...5114
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5114
    Fuse...5114
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5114
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5114
      3. Remove the electrical component cover (located near the battery)...5114
      4. Remove the fuse from the fuse block...5114
      1. Install the fuse. See following WARNING...5114
      2. Install the electrical component cover...5114
      3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5114
    Reverse Warning Buzzer...5115
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5115
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5115
      3. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5115
      4. Remove the plastic rivets securing the reverse warning buzzer, and remove the reverse warning buzzer (Figure 12a-6, Page 12a-7)...5115
      1. Install the reverse warning buzzer, and secure it with two plastic rivets...5115
      2. Connect the black wire from the wire harness to the negative (-) terminal on the buzzer...5115
      3. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer...5115
      4. Reverse the removal procedure to install the instrument panel on the vehicle...5115
      5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5115
    Reverse Warning Buzzer Limit Switch...5115
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5116
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5116
      3. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5116
      4. Disconnect the wires from the reverse warning buzzer limit switch (Figure 12a-6, Page 12a-7)...5116
      5. Remove the screws, nuts, washers, and lockwashers that secure the limit switch...5116
      6. Remove the limit switch...5116
      1. Install the reverse warning buzzer limit switch in the reverse order of removal...5116
      2. Place the Forward/Reverse handle in the REVERSE position...5116
      3. Tighten the limit switch mounting screws so that they are snug but the limit switch can still be rotated in the adjustment slot (Figure 12a-7, Page 12a-8)...5116
      4. Rotate the limit switch so that the lobe on the Forward/Reverse handle activates the limit switch as shown (Figure 12a-8, Page 12a-8)...5116
      5. Hold the limit switch in position, and tighten the mounting screws and nuts to 4 in-lb (0.5 N·m). See following CAUTION...5116
      6. Place the Forward/Reverse handle in NEUTRAL and then back to REVERSE to ensure that the limit switch lever is being properly activated...5116
      7. Connect the 18-gauge red and 18-gauge red/white wires to the limit switch...5116
      8. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5117
      9. Turn the key switch to the ON position. With the Forward/Reverse handle in REVERSE, the buzzer should sound...5117
    Low Oil Warning Light...5117
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5117
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5117
      3. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5117
      4. Disconnect the wires from the low oil warning light (1) (Figure 12a-9, Page 12a-9)...5117
      5. Press the retaining tabs and remove the low oil warning light from the instrument panel...5117
      1. Push a new low oil warning light into the hole in the instrument panel until the plastic tabs are securely engaged (Figure 12a-9, Page 12a-9)...5117
      2. Connect the 18-gauge purple and 18-gauge black/white wires from the wire harness to the low oil warning light...5118
      3. Install the instrument panel in reverse order of removal...5118
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5118
    Fuel Gauge/Hour Meter...5118
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5118
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5118
      3. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5118
      4. Disconnect the wires from the fuel gauge/hour meter (2) (Figure 12a-9, Page 12a-9)...5118
      5. Remove the two hex nuts (3) and lockwashers (4) from the threaded studs on the back of the gauge. Remove the mounting bracket (5) from the back side of the gauge/meter, and remove it from the instrument panel...5118
      1. Install a new fuel gauge/hour meter into the hole in the instrument panel until the flange seats against the instrument panel (Figure 12a-9, Page 12a-9)...5118
      2. Slide the mounting bracket onto the two threaded studs on the fuel gauge/hour meter. Secure with two lockwashers and two hex ...5118
      3. Connect the wires to the fuel gauge/hour meter. See Wiring Diagram, Section 11a, Page 11a-6...5118
      4. Coat the terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5118
      5. Install the instrument panel in reverse order of removal...5118
      6. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5118
    Fuel Level Sending Unit...5119
    Ignition Coil and Charge Coil...5119
    Charge Coil...5119
    Oil Pressure Sensor...5119
    Headlights...5120
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5120
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5120
      3. From the front of the vehicle, reach under the cowl and turn the wire harness/halogen bulb assembly (4 and 6) clockwise one-quarter turn (Figure 12a-10, Page 12a-12)...5120
      4. Remove the wire harness/halogen bulb assembly (4 and 6) from the headlight lens (7)...5120
      5. Lift the retaining tabs on the connector (4), and remove the halogen bulb assembly (6)...5120
      1. Connect the wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halogen bulb assembly (Figure 12a-10, Page 12a-12)...5120
      2. From the front of vehicle, reach under the cowl and insert the wire harness/halogen bulb assembly (4 and 6) into the headlight lens (7)...5120
      3. Turn the wire harness/halogen bulb assembly (4 and 6) counterclockwise one-quarter turn...5120
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5120
    Light Switch...5121
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5121
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5121
      3. Loosen the set screw locking the light switch knob to the shaft...5121
      4. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5121
      5. Disconnect the wires from the light switch...5121
      6. Remove the outer nut from the light switch (3), and remove the switch...5121
      1. Connect the wires to the light switch. See Wiring Diagram, Section 11a, Page 11a-6...5121
      2. Thread the check nut onto the switch until an equal number of threads show on both sides. Install to the instrument panel with the nut on the outside of the instrument panel, and tighten the nut to 14 in-lb (1.6 N·m)...5121
      3. Push the light switch shaft in. Screw the knob onto the end of the shaft until the knob touches the outer nut. Turn the knob ...5121
      4. Install the instrument panel in reverse order of removal...5121
      5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5121
    Wire Harness Diodes...5121
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5121
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5121
      3. Locate the diode to be replaced by removing the wire conduit and tracing the wire...5121
      4. Note the polarity of the diode as indicated by the white stripe on one side of the diode, and mark the wire on the side of the white stripe...5121
      5. Cut the wires attached to each side of the diode and discard the diode...5121
      1. Slide a piece of heatshrink tubing over one of the wire ends where the diode will be attached...5122
      2. Install the new diode using in-line wire splicing connectors. Make sure to observe polarity and place the side of the diode with the white stripe on the wire that was marked when the diode was removed...5122
      3. Slide the heatshrink tubing over the diode and ensure that it will, after being activated, adequately cover the uninsulated diode leads...5122
      4. Activate the heatshrink by carefully applying heat to the tubing...5122
      5. Bundle the wires into the plastic wire conduit and replace any wire ties that were removed when the wires were traced...5122
      6. Restore the wire harness routing to the original routing, and secure the harness with wire ties as required...5122
      7. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5122
    Bed Lift Switch...5122
      1. Remove the instrument panel. See Instrument Panel Removal on page 12a-4...5122
      2. Remove the wires from the bed lift toggle switch...5122
      3. Remove the nut and washer securing the bed lift toggle switch to the instrument panel and remove the switch...5122
      1. Connect the wires to the bed lift toggle switch as shown (Figure 12a-11, Page 12a-14)...5123
      2. Secure the bed lift toggle switch to the instrument panel with the washer and nut...5123
      3. Install the instrument panel. See Instrument Panel Installation on page 12a-5...5123
    Bed Lift Circuit Breaker...5123
      1. Open and remove the dashboard access panel located above the steering column...5123
      2. Locate the bed lift circuit breaker on the orange wire in the black plastic conduit (Figure 12a-12, Page 12a-15)...5123
      3. Pull the circuit breaker from the in-line fuse holder and remove the circuit breaker...5123
    Battery...5124
      General Information...5124
        1. To keep the battery in good operating condition, remove corrosion immediately. Post connections should be clean and tight. Fr...5124
        2. The battery should be kept clean and dry to prevent self-discharge. Dirt, grime, and acid spillage should be removed. Wash th...5124
        3. Maintain the proper water level. See Water Level on page 12a-17...5124
        4. Check the battery periodically to ensure that it is in a full state of charge. See Charging the Battery on page 12a-18...5124
        5. Keep the battery hold-down clamp tight. See Vibration Damage on page 12a-17...5124
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5125
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5125
        3. Remove the driver-side seat...5125
        4. Remove the battery hold-down located on the bottom of the battery...5125
        5. Remove the battery. See following WARNING...5125
        1. Charge the battery with an automotive type 12-volt battery charger. Follow all warnings and procedures supplied by the battery charger manufacturer...5126
        2. Attach the charger, positive (+) cable to the positive (+) battery post, and negative (-) cable to the negative (-) battery post...5126
        3. The battery may be charged with a slow charge (3-10 amps) or a fast charge (20-30 amps). Charge until the specific gravity reaches 1.250. See following WARNING...5126
        1. Place the battery into the vehicle with the battery posts facing the rear of the vehicle...5126
        2. Secure the battery to the vehicle with the clamp at the bottom of the battery. Tighten the clamp retaining bolt to 9 ft-lb (12.2 N·m)...5126
        3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5126
        1. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 12a-16...5126
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5126
        3. Fully charge the battery prior to storage...5126
        4. Store in a cool, dry area. The colder the area in which the battery is stored, the less the battery will self- discharge. A b...5126
        5. Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and crack. If the specific gravity drops below 1.220, the battery should be recharged. See following WARNING...5127
        6. The frequency of recharging required depends on the temperature of the storage area, but it is recommended that the battery b...5127
  Section 12b - Electrical Components: Diesel Vehicles...5129
    Starter and Starter Solenoid...5129
    Relays...5129
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5130
      2. Remove the electrical component cover...5130
      3. Remove the relay from the multi-pin connector...5130
      1. Insert the relay into the multi-pin connector. See following NOTE...5130
    Neutral Switch...5130
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5130
      2. Disconnect the two-pin connector between the neutral switch and the wire harness...5130
      3. Use a wrench to loosen and remove the neutral switch from the transmission housing...5130
      1. Install the neutral switch to the transmission housing. Tighten to 20.5 ft-lb (27.8 N·m)...5130
      2. Connect the two-pin connector between the neutral switch and the wire harness...5130
      3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5130
    Fuel Solenoid...5130
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5130
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2...5131
      3. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 12b-3, Page 12b-3)...5131
      4. Remove the two bolts securing the fuel solenoid to the engine block, and lift the solenoid from the engine (Figure 12b-3, Page 12b-3)...5131
      1. Place the pin on the end of the fuel solenoid lever into the slot of the engine throttle (Figure 12b-4, Page 12b-3)...5131
      2. Secure the fuel solenoid to the engine block with two bolts. Tighten the bolts to 6.4 ft-lb (8.7 N·m)...5131
      3. Connect the three-pin connector from the fuel solenoid to the wire harness (Figure 12b-3, Page 12b-3)...5131
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5131
    50-Amp Circuit Breaker...5131
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5131
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2...5131
      3. Remove the electrical component cover, and locate the 50-amp circuit breaker on the electrical component mounting plate just beneath the fuse block...5131
      4. Remove the locknuts that secure the two 10-gauge wires to the circuit breaker (Figure 12b-5, Page 12b-4)...5132
      5. Press the tabs on the plastic fasteners, and gently pry the circuit breaker from the electrical component mounting plate...5132
      1. Secure the 50-amp fuse to the electrical component mounting plate with the two plastic fasteners (Figure 12b-5, Page 12b-4)...5132
      2. Attach each of the 10-gauge red wires to the posts on the 50-amp circuit breaker...5132
      3. Tighten the two locknuts to 28 in-lb (3.2 N·m)...5132
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5132
    Instrument Panel...5132
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5132
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5132
      3. Loosen the Tuflok screws, but do not remove screws completely, as shown in Detail A (Figure 12b-6, Page 12b-5)...5132
      4. Remove Tuflok screws from instrument panel as shown in Detail B...5132
      5. Pull forward on top of instrument panel...5132
      6. If required, disconnect the electrical components...5132
      1. Reverse removal procedures to install the instrument panel...5133
      2. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5133
    Key Switch...5133
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5134
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5134
      3. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5134
      4. Remove the multi-pin connector from the key switch...5134
      5. Remove the remaining 18-gauge light green wire (w44) from the GR key switch terminal...5134
      6. Remove the key switch nut, and remove the key switch from the back side of the instrument panel...5134
      1. Reverse the removal procedure to install key switch in the instrument panel. Tighten the key switch nut firmly...5134
      2. Connect the multi-pin connector to the key switch...5134
      3. Connect the 18-gauge light green wire (w44) to the GR key switch terminal...5134
      4. Install the instrument panel in reverse order of removal...5134
      5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5134
    Fuse...5134
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5134
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5134
      3. Remove the electrical component cover (located near the battery)...5134
      4. Remove the fuse from the fuse block...5134
      1. Install the fuse. See following WARNING...5134
      2. Install the electrical component cover...5134
      3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5134
    Reverse Warning Buzzer...5135
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5135
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5135
      3. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5135
      4. Remove the plastic rivets securing the reverse warning buzzer, and remove the reverse warning buzzer (Figure 12b-7, Page 12b-7)...5135
      1. Install the reverse warning buzzer and secure it with two plastic rivets...5135
      2. Connect the black wire from the wire harness to the negative (-) terminal on the buzzer...5135
      3. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer...5135
      4. Reverse the removal procedure to install the instrument panel on the vehicle...5135
      5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5135
    Reverse Warning Buzzer Limit Switch...5136
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5136
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5136
      3. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5136
      4. Disconnect the wires from the reverse warning buzzer limit switch (Figure 12b-7, Page 12b-7)...5136
      5. Remove the screws, nuts, washers, and lockwashers that secure the limit switch...5136
      6. Remove the limit switch...5136
      1. Install the reverse warning buzzer limit switch in the reverse order of removal...5136
      2. Place the Forward/Reverse handle in the REVERSE position...5136
      3. Tighten the limit switch mounting screws so that they are snug, but the limit switch can still be rotated in the adjustment slot (Figure 12b-8, Page 12b-8)...5136
      4. Rotate the limit switch so that the lobe on the Forward/Reverse handle activates the limit switch as shown (Figure 12b-9, Page 12b-8)...5136
      5. Hold the limit switch in position, and tighten the mounting screws and nuts to 4 in-lb (0.5 N·m). See following CAUTION...5136
      6. Place the Forward/Reverse handle in NEUTRAL and then back to REVERSE to ensure that the limit switch lever is being properly activated...5137
      7. Connect the 18-gauge red and 18-gauge red/white wires to the limit switch...5137
      8. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5137
      9. Turn the key switch to the ON position. With the Forward/Reverse handle in REVERSE, the buzzer should sound...5137
    Low Oil Warning Light...5137
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5137
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5137
      3. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5137
      4. Disconnect the wires from the low oil warning light (1) (Figure 12b-10, Page 12b-10)...5137
      5. Press the retaining tabs and remove the low oil warning light from the instrument panel...5137
      1. Push a new low oil warning light into the hole in the instrument panel until the plastic tabs are securely engaged (Figure 12b-10, Page 12b-10)...5137
      2. Connect the 18-gauge purple and 18-gauge black/white wires from the wire harness to the low oil warning light...5137
      3. Install the instrument panel in reverse order of removal...5137
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5137
    Fuel Gauge/Hour Meter...5138
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5138
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5138
      3. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5138
      4. Disconnect the wires from the fuel gauge/hour meter (2) (Figure 12b-10, Page 12b-10)...5138
      5. Remove the two hex nuts (3) and lockwashers (4) from the threaded studs on the back of the gauge. Remove the mounting bracket (5) from the back side of the gauge/meter, and remove it from the instrument panel...5138
      1. Install a new fuel gauge/hour meter into the hole in the instrument panel until the flange seats against the instrument panel (Figure 12b-10, Page 12b-10)...5139
      2. Slide the mounting bracket onto the two threaded studs on the fuel gauge/hour meter. Secure the fuel gauge/hour meter with tw...5139
      3. Connect the wires to the fuel gauge/hour meter. See Wiring Diagram, Section 11b, Page 11b-6...5139
      4. Coat the terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5139
      5. Install the instrument panel in reverse order of removal...5139
      6. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5139
    Electric Fuel Pump...5139
    Fuel Level Sending Unit...5139
    Alternator...5140
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5140
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5140
      3. Disconnect the 18-gauge purple wire from the alternator (Figure 12b-11, Page 12b-12)...5140
      4. Disconnect the 10-gauge red wire from the alternator (Figure 12b-12, Page 12b-12)...5140
      5. Loosen and remove the belt tension adjustment bolt at the top of the alternator (Figure 12b-13, Page 12b-13)...5140
      6. Loosen and remove the alternator mounting bolt at the bottom of the alternator (Figure 12b-14, Page 12b-13)...5140
      7. Remove the belt shield and the alternator from the engine compartment...5140
      8. If necessary, remove the V-belt...5140
      1. Place the alternator and belt shield on the engine, and insert the alternator mounting bolt through the shield and alternator...5141
      2. Insert the belt tension adjustment bolt through the belt shield mounting hole and adjustment slot and into the alternator hou...5141
      3. Place the V-belt on the alternator pulley...5141
      4. Place a belt tension gauge on the V-belt, and use a pry bar to increase the belt tension. Use a Krikit brand belt tension gau...5141
      5. Hold the pry bar to maintain the proper belt tension adjustment, and tighten the belt tension adjustment bolt to 19.0 ft-lb (25.8 N·m) (Figure 12b-13, Page 12b-13)...5141
      6. Tighten the alternator mounting bolt to 19.0 ft-lb (25.8 N·m) (Figure 12b-14, Page 12b-13). See following CAUTION...5141
      7. Connect the 10-gauge red wire to the alternator (Figure 12b-12, Page 12b-12). Tighten the nut to 7.0 ft-lb (9.5 N·m)...5141
      8. Connect the 18-gauge purple wire to the alternator (Figure 12b-11, Page 12b-12)...5141
      9. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5141
    Oil Pressure Sensor...5142
    Headlights...5142
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5142
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5142
      3. From the front of the vehicle, reach under the cowl and turn the wire harness/halogen bulb assembly (4 and 6) clockwise one-quarter turn (Figure 12b-15, Page 12b-14)...5142
      4. Remove the wire harness/halogen bulb assembly (4 and 6) from the headlight lens (7)...5142
      5. Lift the retaining tabs on the connector (4), and remove the halogen bulb assembly (6)...5142
      1. Connect the wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halogen bulb assembly (Figure 12b-15, Page 12b-14)...5143
      2. From the front of vehicle, reach under the cowl and insert the wire harness/halogen bulb assembly (4 and 6), into the headlight lens (7)...5143
      3. Turn the wire harness/halogen bulb assembly (4 and 6) counterclockwise one-quarter turn...5143
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5143
    Light Switch...5143
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5143
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5143
      3. Loosen the set screw locking the light switch knob to the shaft...5143
      4. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5143
      5. Disconnect the wires from the light switch...5143
      6. Remove the outer nut from the light switch (3), and remove the switch...5143
      1. Connect the wires to the light switch. See Wiring Diagram, Section 11b, Page 11b-6...5143
      2. Thread the check nut onto the switch until an equal number of threads show on both sides. Install to the instrument panel with the nut on the outside of the instrument panel, and tighten the nut to 14 in-lb (1.6 N·m)...5143
      3. Push the light switch shaft in. Screw the knob onto the end of the shaft until the knob touches the outer nut. Turn the knob ...5143
      4. Install the instrument panel in reverse order of removal...5143
      5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5143
    Thermostat Switch...5144
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5144
      2. Disconnect the two-pin connector between the thermostat switch and the wire harness (Figure 12b-16, Page 12b-16). See following WARNING...5144
      3. Loosen the radiator cap to relieve pressure...5144
      4. Unscrew the thermostat switch from the engine block. See preceding WARNING...5144
      1. Apply Loctite 567 Liquid Thread Sealer to the threads of the thermostat switch. See following CAUTION...5144
      2. Hand-tighten the thermostat switch, and then tighten two full revolutions...5144
      3. Connect the two-pin connector from the thermostat switch to the wire harness...5144
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5145
    Fan Motor...5145
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5145
      2. Disconnect the two-pin connector between the fan motor and the wire harness (Figure 12b-17, Page 12b-17)...5145
      3. Remove the radiator. See Radiator Removal on page 15-4...5145
      4. Remove the four bolts securing the fan to the radiator (Figure 12b-18, Page 12b-17)...5145
      5. Remove the fan from the radiator...5145
      1. Secure the fan to the radiator with four bolts (Figure 12b-18, Page 12b-17). Tighten the hardware to 4.0 ft-lb (5.8 N·m)...5145
      2. Install the radiator. See Radiator Installation on page 15-8...5145
      3. Connect the two-pin connector from the fan motor to the wire harness (Figure 12b-17, Page 12b-17)...5145
      4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5145
    Wire Harness Diodes...5146
      1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5146
      2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5146
      3. Locate the diode to be replaced by removing the wire conduit and tracing the wire...5146
      4. Note the polarity of the diode as indicated by the white stripe on one side of the diode, and mark the wire on the side of the white stripe...5146
      5. Cut the wires attached to each side of the diode, and discard the diode...5146
      1. Slide a piece of heatshrink tubing over one of the wire ends where the diode will be attached...5146
      2. Use in-line wire splicing connectors to install the new diode. Make sure to observe polarity, and place the side of the diode with the white stripe on the wire that was marked when the diode was removed...5146
      3. Slide the heatshrink tubing over the diode and ensure that it will adequately cover the uninsulated diode leads after the tubing has been activated...5146
      4. Activate the heatshrink by carefully applying heat to the tubing...5146
      5. Bundle the wires into the plastic wire conduit, and replace any wire ties that were removed when the wires were traced...5146
      6. Restore the wire harness routing to the original routing, and secure the harness with wire ties as required...5146
      7. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5146
    Bed Lift Switch...5146
      1. Remove the instrument panel. See Instrument Panel Removal on page 12b-4...5146
      2. Remove the wires from the bed lift toggle switch...5146
      3. Remove the nut and washer securing the bed lift toggle switch to the instrument panel and remove the switch...5146
      1. Connect the wires to the bed lift toggle switch as shown (Figure 12b-19, Page 12b-19)...5147
      2. Secure the bed lift toggle switch to the instrument panel with the washer and nut...5147
      3. Install the instrument panel. See Instrument Panel Installation on page 12b-5...5147
    Bed Lift Circuit Breaker...5147
      1. Open and remove the dashboard access panel located above the steering column...5147
      2. locate the bed lift circuit breaker on the orange wire in the black plastic conduit (Figure 12b-20, Page 12b-20)...5147
      3. Pull the circuit breaker from the in-line fuse holder and remove the circuit breaker...5147
    Battery...5148
      General Information...5148
        1. To keep the battery in good operating condition, remove corrosion immediately. Post connections should be clean and tight. Fr...5149
        2. The battery should be kept clean and dry to prevent self-discharge. Dirt, grime or acid spillage should be removed. Wash the ...5149
        3. Maintain the proper water level. See Water Level on page 12b-21...5149
        4. Check the battery periodically to ensure that it is in a full state of charge. See Charging the Battery on page 12b-22...5149
        5. Keep the battery hold-down clamp tight. See Vibration Damage on page 12b-21...5149
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5150
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5150
        3. Remove the driver-side seat...5150
        4. Remove the battery hold-down located on the bottom of the battery...5150
        5. Remove the battery. See following WARNING...5150
        1. Charge the battery with an automotive type 12-volt battery charger. Follow all warnings and procedures supplied by the battery charger manufacturer...5150
        2. Attach the charger, positive (+) cable to the positive (+) battery post, and negative (-) cable to the negative (-) battery post...5150
        3. The battery may be charged with a slow charge (3-10 amps) or a fast charge (20-30 amps). Charge until the specific gravity reaches 1.250. See following WARNING...5150
        1. Place the battery into the vehicle with the battery posts facing the rear of the vehicle...5151
        2. Secure the battery to the vehicle with the clamp at the bottom of the battery. Tighten the clamp retaining bolt to 9 ft-lb (12.2 N·m)...5151
        3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5151
        1. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 12b-21...5151
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5151
        3. Fully charge the battery prior to storage...5151
        4. Store in a cool, dry area. The colder the area in which the battery is stored, the less the battery will self- discharge. A b...5151
        5. Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and crack. If the specific gravity drops below 1.220, the battery should be recharged. See following WARNING...5151
        6. The frequency of recharging required depends on the temperature of the storage area, but it is recommended that the battery b...5151
  Section 13a - Gasoline Engine, Muffler, Fuel System, and Clutches...5153
    Gasoline Engine...5153
      Engine Removal...5153
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5153
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2...5153
        3. Remove the cargo bed. See Cargo Bed Removal, Section 4, Page 4-10...5153
        4. Remove the ROPS (Roll Over Protection Structure). See ROPS Removal, Section 4, Page 4-6...5153
        5. Remove the lower rear ROPS bars. See ROPS Removal, Section 4, Page 4-6...5153
        6. Remove the seat frame. See Seat Frame Removal, Section 4, Page 4-7...5153
        7. Remove the engine cover plate. See following NOTE...5153
        8. Remove the engine name plate. See following NOTE...5153
        9. Close the shut-off valve on the fuel tank...5153
        10. Remove the fuel line and in-line filter from the engine. See following DANGER...5153
        11. Remove the governor cable. See Governor Cable Removal on page 13a-21...5154
        12. Remove the choke cable. See Choke Cable Removal on page 13a-27...5154
        13. Remove the engine air inlet hose from the engine. See Air Filter Outlet Hose Removal on page 13a-30...5154
        14. Remove the muffler. See Muffler Removal on page 13a-5...5154
        15. Remove the intermediate exhaust pipe. See Intermediate Pipe Removal on page 13a-5...5154
        16. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13a-40...5154
        17. Remove the clutches. See Drive Clutch Removal on page 13a-33. Also See Driven Clutch Removal on page 13a-37...5154
        18. Remove the clutch inner cover. See Clutch Inner Cover Removal on page 13a-41...5154
        19. Remove the manifold pipe...5154
        20. Remove the electrical connectors:...5154
        21. Drain the engine oil. See Engine Oil and Filter Change, Section 10, Page 10-7...5154
        22. Remove engine oil inlet and outlet hoses from the engine. See Oil Filter Hose Removal on page 13a-17. See also following NOTE...5154
        23. Remove the engine mounting hardware (Figure 13a-1, Page 13a-3)...5154
        24. Use the engine lift tabs to lift the engine off the mounting plate...5154
        25. If a new engine will be installed, remove and retain the following:...5154
      Engine Installation...5155
        1. Before a new engine is installed, the following components must be installed:...5155
        2. Lower the engine into the engine compartment and closely align the base mount with holes in the engine plate...5155
        3. Loosely install new flange-head bolts and flange-head locknuts on the engine base slotted mounts. See following NOTE...5155
        4. Secure the engine oil inlet and outlet hoses to the engine ports with new clamps. See Oil Filter Hose Installation on page 13a-17...5155
        5. Connect all electrical connections. See Figure 11a-1, Section 11a, Page 11a-6...5155
        6. Use new gaskets, and install the exhaust manifold. Tighten the hardware to 21 ft-lb (28 N·m)...5155
        7. Install the clutch inner cover. See Clutch Inner Cover Installation on page 13a-41...5156
        8. Tighten the engine mounting bolts to 39 ft-lb (53 N·m)...5156
        9. Install the clutches. See Drive Clutch Installation on page 13a-37. Also See Driven Clutch Installation on page 13a-39...5156
        10. Install the drive belt. See Drive Belt Installation on page 13a-33...5156
        11. Install the clutch outer cover. See Clutch Outer Cover Installation on page 13a-40...5156
        12. Install the engine air inlet hose to the filter. See Air Filter Outlet Hose Installation on page 13a-31...5156
        13. Install the intermediate exhaust pipe. See Intermediate Pipe Installation on page 13a-6...5156
        14. Install the muffler. See Muffler Installation on page 13a-6...5156
        15. Install the engine name plate, and tighten the screws to 38 in-lb (4 N·m)...5156
        16. Connect the choke cable. See Choke Cable Installation on page 13a-28...5156
        17. Feed the governor cable through the grommet in the engine name plate, and connect the cable. Adjust the cable as necessary. ...5156
        18. Feed the fuel line through the grommet in the engine name plate. Secure the fuel line to the in-line filter on the engine with a new clamp. See following DANGER...5156
        19. Open the fuel valve on the fuel tank...5156
        20. Install the engine cover plate. The engine lift tab should be on the passenger side...5156
        21. Install the seat frame and lower rear ROPS (Roll Over Protection Structure) bars. See Seat Frame Installation, Section 4, Page 4-7 and ROPS Installation, Section 4, Page 4-6...5156
        22. Install the upper ROPS frame. See ROPS Installation, Section 4, Page 4-6...5156
        23. Install the cargo bed. See Cargo Bed Installation, Section 4, Page 4-10...5156
        24. Add engine oil. See Engine Oil and Filter Change, Section 10, Page 10-7...5156
        25. Check the engine oil level. See Engine Oil Level Check, Section 10, Page 10-7...5156
        26. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5156
        27. Adjust the engine RPM setting. See Engine RPM Adjustment on page 13a-25...5156
        28. Install the center seat plate...5156
        29. Install both seats...5156
        30. Test-drive the vehicle to ensure all systems are functional and adjusted correctly...5156
    Exhaust System...5157
      Muffler Removal...5157
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5157
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5157
        3. Remove the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5157
        4. Loosen the muffler spring suspension bracket bolts...5157
        5. Remove the two springs that secure the muffler inlet to the intermediate pipe (Figure 13a-2, Page 13a-5). See following NOTE...5157
        6. Remove the two bolts and large flat washers that secure the muffler bracket and springs to the muffler body, and remove the muffler. See following WARNING and NOTE...5157
      Intermediate Pipe Removal...5157
        1. Loosen the muffler spring suspension bracket bolts...5157
        2. Remove the springs from the intermediate pipe and muffler inlet. See following WARNING and NOTE...5157
        3. Remove the springs from the intermediate pipe and engine manifold, and remove the pipe...5158
      Intermediate Pipe Installation...5158
        1. Secure the intermediate pipe to the manifold pipe with new springs. See following WARNING and NOTE...5158
        2. Secure the intermediate pipe to the muffler inlet with new springs. See previous NOTE and WARNING...5158
        3. Align the muffler with the intermediate pipe, and tighten the muffler spring suspension bracket bolts to 21 ft-lb (29 N·m)...5158
      Muffler Installation...5158
        1. Loosely secure the muffler and spring suspension bracket to the vehicle frame plate with two bolts and large flat washers (Figure 13a-3, Page 13a-6)...5158
        2. Secure the outlet pipe of the muffler to the manifold extension pipe with new springs. See following WARNING and NOTE...5158
        3. Align the muffler with the intermediate pipe, and tighten the muffler spring bracket to 21 ft-lb (29 N·m)...5159
        4. Connect the spark plug wires...5159
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5159
        6. Place the Forward/Reverse handle in NEUTRAL, and turn the key switch to start the engine. Check for exhaust leaks and proper engine operation. See following DANGER...5159
    Fuel System...5159
      Carburetor...5159
      Main Jet Elevation/Size Chart...5160
      Fuel Filter...5160
      Fuel Pump...5160
      Fuel Level Sending Unit...5162
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5162
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5162
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5162
        4. Remove the passenger seat. See Seat Removal, Section 4, Page 4-7...5162
        5. Remove the rubber boot (8) from the center post on the fuel level sending unit. Remove the nut (9) from the center post, and remove the orange wire (7) (Figure 13a-5, Page 13a-10). Retain the hardware...5163
        6. Remove the hex-head plastic thread screw (10) securing the black ground wire (6) to the fuel level sending unit, and remove the black ground wire. Retain the hardware...5163
        7. Remove the four remaining hex-head plastic thread screws from the fuel level sending unit flange (5). Retain the hardware...5163
        8. Carefully remove the sending unit and gasket (3). Feed the rheostat arm and float (4) through the fuel tank hole. Immediately place the fuel level sending unit in a pan to catch fuel. See following DANGER and NOTE...5163
        1. Place a new rubber gasket on the fuel tank with the notch (2) centered between the flange identification mounting holes (1) (Figure 13a-6, Page 13a-12). See following NOTE...5163
        2. Feed a new sending unit rheostat arm and float (4) into the fuel tank (Figure 13a-5, Page 13a-10). The rheostat arm and float should be positioned toward the outside surface of the fuel tank (Figure 13a-7, Page 13a-12)...5163
        3. Align the flange identification mounting holes (1) directly over the corresponding mounting holes in the gasket and fuel tank (Figure 13a-6, Page 13a-12). See following CAUTION and NOTE...5163
        4. Carefully thread each hex-head screw by hand, with the ring terminal on the black ground wire (6) under the screw head closest to the engine (Figure 13a-5, Page 13a-10). See following CAUTION...5164
        5. Use a crisscross pattern to tighten the hardware to 9 in-lb (1 N·m). If the hardware cannot be tightened to 9 in-lb (1 N·m), the fuel tank must be replaced. See following CAUTION...5164
        6. Secure the orange wire (7) to the center post with the nut (9) previously removed (Figure 13a-5, Page 13a-10). Tighten the hardware to 17 in-lb (1.9 N·m), and secure the rubber boot (8) to the center post...5164
        7. Install the passenger seat. See Seat Installation, Section 4, Page 4-7...5164
        8. Connect the spark plug wires...5164
        9. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5164
      Fuel Tank...5165
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5165
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5165
        3. Remove both seats...5165
        4. Remove the center seat plate...5165
        5. Remove the upper portion of the ROPS. See ROPS Removal, Section 4, Page 4-6...5165
        6. Remove the bolts, washers and flanged locknuts from the seat frame, seat side plates, and engine cover plate...5165
        7. Turn the fuel shut-off valve to the closed (OFF) position (Figure 13a-10, Page 13a-16)...5165
        8. Run the engine until all fuel in the carburetor, fuel pump, and fuel lines is used and the engine stalls...5165
        9. Loosen the clamp, and disconnect the fuel line from the fuel tank shut-off valve (Figure 13a-8, Page 13a-13)...5165
        10. Loosen the clamp, and remove the vent tube from the fuel tank...5165
        11. Remove the fuel tank cap...5165
        12. Use a siphon with a built-in suction device to siphon all fuel from the tank and into an approved container. See following DANGER and WARNING...5165
        13. Disconnect the black wire and orange wire from the fuel level sensor on the tank. Do not remove the lower nut from the center stud of the sensor...5166
        14. Remove the nut from the strap end below the passenger seat area...5166
        15. Lift the strap end, and remove the opposite end from the slotted bracket...5166
        16. Remove the passenger side bed latch bracket from the frame...5166
        17. Remove the fuel tank...5166
        1. Remove the cap from the tank and thoroughly rinse it with water. The cap may be discarded or kept as a spare...5166
        2. Use a well-ventilated area, and flush the fuel tank with water to remove any remaining fuel...5166
        3. Set the tank upside down in a well-ventilated area so that the water can drain. Allow the tank to sit for 24 hours to dry. See following WARNING...5166
        4. Store the tank upside down with the cap installed in a well-ventilated area...5166
        1. Install the fuel tank in the vehicle...5166
        2. Insert the tab end of the strap into the frame bracket, and place the strap in the indentions on the tank...5166
        3. Feed the threaded tab end down into the bottom of the frame. Install a nylon locknut, and tighten the nut to 40 in-lb (4.5 N·m). See following NOTE...5166
        4. Connect the clear vent tube to the fuel tank vent, and secure the tube with a new clamp...5166
        5. Connect the fuel line to the fuel tank shut-off valve, and secure the line with a new clamp...5166
        6. Connect the black wire and orange wire to the sensor (Figure 13a-9, Page 13a-15)...5166
        7. Slide the rubber boot over the stud...5166
        8. Install the passenger-side bed latch bracket on the frame with a bolt and flanged nylon locknut. Tighten the hardware to 20 ft-lb (27 N·m)...5166
        9. Install the seat frame on the vehicle frame. Secure the seat side plates with bolts, flat washers, and flanged locknuts. Tighten the nut to 37 ft-lb (50 N·m)...5166
        10. Install the top portion of the ROPS. See ROPS Installation, Section 4, Page 4-6...5166
        11. Install the center seat plate...5167
        12. Add the appropriate fuel to the fuel tank...5167
        13. Ensure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 13a-11, Page 13a-16 and Figure 13a-12, Page 13a-16)...5167
        14. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5167
        15. Install both seats...5167
        16. With the Forward/Reverse handle in NEUTRAL, start the engine and allow it to idle. Run the engine for a few minutes to ensure that the fuel lines are full of fuel. See following DANGER...5167
        17. Inspect each fuel line connection for leaks...5167
      Fuel Lines...5167
      Fuel Shut-Off Valve...5168
      Oil Filter Hoses...5169
        1. Drain the engine oil. See Engine Oil Draining, Section 10, Page 10-7...5169
        2. Place a pan under the oil filter hose connections on the engine. See following NOTE...5169
        3. Loosen the clamps on the oil hoses at the engine ports and slide them from the engine port nozzles...5169
        4. Loosen the clamps on the oil hoses at the filter ports and slide them from the filter port nozzles...5169
        1. Replace the oil hoses (1) with like hoses. See following NOTE...5169
        2. Secure the hoses to the port nozzles (2) with clamps (3) and tighten to 9 in-lb (1 N·m) (Figure 13a-13, Page 13a-17). See following NOTE...5169
        3. Fill the engine with engine oil. See Engine Oil Filling, Section 10, Page 10-10...5169
    Engine Control Linkages...5170
      Accelerator Cable...5170
        1. Turn the key switch OFF, and place the Forward/Reverse handle in NEUTRAL. Remove the key. Chock the rear wheels...5170
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5170
        3. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...5170
        4. Remove the passenger-side seat. See Seat Removal, Section 4, Page 4-7...5170
        5. Disconnect the Z-shaped end (1) on the accelerator cable from the pedal (Figure 13a-14, Page 13a-18)...5170
        6. Release the retention clip at the pedal bracket (Figure 13a-15, Page 13a-18)...5170
        7. Disconnect the accelerator cable (5) from the engine (Figure 13a-16, Page 13a-19)...5170
        8. Remove the accelerator cable from the plastic retaining clips under the passenger side of the frame. Pull the cable at the dashboard to remove it from the engine compartment. See following NOTE...5171
        1. Feed the pedal end and governor end of the accelerator cable up into place from under the vehicle on the passenger side. See following NOTE...5171
        2. Secure the cable to the plastic retaining clips under the passenger side of the frame...5171
        3. Connect the accelerator cable to the pedal...5171
        4. Connect the accelerator cable (5) to the governor arm (4) in the engine compartment (Figure 13a-16, Page 13a-19)...5171
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5172
      Governor Guard...5173
        1. Remove the passenger seat. See following NOTE...5173
        2. Remove the two hex-head bolts (1) from the front (cable side) of the governor guard (Figure 13a-18, Page 13a-21)...5173
        3. Remove the nylon locknut (2) from the rear (transmission side) of the governor guard (Figure 13a-19, Page 13a-21)...5173
        4. Slide the guard off the bolts...5173
        1. Slide the rear of the governor guard onto the bolts that extend through the transmission case...5173
        2. Install the front (cable side) governor guard bolts (1) (Figure 13a-18, Page 13a-21). Tighten the hardware to 21 ft-lb (28 N·m)...5173
        3. Install a new nylon locknut on the bolt (2) at the rear (transmission side) of the governor guard (Figure 13a-19, Page 13a-21). Tighten the hardware to 21 ft-lb (28 N·m)...5173
        4. Install the passenger seat...5173
      Governor Cable...5173
        1. Remove the governor guard. See Governor Guard Removal on page 13a-21...5173
        2. Remove the cable sheath strain relief from the cable bracket on the transmission (Figure 13a-20, Page 13a-22)...5173
        3. Remove the Z-shaped end of the governor cable from the governor arm on the transmission...5173
        4. Remove the spring end of the cable from the engine bracket (Figure 13a-21, Page 13a-22)...5173
        5. Slide the cable away from the throttle control wire loop. See following NOTE...5174
        6. Remove the cable sheath strain relief from the engine bracket, and remove the governor cable...5174
        1. Secure the spring loop on the engine end of the cable to the engine bracket (Figure 13a-21, Page 13a-22)...5174
        2. Slide the cable into the throttle wire loop. Ensure the small washer is positioned between the throttle wire loop and the cable/spring attachment...5174
        3. Secure the cable sheath to the engine bracket...5174
        4. Secure the Z-shaped end of the governor cable to the governor arm on the transmission...5174
        5. Secure the cable sheath to the transmission bracket...5174
        6. Install the governor guard. See Governor Guard Installation on page 13a-21...5174
      Accelerator Cable Retention Clip Adjustment...5174
        1. Release the cable sheath retention clip (Figure 13a-15, Page 13a-18)...5174
        2. Push the carburetor throttle shaft toward the closed direction until it contacts the throttle stop...5174
        3. Adjust the accelerator cable at the pedal until there is a washer-width space between the washer and the governor wire form as shown (Figure 13a-22, Page 13a-23)...5175
        4. Press the retention clip to hold accelerator cable in correct adjustment position...5175
        5. Start the engine and verify correct idle speed. Also, verify that the governor cable is not putting pressure on the governor wire form while the engine is idling...5175
      Ground Speed (Transmission) Governor Arm Adjustment...5175
        1. Remove the governor guard. See Governor Guard Removal on page 13a-21...5175
        2. Loosen the pinch bolt (7) with a 7/16-inch socket to allow vertical movement of the ground speed (transmission) governor arm (4) (Figure 13a-23, Page 13a-24)...5175
        3. Set the distance from the top of the pin to the ground speed (transmission) governor arm to 1/4-inch (6.4 mm) as shown (Figure 13a-24, Page 13a-24). Hold the pin in place...5175
        4. Push and hold the transmission governor arm (4) in the full-throttle position so that the washer (8) is just touching the governor wire (9) (Figure 13a-23, Page 13a-24). See following CAUTION...5175
        5. Use a flat-head screwdriver to turn the pin (10) counter-clockwise until it stops. Hold the screwdriver in place, and use a 7/16-inch socket to tighten the pinch bolt (7) to 35 in-lb (4 N·m)...5175
        6. Install the governor guard. See Governor Guard Installation on page 13a-21...5175
      Engine Governor Arm...5177
        1. Remove the governor guard. See Governor Guard Removal on page 13a-21...5177
        2. Disconnect the intake hose from the engine...5177
        3. Disconnect the governor wire spring (11) from the engine governor arm (6) (Figure 13a-23, Page 13a-24)...5177
        4. Disengage the governor wire (12) from the carburetor, and remove it from the engine governor arm (6)...5177
        5. Disengage the idle spring (13) from the engine governor arm (6) and idle adjuster (14)...5177
        6. Loosen the pinch nut (15) until the governor arm (6) can be removed from the slotted pin (16)...5177
        1. Slide the engine governor arm (6) onto the slotted pin (16) (Figure 13a-23, Page 13a-24)...5177
        2. Insert the straight end of the governor wire (12) through the top hole in the engine governor arm as shown (Figure 13a-23, Page 13a-24)...5177
        3. Insert the bent end of the engine governor wire (12) into the carburetor throttle. Secure the wire with a clip...5177
        4. Insert the governor wire spring (11) into the bottom hole in the engine governor arm as shown (Figure 13a-23, Page 13a-24)...5177
        5. Ensure the governor cable is inserted into the loop in the governor wire (9). Insert the idle spring (13) into the engine governor arm (6), and stretch it to insert it into the idle adjuster (14)...5177
        6. Ensure the engine governor arm is in the wide-open throttle position and that it is securely positioned on the slotted pin (16)...5177
        7. Ensure the engine governor arm is in the wide-open throttle position. Use a flat-blade screwdriver to rotate the slotted pin ...5177
        8. Connect the intake hose to the engine...5177
        9. Check the engine idle speed. See Idle RPM Adjustment on page 13a-25...5177
        10. Install the governor guard. See Governor Guard Installation on page 13a-21...5177
      Engine RPM Adjustment...5177
        1. Turn the key switch to start and run the engine, and place the Forward/Reverse handle in NEUTRAL. Place a tachometer (CCI P/N 1016112) close to the spark plug wire and plug...5177
        2. Hold the throttle against the stop screw, and adjust the idle-adjustment screw on the carburetor until the tachometer displays 1125 ± 25 RPM. See following NOTE...5177
        3. Release the throttle...5177
        4. Adjust the idle-adjustment screw above the No. 2 cylinder exhaust port until the tachometer displays 1300 ± 50 RPM. See previous NOTE...5178
        1. Press the accelerator pedal all the way to the floor...5178
        2. Place a tachometer (CCI P/N 1016112) close to the spark pug wire and plug...5178
        3. Adjust the high-speed adjustment screw (1) until the tachometer displays 3825 ± 25 RPM (Figure 13a-25, Page 13a-26). See following NOTE...5178
        4. Release the accelerator pedal...5178
    Choke and Air Intake System...5178
      Air Filter Replacement...5178
        1. Release both canister tab locks (Figure 13a-26, Page 13a-27)...5179
        2. Pull the canister cap away from the canister...5179
        3. Remove the air filter cartridge. See following NOTE...5179
        1. Push the new filter cartridge onto the nozzle inside the canister...5179
        2. Position the canister cap so the TOP mark is at the top center of the canister (Figure 13a-26, Page 13a-27)...5179
        3. Use both tab locks on the sides of the cap to secure the canister cap...5179
      Choke Cable Removal...5179
        1. Turn the key switch OFF, and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL, and chock the rear wheels...5179
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5179
        3. Remove both seats...5179
        4. Remove the center seat plate...5179
        5. Remove the engine cover plate...5179
        6. Remove the cable sheath strain relief from the engine bracket (Figure 13a-27, Page 13a-28)...5179
        7. Remove the Z-shaped cable end from the choke control on the carburetor...5179
        8. Remove the instrument panel. See Instrument Panel Removal, Section 12a, Page 12a-4...5179
        9. Compress the choke ferrule tines on the back side of the instrument panel. Pull the cable up from the engine compartment, and remove the cable. See following NOTE...5179
      Choke Cable Installation...5180
        1. Secure a new choke cable to the nylon cord outside of the instrument panel. Pull the cable from the engine compartment down to the choke cable bracket and choke control (Figure 13a-27, Page 13a-28)...5180
        2. Push the choke cable ferrule into the instrument panel hole so the tines engage behind the panel...5180
        3. Secure the instrument panel to the dashboard...5180
        4. Secure the choke cable to the frame with the plastic retention clips...5180
        5. Install the Z-shaped end of the choke cable on the choke control at the carburetor...5180
        6. Secure the cable sheath strain relief to the choke cable bracket on the engine...5180
        7. Install the engine cover plate...5180
        8. Install the center seat plate...5180
        9. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5180
        10. Install both seats...5180
      Air Canister Removal...5180
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5180
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5180
        3. Remove the air filter cartridge. See Air Filter Removal on page 13a-27...5180
        4. Remove the bottom (inlet) hose from the canister (Figure 13a-31, Page 13a-30)...5180
        5. Remove the top (outlet) hose from the canister...5180
        6. Remove the two bolts and park brake cable from the canister, and remove the canister...5180
      Air Canister Installation...5181
        1. Position the canister next to the frame bracket with the rubber valve down...5181
        2. Install two bolts to secure the canister base bracket and vehicle frame bracket. Tighten the hardware to 21 ft-lb (28.5 N·m)...5181
        3. Secure the bottom (inlet) hose to the canister port...5181
        4. Secure the top (outlet) hose to the canister port...5181
        5. Install a new air filter cartridge. See Air Filter Installation on page 13a-27...5181
        6. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5181
      Air Filter Intake Hose Removal...5181
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5181
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5181
        3. Remove the hose from under the filter canister...5181
        4. Remove the hose from under the vehicle body on the frame...5181
        5. Slide the hose through the frame support bracket, and remove the hose from the vehicle (Figure 13a-29, Page 13a-30)...5181
      Air Filter Intake Hose Installation...5182
        1. Slide the air intake hose through the frame support bracket (Figure 13a-29, Page 13a-30)...5182
        2. Secure the air intake hose to the air port under the vehicle body (Figure 13a-30, Page 13a-30)...5182
        3. Secure the air intake hose under the filter canister (inlet) port (Figure 13a-31, Page 13a-30). See following NOTE...5182
        4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5182
      Air Filter Outlet Hose Removal...5182
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5182
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5182
        3. Remove the hose end from the air filter canister outlet port...5182
        4. Remove the hose end from the carburetor inlet port, and remove the hose...5182
      Air Filter Outlet Hose Installation...5183
        1. Connect the air filter outlet hose to the air filter outlet port, and secure it with a clamp...5183
        2. Connect the air filter outlet hose to the carburetor inlet port, and secure it with a clamp...5183
        3. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5183
    Clutches...5183
      Clutch Troubleshooting...5184
        1. Check the ground speed governor and throttle settings. See Governor Cable Installation on page 13a-22...5184
        2. Inspect both clutches for dirt and debris buildup on component parts. Clean the exterior surfaces of both clutches with water...5184
        3. Check the clean clutches for wear...5184
        4. If cleaning both clutches does not solve the problem, disassemble and thoroughly clean all parts in the drive and driven clutches...5184
        5. Check the drive clutch rollers and weights for wear. See Drive Clutch Cleaning and Inspection on page 13a-34...5184
      Drive Belt...5184
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5184
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5184
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5184
        4. Remove the outer clutch cover. See Clutch Outer Cover Removal on page 13a-40...5184
        5. Grasp the belt midway between the drive and driven clutches, and squeeze the belt together as tightly as possible (Figure 13a-33, Page 13a-32)...5185
        6. Guide the belt over the driven clutch and roll the belt off the driven clutch by rotating the clutch clockwise. See following CAUTION...5185
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5185
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5185
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5185
        4. Remove the outer clutch cover. See Clutch Outer Cover Removal on page 13a-40...5185
        5. Position the new belt on the drive clutch, and then start the belt over the top of the driven clutch...5185
        6. Rotate the driven clutch clockwise, and roll the belt over the driven clutch sheaves and onto the clutch...5185
        7. Install the outer clutch cover. See Clutch Outer Cover Installation on page 13a-40...5185
        8. Connect the spark plug wires...5185
        9. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5185
      Drive Clutch...5185
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5185
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5185
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5185
        4. Remove the top air filter hose (outlet) from the air filter canister...5185
        5. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13a-40...5185
        6. Remove the drive belt. See Drive Belt Removal on page 13a-32...5185
        7. Remove the bolt and washer from the center of the clutch...5185
        8. Thread the clutch removal tool (CCI P/N 102686101) into the drive clutch center, and advance the tool until the clutch shaft is released from the crankshaft. See following CAUTION...5185
        9. Remove the drive clutch from the vehicle. See following CAUTION...5186
        1. Use a dry, lint-free cloth to clean clutch parts. See following CAUTION...5186
        2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced...5186
        1. Use a 7/16-inch socket to remove the four bolts (1) and washers (2) that secure the plate (3) to the clutch cover (4) (Figure 13a-35, Page 13a-36)...5187
        2. Remove the cover (4) and spring (5) from the clutch spider (6)...5187
        3. Inspect the torque rollers (7), weights (11) and rollers (10). Replace if necessary...5187
        4. Secure the Fixed sheave tool (CCI P/N 102601501) into a vice, or mount the tool to a flat work surface (Figure 13a-34, Page 13a-34)...5187
        5. Place the fixed sheave of the drive clutch onto the service tool so that the drive clutch is stationary...5187
        6. Place the Spider removal tool (CCI P/N 102607501) on top of the spider...5187
        7. Use a 1/2-inch drive ratchet to disengage the moveable sheave (14) and spider (6), which will come off as an assembly, from the fixed sheave (15) (Figure 13a-35, Page 13a-36)...5187
        1. Use a feeler gauge to inspect the torque rollers (7), and replace the rollers if necessary (Figure 13a-35, Page 13a-36)...5187
        2. Inspect the rollers (10) and weights (11). There should be no noticeable wear. If the rollers or weights are worn, scratched, or damaged, replace them...5187
        1. Place the moveable sheave (14) and spider (6) onto the fixed sheave (15). Note the location of the X so the remaining components with an X can be aligned...5187
        2. Use a spider removal tool (CCI P/N 102607501) to tighten the moveable sheave and spider to 225 ft-lb (305 N·m)...5187
        3. Install the spring (5) onto the shaft...5187
        4. Install the cover (4) onto the shaft...5187
        5. Align the plate that has holes in the cover with arrows on the same side. Pull the moveable sheave upward and start threading the bolts with washers into holes. See following NOTE...5187
        6. Use a crisscross pattern to continue tightening the hardware...5187
        7. Tighten the bolts to 10 ft-lb (14 N·m)...5187
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5189
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5189
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5189
        4. Place the drive clutch assembly on the crankshaft taper...5189
        5. Install the mounting washer and retaining bolt. Tighten the hardware to 39 ft-lb (53 N·m)...5189
        6. Install the drive belt as instructed. See Drive Belt Installation on page 13a-33...5189
        7. Install the clutch outer cover, and tighten the bolts to 6 ft-lb (8.0 N·m)...5189
        8. Secure the top air filter hose (outlet) to the filter canister. See following NOTE...5189
        9. Connect the spark plug wires...5189
        10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5189
        11. Drive the vehicle and check for proper operation...5189
      Driven Clutch...5189
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle is in NEUTRAL...5189
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5189
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5189
        4. Remove the top air filter hose from the filter canister...5189
        5. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13a-40...5189
        6. Remove the drive belt as instructed. See Drive Belt Removal on page 13a-32...5189
        7. Remove the bolt and washer from the center of the clutch...5189
        8. Remove the driven clutch from the vehicle. See following CAUTION...5189
        1. Place the driven clutch onto the Spring compression base (CCI P/N 102603501) (Figure 13a-36, Page 13a-38)...5190
        2. Place the Spring compression collar (CCI P/N 102605201) onto the driven clutch...5190
        3. Thread the Spring compression nut (CCI P/N 102606101) down onto the threaded post enough to release the pressure on the snap ring...5190
        4. Use snap-ring pliers to remove the snap ring (1) (Figure 13a-37, Page 13a-39)...5190
        5. Slowly remove the spring compression nut. The collar will then rise and release tension on the spring (3)...5190
        6. Remove the cup (2) and spring (3)...5190
        7. Remove the moveable sheave (4) from the fixed sheave (5). See following NOTE...5190
        1. Place the fixed sheave (5) onto the spring compression base and note the location of the X so the X on the moveable sheave (4) can be aligned correctly (Figure 13a-37, Page 13a-39)...5191
        2. Place the moveable sheave (4) onto the fixed sheave (5), and align the X’s on both components...5191
        3. Place the spring (3), cup (2), and snap ring (1) onto the clutch...5191
        4. Place the spring compression collar onto the cup (Figure 13a-36, Page 13a-38)...5191
        5. Tighten the spring compression nut just enough to enable the snap ring to be installed...5191
        6. Use snap ring pliers to install the snap ring...5191
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle is in NEUTRAL...5191
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5191
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5192
        4. Install the driven clutch assembly on the transmission shaft taper...5192
        5. Install the mounting washer and retaining bolt and tighten to 39 ft-lb (53 N·m)...5192
        6. Install the drive belt as instructed. See Drive Belt Installation on page 13a-33...5192
        7. Install the clutch outer cover, and tighten the screws to 6 ft-lb (8 N·m)...5192
        8. Install the top air filter hose on the filter canister. See following NOTE...5192
        9. Connect the spark plug wires...5192
        10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5192
        11. Drive the vehicle and check for proper operation...5192
      Clutch Cover...5192
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle is in NEUTRAL...5192
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5192
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5192
        4. Remove the top air filter hose from the filter canister...5192
        5. Remove the self-rolling screws, and remove the clutch outer cover. See following WARNING...5192
        1. Align the mounting holes in the clutch cover with the mounting holes in the inner cover...5192
        2. Install the screws and tighten the hardware to 6 ft-lb (8 N·m)...5192
        3. Install the top air filter hose on the filter canister...5193
        4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). See following NOTE...5193
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle is in NEUTRAL...5193
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5193
        3. Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5193
        4. Remove the outer clutch cover. See Clutch Outer Cover Removal on page 13a-40...5193
        5. Remove the drive belt. See Drive Belt Removal on page 13a-32...5193
        6. Remove the drive clutch. See Drive Clutch Removal on page 13a-33...5193
        7. Remove the driven clutch. See Driven Clutch Removal on page 13a-37...5193
        8. Remove the bolts and washers from the clutch inner cover (Figure 13a-38, Page 13a-42)...5193
        9. Remove the clutch inner cover...5193
        1. Align the mounting holes in the clutch cover with the transmission and engine bolt holes...5193
        2. Loosely install one bolt and washer in each transmission and engine mounting hole...5193
        3. Finger-tighten the bolts and washers...5193
        4. Tighten the clutch inner cover engine bolts and washers to 21 ft-lb (28.5 N·m)...5193
        5. Tighten the transmission bolts and washers to 21 ft-lb (28.5 N·m)...5193
        6. Install the driven clutch. See Driven Clutch Installation on page 13a-39...5193
        7. Install the drive clutch. See Drive Clutch Installation on page 13a-37...5193
        8. Install drive belt. See Drive Belt Installation on page 13a-33...5193
        9. Install the clutch outer cover. See Clutch Outer Cover Installation on page 13a-40...5193
        10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5193
  Section 13b - Diesel Engine, Muffler, Fuel System, and Clutches...5195
    Diesel Engine...5195
      Engine Removal...5195
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5195
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally...” in General Warning, Section 1, Page 1-2...5195
        3. Remove the cargo bed. See Cargo Bed Removal, Section 4, Page 4-10...5195
        4. Remove the top of the ROPS (Roll Over Protection Structure). See ROPS Removal, Section 4, Page 4-6...5195
        5. Remove the lower rear ROPS bars and seat frame assembly. See ROPS Removal, Section 4, Page 4-6...5195
        6. Drain the engine and radiator coolant system. See Engine Coolant Change, Section 15, Page 15-1...5195
        7. Release the clamp, and remove the engine coolant return hose from the steel coolant pipe outlet (under passenger side)...5195
        8. Release the clamp, and remove the engine coolant outlet hose from the steel coolant pipe outlet (under driver side)...5195
        9. Release the clamp, and remove the coolant overflow/bypass hose from the steel coolant pipe outlet (under driver side)...5195
        10. Remove the fuel supply line at the engine fuel injection pump, and securely plug the fuel supply line (Figure 13b-1, Page 13b-2). See following DANGER...5196
        11. Remove the fuel return line at the engine relief valve port, and securely plug the fuel return line (Figure 13b-2, Page 13b-2). See previous DANGER...5196
        12. Remove the accelerator cable from the accelerator lever (Figure 13b-3, Page 13b-3)...5196
        13. Remove the accelerator cable sheath strain relief from the engine bracket...5196
        14. Disconnect the three-pin connector on the fuel solenoid valve from the engine (Figure 13b-4, Page 13b-3)...5196
        15. Disconnect the thermostat switch connector from the wire harness (Figure 13b-5, Page 13b-3)...5196
        16. Disconnect the starter solenoid wire connector from the wire harness (Figure 13b-6, Page 13b-4)...5196
        17. Disconnect the two black ground wires from the engine block...5196
        18. Disconnect the engine air inlet hose from the filter. See Air Filter Outlet Hose Removal on page 13b-28...5197
        19. Remove the muffler. See Muffler Removal on page 13b-6...5197
        20. Remove the intermediate exhaust pipe. See Intermediate Pipe Removal on page 13b-6...5197
        21. Remove the manifold exhaust pipe. See Manifold Pipe Removal on page 13b-7...5197
        22. Remove the outer clutch cover. See Clutch Outer Cover Removal on page 13b-37...5197
        23. Remove the clutches. See Drive Clutch Removal on page 13b-31. Also See Driven Clutch Removal on page 13b-35...5197
        24. Remove the clutch inner cover. See Clutch Inner Cover Removal on page 13b-38...5197
        25. Remove the engine mounting hardware (Figures 13b-7 and 13b-8, Page 13b-4)...5197
        26. Use the engine lift tabs on top of the engine to lift the engine from the mounting plate...5197
      Engine Installation...5198
        1. Lower the engine into the engine compartment, and fit the engine block between the base plate brackets (Figure 13b-7, Page 13b-4). Also see Figure 13b-8, Page 13b-4...5198
        2. Loosely secure new bolts and flat washers to the engine block mounts...5198
        3. Secure the overflow/bypass hose from the engine to the steel coolant pipe outlet (under driver side of vehicle). Use a new clamp...5198
        4. Secure the coolant outlet hose to the steel coolant pipe (engine inlet) (under driver side). Use a new clamp...5198
        5. Secure the coolant return hose to the steel coolant pipe (engine outlet) under the passenger side. Use a new clamp...5199
        6. Connect the two black ground wires to the engine block, and tighten the bolt to 39 ft-lb (53 N·m)...5199
        7. Connect the starter solenoid connector to the wire harness (Figure 13b-6, Page 13b-4)...5199
        8. Connect the thermostat switch connector to the wire harness (Figure 13b-5, Page 13b-3)...5199
        9. Connect the fuel solenoid valve 3-pin connector to the engine (Figure 13b-4, Page 13b-3)...5199
        10. Connect the accelerator cable sheath to the engine bracket (Figure 13b-3, Page 13b-3)...5199
        11. Connect the accelerator cable to the throttle lever...5199
        12. Remove the plug, and secure the fuel return line to the engine relief valve with a new clamp (Figure 13b-2, Page 13b-2). See following DANGER...5199
        13. Remove the plug, and secure the fuel supply line to the fuel injector assembly with a new clamp (Figure 13b-1, Page 13b-2). See previous DANGER...5199
        14. Install the clutch inner cover. See Clutch Inner Cover Installation on page 13b-39...5199
        15. Install the clutches. See Drive Clutch Installation on page 13b-34. Also See Driven Clutch Installation on page 13b-37...5199
        16. Install the drive belt. See Drive Belt Installation on page 13b-30...5199
        17. Install the clutch outer cover. See Clutch Outer Cover Installation on page 13b-37...5199
        18. Install the manifold exhaust pipe. See Manifold Pipe Installation on page 13b-7...5199
        19. Install the intermediate exhaust pipe. See Intermediate Pipe Installation on page 13b-7...5199
        20. Install the muffler. See Muffler Installation on page 13b-8...5199
        21. Secure the engine air inlet hose to the filter. See Air Filter Outlet Hose Installation on page 13b-28...5199
        22. Install seat frame and lower ROPS (Roll Over Protection Structure). See Seat Frame Installation, Section 4, Page 4-7...5199
        23. Install the upper ROPS frame. See ROPS Installation, Section 4, Page 4-6...5199
        24. Install the cargo bed. See Cargo Bed Installation, Section 4, Page 4-10...5199
        25. Check the engine oil level. See Engine Oil Level Check, Section 10, Page 10-7...5199
        26. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5199
        27. Adjust the engine RPM setting. See Engine RPM Adjustment on page 13b-22...5199
        28. Install both seats...5199
        29. Test-drive the vehicle to ensure all systems are functional and adjusted correctly...5199
    Exhaust System...5200
      Muffler Removal...5200
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5200
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5200
        3. Loosen the muffler spring suspension bracket bolts...5200
        4. Remove the two springs that secure the muffler inlet to the intermediate pipe (Figure 13b-9, Page 13b-6). See following NOTE...5200
        5. Remove the two bolts and large flat washers that secure the muffler bracket and springs to the muffler body and remove the muffler. See following WARNING and NOTE...5200
      Intermediate Pipe Removal...5200
        1. Loosen the muffler spring suspension bracket bolts...5200
        2. Remove the springs from the intermediate pipe and muffler inlet. See following WARNING and NOTE...5200
        3. Remove the springs from the intermediate pipe and header. Remove the pipe...5201
        4. Remove the header pipe...5201
      Manifold Pipe Removal...5201
        1. Remove the manifold bolts and flange-head locknuts (Figure 13b-10, Page 13b-7)...5201
        2. Separate the manifold pipe from the engine exhaust manifold...5201
      Manifold Pipe Installation...5201
        1. Clean both the engine manifold and the manifold pipe flanges with a scraper or wire brush...5201
        2. Use a new high-temperature flange gasket (CCI P/N 102422301), and align the manifold pipe so the bend directs the pipe in and slightly down...5201
        3. Install new bolts and flange-head locknuts. Tighten the hardware to 21 ft-lb (28.5 N·m) (Figure 13b-10, Page 13b-7)...5201
      Intermediate Pipe Installation...5201
        1. Secure the header pipe to the engine manifold...5201
        2. Secure the intermediate pipe to the header pipe with new springs. See following WARNING and NOTE...5201
        3. Secure the intermediate pipe to the muffler inlet with new springs. See previous NOTE and WARNING...5202
        4. Align the muffler with the intermediate pipe, and tighten the muffler spring suspension bracket bolts to 21 ft-lb (29 N·m)...5202
      Muffler Installation...5202
        1. Loosely secure the muffler and spring suspension bracket to the vehicle frame plate with two bolts and large flat washers (Figure 13b-11, Page 13b-8)...5202
        2. Secure the outlet pipe of the muffler to the manifold extension pipe with new springs. See following WARNING and NOTE...5202
        3. Align the muffler with the intermediate pipe, and tighten the muffler spring bracket to 21 ft-lb (29 N·m). See previous NOTE and WARNING...5202
        4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5202
        5. Place the Forward/Reverse handle in NEUTRAL, start the engine and check for exhaust leaks and proper engine operation. See following DANGER...5202
    Fuel System...5203
      Fuel Line Hose Replacement...5203
      Fuel Filter Replacement...5203
      Draining Water from the Secondary Fuel Filter...5203
        1. Place a pan under the fuel filter...5203
        2. Lift the passenger-side seat...5203
        3. Locate the valve (1) on the underside of the filter. Turn the valve clockwise until water begins to stream from the filter (Figure 13b-13, Page 13b-10)...5203
        4. Drain the water until it changes color. When the fluid changes color, fuel has begun to escape. See following WARNING and NOTE...5203
        5. Close the valve. Rotate the valve counterclockwise until it is firmly sealed...5203
        6. To resupply the filter with fuel, turn the key switch to the ON position for 10 seconds...5203
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5205
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5205
        3. Place a large pan under the fuel tank to catch fuel...5205
        4. Disconnect the fuel tank hose (1) from the top (inlet) port of the primary fuel filter (7) (Figure 13b-14, Page 13b-13). See following WARNING...5205
        5. Disconnect the fuel pump line (2) from the bottom (outlet) of the primary fuel filter...5205
        6. Remove the flange-head, self threading bolt and P-clamp from the fuel filter body and remove the filter...5205
        1. Position the fuel filter body and P-clamp on the filter plate assembly (Figure 13b-12, Page 13b-10)...5205
        2. Secure the P-clamp with a new flange-head bolt, and tighten the hardware to 21 ft-lb (28 N·m)...5205
        3. Secure the bottom (outlet) hose (2) to the filter port with a new clamp (Figure 13b-14, Page 13b-13)...5205
        4. Secure the top (inlet) hose (1) to the filter port with a new clamp...5205
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5205
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5205
        3. Place a large pan under the fuel filters to catch fuel...5205
        4. Disconnect the top (inlet) hose (3) from the fuel pump (9) (Figure 13b-14, Page 13b-13). See following WARNING...5205
        5. Disconnect the bottom (outlet) hose (4) from the secondary fuel filter...5205
        6. Remove the two hex-head bolts from the fuel filter manifold bracket, and remove the filter...5205
        1. Position the secondary fuel filter manifold bracket on the filter plate assembly. Align the bracket mounting holes with the plate mounting holes (Figure 13b-12, Page 13b-10)...5206
        2. Secure the manifold bracket with hex-head bolts, and tighten the bolts to 21 ft-lb (28 N·m)...5206
        3. Secure the bottom (outlet) hose (4) to the filter port with a new clamp (Figure 13b-14, Page 13b-13)...5206
        4. Secure the top (inlet) hose (3) to the filter port with a new clamp. See following NOTE...5206
      Electric Fuel Pump...5206
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5206
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5206
        3. Disconnect the white/black wire connector from the wire harness...5206
        4. Place a large pan under the fuel pump to catch fuel. See following DANGER and WARNING...5206
        5. Disconnect and securely plug the top outlet hose (1) from the fuel pump (9) (Figure 13b-14, Page 13b-13). See previous DANGER and WARNING...5206
        6. Disconnect and securely plug the remaining top (outlet) hose (3) from the fuel pump...5206
        7. Disconnect and securely plug the bottom (inlet) hose (2) from the fuel pump...5206
        8. Remove the ground lug bolt from the left side of the fuel pump bracket (Figure 13b-12, Page 13b-10). See following NOTE...5206
        9. Remove the flange-head bolt from the right side of the fuel pump bracket, and remove the fuel pump...5206
        1. Position a new fuel pump between the fuel filters (Figure 13b-12, Page 13b-10)...5208
        2. Loosely secure a new flange-head bolt to the right side of the fuel pump bracket...5208
        3. Loosely secure the ground terminal from the fuel pump coil to the left side of the fuel pump bracket with a hex-head bolt...5208
        4. Tighten the right side flange-head bolt to 21 ft-lb (28 N·m)...5208
        5. Tighten the left side hex-head bolt to 4 ft-lb (5 N·m)...5208
        6. Secure the bottom (inlet) hose (2) to the bottom port of the fuel pump (9) (Figure 13b-14, Page 13b-13)...5208
        7. Secure the top (outlet) hose (3) to the top port of the fuel pump...5208
        8. Connect the white/black wire connector to the wire harness...5208
      Fuel Level Sending Unit...5208
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5209
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5209
        3. Remove the passenger seat. See Seat Removal, Section 4, Page 4-7...5209
        4. Remove the rubber boot (8) from the center post on the fuel level sending unit. Remove the nut (9) from the center post, and remove the orange wire (7) (Figure 13b-15, Page 13b-14). Retain the hardware...5209
        5. Remove the hex-head plastic thread screw (10) securing the black ground wire (6) to the fuel level sending unit, and remove the black ground wire. Retain the hardware...5209
        6. Remove the four remaining hex-head plastic thread screws from the fuel level sending unit flange (5). Retain the hardware...5209
        7. Carefully remove the sending unit and gasket (3). Feed the rheostat arm and float (4) through the fuel tank hole. Immediately place the fuel level sending unit in a pan to catch fuel. See following DANGER and NOTE...5209
        1. Place a new rubber gasket on the fuel tank with the notch (2) centered between the flange identification mounting holes (1). (Figure 13b-16, Page 13b-16). See following NOTE...5209
        2. Feed a new sending unit rheostat arm and float (4) into the fuel tank (Figure 13b-15, Page 13b-14). The rheostat arm and float should be positioned toward the outside surface of the fuel tank (Figure 13b-17, Page 13b-17)...5209
        3. Align the flange identification mounting holes (1) directly over the corresponding mounting holes in the gasket and fuel tank (Figure 13b-16, Page 13b-16). See following CAUTION and NOTE...5210
        4. Carefully thread each hex-head screw by hand, with the ring terminal on the black ground wire (6) under the screw head closest to the engine (Figure 13b-15, Page 13b-14). See following CAUTION...5210
        5. Use a crisscross pattern to tighten the hardware to 9 in-lb (1 N·m). If the hardware cannot be tightened to 9 in-lb (1 N·m), the fuel tank must be replaced. See following CAUTION...5210
        6. Secure the orange wire (7) to the center post with the nut (9) previously removed (Figure 13b-15, Page 13b-14). Tighten the hardware to 17 in-lb (1.9 N·m), and secure the rubber boot (8) to the center post...5211
        7. Install the passenger seat. See Seat Installation, Section 4, Page 4-7...5211
        8. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5211
      Fuel Tank...5211
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5211
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5211
        3. Remove both seats...5212
        4. Remove the center seat plate...5212
        5. Remove the upper portion of the ROPS (Roll Over Protection Structure) frame. See ROPS Removal, Section 4, Page 4-6...5212
        6. Remove the seat frame. See Seat Frame Removal, Section 4, Page 4-7...5212
        7. Disconnect the fuel feed line (1) from the fuel tank to the primary fuel filter, and raise the end of the hose above the fuel tank. Plug the line (Figure 13b-14, Page 13b-13). See following NOTE and DANGER...5212
        8. Disconnect the fuel return line (5) from the engine, and raise the end of the hose above the fuel tank. Plug the line. See previous NOTE and DANGER...5212
        9. Loosen the clamp, and remove the vent tube from the fuel tank...5212
        10. Remove the fuel tank cap...5212
        11. Use a siphon with a built-in suction device to siphon all fuel from the tank and into an approved container. See following DANGER and WARNING...5212
        12. Disconnect the black wire and orange wire from the fuel level sensor on the tank. Do not remove the lower nut on the center stud of the sensor...5213
        13. Remove the nut from the fuel tank strap below the passenger seat area. See following NOTE...5213
        14. Lift the strap end, and remove the opposite end from the slotted bracket...5213
        15. Remove the passenger-side bed latch bracket from the frame...5213
        16. Remove the fuel tank...5213
        1. Remove the cap from the tank and thoroughly rinse it with water. The cap may be discarded or kept as a spare...5213
        2. Use a well-ventilated area, and flush the fuel tank with water to remove any remaining fuel...5213
        3. Set the tank upside down in a well-ventilated area so that the water can drain. Allow the tank to sit for 24 hours to dry. See following WARNING...5213
        4. Store the tank upside down with the cap installed in a well-ventilated area...5213
        1. Place the fuel tank in the vehicle...5213
        2. Insert the tab end of the strap into the frame bracket, and place the strap in the indentions on the tank...5213
        3. Feed the threaded tab end down into the bottom of the frame. Install a nylon locknut, and tighten the nut to 40 in-lb (4.5 N·m)...5213
        4. Connect the clear vent tube to the fuel tank vent, and secure the tube with a new clamp...5213
        5. Connect the fuel line to the primary fuel filter on the vehicle frame, and secure it with a new clamp...5213
        6. Connect the fuel return line to the engine, and secure it with a new clamp...5213
        7. Connect the black wire and orange wire to the sensor (Figure 13b-19, Page 13b-19)...5214
        8. Slide the rubber boot over the stud...5214
        9. Install the passenger-side bed latch bracket on the frame with a bolt and flanged nylon locknut. Tighten the hardware to 20 ft-lb (27 N·m)...5214
        10. Install the seat frame. Tighten the nut to 37 ft-lb (50 N·m). See Seat Frame Installation, Section 4, Page 4-7...5214
        11. Install the top portion of the ROPS (Roll Over Protective Structure). See ROPS Installation, Section 4, Page 4-6...5214
        12. Install the center seat plate...5214
        13. Add the appropriate fuel to the fuel tank...5214
        14. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5214
        15. Install both seats...5214
        16. Place the Forward/Reverse handle in NEUTRAL, turn the key switch to start the engine, and allow it to idle. See following DANGER...5214
        17. Run the engine for a few minutes to ensure that the fuel lines are full of fuel...5214
        18. Inspect each fuel line connection for leaks...5214
      Fuel Lines...5214
    Engine Control Linkages...5215
      Accelerator Cable...5215
        1. Turn the key switch OFF, and place the Forward/Reverse handle in NEUTRAL. Remove the key. Chock the rear wheels...5215
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5215
        3. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-2...5215
        4. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...5215
        5. Remove the passenger seat. See Seat Removal, Section 4, Page 4-7...5215
        6. Disconnect the Z-shaped end (1) of the accelerator cable from the pedal (Figure 13b-20, Page 13b-21)...5215
        7. Disconnect the cable strain relief at the pedal bracket (Figure 13b-21, Page 13b-21)...5215
        8. Disconnect the Z-shaped end of the accelerator cable from the engine (Figure 13b-3, Page 13b-3)...5215
        9. Remove the cable strain relief from the engine bracket at the engine...5215
        10. Remove the cable from the rubber grommets under the passenger side of the frame and pull the cable at the dashboard away from the engine compartment. See following NOTE...5215
        1. Feed the engine end of the accelerator cable down into place from the dashboard area. See following NOTE...5216
        2. Connect the accelerator cable to the pedal (Figure 13b-22, Page 13b-22)...5216
        3. Secure the strain relief on the accelerator cable sheath to the slot at the back of the pedal bracket (Figure 13b-21, Page 13b-21)...5216
        4. Secure the engine end of the accelerator cable to the throttle lever on the engine (Figure 13b-3, Page 13b-3)...5216
        5. Secure the strain relief on the accelerator cable sheath to the engine bracket...5216
        6. Secure the accelerator cable to the rubber grommets under the passenger side of the frame...5216
        7. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...5216
        8. Install the instrument panel. See Instrument Panel Installation, Section 4, Page 4-4...5216
        9. Install the passenger seat. See Seat Installation, Section 4, Page 4-7...5216
        10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5216
      Engine RPM Adjustment...5216
        1. Turn the key switch OFF, and place the Forward/Reverse handle in NEUTRAL. Remove the key. Chock the rear wheels...5217
        2. Clean paint, grease, and dirt from one of the three fuel injector lines (Figure 13b-24, Page 13b-23). See following NOTES...5217
        3. Secure the fuel line probe clamp to the clean area of the fuel injector line (Figure 13b-25, Page 13b-23)...5217
        4. Secure the negative (-) line clamp to the negative (-) battery post (Figure 13b-26, Page 13b-23)...5217
        5. Secure the diesel probe to the tachometer (Figure 13b-23, Page 13b-23). See following NOTE...5217
        6. Turn the key switch to start and run the engine at idle. Measure the RPM with the tachometer and diesel probe attachment. Note the RPM reading. The correct idle RPM setting for this diesel engine is 1250 RPM ± 25...5218
        7. Turn the key switch OFF. Turn the low-speed adjustment screw 1/4 turn clockwise to raise the RPM, or counterclockwise to lower the RPM (Figure 13b-27, Page 13b-24)...5218
        8. Turn the key switch to start the engine, and allow it to idle. Measure the RPM. Repeat steps 6 and 7 until the idle RPM is correct. See following NOTE...5218
        1. Clean paint, grease, and dirt from any one of the three fuel injector lines (Figure 13b-24, Page 13b-23). See following NOTE...5218
        2. Secure the fuel line clamp to the clean area of the fuel injector line (Figure 13b-25, Page 13b-23)...5218
        3. Secure the negative (-) line clamp to the negative (-) battery post (Figure 13b-26, Page 13b-23)...5218
        4. Secure the diesel probe to the tachometer (Figure 13b-23, Page 13b-23). See following NOTE...5218
        5. Turn the key switch to start, and allow the engine to idle. Press the accelerator pedal all the way to the floor. Measure the RPM with the tachometer and diesel probe attachment. Note the RPM reading...5218
        6. Turn the key switch OFF, and remove the key. Turn the high-speed adjustment screw 1/4 turn clockwise to raise the RPM, or counterclockwise to lower the RPM...5218
        7. Turn the key switch to start, and allow the engine to idle. Press the accelerator pedal all the way to the floor. Measure the RPM. Repeat steps 5 and 6 until the high-speed RPM is correct...5218
    Air Intake System...5219
      Air Filter Replacement...5219
        1. Release both canister tab locks (Figure 13b-29, Page 13b-25)...5219
        2. Pull the canister cap away from the canister...5219
        3. Remove the air filter cartridge. See following NOTE...5219
        1. Push the new filter cartridge onto the inside canister nozzle...5219
        2. Place the canister cap, marked TOP, on the top center of the canister (Figure 13b-29, Page 13b-25)...5219
        3. Secure the canister cap with both tab locks...5219
      Air Canister Removal...5220
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5220
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5220
        3. Remove the air filter cartridge. See Air Filter Removal on page 13b-25...5220
        4. Remove the bottom (inlet) hose from the canister (Figure 13b-33, Page 13b-28)...5220
        5. Remove the top (outlet) hose from the canister...5220
        6. Remove the two bolts and park brake cable from the canister, and remove the canister...5220
      Air Canister Installation...5220
        1. Position the canister next to the frame bracket with the tab lock released, and oriented toward the passenger side...5220
        2. Install two bolts on the canister base bracket and vehicle frame bracket. Tighten the bolts to 21 ft-lb (28.5 N·m)...5220
        3. Secure the bottom (inlet) hose to the canister port...5220
        4. Secure the top (outlet) hose to the canister port...5220
        5. Install a new air filter cartridge. See Air Filter Installation on page 13b-25...5220
        6. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5220
      Air Filter Intake Hose Removal...5220
        1. Turn the key switch OFF, and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5221
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5221
        3. Disconnect the air intake hose from under the filter canister...5221
        4. Disconnect the air intake hose from the frame under the vehicle body...5221
        5. Slide the air intake hose through the frame support bracket, and remove the hose from the vehicle (Figure 13b-31, Page 13b-27)...5221
      Air Filter Intake Hose Installation...5221
        1. Slide the air intake hose through the frame support bracket (Figure 13b-31, Page 13b-27)...5221
        2. Secure the air intake hose to the air port under the vehicle body (Figure 13b-32, Page 13b-28)...5221
        3. Secure the air intake hose under filter canister (inlet) port (Figure 13b-33, Page 13b-28)...5221
        4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5221
      Air Filter Outlet Hose Removal...5222
        1. Turn the key switch OFF, and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5222
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5222
        3. Disconnect the air outlet hose from the air filter canister outlet port...5222
        4. Disconnect the air outlet hose from the carburetor inlet port, and remove the hose...5222
      Air Filter Outlet Hose Installation...5222
        1. Install the air outlet hose at the carburetor inlet port, and secure the air outlet hose with a clamp...5222
        2. Install the air outlet hose at the air filter outlet port, and secure the air outlet hose with a clamp...5222
        3. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5222
    Clutches...5222
      Clutch Troubleshooting...5223
        1. Check the governor and throttle settings. See Engine RPM Adjustment on page 13b-22...5223
        2. Inspect both clutches for dirt and debris buildup on component parts. Clean the exterior surfaces of both clutches with water...5223
        3. Check the clean clutches for wear...5223
        4. If cleaning both clutches does not solve the problem, disassemble and thoroughly clean all parts in the drive clutch. See Drive Clutch Cleaning and Inspection on page 13b-31...5223
        5. Check the drive clutch rollers and weights for wear...5223
      Drive Belt...5224
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5224
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5224
        3. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13b-37...5224
        4. Grasp the belt midway between the drive and driven clutches, and squeeze the belt together as tightly as possible...5224
        5. Guide the belt over the driven clutch and roll the belt off the driven clutch by rotating the clutch clockwise (Figure 13b-35, Page 13b-30). See following CAUTION...5224
        1. Position the new belt on the drive clutch, and then start the belt over the top of the driven clutch...5224
        2. Rotate the driven clutch clockwise, and roll the belt over the driven clutch sheaves and onto the clutch...5224
        3. Install the clutch outer cover. See Clutch Outer Cover Installation on page 13b-37...5224
        4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5224
      Drive Clutch...5225
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5225
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5225
        3. Remove the top air filter hose (outlet) from the air filter canister...5225
        4. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13b-37...5225
        5. Remove the drive belt. See Drive Belt Removal on page 13b-30...5225
        6. Remove the center bolt on the drive clutch...5225
        7. Thread the clutch removal tool (CCI P/N 102686101) into the drive clutch center, and advance the tool until the clutch shaft is released. See following CAUTION...5225
        8. Remove the drive clutch from the vehicle. See following CAUTION...5225
        1. Use a dry, lint-free cloth to clean clutch parts. See following CAUTION...5225
        2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced...5225
        1. Use a 7/16-inch socket to remove the four bolts (1) and washers (2) that secure the plate (3) to the clutch cover (4) (Figure 13b-37, Page 13b-33)...5226
        2. Remove the cover (4) and spring (5) from the clutch spider (6)...5226
        3. Inspect the torque rollers (7), weights (11) and rollers (10). Replace if necessary...5226
        4. Secure the Fixed sheave tool (CCI P/N 102601501) into a vice, or mount the tool to a flat work surface (Figure 13b-36, Page 13b-32)...5226
        5. Place the fixed sheave of the drive clutch onto the service tool so that the drive clutch is stationary...5226
        6. Place the Spider tool (CCI P/N 102607501) on top of the spider...5226
        7. Use a 1/2-inch drive ratchet to disengage the moveable sheave (14) and spider (6), which will come off as an assembly, from the fixed sheave (15) (Figure 13b-37, Page 13b-33)...5226
        1. Use a feeler gauge to inspect the torque rollers (7), and replace the rollers if necessary (Figure 13b-37, Page 13b-33)...5228
        2. Inspect the rollers (10) and weights (11). There should be no noticeable wear. If the rollers or weights are worn, scratched, or damaged, replace them...5228
        1. Place the moveable sheave (14) and spider (6) onto the fixed sheave (15). Note the location of the X so the remaining components with an X can be aligned...5228
        2. Use a spider removal tool (CCI P/N 102607501) to tighten the moveable sheave and spider to 225 ft-lb (305 N·m)...5228
        3. Install the spring (5) onto the shaft...5228
        4. Install the cover (4) onto the shaft...5228
        5. Align the plate that has holes in the cover with the arrows on the same side. Pull the moveable sheave upward and start threading bolts with washers into holes. See following NOTE...5228
        6. Use a crisscross pattern to continue tightening the hardware...5228
        7. Tighten the bolts to 10 ft-lb (14 N·m)...5228
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5228
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5228
        3. Place the drive clutch assembly on the crankshaft taper...5228
        4. Install the mounting washer and retaining bolt. Tighten the hardware to 39 ft-lb (53 N·m)...5228
        5. Install the drive belt as instructed. See Drive Belt Installation on page 13b-30...5228
        6. Install the clutch cover, and tighten the bolts to 6 ft-lb (8.0 N·m)...5228
        7. Secure the top air filter hose (outlet) to the filter canister...5228
        8. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5228
        9. Drive the vehicle and check for proper operation...5228
      Driven Clutch...5229
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle is in NEUTRAL...5229
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5229
        3. Remove the top air filter hose from the filter canister...5229
        4. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 13b-37...5229
        5. Remove the drive belt as instructed. See Drive Belt Removal on page 13b-30...5229
        6. Remove the bolt and washer from the center of the clutch...5229
        7. Thread the clutch removal tool (CCI P/N 102686101) into the driven clutch center, and advance the tool until the clutch shaft is released. See following CAUTION...5229
        8. Remove the driven clutch. See following CAUTION...5229
        1. Place the driven clutch onto the Spring compression base (CCI P/N 102603501) (Figure 13b-38, Page 13b-35)...5230
        2. Place the Spring compression collar (CCI P/N 102605201) onto the driven clutch...5230
        3. Thread the Spring compression nut (CCI P/N 102606101) down onto the threaded post enough to release the pressure on the snap ring...5230
        4. Use snap-ring pliers to remove the snap ring (1) (Figure 13b-39, Page 13b-36)...5230
        5. Slowly remove the spring compression nut. The collar will then rise and release tension on the spring (3)...5230
        6. Remove the cup (2) and spring (3)...5230
        7. Remove the moveable sheave (4) from the fixed sheave (5). See following NOTE...5230
        1. Place the fixed sheave (5) onto the spring compression base and note the location of the X so that the X on the moveable sheave (4) can be aligned correctly (Figure 13b-39, Page 13b-36)...5231
        2. Place the moveable sheave (4) onto the fixed sheave (5), and align the X’s on both components...5231
        3. Place the spring (3), cup (2), and snap ring (1) onto the clutch...5231
        4. Place the spring compression collar onto the cup (Figure 13b-38, Page 13b-35)...5231
        5. Tighten the spring compression nut just enough to enable the snap ring to be installed...5231
        6. Use the snap ring pliers to install snap ring...5231
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5231
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5231
        3. Install the driven clutch assembly on the transmission shaft taper...5231
        4. Install the mounting washer and retaining bolt. Tighten the hardware to 39 ft-lb (53 N·m)...5231
        5. Install the drive belt as instructed. See Drive Belt Installation on page 13b-30...5231
        6. Install the clutch outer cover and tighten the screws to 6 ft-lb (8 N·m)...5231
        7. Install the top air filter hose on the filter canister...5231
        8. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5231
        9. Drive the vehicle and check for proper operation...5231
      Clutch Cover...5231
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle is in NEUTRAL...5231
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5231
        3. Remove the top air filter hose from the filter canister...5231
        4. Remove the self-rolling screws, and remove the clutch outer cover...5231
        1. Align the mounting holes in the clutch outer cover with the mounting holes in the clutch inner cover...5231
        2. Install the screws, and tighten the hardware to 6 ft-lb (8 N·m)...5231
        3. Install the top air filter hose on the filter canister...5231
        4. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305). See following NOTE...5231
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL...5232
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5232
        3. Remove the outer clutch cover. See Clutch Outer Cover Removal on page 13b-37...5232
        4. Remove the drive belt. See Drive Belt Removal on page 13b-30...5232
        5. Remove the drive clutch. See Drive Clutch Removal on page 13b-31...5232
        6. Remove the driven clutch. See Driven Clutch Removal on page 13b-35...5232
        7. Remove the bolts, nuts, and washers from the inner clutch cover (Figure 13b-41, Page 13b-38). See following NOTE...5232
        8. Remove the clutch cover...5232
        9. Remove the inner cover spacer between the inner cover and the engine block (Figure 13b-42, Page 13b-38)...5232
        1. Position the inner cover spacer on the engine block, and use the stud bolts for alignment (Figure 13b-42, Page 13b-38)...5233
        2. Align the mounting holes in the clutch cover with the transmission and engine bolt holes...5233
        3. Loosely install one bolt and washer in each transmission and engine bolt hole...5233
        4. Finger-tighten the bolts and washers (Figure 13b-41, Page 13b-38). See following NOTE...5233
        5. Tighten the engine bolts and washers to 21 ft-lb (28.5 N·m) (Figure 13b-40, Page 13b-38)...5233
        6. Tighten the engine stud bolt nuts to 21 ft-lb (28.5 N·m)...5233
        7. Tighten the transmission bolts and washers to 21 ft-lb (28.5 N·m)...5233
        8. Install the driven clutch. See Driven Clutch Installation on page 13b-37...5233
        9. Install the drive clutch. See Drive Clutch Installation on page 13b-34...5233
        10. Install the drive belt. See Drive Belt Installation on page 13b-30...5233
        11. Install the outer clutch cover. See Clutch Outer Cover Installation on page 13b-37...5233
        12. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5233
  Section 14 - Drivetrain Components...5235
    Half Shafts...5235
      Half Shaft Removal...5235
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Chock the rear wheels...5235
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5235
        3. Loosen the lug nuts on both front wheels...5235
        4. Remove the rubber spindle nut covers from both front wheels...5235
        5. Loosen the spindle nuts, and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5235
        6. Place jack stands under the lower A-frame plates, and lower the vehicle onto the stands (Figure 14-1, Page 14-1)...5235
        7. Remove both front wheels...5235
        8. Remove both spindle nuts and large washers...5235
        9. Remove the upper shock absorber bolt and locknut (Figure 14-2, Page 14-1)...5236
        10. Remove the lower shock absorber bolts and flanged locknuts. Remove the shock absorber and coil-over spring...5236
        11. Remove the two hex-head bolts (shown with white marks on bolt heads) securing the caliper to the upright, and remove the caliper and discs (Figure 14-3, Page 14-2)...5236
        12. Position the caliper and discs on the top of the upper A-frame, and secure them with a wire tie. See following CAUTION...5236
        13. Remove the two flanged bolts and square nuts from the camber adjustment bar (Figure 14-4, Page 14-2)...5236
        14. Lift the wheel hub up and away from the lower A-frame to remove the half shaft spindle from the wheel hub, and remove the camber bar from the lower A-frame...5236
        15. Separate the half shaft hub from the differential, and remove the half shaft (Figure 14-5, Page 14-3). See following NOTE...5236
        16. Repeat steps 9 through 15 for the remaining half shaft...5236
      Half Shaft Installation...5237
        1. Apply a light coat of anti-seize compound to each end of the half shaft splines (Figure 14-7, Page 14-3)...5237
        2. Install the half shaft into the front differential. Advance the half shaft until the compression ring seats into the groove inside the differential housing...5237
        3. Lift the wheel hub and upper A-frame. Slide the half shaft spindle into the wheel hub, and insert the camber adjustment bar into the lower A-frame slot...5237
        4. Loosely secure the flanged bolts and new square nuts to the camber adjustment bar and lower A-frame (Figure 14-4, Page 14-2)...5237
        5. Install a large washer and new nut on the half shaft spindle and wheel hub. Finger-tighten the hardware...5237
        6. Secure the caliper and discs to the upright and wheel hub disc with new lock-patch bolts. Tighten the hardware to 36 ft-lb (49 N·m) (Figure 14-3, Page 14-2). See following CAUTION...5238
        7. Secure the lower shock absorber mount to the upper A-frame with new flanged-head bolts and locknuts. Tighten the hardware to 22 ft-lb (30 N·m)...5238
        8. Secure the top shock absorber mount to the flanged brackets on the frame with a new flanged-head bolt and flanged locknut. Tighten the hardware to 73 ft-lb (99 N·m) (Figure 14-2, Page 14-1)...5238
        9. Install the tire and wheel, and finger-tighten the lug nuts...5238
        10. Repeat steps 1 through 9 for the remaining half shaft and wheel...5238
        11. Lift the front of the vehicle with a chain hoist or floor jack, remove the jack stands, and lower the vehicle to the ground. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5238
        12. Use a crisscross pattern to tighten the lug nuts on both front wheels to 85 ft-lb (115 N·m)...5238
        13. Tighten both spindle locknuts to 150 ft-lb (203 N·m)...5238
        14. Adjust the front wheel camber. See Camber Adjustment, Section 7, Page 7-11...5238
        15. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5238
    Front Differential...5238
      Front Differential Removal...5238
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5238
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5238
        3. Loosen the lug nuts on both front wheels...5238
        4. Loosen the spindle nuts and lift the front of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5238
        5. Place jack stands under the lower A-frame plates, and lower the vehicle onto the stands (Figure 14-1, Page 14-1)...5238
        6. Remove both half shafts. See Half Shaft Removal on page 14-1...5238
        7. Remove the roll pin from the differential output shaft and front drive shaft (Figure 14-8, Page 14-5). See following NOTE...5238
        8. Remove the vent tube from the differential housing (Figure 14-9, Page 14-5)...5239
        9. Disconnect the electric clutch line from the differential at the connector behind the splash guard (Figure 14-10, Page 14-5). See following NOTE...5239
        10. Remove the four flange-head bolts from the frame support weldments (Figure 14-11, Page 14-5). See following NOTE...5239
        11. Pull the front differential, differential plate, and driveshaft forward and away from the transmission end of the splined universal joint. Tip the unit downward, and remove it from the vehicle. See following NOTE...5239
      Front Differential Installation...5240
        1. Position the front differential and plate on the two frame support weldments. Align the splined coupling on the universal joint so the roll pin hole in the spline coupling aligns with the roll pin hole in the differential shaft...5240
        2. Slide the driveshaft into place with the transmission end of the universal joint coupling on the transmission splined shaft...5240
        3. Secure the differential plate to the frame support weldments with new flange-head bolts. Tighten the hardware to 23 ft-lb (31 N·m) (Figure 14-11, Page 14-5)...5240
        4. Connect the electric clutch line to the connector behind the splash guard (Figure 14-10, Page 14-5)...5240
        5. Connect the vent tube to the differential housing (Figure 14-9, Page 14-5). See following NOTE...5240
        6. Drive a new roll pin into the differential shaft and driveshaft universal joint coupling. See following NOTE...5240
        7. Fill the front differential with the specified lubricant. See Lubrication Change for Front Differential, Transmission, and Rear Differential, Section 10, Page 10-11...5240
        8. Install the half shafts. See Half Shaft Installation on page 14-3...5240
        9. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5240
    Front Driveshaft...5240
      Front Driveshaft Removal...5240
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Chock the rear wheels...5240
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5240
        3. Remove the roll pin from the differential output shaft and front drive shaft (Figure 14-8, Page 14-5). See following NOTE...5240
        4. Remove the bolts from the front differential plate, and slide the differential as far forward as possible...5240
        5. Slide the front driveshaft toward the transmission until the universal joint clears the front differential...5241
        6. Slide the driveshaft away from the transmission, through the tube-shaped frame shield, and remove the driveshaft from vehicle...5241
      Front Driveshaft Installation...5241
        1. Apply a light coat of anti-seize compound to the splined output shaft on the front differential...5241
        2. Slide the front driveshaft through the tube-shaped frame shield and onto the splined shaft of the transmission...5241
        3. Slide the front differential shaft into the universal joint so the roll pin holes in the driveshaft and differential shaft are aligned...5241
        4. Secure the differential plate to the frame support weldments with new flange-head bolts. Tighten the hardware to 23 ft-lb (31 N·m) (Figure 14-11, Page 14-5)...5241
        5. Drive a new roll pin into the differential shaft and driveshaft universal joint coupling. See following NOTE...5241
        6. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5241
    Rear Receiver Hitch...5241
      Rear Receiver Hitch Removal...5241
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Chock the rear wheels...5241
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5241
        3. Remove the hydraulic line T-bracket from the passenger side of the receiver hitch...5241
        4. Remove the hydraulic line from the rubber grommets and hitch frame...5241
        5. Remove the four bolts, washers, and flanged locknuts from the receiver hitch frame and swing arm mounting plates, and remove the receiver hitch...5241
      Rear Receiver Hitch Installation...5241
        1. Position the receiver hitch onto the swing arm mounting plates and mounting holes...5241
        2. Secure the receiver hitch with new bolts, flat washers, and new flanged locknuts. Tighten the hardware to 82 ft-lb (111 N·m)...5241
        3. Secure the hydraulic brake line T-fitting, and tighten the hardware to 48 in-lb (7 N·m) (Figure 14-13, Page 14-9)...5241
        4. Secure the hydraulic brake line in the rubber grommets on the hitch frame...5242
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5242
    Rear Axle...5242
      Rear Axle Removal...5242
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the front wheels...5242
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5242
        3. Loosen the lug nuts on the rear wheels, and lift the rear of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5242
        4. Place jack stands under the outside frames, as close to the rear of the vehicle as the frames will support. Lower the vehicle onto the stands (Figure 14-12, Page 14-8). See following DANGER...5242
        5. Remove both rear wheels...5242
        6. Remove the hydraulic brake line T-fitting and bracket from the passenger-side receiver frame (Figure 14-13, Page 14-9)...5242
        7. Remove the hydraulic brake line P-clamp from the rear differential (Figure 14-14, Page 14-9)...5242
        8. Remove the hydraulic brake lines from all frame-mounted rubber grommets...5243
        9. Remove both park brake cables from the rear brake calipers and park brake levers (Figure 14-15, Page 14-10)...5243
        10. Remove the hex-head bolts securing the brake caliper to the axle flange...5243
        11. Install the brake calipers on the swing arms, and fasten them temporarily with wire ties. See following CAUTION...5243
        12. Position the floor jack under the differential, and raise the jack just enough to support the axle (Figure 14-16, Page 14-10)...5243
        13. Remove the rear shock absorbers. See Rear Shock Absorber Removal, Section 9, Page 9-1...5243
        14. Remove the rear receiver hitch. See Rear Receiver Hitch Removal on page 14-7...5243
        15. Remove the roll pin from the differential splined shaft and rear drive shaft universal coupling. See following NOTE...5243
        16. Remove the four bolts, two spacer bars, and flanged locknuts from the axle and swing arm mounting plates. See following NOTE and CAUTION...5243
        17. Support the rear drive shaft, and slide the axle and differential away from the drive shaft universal joint and swing arm brackets. See preceding NOTE...5243
        18. Move the axle and rear differential assembly to a safe area away from the vehicle. See previous NOTE...5243
      Rear Axle Installation...5244
        1. Support the differential with a floor jack, and place the axle assembly under the rear of the vehicle, just below the swing arms...5244
        2. Support the longest end of the axle assembly, and raise the axle up to the swing arm axle mounting plates...5244
        3. Align the differential splined shaft and hole with the drive shaft universal joint and hole...5244
        4. Align the roll pin holes in the differential shaft with the drive shaft coupling, and drive a new roll pin into place. See following NOTE...5244
        5. Secure the axle to the outside of the swing arms at four locations with new bolts and washers. Finger- tighten the hardware...5244
        6. Secure the rear receiver hitch to the inside of the swing arms and axle at four locations with new bolts and washers. Finger-tighten the hardware...5244
        7. Tighten all eight axle mounting bolts to 95 ft-lb (129 N·m)...5244
        8. Secure the bottom end of the shock absorbers to the axle bracket (Figure 14-17, Page 14-11). See following NOTE...5244
        9. Install both rear brake calipers and discs. See Rear Brake Caliper Installation, Section 6, Page 6-9...5245
        10. Secure the hydraulic brake lines to the rubber grommets at all frame locations. See following CAUTION...5245
        11. Secure the P-clamp to the hydraulic brake line on top of the differential body. Tighten the hardware to 11 ft-lb (15 N·m) (Figure 14-14, Page 14-9)...5245
        12. Secure the hydraulic line T-fitting to the receiver hitch frame, and tighten the bolt to 48 in-lb (7 N·m) (Figure 14-13, Page 14-9)...5245
        13. Adjust the park brake. See Park Brake Adjustment, Section 6, Page 6-23...5245
        14. Install both rear wheels, and finger-tighten the lug nuts...5245
        15. Lower and remove the floor jack...5245
        16. Lift the rear of the vehicle with a chain hoist or floor jack, and remove the jack stands. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5245
        17. Use a crisscross pattern to tighten the lug nuts on both rear wheels to 85 ft-lb (115 N·m)...5245
        18. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5245
    Rear Driveshaft...5245
      Rear Driveshaft Removal...5245
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL...5245
        2. Push the car to a position that enables easy access to the roll pin in the rear differential and rear driveshaft. Chock the front wheels...5245
        3. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5245
        4. Gasoline vehicles: Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5246
        5. Remove the roll pin from the rear differential and drive shaft universal joint. See following NOTE...5246
        6. Slide the driveshaft forward on the transmission to release the driveshaft from the differential shaft. Then slide the driveshaft toward the rear, and off the transmission shaft...5246
      Rear Driveshaft Installation...5246
        1. Apply a light coat of anti-seize on the splined shaft of the differential...5246
        2. Slide the universal joint of the drive shaft (with grease fitting) onto the splined transmission shaft...5246
        3. Slide the differential shaft into driveshaft universal joint. Align the roll pin holes in the driveshaft with the pin holes in the differential shaft...5246
        4. Drive a new roll pin into the differential shaft and the driveshaft universal joint coupling. See following NOTE...5246
        5. Gasoline vehicles: Connect the spark plug wires...5246
        6. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5246
    Transmission...5246
      Troubleshooting...5246
        1. Turn the key switch OFF and remove the key...5246
        2. Fully engage the shift lever into forward then reverse gear (Figure 14-18, Page 14-13). If the shift lever contacts the ends ...5247
        3. In addition to checking the shift lever contact with the dash, disconnect the shift cable from the transmission bell crank and shift lever arm (Figure 14-19, Page 14-13 and Figure 14-20, Page 14-13)...5247
        4. Move the shift lever arm, transmission bell crank and shift cable to ensure all components move freely...5247
        5. Inspect the transmission shift cable for any cuts or tears in the cover. Ensure the cable does not have any sharp bends or kinks. Re-route or replace the cable as required. See Forward/Reverse Shifter Cable, Section 14, Page 14-18...5247
        6. Check the cable brackets. Make sure the brackets are not bent and all bracket and cable hardware is tight (Figure 14-20, Page 14-13)...5247
        7. Inspect the bell crank for movement on the transmission shift shaft (Figure 14-21, Page 14-13). If the nut is tight, a loose ...5248
        8. If the steps listed above do not correct the difficult shifting transmission or transmission disengagement, install a new Neutral Switch Repair Kit (CCI P/N 102765101) as described below...5248
        1. Locate the shift detent housing on the right side of the transmission near the transmission bell crank (Figure 14-23, Page 14-14). Clean the area around the detent housing...5248
        2. Disconnect the neutral switch connector...5249
        3. Remove the detent housing. The entire assembly including the neutral switch and detent housing must be removed from the transmission case...5249
        4. Install the Neutral Switch Repair Kit (Figure 14-24, Page 14-14). Apply a small bead of Loctite® 545 Red or equivalent to the...5249
        5. Re-connect the neutral switch connector...5249
      Transmission Removal...5249
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5249
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5249
        3. Gasoline vehicles: Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5249
        4. Remove the outer clutch cover. See Clutch Outer Cover Removal on page 13a-40 (gasoline vehicles) or Clutch Outer Cover Removal on page 13b-37 (diesel vehicles)...5249
        5. Remove the drive belt. See Drive Belt Removal on page 13a-32 (gasoline vehicles) or Drive Belt Removal on page 13b-30 (diesel vehicles)...5249
        6. Remove the drive clutch. See Drive Clutch Removal on page 13a-33 (gasoline vehicles) or Drive Clutch Removal on page 13b-31 (diesel vehicles)...5249
        7. Remove the driven clutch. See Driven Clutch Removal on page 13a-37 (gasoline vehicles) or Driven Clutch Removal on page 13b-35 (diesel vehicles)...5249
        8. Remove the rear driveshaft. See Rear Driveshaft Removal on page 14-11...5249
        9. Remove the inner clutch cover. See Clutch Inner Cover Removal on page 13a-41 (gasoline vehicles) or Clutch Inner Cover Removal on page 13b-38 (diesel vehicles)...5249
        10. Remove the passenger seat...5249
        11. Gasoline vehicles: Remove the governor guard. See Governor Guard Removal, Section 13a, Page 13a-21...5249
        12. Disconnect the accelerator cable and strain relief grommet from the governor arm (Figure 14-25, Page 14-16)...5249
        13. Disconnect the governor cable and strain relief grommet from the governor arm...5249
        14. Remove the governor arm...5249
        15. Remove the transmission Forward/Reverse shifter cable ball socket from the ball on the transmission shifter arm (Figure 14-31, Page 14-20)...5250
        16. Disconnect the neutral sensing connector from the transmission (Figure 14-26, Page 14-16)...5250
        17. Remove the two flange-head bolts, washers, and locknuts from the transmission slotted base brackets and engine mounting plate. See following NOTE...5250
        18. Lift the transmission body slightly to clear the opening in the engine mounting plate. Remove the transmission from the rear of the vehicle...5250
      Transmission Installation...5251
        1. Ensure the base brackets are installed on the transmission, and install the transmission on the engine mounting plate...5251
        2. Align the base bracket slots with the mounting holes in the engine mounting plate. See following NOTE...5251
        3. Secure the clutch inner cover to the engine and clutch body with bolts and washers. Finger-tighten the hardware. See following NOTE...5251
        4. Gasoline vehicles: See Clutch Inner Cover Installation, Section 13a, Page 13a-41. Diesel vehicles: See Clutch Inner Cover Installation, Section 13b, Page 13b-39...5251
        5. Tighten the transmission body base flange-head bolt and flange-head locknut to 39 ft-lb (53 N·m)...5251
        6. If removed, install two new bolts, flat washers, and new flanged locknuts on the transmission base brackets and engine mounting plate. Tighten the hardware to 21 ft-lb (29 N·m)...5251
        7. Connect the neutral sensing connector on the transmission to the wire harness (Figure 14-26, Page 14-16)...5251
        8. Secure the Forward/Reverse shifter cable ball socket to the ball on the transmission shifter arm (Figure 14-31, Page 14-20). See following NOTE...5251
        9. Gasoline vehicles: Install the ground speed governor arm (Figure 14-25, Page 14-16)...5251
        10. Gasoline vehicles: Secure the governor cable from the engine to the governor arm. See Governor Cable Installation, Section 13a, Page 13a-22...5251
        11. Gasoline vehicles: Secure the accelerator cable to the governor arm. See Accelerator Cable Installation, Section 13a, Page 13a-19...5251
        12. Gasoline vehicles: Adjust the ground speed governor arm. See Ground Speed (Transmission) Governor Arm Adjustment, Section 13a, Page 13a-23...5251
        13. Gasoline vehicles: Install the governor guard. See Governor Guard Installation, Section 13a, Page 13a-21...5251
        14. Both gasoline and diesel vehicles: Install the rear driveshaft. See Rear Driveshaft Installation on page 14-12...5251
        15. Install the driven clutch. See Driven Clutch Installation, Section 13a, Page 13a-39 (gasoline vehicles) and Driven Clutch Installation, Section 13b, Page 13b-37 (diesel vehicles)...5251
        16. Install the drive clutch. See Drive Clutch Installation, Section 13a, Page 13a-37 (gasoline vehicles) and Drive Clutch Installation, Section 13b, Page 13b-34 (diesel vehicles)...5251
        17. Install the drive belt. See Drive Belt Installation, Section 13a, Page 13a-33 (gasoline vehicles) and Drive Belt Installation, Section 13b, Page 13b-30 (diesel vehicles)...5252
        18. Install the clutch outer cover. See Clutch Outer Cover Installation, Section 13a, Page 13a-40 (gasoline vehicles) and Clutch Outer Cover Installation, Section 13b, Page 13b-37 (diesel vehicles)...5252
        19. Install the rear axle and differential. See Rear Axle Installation on page 14-10...5252
        20. Remove the transmission fill plug, and fill the transmission with the correct amount of appropriate lubricant (Figure 14-28, Page 14-18). See Lubrication Change for Front Differential, Transmission, and Rear Differential on page 10-11...5252
        21. Tighten wheel lug nuts to 85 ft-lb (115 N·m)...5252
        22. Gasoline vehicles: Connect the spark plug wires...5252
        23. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5252
      Forward/Reverse Shifter Cable...5252
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5252
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5252
        3. Gasoline vehicles: Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5252
        4. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-2...5253
        5. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...5253
        6. Remove the front body. See Front Body Removal, Section 4, Page 4-5...5253
        7. Remove the passenger seat...5253
        8. Disconnect the cable ball socket from the shifter arm ball stud (Figure 14-29, Page 14-19)...5253
        9. Loosen the flanged nuts from the cable at the dash bracket (Figure 14-30, Page 14-19)...5253
        10. Disconnect the cable ball socket from the shifter ball stud on the transmission shifter arm (Figure 14-31, Page 14-20)...5253
        11. Loosen the flanged nuts from the cable bracket that is below the transmission ball socket...5253
        12. Note the positions of the wire ties that secure the cable between the dash and the transmission, and then remove the wire ties. See following NOTE...5253
        13. Remove the shifter cable...5253
        1. Secure a new cable to the transmission end of the nylon cord at the dash frame. Pull and route the cable from the dash frame to the transmission. See following NOTE...5254
        2. Secure the ball socket to the ball stud on the Forward/Reverse shifter handle at the dash (Figure 14-29, Page 14-19)...5254
        3. Loosen the flanged nut farthest from the handle end as far away from the handle end as the thread will allow...5254
        4. Advance the front flanged nut away from the rear nut. Allow enough room to install the cable and two flanged nuts on the Forward/Reverse cable bracket on the dash frame...5254
        5. Adjust the shifter cable. See Forward/Reverse Shifter Cable Adjustment on page 14-20...5254
        1. Loosen the flanged cable nuts from the cable end at the transmission...5254
        2. Verify that the transmission shifter arm is in the neutral position...5254
        3. Secure the ball socket to the ball stud on the transmission shifter arm. See following NOTE...5254
        4. Hold the shifter arm on the transmission in the neutral position, and align the shifter handle with the neutral position mark on the instrument panel. See following NOTE...5254
        5. Advance the front flanged nut, closest to the transmission shifter arm, up against the front side of the Forward/Reverse shifter bracket...5254
        6. Advance the rear flanged nut, farthest away from the transmission shifter arm, down next to the back side of the FNR shifter bracket and tighten the front nut to 25 ft-lb (34 N·m)...5255
        7. Install the front body. See Front Body Installation, Section 4, Page 4-5...5255
        8. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...5255
        9. Install the instrument panel. See Instrument Panel Installation, Section 4, Page 4-4...5255
        10. Move the shifter handle to the FORWARD, NEUTRAL, and REVERSE positions. Ensure that the shifter handle is clear of the instrument panel in the FORWARD and REVERSE positions and is aligned with the center of the two for the neutral position...5255
        11. Install the passenger seat...5255
        12. Gasoline vehicles: Connect the spark plug wires...5255
        13. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5255
      Forward/Reverse Shifter Handle...5255
        1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels...5255
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5255
        3. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-2...5255
        4. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...5255
        5. Disconnect the cable ball socket from the shifter arm ball stud (Figure 14-29, Page 14-19)...5255
        6. Remove the socket-head pivot shoulder bolt, nylon spacer, two large flat washers, and nylon locknut from the shifter handle and frame bracket...5255
        7. Remove the shifter handle...5255
        1. Secure the shifter handle with a new socket-head pivot shoulder bolt (CCI P/N 102684601), nylon spacer, two large flat washers, and a new nylon locknut. Tighten the hardware to 40 in-lb (5 N·m) (Figure 14-29, Page 14-19). See following NOTE...5255
        2. Secure the ball socket to the ball stud on the Forward/Reverse shifter handle at the dash...5255
        3. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...5255
        4. Install the instrument panel. See Instrument Panel Installation, Section 4, Page 4-4...5255
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5255
    Rear Differential and Axles...5256
      Rear Differential Removal...5256
        1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock the front wheels...5256
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1...5256
        3. Gasoline vehicles: Disconnect the spark plug wires. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2...5256
        4. Loosen the lug nuts on the rear wheels, and lift the rear of the vehicle with a chain hoist or floor jack. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5256
        5. Place jack stands under the outside frames, as close to the rear of the vehicle as the frames will support. Lower the vehicle onto the stands (Figure 14-12, Page 14-8)...5256
        6. Remove the rear wheels...5256
        7. Remove the rear wheel hubs and discs. See Wheel Removal, Section 8, Page 8-2...5256
        8. Remove the rear receiver hitch. See Rear Receiver Hitch Removal on page 14-7...5256
        9. Place a large pan under the differential. Remove the drain plug from the bottom of the differential housing. Drain the differential lubricant...5256
        10. Remove the rear axle. See Rear Axle Removal on page 14-8...5256
        11. Remove the rear drive shaft. See Rear Driveshaft Removal on page 14-11. See following NOTE and CAUTION...5256
        12. Remove the six flange-head bolts and flat washers from the passenger-side axle tube and differential...5256
        13. Separate the passenger-side axle tube flange from the differential case. The axle and splined end must be clear of the differential (Figure 14-32, Page 14-23)...5256
        14. Remove the six flange-head bolts and flat washers from the driver-side axle tube and differential...5256
        15. Separate the driver-side axle tube flange from the differential case and pull straight away until the axle and splined end is clear of the differential...5256
      Rear Axle Shafts and Wheel Bearings...5257
        1. Remove the rear differential from the two rear axle housing and axle shaft assemblies. See Rear Differential Removal on page 14-22...5257
        2. Pull the axle shaft out of the axle housing at the differential flange...5257
        3. Remove the outboard snap ring...5257
        4. Use a rod and push the rear seal and wheel bearing toward the wheel hub end and out of the axle housing hub...5257
        5. Repeat steps 1 through 4 for the opposite wheel bearing...5257
        1. Replace the rear seal and wheel bearing in the axle housing hub...5257
        2. Install the outboard snap ring...5257
        3. Slide the axle shaft back into the axle housing from the differential flange end...5257
        4. Repeat steps 1 through 3 for the remaining wheel bearing...5257
      Rear Differential Installation...5257
        1. Clean all mating surfaces on both axle tubes and both flanged sides of the differential housing...5257
        2. Clean the splined area on both axles...5257
        3. Apply a 3/16-inch wide bead of Three Bond No. 1215 (CCI P/N 101928701) to both mating surfaces on the differential housing...5257
        4. Secure the axles and axle tubes to the differential housing. See following NOTE...5257
        5. Apply Loctite 2760 to new flange-head bolts, and install the bolts and flat washers. Use a crisscross pattern to tighten the hardware to 100 ft-lb (136 N·m). See following CAUTION...5258
        6. Install the rear driveshaft. See Rear Driveshaft Installation on page 14-12...5258
        7. Install the rear axle. See Rear Axle Installation on page 14-10...5258
        8. Install rear receiver hitch. See Rear Receiver Hitch Installation on page 14-7...5258
        9. Add lubricant to the differential. See Lubrication Change for Front Differential, Transmission, and Rear Differential on page 10-11...5258
        10. Install the rear wheel hubs and discs. See Rear Wheel Disc Removal, Section 6, Page 6-15...5258
        11. Install the rear wheels, and finger-tighten the lug nuts...5258
        12. Lift the rear of the vehicle with a chain hoist or floor jack, and remove the jack stands. See WARNING “Lift only one end...” in General Warning, Section 1, Page 1-2...5258
        13. Tighten the lug nuts on the rear wheels to 85 ft-lb (115 N·m)...5258
        14. Gasoline vehicles: Connect spark plug wires...5258
        15. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5258
  Section 15 - Radiator and Coolant System (Diesel)...5259
    General Information...5259
      Engine Coolant Check...5259
        1. Check the coolant level in the reservoir. If the coolant level is at or below the LOW mark, add water until the level reaches the FULL mark. See following WARNING and NOTE...5259
      Engine Coolant Change...5259
        1. Turn the key switch OFF, and remove the key. Place the Forward/Reverse handle in NEUTRAL, and chock the rear wheels...5259
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in See General Warning, Section 1, Page 1-1...5259
        3. Open the reservoir cap. See following WARNING...5259
        4. Place a large pan under the radiator and engine drain plugs...5259
        5. Turn the drain valve at the radiator counterclockwise, for one and one-half turns only, to drain coolant from radiator. See following NOTE...5259
        6. Turn the drain valve on the engine counterclockwise to drain coolant (Figure 15-1, Page 15-2)...5260
        7. Remove the engine block coolant plug from the rear of the engine (Figure 15-2, Page 15-2). See following NOTE...5260
        8. Drain coolant from the reservoir, radiator, and engine completely...5260
        9. Check the hoses and clamps for looseness or damage. Replace if necessary...5260
        10. Check the radiator for leaks or severe coil damage. Replace the radiator if damage has created a leak, or has caused flow restriction from crushed coils...5260
        11. Close both drain plugs but leave the engine block coolant plug open...5260
        12. Fill the coolant system with an appropriate coolant mixture at the reservoir. Allow the coolant to fill until it reaches the engine block coolant plug. See following NOTE...5260
        13. Apply Loctite 567 Liquid Thread Sealer to the threads of the block coolant plug...5260
        14. Install the engine block coolant plug and tighten to 12 ft-lb (16 N·m)...5260
        15. Fill the reservoir to the full mark with an appropriate coolant mixture, and check for leaks...5260
        16. Replace the radiator cap and the reservoir cap...5260
        17. Start and run the engine until it reaches operating temperature. Monitor the coolant level in the reservoir...5260
        18. Stop the engine and allow the engine and coolant to cool. See following WARNING...5260
        19. Remove the reservoir cap, and add coolant until the level reaches the FULL mark. See preceding WARNING...5260
        20. Replace the reservoir cap...5260
    Coolant Reservoir...5261
      Coolant Reservoir Removal...5261
        1. Turn the key switch OFF, and remove the key. Place the Forward/Reverse handle in NEUTRAL, and chock the rear wheels...5261
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in See General Warning, Section 1, Page 1-1...5261
        3. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...5261
        4. Remove the reservoir cap. See following WARNING...5261
        5. Place a large pan under the radiator and front differential to collect coolant. See following NOTE...5261
        6. Remove the engine block coolant plug from the rear of the engine (Figure 15-2, Page 15-2)...5261
        7. Loosen the clamp, and remove the reservoir hose at the T-fitting under the front splash guard. Drain the coolant from the reservoir into a pan (Figure 15-3, Page 15-3). See preceding NOTE...5261
        8. Loosen the clamp, and remove the outlet hose from the reservoir (Figure 15-4, Page 15-3)...5261
        9. Loosen the clamp, and remove the vent hose from the reservoir...5261
        10. Gently slide the reservoir toward the vehicle seat and away from the dimpled aluminum bracket and indentions in the reservoir. Remove the reservoir...5261
      Coolant Reservoir Installation...5262
        1. Gently slide the reservoir between the aluminum bracket until the dimples align with the indentations in the reservoir...5262
        2. Feed the reservoir outlet hose through the hole in the splash guard. See following CAUTION...5262
        3. Install the reservoir outlet hose on the reservoir, and secure the hose clamp...5262
        4. Install the reservoir hose on the radiator T-fitting, and secure the hose clamp...5262
        5. Install the reservoir vent hose, and secure the hose clamp...5262
        6. Fill the coolant system with an appropriate coolant mixture at the reservoir. Allow the coolant to fill until it reaches the engine block coolant plug. See following NOTE...5262
        7. Apply Loctite 567 Liquid Thread Sealer to the threads of the block coolant plug...5262
        8. Install the engine block coolant plug and tighten to 12 ft-lb (16 N·m)...5262
        9. Fill the reservoir to the full mark with an appropriate coolant mixture, and check for leaks...5262
        10. Replace the radiator and reservoir caps...5262
        11. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...5262
        12. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5262
        13. Start and run the engine until it reaches operating temperature, and check for leaks...5262
        14. Stop the engine and allow the engine and coolant to cool...5262
        15. If necessary, remove the reservoir cap and add coolant until the coolant level reaches the FULL mark. See following WARNING...5262
    Radiator...5262
      Radiator Removal...5262
        1. Turn the key switch OFF, and remove the key. Place the Forward/Reverse handle in NEUTRAL, and chock the rear wheels...5262
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in See General Warning, Section 1, Page 1-1...5262
        3. Remove the dashboard. See Dashboard Removal, Section 4, Page 4-4...5262
        4. Remove the front body. See Front Body Removal, Section 4, Page 4-5...5263
        5. Drain the radiator and reservoir. See following WARNING...5263
        6. Loosen the clamp, and remove the bottom radiator hose...5263
        7. Remove the radiator bottom shield plate bolts (Figure 15-5, Page 15-5)...5263
        8. Remove the front frame bolts from the radiator guard (Figure 15-6, Page 15-5)...5263
        9. Remove the flanged locknuts from the right and left sides of the upper radiator mount bracket (Figure 15-7, Page 15-6)...5263
        10. Remove the rear flanged bolts from the upper radiator mount bracket at the top of the frame (Figure 15-8, Page 15-6)...5263
        11. Remove the two bolts, locknuts, and washers from the outside upper radiator mount bracket at the front frame guard tube. Remove the brackets (Figure 15-9, Page 15-6)...5264
        12. Remove the two bolts and nylon locknuts from the top radiator guard (Figure 15-10, Page 15-6)...5264
        13. Loosen the clamp, and remove the upper vent hose from the radiator...5264
        14. Loosen the clamp, and remove the top radiator hose...5264
        15. Disconnect the electric fan connector...5264
        16. Remove the two bolts, washers, and locknuts from the inside top front frame guard tube (Figure 15-11, Page 15-7). See following NOTE and CAUTION...5264
        17. Push the back splash guard, and lift the radiator up, forward, and away from the vehicle. See following NOTE...5265
        1. Turn the key switch OFF, and remove the key. Set the park brake, and chock the wheels...5265
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in See General Warning, Section 1, Page 1-1...5265
        3. Remove the front body. See Front Body Removal, Section 4, Page 4-5...5265
        4. Locate the blue wire and black wire that extend from the fan motor. Disconnect the two-pin connector from the wire harness...5265
        5. Remove the four bolts from the fan shroud and radiator shroud. See following NOTE...5265
        6. Remove the electric fan assembly...5265
        1. Position the electric fan shroud on the aluminum radiator shroud so that the electrical wiring and connector are just below the radiator fill spout...5265
        2. Secure the fan shroud to the vehicle with four lock-patch bolts, and tighten the hardware to 4 ft-lb (5 N·m)...5265
        3. Connect the two-pin connector on the blue wire and black wire from the fan motor to the blue wire and black wire that extend from the vehicle wire harness...5265
        4. Install the front body. See Front Body Installation, Section 4, Page 4-5...5265
        5. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5265
      Radiator Installation...5266
        1. Slide the radiator into place with the bottom in the aluminum frame channel...5266
        2. Connect the top radiator hose and clamp...5266
        3. Connect the bottom radiator hose and clamp...5266
        4. Connect the electric fan wiring connector...5266
        5. Connect the top radiator vent hose and clamp...5266
        6. Install two new top front frame guard tube bolts, washers, and new locknuts at both inside locations (Figure 15-11, Page 15-7). Tighten the hardware to 37 ft-lb (50 N·m)...5266
        7. Install the top radiator guard (Figure 15-10, Page 15-6). Tighten the bolts and nylon locknuts to 21 ft-lb (28 N·m)...5266
        8. Install the left- and right-side radiator top brackets...5266
        9. Install the radiator guard...5266
        10. Install the coolant reservoir. See Coolant Reservoir Installation on page 15-4...5266
        11. Install the front body. See Front Body Installation, Section 4, Page 4-5...5266
        12. Install the dashboard. See Dashboard Installation, Section 4, Page 4-4...5266
        13. Connect the battery cables, positive (+) cable first, and tighten the hardware to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5266
    Coolant Pipe Weldment (Steel)...5266
      Coolant Pipe Weldment Removal...5266
        1. Turn the key switch OFF, and place the Forward/Reverse handle in NEUTRAL. Remove the key. Chock the rear wheels...5266
        2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in See General Warning, Section 1, Page 1-1...5266
        3. Drain the radiator and reservoir. See following WARNING...5266
        4. Place a large pan under each hose end for each coolant pipe...5267
        5. Remove the bolt securing the front of the weldment to the vehicle frame...5267
        6. Remove the two bolts securing the rear of the weldment to the vehicle frame...5267
        7. Remove the bolt, washer, and clamp from each coolant pipe that is closest to the engine. Remove the pipes...5267
        8. Remove the clamps from the overflow coolant pipe, and remove the coolant pipe weldment...5267
      Coolant Pipe Weldment Installation...5267
        1. Position the coolant pipe weldment under the vehicle frame with the two adjacent ends closest to the front of the vehicle...5267
        2. Secure the front of the coolant pipe weldment to the vehicle frame with a bolt. Tighten the bolt to 21 ft- lb (28 N·m)...5267
        3. Secure the rear of the coolant pipe weldment to the vehicle frame with two bolts. Tighten the bolts to 21 ft-lb (28 N·m)...5267
        4. Install a clamp and bolt on each end of the coolant pipe hose connections. Tighten the hardware to 21 ft- lb (28 N·m)...5268
        5. Secure the engine coolant inlet hose (outlet from radiator) to the engine port...5268
        6. Secure the engine coolant outlet hose (return to radiator) to the engine port...5268
        7. Secure the radiator outlet (outlet from radiator) to the engine inlet coolant pipe...5268
        8. Secure the radiator return (inlet to radiator) to the engine outlet coolant pipe...5268
        9. Secure the overflow hose from the engine to the overflow pipe...5268
        10. Secure the overflow pipe hose to the radiator overflow and reservoir T-connection...5268
        11. Close the drain valves...5268
        12. Fill the coolant system at the reservoir with the appropriate coolant mixture. Allow the coolant to fill until it reaches the engine block coolant plug. See following NOTE...5268
        13. Apply Loctite 567 Liquid Thread Sealer to the threads of the block coolant plug...5268
        14. Install the engine block coolant plug and tighten to 12 ft-lb (16 N·m)...5268
        15. Fill the reservoir to the FULL mark with an appropriate coolant mixture, and check for leaks...5268
        16. Install the reservoir cap...5268
        17. Connect the battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16 N·m). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305)...5268
        18. Start and run the engine until it reaches operating temperature and check for leaks...5268
        19. Stop the engine, and allow the engine and coolant to cool...5268
        20. If necessary, add coolant to the reservoir until the coolant level reaches the full mark. See following WARNING...5268
  Section 16 - Transmission Models 420317 and 420682...5269
    General Information...5269
    Model Identification...5269
    Service Fixture...5269
    Transmission Removal...5270
    Transmission Disassembly...5270
      1. Position the transmission case on the service fixture with the drain plug over the right side edge allowing the transmission ...5270
      2. Position a service fixture, built like the one illustrated, with the through hole for the output shaft located to the right o...5271
      3. Remove hex-head case bolts (Figure 16-5, Page 16-3)...5271
      4. Separate the case halves. See following NOTE...5271
      5. Remove the neutral sensing switch, plunger and spring from the case (Figure 16-7, Page 16-4)...5271
      6. Remove the top half of the case (Figure 16-8, Page 16-4)...5271
      7. Remove the input shaft, gear and ground speed governor assembly (Figure 16-9, Page 16-4). See following NOTES...5272
      8. Remove the ground speed governor yoke bracket from the governor shaft (Figure 16-10, Page 16-5)...5272
      9. Remove the ground speed governor shaft and seal from the case by tapping gently with a small hammer from inside the case (Figure 16-11, Page 16-5). See following CAUTION...5272
      10. Remove the input shaft bearing from the case cavity (Figure 16-12, Page 16-5)...5273
      11. Press the input shaft helical gear bearing from the shaft if the bearing is worn or damaged and replace with a new bearing. See Input Shaft Disassembly on page 16-8. See following CAUTION...5273
      12. Lift the intermediate and output shafts and gear assemblies slightly so that the shaft bearings are free from the back side case...5273
      13. Hold the shafts and gear assemblies up and move them away from the engagement gear fork...5274
      14. Rotate the bell crank arm downward allowing the shifter fork and gear fork shaft pin to separate (Figure 16-13, Page 16-6)...5274
      15. Lift the gear fork from the transmission (Figure 16-14, Page 16-6). See following NOTE...5274
      16. Lift the intermediate and output shafts and gear assemblies from the case (Figure 16-15, Page 16-6)...5274
      17. Remove the back half of the case from the service fixture and cover the fixture with a heavy cloth...5274
      18. Position the intermediate and output shaft gear assembly onto the fixture covered with a heavy cloth to reduce the chance of damage to gear and sprocket teeth (Figure 16-16, Page 16-7)...5275
      19. Separate the intermediate and output gear assemblies by removing the chain drive from the large sprocket on the output shaft (Figure 16-17, Page 16-7) and (Figure 16-18, Page 16-7). See following NOTE...5275
      20. Remove the chain from the intermediate gear assembly small sprocket and the output gear assembly large sprocket (Figure 16-19, Page 16-7)...5275
      Input Shaft Disassembly...5276
        1. If the input shaft is to be re-used, press the old bearing from the helical gear end of the shaft, using a hydraulic press and bearing puller (CCI P/N 1012812), or three-jaw screw type bearing puller (Figure 16-20, Page 16-8). See following CAUTION...5276
      Input Shaft Assembly...5276
        1. Press a new bearing onto the input shaft, pushing the inner race until bearing seats against the helical gear hub (Figure 16-21, Page 16-8). See following CAUTION...5276
      Intermediate Shaft Disassembly...5276
        1. Position a bearing puller wedge attachment between the large helical gear and the intermediate shaft bearing and support the wedge attachment on press blocks to clear gear (Figure 16-22, Page 16-9)...5276
        2. Position a bar or socket slightly smaller in diameter than the intermediate shaft and press the bearing from the helical gear and intermediate shaft (Figure 16-23, Page 16-9). See following CAUTION...5276
        3. Remove the E-clip and flat washer from the intermediate shaft and the large helical gear and slide the gear from the splined shaft (Figure 16-24, Page 16-9)...5277
        4. Remove the E-clip and splined-cut washer from the intermediate shaft and small chain sprocket (Figure 16-25, Page 16-9). See following NOTE...5277
        5. Slide the sprocket and engagement gear from the shaft and two needle bearing assemblies (Figure 16-27, Page 16-10)...5277
        6. Slide the engagement dog gear from the intermediate gear assembly shaft (Figure 16-27, Page 16-10)...5278
        7. Remove the two needle bearing assemblies from the intermediate shaft. See following NOTE...5278
        8. Remove the engagement dog ring from the intermediate shaft (Figure 16-28, Page 16-10)...5278
        9. Position a bearing puller wedge attachment between the small helical gear and the intermediate shaft bearing, and support the wedge attachment on press blocks to clear the gear (Figure 16-30, Page 16-11). See following CAUTION...5278
        10. Position a bar or socket slightly smaller in diameter than the intermediate shaft and press the bearing from the helical gear and intermediate shaft (Figure 16-31, Page 16-11)...5279
        11. Remove the snap ring and flat washer next to the small helical gear (Figure 16-32, Page 16-11)...5279
        12. Slide the small helical and engagement gear assembly from the intermediate shaft and two needle bearing assemblies (Figure 16-33, Page 16-11)...5279
        13. Slide the two needle bearing assemblies off the intermediate shaft (Figure 16-34, Page 16-12)...5279
      Output Shaft Disassembly...5280
        1. Position a bearing puller wedge attachment between the large chain sprocket and the output shaft bearing and support the wedge attachment on press blocks to clear the gear (Figure 16-35, Page 16-12)...5280
        2. Position a bar or socket slightly smaller in diameter than the output shaft and press the bearing from the large chain sprocket and shaft...5280
        3. Remove the snap ring and flat washer from the large chain sprocket and output shaft (Figure 16-36, Page 16-12)...5280
        4. Remove the splined chain sprocket from the output shaft (Figure 16-37, Page 16-13)...5280
        5. Position a bearing puller wedge attachment between the large helical gear and the output shaft bearing and support the wedge attachment on press blocks to clear the gear (Figure 16-38, Page 16-13)...5280
        6. Press the output shaft through the bearing from the large chain sprocket...5281
        7. Remove the snap ring and flat washer from the shaft and large helical gear (Figure 16-39, Page 16-13)...5281
        8. Remove the large helical gear from the splined output shaft (Figure 16-40, Page 16-13)...5281
      Shifter Shaft Removal...5281
        1. Remove the locknut from the D-shaped bellcrank arm (Figure 16-41, Page 16-14)...5281
        2. Remove the shifter shaft snap ring (Figure 16-42, Page 16-14)...5281
        3. Slide the shifter shaft and fork to the inside of the case and remove the shaft (Figure 16-43, Page 16-14)...5282
        4. Use a small bearing puller and remove the shifter shaft seal from the case (Figure 16-44, Page 16-14)...5282
      Shifter Shaft Installation...5282
        1. Slide a new shifter shaft seal into the case and seat it by tapping on it using a small socket or tube slightly smaller than the outside diameter of the seal (Figure 16-44, Page 16-14)...5282
        2. Slide a new shifter shaft and fork from inside the case and through the seal...5282
        3. Install a new snap ring onto the shifter shaft next to the shaft seal (Figure 16-42, Page 16-14)...5282
        4. Install bell crank arm onto the D-shaped end of the shifter shaft...5282
        5. Install a nylon locknut onto the shifter shaft and tighten nut to 16 ft-lb (22 N·m) (Figure 16-41, Page 16-14)...5282
      Case Inspection...5282
        1. Inspect case for cracks and worn bearing cavities...5282
        2. If any bearing seat has become worn or damaged, both halves will have to be replaced...5282
      Shaft Seal Removal...5283
        1. Position a case half with shaft seals up...5283
        2. Use a socket or thick wall tube slightly smaller in diameter than the seal and gently drive the seal from outside to inside the case to remove each seal (Figure 16-45, Page 16-15). See following NOTE...5283
        3. Clean and remove any dirt and debris from the seal area...5283
      Shaft Seal Installation...5283
        1. Position a case half with shaft seals up...5283
        2. Position seals with lips to the inside of the case and gently drive the seals flush with the outside of the case using a seal...5283
      Output Shaft Assembly...5283
        1. Inspect the output shaft for worn splined areas and shaft journals and replace the shaft if necessary...5283
        2. Position the shaft so that the helical gear spline is to the right of the center portion of the shaft. Slide the large helical gear onto the output shaft and up against the center hub (Figure 16-47, Page 16-16)...5283
        3. Position the opposite end of the output shaft down through the shaft hole in the service fixture with the helical gear up...5283
        4. Install a flat washer onto the output shaft against the helical gear hub (Figure 16-48, Page 16-16)...5283
        5. Install a snap ring onto the output shaft and helical gear (Figure 16-49, Page 16-16)...5283
        6. Reposition the output shaft with the helical gear shaft end down through the shaft hole in the service fixture (Figure 16-50, Page 16-16)...5283
        7. Install the large chain sprocket onto the splined portion of the output shaft opposite the helical gear (Figure 16-51, Page 16-16)...5283
        8. Install the chain sprocket flat washer (Figure 16-52, Page 16-16)...5285
        9. Install the chain sprocket snap ring (Figure 16-53, Page 16-17)...5285
        10. Install the chain sprocket bearing snap ring (Figure 16-54, Page 16-17)...5285
        11. Position the output shaft with the large helical gear splined end down against a metal plate on a press platen. Hold the sha...5285
        12. Press the large chain sprocket bearing onto the output shaft (Figure 16-56, Page 16-17). See following CAUTION...5285
        13. Position the output shaft with the large chain sprocket splined end down against a metal plate on a press platen. Hold the s...5286
        14. Press the large helical gear bearing onto the output shaft (Figure 16-58, Page 16-18)...5286
        15. Place a protective cloth over the service fixture...5286
        16. Place the output shaft assembly on the fixture and make sure that the completed assembly is oriented correctly (Figure 16-59, Page 16-18)...5286
      Intermediate Shaft Assembly...5286
        1. Inspect the intermediate shaft for worn splined areas and shaft journals. Replace the shaft if necessary...5286
        2. Install bearings on the shaft for the small chain sprocket (Figure 16-61, Page 16-19). See following CAUTION...5286
        3. Position the intermediate shaft with the small chain sprocket end up and the small helical gear end down through the shaft hole in the service fixture (Figure 16-62, Page 16-19)...5287
        4. Install the small chain sprocket onto the shaft and needle bearing assemblies (Figure 16-63, Page 16-19)...5287
        5. Install the splined flat washer against the small chain sprocket (Figure 16-64, Page 16-19)...5287
        6. Install an E-clip onto the shaft and chain sprocket (Figure 16-65, Page 16-20)...5287
        7. Install large helical gear onto splined intermediate shaft next to the small chain sprocket (Figure 16-66, Page 16-20)...5287
        8. Install an E-clip onto the intermediate shaft to secure the large helical gear (Figure 16-67, Page 16-20)...5288
        9. Check the orientation of components for proper assembly (Figure 16-68, Page 16-20)...5288
        10. Position the intermediate shaft with the small helical gear end up and large helical gear down against the service fixture, and slide new roller bearing assemblies onto the gear race (Figure 16-69, Page 16-21)...5288
        11. Slide the splined engagement gear ring onto the splined intermediate shaft and small chain sprocket (Figure 16-70, Page 16-21)...5288
        12. Install the small helical gear onto intermediate shaft (Figure 16-71, Page 16-21)...5288
        13. Install the flat washer on helical gear (Figure 16-72, Page 16-21)...5288
        14. Install the snap ring onto shaft to secure the small helical gear (Figure 16-73, Page 16-21)...5288
        15. Position the large helical gear end of intermediate shaft against a steel plate on a press platen and press a new bearing on...5288
        16. Position the small helical gear end of intermediate shaft against a steel plate on a press platen (Figure 16-75, Page 16-22)...5290
        17. Press a new bearing onto large helical gear bearing race until the bearing inner race is flush with the end of the intermediate shaft...5290
      Intermediate and Output Shaft Assembly...5290
        1. Position the output shaft assembly on the service fixture with the large chain sprocket and bearing up and the helical gear end of the output shaft down through the shaft hole in the service fixture (Figure 16-76, Page 16-22)...5290
        2. Slip the chain over the large chain sprocket on the output shaft (Figure 16-77, Page 16-22)...5290
        3. Place the small helical gear end of the intermediate shaft down into the chain and lift up on the chain, placing it on the small sprocket and slide the intermediate shaft assembly next to the output shaft...5290
        4. Begin working the chain onto the large chain sprocket, lifting it up as it’s being attached to the sprocket. See following NOTE...5290
    Transmission Assembly...5291
      1. Position case (back half) onto the service fixture with the output shaft bearing port directly over the shaft hole in the fix...5291
      2. Install the ground speed governor shaft yoke bracket and tighten screws and lock washers to 15 in-lb (1.7 N·m) (Figure 16-80, Page 16-24)...5291
      3. Install the intermediate and output shaft and gear assembly into the back case, aligning the front output shaft down through the case and seal and through the service fixture (Figure 16-81, Page 16-24). See following CAUTION and NOTE...5291
      4. Gently lift the engagement ring up as far as it will go with gears meshed. Hold it in position and slide the engagement fork into the groove in the engagement ring gear, and allow the engagement fork shaft to fit down into the case cavity provided...5292
      5. Position the gear shifter bell crank arm down and slightly to the left, with the shifter arm fork up and slightly to the right (Figure 16-82, Page 16-24)...5292
      6. Hold the engagement gear fork into place, lifting it and holding the engagement gear up, and leaning it slightly to the left, away from the shifter arm fork (Figure 16-83, Page 16-24)...5292
      7. Hold the engagement gear fork shaft up with one hand and at the same time move the fork shaft and pin to the right. Turn the shifter bell crank arm so that the shifter arm fork interlaces with the engagement fork shaft pin (Figure 16-84, Page 16-25)...5292
      8. Allow the engagement fork and gear to drop down to its lowest position, causing the shifter arm bell crank to rotate upward and rest parallel with the case edge (Figure 16-85, Page 16-25)...5292
      9. Tap gently on the top of both shafts with a rubber mallet until the bearings are seated in the case cavities...5292
      10. Install the input shaft into the bearing in the case cavity (Figure 16-86, Page 16-25). See following CAUTION...5293
      11. Fit the front half of the case onto the back half, allowing the input shaft and rear output shaft to pass through the shaft seals. See following CAUTION...5293
      12. Install the neutral limit switch and detent barrel assembly and tighten to 21 ft-lb (28 N·m) (Figure 16-88, Page 16-26)...5294
      13. Apply a 1/8-inch (2 mm) wide coat of Three Bond sealant or Loctite 5699 Gasket Eliminator to the bottom half of the case. See following CAUTION...5294
      14. Gently press on the case and allow the bearings to begin seating in the case. Gently tap on the case at positions close to each shaft area to help seat the bearings and sealant (Figure 16-89, Page 16-26)...5294
      15. Install the case bolts and tighten the middle area of the case in a criss-cross pattern first, then the ends of the case also in a criss-cross pattern to 25 ft-lb (34 N·m) (Figure 16-90, Page 16-26)...5294
      16. Install the drain plug and washer and tighten to 8 ft-lb (11 N·m)...5294
      17. Remove the fill and level plugs and fill the case through the top fill plug with 20 ounces (600 mL) of Bobcat Trans/Differential Fluid P/N 6687120. See following NOTE...5295
      18. Install the level plug using a small amount of Loctite 545 thread sealant on the threads and tighten to 20 ft-lb (27 N·m)...5295
      19. Install the fill plug on the top of the case using a small amount of Loctite 545 thread sealant on the threads and tighten to 20 ft-lb (27 N·m)...5295
    Transmission Installation...5295
  Section 17 - Front Differential Models 6203-01-139-S and 6203-01-189-S...5297
    General Information...5297
    Axle Half Shaft Removal...5297
    Front Differential Removal...5298
      Tools Required For This Section...5299
    Front Differential Coil And Output Cover...5299
      Coil and Output Cover Removal...5299
        1. Position the front differential case over a pan or container suitable for draining oil and remove the drain plug from the bottom of the case. Drain the oil from the case and dispose of the oil properly (Figure 17-4, Page 17-3)...5299
        2. Position differential case on a clean solid surface with the coil and output cover up...5299
        3. Remove bolts from the output cover (Figure 17-5, Page 17-3)...5299
        4. Gently tap on the output cover flange with a plastic or rubber mallet to loosen the cover (Figure 17-6, Page 17-4)...5300
        5. Remove output cover, coil, and male splined hub (Figure 17-7, Page 17-4)...5300
        1. Position the output cover on a clean solid surface with the splined hub up (Figure 17-8, Page 17-4)...5300
        2. Remove the thrust plate from the cover...5300
        3. Remove the retaining ring from around the inside edge of the cover flange (Figure 17-9, Page 17-4)...5300
        4. Remove armature plate shim (Figure 17-10, Page 17-5)...5300
        5. Remove armature plate (Figure 17-11, Page 17-5)...5300
        6. Hold the output cover vertical by holding the splined hub (Figure 17-12, Page 17-5)...5301
        7. Use a small diameter wooden or rubber mallet, or wooden or fiberglass tool handle, and gently tap the hub and bearing from the cover (Figure 17-13, Page 17-5)...5301
        1. Position a new coil and output cover on a clean solid surface and install the male hub and bearing into the bearing cavity by gently tapping the dowel pin end of the hub (Figure 17-14, Page 17-6)...5301
        2. Position armature plate around hub and bearing (Figure 17-11, Page 17-5). See following NOTE...5301
        3. Install the armature plate shim (Figure 17-10, Page 17-5)...5301
        4. Install the armature retaining ring (Figure 17-9, Page 17-4)...5301
        5. Install the thrust plate on the output cover (Figure 17-15, Page 17-6). See following NOTE...5302
        6. Install the needle sized roller thrust bearing onto the male pin of the hub (Figure 17-16, Page 17-7). See following NOTE...5302
      Coil and Output Cover Installation...5302
        1. Position the ring gear and housing assembly on a clean solid surface with the ring gear hub up...5302
        2. Use the pinion gear shaft and turn the gear so that one of the tab slots in the ring gear hub and bearing cage assembly is in line with the pinion gear shaft (Figure 17-17, Page 17-7)...5302
        3. Position the armature plate on the hub cover so that one of the tabs will align with the pinion shaft and corresponding slot in the ring gear hub bearing and cage assembly. See following NOTE...5302
        4. Gently place the coil and output cover plate, with the armature tabs seating down into the tab slots in the ring gear bearing and cage assembly, down onto the case and tighten the case bolts in a criss-cross pattern to 17 ft-lb (23 N·m)...5302
        5. Adjust the backlash set screw. See Backlash Adjustment on page 17-7...5302
        1. Locate the backlash adjustment set screw on the right front, coil side, of the differential (Figure 17-19, Page 17-7)...5303
        2. Use a 3/32-inch Allen wrench and turn the screw clockwise until it stops (do not apply torque)...5303
        3. Turn the Allen wrench and set screw counterclockwise slowly while turning the pinion gear shaft clockwise. Continue this process until the pinion gear shaft can rotate four complete turns freely and without any tight spots...5303
    Front Differential...5304
      Front Differential Disassembly...5304
        1. Position the front differential case over a pan or container suitable for draining oil and remove the drain plug from the bottom of the case. Drain the oil from the case and dispose of the oil properly (Figure 17-4, Page 17-3)...5304
        2. Position differential case on a clean solid surface with the coil and output cover up...5304
        3. Remove bolts from the output cover (Figure 17-5, Page 17-3)...5304
        4. Gently tap on the output cover flange with a plastic or rubber mallet to loosen the cover (Figure 17-6, Page 17-4)...5304
        5. Remove output cover, coil, and male splined hub (Figure 17-7, Page 17-4)...5304
        6. Remove ring gear with roll cage and roller bearing assembly (Figure 17-20, Page 17-8)...5304
        7. Remove the needle sized roller thrust bearing (Figure 17-21, Page 17-8)...5304
        8. Use a small diameter wooden or rubber mallet, or wooden or fiberglass tool handle, and gently tap the hub and bearing from the gearcase (Figure 17-22, Page 17-8)...5305
        9. Remove gear case hub seal by gently driving the seal from the outside of the case (Figure 17-23, Page 17-8). See following NOTE...5305
        10. Remove input cover plate bolts (Figure 17-24, Page 17-9)...5305
        11. Gently slide the cover plate and seal off of the splined shaft of the pinion gear (Figure 17-25, Page 17-9)...5305
        12. Inspect the O-ring seal for damaged areas (Figure 17-26, Page 17-9)...5305
        13. Gently slide the pinion gear shaft and bearing from the gearcase (Figure 17-27, Page 17-9)...5305
        14. Hold the pinion gear and shaft and gently turn the outside bearing race. The bearing should roll easily with no rough or flat spots and no excess play. Replace with a new bearing if necessary (Figure 17-31, Page 17-11). See following NOTE...5306
        15. Inspect the pinion shaft seal in the cover plate for damaged or worn areas that could be providing for oil leaks (Figure 17-28, Page 17-10). See following NOTE...5306
        1. Place the input cover plate and seal between jaws of a heavy duty vise (Figure 17-28, Page 17-10). See following NOTE...5306
        2. Push the seal out of the cover plate using a seal installation tool or large socket slightly smaller in diameter than the seal. Press the seal out from the outside of the cover plate. See following NOTE...5306
        1. Position a new three-lip seal on the cover plate (Figure 17-29, Page 17-10)...5306
        2. Press a new seal into the input cover plate, using a seal installation tool, until the surface of the seal is flush with the input cover plate (Figure 17-30, Page 17-11)...5306
        3. Inspect the pinion gear and splined portion of the shaft. If the gear is worn, damaged, or the splined portion is worn or damaged, replace the pinion and shaft with a new one. See following NOTE...5307
        4. Inspect the pinion gear shaft bushing inside the gearcase (Figure 17-32, Page 17-11). See following NOTE...5307
        1. Position the ring gear and clutch cage with roller bearings on a clean solid surface (Figure 17-33, Page 17-12)...5307
        2. Gently raise the clutch cage and the first level of roller bearings to a height where the roller bearings begin to release from the cage (Figure 17-34, Page 17-12). See following NOTE...5307
        3. Remove the first level of roller bearings from the clutch cage (Figure 17-35, Page 17-12)...5308
        4. Gently raise the clutch cage and bring the second level of roller bearings to a height where the roller bearings begin to release from the cage (Figure 17-36, Page 17-12)...5308
        5. Lift the clutch cage from the inside of the ring gear hub. See following NOTE...5308
        6. Remove the fourteen spring clips from the clutch cage. See following NOTE...5308
        7. Inspect the clutch cage for cracked and broken segments...5308
        1. Position the ring gear with the gear down against a clean solid surface...5309
        2. Position a clutch cage and roller bearings close to the ring gear and hub (Figure 17-37, Page 17-13)...5309
        3. Slide a clutch cage into the ring gear hub deep enough to allow insertion of roller bearings into the spring clips and hold them into place (Figure 17-38, Page 17-13)...5309
        4. Assemble the first level of roller bearings into the clutch cage and ring gear hub and slide the clutch cage down to the second (or top) bearing level (Figure 17-39, Page 17-14)...5309
        5. Assemble the second (or top) level of roller bearings into the clutch cage (Figure 17-40, Page 17-14)...5309
        6. Complete the assembly of clutch and ring gear by pushing the clutch cage and roller bearings down so the clutch is flush with the ring gear hub (Figure 17-41, Page 17-14)...5309
      Front Differential Assembly...5310
        1. Position the gearcase on a clean solid surface with the output seal cavity up. See following NOTE...5310
        2. Install a seal into the gearcase cavity using a seal installation tool or large socket, slightly smaller than the seal body diameter (Figure 17-42, Page 17-15)...5311
        3. Gently tap the seal body down until the face of the seal is 1/8-inch (3 mm) below the cavity surface...5311
        4. Position the gearcase on a clean solid surface with the output seal down (Figure 17-43, Page 17-15). See following NOTE...5311
        5. Install a female output hub and bearing into the gearcase bearing cavity and gently tap the hub until the bearing seats in the gearcase (Figure 17-44, Page 17-15)...5311
        6. Install the ring gear hub with clutch and roller bearing assembly into the gearcase and down around the female output hub (Figure 17-45, Page 17-15)...5311
        7. Push the clutch cage and bearing assembly down to be flush with the top surface of the ring gear hub (Figure 17-46, Page 17-16)...5311
        8. Use the pinion gear shaft and turn the gear so that one of the tab slots in the ring gear hub and bearing cage assembly is in line with the pinion gear shaft (Figure 17-17, Page 17-7). See following NOTE...5312
        9. Prepare a coil and output cover assembly for installation on the gearcase. See Coil and Output Cover Assembly on page 17-5...5312
        10. Position the armature plate on the hub cover so that one of the tabs will align with the pinion shaft and corresponding slot in the ring gear hub bearing and cage assembly. See following NOTE...5312
        11. Gently place the cover plate down onto the case, with the seven armature tabs seating down into the tab slots in the ring gear bearing and cage assembly (Figure 17-47, Page 17-16)...5312
        12. Install input pinion gear, shaft and bearing. Gently tap on the input shaft with a rubber or wooden mallet to seat the bearing (Figure 17-48, Page 17-17). See following NOTE...5312
        13. Seat the pinion gear bearing into the gearcase cavity (Figure 17-49, Page 17-17). See following NOTE...5312
        14. Install input cover plate and three-lip seal on input shaft (Figure 17-50, Page 17-17)...5313
        15. Install the input cover plate bolts and tighten, in a criss-cross pattern, to 17 ft-lb (23 N·m)...5313
        16. Adjust the backlash set screw. See Backlash Adjustment on page 17-7...5313
        17. Remove the oil fill plug and add 5 ounces (150 ml) of Bobcat Trans/Differential Fluid P/N 6687120...5313
        18. Install the oil fill plug and tighten the plug to 10 ft-lb (13 N·m)...5313
    Front Differential Installation...5314
    Axle Half Shaft Installation...5314
  Section 18 - Rear Differential Models 420366 and 420851...5315
    General Information...5315
    Axle Shafts and Differential Removal...5316
    Rear Differential Disassembly...5316
      1. Remove the bottom drain plug (4) and plug washer (5) and drain the lubrication oil from the differential housing (Figure 18-4, Page 18-3)...5316
      2. Clean the outside surfaces of the differential housing...5316
      3. Gently scrape any sealant or gasket material from the housing surfaces where the flanged portion of the axles bolted to the differential...5316
      4. Move the differential assembly to a clean bench area...5316
      5. Remove the nine hex flanged-head bolts (2) from the housing (Figure 18-4, Page 18-3)...5317
      6. Use two flat wrenches or flat metal bars and gently pry the top portion of the housing away from the bottom portion (Figure 18-5, Page 18-4). See following CAUTION...5317
      7. Position the bottom half of the housing with the differential pinion and ring gear assemblies so that the ring gear is to the right (driver side) and back (Figure 18-6, Page 18-4). See following CAUTION...5318
      Pinion Gear Removal...5318
        1. Remove the pinion shaft oil seal (7) (Figure 18-4, Page 18-3)...5318
        2. Remove the pinion gear and shaft (6) with bearings...5318
        1. Place the pinion gear face on a solid flat surface (Figure 18-7, Page 18-5)...5318
        2. Remove the snap ring and thin washer adjacent to the splined end of the pinion shaft (Figure 18-8, Page 18-5)...5318
        3. Use a bearing puller wedge and press the splined end ball bearing from the pinion shaft (Figure 18-9, Page 18-5)...5318
        4. Remove the pinion gear roller bearing and large thin washer (Figure 18-10, Page 18-5)...5318
        1. Place the pinion gear face onto a solid flat surface (Figure 18-7, Page 18-5)...5318
        2. Slide the thin washer (12) down onto the pinion gear race (Figure 18-4, Page 18-3)...5318
        3. Slide a new roller bearing down on the pinion shaft and next to the thin flat washer and pinion gear (Figure 18-10, Page 18-5)...5318
        4. Press a new ball bearing onto the pinion shaft...5318
        5. Slide the thin washer (9) down onto ball bearing race (Figure 18-4, Page 18-3)...5318
        6. Install the snap ring onto the pinion shaft adjacent to the thin washer and ball bearing race (Figure 18-8, Page 18-5)...5318
      Ring Gear Removal...5320
        1. Remove the two axle shaft oil seals (14) from the differential housing (Figure 18-4, Page 18-3)...5320
        2. Remove the ring gear, bearings and clutch carrier assembly...5320
        3. Place the assembly with the ring gear and bearing up on a solid flat surface (Figure 18-11, Page 18-6)...5320
        4. Remove the ring gear bolts from the ring gear and clutch carrier assembly. See following CAUTION...5320
        1. Use a bearing puller wedge and press the bearing from the ring gear hub (Figure 18-12, Page 18-6)...5320
        2. Properly support the ring gear surface and press a new bearing onto the ring gear hub (Figure 18-13, Page 18-6)...5320
      Clutch Carrier Assembly...5321
        1. Place the clutch carrier bearing down against a clean flat surface with ring gear and bearing up (Figure 18-11, Page 18-6)...5321
        2. Remove the ring gear bolts...5321
        3. Remove the ring gear from the clutch carrier assembly...5321
        1. Position the new clutch carrier assembly with the carrier bearing down and remove the protective plastic plate from the new clutch carrier assembly (Figure 18-15, Page 18-8). See following CAUTION...5321
        2. Carefully position the ring gear and bearing onto the clutch carrier assembly (Figure 18-16, Page 18-8)...5321
        3. Align the bolt holes and install ring gear bolts and finger tighten (Figure 18-17, Page 18-8)...5321
        4. Tighten ring gear bolts, in a crisscross pattern, to 33 ft-lb (45 N·m)...5321
        1. Place the ring gear down against a clean flat surface with the clutch carrier hub bearing up (Figure 18-14, Page 18-6)...5321
        2. Carefully place a bearing puller wedge between the clutch carrier and the inside bearing surface...5321
        3. Position the clutch carrier assembly and ring gear between press platton bars and press the bearing from the clutch carrier...5321
      Ring Gear Installation...5322
        1. Position the differential housing so that the fill plug is to the back and left (Figure 18-18, Page 18-8)...5322
        2. Position the ring gear, bearings and clutch carrier assembly into the differential housing with the ring gear to the right, or driver side of the housing cavity (Figure 18-20, Page 18-9)...5322
        3. Seat the ring gear bearing into the driver side housing groove and the clutch carrier bearing into the passenger side housing groove...5322
        4. Install two new oil seals (14), one on each side of the ring gear and carrier assembly, and seat them in housing (Figure 18-4, Page 18-3). Also see Figure 18-20, Page 18-9...5322
      Pinion Gear Installation...5323
        1. Position the pinion gear assembly into the differential housing, meshing the pinion gear with the ring gear (Figure 18-21, Page 18-9)...5323
        2. Seat bearings and align large thin pinion bearing washer in housing groove (Figure 18-22, Page 18-9)...5323
      Rear Differential Assembly...5323
        1. Provide a continuous 1/8 inch (3 mm) wide bead of ThreeBond® 1215 gasket compound to the bolt flange on the bottom half of the differential housing (Figure 18-24, Page 18-10). See following NOTE...5323
        2. Place the top half of the differential housing on the bottom half, making sure that the three oil seals and bearings align in their respective grooves...5323
        3. Install a new oil seal on the splined end of the pinion shaft and seat in housing (Figure 18-23, Page 18-10)...5323
        4. Install the four hex flanged-head bolts in the larger ring gear cavity first, and finger tighten (Figure 18-25, Page 18-10)...5324
        5. Install the four hex flanged-head bolts in the pinion cavity last, and finger tighten...5324
        6. Tighten the ring gear cavity bolts first, using a criss cross pattern, with bolt number nine last, to 25 ft-lb (34 N·m) (Figure 18-26, Page 18-10)...5324
        7. Tighten the pinion gear cavity bolts last, using a criss cross pattern to 25 ft-lb (34 N·m)...5324
        8. Clean and install the drain plug and washer before filling the rear differential with new lubricant. Tighten the drain plug to 8 ft-lb (10.8 N·m)...5324
        9. Add 20 oz. (600mL) Bobcat Trans/Differential Fluid P/N 6687120. Use a funnel when filling the differential through the lubricant level indicator hole (1)...5324
        10. Apply Loctite 567 to the threads of the level indicator plug, and tighten to 21 ft-lb (28 N·m)...5324
    Axle Shafts and Differential Installation...5325
  Section 19 - Kubota D722 Diesel Engine Manual...5327
  Section 20 - Honda GX 620 Gasoline Engine Manual...5381
6904892 (5-09) - 2300 Operation & Maintenance Manual...5491
  Safety Decal and Feature Identification...5496
    2300 Diesel Vehicle...5497
    2300 Diesel Vehicle...5498
  Practice Safety...5499
  Proposition 65 - State of California...5499
  Safety Details...5500
  General Warnings...5501
  General Information...5503
  Model Identification...5503
  Controls and Indicators...5504
    Joystick ON/OFF Switch...5505
    Key Switch...5506
    Forward/Reverse Control...5506
    Accelerator Pedal...5506
    Brake Pedal...5506
    Park Brake...5507
    Steering Adjustment Lock...5507
    12-VOLT Accessory OUTLET...5507
    Safety belt Warning light...5507
    Low Oil Warning light...5508
    Fuel Gauge/Hour Meter...5508
    Headlight control...5508
    High-Temperature Warning light...5508
    hYDRAULIC cONTROLS...5509
  Roll-Over Protective Structure (ROPS) and Safety Belts...5511
    Cargo Cage Headrests...5513
  Seat Latch and Adjustment...5514
  Pre-Operation and Daily Safety Checklist...5515
  Performance Inspection...5516
  Driving Instructions...5516
    Starting The Vehicle...5517
    All-Wheel Drive (AWD) Operation...5518
    Stopping The Vehicle...5519
    Parking And Leaving The Vehicle...5519
  Bed Latch and Prop Rod...5519
  Attachments and Buckets...5520
    Pallet Fork...5521
    Installing And Removing an Attachment...5521
    OPERATING with Attachments...5524
    REMOVing AND INSTALLIng the ATTACHMENT ARM MECHANISM...5527
  Loading and Unloading the Cargo Bed...5531
  Vehicle Load Capacities...5531
  Towing with the Vehicle...5533
  Transporting on a Trailer...5533
  Storage...5534
    Preparing the Vehicle for Extended Storage...5534
    Returning the Stored Vehicle to Service...5535
  Maintenance...5535
  Periodic Service Schedule...5536
  Periodic Lubrication Schedule...5539
  Brake Fluid Reservoir...5541
    Brake Fluid...5541
  Engine Oil...5541
    Engine Oil Level Check...5541
    Engine Oil and Filter Change...5542
    Oil Viscosity...5545
  Gearcase Lubrication...5545
    Lubrication Level Check for Front Differential, Transmission, and Rear Differential...5545
    Lubrication Change for Front Differential, Transmission, and Rear Differential...5545
  Hydraulic System...5547
  Engine Coolant - Diesel Vehicles...5548
    Engine Coolant Level Check...5548
  Air Intake System...5548
    Air Filter Replacement...5548
  Fueling Instructions...5549
    Draining Water from Fuel Filter...5551
  Battery...5552
  Using a Booster Battery (Jump Starting)...5553
  Cleaning the Vehicle...5555
  Accessories...5555
    Electric Winch Accessory...5555
    Mud Tire OPtion...5556
  Subsequent Owner Registration...5556
  Vehicle Specifications...5557
    Bobcat Utility Vehicles...5559
6904893 (12-09) - 2200, 2200S, 2300 Service Manual...5563
  Section 1 - Safety...5583
    General Warning...5583
  Section 2a - Vehicle Specifications: Honda Gas & Kubota Diesel Powered...5587
    2200 and 2200S Specifications...5587
    2300 Specifications...5589
  Section 2b - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered...5591
    2200 and 2200S Specifications...5591
    2200 Homologated Specifications...5593
    2300 Specifications...5595
  Section 3 - General Information...5597
    General Information...5597
    Model Identification...5597
    Engine Serial Number Locations...5598
      Gasoline EngineS...5598
      Diesel Engine...5598
    Storage...5598
      Preparing the Vehicle for Extended Storage...5599
      Returning the Stored Vehicle to Service...5600
    Using A Booster Battery (Jump Starting)...5601
  Section 4 - Body and Trim...5603
    Cleaning the Vehicle...5603
      Seat Cleaning...5603
    Front Body Repair...5604
      Light Scratches...5604
      Abrasions and Haze...5604
      Large Scratches and Abrasions...5604
    Front Body Components...5605
      Instrument Panel Removal...5605
      Instrument Panel Installation...5605
      Front Fascia Removal...5606
      Front Fascia Installation...5606
      Hood Removal...5606
      Hood Installation...5606
      Center Cowl Panel Removal...5606
      Center Cowl Panel Installation...5607
      Side Cowl Panel (Fender) Removal...5607
      Side Cowl Panel (Fender) Installation...5607
      Front Fender Flare Removal...5608
      Front Fender Flare Installation...5608
    Roll-Over Protective Structure (ROPS)...5608
      ROPS Removal...5609
      ROPS Installation...5610
    Seat...5611
      Seat Removal...5611
      Seat Adjustment...5611
      Seat Installation...5611
      Seat Support Removal...5612
      Seat Support Installation...5612
    Safety Belts...5612
      Safety Belt Removal...5612
      Safety Belt Installation...5613
    Cargo Bed - Electric Lift...5613
      Testing the Bed Lift Motor...5613
      Bed Lift Motor Removal...5613
      Bed Lift Motor Installation...5614
      Cargo Bed Removal...5614
      Cargo Bed Installation...5614
    Cargo Bed - Manual Lift...5615
      Cargo Bed Removal...5615
      Cargo Bed Installation...5615
    Rear Fender...5617
      Rear Fender Removal...5617
      Rear Fender Installation...5617
    Floor Mat...5617
      Floor Mat Removal...5617
      Floor Mat Installation...5617
  Section 5 - Accelerator and Brake Pedal Assemblies...5619
    Accelerator Pedal...5619
      Accelerator Pedal Removal...5619
      Accelerator Pedal Installation...5620
      Accelerator Pedal and RPM Adjustment...5620
    Brake Pedal...5621
      Brake Pedal Removal...5621
      Brake Pedal Installation...5621
      Brake Pedal Adjustment...5622
    Park Brake Pedal...5622
      Park Brake Pedal Assembly Removal...5622
      Park Brake Pedal Assembly Installation...5622
  Section 6 - Hydraulic and Park Brake Systems...5625
    Brake System Inspection...5625
    Brake System Troubleshooting...5627
    Brake Pads and Caliper...5629
      Front Brake Pad and Caliper Removal...5629
      Front Brake Pad and Caliper Installation...5631
      Rear Brake Pad and Caliper Removal...5632
      Rear Brake Pad and Caliper Installation...5633
    Brake Disc and Hub...5634
      Front Wheel Disc and Hub Removal...5634
      Front Wheel Disc and Hub Installation...5638
      Rear Wheel Disc Removal...5639
      Rear Wheel Disc Installation...5640
    Hydraulic Line Replacement...5641
      Front Brake Line Removal...5641
      Front Brake Line Installation...5641
      Rear Brake Line Removal...5642
      Rear Brake Line Installation...5643
    Master Cylinder and Reservoir...5644
      Filling the Hydraulic System...5644
      Reservoir Removal...5644
      Reservoir Installation...5644
      Master Cylinder Removal...5645
      Master Cylinder Installation...5645
    Bleeding the Hydraulic Brake System...5646
      Bleeding Brakes on a DOT 5 Fluid Filled System...5646
      Purging the Hydraulic System...5648
    Park Brake System...5649
      Park Brake Adjustment...5649
      Park Brake Cable Adjustment...5649
      Park Brake Wheel Cables...5650
      Front Park Brake Cable Removal...5651
      Front Park Brake Cable Installation...5652
      Park Brake Equalizer Removal...5652
      Park Brake Equalizer Installation...5652
  Section 7 - Steering and Front Suspension...5655
    Steering Wheel...5655
      Steering Wheel Removal...5655
      Steering Wheel Installation...5656
    Steering Column...5656
      Steering Column Removal...5656
      Steering Column Installation...5657
    Rack and Pinion...5657
      Rack and Pinion Removal...5657
      Rack and Pinion Installation...5658
      Rack and Pinion Disassembly...5659
      Rack and Pinion Assembly...5663
    Front Suspension...5665
      Wheel Alignment...5665
    Front Suspension Components...5667
      Steering Upright Removal...5667
      Upper A-Arm Removal...5668
      Upper A-Arm Installation...5670
      Lower A-Arm Removal...5670
      Lower A-Arm Installation...5671
      Front Coil-Over Shock Absorber Removal...5672
      Front Coil-Over Shock Absorber Installation...5673
      Steering Upright Installation...5673
  Section 8 - Wheels and Tires...5675
    General Information...5675
    Wheels...5676
      Wheel Removal...5676
      Wheel Installation...5676
    Tires...5676
      Tire Removal...5676
      Tire Installation...5677
  Section 9 - Rear Suspension...5679
    Rear Coil-Over Shock Absorber...5679
    Swing Arms...5680
      Swing Arm Removal...5680
      Swing Arm Installation...5681
  Section 10a - Periodic Maintenance: Honda Gasoline & Kubota Diesel Vehicles...5683
    Periodic Service Schedule...5683
    Periodic Lubrication Schedule - 2200...5686
    Periodic Lubrication Schedule - 2300...5688
    Lubricating The Attachment Arm And Interface...5689
    Brake Fluid Reservoir...5690
      Brake Fluid...5690
    Engine Oil...5690
      Oil Pressure - Gasoline Engine...5691
      Engine Oil Level Check...5691
      Engine Oil and Filter Change...5692
      Oil Viscosity...5695
    Gearcase Lubrication...5696
      Lubrication Level Check for Front Differential, Transmission, and Rear Differential...5696
      Lubrication Change for Front Differential, Transmission, and Rear Differential...5696
    Hydraulic System - 2300 Vehicle...5698
    Engine Coolant - Diesel Vehicles...5699
      Engine Coolant Level Check...5699
    Fueling Instructions...5699
      Draining Water from Fuel Filter...5700
    Battery...5701
  Section 10b - Periodic Maintenance: Kawasaki Gasoline & Kubota Diesel Powered Vehicles...5703
    Periodic Service Schedule...5703
    Periodic Lubrication Schedule - 2200...5706
    Lubricating The Attachment Arm And Interface...5708
    Brake Fluid Reservoir...5709
      Brake Fluid...5709
    Engine Oil...5709
      Oil Pressure - Gasoline Engine...5710
      Engine Oil Level Check...5710
      Engine Oil and Filter Change...5710
      Oil Viscosity...5713
    Spark Plugs...5714
      Spark Plug Cleaning And Inspection...5714
      Spark Plug Gap Inspection...5714
    Gearcase Lubrication...5715
      Lubrication Level Check for Front Differential, Transmission, and Rear Differential...5715
      Lubrication Change for Front Differential, Transmission, and Rear Differential...5715
    Hydraulic System - 2300 Vehicle...5717
    Engine Coolant - Diesel Vehicles...5718
      Engine Coolant Level Check...5718
    Fueling Instructions...5718
      Draining Water from Fuel Filter...5719
    Battery...5720
  Section 11a - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles...5721
    Troubleshooting Guide...5721
    Wiring Diagram...5726
    Test Procedures...5728
      Index of Test Procedures...5728
  Section 11b - Troubleshooting and Electrical System: Honda Powered Gasoline Vehicles...5763
    Troubleshooting Guide...5763
    Wiring Diagram...5768
    Test Procedures...5770
      Index of Test Procedures...5770
  Section 11c - Troubleshooting and Electrical System: Diesel Vehicles...5803
    Troubleshooting Guide...5803
    Wiring Diagram...5808
    Test Procedures...5814
      Index of Test Procedures...5814
  Section 12a - Electrical Components: Kawasaki Powered Gasoline Vehicles...5857
    Starter and Starter Solenoid...5857
    Relays...5857
    Neutral Switch...5858
    Carburetor Solenoid...5858
    Carburetor Heater...5859
    Voltage Regulator...5860
    Warning Lights...5861
    Fuel Gauge/Hour Meter...5862
    Key Switch...5863
    12-Volt Accessory Receptacle...5864
    Bed Lift Switch...5865
    Bed Lift Circuit Breaker...5865
    Light Switch...5866
    Fuse...5866
    Reverse Warning Buzzer (If Equipped)...5867
    Reverse Warning Buzzer Limit Switch (If Equipped)...5868
    Front Differential Switch...5869
    Fuel Level Sending Unit...5870
    Ignition Coil and Charge Coil...5871
    Oil Pressure Sensor...5871
    Headlights...5871
    Wire Harness Diodes...5872
    Battery...5873
      General Information...5873
  Section 12b - Electrical Components: Honda Powered Gasoline Vehicles...5877
    Starter and Starter Solenoid...5877
    Relays...5877
    Neutral Switch...5878
    Carburetor Solenoid...5878
    Voltage Regulator...5879
    Warning Lights...5880
    Fuel Gauge/Hour Meter...5881
    Key Switch...5882
    12-Volt Accessory Receptacle...5883
    Bed Lift Switch...5884
    Bed Lift Circuit Breaker...5884
    Light Switch...5885
    Fuse...5885
    Reverse Warning Buzzer...5886
    Reverse Warning Buzzer Limit Switch...5887
    Fuel Level Sending Unit...5888
    Ignition Coil and Charge Coil...5888
    Charge Coil...5889
    Oil Pressure Sensor...5889
    Headlights...5889
    Wire Harness Diodes...5890
    Battery...5891
      General Information...5891
  Section 12c - Electrical Components: Diesel Vehicles...5895
    Starter and Starter Solenoid...5895
    Relays...5895
    Neutral Switch...5896
    Fuel Solenoid...5896
    60-Amp Fusible Link...5897
    Warning Lights...5898
    Fuel Gauge/Hour Meter...5900
    Key Switch...5901
    12-Volt Accessory Receptacle...5901
    Bed Lift Switch...5902
    Bed Lift Circuit Breaker...5902
    Light Switch...5903
    Fuse...5903
    Reverse Warning Buzzer (If Equipped)...5904
    Reverse Warning Buzzer Limit Switch (If Equipped)...5905
    Electric Fuel Pump...5906
    Fuel Level Sending Unit...5906
    Alternator...5907
    Oil Pressure Sensor...5909
    Headlights...5909
    Thermostat Switch...5910
    Fan...5911
    Wire Harness Diodes...5912
    Battery...5913
      General Information...5913
  Section 13a - Kawasaki Gasoline Engine, Muffler, Fuel System, and Clutches...5917
    Gasoline Engine...5917
      Engine Removal...5917
      Engine Installation...5919
      Oil Filter Hoses...5921
    Exhaust System...5922
      Muffler Removal...5922
      Intermediate Pipe Removal...5923
      Intermediate Pipe Installation...5923
      Muffler Installation...5924
    Fuel System...5925
      Fuel Lines...5926
      Fuel Filter...5926
      Fuel Pump...5926
      Carburetor...5926
      Fuel Level Sending Unit...5929
      Fuel Tank...5932
      Fuel Shut-Off Valve...5935
    Engine Control Linkages...5936
      Accelerator Cable...5936
      Choke Cable...5938
      Engine Governor Arm...5940
      Engine RPM Adjustment...5940
    Air Intake System...5941
      Air Filter Replacement...5941
      Air Canister Removal...5942
      Air Canister Installation...5942
      Air Filter Intake Hose Removal...5943
      Air Filter Intake Hose Installation...5943
      Air Filter Outlet Hose Removal...5944
      Air Filter Outlet Hose Installation...5944
    Clutches...5945
      Clutch Troubleshooting...5945
      Drive Belt...5946
      Drive Clutch...5947
      Driven Clutch...5952
      Clutch Cover...5955
  Section 13b - Honda Gasoline Engine, Muffler, Fuel System, and Clutches...5957
    Gasoline Engine...5957
      Engine Removal...5957
      Engine Installation...5959
    Exhaust System...5961
      Muffler Removal...5961
      Intermediate Pipe Removal...5961
      Intermediate Pipe Installation...5962
      Muffler Installation...5962
    Fuel System...5963
      Fuel Lines...5964
      Fuel Filter...5964
      Fuel Pump...5964
      Carburetor...5964
      Fuel Level Sending Unit...5965
      Fuel Tank...5968
      Fuel Shut-Off Valve...5971
      Oil Filter Hoses...5972
    Engine Control Linkages...5972
      Accelerator Cable...5972
      Governor Guard...5975
      Governor Cable...5975
      Accelerator Cable Retention Clip Adjustment...5976
      Ground Speed (Transmission) Governor Arm Adjustment...5977
      Engine Governor Arm...5979
      Engine RPM Adjustment...5979
    Choke and Air Intake System...5980
      Air Filter Replacement...5980
      Choke Cable Removal...5981
      Choke Cable Installation...5982
      Air Canister Removal...5982
      Air Canister Installation...5983
      Air Filter Intake Hose Removal...5983
      Air Filter Intake Hose Installation...5984
      Air Filter Outlet Hose Removal...5984
      Air Filter Outlet Hose Installation...5985
    Clutches...5985
      Clutch Troubleshooting...5986
      Drive Belt...5986
      Drive Clutch...5987
      Driven Clutch...5992
      Clutch Cover...5995
  Section 13c - Diesel Engine, Muffler, Fuel System, and Clutches...5997
    Diesel Engine...5997
      Engine Removal...5997
      Engine Installation...5999
    Exhaust System...6001
      Muffler Removal...6001
      Intermediate Pipe Removal...6001
      Manifold Pipe Removal...6002
      Manifold Pipe Installation...6002
      Intermediate Pipe Installation...6002
      Muffler Installation...6003
    Fuel System...6004
      Fuel Lines...6005
      Fuel Filter Replacement...6005
      Draining Water from the Secondary Fuel Filter...6005
      Electric Fuel Pump...6007
      Fuel Level Sending Unit...6008
      Fuel Tank...6012
    Engine Control Linkages...6015
      Accelerator Cable...6015
      Engine RPM Adjustment...6016
    Air Intake System...6019
      Air Filter Replacement...6019
      Air Canister Removal...6019
      Air Canister Installation...6020
      Air Filter Intake Hose Removal...6020
      Air Filter Intake Hose Installation...6021
      Air Filter Outlet Hose Removal...6022
      Air Filter Outlet Hose Installation...6022
    Clutches...6023
      Clutch Troubleshooting...6023
      Drive Belt...6024
      Drive Clutch...6025
      Driven Clutch...6029
      Clutch Cover...6031
  Section 14 - Drivetrain Components...6035
    Half Shafts...6035
      Half Shaft Removal...6035
      Half Shaft Installation...6037
    Front Differential...6038
      Front Differential Removal...6038
      Front Differential Installation...6040
    Front Driveshaft...6040
      Front Driveshaft Removal...6040
      Front Driveshaft Installation...6041
    Rear Receiver Hitch...6041
      Rear Receiver Hitch Removal...6041
      Rear Receiver Hitch Installation...6041
    Rear Axle...6042
      Rear Axle Removal...6042
      Rear Axle Installation...6044
    Rear Driveshaft...6045
      Rear Driveshaft Removal...6045
      Rear Driveshaft Installation...6046
    Transmission...6046
      Transmission Removal...6046
      Transmission Installation...6048
      Forward/Reverse Shifter Cable...6049
      Forward/Reverse Shifter Handle...6052
    Rear Differential and Axle Shafts...6052
      Rear Differential and Axle Shaft Removal...6052
      Rear Differential and Axle Shaft Installation...6054
      Rear Wheel Bearings...6054
  Section 15 - Radiator and Coolant System (Diesel)...6057
    General Information...6057
      Engine Coolant Level Check...6057
      Engine Coolant Change...6057
    Coolant Reservoir...6059
      Coolant Reservoir Removal...6059
      Coolant Reservoir Installation...6060
    Radiator...6060
      Radiator Removal...6060
      Radiator Installation...6061
    Coolant Pipe Weldment...6062
      Coolant Pipe Weldment Removal...6062
      Coolant Pipe Weldment Installation...6062
    Fan...6063
      Fan Removal...6063
      Fan Installation...6063
  Section 16 - Transmission Models 421274 and 421275...6065
    General Information...6065
    Model Identification...6065
    Service Fixture...6066
    Transmission Removal...6066
    Transmission Disassembly...6067
      Input Shaft Disassembly...6072
      Input Shaft Assembly...6072
      Intermediate Shaft Disassembly...6072
      Output Shaft Disassembly...6076
      Shifter Shaft Removal...6077
      Shifter Shaft Installation...6078
      Case Inspection...6078
      Shaft Seal Removal...6079
      Shaft Seal Installation...6079
      Output Shaft Assembly...6079
      Intermediate Shaft Assembly...6082
      Intermediate and Output Shaft Assembly...6086
    Transmission Assembly...6087
    Transmission Installation...6091
  Section 17 - Front Differential Models 6203-01-139-S and 6203-01-189-S...6093
    General Information...6093
    Axle Half Shaft Removal...6093
    Front Differential Removal...6094
      Tools Required For This Section...6095
    Front Differential Coil And Output Cover...6095
      Coil and Output Cover Removal...6095
      Coil and Output Cover Installation...6098
    Front Differential...6100
      Front Differential Disassembly...6100
      Front Differential Assembly...6106
    Front Differential Installation...6110
    Axle Half Shaft Installation...6110
  Section 18 - Rear Differential Models 420366 and 420851...6111
    General Information...6111
    Axle Shafts and Differential Removal...6112
    Rear Differential Disassembly...6112
      Pinion Gear Removal...6114
      Ring Gear Removal...6116
      Clutch Carrier Assembly...6117
      Ring Gear Installation...6118
      Pinion Gear Installation...6119
      Rear Differential Assembly...6119
    Axle Shafts and Differential Installation...6121
  Section 19 - Kubota D722 Diesel Engine Manual...6123
  Section 20a - Kawasaki FH680D Gasoline Engine Manual...6177
  Section 20b - Honda GX 620 Gasoline Engine Manual...6291
  Section 21 - Hydraulic Attachment System...6391
    Model Identification...6391
    Relieving Hydraulic System Pressure...6391
      To Relieve Hydraulic Fluid Pressure...6391
    Attachment Interface...6392
      Inspection...6392
      Removing and Installing the Attachment Arm Mechanism...6393
    Electrical...6398
      Joystick...6400
      Joystick ON/OFF Switch...6402
      Attachment Arm Float Switch...6404
      Auxiliary Hydraulic Switch...6405
      Relays...6407
      Solenoid...6409
      Circuit Breaker...6410
      Control Valves...6411
    Hoses...6413
      Hose Routing...6413
      Hose Removal...6414
      Hose Installation...6414
    Quick Connect Fittings (Auxiliary Hydraulic Circuit only)...6415
      Quick Connect Removal...6415
      Quick Connect Installation...6415
    Cylinders...6416
      Vehicle Mounted Cylinders...6416
      Auxiliary Cylinder (Optional)...6417
      Cylinder Disassembly...6419
      Cylinder Assembly...6422
      Cylinder Bushings (If Equipped)...6427
    Angle Frame Bushings...6429
      Snow Blade Angle Frame...6429
      Whisk Broom Angle Frame...6430
    Front Mount...6431
      Front Mount Removal...6431
      Front Mount installation...6432
    Hydraulic Pump Assembly...6433
      Fluid Level Inspection...6433
      Fluid Change...6433
      Pump Assembly...6434
      Reservoir...6437
      Motor...6438
      Pump...6439
      Priming the Pump...6439
    A...6441
      a-arm, lower...6441
      a-arm, upper...6441
      accelerator...6441
      air canister (diesel vehicles)...6441
      air canister (gasoline vehicles)...6441
      air filter (diesel vehicles)...6441
      air filter (gasoline vehicles)...6441
      alternator (diesel vehicles)...6441
      antifreeze...6441
      attachment arm...6441
      attachment interface (hydraulic attachment vehicles)...6441
      axle half shaft...6441
      axle shaft and differential...6441
      axle, rear...6441
    B...6441
      ball joint, lower...6441
      ball joint, upper...6441
      battery (diesel vehicles) 12c-19...6441
      battery (gasoline vehicles) 12a-17, 12b-15...6441
      bed lift circuit breaker (diesel vehicles)...6441
      bed lift circuit breaker (gasoline vehicles)...6441
      bed lift motor...6441
      bed lift motor (diesel vehicles)...6441
      bed lift motor (gasoline vehicles)...6441
      bed lift switch (diesel vehicles)...6442
      bed lift switch (gasoline vehicles)...6442
      bed, cargo...6442
      belt, drive...6442
      belt, seat...6442
      body, front...6442
      box bed...6442
      brakes...6442
      bushings...6442
    C...6442
      cable, accelerator...6442
      cable, forward/reverse...6442
      cable, governor...6442
      camber...6442
      carburetor (diesel vehicles)...6442
      carburetor (gasoline vehicles)...6442
      carburetor heater (gasoline vehicles)...6442
      carburetor heater relay (gasoline vehicles)...6442
      carburetor solenoid (gasoline vehicles)...6442
      cargo bed...6443
      CAUTION...6443
      charge coil (gasoline vehicles) 12a-15, 12b-12...6443
      choke cable (gasoline vehicles)...6443
      circuit breaker, bed lift (diesel vehicles)...6443
      circuit breaker, bed lift (gasoline vehicles)...6443
      circuit breaker, hydraulic attachment...6443
      cleaning...6443
      clutch and ring gear...6443
      clutch carrier...6443
      clutch inner cover (diesel vehicles)...6443
      clutch inner cover (gasoline vehicles)...6443
      clutch outer cover (diesel vehicles)...6443
      clutch outer cover (gasoline vehicles)...6443
      clutch, drive...6443
      clutch, driven...6443
      coil and output cover...6443
      coil, charge (gasoline vehicles) 12a-15, 12b-12...6443
      coil, ignition (gasoline vehicles) 12a-15, 12b-12...6443
      column, steering...6443
      coolant reservoir (diesel vehicles)...6443
      coolant temperature warning light circuit (diesel vehicles)...6443
      coolant, engine (diesel vehicles)...6443
      cylinder, auxiliary...6443
      cylinder, hydraulic...6443
      cylinder, vehicle mounted...6443
    D...6443
      DANGER...6443
      differential relay (diesel vehicles)...6443
      differential relay (gasoline vehicles)...6443
      differential, front...6443
      differential, rear...6443
      diode, wire harness (diesel vehicles)...6443
      diode, wire harness (gasoline vehicles)...6444
      drive belt (diesel vehicles)...6444
      drive belt (gasoline vehicles)...6444
      drive clutch (diesel vehicles) 13c-27...6444
      drive clutch (gasoline vehicles) 13a-29, 13b-29...6444
      driven clutch (diesel vehicles) 13c-27...6444
      driven clutch (gasoline vehicles) 13a-29, 13b-29...6444
      driveshaft, front...6444
      driveshaft, rear...6444
    E...6444
      engine (diesel vehicles)...6444
      engine (gasoline vehicles)...6444
      engine governor arm...6444
      engine oil...6444
      exhaust system (diesel vehicles)...6444
      exhaust system (gasoline vehicles)...6444
    F...6444
      fan motor (diesel vehicles)...6444
      fan relay (diesel vehicles)...6444
      fender, front...6444
      fender, rear...6444
      floor mat...6444
      fluid...6444
      fluid, brake 10a-8, 10b-7...6444
      forward/reverse cable...6444
      forward/reverse shifter handle...6444
      front differential...6444
      front drive gearcase coil (diesel vehicles)...6445
      front drive gearcase coil (gasoline vehicles)...6445
      front driveshaft...6445
      front mount...6445
      fuel filter (gasoline vehicles) 13a-10, 13b-8...6445
      fuel filter, primary (diesel vehicles)...6445
      fuel filter, secondary (diesel vehicles)...6445
      fuel gauge/hour meter (diesel vehicles)...6445
      fuel gauge/hour meter (gasoline vehicles)...6445
      fuel level sending unit (diesel vehicles)...6445
      fuel level sending unit (gasoline vehicles)...6445
      fuel pump (diesel vehicles)...6445
      fuel pump (gasoline vehicles) 13a-10, 13b-8...6445
      fuel shut-off valve (gasoline vehicles) 13a-19, 13b-15...6445
      fuel solenoid (diesel vehicles)...6445
      fuel system (diesel vehicles) 13c-8...6445
      fuel system (gasoline vehicles) 13a-9, 13b-7...6445
      fuel tank (diesel vehicles)...6445
      fuel tank (gasoline vehicles)...6445
      fueling instructions 10a-17, 10b-16...6445
      fuse (diesel vehicles)...6445
      fuse (gasoline vehicles)...6445
      fusible link (diesel vehicles)...6445
    G...6445
      gearcase...6445
      gearcase coil...6445
      glow plug circuit (diesel vehicles)...6445
      governor arm, engine (gasoline vehicles)...6445
      governor arm, transmission (gasoline vehicles)...6445
      governor cable (gasoline vehicles)...6445
      governor guard (gasoline vehicles)...6445
      ground cables (diesel vehicles)...6445
      ground cables (gasoline vehicles)...6445
    H...6445
      half shaft...6445
      handle, forward/reverse shifter...6446
      headlight (diesel vehicles)...6446
      headlight (gasoline vehicles)...6446
      hitch, receiver...6446
      hoses, hydraulic...6446
      hydrometer test (diesel vehicles) 11c-13...6446
      hydrometer test (gasoline vehicles) 11a-9, 11b-9...6446
    I...6446
      ignition (gasoline vehicles)...6446
      ignition coil (gasoline vehicles) 12a-15, 12b-12...6446
      input shaft...6446
      input shaft seal...6446
      inspection...6446
      instrument panel...6446
      intake hose, air (diesel vehicles)...6446
      intake hose, air (gasoline vehicles)...6446
      intermediate and output shaft...6446
      intermediate shaft...6446
    J...6446
      jetting, carburetor (gasoline vehicles) 13a-12, 13b-8...6446
      joystick (hydraulic attachment vehicles)...6446
    K...6446
      key switch (diesel vehicles)...6446
      key switch (gasoline vehicles)...6446
      kill circuit, engine (gasoline vehicles)...6446
      kill wire, engine (gasoline vehicles)...6446
    L...6446
      lubrication...6446
    M...6447
      maintenance...6447
      manifold (diesel vehicles)...6447
      motor, hydraulic pump...6447
      muffler...6447
      muffler (diesel vehicles)...6447
      muffler (gasoline vehicles)...6447
    N...6447
      neutral switch (diesel vehicles)...6447
      neutral switch (gasoline vehicles)...6447
    O...6447
      oil filter...6447
      oil warning light, low (diesel vehicles)...6447
      oil warning light, low (gasoline vehicles)...6447
      oil, engine 10a-8, 10b-7...6447
      outlet hose, air (diesel vehicles)...6447
      outlet hose, air (gasoline vehicles)...6447
      output shaft...6447
    P...6447
      panel, instrument...6447
      park brake...6447
      pedal, accelerator...6447
      pedal, brake...6447
      periodic lubrication schedule 10b-4...6447
      periodic lubrication schedule - 2200 10a-4...6447
      periodic lubrication schedule - 2300 10a-6...6447
      periodic service schedule 10a-1, 10b-1...6447
      pinion gear...6447
      pump assembly, hydraulic...6447
      pump, fuel (diesel vehicles)...6447
      pump, fuel (gasoline vehicles) 13a-10, 13b-8...6448
      pump, hydraulic...6448
    Q...6448
      quick connect fitting...6448
    R...6448
      rack and pinion...6448
      radiator (diesel vehicles)...6448
      rear axle...6448
      rear differential...6448
      rear driveshaft...6448
      rear wheel bearing...6448
      receiver hitch...6448
      relay, accessory (diesel vehicles)...6448
      relay, accessory (gasoline vehicles)...6448
      relay, differential (diesel vehicles)...6448
      relay, differential (gasoline vehicles)...6448
      relay, float...6448
      relay, start (diesel vehicles)...6448
      relay, start (gasoline vehicles)...6448
      reservoir, coolant...6448
      reservoir, hydraulic fluid...6448
      reverse buzzer (diesel vehicles)...6448
      reverse buzzer (gasoline vehicles)...6448
      ring gear...6448
      ROPS (roll-over protective structure)...6448
      RPM adjustment (diesel vehicles)...6448
      RPM adjustment (gasoline vehicles)...6448
    S...6448
      safety...6448
      safety belt...6449
      seat...6449
      seat belt...6449
      seat frame...6449
      serial number, vehicle 3-1...6449
      service schedule...6449
      service tools...6449
      shaft seal...6449
      shifter shaft...6449
      shock absorber...6449
      solenoid, fuel (diesel vehicles)...6449
      solenoid, hydraulic attachment...6449
      spark plug (gasoline vehicles)...6449
      specifications...6449
      start relay (diesel vehicles)...6449
      start relay (gasoline vehicles)...6449
      starter control circuit (diesel vehicles)...6449
      starter control circuit (gasoline vehicles)...6449
      steering...6449
      steering column...6449
      steering upright...6449
      steering wheel...6449
      storage...6449
      suspension, front...6449
      suspension, rear...6449
      switch, auxiliary...6449
      switch, bed lift (diesel vehicles)...6449
      switch, bed lift (gasoline vehicles)...6450
      switch, float...6450
      switch, joystick ON/OFF...6450
      switch, neutral (diesel vehicles)...6450
      switch, neutral (gasoline vehicles)...6450
    T...6450
      12-volt accessory receptacle (diesel vehicles)...6450
      12-volt accessory receptacle (gasoline vehicles)...6450
      test procedures (diesel vehicles)...6450
      test procedures (hydraulic attachment vehicles)...6450
      test procedures (gasoline vehicles)...6450
      test procedures, index of (diesel vehicles) 11c-12...6450
      test procedures, index of (gasoline vehicles) 11a-8, 11b-8...6450
      thermostat switch (diesel vehicles)...6451
      throttle...6451
      tire...6451
      tools...6451
      torque converter (diesel vehicles) 13c-27...6451
      torque converter (gasoline vehicles) 13a-29, 13b-29...6451
      transmission...6451
      transmission governor arm...6451
      troubleshooting...6451
    V...6451
      v-belt (diesel vehicles)...6451
      voltage regulator (gasoline vehicles)...6451
    W...6451
      WARNING...6451
      wheel...6451
      wheel bearing...6451
      wheel, steering...6451
      wire continuity (diesel vehicles)...6451
      wire continuity (gasoline vehicles)...6451
      wire harness diode (diesel vehicles)...6451
      wire harness diode (gasoline vehicles)...6451
      wiring diagram (diesel vehicles) 11c-6...6451
      wiring diagram (gasoline vehicles) 11a-6, 11b-6...6451
      wiring diagram (hydraulic attachment) 21-8...6451
6904895 (5-09) - 2200, 2200S Operation & Maintenance Manual...6455
  Safety Decal and Feature Identification...6460
    2200 Gas/Diesel Vehicles...6461
    2200 Gas/Diesel Vehicles...6462
    2200S Gas/Diesel Vehicles...6463
    2200S Gas/Diesel Vehicles...6464
  Practice Safety...6465
  Proposition 65 - State of California...6465
  Safety Details...6466
  General Warnings...6467
  General Information...6469
  Model Identification...6469
  Controls and Indicators...6470
    Key Switch - Gasoline Vehicles...6471
    Key Switch - dIESEL vEHICLES...6471
    Forward/Reverse Control...6472
    Accelerator Pedal...6472
    Brake Pedal...6472
    Park Brake...6472
    Steering Adjustment Lock...6473
    12-VOLT Accessory OUTLET...6473
    Low Oil Warning light...6473
    Fuel Gauge/Hour Meter...6473
    Headlight control...6474
    Electric Bed Lift...6474
    High-Temperature Warning Light (Diesel Vehicles Only)...6474
  Roll-Over Protective Structure and Safety Belts...6474
  Seat Latch and Adjustment...6476
  Pre-Operation and Daily Safety Checklist...6476
  Performance Inspection...6477
  Driving Instructions...6478
    Starting The Vehicle...6479
    All-Wheel Drive (AWD) Operation...6480
    Stopping The Vehicle...6480
    Parking And Leaving The Vehicle...6481
  Bed Latch and Prop Rod...6481
  Loading and Unloading Cargo...6482
  Vehicle Load Capacities...6483
  Towing with the Vehicle...6484
  Transporting on a Trailer...6484
  Storage...6485
    Preparing the Vehicle for Extended Storage...6486
    Returning the Stored Vehicle to Service...6487
  Maintenance...6488
  Periodic Service Schedule...6489
  Periodic Lubrication Schedule...6492
  Brake Fluid Reservoir...6494
    Brake Fluid...6494
  Engine Oil...6494
    Oil Pressure - Gasoline Engine...6494
    Engine Oil Level Check...6495
    Engine Oil and Filter Change...6495
    Oil Viscosity...6499
  Gearcase Lubrication...6500
    Lubrication Level Check for Front Differential, Transmission, and Rear Differential...6500
    Lubrication Change for Front Differential, Transmission, and Rear Differential...6500
  Engine Coolant - Diesel Vehicles...6501
    Engine Coolant Level Check...6501
  Air Intake System...6502
    Air Filter Replacement...6502
  Fueling Instructions...6503
    Draining Water from Fuel Filter...6504
  Battery...6505
  Using A Booster Battery (Jump Starting)...6507
  Cleaning the Vehicle...6508
  Accessories...6508
    Electric Winch Accessory...6509
    Mud Tire OPtion...6509
  Subsequent Owner Registration...6510
  Vehicle Specifications...6510
    Bobcat Utility Vehicles...6513
  Technical & Consumer Information (Gasoline Engines)...6514
    CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT...6516
    YOUR WARRANTY RIGHTS AND OBLIGATIONS...6516
    Bobcat Explanation of Emission Control Warranty...6516
6987392 (4-09) - 2100 Operation & Maintenance Manual...6521
  Safety Decal and Feature Identification...6526
    2100...6527
    2100...6528
  Practice Safety...6529
  Proposition 65 - State of California...6529
  Safety Details...6530
  General Warnings...6531
  General Information...6532
  Model Identification...6532
  Controls and Indicators...6533
    KEY SWITCH...6533
    FORWARD/REVERSE CONTROL...6534
    Accelerator Pedal...6534
    Brake Pedal...6535
    Park Brake...6535
    CHOKE...6535
    Differential Lock...6536
    Low Oil Warning Light...6536
    Fuel Gauge/Hour Meter...6536
    Headlight control...6537
  Seat Latch and Adjustment...6537
  Pre-Operation and Daily Safety Checklist...6537
    Performance Inspection...6538
  Driving Instructions...6539
    Starting the vehicle...6540
    Stopping the vehicle...6540
    Parking and leaving the vehicle...6541
  Bed Latch and Prop Rod...6541
  Front Shock Absorbers...6542
  Loading and Unloading...6542
  Towing with the Vehicle...6543
  Transporting on a Trailer...6544
  Storage...6544
    Preparing the Vehicle for Extended Storage...6545
    Returning the Stored Vehicle to Service...6546
  Maintenance...6548
  Periodic Service Schedule...6549
  Periodic Lubrication Schedule...6551
  Master Cylinder...6552
    Brake Fluid...6552
  Engine Oil...6553
    Engine Oil Level Check...6553
    Engine Oil And Filter Change...6553
    Oil Viscosity...6556
  Fueling Instructions...6557
  Battery...6558
  Cleaning the Vehicle...6560
  Accessories...6561
    Electric Winch Accessory...6561
  Subsequent Owner Registration...6561
  Vehicle Specifications...6562
    Bobcat Utility Vehicles...6564
    CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT...6564
    YOUR WARRANTY RIGHTS AND OBLIGATIONS...6564
    Bobcat Explanation of Emission Control Warranty...6565