Hydraulics

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 HYDRAULICS
Hydraulic System Overview

The 400 series 3 skid steers use an open center hydraulic system to operate two
loader cylinders, two bucket cylinders, and auxiliary hydraulic flow. Through this
overview we will explain the components used in the open center hydraulic system to
control the loader functions and auxiliary functions.

The reservoir is located in the right rear loader frame upright. The fill cap controls the
pressure of the reservoir. The filler cap controls the pressure to 5 psi, and will allow
make-up air to enter at .5 psi vacuum. There is also a drain plug at the bottom of the
reservoir to be used in conjunction with the filter buggy to clean up the system. The
plug used on the machine is also magnetic to draw any heavy metallic pieces away
from the inlet of the suction screen. A suction screen is used in the reservoir outlet
fitting in the bottom of the tank.

The gear type hydraulic pump is mounted at the rear of the tandem piston pump,
driven directly from the flywheel end of the engine.

From the pump, the oil flows directly to a three spool open center loader control valve.
The main relief valve for the complete hydraulic system is located at the inlet to the
loader valve. The main relief valve setting is different depending on machine. The
main relief valve is not adjustable and should be replaced if the pressure is found to be
lower than specification. The first spool in the valve controls the loader functions- raise,
neutral, lower and float. The second spool in the valve controls the bucket cylinders -
rollback, neutral, and dump. The third spool in the valve controls the oil flow to the
auxiliaries. This spool can be controlled either mechanically or by charge pressure
depending on how the machine is equipped. The valves have one load check valve for
each spool to prevent the load from dropping as the spool is slowly engaged to the
power position.

A circuit relief valve is integrated into the loader valve in the loader spool for the base
end of the cylinders. The circuit relief valve is used to protect the loader cylinders from
pressure spike while the spools are in the neutral position.

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HYDRAULICS

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 HYDRAULICS
Hydraulic System Overview

The auxiliary circuit can be supplied with oil if the loader lift spool or the bucket spool is
either in neutral or if the circuit is still able to flow oil, (i.e.), cylinder not at the end of
travel. The auxiliary couplers are located at the left side of the loader frame crossbar.
The main relief valve in the loader valve also limits the maximum pressure available to
the auxiliary circuit.

The oil cooler is mounted on the back of the unit for ease of cleaning. There is
one filter in the complete hydraulic/hydrostatic system. The filter manifold has a 50 psi
differential bypass relief valve to protect the filter element during cold weather
operation. The filter manifold also has a 40 psi differential pressure switch to signal
when the filter requires changing. The hydraulic system has a filter installed in the oil
return. To check the condition of the filter, operate the engine at full throttle with the oil
at operating temperature, and then observe the filter indicator light. The filter light will
come on and the filter bypass will open when the hydraulic oil is cool. Because of this,
it is recommended to limit the maximum engine speed while the oil is cold.

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Loader Raise and Bucket Neutral

The below picture represents oil flowing into the inlet port of the loader valve passing through the loader spool which is
stroked into the raised position flowing oil to the base end of the loader cylinder. Oil forces the loader cylinder to
extend which in turn pushes the remaining oil from the rod side of the cylinder back through the loader spool and back
through the open center passage.

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 LoaderHYDRAULICS
Lower and Bucket Neutral

The below picture represents oil flowing into the inlet port of the loader valve passing through the loader spool which is stroked
into the lower position flowing oil to the rod end of the loader cylinder. Oil forces the loader cylinder to retract which in turn
pushes the remaining oil from the base side of the cylinder back through the loader spool and back through the open center

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 HYDRAULICS
Loader Float and Bucket Neutral
The below picture represents oil flowing into the inlet port of the loader valve passing
through the loader spool which is stroked into the float position flowing oil to the rod end
of the loader cylinder to the base end. Since the base and the rod end of the cylinder do
not share the same volume of oil the valve has opened a passage to tank to draw oil in
when needed and to expel oil when needed.

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R
 HYDRAULICS
Loader Lower and Bucket Curl

The below picture represents oil flowing into the inlet port of the loader valve passing through the loader spool which is stroked
into the lower position flowing oil to the rod end of the loader cylinder. Oil forces the loader cylinder to retract which in turn
pushes the remaining oil from the base side of the cylinder back through the loader spool and on to the rod side of the bucket
cylinder which in turn pushes return oil from the base end of the bucket cylinder out to the tank passage.

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Loader Raise and Bucket Dump

The below picture represents oil flowing into the inlet port of the loader valve passing through the loader spool which is stroked
into the raise position flowing oil to the base end of the loader cylinder. Oil forces the loader cylinder to extend which in turn
pushes the remaining oil from the rod side of the cylinder back through the loader spool and on to the base side of the bucket
cylinder which in turn pushes return oil from the rod end of the bucket cylinder out to the tank passage.

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 HYDRAULICS
Loader Neutral and Bucket Curl

The below picture represents oil flowing into the inlet port of the loader valve passing through the loader spool which is
stroked into the neutral position flowing oil to the bucket spool which is stroked into the curl position. Oil flows to the rod
end of the cylinder which in turn pushes base end oil out of the cylinder and out to the tank line.

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 HYDRAULICS
Loader Neutral and Bucket Dump
The below picture represents oil flowing into the inlet port of the loader valve passing through the loader spool
which is stroked into the neutral position flowing oil to the bucket spool which is stroked into the dump position. Oil
flows to the base end of the cylinder which in turn pushes rod end oil out of the cylinder and out to the tank line.

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 HYDRAULICS
Electro Hydraulic Control Valve

Load check passage used only on Load Check Passages

machines NOT equipped with high flow.
High flow machines will have the check
removed and a “NC” or white painted “X”
installed onto the cap.

Auxiliary Section

Bucket
Section

Loader Section

Main Relief Valve

Work Ports Several changes have been
made to the relief. Early series
1 versions (shown) were
equipped with direct acting
relief’s.
Late model series 1 and all
series 3 machines use a pilot
operated relief installed on the
side of the valve (blue arrow)
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HYDRAULICS

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Electro Hydraulic Control Valve

Out to Tank

High Flow
Inlet Auxiliary / High Flow
Control Solenoids

Bucket circuit relief

ports. Early Series 1
machines did not have
relief’s installed. Refer
to service bulletin NSL
SB 001 06 for more
information.

Inlet from Pump

Loader Base End
Circuit Relief
3350 PSI

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 HYDRAULICS
Standard Loader Control Valve

Circuit relief passages

Loader used on all series 3 and
cylinder base late model series 1
end circuit machines. Refer to service
relief 3335 PSI Bulletin NSL SB 001 06.

Inlet from the

hydraulic pump

Main relief valve

Aux spool neutral

switch. Used in
Interlock solenoids the interlock
system.

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 HYDRAULICS

Aux spool neutral

Interlock solenoids switch. Used in
the interlock
system.

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 HYDRAULICS
High Flow System
The 400 series 3 high flow system is based upon three major components. First
is an additional gear pump added to the base machine. This pump can be a tandem
gear pump system which shares half of the pump for boom and bucket and the other
half for high flow on series 1 420 and 435machines. The 420, 430, 435, 440, 445, 450
and 465 use the engine PTO located underneath the injection pump assembly. The
450 and 465 early production series 1 machines use another gear pump added to one
of the M46 (Hydrostatic) piston pump. The second major component is the high flow
control valve. The high flow control valve houses an on off solenoid, isolation check,
and the high flow relief valve. The third major component is the loader control valve. In
order for the 400 series1 and 3 machines to have high flow the electronically/charge
pressure controlled valve (Electro Hydraulic) must be used or installed. The high flow
is developed by combining the standard hydraulic systems GPM (different for each
machine) and the additional high flow pumps GPM rating.

The flow combines at the inlet of the loader control auxiliary spool and is
directed by the aux valve itself out to the auxiliary hydraulic couplers. The high flow
control valve houses the high flow relief valve which is higher than the main relief
pressure specification of 3000 +/- 50. The high flow main relief valve comes into play
when the high flow system does not have access to the main relief valve. In order to
check the pressure of the high flow relief valve you will need a 5000 psi pressure
gauge installed in one of the four aux hydraulic quick disconnects. To see the pressure
of the high flow relief valve:

1. Heat the hydraulic system to 125 degrees Fahrenheit.

2. Turn the high flow system on.

3. Raise the engine speed to the high idle position.

4. Engage the Aux hydraulics by pushing the control button on the control handle.

5. Curl the bucket and continue to hold it over relief.

6. Record the pressure on the 5000 psi gauge in the hydraulic quick disconnect.

If the pressure recorded is not correct remove the cap on the relieve valve and adjust as
necessary.

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 HYDRAULICS
High Flow System
Flow testing the high flow pump and control valve separately from the loader
hydraulic circuit is possible. In order to perform the test the main relief valve from the
loader control valve must be removed and a plug installed. By removing the loader
control main relief valve the bucket can now be held in the curl position. This allows all
oil from the loader hydraulic pump to return to tank and the high flow pump only to flow
oil to the auxiliary quick connects. The flow test can now be performed in the same
fashion as a standard flow test. The main relief valve was removed to reduce engine
load and prevent damage to the main relief valve due to high heat generated by
flowing oil over the valves setting.

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 HYDRAULICS
High Flow System Schematic

High Flow Relief Valve

used only when the main
relief valve is open
(example: bucket held in
the curl position over
relief).

Accumulator used to stroke the

aux with the engine off to
relieve pressure at the aux
quick disconnects.

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 HYDRAULICS
Secondary Low Flow Auxiliary System

The secondary low flow system is accessory that is installed in order to operate
cold planer side shift features. This option is installed on Electro Hydraulic control valves
ONLY. The system is operated by a foot pedal installed at the front of the operator’s feet
and adds a pair of low flow auxiliary hydraulic couplers on the right hand side loader
arm.

The low flow auxiliary option is installed between the equipment hydraulic pump
output and the loader control valve inlet. This gives the valve priority over the loader
valve and allows the high flow pump to sustain flow to the attachment (example: the
rotating drum on a cold planer.

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Circuit Relief Valve/Anti-Cavitation Check Valve

Direct Acting Circuit Relief Valve

Circuit relief/anti-cavitation check valves are used in the loader control valve at the inlet
port for the main relief and the B1 port of the loader lift circuit. Circuit relief valves
protect cylinders and lines from being over pressurized by outside forces or shock
loads when control valve spools are in the neutral position and are also used as a main
relief valve to protect the pump from over pressurization when the cylinders or auxiliary
hydraulics encounter high resistance to flow.

The anti-cavitation check valve function of the circuit relief valve operates when the
cylinder moves with no oil supply to the circuit. This could happen as the circuit relief
valve on the opposite work port opens and creates a void in a work port.

Circuit Relief / Main Relief Valve Operation: Circuit relief valves are of the direct
acting type. They are normally closed, requiring hydraulic pressure to open. The valve
is a poppet held against a seat by spring force. The poppet opens when hydraulic force
against the poppet exceeds spring force. Oil passing the poppet enters the return
passage of the control valve and continues on to the reservoir. Circuit relief valves
should be checked using a hand pump. Main relief valves should be tested using a
5000 psi pressure gauge installed in the auxiliary hydraulic coupler or by using a flow
meter.

Anti-Cavitation Check Valve Operation: If the cylinder travels with the control spool
in neutral, the pressure in the work port is then less than the pressure in the valve
return passage. The lift check valve spring at the right end would then collapse
allowing the circuit relief valve cartridge to move away from the valve body allowing
return oil to flow into the work port. This would keep the cylinder full of oil.

Circuit Relief Valve Cartridge

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 HYDRAULICS
CIRCUIT RELIEF VALVE - ANTI - CAVITATION CHECK VALVE

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 HYDRAULICS
Self - Leveling Valve

Bucket Self - Leveling

The function of the bucket self-leveling circuit is to maintain the bucket in the "level"
position as the loader frame is raised. If self-leveling is not used, and the bucket is fully
rolled back at ground level, spillage can occur from the rear of the bucket as the loader
frame is raised.

To maintain a level bucket without spillage requires manual operation of the bucket
control by the operator as the loader frame is raised. However, installing a leveling
valve automatically levels the bucket as the loader frame is raised. The system is
designed to level the bucket only in the raised mode, not in the lower.

The self-leveling control valve has four ports. The "out" port is connected to the rod
end of the loader lift cylinders. The "in" port is connected to the loader down (A1 port)
of the loader control valve.

The rod ends of the bucket cylinders are plumbed in a tee configuration to the "rod
port" of the leveling-valve.

The base ends of the bucket cylinders are plumbed in a tee configuration to the "base
port" of the leveling-valve.

The self-leveling control valve consists of a spring loaded flow divider spool with an
orifice plate in each end. The orifice plates size, regulate the amount of leveling that
the bucket will do. The valve also has a check valve assembly to allow the self-
leveling oil flow to the base end of the bucket cylinder and to prevent oil from back
feeding through the self-leveling valve when the bucket spool is actuated. There is also
a metering spool, which allows oil to escape from the rod end of the bucket cylinder
as the self-leveling takes place. The leveling-control valve also has a pilot operated
relief valve, which is set at approximately 500 psi (34.5 bar) to allow a flow path for
the leveling oil in the event the bucket cylinders are bottomed out to the full dump
position.

Because bucket leveling, is controlled by a flow divider spool, the amount of leveling
that occurs depends on the oil flow from the loader lift cylinder and therefore changes
with engine speed. The system is designed to operate correctly with the engine at high
idle, as this is the recommended operating speed of the unit. At speeds less than high
idle, the bucket may not maintain level as the loader is raised. Also, raising the loader
very slowly can affect the bucket leveling, as sufficient oil flow is not available to
provide adequate pressure to drop through the flow divider orifices.

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 HYDRAULICS
Self - Leveling Valve
Loader Raise Bucket Self Level

1. Check Valve 5. "Out" Port 9. Spring 13. Pilot Operated

Poppet Relief Valve
2. Spring 6. Orifice Plate 10. Spring 14. Dampening Orifice
3. "Base" Port 7. Flow Divider 11. Metering
Spool Spool
4. Orifice Plate 8. "In" Port 12. "Rod" Port

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 HYDRAULICS
Loader Raise - Bucket Self - Leveling

To prevent spillage over the back of the bucket, the leveling circuit keeps the bucket
level as the loader is raised.

As the loader is raised with the bucket rolled back, the following happens:

1. The loader control valve lift spool will be activated to send pump flow to the base
end of the lift cylinders.

2. The oil returning from the rod end of the lift cylinders enters the "out" port of the
leveling valve. This flow is directed to the center of the flow divider spool. Orifice
plates at each end of the flow divider spool split the flow between tank and the base
end of the bucket cylinder, to keep the bucket level.

A. The flow divider spool shifts as the flow not required to position the bucket exits
the leveling valve at the "in" port and flows back through the loader control valve
lift spool. This return flow is then directed to the next section of the control valve
or out the loader control valve outlet.

B. The bucket-leveling flow exits the flow divider spool and goes through a
passage to the poppet check valve, to the backside of the metering spool and
also to the pilot operated relief valve. This flow will perform the following
functions.

1. The leveling flow unseats the poppet check valve and exits the leveling valve
at he "base' port. This flow goes to the base end of the bucket cylinders,
causing it to extend to keep the bucket level.

2. For the bucket cylinder to move, some oil must escape from the rod end.
The metering spool allows for the gradual release of this oil. Approximately
50 to 60 psi (3.4 to 4.1 bar) must be present at the backside of the metering
spool to shift it into a position to allow flow from the rod end of the bucket
cylinder. As the metering spool is shifted, oil from the rod end of the bucket
cylinder flows into the 'rod' port of the leveling valve and then out of the 'in'
port of the leveling valve to the lift spool area of the loader control valve.

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 HYDRAULICS
Bucket Leveling Circuit

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 HYDRAULICS

1. Check Valve 5. "Out" Port 9. Spring 13. Dampening

Poppet Orifice
2. Spring 6. Orifice Plate 10. Spring
3. "Base" Port 7. Flow Divider 11. Metering 14. Pilot Operated
Spool Spool Relief Valve
4. Orifice Plate 8. "In" Port 12. "Rod" Port

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 HYDRAULICS
Loader Raise - Bucket At Full Dump

As the loader is raised with the bucket at full dump, the following will occur:

1. The loader control valve lift spool will be activated to send pump flow to the base
end of the lift cylinders.

2. The oil returning from the rod end of the lift cylinders enters the "out" port of the
leveling valve. 'This flow is directed to the center of the flow divider spool. Orifice
plates at each end of the flow divider spool split the flow between the base end of
the bucket cylinder and tank.

A. The flow divider spool shifts as the flow not required to position the bucket exits
the leveling valve at the "in" port and flows back through the loader control valve
lift spool. This return flow is then directed to the next section of the control valve
or out of the loader control valve outlet.

B. The bucket leveling flow exits the flow divider spool and goes through a
passage to the poppet check valve, to the backside of the metering spool and
also to the pilot operated relief valve.

3. With the bucket in the full dump position, the oil directed to the base end of the
bucket cylinder has no place to go.

4. The flow available to the base end port of the leveling valve is also connected to
the pilot operated relief valve. The relief valve is set at 500 psi (34.5 bar). With no
other place to flow, the bucket leveling oil flows over the relief valve into the "in"
port passage of the leveling valve.

5. This flow exits the leveling valve through the "in" port and flows back through the
loader control valve, lift spool.

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 HYDRAULICS
Loader Raise and Bucket Dumped

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 HYDRAULICS
Loader Lower No Self Leveling

As the loader is lowered, the following will happen:

1. The operator shifts the loader lift control spool to the lower position. The oil flows
from the loader control valve to the "in" port of the leveling valve.

2. The flow divider spool is spring biased to the left. The oil flows through the fixed
orifice at the spring end of the flow divider spool, and then exits the leveling valve at
the "out" port. The oil from the "out" port is then sent to the rod end of the lift
cylinders and lowers the loader.

3. The exhaust flow from the base end of the loader lift cylinders is then returned to
the raise "B" port of the loader control valve, lift spool. This return flow is then
directed to the next section of the loader control valve or out the control valve
outlet.

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 HYDRAULICS
Bucket Leveling Circuit

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 HYDRAULICS

1. Check Valve 5. "Out" Port 9. Spring 13. Dampening

Poppet Orifice
2. Spring 6. Orifice Plate 10. Spring
3. "Base" Port 7. Flow Divider 11. Metering 14. Pilot Operated
Spool Spool Relief Valve
4. Orifice Plate 8. "In" Port 12. "Rod" Port

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 HYDRAULICS
Bucket Dump Loader Neutral (No self leveling)

As the bucket is bumped, the following will happen.

1. The operator shifts the bucket control spool to the dump position. The oil flows
from the loader control valve to the base port of the bucket cylinder and travels
on to the leveling valve.

2. Once the oil flows to the leveling valve the check valve seats causing a blocked
passage.

3. The exhaust flow from the rod end of the bucket cylinder travels back through
the loader control valve and flows into the return. Oil can also travel to the
metering spool where it is blocked. If bucket circuit drift is present the “Base
Port” must be capped to determine if the check valve is malfunctioning.

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 HYDRAULICS
Bucket Dump Loader Neutral

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 HYDRAULICS
Metering Spool

Check Valve

Pilot Operated
Relief Valve

Flow
Divider

24. Self Leveling Valve 25. Rod Port

26. Base Port 27. In Port
28. Out Port

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Symptom
Bucket does not maintain
level while raising at
different engine speeds.
Bucket does not maintain
level while raising at high
idle.
Excessive bucket drift
towards the dump direction.
Excessive bucket drift
towards the roll back
direction.
HYDRAULICS
Troubleshooting
Possible Cause Correction
Bucket self-leveling is Run engine at high idle.
designed to work at high
idle.
Flow divider spool is stuck. Check flow divider spool for
free operation.
Incorrect orifice plate in flow Replace orifice in flow
divider spool. divider spool.
Metering spool is stuck in Check metering spool for
leveling valve. free operation.
Bad bucket cylinder Repack cylinder.
packing
Replace loader valve.
Excessive loader control
valve port leakage.
Check metering spool for
Metering spool in the free operation.
leveling valve stuck.
Bad bucket cylinder Repack cylinder.
packing.
Replace loader valve.
Excessive loader control
valve leakage.
Check valve for leakage.
Defective check valve
poppet in the leveling valve.
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 HYDRAULICS
Ride Control

Ride control is an option that can be either added at the plant or field installed.
Ride control allows the operator to open the base end of the loader cylinder to a gas
charged accumulator to provide the boom with a cushioned ride that eliminates the
rocking forward to backward motion typical with skid steers. In order to allow the
cylinder to retract and extend freely we also tie the rod side of the cylinder to a tank
passage so that the cylinder does not hydraulically lock.

During troubleshooting for drift complaints of the loader circuit the ride control
valve MUST be capped off to isolate the components in the loader circuit.

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 HYDRAULICS
Hydraulic Coupler Option
The new 400 series skid steers offer two different attachment couplers. The two
couplers are either lever operated (Manual) and hydraulically operated. Hydraulic operated
couplers appear the same as past XT models however they operate very differently. In order to
install a hydraulic coupler on a 400 series machine the machine MUST be ordered with the
optional case drain return line on the loader frame. This option allows return oil from the lock
cylinders to return to tank. To operate the coupler the operator must open the access panel
located on the left hand side (operator seated in the seat) and push the rocker switch to the
unlock position (symbol shows a padlock unlocked). In order to retract the bucket latching pins
the operator must curl the bucket and over relief until the flags have raise up out of the coupler.
A red and green flag will be visible on the left and right hand side of the coupler. This indicates
to use CAUTION because the attachment is now unlocked and ready to either remove the
attachment or couple into another attachment.
Once an attachment is secured onto the coupler the operator must push the rocker switch
to the lock position (symbol shows a padlock in the locked position). Now curl the bucket over
relief and watch the flags. Once the flags retract the only visible portion of the flag is colored
green. Green indicates that the coupler has now locked itself to the attachment and is now ready
for work.

NOTE: (Series 1 machines) As a product improvement oil being supplied to connection H5 has
been moved to the open center hydraulic circuit. This improvement was made to reduce bucket
circuit leak down complaints. For machines that are still plumbed to receive oil from the rod
side of the bucket circuit refer to service bulletin NSL SB 020 06. Refer to the below table
for serial number breaks.

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HYDRAULICS

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 HYDRAULICS
Filter Restriction Indicator

The filter restriction indicator is a differential pressure switch that senses both the inlet
and outlet pressure of the filter. The pressure on the inlet side of the element is ported
to the outboard, non-spring end of the nylon piston. The pressure on the downstream
side of the element is ported to the inboard, spring end of the nylon piston. The
sensing spring forces the nylon piston towards the inlet area, until the pressure
differential across the element is greater than the strength of the spring. When the
filter inlet pressure exceeds the outlet pressure by the strength of the spring, the piston
moves inward until it contacts a ledge in the filter head. The pressure switch should
close to activate the filter light at 40 psi differential pressure.

The restriction indicator activates an indicator light when the preset differential is
reached. Through the keyswitch, power is fed to a filter indicator light in the instrument
cluster. To activate the light, the restriction indicator completes the circuit to ground
when the filter becomes plugged. A wire connects the light in the instrument cluster to
the electrical connection of the indicator switch. The restriction indicator electrical
connection is insulated from filter head and can only complete the circuit to ground
when the grounding washer on the inboard end of the sensing piston contacts the
ledge in the filter head.

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 HYDRAULICS
Filter Restriction Indicator

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 HYDRAULICS
Main Hydraulic pump

The hydraulic pump is mounted to the rear of the tandem hydrostatic piston pump, at
the front of the unit, and is driven directly from the flywheel end of the engine. The
main hydraulic pump provides oil flow to the loader, bucket, and auxiliary functions. Oil
flows from the reservoir directly to the pump after flowing through a 100 mesh suction
screen. The hydraulic pump supplies the loader valve first. The pump is supplied by
Sauer Danfoss.

Drive train from a 410–420

shown. The Hydraulic
pump is circled.

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HYDRAULICS
NOTES

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 HYDRAULICS
Auxiliary Control Valve

The units are equipped with an auxiliary hydraulic system. The auxiliary portion of the
loader valve will be supplied with oil, only if the loader lift spool or bucket spool is either
in neutral or the loader circuit is still able to flow oil in the stroked position with the
bucket spool in neutral, (i,e.), cylinder not at the end of travel. This portion of the
loader valve controls the flow to the hydraulic couplers on the loader frame near the
bucket. The oil is routed through plumbing on the left rear loader frame, through the
loader pivot point. The auxiliary couplers are located at the left side of the loader
frame arm. The main relief valve in the loader valve also limits the maximum pressure
available to the auxiliary circuit. Return oil from the auxiliary valve returns to the oil
cooler.

Service Tip: Many times the auxiliary valve control spool will remain in the engaged
position after attachments have been removed. The spool being engaged while
attempting to start the unit can give the symptom of a defective cranking system as the
starter relay and fuel relay will have not power on non-EH machines.
Out to Tank
Auxiliary / High Auxiliary / High Flow Section
Flow work ports of the loader valve.

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 Auxiliary Hydraulic Flow (boom raise and aux out male coupler)
HYDRAULICS
The below schematic represents the loader spool in the raise position and the auxiliary
spool in the male outlet direction. A loop hose has been installed on the couplers to show
the flow through the return.

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Loader Raise, Bucket Curl, and Aux out the Male coupler
HYDRAULICS
The below Schematic represents what happens when the bucket
function is used. The return oil which fed the aux with the loader
only is now gone. The bucket cylinders have re-directed this flow
to bypass the Aux circuit.

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 HYDRAULICS
Hydraulic System Cleanup
General information
Contamination in the hydraulic and hydrostatic system is a major cause of malfunction
of components. Contamination is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic and hydrostatic system in any of the following
ways:
1. When you drain the hydraulic oil or disconnect a line.
2. When you disassemble hydraulic or hydrostatic components.
3. From normal wear of the components.
4. From damaged components.

The best way to remove contamination from the hydraulic system is to use the portable
filter, CAS-10162A. If severe contamination is present, disassembly and repair will be
necessary.
The best way to remove contamination from the hydrostatic system is to disassemble
the components and clean the system.

Types of Contamination
There are two types of contamination, microscopic and visible. Microscopic
contamination occurs when very fine particles of foreign material are in suspension in
the hydraulic oil. These particles are too small to see or feel. Microscopic
contamination can be found by the identification of the problems the microscopic
contamination causes, or by testing in the laboratory. Examples of problems caused
by microscopic contamination include the following:
1. Cylinder rod seals leak.
2. Control valve spools do not return to neutral properly.
3. The hydraulic system has a high operating temperature.
4. Rapid wear of components.
Visible contamination is foreign material that can be found by sight, touch, or odor.
Visible contamination can cause a sudden failure of a component. Examples of visible
contamination include the following:
1. Particles of metal or dirt in the oil.
2. Air in the oil.
3. Odor of burned oil.
4. Water in the oil, which will cause the oil to appear cloudy and milky.

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Cleaning the Hydraulic System
1. Prepare the portable filter for the clean up process by doing the following steps:
a. Remove all of the oil from the inlet and outlet hoses for the portable filter.
b. Remove the filter element from the portable filter.
c. Clean the filter housing and install a new element in the portable filter.
2. You must know whether the contamination is microscopic or visible. See types
of contamination on preceding page.
3. If the contamination is microscopic, do the following steps:
a. Check the maintenance schedule for the machine to learn whether or not
the hydraulic oil must be changed. If necessary, change the oil and filter.
b. Do steps 6 through 36.
4. If the contamination is visible, do the following steps:
a. Change the hydraulic oil and filters.
b. Do steps 5 through 36.
5. Check the amount of contamination in the hydraulic system by doing the
following steps:
a. Disassemble one cylinder in two different circuits. Check for damage to
the seals, scoring of the cylinder walls, etc. Repair the cylinders as necessary.
b. If, in your judgement, the damage to the cylinders was caused by severe
contamination and is not the result of normal wear, it is necessary to remove,
clean, and repair all valves, pumps, lines, cylinders, etc. in the hydraulic system.
c. Continue with steps 6 through 36.
6. Remove the filler cap from the reservoir.
7. Connect a vacuum pump to the reservoir.
8. Start the vacuum pump.
9. Loosen and remove the drain plug from the bottom of the reservoir.
10. Install a shutoff valve into the drain plug hole. Make sure the valve is closed.
11. Stop the vacuum pump.
12. Connect the inlet hose of the portable filter to the valve.
13. Disconnect the vacuum pump from the reservoir.
14. Put the return hose from the portable filter into the reservoir.
15. Open the valve at the bottom of the reservoir.
16. Turn the portable filter on to circulate oil from the reservoir.
17. Start and run the engine at half throttle.
18. Run the portable filter for 10 minutes with the engine running at half throttle.
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19. Heat the oil to operating temperature.
a. Increase the engine speed to full throttle.
b. Hold the bucket control lever in the rollback position for 15 seconds.
c. Return the bucket control lever to neutral for 30 seconds.
d. Repeat these steps until the oil is at operating temperature.
20. With the engine running at full throttle and the portable filter running, completely
extend and retract each cylinder or group of cylinders. Continue to operate
each cylinder or group of cylinders two times, one after the other, for 30
minutes.
21. Decrease the engine speed to low idle.
22. Continue to run the portable filter for 10 minutes. During this time, move the
return hose from the filter up and down in the reservoir to help mix the oil.
23. Stop the portable filter.
24. Stop the engine.
25. Remove the hose from the reservoir.
26. Connect the vacuum pump to the reservoir.
27. Close the valve at the bottom of the reservoir.
28. Disconnect the filter inlet hose from the valve.
29. Start the vacuum pump.
30. Loosen and remove the valve at the bottom of the reservoir.
31. Install and tighten the drain plug.
32. Stop the vacuum pump.
33. Disconnect the vacuum pump from the reservoir.
34. Install the filler cap.
35. Replace the hydraulic filters.
36. Check the level of oil in the reservoir and add oil as required.

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Cleaning the Hydrostatic system
The hydrostatic system is a closed loop. Any contamination in the hydrostatic system
will stay in the closed loop. If the piston pump or a motor in the hydrostatic system is
removed for repair or replacement, you must clean the hydrostatic system. If any
contamination is left in the closed loop, the contamination will cause repeat damage
and failure of the components of the hydrostatic system.
If obvious contamination is present in the hydrostatic system:
1. Remove the piston pumps and at least the motor in the circuit that that failed. If
there is a large quantity of contamination present, removal of the opposite motor is
also required.
2. Disassemble, clean, inspect, and repair the piston pumps and motor(s).
3. Clean all hoses and tubes in the hydrostatic system. Remove each hose and tube
from the machine. Flush and clean them with cleaning solvent or hot soapy water.
Hoses and tubes must be dry before installing.
4. Install inspected, repaired or new piston pumps and motors.
5. Change the hydraulic filter.
6. Make sure that the hydraulic system is clean so that the charge pump will not
cause new contamination to enter the closed loop. Remember that the oil cooler may
have internal passages that can trap and hold contamination that can be dislodged
later and cause a repeat failure.

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