60XT 70XT Skid Steer Service Manual

SECTION INDEX
GENERAL
Section Title Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
Loctite Product Chart
Copyright © 2001 Case Corporation

All rights reserved.
CASE CORPORATION
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-45740 Issued November, 2001
1001
Section
1001
FLUIDS AND LUBRICANTS
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright © 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-44860 September, 2001
1001-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bur 6-44860 Issued 9-01 Printed in U.S.A.

1001-3
CAPACITIES AND LUBRICANTS

FUEL TANK
Capacity ..................................................................................................................... 83.3 litres (22 U.S. gallons)
Specifications .......................................................................................... See diesel fuel specifications on page 5
COOLING SYSTEM
Capacity .............................................................................................................................16.6 litres (17.5 quarts)
Recovery bottle capacity .......................................................................................................... 2 litres (2.1 quarts)
Specifications ................................................................................................ 50% water and 50% ethylene glycol
HYDRAULIC SYSTEM
Capacity - System ........................................................................................................... 50.2 litres (13.3 gallons)
Specifications ................................................................................................ Case No. 1 Engine Oil SAE 10W30
........................................................................................................ add 1.4 litres (1.5 quarts) HTA Wear Additive
CHAIN COMPARTMENTS
Capacity - Each Side ............................................................................................................ 5.7 litres (6.0 quarts)
Specifications ............................................................................................... Case No. 1 Engine Oil, SAE 10W30
BATTERY
Quantity .............................................................................................................................................. As required
Specifications ................................................................................................................................. Distilled water
GREASE FITTINGS
Quantity .............................................................................................................................................. As required
Attachments (If equipped) ..................................................................................................... Quantity as required
Specifications .............................................................................................................. Case molydisulfide grease
ENGINE CRANKCASE OIL
Capacity - with filter change .............................................................................................. 10.4 litres (11.0 quarts)
Capacity - without filter change ........................................................................................... 9.5 litres (10.0 quarts)
Specifications ................................................................. Case No. 1 Engine Oil SAE 15W-40 (API service CH-4)
.................................................................................... (See Oil Viscosity/Temperature Ranges Chart on page 4)
ENVIRONMENT
Before you service this machine and dispose of oil, fluids and lubricants, always remember the environment. Do
not put oil or fluids into the ground or into containers that can leak. Check with your local environmental, recycling
center or your Case dealer for correct disposal information.

1001-4
ENGINE LUBRICATION
Engine Oil Selection

Case No. 1 Engine Oil is recommended for use in
your Case Engine. Case Engine Oil will lubricate your
engine correctly under all operating conditions.
.
Case Multi-Viscosity Engine Oil

meets API engine oil service
category CH-4 RH99K130
See the chart below for recommended viscosity at

ambient temperature ranges.
NOTE: Do not put Performance Additives or other oil
additive products in the engine crankcase. The oil
change intervals given in the operating manual are
according to tests with Case lubricants. BS00H001
Oil Viscosity/Temperature Ranges
BS99N019

1001-5
DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
power and high fuel consumption. If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following:
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel as cool as possible. Remove water from the storage
requirements in your area. If the temperature of the container at regular periods of time.
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel Fill the fuel tank at the end of the daily operating
filter and cause the engine to loose power or not period to prevent condensation in the fuel tank.
start.
The diesel fuel used in this machine must meet the
specifications below, “Specifications for Acceptable
No. 2 Diesel Fuel” or Specification D975-81 of the
American Society for Testing and Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API Gravity, Minimum ............................................................................................................................................ 34
Flash Point, Minimum ............................................................................................................................60°C (140°F)
Cloud Point (wax appearance point), Maximum .................................................................................... -20°C (-5°F)
Pour Point, Maximum ............................................................................................................................ -26°C (-15°F)
Distillation Temperature, 90% Point ...............................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ............................................................................................................................................. 2.0 to 4.3
Saybolt Seconds Universal ....................................................................................................................... 32 to 40
Cetane Number, Minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and Sediment, by Volume, Maximum ............................................................................................... 0.5 of 1%
Sulphur, by Weight, Maximum .....................................................................................................................0.5 of 1%
Copper Strip Corrosion, Maximum ................................................................................................................... No. 2
Ash, by Weight, Maximum .......................................................................................................................... 0.1 of 1%

1001-6
NOTES

Loctite Product Chart
8-98902
SECTION INDEX
ENGINE

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
For Engine Repair, see the Engine Service Manual

CASE CORPORATION Printed in U.S.A.
700 State Street
2000
Section
2000
ENGINE AND RADIATOR REMOVAL AND

INSTALLATION
CASE CORPORATION Copyright © 2001 Case Corporation

Racine, WI 53404 U.S.A. Bur 6-45950 November, 2001
2000-2
TABLE OF CONTENTS
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2000-3
RADIATOR
Removal STEP 7
NOTE: Put caps on all fittings and plugs in all
disconnected hoses.
STEP 1
Park the machine on a level surface. Remove the
bucket or attachment from the loader arms. Raise the
loader arms and lock the loader arms into the raised
position.
STEP 2
Turn the ignition switch and the master disconnect
switch (if equipped) to the OFF position.
STEP 3
Disconnect the negative battery cable from the
battery.
STEP 4
Tilt the cab forward.
STEP 5 BS01F166
O p e n t h e h o o d a n d re a r a cc e s s d o o r o n th e If equipped with a heater, open the heater coolant

machine. valves on the engine.
STEP 6 STEP 8
2 21
8
BD01C113 BD01C133
Let unite cool then slowly loosen the radiator cap (2). Install a hose on the drain valve (8) and drain the
Disconnect the overflow hose (21) from the radiator ra d ia to r ( 1 ) int o a cle a n co n ta in er t ha t h old s
neck. approximately 17 litres (4.5 gallons).
NOTE: Refer to illustration on page 5. NOTE: Refer to illustration on page 5.
STEP 9
If equipped with a heater, close the heater coolant
valves on the engine.

2000-4
STEP 10 STEP 13
Loosen the clamps (4) on the lower radiator hose (5)
and clamps (3) on the upper radiator hose (6).
NOTE: Refer to illustration on page 5.
STEP 11
Remove the three bolts (25), washers (26), and nuts
(29) that fasten the fan guard (24) to the radiator (1).
Remove the fan guard.
NOTE: During assembly torque the bolts (25) 15 to
20 Nm (120 to 180 pound-inches).
BD01J077
STEP 12 Loosen and remove the bolts (15), washers (16, 17,
and 19), mounts (18), and nuts (20) that fasten the
right side and left side of the radiator (1) to the frame.
NOTE: During assembly torque the bolts (15) 30 to
36 Nm (265 to 319 pound-inches).
STEP 14
Move the radiator (1) away from the upper radiator
hose (6) and lower radiator hose (5). Remove the
radiator (1) from the machine.
STEP 15
Remove the over flow bottle (23) and bracket (22).
BD01M004
Loosen and remove the bolts (9), washers (10, 11, Installation
and 13), mounts (12), and nuts (14) that fasten the
bottom of the radiator (1) to the frame.
STEP 16
NOTE: During assembly torque the bolt (9) 30 to 36 Installation of the radiator is the revers of removal.
Nm (265 to 319 pound-inches).

2000-5
15 6
16
17
3
18 3
2 15
16
17
19
20 22
18 23
19
21 20
9
8
10
11
1
5 13
4
4 12
14
BC01K149
1. RADIATOR 7. HOSE HEAT GUARD 13. WASHER 19. WASHER
2. RADIATOR CAP 8. DRAIN VALVE 14. NUT 20. NUT
3. HOSE CLAMP 9. BOLT 15. BOLT 21. OVER FLOW HOSE
4. HOSE CLAMP 10. WASHER 16. WASHER 22. BRACKET
5. LOWER RADIATOR HOSE 11. WASHER 17. WASHER 23. OVER FLOW BOTTLE
6. UPPER RADIATOR HOSE 12. MOUNT 18. MOUNT
RADIATOR

2000-6
ENGINE
Removal STEP 5
STEP 1
Remove the radiator from the machine.
STEP 2
Install plugs and caps on all disconnected hoses and
fittings.
STEP 3
Tag all electrical connection for identification during
assembly.
STEP 4 BD01C112
Disconnect the electrical connectors from the rear tail

lamps on both sides and the rear work light on the
rear access door. Put the electrical harness out of
the way.
STEP 6
BD01C112
Tag and disconnect the hoses from the oil cooler on

the rear access door.
BS01F166
If equipped with a heater, disconnect the heater STEP 7

hoses. Connect acceptable lifting equipment to the rear
access door.

2000-7
STEP 8 STEP 11
BD01C112 BD01K022
Loosen and remove the nut, spacer, bolt, and washer Remove the bolt, washer, and nut from the hood
from the door. catch cable.
STEP 9 STEP 12
Remove the door from the machine. Push the hood to the right hand side of the machine
and remove the left hand side of the hood from the
STEP 10 pivot pin. Remove the hood from the machine.
STEP 13
BD01K023
1. CYLINDER PIVOT BOLT
Remove the nut from cylinder pivot bolt (1) on the BD01M007
1. AIR RESTRICTION INDICATOR SWITCH
hood end of the cylinder.
2. STARTING AID
Disco nnect the electrica l connector for the air

restriction indicator switch (1) and starting aid switch
(2).

2000-8
STEP 14 STEP 19
BD01M007 BD01M006
Loosen the clamps (49) on the intake manifold hose Loosen the exhaust clamp (76) and remove the
(50). Remove the hose from the intake and air filter muffler (61) from the exhaust outlet elbow (75).
assembly (48).
NOTE: Torque clamps (49) 3 to 4 Nm (25 to 35 STEP 20
pound-inches) during assembly. Remove the bolts (27), washers (28), fan blade (30),
and spacer (31) from the engine (38).
STEP 15
Loosen and remove the bolts (55), and washers (56) STEP 21
from the air filter clamp bracket (51).
STEP 16
Remove the air filter (48) assembly, air filter clamp
(52), and bracket (51) from the machine.
STEP 17
Remove the elbow (59) by loosing the clamp (58) on
the engine intake side.
NOTE: Refer to illustration on page 14. 1
2
STEP 18 BD01M015
1. STARTER WIRES
2. GROUND STRAP
Disconnect the wires (1) from the starter solenoid.
STEP 22
Loosen and remove the starter mounting bolt and
washer that holds the ground strap (2). Remove the
ground strap from the bolt. Install the washer and
starter mounting bolt.
STEP 23
Remove the bolt and wire harness clamp from the LH
BD01M015 side of the engine.
Loosen and remove the bolts (63), lock washer (64),
and washer (65) from the bracket (62).

2000-9
STEP 24 STEP 30
Find the ground wires on the left hand side of the Move the wiring harness out of the way.
engine. Loosen and remove the bolts that fastens the
ground wires to the engine. Keep all ground wires STEP 31
together. Close the fuel feed line valve.
STEP 25 STEP 32
BD01K021
BD01C188
Disconnect the wires from the alternator.
STEP 26 4
Loosen and remove the nut (33) that fastens the
throttle linkage (32) to the fuel injection pump and
throttle handle (34).
2
STEP 27
Disconnect the wire for the engine temperature
switch. Cut the tie strap holding it to the engine and
move out of the way.
BD01M010
STEP 28 1. FUEL 2. FUEL RETURN 3. CLAMP 4. CLAMP

FEED LINE LINE
Loosen the hose clamp (3) and disconnect the fuel
line (1) from the fitting. Disconnect the fuel return line
(2) from the engine by loosening the clamp (4) and
removing the hose from the fitting.
STEP 33
Tag and disconnect all electrical connectors for the
control valve. Cut the tie straps holding the wire
harness to the engine and move the harness out of
the way.
BD01M010
Disconnect the wire connector for the fuel injection

pump solenoid.
STEP 29
Loosen and remove the bolts that fasten the wire
harness to the right side of the machine.

2000-10
STEP 34 STEP 37
1 1
2
BD01M003 BD01K021
1. BOLT
Remove the tube from the hydraulic oil filter.
2. PUMP
Loosen and remove the bolts (1) that fasten the gear STEP 38
pump (2) to the engine. Move the gear pump out of
the way.
NOTE: During assembly apply anti-seize to the
splined shaft.
STEP 35
1
BD01M005
Remove the hose from the hydraulic oil filter.
STEP 39
Remove the hydraulic oil filter. Remove the bolts and
hydraulic oil filter bracket from the machine.
BD01M004
1. HIGH FLOW CONTROL VALVE
STEP 40
L o o s e n a n d r e m o v e t h e b o lt s , w a s h e r s a n d
self-locking nuts. Move the high flow control valve (1)
toward the rear of the machine and out of the way.
STEP 36
Disconnect the hoses from the high flow pump.
BD01M017
Disconnect the hydraulic lines shown from the left

side of the tandem pump.

2000-11
STEP 41 STEP 45
Connect equipment to the tandem pump that will hold Connect acceptable lifting equipment to the engine
the tandem pump in position when the engine is lifting eyes (47).
removed.
STEP 46
STEP 42
BD01M015
BD01M015 Remove the bolts (39), washers (40 and 42), spacer
Loosen and remove the bolt (36) and washer (37) (41), and nut (43) from the engine mounts.
that fastens the wiring harness clamp and tube clamp
NOTE: Torque the bolts 183 to 224 Nm (135 to 165
to the tandem pump mounting plate (35). Move the
pound-feet) during assembly.
wiring harness and tube out of the way.
NOTE: Refer to illustration on page 12. STEP 47
Remove the bolt (44), washer (45), and spacer (46)
STEP 43 from the engine front mount.
NOTE: Torque the bolts 183 to 224 Nm (135 to 165
pound-feet) during assembly.
1
STEP 48
Mo ve the engine away from the tandem pump
mounting plate until the splined shaft on the tandem
pump disengages the coupling.
STEP 49
Remove the engine (38) from the machine.
1
BD01M001
Installation
1. CONTROL ROD
Disconnect the control rods (1) from the tandem STEP 50

pump by removing the nut from the rod end. Installation of the engine is the reverse of removal.
STEP 44
Remove the bolts and washers that fasten the
tandem pump to the mounting plate (35) on the
engine (38).
NOTE: During assembly torque the bolts 39 to 47

2000-12
21 2
23 22
1
15
29 16
26 24
3 17
25
6 30 18
19
28 27 20
9
31
10
7 11
47 8
3 12
13
14
46
32
45
34 33
44
4
39 38 4 5
40
41
42
43
35
36 37
BS01M039
1. RADIATOR 11. WASHER 21. OVER FLOW HOSE 31. SPACER 41. MOUNT
2. RADIATOR CAP 12. MOUNT 22. BRACKET 32. THROTTLE ROD 42. WASHER
3. HOSE CLAMP 13. WASHER 23. OVER FLOW BOTTLE 33. NUT 43. NUT
4. HOSE CLAMP 14. NUT 24. FAN GUARD 34. THROTTLE HANDLE 44. BOLT
5. LOWER RADIATOR HOSE 15. BOLT 25. BOLT 35. PUMP MOUNT PLATE 45. WASHER
6. UPPER RADIATOR HOSE 16. WASHER 26. WASHER 36. BOLT 46. MOUNT
7. HOSE HEAT GUARD 17. WASHER 27. BOLT 37. WASHER 47. LIFTING EYE
8. DRAIN VALVE 18. MOUNT 28. WASHER 38. ENGINE
9. BOLT 19. WASHER 29. NUT 39. BOLT
10. WASHER 20. NUT 30. FAN 40. WASHER
ENGINE MOUNTING

2000-13
48
49
49 50
52
51
54
53
55
56
57
BS01M037
48. AIR FILTER HOUSING 51. BRACKET 54. WASHER 57. NUT
49. HOSE CLAMP 52. HOUSING CLAMP 55. BOLT
50. INTAKE HOSE 53. BOLT 56. WASHER
AIR FILTER ASSEMBLY

2000-14
80
58
58 60
59
68 62
66
67
63
64
61
65
78
79 76
75
80 77
74
69
73
70
72 71
BS01M038
58. CLAMP 64. LOCK WASHER 70. LOCK WASHER 76. CLAMP
59. ELBOW 65. WASHER 71. WASHER 77. CLAMP
60. COUPLING 66. BOLT 72. BRACKET 78. CLAMP
61. MUFFLER 67. WASHER 73. BOLT 79. EXHAUST PIPE
62. FRONT BRACKET 68. NUT 74. WASHER 80. PLUG
63. BOLT 69. BOLT 75. EXHAUST OUTLET ELBOW
MUFFLER ASSEMBLY

SECTION INDEX
FUEL SYSTEM

For Fuel System Repair, See the Engine Service Manual

CASE CORPORATION
SECTION INDEX
ELECTRICAL SYSTEM

Electrical System - “How it Works” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
Starter and Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4006
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4007

CASE CORPORATION
Section
4000
ELECTRICAL SYSTEM
“HOW IT WORKS”
4000
CASE CORPORATION
700 State Street
4000-2
TABLE OF CONTENTS
INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTERLOCK SYSTEM
The Low Range XT Skid Steers have an interlock system that requires the operator to be in the seat with the lap
bar in the operating position before the loader controls can be activated and the parking brake/travel solenoid (51)
releases.
This interlock consists of a power feed through a 15 ampere fuse (7) in the primary fuse block to the seat switch
(18) and the seat bar switch (19). This power feed also supplies power to terminal 30 of the engine shut down relay
(15) and power to illuminate the interlock power lamp on the RH instrument cluster (21).
When the seat switch (18) closes, the power is routed to the seat timer in the LH instrument cluster (20). The seat
timer supplies an ignition enable signal from the LH instrument cluster (20) to the RH instrument cluster (21). The
seat timer maintains power at the seat timer output for 2 seconds after the seat switch (18) opens to allow the
operator to momentarily rise from the seat while still maintaining control function. As long as the ignition enable
signal is present, the RH instrument cluster (21) sends out an engine relay excite signal to the control coil, terminal
86, of the engine shut down relay (15). This power feed to the control coil causes the engine shut down relay (15) to
interconnect terminal 30 and terminal 87, supplying power to terminal 30 of the loader valve solenoid relay (16).
The engine shut down relay (15) also provides power to the fuel hold in solenoid (9) or (14) to energize it, allowing
fuel to flow to the engine.
With the seat switch (18) open and the seat bar in the up position, power flows through the seat bar switch (19) to
provide the ignition enable signal to the RH instrument cluster (21). This allows the engine to run when the operator
is not present in the seat. In this configuration, power does not flow to the loader valve solenoids (17), therefore the
loader controls are locked out.
With the seat bar in the down position, power flows through the seat bar switch (19) to the RH instrument cluster
(21) to illuminate the seat bar indicator lamp and also to the control coil, terminal 86, of the loader valve solenoid
relay (16). This power feed to the control coil causes the loader valve solenoid relay (16) to interconnect terminal 30
and terminal 87. As described above, terminal 30 of the loader valve solenoid relay (16) receives power from the
engine shut down relay (15) as long as the seat switch (18) is closed.
The loader valve solenoid relay (16) sends power to the energize the loader valve solenoids (17). When energized,
these solenoids (in the loader control valve) release the plungers that secure the spools in neutral. If the optional
front door is installed, the door must be closed for the power to go through the cab door switch (44) to the loader
valve solenoids (17). If the cab door is not installed, the power flows through a diode (44A) in the harness. The
diode (44A) acts only as a jumper across the terminals.
The loader valve solenoid relay (16) also sends power to the brake release/travel solenoid (51). The brake release/
travel solenoid (51) allows the servo control pistons in the ground drive tandem pump to function and also controls
the release of the spring applied, hydraulically released parking brake (if equipped). Depending on the brake option
installed, the power may go through a push-button brake switch (52) in the left hand control.
There is a brake indicator lamp in the left hand instrument cluster (21). This lamp is illuminated whenever the seat
bar is in the up position with the ignition switch (5) in the ACC or RUN position. If the optional electrohydraulic
brakes are installed, power flows through a pressure switch in the hydraulic brake circuit to illuminate the brake
lamp.

4000-3
SAFETY INTERLOCK SYSTEM
311B
Components
200E
15 16 1. Battery
85 86 85 86 A CLEAN GROUND
300A 87a 87a
30 30 300H
313E
B
C
INTERLOCK POWER LAMP
SEAT BAR DOWN LAMP
5. Ignition Switch
311E
311J
87 87
7 8 602B D ENGINE RELAY EXCITE
7 15A 612A E IGNITION ENABLE SIGNAL 7. Primary Fuse Block
F
603B 303C G SEAT OCCUPIED LAMP
300B 311B 18 H 9. Fuel Hold In Solenoid
200H
UNOCCUPIED
178F
(Normally Aspirated Engines)
612A
OCCUPIED
SPL 1 303D 303E 21
130A 52
303C
15A 602A 313A
300D 314B
14. Fuel Hold In Solenoid
300H
313E
311A
SPL 8
536B (Turbo Engines)
530B
130B
258C A BRAKE LAMP

200G
300E 300F
303A 303B
B
C SEAT TIMER INPUT
15. Engine Shut Down Relay
D 536C
603A
603E
178E
SPL 2
313D
16. Loader Valve Solenoid Relay
536A
SPL 4 E
300G
303E F SEAT TIMER OUTPUT
5
314A
SPL 3
602B
UP
DOWN SPL 10
20
17. Loader Valve Solenoids
314C 314D
ACC IGN ST 19 18. Seat Switch
313B
BATT SPL 14
POS
311F 311G 19. Seat Bar Switch
603D
OPEN
CLOSED
51 20. LH Instrument Cluster
311H
44 17
(6-Pin Connector)
21. RH Instrument Cluster
178BD
311A 311C 313F
178K
NEG
1 9 14 311F 311D 313H (8-Pin Connector)

44A 44. Cab Door Switch (Optional)
44A.Diode (w/o Cab Door)
51. Brake Release/Travel l Solenoid
52. Brake Switch (Optional)
INTERLOCKS
Circuits Circuits Circuits

NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
NEG 50 Black Chassis Ground Battery (-) 300H 0.8 Red Splice 2 RH Instrument Cluster (8-Pin, B) 313E 0.8 Tan Splice 3 RH Instrument Cluster (8-Pin, C)
POS 50 Red Battery (+) Starter Solenoid (+) 303A 0.8 Tan Seat Switch Splice 4 313F 1.0 Tan Front Door Connector Cab Door Switch Connector
130A 2.0 Red 15 Ampere Circuit Breaker Cab Harness Connector (A1) 303B 0.8 Tan Splice 4 LH Instrument Cluster (6-Pin, C) 313H 1.0 Tan Cab Door Switch Connector Front Door Connector
130B 2.0 Red Cab Harness Connector (A1) Ignition Switch (Batt) 303C 0.8 Tan Splice 4 RH Instrument Cluster (8-Pin, G) 314A 0.8 Tan Diode Diode
178E 1.0 Black Engine Shut Down Relay (85) Ground 303D 0.8 Tan Diode Splice 8 314B 0.8 Tan Diode Splice 8
178F 1.0 Black Engine Shut Down Relay(85) Loader Valve Solenoid Relay (85) 303E 0.8 Tan LH Instrument Cluster (6-Pin, F) Diode 314C 0.8 tan Seat Bar Switch Diode
178K 1.0 Black Loader Valve Solenoid Ground 311A 1.0 Tan Loader Valve Solenoid Relay (87) Cab Harness Connector (H2) 314D 0.8 Tan Diode Splice 10 (Hydraulic Brakes)
178BC 3.0 Black Fuel Solenoids Ground 311B 1.0 Pink Loader Valve Solenoid Relay (87) Chassis Options Harness 530B 1.0 Red Brake Switch Connector Brake Switch
178BD 1.0 Black Loader Valve Solenoid Ground 311C 1.0 Tan Cab Harness Connector (H2) Front Door Connector 536A 1.0 Lt. Blue Brake Switch Connector Brake Release Solenoid
200E 1.0 Black/White RH Instrument Cluster (8-Pin, A) Clean Ground 311D 1.0 Tan Front Door Connector Cab Harness Connector (C1) 536B 1.0 Lt. Blue Brake Switch Brake Switch Connector
200G 2.0 Red Ignition Switch (Ign) Cab Harness Connector (B1) 311E 1.0 Pink Chassis Options Harness Brake Switch Connector 536C 1.0 Lt. Blue Brake Switch Brake Switch
200H 2.0 Red Cab Harness Connector (B1) Primary Fuse Block (15A) 311F 1.0 Tan Cab Harness Connector (C1) Splice 14 602A 1.0 White Cab Harness Connector (J2) Engine Shut Down Relay (86)
258C 0.8 Yellow Splice 10 LH Instrument Cluster (6-Pin, A) 311G 1.0 Tan Splice 14 Loader Valve Solenoid 602B 0.8 White RH Instrument Cluster (8-Pin, D) Cab Harness Connector (J2)
300A 2.0 Red Primary Fuse Block (15A) Splice 1 311H 1.0 Tan Splice 14 Loader Valve Solenoid 603A 1.0 White Engine Shut Down Relay (87) Fuel Supply System Connector
300B 2.0 Red Splice 1 Engine Shut Down Relay (30) 311J 1.0 Pink Chassis Options Harness Brake Release Solenoid 603B 1.0 White Engine Shut Down Relay (87) Engine Shut Down Relay (30)
300D 1.0 Red Splice 1 Cab Harness Connector (D2) 313A 1.0 Tan Cab Harness Connector (C2) Loader Valve Solenoid Relay (86) 603D 1.0 White Fuel Supply System Connector Fuel Hold In Solenoid
300E 1.0 Red Cab Harness Connector (D2) Splice 2 313B 0.8 Tan Seat Bar Switch Splice 3 603E 1.0 White Engine Shut Down Relay (87) Fuel Hold Solenoid
300F 0.8 Red Splice 2 Seat Switch 313D 0.8 Tan Cab Harness Connector (H2) Splice 3 612A 0.8 White Splice 8 RH Instrument Cluster (8-Pin, E)
300G 0.8 Red Splice 2 Seat Bar Switch

4000-4
NOTES

4001
Section
4001
ELECTRICAL SYSTEM
SPECIFICATIONS AND TROUBLESHOOTING
CASE CORPORATION
700 State Street
4001-2
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit Diagram Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LEFT HAND INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard RIGHT HAND INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Optional Engine Shutdown System
Right Hand INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Left Hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Right Hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HOW TO TEST A WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing for Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Finding An Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing for Short Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Finding a Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Testing for a High Resistance Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Finding a High Resistance Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4001-3
GENERAL INFORMATION
Circuit Diagram Legends
Wire Identification:
Earth connection terminal
R (131) 1.0
Intersection of two wires with connecting points Wire Size
Wire Number
Intersection of two wires without connecting points Wire Color
Indicates Internally
Grounded Components Harness Connector:
Male
Indicates External Ground Female Terminal
Terminal
Diode Harness Connector With Pin Number:

B3 Male
5 Indicates test point Terminal
Female
Terminal Connector Pin Number
9 Indicates frame continued on
6 Indicates component number Harness Connector With Pin Number

And Connector Number:
Bulb or lamp
C4 Male
Terminal
Color Abbreviations Female A
Terminal Connector Pin
Number
B---Black LG--Light Green T---Tan
Harness Connector Reference Letter
BR-Brown O---Orange V---Violet
G---Gray P---Pink W---White
LB-Light Blue R---Red Y---Yellow
WIRE SIZE IN MM WIRE SIZE IN STANDARD
0.8 mm 2.0 mm 18 - Gauge 14 - Gauge
1.0 mm 5.0 mm 16 - Gauge 10 - Gauge
Fuses
PRIMARY FUSE BLOCK OPTIONS FUSE BLOCK
1 5
1. Lights 5. Accessories/Brake Light
2 20 AMPERE 2. Wiper/Heater 6 10 AMPERE 6. Miscellaneous Power
30 AMPERE 3. Backup Alarm/Horn 10 AMPERE 7. Beacon/Front Electrics

3 7
10 AMPERE 10 AMPERE
4. Interlock System 8. Hydraulic Coupler/Self Level
4 15 AMPERE 8 10 AMPERE

4001-4
LEFT HAND INSTRUMENT PANEL
1 2 3 4
10
13
11
6 A F
B E
8 12 9 C D
17 14
15
A K
18 B J
16 C H
D G
19 F
20 E
25
21
26
27
28 22
29 23
24
1. FUEL LEVEL GAUGE 8. AIR FILTER RESTRICTED 15. OPEN 23. OPEN
2. LOW ENGINE OIL INDICATOR 16. OPEN 24. 12VDC INPUT
PRESSURE INDICATOR AND 9. HYDRAULIC FILTER 17. BRAKE ON SIGNAL 25. FUEL LEVEL SIGNAL
ALARM RESTRICTED INDICATOR 18. OPEN 26. OPEN
3. ENGINE COOLANT 10. SEAT BELT REMINDER 19. SEAT SWITCH TIMER 27. AIR FILTER RESTRICTION
OVER-TEMP INDICATOR 11. OPERATORS MANUAL OUTPUT SIGNAL
4. HYDRAULIC OIL OVER-TEMP REMINDER 20. LOW ENGINE OIL 28. HYDRAULIC FILTER
INDICATOR 12. HOURMETER PRESSURE SIGNAL RESTRICTION SIGNAL
5. LOW VOLTAGE INDICATOR 13. SYSTEMS NORMAL 21. ENGINE COOLANT 29. CLEAN GROUND
6. PARKING BRAKE ON INDICATOR OVER-TEMP SIGNAL
INDICATOR 14. SEAT SWITCH TIMER 22. HYDRAULIC OIL OVER-TEMP
7. NOT USED OUTPUT SIGNAL

4001-5
STANDARD RIGHT HAND INSTRUMENT PANEL
3 4
2 6
5 7
9
8
1 STOP
10
12
11
15 16 21 23
14 22
13
F E D
A B C
26
17
18 24 25
19
20 H G F E
A B C D
1. KEY SWITCH 10. LAMP SWITCH (ROAD POSITION) 19. SEAT BAR DOWN SIGNAL
2. ACCESSORY POSITION 11. LAMP SWITCH (WORK POSITION) 20. ENGINE SHUT DOWN RELAY EXCITE
3. STOP POSITION 12. THERMOSTART SWITCH(IF EQUIPPED) 21. NOT USED
4. RUN POSITION 13. OPEN 22. NOT USED
5. START POSITION 14. SEAT OCCUPIED SIGNAL 23. NOT USED
6. NOT USED 15. OPEN 24. NOT USED
7. INTERLOCK SYSTEM POWER INDICATOR 16. IGNITION ENABLE SIGNAL 25. NOT USED
8. SEAT SWITCH INDICATOR 17. CLEAN GROUND 26. NOT USED
9. SEAT BAR INDICATOR 18. INTERLOCK SYSTEM POWER SIGNAL

4001-6
OPTIONAL ENGINE SHUTDOWN SYSTEM

RIGHT HAND INSTRUMENT PANEL
3
4 6 7 8 9
2
5
27
1 28
29
30
10 31
32
12
11 33 34
15 16 21 23
14 22
13
F E D
A B C
26
17
18 24 25
19
20 H G F E
A B C D
1. KEY SWITCH 13. OPEN 25. ENGINE OIL PRESSURE SENSOR SIGNAL
2. ACCESSORY POSITION 14. SEAT OCCUPIED SIGNAL 26. ENGINE OIL PRESSURE SENSOR POWER
3. STOP POSITION 15. OPEN 27. TACHOMETER DISPLAYED INDICATOR
4. RUN POSITION 16. IGNITION ENABLE SIGNAL 28. ENG. OIL PRESSURE DISPLAYED INDICATOR
5. START POSITION 17. CLEAN GROUND 29. ENG. COOLANT TEMP DISPLAYED INDICATOR
6. NOT USED 18. INTERLOCK SYSTEM POWER SIGNAL30. HYD. OIL TEMP DISPLAYED INDICATOR
7. INTERLOCK SYSTEM POWER INDICATOR19. SEAT BAR DOWN SIGNAL 31. SERVICE INTERVAL DISPLAYED INDICATOR
8. SEAT SWITCH INDICATOR 20. ENGINE SHUT DOWN RELAY EXCITE 32. COMBINATION LCD DISPLAY
9. SEAT BAR INDICATOR 21. ENGINE OIL PRESSURE SIGNAL 33. DISPLAY SELECTION SWITCH
10. LAMP SWITCH (ROAD POSITION) 22. HYDRAULIC OIL TEMP SIGNAL 34. MODE/UNITS SWITCH
11. LAMP SWITCH (WORK POSITION) 23. ENGINE COOLANT TEMP SIGNAL
12. THERMOSTART SWITCH(IF EQUIPPED) 24. TACHOMETER SIGNAL

4001-7
CONTROL LEVERS
Left Hand Control Lever Right Hand Control Lever
2 3
2
1
3
4 1
4 4 5 5
3
4
HD01E016 BD01C234
1. BRAKE SWITCH (PUSH BUTTON, ALTERNATE ACTION) 1. HORN BUTTON (PUSH BUTTON, MOMENTARY ACTION)
2. HIGH FLOW SWITCH (REVERSE/NEUTRAL/FORWARD) 2. RIDE CONTROL BUTTON (PUSH BUTTON, MOMENTARY
3. LEFT SIDE STEERING (FORWARD/REVERSE) ACTION)
4. LOADER CONTROL (RAISE/LOWER/FLOAT) 3. FRONT ELECTRICS CONTROL SWITCH (TOGGLE)
5. BRAKE CIRCUIT CONNECTOR 4. RIGHT SIDE STEERING (FORWARD/REVERSE)
6. HIGH FLOW CIRCUIT CONNECTOR 5. BUCKET CONTROL (ROLLBACK/DUMP)
6. HORN CIRCUIT CONNECTOR
7. RIDE CONTROL CIRCUIT CONNECTOR
8. FRONT ELECTRICS CIRCUIT CONNECTOR
5 6
6 8
HI01E007
HI01E008

4001-8
HOW TO TEST A WIRING HARNESS
Visual Inspection Finding An Open Circuit

Carefully inspect the complete wiring harness for Using a Digital Multimeter set to the Ohms (Ω) scale,
damage. Check for loose or broken wires. Make sure connect one probe to each end of the broken wire.
the connector terminals are fully seated and locked in Move along the length of the harness, flexing the
the connector. Insure that the terminals are clean harness by hand, while watching the Multimeter. Any
and not damaged. Use Lectra Clean, part number change on the ohmmeter indicates the damaged
B17400, as recommended. Silicone Compound area has been located. If the damage cannot be
Dielectric Grease, part number 345-92, can be used located, find the approximate middle of the harness
for lubricant and corrosion protection. length. Carefully cut the outer jacket of the harness to
reach the wire to be tested. Insert a needle or pin
Testing for Open Circuits through the wire insulation and connect the meter to
the needle or pin. If the cable is strapped down, it will
An OPEN circuit is defined as a place in a circuit that be necessary to add a length of wire to one probe of
is separated and does not permit a path for electrical the meter to lengthen the meter leads.
current to flow. This could be a disconnected
connector or a broken wire. Because the circuit is Test for continuity between the middle and the end of
open, the circuit resistance, when measured with a the wire. If there is continuity, move to another test
Digital Multimeter, will indicate infinite resistance (OL point farther down the wire and test again.
or Open Lead). When no continuity is obtained, the break in the
Test for an OPEN circuit by folding the harness in half circuit will be between the last points tested which will
so that the two connectors are side by side. Test for permit the exact location to be determined.
continuity through each wire using a Digital
Multimeter. Use wire colors or connector pin
identification numbers to identify the wires at each
end of the harness. If the harness is not easily folded
in half because of being strapped down, connect two
pins together at one connector with a jumper wire.
A A
B B
C
C
D D
E E
F F
G G
H H
I I
J J
K K
L L
BS99F034
OPENS

4001-9
Testing for Short Circuits By progressively moving through the pin count, no
c o m b i n a t i o n o f t wo c o n d u c t o r s a r e m i s s e d .
A SHORT circuit is defined as an unintended, low Continuity should NOT be found between any wires
resistance current path. This means that the current or ground unless shown on the wiring schematic.
is taking a shorter path than it was intended in the
original circuit. This could be a result of two or more NOTE: If continuity is found, the wires are shorted.
wires rubbing together (copper to copper) or a wire
rubbing the system ground (copper to iron). This Finding a Short Circuit
results in the shorted circuit having resistance much
Connect the Ohm meter probes to the wires in the
smaller than specifications as shown on the next
harness that are shorted to each other. Move along
page.
the harness flexing the harness by hand while
Disconnect the harness at both ends. Using a Digital watching the Digital Multimeter. Any changes in the
Multimeter set to the Ohms scale, test for continuity meter indicates that the damaged area has been
between the wires. To accomplish this, at one of the located. Carefully cut the outer jacket of the harness
harness connectors, test for continuity between pins to repair the shorted wires.
as follows:
1-grd 2-grd 3-grd 4-grd
1-2 2-3 3-4 4-5
1-3 2-4 3-5 4-6
1-4 2-5 3-6 4-7
1-5 2-6 3-7 4-8
etc. etc. etc. etc.
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
BS99F035
SHORTS

4001-10
Testing for a High Resistance Finding a High Resistance Circuit

Circuit A Digital Multimeter is used (set to the volts scale) to
A HIGH RESISTANCE circuit is defined as an test for a high resistance circuit. The Digital
unintended resistance to current flow. This means Multimeter is placed in the circuit so that it becomes
that the circuit must overcome more resistance than a parallel path for the circuit. The completed circuit
normally found in the circuit. This could be caused by voltage (as shown on the Multimeter) is then checked
corroded connectors or wires, or a wire in the circuit between segments of the circuit. The problem area
that is nearly pinched in half. This may cause the has been located when the voltage changes
circuit to work erratically or not at all. If the circuit is noticeably on a segment being checked. As an
tested while disconnected from the load, the circuit example, refer to the next page, the DVM indicated
may or may not indicate the proper resistance and/or circuit voltage for three of the segments of 0.1 volt
voltage level. A high resistance circuit can generally indicated low resistance. The fourth segment of the
only be tested when the circuit is under a load (i.e. circuit indicates .20 volts, indicating high resistance.
solenoid activated, control module resetting, etc.) To The original circuit is using the DVM to indicate the
properly test for a high resistance circuit, the Digital higher circuit resistance in the fourth segment.
Multimeter (set to the VOLT scale) has to be installed
into the completed circuit and OPERATED. If a high
resistance circuit is present, the voltage recorded
when operating the circuit will be lower than
specifications.

4001-11
FUEL PUMP ETHER

B+
CLEAN B+
B+ (ACC)
B+ (IGN)
CLEAN B+ (IGN)
CLEAN B+ (ACC)
B+ (EOP)
R-2.0-138
.12
TEST POINT 20A
(1)
W - 1.0 - 610 6
11 ETHER
SWITCH
12
W - 1.0 - 610
1
W - 1.0 - 610
TEST POINT TEST POINT

(2) (3)
W - 1.0 - 610
7 11
13
69 63 70 64
D ETHER
W - 1.0 - 641
39 SOLENOID
10
(1 OHM)
1 TEST POINT
(4)
A
43
B
43
W - 1.0 - 610
FUEL
M TANK
W - 1.0 - 116
18
1 C 36
B - 1.0
CLEAN GROUND
CLEAN GROUND
CHASSIS GROUND
BS99F037

4001-12
TROUBLESHOOTING EXAMPLE
What electrical test

should indicate.
Number and component Indicates number and One or more possible
Location to connect component on electrical schematic (white bubble reasons for and indication
leads of electrical with black number). which is not correct.
tester.
1 STARTER RELAY
Check Points Reading Possible Cause of Bad Readings
10 Terminal for wire 178A1 to ground Continuity Bad ground circuit.
11 Terminal for wire 170 to ground 12 volts Check the circuit between the starter relay and the 40 ampere circuit
breaker in the buss bar (4). Also check the 40 ampere circuit breaker
and the bus bar (3).
NOTE: Make sure all electrical switches except the key switch are in the OFF position. Have another person hold the
key switch in the start position.
12 Terminal for wire 622 to ground 12 volts Check the circuit between the starter relay and the key switch (11).
Also check the key switch (11).
13 Terminal for wire 625 to ground 12 volts Bad starter relay.
NOTE: If the readings are good, replace the starter relay.
This number indicates the number of the

component on the electrical schematic (white
This statement assumes that all mechanical, bubble with black number).
hydraulic, and other electrical problems have been
solved at this point.

4001-13
TROUBLESHOOTING
1 Battery
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a
multimeter for the following tests.
2 Starter Motor and Solenoid

1 Battery terminal of starter to ground 12 volts Check the battery cable to the positive post of the battery.
NOTE: Have another person hold the ignition switch in the START position.
2 Terminal for wire 625A to ground 12 volts Check the circuit between the starter and starting relay. Also check the
starting relay (4).
NOTE: If the readings are good, the starter motor and solenoid should be bench tested.
3 Alternator
3 Terminal for wire 120A to ground 12 volts Check wire 120A between the alternator and the starter battery terminal.
Also check the starter (2).
NOTE: Put the ignition switch in the RUN position.
4 Terminal for wire 121A to ground Approximately Check the circuit from the alternator through the 25 ohm resistor to the fuse
1.1 volts block (7). Also check the 25 ohm resistor and the fuse block (7).
NOTE: Start the engine.
5 Terminal for wire 124A to ground Voltage varies Bad alternator.

with engine RPM
4 Starting Relay
6 Terminal for wire 178A to ground Continuity Bad ground circuit.
7 Terminal for wire 170A to ground 12 volts Check the circuit between the starter relay and the 40 ampere circuit
breaker. Also check the 40 ampere circuit breaker and the buss bar.
NOTE: Make sure all electrical switches except the ignition switch are in the OFF position. Have another person hold the ignition switch in
the START position.
8 Terminal for wire 622A to ground 12 volts Check the circuit between the starter relay and the ignition switch (5). Also
check the ignition switch (5).
9 Terminal for wire 625A to ground 12 volts Bad starter relay.

4001-14
5 Ignition Switch
10 Terminal for wire 130B to ground 12 volts Check the circuit between the ignition switch and the 15 amp circuit breaker.
Also check the 15 ampere circuit breaker.
NOTE: Disconnect the connector from the ignition switch. Put the ignition switch in the RUN position.
11 Check between the BAT terminal and Continuity Bad ignition switch.
the IGN terminal of the ignition switch
the ACC terminal of the ignition switch
the START terminal of the ignition switch
the IGN terminal of the ignition switch
6 Main Power Relay

15 Terminal for wire 178B to ground Continuity Bad ground circuit.
16 Terminal for wire 190A to ground 12 volts Check the circuit between the main power relay and the 40 ampere circuit
breaker in the buss bar. Also check the 40 ampere circuit breaker and the
buss bar.
17 Terminal for wire 131A to ground 12 volts Check the circuit between the main power relay and the ignition switch (5).
Also check the ignition switch (5).
18 Terminal for wire 137A to ground 12 volts Bad main power relay.

4001-15
7 Primary Fuse Block
19 Terminal for wire 137A to ground 12 volts Check the circuit between the fuse block and the main power relay (6). Also
check the main power relay (6).
20 Terminal for wires 121B and 780A to 12 volts Bad 20 ampere fuse or missing fuse.
ground
21 Terminal for wire 830A to ground 12 volts Bad 30 ampere fuse or missing fuse.
22 Terminal for wires 890A and 895A to 12 volts Bad 10 ampere fuse or missing fuse.
ground
23 Terminal for wire 200H to ground 12 Volts Check the circuit between the fuse block and the ignition switch (5). Also
8 Options Fuse Block

25 Terminal for wire 137C to ground 12 volts Check the circuit between the options fuse block and the primary fuse block
(7). Also check the primary fuse block (7).
26 Terminal for wires 818A and 818B to 12 volts Bad 10 ampere fuse or missing fuse.
ground
28 Terminal for wires 751B and 751F to 12 volts Bad 10 ampere fuse or missing fuse.
ground
29 Terminal for wires 540B and 540P to 12 volts Bad 10 ampere fuse or missing fuse.
ground

4001-16
6
4 5
8
7
3 1
HI01E015
CHASSIS HARNESS/CAB HARNESS PIN CIRCUIT PIN CIRCUIT

CONNECTOR A1 130A K2 830A
B1 200H B3 622A
K J H G F E DC B A C1 311F D3 PLUGGED
1
2 D1 PLUGGED G3 PLUGGED
3 E1 706D J3 239A
4 F1 234A A4 786B
G1 257A B4 124A
H1 641B C4 313A
J1 266A D4 PLUGGED
K1 200D E4 255A
A2 780A F4 235A
B2 131A G4 264A
D2 300D H4 311A
G2 261A J4 PLUGGED
J2 602A K4 178S

4001-17
STARTING SYSTEM POWER DISTRIBUTION
121B 121B
200H
5 3A 3A 4 4 6 8 7 7 4 9 9
622C
190B
780A
830A
890A
895A
300A
25 Ω 190A 190A
170A
20 21 22 24
178E
40A 6
124A
85 86
5 15A 30 87a 85 86
1 2 3 4 5 6 7 8
87 4 30 87a
7 20A 30A 10A 15A
121B 121A 87
3 7
120B
130A
4 8
D+ W
3 B+ 137B 23
311B
6 178B 178B 17
GND 137A 19
625A 9
200H
15 16 18 311J
120A
131A 131A
1 622A
2 137C
311E
622B 25
200G
10 200A 5
POS
11 130B 131B
13 8 10A 10A 10A 10A
12 132A 10 1 2 3 4 5 6 7 8
13 12
1 5 14
178A
818A
818B
860A
751B
540B
540P
751F
26 27 28 29
2
ACC IGN ST
NEG
BATT
11 9 16 11 15 12 12
11 14
1 2
HI01H003
Components Circuits Circuits

1. Battery 5. Ignition Switch NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
2. Starter Motor and Solenoid 6. Main Power Relay 131B 1.0 Red Ignition Switch (ACC) Cab Harness Connector (B2) 311E 1.0 Pink Chassis Options Harness Brake Switch Connector
3. Alternator 7. Primary Fuse Block 132A 1.0 Red Ignition Switch (IGN) Cold Start Switch 311J 1.0 Pink Chassis Options Harness Brake Release Solenoid
4. Starting Relay 8. Options Fuse Block 137A 5.0 Red Main Power Relay (87) Primary Fuse Block (Buss) 540B 1.0 Red Options Fuse Block (10A) Hydraulic Coupler Circuit
137B 5.0 Red Primary Fuse Block (Buss) Chassis Options Harness 540P 1.0 Red Options Fuse Block (10A) Self Level Circuit Connector
Circuits 137C 5.0 Red Chassis Options Harness Options Fuse Block (Buss) 622A 1.0 White Cab Harness Connector (B3) Starting Relay (86)
170A 5.0 Red 40 Ampere Circuit Breaker Starting Relay (30) 622B 1.0 White Ignition Switch (ST) Cab Harness Connector (B3)
NO. GA. COLOR FROM: TO: 178A 2.0 Black Starting Relay (85) Chassis Ground 622C 1.0 White Starting Relay (86) Fuel Sol. Pull in Relay (86)
0 50.0 Black Chassis Ground Battery (-) 178B 1.0 Black Starting Relay (85) Main Power Relay (85) 625A 5.0 White Starting Relay (87) Starter Solenoid (START)
0 50.0 Red Battery (+) Starter Solenoid (+) 178E 1.0 Black Main Power Relay (85) Engine Shut Down Relay (85) 751B 1.0 Red Options Fuse Block (10A) Rotating Beacon Circuit
120A 8.0 Red Starter Solenoid (+) Alternator (B+) 190A 5.0 Red 40 Ampere Circuit Breaker Main Power Relay (30) 751F 1.0 Red Options Fuse Block (10A) Front Elec. Connector
120B 8.0 Red Starter Solenoid (+) Buss Bar 190B 3.0 Red 40 Ampere Circuit Breaker Fuel Sol. Pull In Relay (30) 780A 3.0 Red Primary Fuse Block (20A) Cab Harness Connector (A2)
121A 1.0 Yellow Alternator Resistor Alternator Field Excite Terminal LH Instrument Cluster 10-Pin 818A 1.0 Red Options Fuse Block (10A) Elec. Accessory Socket Circuit
200A 0.8 Red Ignition Switch (IGN)
121B 1.0 Red Primary Fuse Block (20A) Alternator Resistor Connector (Ignition Power-IN) 818B 1.0 Red Options Fuse Block (10A) Brake Pressure Switch
124A 1.0 Red Alternator (W) Cab Harness Connector (B4) 200G 2.0 Red Ignition Switch (IGN) Cab Harness Connector (B1) 830A 3.0 Red Primary Fuse Block (30A) Cab Harness Connector (K2)
130A 2.0 Red 15 Ampere Circuit Breaker Cab Harness Connector (A1) 200H 2.0 Red Cab Harness Connector (B1) Primary Fuse Block (15A) 860A 2.0 Orange Options Fuse Block (20A) Miscellaneous Power Circuit
130B 2.0 Red Cab Harness Connector (A1) Ignition Switch (BATT) 300A 2.0 Red Primary Fuse Block (15A) Splice 1 (Interlock System) 890A 1.0 Red Primary Fuse Block (10A) Horn Switch Circuit
131A 1.0 Red Cab Harness Connector (B2) Main Power Relay (86) 311B 1.0 Pink Loader Valve Sol. Relay (87) Chassis Options Harness 895A 1.0 Orange Primary Fuse Block (10A) Backup Alarm Switch #1

4001-18
9 Fuel Hold In Solenoid

(Naturally Aspirated Engines)
1 Between the housing of the solenoid Continuity Bad ground connection.

and ground
NOTE: Put the key switch in the RUN position. Have someone sit in the operators seat with the seat bar in the down position.
2 Terminal for wire 603D to ground 12 volts Check the circuit between the fuel hold in solenoid and the engine shut
down relay (15). Also check the engine shut down relay (15).
10 Fuel Timing Heater

Ensure the engine is cooler than 160°F. Start the engine and jumper across the two terminals on the fuel timing temperature switch. After a
short period of time, the engine should change sound and run smoother as the wax pellet in the fuel timing heater melts and the injection
pump timing changes. This signifies that the fuel timing heater is operating properly.
11 Fuel Timing Temperature Switch

Ensure the engine is cooler than 160°F. Turn the key switch to the RUN position. There should be 12 volts on the terminal for wire 603C and
0 volts on the other terminal. Start the engine and let it warm to above 160° F. There should now be 12 volts on both terminals. This signifies
that the fuel timing temperature switch is operating properly.
12 Fuel Solenoid Pull In Relay

3 Terminal for wire 178BB to ground Continuity Bad ground circuit.
4 Terminal for wire 190B to ground 12 volts Check the circuit between the fuel solenoid pull in relay and the 40 ampere
circuit breaker. Also check the 40 ampere circuit breaker and the buss bar.
5 Terminal for wire 622C to ground 12 volts Check the circuit between the fuel solenoid pull in relay and the ignition
switch (5). Also check the ignition switch (5).
6 Terminal for wire 604A to ground 12 volts Bad fuel solenoid pull in relay.

4001-19
13 Fuel Pull In Solenoid
7 Terminal for wire 178BC to ground Continuity Bad ground circuit.
8 Terminal for wire 604A to ground 12 volts Check the circuit between the fuel pull in solenoid and the fuel solenoid pull
in relay (12). Also check the fuel solenoid pull in relay (12).
NOTE: If the readings are ok, replace the fuel pull in solenoid.
14 Fuel Hold In Solenoid

(Turbo Engines)
9 Terminal for wire 178BC to ground Continuity Bad ground circuit.
10 Terminal for wire 603E to ground 12 volts Check the circuit between the fuel hold in solenoid and the engine shut
down relay (15). Also check the engine shut down relay (15).
15 Engine Shut Down Relay

11 Terminal for wire 178E to ground Continuity Bad ground circuit.
12 Terminal for wire 300B to ground 12 volts Check the circuit between the engine shut down relay and the 15 ampere
fuse in the primary fuse block (7). Also check the 15 ampere fuse and the
fuse block (7).
13 Terminal for wire 602A to ground 12 volts Check the circuit between the engine shutdown relay and the RH
instrument cluster 8-pin connector (21). Also check the RH instrument
cluster 8-pin connector (21).
14 Terminal for wires 603A and 603B to 12 volts Bad engine shut down relay.
ground

4001-20
16 Loader Valve Solenoid Relay
15 Terminal for wire 178F to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have someone sit in the operators seat with the seat bar in the down position.
16 Terminal for wire 603B to ground 12 volts Check the circuit between the loader valve solenoid relay and the engine
shut down relay (15). Also check the engine shut down relay (15).
17 Terminal for wire 313A to ground 12 volts Check the circuit between the loader valve solenoid relay and the seat bar
switch (19). Also check the seat bar switch (19).
18 Terminal for wires 311A and 311B to 12 volts Bad loader valve solenoid relay.
ground
17 Loader Valve Solenoids

19 Terminal for wire 178K to ground Continuity Bad ground circuit.
20 Terminal for wire 178BD to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have someone sit in the operators seat with the seat bar in the down position. Ensure
that the cab door (if installed) is closed and latched.
21 Terminal for wire 311G to ground 12 volts Check the circuit between the loader valve solenoid and the cab door switch
(44). Also check the cab door switch (44).
NOTE: If the front door option is not installed, check the diode installed in
the front door interlock connector in the cab harness.
22 Terminal for wire 311H to ground 12 volts Check the circuit between the loader valve solenoid and splice 14.
NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the
solenoid. If the solenoid magnetizes, the problem may be in the hydraulic system.
18 Seat Switch
23 Terminal for wire 300F to ground 12 volts Check the circuit between the seat switch and the 15 ampere fuse in the
primary fuse block (7). Also check the 15 ampere fuse and the primary fuse
block (7).
NOTE: Disconnect the seat switch connector from the cab harness.
24 Between the terminals in the Open Bad seat switch.

connector for the seat switch.
NOTE: Have another person sit in the operators seat.
25 Between the terminals in the Continuity Bad seat switch.

connector for the seat switch.

4001-21
19 Seat Bar Switch
26 Terminal for wire 300G to ground 12 volts Check the circuit between the seat bar switch and the 15 ampere fuse in the
primary fuse block (7). Also check the 15 ampere fuse and the primary fuse
block (7).
NOTE: Disconnect the seat bar switch connector from the cab harness. Make sure the seat bar is in the up position.
27 Between the terminal for wire 313B Open Bad seat bar switch.
and the terminal for wire 300G in the
connector for the seat bar switch.
NOTE: Move the seat bar to the down position.
28 Between the terminal for wire 313B Continuity Check seat bar adjustment (See section 9001).
and the terminal for wire 300G in the Bad seat bar switch.
connector for the seat bar switch.
20 LH Instrument Cluster (6-Pin Connector)

NOTE: Disconnect the connector from the instrument cluster. Put the ignition switch in the RUN position. Have another person sit in the
operators seat. Make sure the seat bar is in the up position.
29 Terminal for wire 303B to ground 12 volts Check the circuit between the connector and the seat switch (18). Also
check the seat switch (18).
30 Terminal for wire 258C to ground 12 volts Check the circuit between the LH instrument cluster 6-pin connector and
the seat bar switch (19). Also check the seat bar switch (19). Also check the
diode.
NOTE: Connect the connector to the instrument cluster. Remove the diode from the cab harness at the connector for wires 303D and
303E. Put the ignition switch in the RUN position. Have another person sit in the operators seat.
31 Terminal for wire 303E in the diode 12 volts Check the circuit between the LH instrument cluster 6-pin connector and
connector to ground the connector for the diode.
Bad seat timer in the instrument cluster.
NOTE: Have the other person get out of the operators seat.
32 Terminal for wire 303E in the diode 0 volts after Bad seat timer in the instrument cluster.
connector to ground 2 seconds

4001-22
21 RH Instrument Panel (8-Pin Connector)
NOTE: Disconnect the connector from the instrument cluster.
33 Terminal for wire 200E to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have another person sit in the operators seat. Make sure the seat bar is in the down
position.
34 Terminal for wire 300H to ground 12 volts Check the circuit between the instrument panel connector and the 15
ampere fuse in the primary fuse block (7). Also check the 15 ampere fuse
and the primary fuse block (7).
35 Terminal for wire 313E to ground 12 volts Check the circuit between the connector and the seat bar switch (19). Also
check the seat bar switch (19).
36 Terminal for wire 612A to ground 12 volts Check the circuit between the connector and the LH instrument cluster 6-
pin connector (20). Also check the LH instrument cluster 6-pin connector
(20) and the diode.
37 Terminal for wire 303C to ground 12 volts Check the circuit between the connector and the seat switch (18). Also
check the seat switch (18).
NOTE: Connect the 8-pin connector to the instrument cluster. Remove the engine shut down relay (15) from the connector on the chassis
harness. Put the ignition switch in the RUN position. Have another person sit in the operators seat. Make sure the seat bar is in the down
position.
38 Terminal for wire 602A on the engine 12 volts Check the circuit between the RH instrument cluster 8-pin connector and
shut down relay connector to ground the engine shut down relay (15).
Bad instrument cluster.

4001-23
NOTES

4001-24
16 20
15 21
19
18
11 14 13
17
HI01E015

B1 200H B3 622A
1
3 E1 706D J3 239A
4 F1 234A A4 786B
G1 257A B4 124A
H1 641B C4 313A
J1 266A D4 PLUGGED
K1 200D E4 255A
A2 780A F4 235A
B2 131A G4 264A
D2 300D H4 311A
G2 261A J4 PLUGGED
J2 602A K4 178S

4001-25
FUEL SUPPLY SYSTEM FUEL SUPPLY SYSTEM SAFETY INTERLOCK SYSTEM

(Naturally Aspirated Engines) (Turbo Engines)
178BB 178BB
4 1 1 3 2 2 2 9
30
603A
258C A
20
311B
29 B
178BB
603A
300A
178E
622C
190B
C
12 15 16 32 D
31 33 E
85 86 85 86 85 86 303E F
30 87a 30 87a 30 87a 200E
303B
178BB
87 12 87 16 87 34
603C
38 A
B 21
13
603D
17 313E C
11 D
15
2 T 300B 603B
35 E
3 4 18 36 F
604A
6 5 178F G
303D
SPL 1 14
9 10 11 311A 18 UNOCCUPIED H
8 603E 603E OCCUPIED
37
303C
612A
602A 313A
10 300D
300H
603A SPL 3
21 SPL 14 314B
311G 311F 24 25
1 300E 300F 303A
SPL 8
19
314A
300G
313A 23
311H
178BC
602B SPL 2 UP SPL 4

17 24 DOWN 27 28
313B
22
25 19 314C 314D
7 9 20 8 8
26 9
178BD
178K
13 14 27
28
3 3A 4
HI01H004
Circuits Circuits
Components NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
9. Fuel Hold In Solenoid 17. Loader Valve Solenoids 200E 1.0 Black/White RH Instrument Cluster (8-Pin, A) Clean Ground 313A 1.0 Tan Cab Harness Connector (C2) Loader Valve Sol. Relay (86)
10. Fuel Timing Heater 18. Seat Switch 300A 2.0 Red Primary Fuse Block (15A) Splice 1 313B 0.8 Tan Seat Bar Switch Splice 3
11. Fuel Timing Temperature Switch 19. Seat Bar Switch 300B 2.0 Red Splice 1 Engine Shut Down Relay (30) 313E 0.8 Tan Splice 3 RH Instrument Cluster (8-Pin, C)
12. Fuel Solenoid Pull In Relay 20. LH Instrument Cluster 300D 1.0 Red Splice 1 Cab Harness Connector (D2) 314A 0.8 Tan Diode Diode
13. Fuel Pull In Solenoid (6-Pin Connector) 300E 1.0 Red Cab Harness Connector (D2) Splice 2 314B 0.8 Tan Diode Splice 8
14. Fuel Hold In Solenoid 21. RH Instrument Cluster
300F 0.8 Red Splice 2 Seat Switch 314C 0.8 tan Seat Bar Switch Diode
15. Engine Shut Down Relay (8-Pin Connector)
300G 0.8 Red Splice 2 Seat Bar Switch 314D 0.8 Tan Diode Splice 10 (Hydraulic Brakes)
16. Loader Valve Solenoid Relay
300H 0.8 Red Splice 2 RH Instrument Cluster (8-Pin, B) 602A 1.0 White Cab Harness Connector (J2) Engine Shut Down Relay (86)
303A 0.8 Tan Seat Switch Splice 4 602B 0.8 White RH Instrument Cluster (8-Pin, D) Cab Harness Connector (J2)
Circuits 303B 0.8 Tan Splice 4 LH Instrument Cluster (6-Pin, C) 603A 1.0 White Engine Shut Down Relay (87) Fuel Supply System Connector
NO. GA. COLOR FROM: TO: 303C 0.8 Tan Splice 4 RH Instrument Cluster (8-Pin, G) 603B 1.0 White Engine Shut Down Relay (87) Engine Shut Down Relay (30)
178E 1.0 Black Main Power Relay (85) Engine Shut Down Relay (85) 303D 0.8 Tan Diode Splice 8 603C 1.0 White Fuel Supply System Connector Fuel Timing Temp. Switch
178F 1.0 Black Engine Shut Down Relay (85) Loader Valve Sol. Relay (85) 303E 0.8 Tan LH Instrument Cluster (6-Pin, F) Diode 603D 1.0 White Fuel Supply System Connector Fuel Hold In Solenoid
178K 1.0 Black Loader Valve Solenoid Chassis Ground 311A 1.0 Tan Loader Valve Sol. Relay (87) Cab Harness Connector (H2) 603E 1.0 White Engine Shut Down Relay (87) Fuel Hold In Solenoid
178BB 1.0 Black Loader Valve Solenoid Relay (85) Fuel Solenoid Pull In Relay (85) 311B 1.0 Pink Loader Valve Sol. Relay (87) Chassis Options Harness 604A 3.0 White Fuel Solenoid Pull In Relay (87) Fuel Pull In Solenoid
178BC 3.0 Black Fuel Solenoids Ground 311F 1.0 Tan Cab Harness Connector (C1) Splice 14 612A 0.8 White Splice 8 RH Instrument Cluster (8-Pin, E)
178BD 1.0 Black Loader Valve Solenoid Chassis Ground 311G 1.0 Tan Splice 14 Loader Valve Solenoid 622C 1.0 White Starting Relay (86) Fuel Solenoid Pull In Relay (86)
190B 3.0 Red 40 Ampere Circuit Breaker Fuel Solenoid Pull In Relay (30) 311H 1.0 Tan Splice 14 Loader Valve Solenoid

4001-26
22 LH Instrument Panel (10-Pin Connector)

NOTE: Disconnect the 10-pin connector from the LH instrument panel.
1 Terminal A in connector to ground 0 to 90 ohms Check the circuit between the connector and the fuel sender (29). Also
(Depending on check the fuel sender (29).
fuel level.)
NOTE: Connect the 10-pin connector to the LH instrument panel. Put the ignition switch in the RUN position.
Disconnect wire 234A from the fuel sender. Full (After 40 Bad fuel level gauge.
Check the reading of the fuel gauge. seconds.)
Connect wire 234A to ground at fuel Empty (After 40 Bad fuel level gauge.
sender. seconds.)
NOTE: Put the ignition switch in the OFF position. Disconnect the 10-pin connector from the instrument panel.
2 Terminal C in connector to ground Open Check the circuit between the connector and the air filter restriction switch
(28). Also check the air filter restriction switch (28).
3 Terminal D in connector to ground Open Check the circuit between the connector and the hydraulic filter pressure
switch (27). Also check the hydraulic filter pressure switch (27).
4 Terminal E in connector to ground Continuity Bad ground connection.
5 Terminal H in connector to wire 264H Open, with Check the circuit between the connector and the hydraulic oil temperature
at the hydraulic oil temperature switch hydraulic system switch (26). Also check the hydraulic oil temperature switch (26).
temp. below
230°F
6 Terminal J in connector to wire 257A Open, with Check the circuit between the connector and the engine coolant
at the engine coolant temperature switch coolant temp. temperature switch (25). Also check the engine coolant temperature switch
below 230°F (25).
7 Terminal K in connector to ground Continuity Check the circuit between the connector and the engine oil pressure switch
(24). Also check the engine oil pressure switch (24).
8 Terminal F in connector to ground 12 volts Check the circuit between the connector and the ignition switch (5). Also

4001-27
23 RH Instrument Cluster (6-Pin Connector)
Check the engine oil pressure sensor (30), the engine coolant temperature sender (31), the hydraulic oil temperature sender (32) and the
alternator (3) tachometer output. If the readings are good, check the continuity of each of the wires between the components and the RH
instrument cluster 6-pin connector. If the readings are good, replace the RH instrument cluster.
24 Engine Oil Pressure Switch

9 Check between the housing of the Continuity Bad ground connection between the engine oil pressure switch and the
engine oil pressure switch and the engine engine block.
block.
NOTE: Put the ignition switch in the RUN position. Disconnect the connector from the engine oil pressure switch.
10 Terminal for wire 255A to ground Approx. Check the circuit between the engine oil pressure switch and the LH
7 volts instrument cluster 10-pin connector (22). Also check the LH instrument
NOTE: Connect the connector to the engine oil pressure switch. Put the ignition switch in the RUN position. Engine should not be
running.
11 Terminal for wire 255A to ground Approx. Bad engine oil pressure switch.
0 volts
NOTE: Start and run the engine at low idle.
12 Terminal for wire 255A to ground Approx. Engine oil pressure less than 70 kPa (10 psi).
7 volts
NOTE: If the readings for check points 11 and 12 and are not good, replace the engine oil pressure switch.
25 Engine Coolant Temperature Switch

13 Check between the housing of the Continuity Bad ground connection between the engine coolant temperature switch
engine temperature switch and the and the engine block.
engine block.
NOTE: Disconnect the connector from the engine coolant temperature switch. Put the ignition switch in the RUN position.
14 Terminal for wire 257A to ground Approx. Check the circuit between the engine coolant temperature switch and the
7 volts LH instrument cluster 10-pin connector (22). Also check the LH
instrument cluster 10-pin connector (22).
NOTE: If the readings are good, check from switch terminal to switch case with temperature below 225 °F. If continuity is
found, replace the switch.

4001-28
26 Hydraulic Oil Temperature Switch
15 Check between the housing of the Continuity Bad ground connection between the hydraulic oil temperature switch and
hydraulic oil temperature switch and the the tandem pump housing or the machine frame.
machine frame.
NOTE: Disconnect the connector from the hydraulic oil temperature switch. Put the ignition switch in the RUN position.
16 Terminal for wire 264A to ground Approx. Check the circuit between the hydraulic oil temperature switch and the LH
NOTE: If the readings are good, check from switch terminal to ground with temperature below 225°F. If continuity is found, replace
switch.
27 Hydraulic Filter Pressure Switch

17 Check between the housing of the Continuity Bad ground connection between the hydraulic filter pressure switch and
hydraulic filter pressure switch and the the filter housing.
filter housing.
18 Check between switch housing and Continuity Bad ground connection between filter housing and frame.
engine ground.
19 Terminal for wire 261A to ground Approx. Check the circuit between the hydraulic filter pressure switch and the LH
NOTE: If the readings are good, replace the hydraulic filter pressure switch.
28 Air Filter Restriction Switch

20 Terminal for wire 178G to ground. Continuity Bad ground circuit.
21 Terminal for wire 266A to ground Approx. Check the circuit between the air filter restriction switch and the LH
NOTE: If the readings are good, remove the air filter restriction switch and apply 64m Bar vacuum to the port. Check between the
terminals of the switch. If continuity is not found, the switch is bad.

4001-29
29 Fuel Level Sender
NOTE: Check the level of fuel in the fuel tank.
22 Terminal for wire 178H to ground. Continuity Bad ground circuit.
NOTE: Disconnect the connector for wire 234A from the fuel sender. Put the ignition switch in the RUN position.
23 Terminal for wire 234A to ground Approx. Check the circuit between the fuel level sender and the LH instrument
7 volts cluster 10-pin connector (22). Also check the LH instrument cluster 10-
pin connector (22).
NOTE: If the readings are good, use an ohmmeter and check the resistance of the fuel level sender. When the fuel tank is full, the
resistance should be approximately 86 to 94 ohms. If the fuel tank is empty, the resistance should be 0 to 3 ohms. If the ohmmeter
readings are not correct, replace the fuel level sender.
30 Engine Oil Pressure Sensor (Optional)

24 Terminal for wire 200J to ground Continuity Bad ground circuit.
NOTE: Disconnect the connector from the engine oil pressure sensor. Disconnect the 6-pin connector from the RH instrument cluster.
25 Terminal for wire 230D at the engine Continuity Check the circuit between the engine oil pressure sensor and the RH
oil pressure sensor to terminal for wire instrument cluster 6-pin connector (23).
230C at the instrument cluster connector.
NOTE: Connect the 6-pin connector to the RH instrument cluster. Put the ignition switch in the RUN position.
26 Terminal for wire 230B to ground Approx. Check the circuit between the engine oil pressure sensor and the RH
5 volts instrument cluster 6-pin connector (23). Also check the RH instrument
If the readings are good, create a jumper harness made up of three lengths of 18 or 16 ga. wire and the following Case Service Parts
numbers: (1) 198456A1 Connector Body, (3) 221382A1 Terminals, (3) 394033A1 Terminals. Wrap each of the 394033A1 terminals with
electrical tape to insulate them from each other. Plug the connector on the jumper into the connector on the engine oil pressure sensor.
Plug each of the free terminals into their matching cavity on the main harness. Cut the wire on the jumper harness connected to the
yellow wire on the main harness and connect a voltmeter between to two cut ends. With the ignition On and the engine OFF, the voltmeter
should read approximately 0.5V. If no reading is present, replace the sensor.
Remove the oil pressure switch located just forward of the sensor on the engine block and insert a pressure gauge. Start the engine and
note the voltage shown on the meter and the pressure reading (psi) at idle. Divide the pressure reading by 25.135 and add 0.508.
Compare this number with the voltage measured at the meter. The numbers should match within 10%. If not, replace the sensor. If the
numbers match, replace the RH instrument cluster.

4001-30
31 Engine Coolant Temperature Sender (Optional)
27 Check between the housing of the Continuity Bad ground connection between the engine coolant temperature sender
engine coolant temperature sender and and the engine block.
the engine block.
NOTE: Disconnect the wire from the engine coolant temperature sender. Disconnect the 6-pin connector from the RH instrument
cluster.
28 Terminal for wire 235A at sender Continuity Check the circuit between the engine coolant temperature sender and the
end to terminal for wire 235B at RH instrument cluster 6-pin connector (23).
instrument cluster end.
If the readings are good, remove the engine coolant temperature sender from the engine block. Immerse the probe area of the sender in
boiling water and measure the resistance from the screw terminal to the sender housing. The resistance should be 175 ohms ±10%. If
the reading is bad, replace the sender. If the reading is good, replace the RH instrument cluster.
32 Hydraulic Oil Temperature Sender (Optional)

29 Check between the housing of the Continuity Bad ground connection between the hydraulic oil temperature sender and
hydraulic oil temperature sender and the the engine block.
engine block.
NOTE: Disconnect the wire from the hydraulic oil temperature sender. Disconnect the 6-pin connector from the RH instrument cluster.
30 Terminal for wire 239A at sender Continuity Check the circuit between the hydraulic oil temperature sender and the
end to terminal for wire 239B at RH instrument cluster 6-pin connector (23).
instrument cluster end.
If the readings are good, remove the hydraulic oil temperature sender from the engine block. Immerse the probe area of the sender in
boiling water and measure the resistance from the screw terminal to the sender housing. The resistance should be 175 ohms ±10%. If
the reading is bad, replace the sender. If the reading is good, replace the RH instrument cluster.

4001-31
33 Work/Road Light Switch
31 Terminal for wire 780B to ground 12 volts Check the circuit between the work/road light switch and the 20 ampere
fuse in the primary fuse block (7). Also check the 20 ampere fuse and
primary fuse block (7).
32 Terminal for wire 780D to ground 12 volts Check the jumper wire 780C between terminals E and B of the work/road
light switch.
NOTE: Put the work/road light switch in the ROAD position.
33 Terminal for wire 706B to ground 12 volts Bad lamp switch.
34 Terminal for wire 786A to ground 0 volts Bad lamp switch.
35 Terminal for wire 781C to ground 12 volts Bad lamp switch.
36 Terminal for wire 781B to ground 12 volts Check the jumper wire 781A between terminals D and F of the work/road
light switch.
NOTE: Put the work/road light switch in the WORK position.
38 Terminal for wire 786A to ground 12 volts Bad lamp switch.
34 Rear Halogen Work Lamp

40 Terminal for wire 178D to ground Continuity Bad ground circuit.
41 Between the terminals of the lamp Continuity Bad bulb.
NOTE: Put the ignition switch in the RUN position. Put the work/road light switch in the WORK position.
42 Terminal for wire 786B to ground 12 volts Check the circuit between the rear halogen work lamp and the work/road
light switch (33). Also check the work/road light switch (33).
35 LH Rear Positional Lamp

43 Terminal for wire 178L to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Put the work/road light switch in the ROAD position.
45 Terminal for wire 706A to ground 12 volts Check the circuit between the LH rear positional lamp and the work/road
light switch (33). Also check the work/road light switch (33).

4001-32
36 RH Rear Positional LAMP
46 Terminal for wire 178C to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Put the work/road light switch in the ROAD position.
48 Terminal for wire 706C to ground 12 volts Check the circuit between the RH rear positional lamp and the LH rear
positional lamp (35). Also check the LH rear positional lamp (35).
37 Left Front Halogen Work Lamp

49 Terminal for wire 178R to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Put the work/road light switch in either the ROAD or WORK position.
51 Terminal for wire 781B to ground 12 volts Check the circuit between the left front halogen work lamp and the work/
road light switch (33). Also check the work/road light switch (33).
38 Right Front Halogen Work Lamp

52 Terminal for wire 178P to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Put the work/road light switch in either the ROAD or WORK position.
54 Terminal for wire 781C to ground 12 volts Check the circuit between the right front halogen work lamp and the
work/road light switch (33). Also check the work/road light switch (33).

4001-33
NOTES

4001-34
37
22
23 33
27 38
29
35
28
26 32
34
36
25 31 24 30
HI01E015

B1 200H B3 622A
1
3 E1 706D J3 239A
4 F1 234A A4 786B
G1 257A B4 124A
H1 641B C4 313A
J1 266A D4 PLUGGED
K1 200D E4 255A
A2 780A F4 235A
B2 131A G4 264A
D2 300D H4 311A
G2 261A J4 PLUGGED
J2 602A K4 178S

4001-35
Components
INSTRUMENT CLUSTER STANDARD LAMPS
22. LH Instrument Cluster
(10-Pin Connector)
23. RH Instrument Cluster
(6-Pin Connector)
1 13 2
24. Engine Oil Pressure Switch
25. Engine Coolant Temp Switch
26. Hydraulic Oil Temp Switch
200A
22 234A
786B 27. Hydraulic Filter Pressure Switch
706D
28. Air Filter Restriction Switch
780A
266A
1 A 234B
261A
786A 29. Fuel Level Sender
706A
B 264A
2 C 266B 19 30. Engine Oil Pressure Sender
257A
D 261B 14 16 23
255A 31. Engine Coolant Temp Sender
706B
200E
E
4 10 24 25 26 27 28 29 36
3 F 21 33 32. Hydraulic Oil Temp Sender
5
255D
G 11 37 34 35 36 37 38 33. Work/Road Light Switch

H 264B P T T P V
8 257B 12 34. Rear Halogen Work Lamp
J
10
781A
K 255B 9 26 13 15 35. LH Rear Positional Lamp
17 35
6 7 239A
18 22 36. RH Rear Positional Lamp
780D
235A 34
24 52 37. Left Front Halogen Work Lamp
178P
780B
200C
25 38 43 46 49 53 38. Right Front Halogen Work Lamp
44
23 30
28
28 30 33 41 40 44 47 50
45
39 42 41 706C
200F
F 255C T T
32 178C
47 50
E 239B
178G
178H
D 235B 27 29 48 51 53
31 32
780C
178D
C 230A 230B 30
B 230C 230D
54
31 781B
A 124B 781C
124A
25
200D
178R
178U
200J
178L
1
5 6
HI01H005

NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
NO. GA. COLOR FROM: TO:
230B 1.0 Red Cab Harness Connector (D1) Engine Oil Pressure Sensor 264A 1.0 Yellow Hydraulic Oil Temp Sender Cab Harness Connector (G4)
124A 1.0 Red Alternator (W) Cab Harness Connector (B4)
230C 0.8 Yellow RH Instrument Cluster (6-Pin, B) Cab Harness Connector (J4) 264B 0.8 Yellow Cab Harness Connector (G4) LH Instrument Cluster (10-Pin, H)
124B 0.8 Red Cab Harness Connector (B4) RH Instrument Cluster (6-Pin, A)
230D 1.0 Yellow Cab Harness Connector (J4) Engine Oil Pressure Sensor 266A 1.0 Yellow Air Filter Restriction Switch Cab Harness Connector (J1)
178C 1.0 Black LH Rear Positional Lamp RH Rear Positional Lamp
234A 1.0 Yellow Fuel Level Sender Cab Harness Connector (F1) 266B 0.8 Yellow Cab Harness Connector (J1) LH Instrument Cluster (10-Pin, C)
178D 1.0 Black RH Rear Positional Lamp Rear Halogen Work Lamp
234B 1.0 Tan Cab Harness Connector (F1) LH Instrument Cluster (10-Pin, A) 706A 2.0 Pink Connector (On Road Lamps) LH Rear Positional Lamp
178G 1.0 Black Air Filter Restriction Switch Chassis Ground
235A 1.0 Yellow Engine Coolant Temp Sender Cab Harness Connector (F4) 706B 2.0 Pink Work/Road Light Switch Cab Harness Connector (E1)
178H 1.0 Black Fuel Level Sender Chassis Ground
235B 0.8 Yellow Cab Harness Connector (F4) RH Instrument Cluster (6-Pin, D) 706C 1.0 Pink LH Rear Positional Lamp RH Rear Positional Lamp
178L 2.0 Black LH Rear Positional Lamp Chassis Ground
239A 1.0 Yellow Hydraulic Oil Temp Sender Cab Harness Connector (J3) 706D 2.0 Pink Cab Harness Connector (E1) Connector (On Road Lamps)
178P 1.0 Black Right Front Halogen Work Lamp Optional Switch Connector
239B 0.8 Yellow Cab Harness Connector (J3) RH Instrument Cluster (6-Pin, E) 781A 1.0 Pink Work/Road Light Switch Work/Road Light Switch
178R 1.0 Black Left Front Halogen Work Lamp Chassis Ground
255A 1.0 Yellow Engine Oil Pressure Switch Cab Harness Connector (E4) 781B 1.0 Pink Work/Road Light Switch Left Front Halogen Work Lamp
178U 1.0 Black Optional Switch Connector Chassis Ground
255B 0.8 Yellow Splice 15 LH Instrument Cluster (10-Pin, K) 781C 1.0 Pink Work/Road Light Switch Right Front Halogen Work Lamp
200A 0.8 Red Ignition Switch (Ign) LH Instrument Cluster (10-Pin, F)
255C 0.8 Yellow Splice 15 RH Instrument Cluster (6-Pin, F) 780A 3.0 Red Primary Fuse Block (20A) Cab Harness Connector (A2)
200C 1.0 Black/White LH Instrument Cluster (10-Pin, E) Splice 6
255D 0.8 Yellow Cab Harness Connector (E4) Splice 15 780B 3.0 Red Cab Harness Connector (A2) Work/Road Light Switch
200D 2.0 Black/White Cab Harness Connector (K1) Clean Ground
257A 1.0 Yellow Engine Coolant Temp Switch Cab Harness Connector (G1) 780C 2.0 Red Work/Road Light Switch Work/Road Light Switch
200E 1.0 Black/White Splice 6 RH Instrument Cluster (8-Pin, A)
257B 0.8 Yellow Cab Harness Connector (G1) LH Instrument Cluster (10-Pin, J) 780D 1.0 Red Work/Road Light Switch Dome Light Circuit
200F 2.0 Black/White Splice 6 Cab Harness Connector (K1)
261A 1.0 Yellow Hydraulic Filter Pressure Switch Cab Harness Connector (G2) 786A 1.0 Pink Work/Road Light Switch Cab Harness Connector (A3)
200J 1.0 Black/White Engine Oil Pressure Sensor Clean Ground
261B 1.0 White Cab Harness Connector (G2) LH Instrument Cluster (10-Pin, D) 786B 1.0 Pink Cab Harness Connector (A3) Rear Halogen Work Lamp
230A 0.8 Red RH Instrument Cluster (6-Pin, C) Cab Harness Connector (D1)

4001-36
39 Horn
1 Terminal for wire 178M to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Have another person hold down the horn switch.
2 Terminal for wire 892C to ground 12 volts Check the circuit between the horn and the horn switch (40). Also
check the horn switch (40).
NOTE: If the readings are good and the horn does not work, replace the horn.
40 Horn Switch
NOTE: Put the ignition switch in the RUN position. Disconnect the horn switch connector.
3 Terminal for wire 890A to ground 12 volts Check the circuit between the horn switch and the 10 ampere fuse in
the primary fuse block (7). Also check the 10 ampere fuse and
4 Between terminals of horn switch Open Bad horn switch.
NOTE: Have another person hold down the horn switch.
5 Between terminals of horn switch Continuity Bad horn switch.
41 Backup Alarm Switch #1

NOTE: Put the ignition switch in the RUN position. Disconnect the electrical connector from backup alarm switch #1.
6 Terminal for wire 895A to ground 12 volts Check the circuit between backup alarm switch #1 and the 10 ampere
fuse in the primary fuse block (7). Also check the 10 ampere fuse and
the primary fuse block (7).
NOTE: Put the ignition switch in the OFF position.
7 Between the terminals of backup Open Bad backup alarm switch #1

alarm switch #1
NOTE: Raise the machine until the tires are off the ground. Put blocks under the machine to hold it in position. Jumper the seat switch
closed and lower the seat bar. Start the machine and move both control levers to the rear.
8 Between the terminals of backup Continuity Bad backup alarm switch #1

alarm switch #1

4001-37
42 Backup Alarm Switch #2
NOTE: Disconnect the electrical connectors from backup alarm switch #1 and backup alarm switch #2.
9 Terminal for wire 895B at backup Continuity Bad circuit between backup alarm switch #2 and backup alarm switch #1.
alarm switch #1 end to terminal for wire
895B at backup alarm switch #2 end
10 Between the terminals of backup Open Bad backup alarm switch #2.
alarm switch #2
NOTE: Raise the machine until the tires are off the ground. Put blocks under the machine to hold it in position. Jumper the seat switch
closed and lower the seat bar. Start the machine and move both control levers to the rear.
11 Between the terminals of backup Continuity Bad backup alarm switch #2.
alarm switch #2
NOTE: If the readings are good, check backup alarm switch #1 (41).
43 Backup Alarm
12 Terminal for wire 178N to ground. Continuity Bad ground circuit.
NOTE: Raise the machine until the tires are off the ground. Put blocks under the machine to hold it in position. Start the machine and
move both control levers to the rear.
13 Terminal for wire 895C to ground 12 volts Check the circuit between the backup alarm and backup alarm switch #2.
Also check backup alarm switch #1 (41) and backup alarm switch #2 (42).
NOTE: If the readings are good but the backup alarm doesn’t sound, replace the backup alarm.
44 Cab Door Switch

NOTE: Disconnect the connector from the cab door switch. Cab door should be open.
14 Between the terminal for the white Open Bad cab door switch.
wire and the terminal for the black wire for
the cab door switch.
NOTE: Close and latch the cab door.
15 Between the terminal for the white Continuity Bad cab door switch.
wire and the terminal for the black wire for
the cab door switch.
NOTE: Have someone sit in the seat with the seat bar in the down position. Put the ignition switch in the RUN position.
16 Terminal for wire 313F to ground 12 volts Check the circuit between the cab door switch and the loader valve solenoid
relay (16). Also check the loader valve solenoid relay (16).

4001-38
45 Washer Pump
17 Terminal for wire 178BV to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Press and hold the washer pump switch.
18 Terminal for wire 835A to ground 12 volts Check the circuit between the washer pump and the wiper motor (46).
Also check the wiper motor (46).
NOTE: If the readings are correct, and the washer pump does not work, replace the washer pump.
46 Wiper Motor
19 Terminal for wire 178BU to ground Continuity Bad ground circuit.
20 Terminal for wire 830K to ground 12 volts Check the circuit between the wiper motor and the 30 ampere fuse in the
primary fuse block (7). Also check the 30 ampere fuse and primary fuse
block (7).
NOTE: Press and hold the washer pump switch.
21 Terminal for wire 835A to ground 12 volts Bad wiper motor.
47 High Flow Switch

22 Terminal for wire 311E to ground 12 volts Check the circuit between the high flow switch and the loader valve solenoid
NOTE: Have another person hold the high flow switch in the FWD position.
23 Terminal for wire 545A to ground 12 volts Bad high flow switch or internal handle wiring. Disassemble handle and
check the circuit between the high flow switch and the connector. If OK,
replace the high flow switch.
NOTE: Have another person hold the high flow switch in the REV position.
24 Terminal for wire 546A to ground 12 volts Bad high flow switch or internal handle wiring. Disassemble handle and
check the circuit between the high flow switch and the connector. If OK,
replace the high flow switch.

4001-39
48 Forward High Flow Solenoid
25 Terminal for wire 178AY to ground Continuity Bad ground circuit.
NOTE: Have someone sit in the seat with the seat bar in the down position. Put the ignition switch in the RUN position. Have the other
person hold the high flow switch in the FWD position.
26 Terminal for wire 545C to ground 12 volts Check the circuit between the forward high flow solenoid and the high flow
switch (47). Also check the high flow switch (47).
49 Reverse High Flow Solenoid

27 Terminal for wire 178AX to ground Continuity Bad ground circuit.
NOTE: Have someone sit in the seat with the seat bar in the down position. Put the ignition switch in the RUN position. Have the other
person hold the high flow switch in the REV position.
28 Terminal for wire 546C to ground 12 volts Check the circuit between the reverse high flow solenoid and the high flow
switch (47). Also check the high flow switch (47).
50 Brake Pressure Switch

29 Terminal for wire 818B to ground 12 volts Check the circuit between the brake pressure switch and the 10 ampere
fuse in the options fuse block (8). Also check the 10 ampere fuse and the
options fuse block (8).
NOTE: Start the engine and let it run at low idle. Raise the seat bar.
30 Terminal for wire 258D to ground 12 volts Bad brake pressure switch.
NOTE: Have the other person lower the seat bar and press the brake switch to the brakes released position.
31 Terminal for wire 258D to ground 0 volts Bad brake pressure switch.

4001-40
51 Brake Release Solenoid
32 Ring terminal for wire 178AF to Continuity Bad ground circuit.

ground
NOTE: Have someone sit in the seat with the seat bar in the down position. Put the ignition switch in the RUN position. Ensure the brake
switch (if equipped) is in the released position.
33 Terminal for wire 536A or 311J to 12 volts Brake switch installed: Check the circuit between the brake release
ground solenoid and the brake switch (52). Also check the brake switch (52).
Brake switch not installed: Check the circuit between the brake release
solenoid and the loader valve solenoid (16). Also check the loader valve
solenoid relay (16).
52 Brake Switch
NOTE: Have someone sit in the seat with the seat bar in the down position. Put the ignition switch in the RUN position. Disconnect the
connector for the brake switch from the wiring harness.
34 Terminal for wire 530B to ground 12 volts Check the circuit between the brake switch and the loader valve solenoid
NOTE: Put the ignition switch in the OFF position. Ensure the brake switch is in the released position.
35 Between the switch terminals Continuity Bad brake switch.
NOTE: Have the person in the operators seat push and release the brake button.
36 Between the switch terminals Open Bad brake switch.

4001-41
NOTES

4001-42
47 52
40
44 45 46
39
41 42 48 49 50 51
43
HI01E015

B1 200H B3 622A
1
3 E1 706D J3 239A
4 F1 234A A4 786B
G1 257A B4 124A
H1 641B C4 313A
J1 266A D4 PLUGGED
K1 200D E4 255A
A2 780A F4 235A
B2 131A G4 264A
D2 300D H4 311A
G2 261A J4 PLUGGED
J2 602A K4 178S

4001-43
OPTIONAL HORN
OPTIONAL FRONT DOOR OPTIONAL HIGH FLOW
Components
47 REV FWD 39. Horn
4 4 2
40. Horn Switch
2 10
16 178BA 24 41. Backup Alarm Switch #1
546A 546B
15 545A 545B
42. Backup Alarm Switch #2
43. Backup Alarm
546C
545C
5 OPEN 14 23
CLOSED 26
4 14 44. Cab Door Switch
40
890C
178AY 530C
44 45. Washer Pump
178AC
3 15 25
830A
SPL-HF1 48 46. Wiper Motor
4 311A 311C 313F 28 47. High Flow Switch
890A 890B
311F 311D 313H
892C 892B 5 17 45 178AX 48. Forward High Flow Solenoid
2 27 49 49. Reverse High Flow
178M 39 Solenoid
18 OPTIONAL ELECTROHYDRAULIC BRAKES
1 2 2 4 4 2 50. Brake Pressure Switch
178BV
835A
46 51. Brake Release Solenoid
830B
314D
SPL 10 258C
OPTIONAL BACKUP ALARM 21
2
258B 258A 258D
52. Brake Switch
830K 30
311J
178BT 178BU 31
20 311E
22 50 P
818B
178AC
19 29
8 32 51
895A 11 12
7 830D 13 13 830F
10
6 178BL 13 13 178BN
9 13 52
41 42 830G 14 14 830H 33
178BP 14 14 178BS
895C
P
895B
P 43 536B
536C 530B 530C
178T
536A
34
178N
35
7 10 12 35
36
8 11 36
9
7 8 9
HI01H006

311E 1.0 Pink Chassis Options Harness Brake Switch Connector 818B 1.0 Red Options Fuse Block (10A) Brake Pressure Switch
178M 1.0 Black Horn Chassis Ground
311F 1.0 Tan Cab Harness Connector (C1) Splice 14 830A 3.0 Red Primary Fuse Block (20A) Cab Harness Connector (K2)
178N 1.0 Black Backup Alarm Chassis Ground
311J 1.0 Pink Chassis Options Harness Brake Release Solenoid 830B 3.0 Red Cab Harness Connector (K2) Wiper Power Connector
178T 3.0 Black Wiper Power Connector Chassis Ground
313F 1.0 Tan Front Door Connector Cab Door Switch Connector 830K 1.0 Red Wiper Power Connector Wiper Motor
178AC 1.0 Black High Flow Solenoids Connector Ground
313H 1.0 Tan Cab Door Switch Connector Front Door Connector 835A 1.0 Orange Wiper Motor Washer Pump
178AX 1.0 Black Reverse High Flow Solenoid Splice HF1
314D 0.8 Tan Diode (Seat Bar Switch) Splice 10 890A 1.0 Red Primary Fuse Block (30A) Horn Switch Connector
178AY 1.0 Black Forward High Flow Solenoid Splice HF1
530B 1.0 Red Brake Switch Connector Brake Switch 890B 1.0 Red Horn Switch Connector Horn Switch
178BA 1.0 Black Splice HF1 High Flow Solenoids Connector
530C 1.0 Red Brake Switch High Flow Switch 890C 1.0 Red Horn Switch Ride Control Switch
178BT 2.0 Black Wiper Power Connector Splice
536A 1.0 Lt. Blue Brake Switch Connector Brake Release Solenoid 892B 1.0 Violet Horn Switch Horn Switch Connector
178BU 1.0 Black Splice Wiper Motor
536B 1.0 Orange Brake Switch Brake Switch Connector 892C 1.0 Orange Horn Switch Connector Horn
178BV 1.0 Black Splice Washer Pump
536C 1.0 Lt. Blue Brake Switch Brake Switch 895A 1.0 Orange Primary Fuse Block (30A) Backup Alarm Switch #1
258A 0.8 Yellow Cab Options Connector Connector
545A 1.0 Tan High Flow Switch Connector High Flow Solenoids Connector 895B 1.0 Orange Backup Alarm Switch #1 Backup Alarm Switch #2
258B 0.8 Yellow Connector Splice 10
545B 1.0 Yellow High Flow Switch High Flow Switch Connector 895C 1.0 Orange Backup Alarm Switch #2 Backup Alarm
258C 0.8 Yellow Splice 10 LH Instrument Cluster (6-pin, A)
545C 1.0 Tan High Flow Solenoids Connector Forward High Flow Solenoid
258D 1.0 Yellow Brake Pressure Switch Cab Options Connector
546A 1.0 Tan High Flow Switch Connector High Flow Solenoids Connector
311A 1.0 Tan Loader Valve Sol. Relay (87) Cab Harness Connector (H2)
546B 1.0 Lt. Blue High Flow Switch High Flow Switch Connector
311C 1.0 Tan Cab Harness Connector (H2) Front Door Connector
546C 1.0 Tan High Flow Solenoids Connector Reverse High Flow Solenoid
311D 1.0 Tan Front Door Connector Cab Harness Connector (C1)

4001-44
53 Cold Start Switch

1 Terminal for wire 132A to ground 12 volts Check the circuit between the cold start switch and the ignition switch (5).
Also check the ignition switch (5).
NOTE: Have another person push in and hold the cold start switch.
2 Terminal for wire 641A to ground 12 volts Bad cold start switch.
54 Thermostart Coil
3 Check between the housing of the Continuity Bad ground connection.

thermostart coil and ground
4 Terminal for wire 641B to ground Continuity Bad thermostart coil.
NOTE: Put the ignition switch in the RUN position. Have another person push in and hold the cold start switch.
5 Terminal for wire 641B to ground 12 volts Check the circuit between the thermostat coil and the cold start
switch (53). Also check the cold start switch (53).
55 Ride Control Solenoid

6 Check between the housing of the Continuity Bad ground connection.

ride control solenoid and ground
NOTE: Put the ignition switch in the RUN position. Have another person press and hold the ride control switch.
7 Terminal for wire 548B to ground 12 volts Check the circuit between the ride control solenoid and the ride control
switch (56). Also check the ride control switch (56).

4001-45
56 Ride Control Switch
8 Terminal for wire 890C to ground 12 volts Check the circuit between the ride control switch and the 10 ampere fuse in
the primary fuse block (7). Also check the 10 ampere fuse and the primary
fuse block (7).
NOTE: Have another person press and hold the ride control switch.
9 Terminal for wire 548A to ground 12 volts Bad ride control switch.
57 Rotating Beacon Switch

10 Terminal for wire 178AJ to ground Continuity Bad ground circuit.
11 Terminal for wire 751A to ground 12 volts Check the circuit between the rotating beacon switch and the 10
ampere fuse in the options fuse block (8). Also check the 10 ampere
fuse and options fuse block (8).
NOTE: Put the rotating beacon switch in the ON position.
12 Terminal for wire 766A to ground 12 volts Bad rotating beacon switch.
NOTE: If the readings were correct and the indicator lamp on the rotating beacon switch does not illuminate, replace the rotating
beacon switch.
58 Rotating Beacon
14 Terminal for wire 178Y to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the RUN position. Put the rotating beacon switch in the ON position.
15 Terminal for wire 766B to ground 12 volts Check the circuit between the rotating beacon and the rotating beacon
switch (57). Also check the rotating beacon switch (57).
NOTE: If the readings are good, replace the rotating beacon.

4001-46
59 Accessory Outlet
16 Terminal for wire 178AD to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the ACC position.
17 Terminal for wire 818C to ground 12 volts Check the circuit between the accessory outlet and the 10 ampere fuse in
the options fuse block (8). Also check the 10 ampere fuse and the options
fuse block (8).
NOTE: If the readings are good, replace the electric accessory socket.
60 Hydraulic Coupler Switch

18 Terminal for wire 178BF to ground Continuity Bad ground circuit.
19 Terminal for wire 540F to ground 12 volts Check the circuit between the hydraulic coupler switch and the 10
ampere fuse in the options fuse block (8). Also check the 10 ampere fuse
and the options fuse block (8)
20 Terminal for wire 539A to ground 12 volts Bad hydraulic coupler switch.
NOTE: Have another person hold the hydraulic coupler switch in the UNLATCH position.
23 Terminal for wire 547C to ground 12 volts Check the circuit between the hydraulic coupler switch and the hydraulic
coupler release timer (62). Also check the hydraulic coupler release timer
(62).
NOTE: Have another person move the hydraulic coupler switch to the LATCH position.
61 Hydraulic Coupler Release Solenoid

26 Terminal for wire 178AF to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the ACC position. Have another person hold the hydraulic coupler switch in the UNLATCH position.
27 Terminal for wire 547A to ground 12 volts Check the circuit between the hydraulic coupler release solenoid and the
hydraulic coupler release timer (62). Also check the hydraulic coupler
release timer (62).

4001-47
62 Hydraulic Coupler Release Timer
NOTE: Remove the hydraulic coupler release timer from its socket.
28 Terminal for wire 178AP to ground Continuity Bad ground circuit.
29 Terminal for wire 539B to ground 12 volts Check the circuit between the hydraulic coupler release timer and the
hydraulic coupler switch (60). Also check the hydraulic coupler switch
(60).
NOTE: Have another person hold the hydraulic coupler switch in the UNLATCH position.
30 Terminal for wire 549B to ground 12 volts Check the circuit between the hydraulic coupler release timer and the
hydraulic coupler switch (60). Also check the hydraulic coupler switch
(60).
NOTE: Replace the hydraulic coupler release timer in its socket. Ensure the ignition switch is in the ACC position. Move the hydraulic
coupler switch to the UNLATCH position and release.
31 Terminal for wire 547A (at the 12 volts for Check the circuit between the hydraulic coupler release timer and the
hydraulic release solenoid) to ground approximately hydraulic coupler solenoid (61).
20 seconds Bad hydraulic coupler release timer.
63 Self Level Override Switch

NOTE: Disconnect the connector from the self level override switch. Put the ignition switch in the ACC position.
32 Terminal for wire 540E to ground 12 volts Check the circuit between the self level override switch and the 10
33 Between the terminals of the self open Bad self level override switch.
level override switch
NOTE: Put the self level override switch in the OFF position.
34 Between the terminals of the self Continuity Bad self level override switch.
level override switch
64 Self Level Override Solenoid

35 Terminal for wire 178BW to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the ACC position. Put the self level override switch in the OFF position.
36 Terminal for wire 414D to ground 12 volts Check the circuit between the self level override solenoid and the self
level override switch (63). Also check the self level override switch (63).

4001-48
65 Loader Valve Float Spool Switch
NOTE: Disconnect the connector from the loader valve float spool switch. Put the ignition switch in the ACC position.
37 Terminal for wire 540S to ground 12 volts Check the circuit between the loader valve float spool switch and the 10
38 Between the terminals of the open Bad loader valve float spool switch.
loader valve float spool switch
NOTE: Move the left control handle to the FLOAT position.
39 Between the terminals of the Continuity Bad loader valve float spool switch.
loader valve float spool switch
66 Loader Valve Tip Spool Switch

NOTE: Disconnect the connector from the loader valve tip spool switch. Put the ignition switch in the ACC position.
40 Terminal for wire 540R to ground 12 volts Check the circuit between the loader valve tip spool switch and the 10
41 Between the terminal for wire open Bad loader valve tip spool switch.
540R and the terminal for wire 414F of
the loader valve tip spool switch
NOTE: Have another person move and hold the right control handle to the DUMP position.
42 Between the terminal for wire Continuity Bad loader valve tip spool switch.
540R and the terminal for wire 414F of
the loader valve tip spool switch

4001-49
NOTES

4001-50
65
58 53
62 57 59 60 63
57 66
54
55 61 64
HI01E015

B1 200H B3 622A
1
3 E1 706D J3 239A
4 F1 234A A4 786B
G1 257A B4 124A
H1 641B C4 313A
J1 266A D4 PLUGGED
K1 200D E4 255A
A2 780A F4 235A
B2 131A G4 264A
D2 300D H4 311A
G2 261A J4 PLUGGED
J2 602A K4 178S

4001-51
OPTIONAL COLD START OPTIONAL ROTATING BEACON OPTIONAL HYDRAULIC COUPLER

15
25 22
540L
2
540A 540B
5
539A 539B
641A 641B 4 414A 414B
1 2 57 58 13
549A 549B
14 85 87
2 24 21 20 547C 62
54
178Z
13 23
53 9 27 31
751B
86 30 25 Ω
178BG
14 60 26
1
547B
11 10 15
3
LATCH UNLATCH 30 178BY
547D
751A 766A 766B 178Y 547A
132A 61
28
549C
12
178AJ 19 18 29
178AP
540F 540N
178AF
178BF
7 OPTIONAL RIDE CONTROL 2 OPTIONAL ELECTRIC ACCESSORY OUTLET OPTIONAL SELF LEVEL 2
ON
63 OFF 65 66
56
3343
540P
59 540E
8 17 33
9 32 39
890C 818A 818C 39
33 36 35 38 42
38
414C
7 16 34 37 41 41
414B
548B 548A SPL SL2
SPL SL1 42 540Q
55 64
178AD
414D
540S 540R
4 14E
178AE
414F
6 178BW
40
10 11 12
HI01H007
Circuits Circuits
Components
53. Cold Start Switch 57. Rotating Beacon Switch 62. Hyd. Coupler Release Timer
54. Thermostart Coil 58. Rotating Beacon 63. Self Level Override Switch 414A 1.0 Lt. Blue Self Level Override Switch Cab Options Connector 547A 1.0 Tan Hydraulic Coupler Release Timer Hyd. Coupler Release Solenoid
55. Ride Control Solenoid 59. Accessory Outlet 64. Self Level Override Solenoid 414B 1.0 Lt. Blue Cab Options Connector Self Level Circuit Connector 547B 1.0 Tan Hydraulic Coupler Release Timer Cab Options Connector
56. Ride Control Switch 60. Hydraulic Coupler Switch 65. Loader Valve Float Spool Switch 414C 1.0 Lt. Blue Splice SL2 Loader Valve Float Spool Switch 547C 1.0 Tan Cab Options Connector Hydraulic Coupler Switch
61. Hyd. Coupler Release Solenoid 66. Loader Valve Tip Spool Switch
414D 1.0 Lt. Blue Splice SL2 Self Level Override Solenoid 547D 1.0 Tan Hyd. Coupler Release Solenoid Diode
Circuits
414E 1.0 Lt. Blue Self Level Circuit Connector Splice SL2 548A 1.0 Violet Ride Control Switch Ride Control Switch Connector
NO. GA. COLOR FROM: TO: 414F 1.0 Lt. Blue Splice SL2 Loader Valve Tip Spool Switch 548B 1.0 Tan Ride Control Switch Connector Ride Control Solenoid
132A 1.0 Red Ignition Switch (Ign) Cold Start Switch 539A 1.0 Tan Hydraulic Coupler Switch Cab Options Connector 549A 1.0 Tan Hydraulic Coupler Switch Cab Options Connector
178Y 1.0 Black Rotating Beacon Chassis Ground 539B 1.0 Tan Cab Options Connector Hydraulic Coupler Release Timer 549B 1.0 Tan Cab Options Connector Hydraulic Coupler Release Timer
178Z 1.0 Black Rotating Beacon Dome Light/Switch 540A 1.0 Red Cab Options Connector Splice 549C 1.0 Tan Hydraulic Coupler Release Timer Hydraulic Coupler Resistor
178AD 1.0 Black Accessory Outlet Chassis Ground 540B 1.0 Red Options Fuse Block (10A) Cab Options Connector 641A 1.0 White Cold Start Switch Cab Harness Connector (H1)
178AE 1.0 Black Self Level Circuit Connector Chassis Ground 540E 1.0 Red Splice Self Level Override Switch 641B 1.0 White Cab Harness Connector (H1) Thermostart Coil
178AF 1.0 Black Hyd. Coupler Release Solenoid Ground 540F 1.0 Red Splice Hydraulic Coupler Switch 751A 1.0 Red Options Fuse Block (10A) Cab Options Connector
178AJ 1.0 Black Rotating Beacon Switch Chassis Ground 540L 1.0 Red Splice Aux. Electric Switch #1 751B 1.0 Red Cab Options Connector Rotating Beacon Switch
178AP 1.0 Black Hyd. Coupler Release Timer Ground 540N 1.0 Red Hydraulic Coupler Switch Hydraulic Coupler Switch 766A 1.0 Pink Rotating Beacon Switch Connector
178BF 1.0 Black Hydraulic Coupler Switch Ground 540P 1.0 Red Options Fuse Block (10A) Self Level Circuit Connector 766B 1.0 Pink Connector Rotating Beacon
178BG 1.0 Black Hyd. Coupler Release Solenoid Diode 540Q 1.0 Red Self Level Circuit Connector Splice SL1 818A 1.0 Red Options Fuse Block (10A) Cab Options Connector
178BW 1.0 Black Self Level Override Solenoid Self Level Circuit Connector 540R 1.0 Red Splice SL1 Loader Valve Tip Spool Switch 818C 1.0 Red Cab Options Connector Accessory Outlet
178BY 1.0 Black Hydraulic Coupler Resistor Hydraulic Coupler Release Timer 540S 1.0 Red Splice SL1 Loader Valve Float Spool Switch 890C 1.0 Red Horn Switch Ride Control Switch

4001-52
67 Dome Lamp with Switch

1 Terminal for wire 178Z to ground Continuity Bad ground circuit.
2 Terminal for wire 780D to ground 12 volts Check the circuit between the dome lamp and the 20 ampere fuse in the
primary fuse block (7). Also check the 20 ampere fuse and the primary
fuse block (7).
NOTE: If the readings are good, replace the dome lamp.
68 Deluxe Heater Blower Switch

3 Terminal for wire 830D to ground 12 volts Check the circuit between the heater blower switch and the 30 ampere
fuse in the primary fuse block (7). Also check the 30 ampere fuse and the
NOTE: Put the heater blower switch in the LOW position.
4 Terminal for wire 822A to ground 12 volts Bad deluxe heater blower switch.
NOTE: Put the heater blower switch in the MEDIUM position.
NOTE: Put the heater blower switch in the HIGH position.
NOTE: If the readings are good, replace the deluxe heater blower switch.

4001-53
69 Deluxe Heater
7 Terminal for wire 178BM to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the ACC position. Put the heater blower switch in the LOW position.
8 Terminal for wire 822A to ground 12 volts Check the circuit between the deluxe heater and the deluxe heater blower
switch (68). Also check the deluxe heater blower switch (68).
NOTE: Put the heater blower switch in the HIGH position.
NOTE: If the readings are good, replace the deluxe heater.
70 Foot Heater Blower Switch

11 Terminal for wire 830J to ground 12 volts Check the circuit between the foot heater blower switch and the 30
ampere fuse in the primary fuse block (7). Also check the 30 ampere fuse
and the primary fuse block (7).
NOTE: Put the foot heater blower switch in the LOW position.
12 Terminal for wire 822B to ground 12 volts Bad deluxe heater blower switch.
NOTE: Put the foot heater blower switch in the MEDIUM position.
13 Terminal for wire 824B to ground 12 volts Bad deluxe heater blower switch.
NOTE: If the readings are good, replace the foot heater blower switch.
71 Foot Heater
14 Terminal for wire 178BM to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the ACC position. Put the foot heater blower switch in the LOW position.
15 Terminal for wire 822B to ground 12 volts Check the circuit between the foot heater and the foot heater blower
switch (70). Also check the foot heater blower switch (70).
16 Terminal for wire 824B to ground 12 volts Check the circuit between the foot heater and the foot heater blower
switch (70). Also check the foot heater blower switch (70).
NOTE: If the readings are good, replace the foot heater.

4001-54
72 Front Electric Control Switch
17 Terminal for wire 540G to ground 12 volts Check the circuit between the front electric control switch and the 10
and the options fuse block (8).
NOTE: Put the front electric control switch in the RIGHT direction.
18 Terminal for wire 757C to ground 12 volts Bad front electric control switch.
NOTE: Put the front electric control switch in the LEFT direction.
19 Terminal for wire 756C to ground 12 volts Bad front electric control switch.
73 Auxiliary Electric Switch #1

20 Terminal for wire 540L to ground 12 volts Check the circuit between the auxiliary electric switch #1 and the 10
NOTE: Put the auxiliary electric switch in the DOWN position.
21 Terminal for wire 541A to ground 12 volts Bad auxiliary electric switch #1.
NOTE: Put the auxiliary electric switch in the UP position.
74 Auxiliary Electric Switch #2

23 Terminal for wire 540M to ground 12 volts Check the circuit between the auxiliary electric switch #2 and the 10
NOTE: Put the auxiliary electric switch in the DOWN position.
NOTE: Put the auxiliary electric switch in the UP position.

4001-55
NOTES

4001-56
67
68 70 73 74
71
69
72
HI01E015

B1 200H B3 622A
1
3 E1 706D J3 239A
4 F1 234A A4 786B
G1 257A B4 124A
H1 641B C4 313A
J1 266A D4 PLUGGED
K1 200D E4 255A
A2 780A F4 235A
B2 131A G4 264A
D2 300D H4 311A
G2 261A J4 PLUGGED
J2 602A K4 178S

4001-57
OPTIONAL DELUXE HEATER OPTIONAL FOOT HEATER OPTIONAL AUXILIARY ELECTRIC OPTIONAL LOADER ARM
AUXILIARY ELECTRICAL
11 6 2
780D 19
178Z
67 18 756B 756A 756D 756D
757B 757A 757D 757D
12 16 72 756C 751F 178BJ 178BJ 178BK
71 757C
1 13 11 15
540G 751G
2 SPL-FE1
824B
822B
10 69 17
824C
7 178BR
824A
4 3 14 178AG
822A 70
178AN
823A
6 5 H M L
8
9
178BM
542A 542B 542C 542C

22 541A 541B 541C 541C
830J
68
21 544A 544B 544C 544C
H M L 543A 543B 543C 543C
73 74
25
178BH 178BH
SPL-DH1
24 OPTIONAL MISCELLANEOUS POWER
20
23
178AG
8 830D 830E 540L 540M
178AH
SPL-FH1 12
178BL 2 860A
8 830F 8 8 830G 830H 8 178BX
SPL-DH2 178BN 8 8 178BP 178BS 8
SPL-FH2
13 14 15 16
HI01H008
Components Circuits Circuits

67. Dome Light with Switch 71. Foot Heater NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
68. Deluxe Heater Blower Switch 72. Front Electric Control Switch 178BX 2.0 Black Miscellaneous Power Connector Ground 756C 1.0 Lt. Blue Front Electric Control Switch Frt. Elec. Connector (RH Handle)
69. Deluxe Heater 73. Auxiliary Electric Switch #1
540G 1.0 Orange Frt. Elec. Connector (RH Handle) Front Electric Control Switch 756D 1.0 Pink Front Aux. Electric Connector Loader Arm Electric Connector
70. Foot Heater Blower Switch 74. Auxiliary Electric Switch #2
540L 1.0 Red Splice Aux. Electric Switch #1 757A 1.0 Pink Front Electric Connector Front Aux. Electric Connector
540M 1.0 Red Aux. Electric Switch #1 Aux. Electric Switch #2 757B 1.0 Pink Frt. Elec. Connector (RH Handle) Front Electric Connector
Circuits 541A 1.0 Tan Aux. Electric Switch #1 Cab Options Connector 757C 1.0 Yellow Front Electric Control Switch Frt. Elec. Connector (RH Handle)
541B 1.0 Tan Cab Options Connector Aux. Electric Connector 757D 1.0 Pink Front Aux. Electric Connector Loader Arm Electric Connector
541C 1.0 Tan Aux. Electric Connector Loader Arm Electric Connector 780D 1.0 Red Primary Fuse Block (20A) Dome Light/Switch
178Z 1.0 Black Rotating Beacon Dome Light/Switch
542A 1.0 Tan Aux. Electric Switch #1 Cab Options Connector 822A 2.0 White Deluxe Heater Blower Switch Deluxe Heater
178AG 1.0 Black front Aux. Electric Connector Ground
542B 1.0 Tan Cab Options Connector Aux. Electric Connector 822B 1.0 White Foot Heater Blower Switch Foot Heater
178AH 1.0 Black Aux. Electric Connector Ground
542C 1.0 Tan Aux. Electric Connector Loader Arm Electric Connector 823A 2.0 Yellow Deluxe Heater Blower Switch Deluxe Heater
178AN 1.0 Black Front Electrical Connector Ground
543A 1.0 Tan Aux. Electric Switch #2 Cab Options Connector 824A 2.0 Orange Deluxe Heater Blower Switch Deluxe Heater
178BH 1.0 Black Splice FE1 Aux. Electric Connector
543B 1.0 Tan Cab Options Connector Aux. Electric Connector 824B 1.0 Orange Foot Heater Blower Switch Foot Heater
178BJ 1.0 Black front Aux. Electric Connector Splice FE1
543C 1.0 Tan Aux. Electric Connector Loader Arm Electric Connector 824C 1.0 Orange Foot Heater Blower Switch Foot Heater Blower Switch
178BK 1.0 Black Splice FE1 Loader Arm Electric Connector
544A 1.0 Tan Aux. Electric Switch #2 Cab Options Connector 830D 2.0 Red Wiper Power Connector Splice DH1
178BL 2.0 Black Wiper Power Connector Splice DH2
544B 1.0 Tan Cab Options Connector Aux. Electric Connector 830E 2.0 Red Splice DH1 Deluxe Heater Blower Switch
178BM 2.0 Black Deluxe Heater Splice DH2
544C 1.0 Tan Aux. Electric Connector Loader Arm Electric Connector 830F 2.0 Red Splice DH1 Wiper Power Connector
178BN 2.0 Black Splice DH2 Wiper Power Connector
751F 1.0 Red Options Fuse Block (10A) Front Electric Connector 830G 2.0 Red Wiper Power Connector Splice FH1
178BP 2.0 Black Wiper Power Connector Splice FH2
751G 1.0 Red Front Electric Connector Frt. Elec. Connector (RH Handle) 830H 2.0 Red Splice FH1 Wiper Power Connector
178BR 1.0 Black Foot Heater Splice FH2
756A 1.0 Pink Front Electric Connector Front Aux. Electric Connector 830J 1.0 Red Splice FH1 Foot Heater Blower Switch
178BS 2.0 Black Splice FH2 Wiper Power Connector
756B 1.0 Pink Frt. Elec. Connector (RH Handle) Front Electric Connector 860A 2.0 Orange Options Fuse Block (20A) Miscellaneous Power Connector

4001-58

Section
4006
STARTER AND STARTER SOLENOID
4006
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 7-53090 Issued June, 1997
4006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NO-LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brushes and Brush Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Field Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starter Solenoid Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4006-3
SPECIFICATIONS
Manufacturer ........................................................................................................................................ Nippondenso
Nippondenso part number .................................................................................................................... 128000-0211
Case part number ................................................................................................................................... 1987559C1
No-Load Test at 80°F (26.7°C)
Volts ................................................................................................................................................................... 11
Current draw .................................................................................................................... 180 amperes maximum
Starter drive speed ....................................................................................................... 3500 r/min (rpm) minimum
LUBRICATION
Interval ....................................... When the starter is disassembled or each time the engine is removed for repairs
Lubricant
Molykote-GN ........................................................................................ Use on shaft at pinion end of starter drive
Case multipurpose grease ....................................................... Use on bearings, gears, idler gear shaft and spring.
NO-LOAD TEST
General Information B. Select the 18 to 40 volt range.
1. The No-Load Test is done with the starter C. Move the volt lead switch to the EXT. position.
removed from the engine. D. Turn the load control to the OFF position.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive housing.
3. Check to see if the starter drive can be turned.
Pull the gear on the starter drive out of the starter
drive housing. Turn the gear to turn the starter
drive and the armature.
4. If the starter drive cannot be turned, disassemble
the starter and make repairs as needed. Then do
the No-Load Test.
Test Equipment
The No-Load Test can be done using a Sun Electric B795328M
VAT-33 Tester, an equivalent tester, or separate 2. Fasten the starter in a vise or use another
pieces of test equipment. method to prevent the starter from moving. This
A hand held tachometer is needed to measure the must be done to prevent personal injury.
speed of the armature shaft. 3. Connect the positive battery cable to the battery
A remote starter button is needed to actuate the terminal on the starter solenoid and the negative
starter. battery cable to the mounting flange of the
starter.
A fully charged 12 volt battery is needed to supply
the electricity to turn the starter.
Test Procedure
The illustrations in this procedure show the use of the
Sun Electric VAT-33 tester. Other test equipment can
be used. Connect the test equipment according to
this procedure and the manufacturer’s instructions.
1. If the VAT-33 tester is being used:
A. Select the 0 to 100 ampere range.
4006-4
1 3
2 2
B831432J
1. 1. RED VOLTMETER LEAD
B831430J
1. 1. POSITIVE BATTERY CABLE 2. 2. MOTOR TERMINAL
2. 2. BATTERY TERMINAL
6. Connect the black voltmeter lead to the mounting
3. 3. NEGATIVE BATTERY CABLE
flange on the starter.
4. Connect the positive load cable to the positive
post of the battery. Connect the negative load
cable to the negative post.
1
1
2
B831433J
1. 1. BLACK VOLTMETER LEAD
7. Fasten the ammeter clamp around the positive

battery cable so that the tip of the arrow is toward
B831431J the starter.
1. 1. POSITIVE LOAD CABLE
2. 2. NEGATIVE LOAD CABLE
5. Connect the red voltmeter lead to the motor

terminal on the starter solenoid.

4006-5
4 3
2
B831434J
1. 1. AMMETER CLAMP
8. Connect the leads from the remote starter button

to the Battery and Switch terminals. 5
B831436J
1. 1. REMOTE STARTER BUTTON
2. 2. LOAD CONTROL
3. 3. VOLTMETER
4. 4. AMMETER
5. 5. HAND HELD TACHOMETER
10. Look at the ammeter and record the amperage.

11. Use a hand held tachometer check and record
the armature shaft speed.
12. Release the remote starter button and turn the
load control to the OFF position.
1 2
Understanding No-Load Test Results
1. If the current draw and the armature shaft speed
3
B831435J are within the ranges listed in Specifications, the
1. 1. REMOTE STARTER BUTTON starter is good.
2. 2. BATTERY TERMINAL
3. 3. SWITCH TERMINAL 2. Low armature shaft speed and high current draw
are indications of too much friction. Possible
IMPORTANT: Steps 9, 10, and 11 must be done
causes for excessive friction are:
rapidly. Do not load the battery for more than 15
seconds at one time. After the battery has been A. Tight, dirty, or worn bearings.
loaded for 15 seconds, let the starter cool for 60
B. A bent armature shaft.
seconds.
C. Loose pole shoes (pole shoes make contact
9. Actuate the remote starter button and turn the
with the armature).
load control until the voltmeter indicates 11 volts.

4006-6
D. A short circuit in the armature coil. B. An open armature coil. Disassemble the
Disassemble the starter. Use an armature starter and check for burned commutator bars.
tester to test the ar mature. Use the Use an armature tester to test the armature.
instructions included with the armature tester. U s e th e i n s t r u c t i o n s in c l u d e d w it h t h e
armature tester.
E. Damaged field coil. Do the test on page 12.
C. Brushes not making good contact with the
3. If the armature does not rotate and the current
commutator bars. Check for high insulation
draw is high, possible causes are:
between the commutator bars, broken brush
A. Field terminal making contact with the field springs, or worn brushes.
frame. Inspect the insulators for the field
5. Low armature shaft speed and low current draw
terminal.
are indications of:
B. Damaged field coil. Do the tests on page 12.
A. Dirt or corrosion on connections.
C. Damaged bearings.
B. Damaged wiring.
4. If the armature does not rotate and the current
C. Dirty commutator bars.
draw is zero, possible causes are:
D. All causes in step 4.
A. An open field armature circuit. Disassemble
the sta rte r an d inspe ct th e fie ld coil 6. High armature shaft speed and high current draw
connections. are indications of a short circuit in the field coil. It
is difficult to find a short circuit in a field coil.
Install a new field coil. Do the No-Load Test
again to check for improvement in the operation
of the starter.
DISASSEMBLY
STEP 1 STEP 3
Pull back the boot on the motor terminal, loosen and remove
the nut and lock washer.
STEP 2
B330733M
Loosen and remove the cap screws.
B330732M
Loosen and remove the screws that hold the cover.

4006-7
STEP 4 STEP 8
B330735M B330739M
Remove the cover. Remove the armature.
STEP 5 STEP 9
B330736M B330740M
Hold the spring away from one of the brushes Fasten the starter solenoid in a vise and loosen and
connected to the field coil and remove the brush from remo ve th e sc rew s tha t h old th e sta rter d rive
the brush holder. Repeat this step for the other brush housing.
connected to the field coil.
STEP 10
STEP 6
B330741M
B330737M Remove the starter drive housing from the starter

Remove the brush holder. solenoid.
STEP 7
Remove the field frame assembly.

4006-8
STEP 11 STEP 15
B330743M B330703M
Push down the starter drive housing as shown to Remove the idler gear.
loosen and remove the starter drive.
STEP 16
STEP 12
B330704M
B330744M Remove the bearing cage.

Remove the steel ball from the starter drive. If
necessary, use a magnet. STEP 17
STEP 13
Remove the O-ring from the groove in the starter
drive housing.
STEP 14
B330705M
Remove the thrust washer.
B330702M
Remove the spring.

4006-9
STEP 18 STEP 21
B330706M B330709M
Loosen and remove the screws that hold the cover. Remove the plunger.
STEP 19 STEP 22
If necessary, use a hammer to loosen the cover.
STEP 20
B330710M
If necessary, remove the gasket from the cover.
B330708M
Remove the cover.
INSPECTION
All parts except the starter drive must be cleaned 3. Use a spring scale to check the tension of the
using mineral spirits and a brush or cloth. Use a brush springs. Pull the brush spring up until the
clean, dry cloth to clean the starter drive. brush spring is just above the brush holder. The
scale indication must be between 1.8 and 4.1 kg
Brushes and Brush Springs (4 and 9 pounds). If a brush spring is not as
specified, use a new brush spring when the
1. If the length of the brush fastened to the brush starter is assembled.
holder is less than 11 mm (7/16 inch), a new
brush holder assembly must be used when the Brush Holder
starter is assembled.
1. 1. Hold the leads of an ohmmeter against the
2. If the length of a brush fastened to the field coil is
frame and the brush holders that have insulation
less than 11 mm (7/16 inch), a new field frame
between the brush holder and frame.
assembly must be used when the starter is
assembled.

4006-10
B313142M B313141M
2. If there is an indication of a complete circuit, 5. If the depth of the groove between the
install a new brush holder. commutator bars is less than 0.2 mm (0.008
inch), cut the insulation between the commutator
Armature bars to a depth of 0.4 to 0.8 mm (1/64 to 1/32
inch). Use sandpaper to remove the rough edges
1. Test the armature on an armature tester. Use the from the commutator bars.
equipment manufacturer’s instructions.
6. Check the bearings on the armature for free
2. Put the armature on vee-blocks as shown and rotation, rough balls, and damage to the inner
check the runout of the armature with a dial race or outer race. If a bearing is to be replaced,
indicator. The runout must not be more than 0.05 use a press and acceptable tools to remove and
mm (0.002 inch). install the bearings.
Field Coil Test

1. Hold the leads of an ohmmeter against one of
the brushes and the field frame. The needle of
the ohmmeter must not move.
B313141M
3. If necessary, put the armature in a lathe and

remove enough material from the commutator to
make the runout less than 0.05 mm (0.002 inch).
4. Measure the diameter of the commutator. If the
diameter is less than 35 mm (1.38 inch), install a
B610614M
new armature.
2. If the needle of the ohmmeter moved, install a
new field frame assembly.
3. Hold the leads of the ohmmeter against one of
the brushes and the end of the cable. The needle
of the ohmmeter must move.

4006-11
B610616M
4. If the needle of the ohmmeter did not move,

install a new field frame assembly.

4006-12
4
1
5
6
2
9 3 7
5
12
8
11
10
2 14
13
15
2
17 18
14
2
1
1
16
22
2
19
18
23
2
22
1
21
17 20
5
3 2
B890680J
1. SCREW 7. STEEL BALL 13. THRUST WASHER 19. FIELD FRAME
2. LOCK WASHER 8. SPRING 14. NUT 20. CAP SCREW
3. FLAT WASHER 9. BEARING CAGE 15. PLUNGER 21. BRUSH HOLDER
4. STARTER DRIVE HOUSING 10. IDLER 16. GASKET 22. BEARING
5. O-RING 11. STARTER SOLENOID ASSEMBLY 17. COVER 23. ARMATURE
6. STARTER DRIVE 12. ROLLER 18. BRUSH 24.

4006-13
ASSEMBLY
STEP 23 STEP 27
Install the plunger in the starter solenoid.
STEP 24
B330714M
Install the bearings in the bearing cage.
B330711M STEP 28
If necessary, install a new gasket in the cover.
STEP 25
B330715M
Lubricate the bearings and teeth of the idler gear with

the grease specified on page 3.
B330708M
Install the cover. STEP 29
STEP 26
B330834M
Install the thrust washer.

B330712M
Install and tighten the screws.

4006-14
STEP 30 STEP 33
B330704M B330838M
Install the bearing cage as shown. Install a new O-ring in the groove in the starter drive housing.
Lubricate the O-ring.
STEP 31
STEP 34
B330703‘M
Install the idler gear. B330841M
Lubricate the open bearing on the starter drive with the grease
STEP 32 specified on page 3.
STEP 35
B330837M
Install the spring.

B330802M
Insert the starter drive into the starter drive housing.

4006-15
STEP 36 STEP 39
B330803M B330805M
Push down on the starter drive housing to push the Install a lock washer, flat washer, and O-ring on the
starter drive all the way into the starter drive housing. screws that hold the starter drive housing to the
starter solenoid. Lubricate the O-rings.
STEP 37
STEP 40
B330804M
Put a small amount of grease in the hole in the B330807M
starter drive and install the steel ball in the hole. Install the screws in the starter drive housing.
STEP 38 STEP 41
B330741M B330740M
Assemble the starter drive housing and starter Fasten the starter solenoid in the vise and tighten the
solenoid. screws that hold the starter drive housing.

4006-16
STEP 42 STEP 45
B330739M B330809M
Install the xxxarmature. Install the brush holder.
STEP 43 STEP 46
B330738M B330810M
Install the field frame assembly. Put the springs on top of the brushes connected to
the brush holder.
STEP 44
STEP 47
B330808M
Use the springs to hold the brushes in the brush B330811M
holder as shown. Install the brushes that are connected to the field coil.

4006-17
STEP 48 STEP 51
B330812M B330815M
Use a cap screw to align the brush holder with the Install and tighten the screws that hold the brush
field frame assembly. holder.
STEP 49 STEP 52
B330813M B330816M
Move the brush holder so that the brush holder is Install a lock washer, flat washer, and O-ring on the
even with the end of the armature. cap screws. Lubricate the O-rings.
STEP 50 STEP 53
B330814M B330818M
Install and align the cover with the brush holder. Install and tighten the cap screws.

4006-18
STEP 54 STEP 55
Pull the boot over the motor terminal.
B330731M
Install the cable, lock washer, and nut on the motor

terminal. Tighten the nut.
STARTER SOLENOID TEST

This test will check the condition of the pull-in 3. Connect a jumper wire to the battery terminal
win ding an d the h old -in w ind ing in the sta rter and the switch terminal in the starter solenoid
solenoid. housing. The jumper wire must be made from
No. 10 or larger wire.
The jumper cable connected to the starter mounting
flange and the motor terminal must have a common 4. Connect the jumper cable with the common
connection at the negative battery post. connection to the starter mounting flange and the
motor terminal in the starter solenoid housing.
Starter Solenoid Test Procedure NOTE: Steps 5 and 7 must be done in a maximum
1. Remove the rubber boot from the motor terminal. of 15 seconds to prevent damage to the pull-in
Remove the nut and lock washer from the motor winding and the hold-in winding.
terminal. Then remove the wire from the motor 5. Connect the jumper cable with the common
terminal. connection to the negative battery post. The
2. Connect a jumper cable to the positive battery pinion gear on the starter drive must come all the
post of a fully charged 12 volt battery. Connect way out rapidly and with force.
the other end of the jumper cable to the battery 6. If the pinion gear did not come out rapidly and
terminal in the starter solenoid housing. with force, the pull-in winding is damaged. The
complete starter solenoid housing assembly
2 must be replaced.
7. Disconnect the jumper cable from the motor
terminal in the starter solenoid housing. The
pinion gear on the starter drive must not move
3 1 toward the starter drive housing.
5 8. If the pinion gear started to move toward the
4 starter drive housing, the hold-in winding is
damaged. The complete starter solenoid housing
assembly must be replaced.
B831438R
1. 12 VOLT BATTERY
2. STARTER
3. BATTERY TERMINAL
4. SWITCH TERMINAL
5. MOTOR TERMINAL

Section
4007
ALTERNATOR
4007

Racine, WI 53404 U.S.A. Bur 7-53100 June, 1997
4007-2
TABLE OF CONTENTS
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection of Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection and Testing of Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection and Testing of Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Testing the Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection and Replacement of Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4007-3
ALTERNATOR
Disassembly STEP 3
STEP 1
B523411M
Remove the tapered bushing and the pulley from the

B518007M
shaft.
Fasten the pulley of the alternator in a vise that has
soft jaws. Loosen and remove the nut and lock STEP 4
washer.
STEP 2
B523413M
Remove the fan from the shaft.
B523405M STEP 5
Hit the face of the pulley with a soft hammer to
loosen the tapered bushing in the pulley.
B8971201M
Loosen and remove the screws and flat washers that

fasten the voltage regulator and brush holder to the
housing.

4007-4
STEP 6 STEP 9
B8971204M B8971213M
Remove the voltage regulator and brush holder. Loosen and remove the nut, flat washer, and fiber
washers from the D+ terminal.
STEP 7
STEP 10
B8971207M
Disconnect the lead for the capacitor. B8971216M
Loosen and remove the nut, flat washer, and fiber

STEP 8 washers from the B+ terminal.
STEP 11
B8971210M
Loosen and remove the screw and the capacitor.

B8971219M
Make an alignment mark on the cover, the stator,

and the housing.

4007-5
STEP 12 STEP 15
B8971222M B8971301M
Loosen and remove the screws that fasten the cover, Remove the rotor from the cover.
stator, and housing together.
STEP 16
STEP 13
1. Screws
B8971304M
B8971231M Loosen and remove the screws that fasten the

Remove the cover and rotor from the stator and rectifier bridge to the housing.
housing. The cover can be difficult to remove. Use a
soft hammer as required to remove the cover. STEP 17
STEP 14
B8971307M
Remove the housing.

B8971508M
Loosen and remove the screws that fasten the

bearing retainer to the cover. The rotor now can be
removed.

4007-6
STEP 18 Inspection of Brushes
STEP 21
B8971310M
Remove the insulator from the B+ terminal.

B9064411M
STEP 19 Use an ohmmeter and check the continuity from
each terminal and brush. If the reading is zero,
replace the brush or voltage regulator and brush
holder.
STEP 22
B8971313M
Remove the insulator from the D+ terminal.
STEP 20
B9064414M
Remove the shield.
B8971319M
Remove the shield from the housing.

4007-7
STEP 23 Inspection and Testing of Rotor
STEP 26
B9064418M
Measure the length of each brush. If the length of

one brush is less than 14 mm (0.55 inch) replace B9064405M
both brushes or the voltage regulator and brush Touch the leads of the ohmmeter to the slip rings.
holder. The reading must be as specified below. If the
reading is not as specified, a new rotor must be
STEP 24 installed.
45 Ampere Alternator . . . . . . . . . . . 8.1 to 9.9 ohms
65 Ampere Alternator . . . . . . . . . 2.52 to 3.08 ohms
STEP 27
B9064421M
To replace the brushes, use a soldering iron to

remove the original brushes. Install the springs and
new brushes and use rosin core solder to solder the
leads to the terminals. Before soldering the terminal
shown, open the sleeve for the brush lead and then B9064407M
crimp the sleeve. Touch the leads to each slip ring and the shaft. If a
reading shows continuity, a new rotor must be
STEP 25 installed.
B9064414M
Install the shield.

4007-8
STEP 28 STEP 31
B9064433M B9064319M
Use a dial indicator and measure the runout of each Touch the leads of the ohmmeter to each lead from
slip ring. If the runout is more than 0.05 mm (0.002 the stator and the common connection. The readings
inch) a new rotor must be used or use a lathe to must be as specified below. If the readings are not as
carefully remove enough material until the runout is specified, a new stator must be installed.
less than specified. 45 Ampere Alternator . . . . . . . . . 0.20 to 0.24 ohms
STEP 29 95 Ampere Alternator . . . . . . . . . 0.05 to 0.06 ohms
B9064436M B9064322M
Measure the diameter of the slip ring. The diameter Touch the leads of the ohmmeter to each lead from
must not be less than 26.8 mm (1.055 inch). th e st at o r a n d t he fr a me . I f a re a d in g sh o w s
continuity, a new stator must be installed.
Inspection and Testing of Stator
STEP 32
STEP 30
Look for burned insulation on the coils of the stator.
This is an indication of a short circuit. Install a new
stator.
B9064502M
Use a high watt soldering iron and rosin core solder

to solder the leads of the stator to the rectifier bridge.

4007-9
Testing the Capacitor STEP 36
STEP 33
B9064332M
Touch the leads of the ohmmeter to a negative diode

B9064424M
and the heat sink as shown. Then reverse the leads.
Touch the leads of the ohmmeter to the capacitor as There must be a high reading and a low or zero
shown. The resistance reading will increase and then reading. Then test the other two negative diodes. If a
return to zero as the capacitor is charged. If there is negative diode did not have readings as specified,
no indication of resistance, a new capacitor must be the negative diode is bad and a new rectifier bridge
installed. The capacitor is used to reduce radio noise. must be installed.
NOTE: If the tester you are using has a diode test
STEP 34 function, use the tester according to the instructions
Touch the terminal to the bracket to discharge the of the manufacturer to check the positive and
condenser. negative diodes.
Testing the Rectifier Bridge

STEP 35
B9064402M
Touch the leads of the ohmmeter to a positive diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero
reading. Then test the other two positive diodes. If a
positive diode did not have readings as specified, the
positive diode is bad and a new rectifier bridge must
be installed.

4007-10
B9064327M B8971429M
B. Remove the bearing retainer.

Inspection and Replacement of
Bearings
STEP 37
B8971432M
C. Use a suitable support between the rear

bearing and the slip ring on the other end of
the rotor shaft. Press the rotor shaft out of the
B8971402M rear bearing.
Inspect the bearings on the rotor. If the bearings are
damaged, use the following procedure to replace the
bearings.
B8971429M
D. Install the bearing retainer on the rotor shaft.
B8971426M
A. Use a suitable support between the front

bearing and the bearing retainer on the rotor
shaft. Press the rotor shaft out of the front
bearing and the spacer.

4007-11
B8971435M
E. Press the new front bearing onto the rotor

shaft until the front bearing stops moving.
B8971504M
F. Press the spacer onto the rotor shaft until the

spacer stops moving.
B8971505M
G. Press the new rear bearing onto the other end

of the rotor shaft.

4007-12
21 18 16
22
24
23
17
23
22 19
23 24
20
21 9
23 10
25
11
26 12
7
27
7 14
15
13
1
2
3
B9402123A
1. NUT 8. COVER 15.STATOR 22.FLAT WASHER

2. LOCK WASHER 9. SPACER 16.SCREW 23.NUT
3. SPACER 10.FRONT BEARING 17.RECTIFIER BRIDGE 24.LOCK WASHER
4. SCREW 11. BEARING RETAINER 18.INSULATOR 25.BRUSH
5. PULLEY 12.KEY 19.SHIELD 26.VOLTAGE REGULATOR
6. FAN 13.ROTOR 20.HOUSING AND BRUSH HOLDER
7. SCREW 14.REAR BEARING 21.FIBER WASHER 27.CAPACITOR

4007-13
Assembly STEP 41
STEP 38
B8971601M
Install the housing on the rectifier bridge.

B8971316M
Install a new shield in the housing. STEP 42
STEP 39 1. SCREWS
B8971304M
Install and tighten the screws that fasten the rectifier

B8971313M
bridge to the housing.
Install the insulator on the D+ terminal.
STEP 43
STEP 40
B8971604M
B8971310M
Install the fiber washers, flat washer, and nut on the
Install the insulator on the B+ terminal. B+ terminal.

4007-14
STEP 44 STEP 47
B8971607M B8971301M
Check for a short circuit between the B+ terminal and Install the rotor in the cover.
the housing. If there is continuity, the insulator is bad.
STEP 48
STEP 45
B8971508M
B8971610M Install and tighten the screws that fasten the bearing
Install the fiber washers, flat washer, and nut on the retainer and rotor to the cover.
D+ terminal.
STEP 49
STEP 46
B8971231M
B8971613M Make sure the marks are in alignment and install the
Check for a short circuit between the D+ terminal and cover and rotor in the stator and housing.
the housing. If there is continuity, the insulator is bad.

4007-15
STEP 50 STEP 53
B8971222M B8971622M
Install and evenly tighten the screws that fasten the Install the voltage regulator and the brush holder. Be
housing, stator, and cover. careful not to damage the brushes.
STEP 51 STEP 54
B8971616M B8971625M
Install the capacitor and tighten the screw. Install the screws and flat washers and tighten the
screws.
STEP 52
STEP 55
B8971616M
Connect the lead to the terminal. B523413M
Install the fan.

4007-16
STEP 56
B523418M
Install the pulley and the tapered bushing.
STEP 57
B523407M
Install the lock washer and start the nut onto the
shaft.
STEP 58
B518009M
Fasten the pulley in a vise with soft jaws. Tighten the

nut to 44 to 60 to 70 Nm (52 pound-feet).

SECTION INDEX
POWER TRAIN

Hydrostatic System - “How it Works” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000
Hydrostatic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
Removal and Installation of Hydrostatic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6004
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
Drive Motors with Spring Applied - Hydraulic Release Brakes
(European and Optional North American Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Sprockets, Chains, and Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011

CASE CORPORATION
Section
6000
HYDROSTATIC SYSTEM
“HOW IT WORKS”
6000
CASE CORPORATION
700 State Street
6000-2
TABLE OF CONTENTS
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MECHANICAL PARKING BRAKE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HYDRAULIC BRAKE OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDROSTATIC CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDROSTATIC SYSTEM CLEANUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HYDROSTATIC START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6000-3
SYSTEM OVERVIEW
The drive system for the 60XT and 70XT Skid Steers The Skid Steers are operated by moving the control
is powered by a tandem hydrostatic pump which levers forward or backward to control the hydrostatic
receives power from the engine. The hydrostatic pump. Each hand control lever is connected to a
pumps drive two hydrostatic motors, located on both control valve in each hydrostatic pump. As the control
sides of the Skid Steer. The hydrostatic drive system valve is rotated, oil is directed through the pumps to
has a single speed range. Each gerotor hydrostatic the hydrostatic drive motors. To move the machine in
drive motor drives a dual sprocket directly, which in a straight line, both control levers are moved
turn drives both axles through a chain drive system. approximately the same distance in the same
The standard Skid Steers have mechanically direction. To steer the unit in either direction, one
operated pin type brakes which are actuated by the control lever is moved less distance in the same
seat bar. The brakes are mounted to the chain tanks direction. To counter-rotate, one control lever is
on the chassis in front of the hydraulic drive motors. moved in the forward direction and the other control
The Skid Steers can optionally be equipped with two lever is moved in the reverse direction.
spring applied and hydraulically released wet disk
parking brakes. The brakes are mounted between
each hydrostatic drive motor and the output shaft to
the drive chain sprockets. The brakes are released
with hydrostatic system charge pressure by the same
control that supplies charge pressure to the servo
control system of the hydrostatic pumps. There are
interlock switches that automatically override the
tandem pump servo controls unless the operator is in
the seat with the lap bar down in the operating
position. The brakes are also engaged. This prevents
the potential for driving through the parking brakes.

6000-4
HS01D051
1. HYDRAULIC FILTER 5. BRAKE SOLENOID VALVE 9. OIL COOLER
2. HYDRAULIC FILTER BYPASS VALVE SWITCH 6. HYDRAULIC CONTROL VALVE 10. SUCTION SCREEN IN RESERVOIR
3. LH DRIVE MOTOR/BRAKE ASSEMBLY 7. HYDROSTATIC PUMP (PISTON)
4. RH DRIVE MOTOR/BRAKE ASSEMBLY 8. HYDRAULIC EQUIPMENT PUMP
HYDROSTATIC DRIVE SYSTEM

6000-5
HS01D052
1. LOADER VALVE 5. BUCKET CYLINDER 9. HYDRAULIC TANK SIGHT GAUGE

2. DRIVE MOTOR 6. LOADER LIFT CYLINDER 10. OIL COOLER
3. TANDEM PUMP 7. AUXILIARY VALVE 11. GEAR PUMP
4. SOLENOID VALVE 8. OIL FILTER
HYDRAULIC COMPONENTS

6000-6
All closed loop hydrostatic power trains are basically The pump is usually a piston type unit which has the
as their name implies, a closed loop. In a standard ability to vary the rate and the direction of the oil flow.
open loop hydraulic system, the oil flows from the This is accomplished by changing the position of the
reservoir, to the pump, to the control valve (to do the pump’s swash plate in relation to the rotating group
work), and then back through the cooler, filter and (made up of pistons and cylinder block). The angle of
then to the reservoir. the swash plate causes the pistons to stroke into and
out of the cylinder block bores as it is rotated.
In a hydrostatic closed loop system, the pump and
Changing this angle varies the piston stroke and,
the drive motor are directly connected to each other.
therefore, the amount of oil being pumped to the
The hydrostatic pump sends oil directly to the motor
motor. Tilting the swash plate in the opposite
and this same oil returns back to the pump.
direction will reverse the flow to the motor and hence
the direction of motor rotation. This causes the unit to
travel in the opposite direction.

6000-7
2
11
5 4
7 10
12
11
6
9
8
HS01D053
1. RESERVOIR 5. HEAT EXCHANGER 9. FLOW BI-DIRECTIONAL
2. CONTROL VALVE 6. CASE DRAIN LINE 10. OUTPUT SHAFT
3. CYLINDER 7. INPUT SHAFT 11. PUMP
4. FILTER 8. RESERVOIR 12. MOTOR
HYDROSTATIC SYSTEM

6000-8
High pressure oil is also used to minimize wear in the swash plate. The same pressure the piston sees
rotating group, as well as drive the motors. To prevent while pumping will be passed through the drilled hole
the slippers on the pistons from wearing out too to provide a column of oil for the piston to ride upon.
rapidly as they rotate, there is a small hole drilled A smaller area of the slipper is pressurized than the
through the piston and slipper to allow oil to area of the piston. This difference in area will keep
constantly form a cushion between the slipper and the slipper held against the swash plate.
HS01D054
1. SWASH PLATE 3. PISTON 5. VALVE PLATE
2. SLIPPER 4. PISTON BLOCK

6000-9
With the high pressures required to drive the In order for the low pressure charge oil to get into the
machines, some of the closed loop oil will leak into closed loop, a check valve is placed between the
the case drain of the components. A system to charge oil supply and each side of the closed loop.
makeup for this lost oil is required to keep the system The pressure on the return side of the loop is low
working. A fixed displacement charge pump is used enough to allow oil to flow from the charge pump
to make up for this loss. The charge pump supplies circuit, through the check valve, to keep the pump
cooled and filtered oil from the reservoir, under a fully supplied with oil. The check valve on the drive
relatively low pressure, to the closed loop, keeping side of the circuit is held closed by the high pressure
the system charged and also supplying fluid to on that side of the loop. When the direction of travel
operate the control system. is reversed, charge flow would then enter the loop on
the opposite side.
HS01D055
1. CONTROL LEVER 7. RESERVOIR 13. BYPASS VALVE
2. SERVO CONTROL 8. NONE 14. CYLINDER BLOCK ASSEMBLY
3. ORIFICE 9. RELIEF/CHECK VALVE 15. FIXED SWASH PLATE
4. INPUT SHAFT 10. CHARGE PUMP 16. FIXED DISPLACEMENT MOTOR
5. SERVO PISTON 11. RELIEF/CHECK VALVE 17. OUTPUT SHAFT
6. VARIABLE DISPLACEMENT PUMP 12. CHARGE RELIEF VALVE
HYDROSTATIC CLOSED LOOP SYSTEM

6000-10
HYDROSTATIC PUMP
The Skid Steers use a tandem axial piston Apply Molykote Type Gn lubricating paste to the
hydrostatic pump supplied by Sauer/Danfoss. A pump input spline to minimize spline wear. The Case
geroter style charge/hydraulic pump is also part of par t number for a 82.8 ml (2.8 ounce) tube of
the assembly. There is a high pressure loop relief Molykote Type Gn paste is 384646R1.
valve for each direction of the hydrostatic pump.
This pump assembly has test ports to allow pressure
The swash plate is servo hydraulic controlled, which test readings to be taken at almost any location that
means that the travel control hand linkage operates a may ever be required. See the following diagrams for
hydraulic control valve, which in turn controls the the location of these test ports.
servo piston.

6000-11
1 2 3 4
HI01E019
9 7 8 6 5
10
11
12
HI01E018
1. RH MOTOR REVERSE TEST PORT 7. RH MOTOR FORWARD TEST PORT

2. RH REVERSE CIRCUIT RELIEF 8. RH FORWARD CIRCUIT RELIEF
3. LH FORWARD CIRCUIT RELIEF 9. CHARGE PRESSURE TEST PORT 1
4. LH MOTOR FORWARD TEST PORT 10. CHARGE PUMP INLET
5. LH MOTOR REVERSE TEST PORT 11. BYPASS/TOW VALVE
6. LH REVERSE CIRCUIT RELIEF 12. CHARGE RELIEF VALVE

6000-12
HS01D057
1. SEAL 9. COVER 17. RETAINER 25. SNAP RING 33. PIN
2. SNAP RING 10. ROLL PIN 18. GUIDE 26. PLATE 34. COVER
3. SNAP RING 11. JOURNAL BEARING 19. RETAINING RING 27. NEEDLE BEARING 35. O-RING
4. BALL BEARING 12. RETAINER 20. PIN 28. GASKET 36. O-RING
5. SHAFT 13. PLATE 21. CYLINDER BLOCK 29. HOUSING 37. O-RING
6. SPECIAL BOLT 14. ROLL PIN 22. WASHER 30. COUPLING
7. SPECIAL BOLT 15. PIN 23. SPRING 31. PIN
8. ROLL PIN 16. PISTON 24. WASHER 32. GEAR
REAR PUMP CYLINDER, BEARINGS, SHAFT AND PLATE

6000-13
HS01D058
1. TANDEM PUMP 8. RETAINING RING 14. SPECIAL BOLT 19. LEVER 26. SPOOL
2. SPECIAL NUT 9. NUT 15. RING 20. SCREW 27. BACKUP RING
3. SCREW 9A. JAM NUT 15A.O-RING 21. BRACKET 28. O-RING
4. HEX PLUG 10. GUIDE 16. PISTON 22. SPRING 29. SLEEVE
5. O-RING 11. SPRING 17. COVER 23. GUIDE 30. RING
6. COVER 12. SLEEVE 18. LOCK NUT 24. BACKUP RING
7. GASKET 13. GUIDE 18A.LOCK WASHER 25. O-RING
REAR PUMP PISTON, COVERS AND BRACKET

6000-14
HS01D059
1. HOUSING 8. O-RING 15. VALVE POPPET
2. PLUG 9. ADAPTER 16. SPRING
3. O-RING 10. BOLT 17. SHIM KIT
4. RELIEF VALVE 11. SEAL 18. O-RING
5. SPRING 12. O-RING 19. HEX PLUG
6. PLUG 13. BACKUP RING 20. PLUG
7. HEX PLUG 14. TOW VALVE 21. O-RING
REAR PUMP VALVES, PLUGS, AND ADAPTER

6000-15
HS01D060
1. ROLL PIN 9. WASHER 17. ROLL PIN 25. SHAFT
2. ROLL PIN 10. CYLINDER BLOCK 18. PIN 26. SNAP RING
3. GASKET 11. PIN 19. RETAINER 27. BALL BEARING
4. NEEDLE BEARING 12. RETAINING RING 20. JOURNAL BEARING 28. SNAP RING
5. PLATE 13. GUIDE 21. ROLL PIN 29. SEAL
6. SNAP RING 14. RETAINER 22. COVER 30. PLATE
7. WASHER 15. PISTON 23. SPECIAL BOLT 31. BOLT
8. SPRING 16. PLATE 24. SPECIAL BOLT
FRONT PUMP CYLINDER, BEARINGS, SHAFT AND PLATES

6000-16
HS01D061
1. HOUSING 9A. JAM NUT 16. PISTON 23. GUIDE
2. SPECIAL NUT 10. GUIDE 17. COVER 24. BACKUP RING
3. HEX PLUG 11. SPRING 18. LOCK NUT 25. O-RING
4. O-RING 12. SLEEVE 18A.LOCK WASHER 26. SPOOL
5. SCREW 13. GUIDE 19. LEVER 27. BACKUP RING
6. COVER 14. SPECIAL BOLT 20. SCREW 28. O-RING
7. GASKET 15. RING 21. BRACKET 29. SLEEVE
8. RETAINING RING 15A.O-RING 22. SPRING 30. RING
9. NUT
FRONT PUMP PISTON, COVERS AND BRACKET

6000-17
NOTE: 2
THIS ILLUSTRATION SHOWS
A TYPICAL HYDROSTATIC
P U M P. A L L VA LV E S A N D
INLETS ARE AS SHOWN.
1
HI01E018
1. BYPASS/TOW VALVE 2. CHARGE PUMP INLET

6000-18
HYDROSTATIC DRIVE MOTOR

The drive motors on 60XT and 70XT Skid Steers are To assure adequate drive loop cooling, a shuttle
geroter type supplied by Eaton (VIS 40, 30cir). valve is incorporated into the drive motor. This shuttle
valve centers when the pump is in neutral and
The gerotor motors require much more oil to
pressure is even on both sides of the drive loop. The
complete one revolution than the pump can put out in
shuttle valve shifts, when the unit is in motion, to
one revolution. Because of this difference in
allow the charge pressure side (low pressure) of the
displacement, the motor output speed is much slower
closed loop to port oil to an orifice. The oil flows from
than the pump drive speed and also the motor output
the orifice to the motor case drain port. This flow of
torque is much higher than what is required to drive
oil through the orifice, at charge pressure, assures an
the pump.
exchange of oil from the closed loop for cooling and
filtration. This loop cooling flow begins as soon as the
drive controls are activated and remains constant, no
matter the pressure required to drive the unit

6000-19
HS01D063
1. END CAP 7. DRIVE SHAFT 13. BEARING HOUSING 19. POPPET

2. O-RING 8. THRUST PLATE 14. CAP SCREW 20. PISTON
3. SEAL 9. RETAINER 15. SHAFT SEAL 21. RETAINING RING
4. VALVE PLATE 10. BACK-UP RING 16. PLUG 22. SHIM
5. GEROLER 11. BACK-UP O-RING 17. BUSHING 23. SHAFT
6. BALL 12. SPACER 18. SPRING 24. POPPET

6000-20
MECHANICAL PARKING BRAKE OVERVIEW

The Skid Steers use a mechanical parking brake system. A spring loaded pin engages one of several notches in
the brake plate mounted to the motor shaft. Because of this design, the parking brake pins must NEVER be
engaged while the machine is moving.
To engage the parking brake pins, raise the seat bar. A linkage rod, attached to the right rear of the lap bar, will
release the brake cables, allowing the springs to push the brake pins to engage in the brake plates.
To make sure the machine will not begin to move with the seat bar up and the parking brake pins engaged, start
and run the engine at low idle. Slowly move both steering control levers into FORWARD until the pins engage a
notch in the brake plate.
To disengage the parking brake pins, lower the lap bar to the operating position. If the pins are side loaded by the
brake plates, start the engine and run at low idle while moving the steering control levers in either direction so the
pins can disengage freely. Tension springs are installed in line with the brake cable to allow the seat bar to be
lowered and the engine started.

6000-21
HS01D064
MECHANICAL PIN BRAKES

6000-22
HYDRAULIC BRAKE OPTION

The Skid Steers can be optionally equipped with two spring-applied, hydraulic-released disc type brakes. The
brakes are integrated into the front of the hydraulic motors which are mounted to the chain tanks on the chassis.
The brakes are activated by depressing the brake switch on the left hand control lever. This action causes the
brakes to engage and the transmission control to go to neutral. This prevents the drive sprocket from turning and
the machine from moving. The park brake indicator illuminates on the left control panel. Depressing the brake
switch again will release the brakes.
Power to release the brakes is supplied by charge pressure from the tandem pump to the brake and travel solenoid
valve, located on the right side of the machine. When the solenoid is de-energized the valve opens the brake port
passage to the reservoir.
In the event of electrical or hydraulic failure, the brake piston will automatically engage the brake disc.
HS01D051
1. HYDRAULIC FILTER 5. BRAKE SOLENOID VALVE 9. OIL COOLER

2. HYDRAULIC FILTER BYPASS VALVE SWITCH 6. HYDRAULIC CONTROL VALVE 10. SUCTION SCREEN IN RESERVOIR
3. LH DRIVE MOTOR/BRAKE ASSEMBLY 7. HYDROSTATIC PUMP
4. RH DRIVE MOTOR/BRAKE ASSEMBLY 8. HYDRAULIC EQUIPMENT PUMP
HYDRAULIC BRAKE SYSTEM

6000-23
.
HS01D066
1. SHAFT 7. STATOR PLATE 13. O-RING 19. BEARING CONE

2. SPROCKET HOUSING 8. LINING ASSEMBLY 14. O-RING 20. BOLT
3. FRICTION HOUSING 9. DISC SPRING 15. O-RING 21. SNAP RING
4. MOTOR FLANGE 10. QUAD SEAL 16. BEARING CUP 22. PORT PLUG
5. PISTON 11. O-RING 17. BEARING CONE 23. SHAFT PLUG
6. FRICTION SHIM 12. O-RING 18. BEARING CUP 24. SHAFT END SEAL
DISC BRAKE

6000-24
HYDROSTATIC CONTROL LEVERS

The travel control levers are attached so that they hydrostatic pump when the travel control lever is
pivot out of the way when the lab bar is raised. The perpendicular to the angled top of the control lever.
control levers are returned to the center position with The control rod for the opposite side should be
a centering spring mechanism in the hydrostatic drive adjusted so that it matches the position of the control
pump. The centering mechanism must be adjusted to lever connected first.
allow full speed operation in both directions of travel.
The Skid Steer should be adjusted to travel in a
The levers must also be adjusted to the same
straight line within 1 bucket width at 100 ft.. Travel
position on both sides.
control lever stops are installed on the control rod
A cross shaft for both right and left travel systems is connected the control handle to eliminate control
supported with bearings for each control lever. A lever response lag and also to adjust the linkage to
control rod, with ball joints at each end, interconnects make the machine track in a straight line. The
the control handle to a bellcrank on the end of the hydrostatic pump servo control valve has more travel
c r o s s s h a f t . T h e c o n t r o l h a n d l e p i vo t s h ave than is required to bring the pump to full speed. The
integrated set screws to adjust maximum lower lever stops should be adjusted to stop the lever travel
position for forward and reverse. just as the pump reaches full speed. This adjustment
will make the control system respond as soon as
Each section of the hydrostatic pump has a spring
either lever is moved away from the full speed
centered control valve system to return the servo
position. After adjusting for control lag, if the machine
control to the neutral position. This spring centering
does not travel in a straight line over long distances,
system also returns the control levers to the neutral
reduce the lever travel on the side that the machine is
position. A ball joint control rod is connected between
turning away from until straight line operation is
the hydrostatic pump and the cross shaft. This
achieved.
control rod is to be adjusted so that the ball joint can
be installed into the servo control lever on the
HS01D068
1. LOADER VALVE OVERRIDE 4. DRIVE CONTROL LINKAGE 7. LOADER CONTROL LINKAGE
2. LAP BAR LOCKOUT LINKAGE 5. CONTROL LEVER ADJUSTMENT 8. HANDLE PIVOT ROD
3. CONTROL LOCKOUT PIVOT 6. LOCKOUT CAM ROLLER
STEERING CONTROL LEVERS AND LINKAGE
6000-25
HYDROSTATIC SYSTEM CLEANUP

The hydrostatic system is a closed loop made up of 3. Clean all hoses and tubes in the hydrostatic
the charging pump, piston pump and the hoses system. Remove all hoses and tubes from the
between these components. The hydraulic cooler machine. Flush and clean the hoses and tubes
and reservoir are also part of the closed loop system. with hot soapy water. Hang and allow them to air
Any contamination in the hydrostatic system will stay dr y. Hoses and tubes must be dr y before
in the closed loop, and probably cause damage. If the installing.
piston pump or a motor in the hydrostatic system is
4. Install inspected and repaired, or new piston
removed for repair or replacement, you MUST clean
pumps and motors.
the hydrostatic system. If any contamination is left in
the closed loop, the contamination will damage the 5. Change the hydraulic filter.
remaining components of the system.
6. Make sure the hydraulic system is clean so that
1. Remove the piston pumps and at least the motor the charge pump will not cause new
in the circuit that failed. If there is a quantity of contamination in the closed loop. Remember that
contamination present, removal of the opposite the oil cooler may have internal passages that
motor is also required. can trap and hold contamination which can be
dislodged later and cause a repeat failure.
2. Disassemble, clean, and inspect the piston
pumps and motor(s).

6000-26
HYDROSTATIC START-UP PROCEDURE

Failure of a pump or motor shortly after installation or 3. Fill reservoir with recommended clean hydraulic
after replacement of a failed hose normally indicates oil. See Operator’s Manual.
an improper start-up procedure.
4. Install a 40 bar (600 PSI) pressure gauge with a
After the machine is in service, the most common dampener valve in the charge pressure test port.
cause of hydraulic system failure is contamination. If
5. Disconnect the wire from the shutoff solenoid on
the smallest particle of foreign material, such as dirt
the injection pump.
or a metal chip, is allowed to reach the precision
moving par ts contained within the hydrostatic 6. Center the control lever on the pump to insure
system, rapid wear will result causing excessive the pump is in neutral.
downtime and costly maintenance. Therefore, when
IMPORTANT: Raise the machine up on supports
disconnecting hydraulic lines or removing one of the
until the tires are up off of the floor. This will allow the
hydraulic components. ALWAYS clean and plug all
ground drive to be operated to get the air out of the
ports and connections. Use lint free rags for cleaning
system. Clear the area of all unauthorized personnel
to prevent contaminants from entering the system.
and operate the starter from the operator’s seat.
WARNING: Hydrostatic systems are highly
NOTE: Cranking the engine will get hydraulic oil into
pressurized. Escaping hydraulic oil, even an invisible
the circuit without harming the components.
pinhole leak, can penetrate body tissue causing
serious injury. Use a piece of wood or cardboard 7. Crank the engine until pressure starts to build on
when looking for leaks. Never use your hands or other the gauge.
parts of your body.
8. Connect the wire for the fuel injection pump.
Relieve hydraulic pressure before disconnecting 9. Start the engine and run at low idle until the 40
circuits. When reassembling, make absolutely certain bar (600 PSI) pressure gauge rises and
that all connections are tight. stabilizes above the minimum pressure specified
in the charge pressure test.
If injured by hydraulic oil escaping under pressure,
10. After proper charge pressure has been reached,
see a doctor immediately. Serious complications may
increase engine to full throttle and operate
arise if medical attention is not given at once.
system to its fullest travel in all directions. If
1. Prior to installation, inspect the pump, motor, charge pressure remains stable, the system is
hoses, adapters, and fittings for cleanliness. satisfactory.
Check for proper pump rotation.
11. Stop the engine. Remove the pressure gauge
2. Install the pump and/or motor with attaching and reinstall the plug. Check all fittings for leaks.
parts on the machine. Be sure to install hoses
12. Check oil level in the reservoir. Add as
properly without twisting. See illustration below.
necessary.
HS01D069

6001
Section
6001
HYDROSTATIC SYSTEM TROUBLESHOOTING
CASE CORPORATION
700 State Street
6001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKS TO DO BEFORE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDROSTATIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
One Transmission (Right or Left) Works Correctly and the Other Does Not . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Machine Does Not Have Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDROSTATIC SYSTEM TROUBLESHOOTING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check 1- Checking Charge Pressure/Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check 2 - Checking Circuit Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6001-3
SPECIFICATIONS
Hydrostatic Pump
Manufacturer ................................................................................................................................... Sauer/Danfoss
Type......................................................................................................................................... Tandem axial piston
Model ..................................................................................................................................................................46
Displacement ................................................................................................................................. 46 cc (2.81 in3)
Pump Control Style ....................................................................................................................................... Servo
System Relief Pressure (forward and reverse).....................................................................34,500 kPa (5004 psi)
Charge Oil Source.................................................................................................................Integral gerotor pump
Charge Pump Displacement ............................................................................................................ 23 cc (1.4 in3)
Charge Pressure (minimum at full throttle)............................................................... 2758 kPa (27.6 bar) (400 psi)
Charge Flow (approximate, depends on motor and pump leakage) ....................................50.2 L/min (13.3 gpm)
Pump Flow at Rated Engine RPM.........................................................................................101 L/min (26.7 gpm)
Pump RPM/Engine RPM Ratio ..........................................................................................................................1:1
Hydrostatic Drive Motors
Manufacturer ................................................................................................................................................. Eaton
Type.............................................................................................................................................................Geroler
Model ............................................................................................................................................................ VIS40
Maximum Displacement ............................................................................................................... 503 cc (30.7 in3)
Speed at Rated Engine RPM at Motor Maximum Displacement..............................................................183 RPM
Torque at Maximum Displacement and Relief Pressure 86% TE..........................................2383 N•m (1752 lb/ft)
Shuttle Oil Flow Per Motor........................................................................................................5.7 L/min (1.5 gpm)
SPECIAL TOOLS
The troubleshooting and adjustment procedures in
this section can be perfor med using common
mechanic’s tools and the CAS-1804 Pressure Test
Kit.
B009638M
CAS-1804 PRESSURE TEST KIT

6001-4
SAFETY RULES
WARNING: Operate the Skid Steer controls from the WARNING: DO NOT LEAVE THE OPERATOR’S
operator’s seat only. SEAT WITH THE ENGINE RUNNING.
WARNING: When servicing the Skid Steer with the WARNING: If the Skid Steer lift arms are raised,
engine running, have another person help you. Follow ALWAYS engage the loader support strut and lower
the instructions in this manual or the operator’s the lift arm to contact the support strut before you
manual. service the machine.
CHECKS TO DO BEFORE TROUBLESHOOTING.

1. Check the oil level, type, and grade in the 5. Check that the tires are correct for the application
hydraulic reservoir. See Section 1001 for correct and surface, same size, and correctly inflated.
hydraulic oil. See operator’s manual for inflation pressure.
2. Check hydraulic oil filter condition and change as 6. Flotation tires are designed for dirt, when used
necessary. See Operators Manual for procedure. on concrete surfaces they can cause resistance
when steering.
3. Check control linkage for correct operation. See
Section 9001 for adjustment. 7. Check for correct balance and counter weights
for attachments and machine application.
4. Check drive chain tension. See Section 9001 for
adjustment procedures. NOTE: This is a Skid Steer. More weight is to be
carried by one pair of tires (front or rear) depending
on the application or portion of the duty cycle. This
allows the tires with the lighter load to skid easily
when turning.

6001-5
HYDROSTATIC SYSTEM TROUBLESHOOTING
One Transmission (Right or Left) Machine Does Not Have Enough

Works Correctly and the Other Power
Does Not 1. Check full throttle and rated engine speeds.
1. Check to see that the direction control levers are A. Is there still a problem? No: Troubleshooting
adjusted correctly. See section 9001. complete. Yes: Go to Step 2.
A. Is there still a problem? No: Troubleshooting 2. Full throttle engine speed is good, rated engine
complete. Yes: Go to Step 2. speed is low. Problem in engine or fuel system.
2. Check for charge pressure at the servo bypass Repair as required.
valve fitting while in neutral. A. Is there still a problem? No: Troubleshooting
A. Charge pressure OK? Stroke the control lever. complete. Yes: Go to Step 3.
A 20 psi or greater drop indicates a leaky 3. Do Check 1 - Checking Charge Pressure. Also
servo. check for damaged par ts. Adjust pressure
B. Is there still a problem? No: Troubleshooting setting.
complete. Yes: Go to Step 3. A. Is there still a problem? No: Troubleshooting
3. Check the pressure setting of the circuit relief complete. Yes: Go to Step 4.
valve for the transmission with the problem. 4. Disassemble and inspect the hydrostatic pump
A. Do Check 2 - Checking Circuit Relief Valve and hydrostatic drive motors. Repair as required.
Pressure.
B. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 4.
4. There is too much leakage in the hydrostatic
system. Disassemble and inspect the piston
pump and drive.

6001-6
HYDROSTATIC SYSTEM TROUBLESHOOTING CHECKS
Check 1- Checking Charge 5. If the pressure is correct go to step 7. If the

pressure is not correct loosen the cap on the
Pressure/Flow hydraulic reservoir. Remove the plug, shim(s),
IMPORTANT: For the following test the machine spring, and poppet for the charge relief valve.
MUST be raised up on supports until the tires are See figure below.
above the floor. This is a safety procedure if the
CHARGE RELIEF VALVE
parking brake latch pins fail to hold.
NOTE: You will need two people to perform this test.
The ROPS canopy must be raised to gain access to
the hydrostatic pumps. In order to start the engine,
someone will need to lower the seat bar to the
operating position and press on the seat to close the
seat switch.
1. Connect a 4,137 kPa (41 bar) (600 psi) pressure
gauge to test port 1, see next figure.
2. If the hydraulic oil is not at operating temperature
run the engine at full throttle and hold the bucket
control lever in the ROLLBACK position for 30 ENGINE
seconds. Then return the bucket control lever to GM98H002
NEUTRAL for 15 seconds. Repeat this cycle until CHARGE RELIEF VALVE LOCATION
the temperature of the oil is at least 52 ° C
6. Inspect the parts of the charge relief valve. If the
(125°F).
parts are good, add shim(s) from the shim kit and
3. Continue to run the engine at full throttle. Read repeat steps 1 through 4 until the pressure is
the pressure gauge and record the Charge correct.
Pressure reading. Stop the engine.
7. After you get the correct charge pressure in
NEUTRAL, do the following steps:
TEST PORT 1
IMPORTANT: For the following test the machine
MUST be raised up on supports until the tires are
above the floor. This is a safety procedure if the
parking brake latch pins fail to hold.
A. Start and run the engine at low idle. With the
par king brake activated (ROPS canopy
raised), slowly move the direction control
levers into FORWARD until the pins for the
par king brake latch engage each brake
sprocket.
B. Increase the engine speed to full throttle.
ENGINE
Slowly move one of the direction control levers
HI01E019 FORWARD to load the hydraulic piston pumps
TEST PORT LOCATION without decreasing the engine speed. Repeat
4. The pressure must be a minimum of 2,758 kPa for the other control lever.
(27.6 bar) (400 psi) at full throttle. C. Read the pressure gauge. The pressure must
be within 138 kPa (1.5 bar) (20 psi) of the
pressure in step 3.
D. Repeat Steps B and C with the direction
control levers in REVERSE.

6001-7
Check 2 - Checking Circuit Relief 3. Run the engine at low idle. Raise the seat bar
and slowly move the direction control levers into
Valve Pressure FORWARD until the pins for the parking brake
IMPORTANT: For the following test the machine latch engage each drive sprocket.
MUST be raised up on supports until the tires are 4. Increase the engine speed to full throttle. Move
above the floor. This is a safety procedure if the the control lever for the circuit being tested one
parking brake latch pins fail to hold. half the distance of full travel and watch the
NOTE: You will need two people to perform this test. pressure gauge. When the pressure gauge stops
The ROPS canopy must be raised to gain access to increasing, read the pressure gauge and move
the hydrostatic pumps. In order to start the engine, the control lever to NEUTRAL.
someone will need to lower the seat bar to the 5. The correct pressure is the gauge reading minus
operating position and press on the seat to close the the charge pressure. If the pressure is not
seat switch. correct, use a new circuit relief valve. For test
1. Connect a 690 bar (10,000 psi) pressure gauge purposes, you can temporarily interchange a
to the test port. See the figure below. functioning reverse circuit relief valve with the
forward circuit relief valve. See the figure below.
RH MOTOR LH MOTOR
REVERSE FORWARD RH REVERSE LH FORWARD
TEST PORT TEST PORT CIRCUIT RELIEF CIRCUIT RELIEF
RH MOTOR LH MOTOR
FORWARD REVERSE
ENGINE TEST PORT TEST PORT RH FORWARD LH REVERSE
ENGINE CIRCUIT RELIEF CIRCUIT RELIEF
HI01E019
RH AND LH MOTOR TEST PORT LOCATIONS HI01E019
CIRCUIT RELIEF VALVE LOCATIONS
2. If the hydraulic oil is not at operating temperature
run the engine at full throttle and hold the bucket
control lever in the ROLLBACK position for 30
seconds. Then return the bucket control lever to
NEUTRAL for 15 seconds. Repeat this cycle until
the temperature of the oil is at least 52 ° C
(125°F).

6001-8
NOTE: 2
THIS ILLUSTRATION SHOWS
A TYPICAL HYDROSTATIC
P U M P. A L L VA LV E S A N D
INLETS ARE AS SHOWN.
1
HI01E018
1. BYPASS/TOW VALVE
2. CHARGE PUMP INLET
HYDROSTATIC TANDEM AXIAL PISTON PUMP

6002
Section
6002
REMOVAL AND INSTALLATION OF

HYDROSTATIC COMPONENTS
CASE CORPORATION
700 State Street Copyright © 2001 Case Corporation
Racine, WI 53404 U.S.A. Printed in U.S.A.
Bur 6-45960 November, 2001
6002-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TANDEM (HYDROSTATIC) PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC (DRIVE) MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC (DRIVE) MOTOR
(EUROPEAN MACHINES AND OPTIONAL NORTH AMERICAN MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6002-3
TORQUE SPECIFICATIONS
Tandem Pump Mounting Bolts...........................................................................102 to 113 Nm (75 to 83 pound-feet)
Hydraulic Drive Motor Mounting Bolts ............ 258 to 284 Nm (190 to 210 pound-feet) plus Turn Additional 38° ± 8°
European and Optional North American Machines with Spring Applied - Hydraulic Release Park Brake
Hydraulic Drive Motor Mounting Bolts .......................................................298 to 339 Nm (220 to 250 pound-feet)
Hydraulic Drive Motor / Brake Assembly
Chassis Mounting Bolts.............................. 258 to 284 Nm (190 to 210 pound-feet) plus Turn Additional 38° ± 8°

6002-4
HS01D052
1. LOADER VALVE 4. SOLENOID VALVE 7. AUXILIARY VALVE 10. OIL COOLER

2. DRIVE MOTOR 5. BUCKET CYLINDER 8. OIL FILTER 11. GEAR PUMP
3. TANDEM PUMP 6. LOADER LIFT CYLINDER 9. HYDRAULIC RESERVOIR
SIGHT GAUGE
HYDROSTATIC DRIVE SYSTEM COMPONENTS

6002-5
BC01D093
1. TANDEM PUMP 11. O-RING 21. HEX PLUG 31. TEE

2. DRIVE MOTOR 12. HOSE 22. TEE 32. O-RING
3. O-RING 13. TEE 23. O-RING 33. 90° ELBOW
4. BOLT 14. TEE 24. HOSE 34. O-RING
5. WASHER 15. O-RING 25. HOSE 35. 45° ELBOW
6. LOCK NUT 16. HOSE 26. 45° ELBOW 36. O-RING
7. ADAPTER 17. 90° ELBOW 27. HOSE
8. O-RING 18. O-RING 28. TEE
9. HOSE 19. HOSE 29. COUPLING
10. ADAPTER 20. SOLENOID VALVE 30. CAP
HYDROSTATIC DRIVE SYSTEM

6002-6
TANDEM (HYDROSTATIC) PUMP
Removal Installation
1. Remove the cap from the hydraulic reservoir. 1. Install the tandem pump (1) in the machine using
a proper harness and lifting device.
2. Connect a vacuum pump to the hydraulic
reservoir. 2. Align the tandem pump drive shaft with the drive
coupling.
3. Start the vacuum pump.
3. Apply Loctite No. 243 to the threads of bolts (2).
4. Tag and disconnect all hoses from the tandem
pump (1). See photo on page 7. 4. Install the washers (3), bolts (2), and tandem
pump (1).
5. Install plugs in the hoses and caps on the fittings.
5. Tighten the bolts (2) to 113 to 101 Nm (83 to 75
6. Stop the vacuum pump.
pound-feet).
7. Disconnect all the electrical connections from the
6. Start the vacuum pump.
tandem pump. See photo on page 7.
7. Install the control linkages (4), washers, and nuts
8. Remove the nuts, washers, and control linkages
to the tandem pump (1).
(4) from the tandem pump (1).
8. Connect the hoses to the tandem pump (1). See
9. Install a harness, attached to a proper lifting
photo on page 7.
device, around the tandem pump (1).
9. Stop the vacuum pump. Disconnect the vacuum
10. Remove the bolts (2) and washers (3) from the
pump from the hydraulic reservoir.
tandem pump mounting flange (engine side).
10. Connect all the electrical connections to the
11. Remove the tandem pump from the machine.
tandem pump (1). See photo on page 7.
11. Clean up any hydraulic fluid from equipment or
floor.
12. Start and run the engine at idle.
13. Stop the engine.
14. Check for oil leakage.
15. Check the level of the oil in the hydraulic
reservoir. See Section 1001 for the correct
hydraulic oil specifications.
16. Install the cap on the hydraulic reservoir.

6002-7
2 3
2 3
BD01J064
3
2
BD01M001
1. TANDEM PUMP 3. WASHER(S)
2. BOLT(S) 4. CONTROL LINKAGE
TANDEM (HYDROSTATIC) PUMP

6002-8
Removal STEP 3
NOTE: It may be necessary to disconnect hydraulic
hoses from the tandem pump, or remove the tandem 1
pump from the machine, to remove the hydraulic
drive motors from the machine. See page 6 for the
procedure to remove the tandem pump from the
machine.
STEP 1
1 2
BD01C252
Remove the brake disk (1).
STEP 4
1
1
BD01C103
Remove the bolts (1) and washers from the chain
tank cover (2). Remove the cover (2) from the 2
machine.
3
STEP 2
2
BD01C253
Remove the drive chains (1) from the drive sprocket
(2). Remove the drive sprocket (2) from the drive
1 motor spline shaft (3).
BD01C251
Remove the center bolt (1) and the retaining plate
(2).

6002-9
STEP 5 Installation
Place a shop towel under the hydraulic drive motor.
STEP 12
STEP 6 Install the drive motor into the mounting location on
Remove the cap from the hydraulic reservoir. the chassis.
STEP 7 STEP 13
Connect a vacuum pump to the hydraulic reservoir.
STEP 8
Start the vacuum pump.
2
STEP 9 1
2
1
1
BD01M017
Install the washers (2) and nuts (1) on the upper and
lower mounting studs of the drive motor. Tighten the
2 mounting nuts to a torque of 258 to 284 Nm (190 to
210 pound-feet) then turn the nuts (1) an additional
38° ± 8°.
BD01M017 STEP 14
Tag and disconnect the hydraulic hoses (1) from the
drive motor (2). Install plugs in the hoses and caps
on the fittings.
STEP 10 1
2
2
1
2 BD01M017
1 Start the vacuum pump. Connect the hydraulic hoses

(1) to the drive motor (2).
STEP 15
Stop the vacuum pump and disconnect the vacuum
BD01M017
pump from the hydraulic reservoir. Install the cap on
Loosen and remove the upper mounting nuts (1) and
the hydraulic reservoir.
wash ers (2) a nd the low er mou nting nuts an d
washers (not shown) from the drive motor mounting
flange.
STEP 11
Remove the drive motor from the machine.

6002-10
STEP 16 STEP 20
1
1
2
3
BD01C253 BD01C259
Install the drive sprocket (2) onto the drive motor Tighten the center bolt to a torque of 247 to 320 Nm
spline shaft (3). Install the drive chains (1) onto the (185 to 235 pound-feet).
drive sprocket (2).
STEP 21
STEP 17
See Section 6007 for the procedure and adjust the
drive chain tension.
STEP 18
1
2
BD01C258
Remove the old sealant and apply new RTV sealant

between the gasket (if equipped), cover, and the
chassis. Install the chain tank cover and the bolts
onto the chassis. Tighten the bolts to a torque of 125
BD01C252
to 150 Nm (93 to 112 pound-feet).
After adjusting the drive chain tension install the
brake disk (1) onto the drive sprocket (2). STEP 22
STEP 19
2
BD01C268
If the wheels were removed, install the wheels and

BD01C251
the wheel nuts. Tighten the wheel nuts to a torque of
Install the retaining plate (2) and the center bolt (1) 135 to 163 Nm (100 to 120 pound-feet).
onto the brake disk.

6002-11
STEP 23 STEP 26
Clean up any hydraulic oil from the equipment or the Stop the engine and check for any oil leakage.
floor.
STEP 27
STEP 24 Check the level of the hydraulic oil in the hydraulic
Start and run the engine at low idle. reservoir. See Section 1001 for the correct hydraulic
oil specifications.
STEP 25
Disengage the park brake and move the machine in
order to remove any air from the hydrostatic system.

6002-12

(EUROPEAN MACHINES AND OPTIONAL NORTH AMERICAN MACHINES)
Removal STEP 5
Connect a vacuum pump to the hydraulic reservoir.
NOTE: It may be necessary to disconnect hydraulic
hoses from the tandem pump, or remove the tandem
pump from the machine, to remove the hydraulic STEP 6
drive motors from the machine. See page 6 for the Start the vacuum pump.
procedure to remove the tandem pump from the
machine. STEP 7
STEP 1
2
1 2
1
BD00K056
Tag and disconnect all of the hydraulic hoses from

BD01C103 the drive motor / brake assembly (2). Install plugs in
Remove the bolts (1) and washers from the chain the hoses and caps on the fittings.
tank cover (2). Remove the chain tank cover (2) from
the machine. STEP 8
Stop the vacuum pump.
STEP 2
STEP 9
Loosen and remove the 4 mounting bolts from the
1 inside of the chain tank which fasten the drive motor /
1 brake assembly to the chassis. Remove the drive
motor / brake assembly from the chassis.
2
3
BD01F305
Remove the drive chains (1) from the drive sprocket

(2). Use acceptable tools and remove the snap ring
from the end of the drive motor shaft (3). Remove the
drive sprocket (2) from the drive motor shaft (3).
STEP 3
Place a shop towel under the hydraulic drive motor /
brake assembly.
STEP 4
Remove the cap from the hydraulic reservoir.

6002-13
STEP 10 STEP 12
BD00M166 BD00M167
Make an alignment mark across the drive motor Loosen and remove the 4 bolts from the drive motor
flange, friction housing, and sprocket housing. mounting flange.
NOTE: The reference marks will be used for correct NOTE: The drive motor flange is under spring load.
alignment of the drive motor with the brake assembly Use caution while releasing the tension on the press.
together in the same position as it was when
removed form the chassis. If the drive motor and STEP 13
brake assembly are not aligned in the same position,
the hose ports will not be in the correct position to
connect the hydraulic hoses to the drive motor and
brake assembly.
STEP 11
BD00M169
Remove the drive motor from the brake housing.
BD00M165
Place the drive motor / brake assembly and apply

just enough tension to hold the complete assembly in
place.

6002-14
Installation STEP 18
Start the vacuum pump.
STEP 14
STEP 19
BD00M169
Use the reference marks made during disassembly BD00K056
and install the drive motor onto the brake assembly. Install and all of the hydraulic hoses (1) to the drive
motor / brake assembly (2).
NOTE: Use caution not to damage the O-ring and
seal on the motor flange during installation of the
drive motor onto the brake assembly. STEP 20
Stop the vacuum pump.
STEP 15
STEP 21
1
1
2
3
BDOOK168
Install the 4 bolts into the motor flange. Tighten the BD01F305
bolts to a torque of 298 to 339 Nm (220 to 250 Install the drive sprocket (2) onto the drive motor
pound-feet). shaft (3). Use acceptable tools and install the snap
ring onto the end of the drive motor shaft (3). Install
STEP 16 the drive chains (1) onto the drive sprocket (2).
Install the drive motor / brake assembly into the
chassis mounting location. STEP 22
See Section 6007 for the procedure to adjust the
STEP 17 drive chain tension.
Install the 4 mounting bolts inside the chain tank
which fasten the drive motor / brake assembly to the STEP 23
chassis. Tighten the mounting bolts to a torque of Adjust the drive chain tension.
275 Nm (200 pound-feet) then turn the bolts an
additional 35°.

6002-15
STEP 24 STEP 26
Clean up any hydraulic oil from the equipment or the
floor.
STEP 27
Start and run the engine at low idle.
STEP 28
Disengage the park brake and move the machine in
order to remove any air from the hydrostatic system.
STEP 29
BD01C258 Stop the engine and check for any oil leakage.
Remove the old sealant and apply new RTV sealant
between the gasket, cover, and the chassis. Install STEP 30
the chain tank cover and the bolts onto the chassis.
Check the level of the hydraulic oil in the hydraulic
Tighten the bolts to a torque of 125 to 150 Nm (93 to
reservoir. See Section 1001 for the correct hydraulic
112 pound-feet).
oil specifications.
STEP 25
BD01C268
If the wheels were removed, install the wheels and

the wheel nuts. Tighten the wheel nuts to a torque of
135 to 163 Nm (100 to 120 pound-feet).

6002-16
14 10
12
13
6
4
12
2
11
3
5
11
BS01K209
1. TANDEM PUMP 6. LOADER VALVE 11. BUCKET CYLINDER
2. LEFT DRIVE MOTOR 7. BRAKE / SOLENOID VALVE 12. LOADER LIFT CYLINDER
3. RIGHT DRIVE MOTOR 8. GEAR PUMP 13. AUXILIARY VALVE
4. LEFT BRAKE 9. OIL COOLER 14. HYDRAULIC RESERVOIR SIGHT GAUGE
5. RIGHT BRAKE 10. HYDRAULIC OIL FILTER
HYDROSTATIC DRIVE SYSTEM (EUROPEAN MACHINES AND OPTIONAL NORTH AMERICAN MACHINES)

Section
6003
6003
DRIVE COUPLER

Racine, WI 53404 U.S.A. Bur 6-45200 Issued September, 2001
6003-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
DRIVE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 6

6003-3
Cross bolt for Pump Drive Coupler ............................................................... 44 to 52 Nm (390 to 460 pound-inches)
Bolts for Pump Drive Flange......................................................................... 45 to 53 Nm (398 to 469 pound-inches)
Bolts for Pump Mounting Plate ..................................................................... 39 to 47 Nm (345 to 416 pound-inches)
Bolts for Tandem Pump Mounting .................................................................310 to 380 Nm (228 to 280 pound-feet)

6003-4
DRIVE COUPLER
Disassembly Inspection
1. Tilt the ROPS canopy forward according to the 1. Inspect the pump drive flange (8) for cracks or
instructions in Section 9004. any other damage. Inspect the splines on the
pump drive flange (8) for wear or any other
2. Drain the oil from the hydraulic reservoir. If the oil damage. Use new parts as required.
is to be reused, ensure that the container is
clean. 2. Inspect the pump drive coupler (7) for cracks or
any other damage. Inspect the splines on the
3. Disconnect the control linkage from the servo inside and outside of the pump drive coupler (7)
controls on the tandem pump. for wear or any other damage. Use new parts as
4. Tag, mark and unplug the electrical connectors required.
on the servo solenoid control valves. 3. Inspect the pump mounting plate (6) for cracks or
any other damage. Use new parts as required.
5. Tag, mark, and disconnect the hydraulic hoses
located on the tandem pump assembly (1).Tags
should indicate front, or rear pump to aid in
installation.
6. Install environmental plugs on all disconnected
hydraulic fittings and plugs on hoses to prevent
contamination of the hydraulic system.
7. Install lifting sling around the tandem pump
assembly (1) and secure the sling to lifting
equipment.
8. Loosen and remove the bolts (4) and washers
(5) from the pump mounting plate (6).
9. Lift and disengage the tandem pump mounting
plate (6) from the bell housing (11), and the input
shaft from the pump drive flange (8). Move the
tandem pump (1) away from the bell housing to
allow for access to the pump drive flange (8).
10. If space to work is not satisfactory, consider
removing the pump mounting plate (6) or the
complete tandem pump assembly (1) from the
unit.
11. Loosen and remove the cross bolt from the pump
drive coupler (7) and remove the pump drive
coupler from the tandem pump (1) input shaft.
NOTE: The drive coupler and cross bolt were
assembled using Locktite. Heat may be required to
loosen and remove.
12. Loosen and remove the bolts (9) from the pump
drive flange (8). Remove the pump drive flange
(8) from the flywheel (10) and the engine bell
housing (11).

6003-5
11
10
5
4
12
8
13
7
BC01H201
1. TANDEM PUMP 6. PUMP MOUNTING PLATE 11. BELL HOUSING

2. BOLT 7. PUMP DRIVE COUPLER 12. BOLT
3. WASHER 8. PUMP DRIVE FLANGE 13. WASHER
4. BOLT 9. BOLT
5. WASHER 10. FLYWHEEL
EXPLODED VIEW OF DRIVE COUPLER

6003-6
Assembly 5. Install the bolts (4) and washers (5) into the
pump mounting plate (6). Tighten the bolts to a
1. Install the pump drive flange (8) onto the flywheel torque of 39 to 47 Nm (345 to 416
(10). Apply Locktite 271 to the bolt threads and pound-inches).
install the bolts (9) into the pump drive flange (8).
Tighten the bolts (9) to a torque of 45 to 53 Nm 6. Remove the lifting equipment and sling from the
(398 to 469 pound-inches). tandem pump (1).
2. Install the pump drive coupler (7) onto the pump 7. Remove the plugs from the hydraulic hoses and
input spline shaft. The outer face of the pump connect all the hydraulic hoses to the tandem
drive coupler should extend 65 mm (2.56 inches) pump (1).
from the pump mounting flange as shown in the 8. Connect all of the electrical connectors to the
illustration below. Apply Locktite 271 to the tandem pump (1).
threads of the pump drive coupler cross bolt.
Install and tighten the pump drive coupler cross 9. Connect the control linkage to the servo controls
bolt to a torque of 44 to 52 Nm (390 to 460 on the tandem pump (1).
pound-inches). 10. If the hydraulic oil was drained from the hydraulic
reservoir and is to be re-used, the hydraulic oil
must be filtered before being returned to the
1 reservoir.
11. If new hydraulic oil will be used, see Section
10 01 for th e corre ct cap acity an d oil
specifications for the hydraulic oil and refill the
hydraulic reservoir.
12. Lower the ROPS canopy according to the
instructions in Section 9004.
13. Start and run the engine at low idle and check for
oil leaks.
BC01H286 14. Stop the engine and check the oil level in the
1. DISTANCE FROM PUMP MOUNTING FLANGE TO OUTER hydraulic reservoir. If the level is low, add only
FACE OF PUMP DRIVE COUPLER 65 MM (2.56 INCHES)
the specified oil to the hydraulic reservoir. See
3. If the pump mounting plate (6) was removed, Section 1001.
install the mounting plate (6) onto the tandem
pump (1). Apply Locktite 243 to the threads of
the bolts (12). Install the tandem pump mounting
bolts (12) and washers (13) into th e pump
mounting plate (6). Tighten the bolts (12) to a
torque of 102 to 113 Nm (75 to 83 pound-feet).
4. Move the tandem pump (1) towards the engine.
Engage the splines on the pump drive coupler
(7) in the splines of the pump drive flange (8).

6003-7
11
10
5
4
12
8
13
7
BC01H201
1. TANDEM PUMP 6. PUMP MOUNTING PLATE 11. BELL HOUSING

2. BOLT 7. PUMP DRIVE COUPLER 12. BOLT
3. WASHER 8. PUMP DRIVE FLANGE 13. WASHER
4. BOLT 9. BOLT
5. WASHER 10. FLYWHEEL
EXPLODED VIEW OF DRIVE COUPLER

6003-8
NOTES

Section
6004
6004
PISTON PUMP

Racine, WI 53404 U.S.A. Bur 6-45210 August, 2001
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SEPaRATING THE PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLING THE PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly, Inspection, and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bur 6-45210 8-01 Printed in U.S.A.

6004-3
SPECIFICATIONS
Manufacturer ..................................................................................................................................Sauer Sundstrand
Type ............................................................................................................................................ Tandem Axial Piston
Model Number ......................................................................................................................................................... 46
Approximate Weight .....................................................................................................................59 kg (130 pounds)
SPECIAL TORQUES
Bolts that hold pumps together............................................................................ 91 to 111 Nm (67 to 82 pound-feet)
Orifice ............................................................................................................... 0.9 to 1.3 Nm (8 to 12 pound-inches)
Bypass valve .................................................................................................... 9 to 13 Nm (84 to 120 pound-inches)
Bolts for servo piston covers .......................................................................... 11 to 15 Nm (96 to 132 pound-inches)
3/8 inch Special bolts for cover..............................................................................53 to 64 Nm (39 to 47 pound-feet)
7/16 inch Special bolts for cover..........................................................................81 to 100 Nm (60 to 74 pound-feet)
GENERAL INFORMATION
Some types of failures will require the disassembly of NOTE: The following steps use photographs of a
the tandem pump for cleaning and inspection. If there typical tandem pump only as a general guide. When
is a failure in the drive motors or tandem pump, disassembling and assembling the rear pump refer to
disassemble both the rear and front pumps, the drive illustrations on pages 15, 16, 17. When
motors, and all hoses between the pumps and drive disassembling and assembling the front pump refer
motors. See Section 8002 for information about to illustrations on pages 18, 19, 20.
cleaning the hydrostatic system.
SEPARATING THE PUMPS

STEP 1 STEP 2
BD01H182 BD01H183
Re mo ve the b olts (1 0) tha t fa ste n the p ump s Remove the nut (11) and bracket from the stud (12).
together, see the illustration on page 20.
NOTE: During assembly, tighten the bolts (10) to 91

6004-4
STEP 3 STEP 4
39
37
38
BD01H185
BD01H184
Separate the pumps. Replace the o-rings (37 and 38) and back-up ring
(39), see the illustration on page 15.
ASSEMBLING THE PUMPS

As s e mb l e t h e p u m p s i n t h e r e v e r se o r d e r o f
separating the pumps.
NOTE: Follow all special torque instructions.
REAR PUMP
Disassembly STEP 6
STEP 5
36
BD01H187
Remove the coupling (31) and pin (32).

BD01H186
Remove the cover (35), see the illustration on page

15. Note the position of the cover and the pin (36) for
use during assembly.

6004-5
STEP 7 STEP 10
BD01H188 BD01H190
Remove the inner gear (33). Remove the special bolts (6 and 7) from the cover
(9).
STEP 8
STEP 11
BD01H189
Remove the outer gear (34). BD01H191
Remove the cover (9), gasket (29), and shaft (5).

STEP 9
STEP 12
BD01H192
Remove the bolt stud. BD01H193
Remove the swash plate (13).

6004-6
STEP 13 STEP 16
BD01H194 BD01H197
Remove the pistons (16) and retainer (17). Remove the wear plate (27)
STEP 14 STEP 17
BD01H195 BD01H198
Remove the guide (18). Be careful not to lose the three pins (20) in the
cylinder block (21). Do not try to disassemble the
STEP 15 cylinder block (21).
STEP 18
BD01H196
Remove the cylinder block (21).

BD01H199
Remove the gasket (29).

6004-7
STEP 19 STEP 22
BD01H200 B518727
Remove the snap ring (2) from the seal (1). Press the shaft (5) out of the cover (9). Inspect the
bearing on the shft. Replace if neccessary.
STEP 20
STEP 23
B5182721
Fasten the cover (9) in a vise with soft jaws. Use a B518840
prybar to remove the seal (1). Inspect the bearings (4) on the cover (9). If the yellow
surface has worn through to the dark base, use new
STEP 21 bearings.
STEP 24
B518724
Remove the snap ring (3).

BD01H201
Remove the screws (3) from the cover (6), see the
illustration on page 16.

6004-8
STEP 25 STEP 28
BD01H202 BD01H230
Pull the piston (18) from the housing. Measure the distance from the end of the special bolt
(15) to the cover (6). Record the measurement.
STEP 26
STEP 29
Turn the cover (6) off of the special bolt (15).
STEP 30
BD01H203
Remove and discard the gasket (7). 10
STEP 27
BD01H231
Fasten the piston (18) in the vise with soft jaws. Hold
the adjusting nut (10) and loosen the jam nut (9).
STEP 31
BD01H229
Prevent the special bolt (15) from turning and remove

the special nut (2).
BD01H232
Hold the special bolt (15) and tighten the adjusting

nut (10) to push the outer spring guide (11) away
from the retaining ring (8).

6004-9
STEP 32 STEP 35
31 16
31
16
BD01H233 BD01H235
Remove the retaining ring (8). The retaining ring (8) Remove and discard the piston rings (16, 31), and
will be difficult to remove. O-rings (17) from the piston (18).
STEP 33 STEP 36
BD01H234 BD01H204
Remove the spring assembly (12). Remove the screws (3) from the cover (19).
STEP 34 STEP 37
14
12
11
10
9
BD01H236 BD01H205
Remove the jam nut (9) and adjusting nut (10). Remove the cover (19) and gasket (7).
Separate the outer spring guide (11), spring (12),
sleeve (13), and inner spring guide (14).

6004-10
STEP 38 STEP 41
BD01H206 BD01H209
Make a mark to show the position of the stop bracket Remove the lock nut (20) and washer (21) from the
(23). spool (27).
STEP 39 STEP 42
25
26
27
BD01H207 BD01H213
Remove the bolts. Remove the spool assembly (27) Remove and discard the backup ring (25) and o-ring
from the housing. (26) from the spool (27).
STEP 40 STEP 43
30
29
28
BD01H209 BD01H214
Remove the sleeve (30) from the housing. Remove and discard the backup ring (28) and o-ring
(29) from the sleeve (30).

6004-11
STEP 44 STEP 47
BD01H215 BD01H217
Remove the hex plug (22) and shims (20) for the Remove the valve poppet (18).
charge pressure relief valve, refer to illustration on
page 17. STEP 48
STEP 45
BD01H218
Make a mark on one of the circuit relief-check valves

BD01H227 (2).
Remove the shims (20) from the hex plug (22). Do
not lose the shims. STEP 49
STEP 46
BD01H219
Remove the hex plug (2) for the circuit relief-check

BD01H216 valve.
Remove the spring (19).

6004-12
STEP 50 STEP 53
BD01H220 BD01H223
Remove the spring (5). Remove the bypass valve (17).
STEP 51 STEP 54
16
15
BD01H221 BD01H228
Remove the circuit relief-check valve (4). Remove and discard the o-ring (15) and backup ring
(16).
STEP 52
BD01H222
Loosen the bypass valve (17).

6004-13
STEP 55 STEP 58
BD01H225 B313327
Meas ure the thickness of each shoe. If the

measurements are not equal to within 0.02 mm
(0.001 inch), use a new cylinder assembly.
STEP 59
Inspect the face of the cylinder block (21) for wear,
scoring, and other damage. Use a new cylinder
assembly as necessary.
STEP 60
Inspect the cylinder bores for wear, scoring, and
other da mage. Use ne w cylin der assemb ly as
BD01H226 necessary.
Remove the 90° elbow then the plug (7).
STEP 61
Inspection Lubricate the pistons and cylinder bores with clean
oil.
STEP 56
Clean all parts in cleaning solvent. STEP 62
Check the fit of the pistons (16) in the bores. The
STEP 57 p i s t o n ( 1 6 ) m u s t m o v e f r e e ly w i t h m in im u m
c le a r a n c e . U s e a n e w c y li n d e r a s s e m b l y a s
necessary.
STEP 63
Inspect the bronze surface of the wear plate (27).
Use a new wear plate (27) as necessary.
STEP 64
Inspect the parts of the charging pump for wear and
damage. Use a new pump as necessary.
STEP 65
B313202 Measure the gear tip clearance between the inner
Measure the free travel between the shoes and the gear (33) and outer gear (34). Clearance must not be
pistons (16), see the illustration on page 15. If all the more than 0.13 mm (0.005 inch).
measurements are not equal to within 0.13 mm
(0.005 inch), use a new cylinder assembly.

6004-14
STEP 66 STEP 68
Measure the width of the inner gear (33) and the Inspect the shaft (5) for damage to the splines and
outer gear (34). The width of each gear must be wear at the seal (1) surfaces.
equal to within 0.05 to 0.06 mm (0.002 to 0.003 inch).
STEP 69
STEP 67 Inspect the bearings (4, 11, and 28). Replace any
Inspect the pistons (16) for wear and damage. use damaged bearings.
new parts as necessary.
STEP 70
Inspect the circular relief valve seats in the housings.

6004-15
36
34
32
38
30
39
35
26
25 29
24 33
23 31
14 18
15
19 8 22
28
10
27
20 21
17
16
4 13
11
9
3
1 7
5 6
37
12
2
BS98F144
1. SEAL 9. COVER 17. RETAINER 25. SPRING SEAT 33. GEAR
2. SNAP RING 10. ROLL PIN 18. GUIDE 26. RING 34. GEAR HOUSING
3. SNAP RING 11. BALL BEARING 19. RETAINING RING 27. PLATE 35. COVER
4. JOURNAL BEARING 12. SNAP RING 20. PIN 28. NEEDLE BEARING 36. PIN
5. SHAFT 13. PLATE 21. CYLINDER BLOCK 29. GASKET 37. O-RING
6. SPECIAL BOLT 14. GUIDE 22. PIN 30. HOUSING 38. O-RING
7. SPECIAL BOLT 15. PIN 23. WASHER 31. COUPLING 39. BACK-UP RING
8. ROLL PIN 16. PISTON 24. SPRING 32. PIN
REAR PUMP CYLINDER, BEARINGS, SHAFT, AND PLATES

6004-16
20
4 21
5 6 22
7
2
8 10 23
9
11
24
3 12
25
26
27
30 28
13 29
18 1
14
15
7
19
17
16 5
31 4
3
BS01H247
1. TANDEM PUMP 8. RETAINING RING 15. SPECIAL BOLT 22. LEVER 29. O-RING
2. SPECIAL NUT 9. NUT 16. RING 23. BRACKET 30. SLEEVE
3. SCREW 10. NUT 17. O-RING 24. GUIDE 31. RING
4. HEX PLUG 11. GUIDE 18. PISTON 25. BACKUP RING
5. O-RING 12. SPRING 19. COVER 26. O-RING
6. COVER 13. GUIDE 20. NUT 27. SPOOL
7. GASKET 14. GUIDE 21. LOCK WASHER 28. BACKUP RING
REAR PUMP PISTON, COVERS, AND BRACKET

6004-17
9
10
13
11
2 12
3 14
5 6
4 8
6
9
7
1
4
5
3
2
23
24 15 16
17
18 19
20
9
21
8 22
BS98F142
1. HOUSING 7. PLUG 13. BOLT 19. SPRING
2. PLUG 8. HEX PLUG 14. SEAL 20. SHIM KIT
3. O-RING 9. O-RING 15. O-RING 21. O-RING
4. RELIEF VALVE 10. HEX PLUG 16. BACKUP RING 22. HEX PLUG
5. SPRING 11. O-RING 17. BY-PASS VALVE 23. PLUG
6. PLUG 12. ADAPTER 18. VALVE POPPET 24. O-RING
REAR PUMP VALVES, PLUGS, AND ADAPTER

6004-18
21
23
24
26 25
27
29
28
31
30
2
1
3
14 11
12
22 5
15
17
18 6
19 7
4 10
9
13
20 16
BS98F143
1. SEAL 9. COVER 17. RETAINER 25. SPRING SEAT
2. PLATE 10. ROLL PIN 18. GUIDE 26. RING
3. SNAP RING 11. BALL BEARING 19. RETAINING RING 27. PLATE
4. JOURNAL BEARING 12. SNAP RING 20. PIN 28. NEEDLE BEARING
5. SHAFT 13. PLATE 21. CYLINDER BLOCK 29. GASKET
6. SPECIAL BOLT 14. RETAINER 22. PIN 30. BOLT
7. SPECIAL BOLT 15. PIN 23. WASHER 31. ROLL PIN
8. ROLL PIN 16. PISTON 24. SPRING
FRONT PUMP CYLINDER, BEARINGS, SHAFT, AND PLATES

6004-19
3
2 20
6
4 7
21
8 10 22
9 11
5
12 23
24
25
26
27
28
13 18 29
14 30
15
1
17 7 19
16 3
31
5
4
BS98F141
1. TANDEM PUMP 8. RETAINING RING 15. SPECIAL BOLT 22. LEVER 29. O-RING
2. SPECIAL NUT 9. NUT 16. RING 23. BRACKET 30. SLEEVE
3. SCREW 10. NUT 17. O-RING 24. GUIDE 31. RING
4. HEX PLUG 11. GUIDE 18. PISTON 25. BACKUP RING
5. O-RING 12. SPRING 19. COVER 26. O-RING
6. COVER 13. GUIDE 20. NUT 27. SPOOL
7. GASKET 14. GUIDE 21. LOCK WASHER 28. BACKUP RING
FRONT PUMP PISTON, COVERS, AND BRACKET

6004-20
14
6
3 8
4 7
9
8
9 10
2
5 11
17 16
15 5
12
19
18 4
13 1 3
2
9
8
BS98F139
1. HOUSING 6. PLUG 11. NUT 16. BACK-UP RING
2. PLUG 7. PLUG 12. STUD 17. BY-PASS VALVE
3. O-RING 8. HEX PLUG 13. O-RING 18. PLUG
4. RELIEF VALVE 9. O-RING 14. PLUG 19. O-RING
5. O-RING 10. BOLT 15. O-RING
FRONT PUMP VALVES AND PLUGS

6004-21
Assembly STEP 74
STEP 71
BD01H222
Tighten the bypass valve (17) to 9 to 13 Nm (84 to

BD01H225
120 pound-inches).
Install and tighten the plug (7) 0.9 to 1.3 Nm (8 to 12
pound-inches), see the illustration on page 17. Then STEP 75
install the 90° elbow.
STEP 72
16
15
B9109025
17 Install the circuit relief-check valve (4).
B9109027
Install a new backup ring (16) and o-ring (15) on the

bypass valve (17).
STEP 73
BD01H220
Install the spring (5).
BD01H223
Install the bypass valve (17).

6004-22
STEP 76 STEP 79
BD01H219 BD01H215
Install and tighten the plug (2). Install the shims (20) into the plug and install the hex
plug (22) for the charge pressure relief valve.
STEP 77
STEP 80
29
28
30
B9109024
Install the valve poppet (18). BD01H214
Install a new o-ring (29) and backup ring (28) on the

STEP 78 sleeve (30), see the illustration on page 16.
STEP 81
26 25
27
BD01H216
Install the spring (19).

BD01H213
Install a new o-ring (26) and backup ring (25) on the

spool (27).

6004-23
STEP 82 STEP 85
BD01H211 BD01H208
Install the spool (27). Refer to the alignment mark Lubricate the spool (27) and install into the sleeve
made during disassembly. (30).
STEP 83 STEP 86
BD01H210 BD01H207
Install the washer (21) and nut (20) on the spool (27). Make sure the marks are in alignment and tighten the
bolts.
STEP 84
STEP 87
14
12
11
15
9 10
BD01H209
Lubricate the sleeve (30). Install the sleeve. Make BD01H236
sure the notch in the end of the sleeve is toward the Assemble the special bolt (15), inner spring guide
open end of the pump. (14), sleeve (13), spring (12), outer spring guide (11),
adjusting nut (10), and jam nut (9).

6004-24
STEP 88 STEP 91
BD01H237 BD01H238
Tighten the adjusting nut (10) to begin compression Hold the special bolt (15) and tighten the adjusting
of the spring (12). nut (10) until the outer spring guide (11) is below the
groove for the retaining ring (8).
STEP 89
STEP 92
16 31
16
31
BD01H235
BD01H239
Install new rings (31, 16) and o-rings (17) on the
Install the retaining ring (8).
piston (18).
STEP 93
STEP 90
BD01H232
BD01H234
Loosen the special bolt (15) just enough so the
Fasten the piston (18) in the vise with soft jaws.
spring (12) and adjusting nut (10) are not loose.
Install the spring assembly (12).

6004-25
STEP 94 STEP 97
BD01H241 BD01H244
Hold the adjusting nut (10) and special bolt (15). Turn the cover (6) onto the special bolt (15) until the
Tighten the jam nut (9). Recheck the special bolt and measurement is equal to the measurement in step 28
spring (12) to make sure the spring is not loose. of Disassembly.
STEP 95 STEP 98
BD01H242 BD01H245
Lubricate the piston (18) with clean oil. Install the When the measurement is correct, install and tighten
piston (18). t h e s c r e w s ( 3 ) t o 11 t o 1 5 N m ( 9 6 t o 1 3 2
pound-inches).
STEP 96
STEP 99
BD01H243
Push the piston (18) into the housing. Install a new BD01H246
gasket (7). Install the cover (6). Hold the special bolt (15) and install the special nut
(2). Install the special nut with sealing surface
inward.

6004-26
STEP 100 STEP 102
BD01H204 B518843
Install the cover (19) with a new gasket (7). Tighten If the ball bearing (11) for the shaft (5) has been
t h e s c r e w s ( 3 ) t o 11 t o 1 5 N m ( 9 6 t o 1 3 2 replaced, install the snap rings (12).
pound-inches).
STEP 103
STEP 101
B518730
B518838 Press the ball bearing (11) and shaft (5) into the
If necessary, install new bearings (4) on the cover cover (9).
(9), refer to illustration on page 15. Make sure the
holes in the bearings (4) engage the roll pins (10) in STEP 104
the cover (9).
NOTE: If a new cover (9) is being used, install new roll

pins (10) so the tops of the roll pins are 2.3 to 2.8 mm
(0.090 to 0.110 inch) above the face of the cover.
B518944
Install the snap ring (3) in the groove just above the
ball bearing (11).

6004-27
STEP 105 STEP 108
B518904 BD01H198
Lubricate the lip o f the seal (1) with clean oil. Make sure the three pins (20) are installed in the
Carefully press the new seal (1), with the lip down, cylinder block (21).
into the cover (9).
STEP 109
STEP 106
BD01H247
BD01H200 Pull the pin retaining collar (19) up to the top of the
Install the other snap ring (2). splines.
STEP 107 STEP 110
26
BD01H197 BD01H196
Install the wear plate (26) with the bronze surface up. Install the cylinder block (21) into the pump.
Make sure the notch in the wear plate engages the
roll pin. Lubricate the wear plate (26) with clean oil.

6004-28
STEP 111 STEP 113
BD01H248 BD01H250
Install the guide (18) on the pins (20).
STEP 112
BD01H251
Lubricate the pistons (16) with clean oil. Install the

pistons (16) into the retainer (17) and cylinder block
BD01H249 one at a time. Make sure the guide (18) is still in
Install the retainer (17) on the guide. position on the three pins (20).
STEP 114
B518618
If a new swash plate (13) or pin (15) is being used,

press the pin (15) so that the end of the pin is 8.4 to
8.9 mm (0.33 to 0.35 inch) above the surface of the
swash plate (13). The slot in the pin (15) must be
toward the center of the swash plate (13).

6004-29
STEP 115 STEP 118
14
B519113 B9109118
Install the retainer (14) on the other pin (22) of the Carefully install the cover (9) and shaft (5). Rotate
swash plate (13). the shaft (5) to align the support and cylinder block.
STEP 116 STEP 119
BD01H193 BD01H190
Install the swash plate(13). The pin (15) must engage Install the special bolts (7 and 6). Use the bolts to
the slot in the body of the control valve and the evenly draw the cover (9) to the housing (30).
retainer (14) must engage the groove in the piston. Tighten the 3/8 inch special bolt to a torque of 53 to
64 Nm (39 to 47 pound-feet). Tighten the 7/16 inch
STEP 117 special bolts to a torque of 81 to 100 Nm (60 to 74
pound-feet).
STEP 120
B9109117
Install a new gasket (28).
BD01H189
Install the gear housing (33) in the cover (34).

6004-30
STEP 121 STEP 123
35
BD01H188 BD01H186
Install the inner gear (32). Lubricate the cover (34) with clean oil. Install the
cover (34) so that the pin (35) engages the hole at
STEP 122 the top of the housing.
STEP 124
Adjust the controls and piston for NEUTRAL.
BD01H187
Install the coupling (30). Make sure the pin (31) in the
coupling (30) engages the slot in the inner gear (32).
FRONT PUMP
Disassembly, Inspection, and

Assembly
Disassembly, inspection, and assembly of the front
pump is the same as the rear pump except for the
shaft and end cover. Repeat steps as necessary for
the front pump, refer to the illustration on page 18 in
place of the illustration on page 15, the illustration on
page 19 in place of the illustration on page 16, and
the illustration on page 20 in place of the illustration
on page 17.

Section
6005
DRIVE MOTORS
6005

6005-2
TABLE OF CONTENTS
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 9

6005-3
DRIVE MOTOR
Disassembly STEP 5
STEP 1
BD01M053
Remove the dash pot and spring from the valve

BD01M049
plate.
Mark all points of separation.
STEP 6
STEP 2
BD01M054
BD01M050
Remove the valve plate.
Loosen the bolts on the end cover.
STEP 7
STEP 3
Set the motor on blocks or in a vise with soft jaws.
Then remove the bolts.
STEP 4
BD01M055
Remove the geroter assembly. Be careful not to

loose the two small check balls in the bottom of the
geroter star.
BD01M052
Remove the end cover.

6005-4
STEP 8 STEP 11
BD01M056 BD01M059
Remove the outer thrust plate. Remove and discard the seal and back-up ring.
STEP 9 STEP 12
BD01M060
BD01M057 Remove the O-ring from the bearing housing.

Remove the inner thrust plate.
STEP 13
STEP 10
BD01M061
Remove the seal from the bearing housing.

BD01M058
Remove the drive shaft.

6005-5
STEP 14 STEP 17
BD01M068
BD01M067
Remove the seal from the geroter housing. Remove the seal from the outer thrust plate.
STEP 15 STEP 18
BD01M065 BD01M062
Remove the outer seal from the valve plate. Remove the plug from the end cover.
STEP 16 STEP 19
BD01M063
BD01M066
Remove the inner O-ring from the valve plate. Remove the dash pot, spring, and poppet from the
cover.

6005-6
STEP 20 STEP 23
BD01M064
Turn the cover on its side and remove the poppet BD01M076
and shuttle piston. Remove the face seal from the bearing housing.
STEP 21 STEP 24
BD01M073
BD01M070 Remove the retainer from the output shaft.

Place the bearing housing in a vise and remove the
snap ring. STEP 25
STEP 22
BD01M074
Remove the O-ring from the retainer.

BD01M071
Set the bearing housing in a vise with soft jaws.

Remove the output shaft, bearing assembly, and
retainer from the bearing housing by carefully taping
the shaft with a punch and hammer. The shaft will fall
out of the bearing housing. Be careful not to damage
the shaft and bearing assembly.

6005-7
STEP 26 Inspection
STEP 28
Clean all parts in cleaning solvent. Use a lint free
cloth, or air dry the parts.
STEP 29
Lubricate all O-rings and seals with clean hydraulic
oil prior to assembly.
STEP 30
Inspect the splines on the drive shaft. If the splines
BD01M075 are worn or damaged, use new parts.
Remove the shaft seal from the front retainer.
STEP 31
STEP 27 Inspect both sides of the thrust plate and balance
plate. Make sure the thrust plate and balance plate
are flat. If the surfaces have pitting or scoring, use
new parts as required.
STEP 32
Inspect the dash pots, springs, poppets, and shuttle
piston of the shuttle valve assembly. Use new parts
as required.
STEP 33
Inspect the splines on the output shaft. If the splines
are worn or damaged, use new part as required.
GM98J621
Remove the shaft retaining ring, tapered bearings,

and bearing spacer from the shaft.

6005-8
2
17
18 8 20
10 28 16
7 27 15
6
22
3
4
5 11 24
19 26
23
1
12 14
13 25 21
9
BS01M189
1. BOLT 8. VALVE PLATE 15. O-RING 22. OUTPUT SHAFT
2. END COVER 9. GEROTER ASSEMBLY 16. BEARING HOUSING 23. RETAINER
3. PLUG 10. OUTER THRUST PLATE 17. SEAL 24. FACE SEAL
4. DASH POT 11. INNER THRUST PLATE 18. SEAL 25. O-RING
5. SPRING 12. DRIVE SHAFT 19. O-RING 26. SHAFT SEAL
6. POPPET 13. BACKUP RING 20. SEAL 27. CHECK BALL
7. SHUTTLE PISTON 14. O-RING 21. SNAP RING 28. SEAL

6005-9
Assembly STEP 37
NOTE: During assembly make sure all alignment
marks made during disassembly are in alignment.
STEP 34
BD01M075
Install a new front shaft seal into the front retainer.

STEP 38
GM98J621
Insta ll tap ere d be aring s, be ar in g sp ace r, an d

retaining ring onto the shaft.
STEP 35
BD01M073
Install the front retainer onto the output shaft.
STEP 39
BD01M076
Install a new face seal into the bearing housing.
STEP 36
BD01F070
Install the shaft assembly into the bearing housing by

carefully tapping the end of the shaft. Push the front
retainer into the housing and install the snap ring.
BD01M074
Install a new O-ring on the front retainer.

6005-10
STEP 40 STEP 43
BD01M061 BD01M068
Install the outer square cut seal on the bearing Install a new seal onto the outer thrust plate.
housing.
STEP 44
STEP 41
BD01M057
BD01M060 Install the inner thrust plate on the bearing housing.

Install a new O-ring on the bearing housing.
STEP 45
STEP 42
BD01M056
BD01M059 Install the outer thrust plate on the bearing housing.

Install the O-ring and backup ring on the bearing
housing with the backup ring on top.

6005-11
STEP 46 STEP 49
BD01M058 BD01M065
Install the drive shaft into the output shaft. Install a new seal onto the valve plate.
STEP 47 STEP 50
BD01M067 BD01M066
Install a new seal onto the geroter housing. Install a new O-ring onto the valve plate.
STEP 48 STEP 51
BD01M055 BD01M054
Install the geroter assembly onto the shaft. Make Install the valve plate.
sure the two small check balls do not fall out.

6005-12
STEP 52 STEP 55
BD01M064 BD01M063
Install the shuttle piston and poppet into the end Install the poppet, spring, dash pot, and plug into the
cover. Use grease to hold them in place. end cover.
STEP 53 STEP 56
Install the spring and dash pot into the cover. Use
grease to hold them in place.
STEP 54
BD01M051
Install the plug on the cover.
BD01M050
Install the end cover and secure it with the bolts.

Torque bolts to 108 Nm (80 pound-feet).

Section
6005
DRIVE MOTORS WITH SPRING APPLIED - HYDRAULIC

RELEASE BRAKES (EUROPEAN AND OPTIONAL
6005
NORTH AMERICAN MACHINES)

6005-2
TABLE OF CONTENTS
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6005-3
DRIVE MOTOR
Disassembly STEP 4
NOTE: The following photos may not match your
machine, the procedure is the same.
STEP 1
BD01M052
Remove the end cover.
STEP 5
BD01M049
Mark all points of separation.
STEP 2
BD01M053
Remove the dash pot and spring from the valve

plate.
BD01M050 STEP 6
Loosen the bolts on the end cover.
STEP 3
Set the motor on blocks or in a vise with soft jaws.
Then remove the bolts.
BD01M054
Remove the valve plate.

6005-4
STEP 7 STEP 10
BD01M055
BD01M058
Remove the geroter assembly. Be careful not to
loose the two small check balls in the bottom of the Remove the drive shaft.
geroter star.
STEP 11
STEP 8
BD01M059
BD01M056 Remove and discard the seal and back-up ring.

Remove the outer thrust plate.
STEP 12
STEP 9
BD01M060
Remove the O-ring from the flange.

BD01M057
Remove the inner thrust plate.

6005-5
STEP 13 STEP 16
BD01M061 BD01M066
Remove the seal from the flange. Remove the inner O-ring from the valve plate.
STEP 14 STEP 17
BD01M067 BD01M068
Remove the seal from the geroter housing. Remove the seal from the outer thrust plate.
STEP 15 STEP 18
BD01M062
BD01M065
Remove the outer seal from the valve plate. Remove the plug from the end cover.

6005-6
STEP 19 STEP 21
2
3
BD01M063
4
Remove the dash pot, spring, and poppet from the BS01M204
cover. 1. PLUG 2. SPRING 3. SHIM(S) 4. POPPET 5. O-RING

Remove the plug (1), spring (2), shim(s) (3), and
STEP 20 poppet (4) from the end cover.
BD01M064
Turn the cover on its side and remove the poppet

and shuttle piston.

6005-7
24
28
25
27 3 28
26
4
5
6
7 6
5
2 4
18
8
17
9
21
20 10
12
16 22
19
15
21
11 13
14
23
BD01M
1. BOLT 8. VALVE PLATE 15. O-RING 22. FLANGE
2. END COVER 9. GEROTER ASSEMBLY 16. SEAL 23. SEAL
3. PLUG 10. OUTER THRUST PLATE 17. SEAL 24. PLUG
4. DASH POT 11. INNER THRUST PLATE 18. SEAL 25. SPRING
5. SPRING 12. DRIVE SHAFT 19. O-RING 26. SHIM
6. POPPET 13. BACKUP RING 20. SEAL 27. POPPET
7. SHUTTLE PISTON 14. O-RING 21. CHECK BALL 28. O-RING
DRIVE MOTOR (EUROPEAN AND OPTIONAL NORTH AMERICAN MACHINES)

6005-8
Assembly STEP 25
STEP 22
BD01M068
Install a new seal onto the outer thrust plate.

BD01M061
Install the outer square cut seal on the flange. STEP 26
STEP 23
BD01M057
Install the inner thrust plate on the flange.

BD01M060
Install a new O-ring on the flange. STEP 27
STEP 24
BD01M056
Install the outer thrust plate on the flange.

BD01M059
Install the O-ring and backup ring on the flange with

the backup ring on top.

6005-9
STEP 28 STEP 31
BD01M058 BD01M065
Install the drive shaft into the output shaft. Install a new seal onto the valve plate.
STEP 29 STEP 32
BD01M067 BD01M066
Install a new seal onto the geroter housing. Install a new O-ring onto the valve plate.
STEP 30 STEP 33
BD01M055 BD01M054
Install the geroter assembly onto the shaft. Make Install the valve plate.
sure the two small check balls do not fall out.

6005-10
STEP 34 STEP 37
BD01M064 BD01M063
Install the shuttle piston and poppet into the end Install the poppet, spring, dash pot, and plug into the
cover. Use grease to hold them in place. end cover.
STEP 35 STEP 38
Install the spring and dash pot into the cover. Use
grease to hold them in place.
STEP 36
BD01M051
Install the plug on the cover.
STEP 39
BD01M050
Install the end cover and secure it with the bolts.

Torque bolts to 108 Nm (80 pound-feet).
1
2
3
4
BS01M204
1. PLUG 2. SPRING 3. SHIM(S) 4. POPPET 5. O-RING

Install the poppet (4), spring (2), shim(s) (3), and plug
(1) into the end cover.

Section
6007
SPROCKETS, CHAINS, AND AXLE ASSEMBLIES
6007
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-45180 Issued September, 2001
6007-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTING THE DEFLECTION OF THE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION OF AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AXLE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AXLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6007-3
Nuts for Axle Housings ..................................................................................223 to 265 Nm (165 to 195 pound-feet)
Nuts for Wheels .............................................................................................135 to 163 Nm (100 to 120 pound-feet)
Bolts for Chain Tank ........................................................................................ 133 to 160 Nm (93 to 112 pound-feet)
Bolts for Drive Sprockets ...............................................................................247 to 320 Nm (185 to 235 pound-feet)
(All threads are to be clean and free of rust, dirt and oil. Apply Loctite 243 to the first 10 to 15 threads of the cap
screw)
NOTE: Be sure to recheck the wheel nuts every two hours until the wheel nuts remain tight. See Operations
Manual.

6007-4
ADJUSTING THE DEFLECTION OF THE CHAINS

1. Lower the loader bucket or attachment to the 13. When the chain deflection (8) is correct, 3.0 to
ground. 20.0 mm (0.12 to 0.79 inch, tighten the axle
mo u n t in g n u t s (2 ) to a to r q u e o f 7 N m ( 5
2. Use a jack or hoist to lift the machine off of the
pound-feet).
ground. Place approved jack strands under the
machine. Loosen and remove the wheel nuts (1) 14. Repeat the previous steps for the remaining drive
and wheels. See illustration on page 5. chains (3).
3. Clean the area around both chain tank inspection 15. Following adjustment of all drive chains (3), start
covers. Loosen and remove the (6) inspection the engine and run at low idle.
cover retaining bolts and special flat washers.
16. Move the drive control levers all of the way
4. Remove the inspection cover and gasket. Check forward for 5 seconds and stop the engine.
the gasket for damage and replace if necessary.
17. Check the deflection of all four drive chains. The
5. Start the machine. drive chains (3) are correctly adjusted if the
6. Push both steering control levers all the way deflection is 3.0 to 20.0 mm (0.12 to 0.79 inch).
forward for 5 seconds. 18. If necessary, tighten or loosen the drive chains to
7. Stop the engine. get the correct deflection.
8. If equipped with pin lock style brakes, loosen and 19. Install the brake disk (10) onto the drive sprocket
remove the center bolt (12) and the retaining (4). Install the retaining plate (11). Install and
plate (11) from the brake disk (10). Remove the tighten the center bolt (12) to a torque of 247 to
brake disk (10) from the drive sprocket (4). 320 Nm (185 to 235 pound-feet).
9. Check the deflection of the chains (3) on the 20. Tighten the axle housing mounting nuts (2) to a
slack side (8). The slack side is on top of the front torque of 223 to 265 Nm (156 to 185 pound-feet).
chain and on the bottom of the rear chain when 21. Apply RTV sealant between the gasket cover and
trav elin g forw ar d. Es tima te th e a mo un t of chassis and install the inspection cover.
deflection by moving the chain up and down. If
deflection is more than 40 mm (1.5 inch) for one 22. Tighten the inspection cover retaining bolts to a
chain, adjust the deflection of all four chains. torque of 125 to 150 Nm (93 to 112 pound-feet).
NOTE: The deflection of the chains can not be 23. Install the four wheels and tighten the wheel nuts
measured with accuracy. (1) to a torque of 135 to 163 Nm (100 to 120
pound-feet).
10. Loosen the axle housing (9) and mounting nuts
(2), so the axle is free to move. NOTE: Be sure to check the wheel nuts (2) every 2
hours until the nuts remain tight.
11. Insert a pry bar against the adjusting spud and
axle housing (9). 24. Remove the approved jack stands and lower the
machine to the ground.
12. Pry against the axle housing (9) until it stops
moving. Tighten one or two axle mounting nuts
(2) to hold the axle housing (9) in place and
check the chain deflection (8).

6007-5
]
9
5
10
7
2 3
6 8
REAR AXLE
9
3 8
4
8 3
7
6
9 8 11 FRONT AXLE
1 3
12 5
10 9
1 2
BS01H205
1. WHEEL NUTS 6. CAP SCREW (DRIVEN SPROCKET) 11. RETAINING PLATE

2. AXLE HOUSING NUTS 7. WASHER 12. BOLT
3. ROLLER CHAIN 8. CENTER OF SLACK SIDE OF CHAIN
4. DRIVE SPROCKET 9. AXLE HOUSING
5. DRIVEN SPROCKET 10. BRAKE DISK (IF EQUIPPED)
ILLUSTRATION OF SPROCKETS, CHAINS, AND AXLE ASSEMBLIES

6007-6
REMOVAL AND INSTALLATION OF AXLES
1. Raise the machine off the floor and place NOTE: Be sure to note the direction of installation,
approved jack stands under the machine. refer to IMPORTANT under step 11 of removal.
2. Loosen and remove the wheel nuts (6) and 1. Install the chain (7) on the sprocket (12) and
wheels. See illustration on page 7. align sprocket (12) with the axle opening in the
chassis.
3. Loosen and remove the chain tank inspection
cover retaining bolts and washers. 2. Install a new O-ring (3) on axle assembly (1).
4. Remove the cover and the gasket. Check the 3. Align the splines on the axle assembly (1) with
gasket for damage and replace if necessary. the splines in sprocket (12) and install axle
as semb lie s (1 ) a nd fla ng e nu ts (2 ) o n th e
5. If equipped with pin lock style brakes, remove
chassis.
bolt (10) and retaining plate (9) from the brake
disk (11). Remove the brake disk (11) from the 4. Install bolt (4) and washer (5) in the axle
drive sprocket (8). assembly (1) through the opening on the inside
of the chassis.
6. Loosen the flange nuts (2) that hold the axle
housings (1) enough to allow the axle housings 5. Tighten the bolt (10) to a torque of 247 to 320
(1) to move, refer to the illustration on page 7. Nm (185 to 235 pound-feet).
7. Insert a pry bar against the adjusting spud and 6. Adjust the deflection of the chains, refer to
the axle housing (1). ADJUSTING DEFLECTION OF THE CHAINS in
this section.
8. Remove the access plug (not shown) from the
chain tank. Remove the axle bolt (4) and the 7. Install the brake disk (11) onto the drive sprocket
washer (5). (8).
9. Pry against the axle housing (1) until the chain 8. Install the retaining plate (9) and the center bolt
(7) is loose. (10) onto the brake disk (11). Tighten the center
bolt to a torque of 247 to 320 Nm (185 to 235
10. Remove the flange nuts (2) and axle assembly
pound-feet).
(1) from the chassis.
9. Install inspection cover and gasket. Tighten
11. Remove the O-ring (3) and discard.
inspection cover retaining bolts to a torque of 125
IMPORTANT: Be sure to note the location of the to 150 Nm (93 to 112 pound-feet).
sprockets. Both sprockets are interchangeable but
10. Install wheels and wheel nuts (6).
face opposite directions.
11. Tighten wheel nuts (6) to a torque of 135 to 163
Nm (100 to 120 pound-feet).
12. Remove supports and lower machine to the
ground.

6007-7
12
5
6 4
1
2
3
1 2
4 5 3
8
1 10
11 9
6
12
BC01G181
1. AXLE ASSEMBLY 4. BOLT 7. CHAIN 10. BOLT

2. FLANGE NUT 5. WASHER 8. DRIVE SPROCKET 11. BRAKE DISC
3. O-RING 6. WHEEL NUTS 9. RETAINING PLATE 12. SPROCKET
EXPLODED VIEW OF 40XT DRIVE LINE

6007-8
AXLE DISASSEMBLY
STEP 1 STEP 3
BP96K019 BP96K022
Put the axle housing in a press for removal of the Install an acceptable puller on the outer bearing cup.
axle.
STEP 4
STEP 2
BP96K023
BP96K020 Turn the axle housing over so that the puller is down.
Press the axle out of the inner bearing and remove Install an acceptable driver on the puller and press
the axle housing from the axle. Remove the inner the outer bearing cup out of the axle housing.
bearing from the axle housing.

6007-9
STEP 5 STEP 7
BP96K024 BP96K028
Remove the outer plastic grease disc from the axle Turn axle housing over so that the puller is down.
housing. Install an acceptable driver on the puller and press
the inner bearing cup out of the axle housing.
STEP 6
STEP 8
BP96K027
Turn the axle housing over and install an acceptable BP96K0330
puller on the inner bearing cup. Install an acceptable puller on the outer bearing and
pull the bearing from the first press fit area of the
axle. Slide the bearing upward to the second press fit
area.

6007-10
STEP 9 AXLE INSPECTION
1. Use cleaning solvent to clean the bearings. Make
sure all grease is removed from the bearings.
2. Remove the grease from the bore of the axle
housing.
3. Inspect the rollers of each bearing for flat areas,
pitting, scoring, or other damage. If you find any
damage, install a new bearing and cup.
4. Inspect each bearing cup for flat areas, pitting,
sc o rin g , o r o th e r d am a ge . If yo u fin d a n y
damage, install a new bearing and cup.
BP96K031
NOTE: If a bearing or bearing cup is to be replaced,
Remove the outer bearing from the second press fit replace both parts at the same time.
area of the axle. 5. Check for wear, cracks or damage to the splines
on the axle. If any damage is found, replace the
STEP 10 axle shaft.
NOTE: Use a new outer axle seal and plastic grease
disc during assembly of the axle housing.
BP96K032
Remove the outer seal from the axle.

6007-11
4 4
7
8
4 4
3 3
1
SEE DETAIL A
6
SEE DETAIL B
BS01H204
1. AXLE SHAFT 4. BEARING CUP 7. BEARING CUP DETAIL

2. AXLE HOUSING 5. AXLE SEAL 8. AXLE SEAL DETAIL
3. BEARING 6. PLASTIC GREASE DISK
CROSS SECTION OF AXLE ASSEMBLY

6007-12
6 1
7
7
6
5
4
3
2
BT00G044
1. AXLE HOUSING 4. STUD 7. BEARING CUP

2. AXLE SHAFT 5. SEAL 8. PLASTIC GREASE DISK
3. SEAL GUARD 6. BEARING
EXPLODED VIEW OF 40XT AXLE ASSEMBLY

6007-13
AXLE ASSEMBLY
STEP 11 STEP 14
BP96K033 BP96K035
Start the inner bearing cup into the axle housing. Start the outer bearing cup into the axle housing.
STEP 12 STEP 15
BP96K034 BP96K036
Use an acceptable driver to press the bearing cup Use an acceptable driver to press the bearing cup
into the axle housing. Press the cup until it is seated into the axle housing. Press the cup until it is seated
against the axle housing shoulder. against the axle housing shoulder.
STEP 13 STEP 16
BP96K024 BP96K037
Turn the axle housing over and install the outer Use No. 2 lithium wheel bearing grease to fill the
plastic grease disc into the axle housing. bearings.

6007-14
STEP 17 STEP 20
BP96K038 BP96K041
Fill the area between the outer grease disc and seal Use an acceptable driver to press the outer seal into
with grease. the housing. Press the seal into the axle housing until
the seal is seated against the shoulder. W hen
STEP 18 properly installed, the outer face of the seal may be
flush or slightly below the axle housing.
STEP 21
BP96K039
Install the bearing into the outer bearing cup.
STEP 19 BP96K042
Start the axle into the outer bearing. Be careful not to

damage the lips on the outer seal during this step.
Install a driver on the flange and press the axle
through the first press fit area of the axle.
NOTE: Be sure to support the axle while pressing.
Once the axle presses past the first press fit area the
axle will drop to the second press fit area and may
damage the seal.
BP96K040
Lubricate the lips of a new seal with No. 2 lithium

grease and start the seal into the housing.

6007-15
STEP 22 STEP 24
BP96K043 BP96K046
Press the axle through the second press fit area. Use an acceptable driver to press the inner bearing
Press the axle until it is seated against the outer onto the axle. Press the bearing until it is seated in
bearing. the cup.
STEP 23
BP96K045
Install the inner bearing onto the axle.

6007-16
NOTES

6011
Section
6011
WHEELS AND TIRES
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-45980 November, 2001
6011-2
TABLE OF CONTENTS
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inflating the Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6011-3
WHEELS AND TIRES
Tire Pressure
Check the air pressure and the condition of the tires every 50 hours of operation.
12.00 x 16.5 Solideal Hauler (10 PR) (Standard) ............................................................................. 380 kPa (55 psi)
12 x 16.5 Galaxy Beefy Baby II (10 PR)........................................................................................... 275 kPa (40 psi)
When used with steel tracks inflate to ..........................................................................................414 kPa (60 psi)
33 x 15.50 x 16.5 Galaxy Hippo (12 PR) ...........................................................................................310 kPa (45 psi)
12 x 16.5 Galaxy King Kong .............................................................................................................275 kPa (40 psi)
When used with steel tracks inflate to ..........................................................................................414 kPa (60 psi)
33/10 x 16.5 Galaxy Slim Jim (10 PR) ..............................................................................................425 kPa (67 psi)
12 x 16.5 Galaxy Hulk (12 PR) ..........................................................................................................345 kPa (50 psi)
33 / 15.50 x 16.5 Galaxy Bulky Hulk..................................................................................................240 kPa (35 psi)
Inflating the Tire Wheel Nut Torque

Always have a qualified tire mechanic service the If the machine is new or you have just installed the
tires and rims on this machine. It is recommended wheels, check the wheel nuts every 2 hours until the
that you have this mechanic inflate the tires. To nuts remain tight. Tighten each nut to a torque of 135
prevent accidents, always use a restraining device to 163 Nm (100 to 120 pound-feet). Do not use an
(tire inflation cage), correct equipment, and correct impact wrench to install or tighten the wheel nuts.
procedure. Explosive separation of the tire can cause
serious injury.
If the tire has lost all the pressure or service to the
tire or rim is required, do the following:
1. Before you add air, have the tire correctly
installed on the machine or put the tire in a
restraining device (tire inflation cage).
2. Use an air hose with remote shut-off valve and a
self-locking air chuck.
3. Stand behind the tread of the tire and make sure
all persons are away from the side of the tire
before you start to add air. BP96N057
4. Inflate the tire to the recommended air pressure. When the tires are installed, make sure that the tread
DO N OT inflate the tire more than the is in the same direction. See the photo above.
recommended pressure.

6011-4
NOTES

SECTION INDEX
BRAKES

Brake System - “How it Works” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000
Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
Removal and Installation of Park Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003
Brakes - Spring Applied - Hydraulic Release
(European and Optional North American Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Brakes - Pin Lock - Cable Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7005
Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7006

CASE CORPORATION
SECTION INDEX
HYDRAULICS

Hydraulic System - “How it Works” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8000
Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
Cleaning the Hydraulic System and the Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Gear (Equipment) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Flat Faced Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
High Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8008
D - 125 Backhoe Control Valve - North American Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8012
Accumulator for Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013

CASE CORPORATION
Section
8000
HYDRAULIC SYSTEM HOW IT WORKS
8000
CASE CORPORATION
700 State Street
8000-2

8000-3
TABLE OF CONTENTS
HYDRAULIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Components Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Functional Overview of the Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Overview of the Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation: Closed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation: Open Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CIRCUIT RELIEF VALVE / ANTI-CAVITATION CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Direct Acting Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LOADER CONTROL VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Loader Spool Actuated to Raise Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Loader Spool Actuated to Lower Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Loader Spool Actuated To Raise, Bucket Spool To Rollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Loader Spool Actuated To Lower, Bucket Spool To Rollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Loader Spool Actuated To Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPOOL LOCK SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
AUXILIARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
AUXILIARY CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
HIGH FLOW HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FILTER RESTRICTION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
BI-DIRECTIONAL SELF-LEVELING (BDSL) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bucket Self-Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Functional Overview of the Bi-Direction Self-Level Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Loader Raise & Bucket Self-Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Loader Raise-Bucket At Full Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Loader Lower & Bucket Self-Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Loader In Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Loader Raise & Bucket Dump Self-Leveling Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
BI-DIRECTIONAL SELF-LEVELING SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8000-4
HYDRAULIC SYSTEM OVERVIEW

The reservoir is located in the left rear loader frame back to the oil cooler. The auxiliary valve will only be
upright. The fill cap controls the pressure of the supplied with oil if the bucket spool is in neutral and
reservoir to 5 psi, and will allow make-up air to enter the loader lift spool is either in neutral or the loader
at .5 psi vacuum. There is also a drain plug at the lift circuit is still able to flow oil (cylinder not at the end
bottom of the reservoir to be used in conjunction with of travel). The single spool auxiliary control valve is
the filter buggy to clean up the system. There is no located at the left rear of the machine and is cable
suction screen inside the reservoir. operated by a pedal between the operator's feet. This
valve controls the flow to the hydraulic quick
The gear type hydraulic pump is mounted at the rear
disconnect couplers on the loader frame near the
of the machine, driven by the crankshaft pulley.
bucket. The oil is routed through plumbing on the left
(Service Note: To replace the fan belt on the engine,
rear loader frame and through the loader pivot point.
do not disconnect the hoses to the pump. Unbolt the
The auxiliary quick disconnect couplers are located
pump and lay it over to the side.)
at the left side of the loader frame crossbar. The main
From the pump, the oil flows directly to a two spool relief valve in the loader valve also limits the
open center loader control valve. The main relief maximum pressure available to the auxiliary circuit.
valve for the complete hydraulic system is located at Return oil from the auxiliary valve, joins the return oil
the inlet to the loader valve. The first spool in the from the loader valve and returns to the oil cooler.
valve controls the loader lift functions - raise, neutral, The oil cooler is mounted on the back door of the unit
lower and float. The second spool in the valve for ease of cleaning.
controls the bucket cylinder functions - rollback,
There is one filter in the complete hydraulic system.
neutral, and dump. The valves have one load check
The filter head has a 50 psi differential bypass relief
valve for each spool to prevent the load from
valve to protect the filter element during cold weather
dropping as the spool is slowly engaged to the power
o p e ra t i o n . T h e f i l t e r h e a d a l s o h a s a 4 0 p s i
position. An optional bi-directional hydraulic bucket
differential pressure switch to signal when the filter
self-leveling system is available. The bi-directional
requires changing. To check the condition of the filter,
self-leveling system is incorporated into the loader
operate the engine at full throttle with the oil at
control valve. A circuit relief/anti-cavitation check
operating temperature and observe the filter indicator
valve is incor porated at each work por t of the
light. The filter light will also come on and the filter
bi-directional self-leveling loader control valve. On
bypass will open when the hydraulic oil is cool.
t h e s t a n d a r d l o a d e r c o n t r o l va l ve, a c i r c u i t
Because of this, it is recommended to limit the
relief/anti-cavitation check valve is incorporated at
maximum engine speed while the oil is cold.
each work port except the A1 port.
Oil returning from the hydrostatic pump and motor
The units are equipped with an auxiliary hydraulic
case drain connections retur ns directly to the
system. The pump supply flows from the power
reservoir and does not flow through the hydraulic
beyond port in the outlet of the loader valve to the
filter. If a failure occurs in the hydrostatic system, the
auxiliary hydraulic valve rather than going directly
hydraulic reservoir must be thoroughly flushed.

8000-5
HS01D070

8000-6
HYDRAULIC COMPONENTS
Components Defined Reservoir
Reservoir - Located in the left rear of chassis. The hydraulic system begins at the reservoir located
Pressurized to 34.5 kPa (5 psi), with a -3.5 kPa in the left rear frame. The reservoir is pressure limited
(-0.5 psi) vacuum breaker. to 34.5 kPa (5 psi). Pressure is controlled by the relief
in the reservoir cap. A vacuum breaker is also
Hydraulic gear pump - Supplies flow to operate the employed in the cap to open at -3.5 kPa, (0.5 psi)
hydraulic system. allowing air to enter the reservoir.
Loader control valve - Is a two spool valve Hydraulic Pump

controlling the loader and bucket circuits. The main
relief valve is also part of the valve assembly. A Sauer/Danfoss gear pump supplies oil for the
hydraulic system. Pump flow is supplied to the
Auxiliary control valve - Is a single spool valve equipment port for use in the hydraulic system by the
controlling the auxiliary circuit. loader, bucket and power beyond circuits. Return oil
from the hydraulic system passes through the filter
Bucket tip cylinders - Used to control the movement and cooler before returning to the reservoir. The
of the bucket. hydraulic pump is mounted to and driven by the
engine.
Loader lift cylinders - Used to raise and lower the
loader frame (with cushioning employed at the rod end
of the cylinder).
Auxiliary disconnects -Located on the left loader

frame for the purpose of auxiliary hydraulic power to
attachments.
Hydraulic filter - Provides 6 Micron filtration for return

oil from the hydraulic system.
Oil cooler - Cools hydraulic system return oil and

hydrostatic drains.
High flow gear pump - Supplies flow to combine with

the unused main hydraulic system flow.
High flow control valve - Is a single spool valve

controlling the high flow auxiliary circuit. (Motor type
spool)

8000-7
HS01D071

8000-8
LOADER CONTROL VALVE
Functional Overview of the Loader Component Overview of the

Control Valve Loader Control Valve
The control valve assembly is a two spool valve, The Main relief valve controls the hydraulic system
open center configuration, with oil ported in a series pressure when flow from the hydraulic pump is
flow path. The valve is Case manufactured, and has stopped. The relief valve is located in the inlet
the following functions: passage to the loader control valve. It is pilot
operated and screw adjustable. Oil passing through
The Loader lift circuit controls raising, lowering, and
the relief valve is ported to the return passage (low
the float position of the loader frame. The loader lift
pressure side) of the control valve and on to the
circuit is the first spool to receive oil flow from the
reservoir.
inlet of the control valve. Shifting the loader spool
outward sends oil out of the B1 port of the valve to Circuit relief/Anti-cavitation check valves are
the base end of the loader cylinders to raise the used in the B port of the loader circuit and both A and
loader frame. Shifting the spool inward sends oil out B por ts of the bucket circuit. Circuit
of the A1 port of the valve to the rod end of the loader relief/Anti-cavitation check valves are used in both
cylinders to lower the loader frame. In either position, the A and B Ports of the loader and bucket circuits of
the oil flow from the pump is ported to the loader control valves with the integral bi-directional
cylinder rod or base end and blocked from the open self-leveling incorporated within it. Circuit relief valves
center. The return oil flow from the loader cylinders is protect cylinders and lines from being
por ted back to the open center passage on the over-pressurized due to outside forces or shock
downstream side of the loader spool, allowing oil flow loads when control valve spools are in neutral. The
to operate other functions as long as the loader lift anti-cavitation check valve function allows make-up
cylinder is moving. If the loader spool is shifted oil to enter each por t as the circuit relief valve
inward past the lower position, it will enter the float activates on the opposite port.
position. A mechanical ball type detent holds the
A Circuit check valve (used in the B1 circuit of the
loader spool in float. Float position connects both
loader lift circuit) is used to block back pressure in the
ends of the loader cylinders to the return passage
series passage when the bucket or power beyond
and allows pump flow to pass through the open
circuit is operating at relief valve opening pressure
center circuit.
and the loader lift circuit is feathered to the down
The Bucket circuit controls the curl and dump position.
positions of the bucket. This is the second spool to
Spool lock solenoids secure the loader and bucket
receive oil flow. The bucket circuit receives oil flow
control spools in the neutral position unless the
from the open center supplied by the pump or return
operator is seated in the operators seat with the lap
flow from the loader lift circuit. If the bucket spool is
bar in the lowered position. This is part of the loader
shifted outward, the base end of the bucket cylinder
interlock system. A mechanical release of the loader
receives flow, from the B2 port, to dump the bucket.
spool is possible if the machine is disabled.
Shifting the bucket spool inward sends oil from the
A2 port to the rod end of the cylinder to curl the
bucket back. Return oil from the bucket cylinders is
ported to the return passage of the control valve.
Load check valves maintain cylinder position until
the pressure under the load check is higher than the
cylinder pressure above the load check when the
control valve is feathered.
The power beyond circuit is ported to and receives
oil from the open center circuit. The power beyond
circuit allows pump flow to be used downstream from
the control valve when all control spools are in
neutral or if the loader lift circuit is actuated, with
cylinders returning oil to the open center passage.

8000-9
HS01D072
STANDARD LOADER CONTROL VALVE

8000-10
MAIN RELIEF VALVE

The main relief valve controls the maximum Operation: Open Position
operating pressure of the hydraulic pump. The valve
is nor mally closed, pilot-operated, and screw When pressure at the main spool exceeds the pilot
adjustable. The main relief valve is positioned at the valve poppet spring setting, the pilot valve poppet
inlet port of the loader control valve. Oil passing opens, allowing oil to flow from the small spring area
through the relief valve is ported to the return side to the reservoir. Oil now flows through the orifice in
(low pressure side) of the control valve and on to the main spool producing a pressure drop. The
reservoir. hydraulic forces on either side of the main spool are
no longer equal due to oil flowing through the orifice.
Operation: Closed Position Pump pressure against the main spool is now greater
than the combined hydraulic force and small spring
When the relief valve is in the closed position, pump force acting against the main spool. This causes the
flow is blocked from entering the return passages by main spool to open the return ports, sending pump
the main spool. The small spring force keeps the flow to the reservoir.
main spool in the closed position as long as the
hydraulic forces are equal on either side of the spool.
The main spool will remain in the closed position until
oil pressure at the pilot valve poppet exceeds the
pilot valve spring setting.

8000-11
HS01D073
1. RETURN TO TANK 4. MAIN SPOOL CLOSED 7. INLET

2. ORIFICE & SCREEN 5. SMALL SPRING 8. OUTLET
3. PUMP PRESSURE 6. PILOT VALVE POPPET CLOSED
MAIN RELIEF VALVE - CLOSED POSITION
HS01D074
1. RETURN PORT TO TANK 3. MAIN SPOOL OPEN 5. PILOT VALVE SPRING 7. OUTLET
2. PUMP PRESSURE 4. PILOT VALVE POPPET OPEN 6. INLET
MAIN RELIEF VALVE - OPEN POSITION

8000-12
CIRCUIT RELIEF VALVE / ANTI-CAVITATION CHECK VALVE
Direct Acting Circuit Relief Valve Circuit Relief Valve Operation: Circuit relief valves
are of the direct acting type. They are normally
Circuit relief/Anti-cavitation check valves are used in closed, requiring hydraulic pressure to open. The
the loader control valve at the A1 and B1 ports of the valve is a poppet held against a seat by spring force.
loader lift circuit and A2 and B2 ports of the bucket The poppet opens when hydraulic force against the
circuit. Circuit relief valves protect cylinders and lines poppet exceeds spring force. Oil passing the poppet
from being over pressurized by outside forces or enters the return passage of the control valve and
shock loads when control valve spools are in the continues on to the reservoir. Circuit relief valves
neutral position. should be checked using a hand pump.
The anti-cavitation check valve function of the circuit Anti-Cavitation Check Valve Operation: If the
relief valve operates when the cylinder moves with no cylinder travels with the control spool in neutral, the
oil supply to the circuit. This could happen as the pressure in the work por t is then less than the
circuit relief valve on the opposite work port opens pressure in the valve return passage. The light check
and creates a void in a work port. 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.
HS01D075

8000-13
HS01D076
CIRCUIT RELIEF VALVE - ANTI-CAVITATION CHECK VALVE

8000-14
LOADER CONTROL VALVE FUNCTION

Oil flow from the equipment pump is sent to the Loader Spool Actuated to Raise
loader control valve. Oil flow enters the control valve
at the inlet port to the open center passage. The
Loader
open center passage is connected to the main relief Shifting the loader spool outward blocks the pump
valve. The control valve is a two spool valve with the flow through the open center, sending pump flow
loader spool receiving oil first. With all spools in through the load check valve and on to the B1 port.
neutral, oil flows through the open center and out the Oil from the B1 port enters the base end of the loader
power beyond port to supply the auxiliary circuit. With cylinders raising the loader frame. Oil returning from
the loader spool activated, return oil from the loader the rod end of the loader cylinders enters the control
circuit flows to the downstream open center passage valve at the A1 port, and flows to the open center
and is available to the bucket spool or to the power passage for use by the bucket or out the power
beyond circuit. With the bucket spool activated, beyond port to auxiliary circuits. If the bucket or
return oil from the bucket circuit flows to the return auxiliary circuit is actuated, the circuit will function
passage of the loader valve and then to the filter. until the loader cylinders come to the end of their
travel. Once the loader cylinders reach the end of
their travel, oil flow is diverted to the main relief valve
and all functions stop. At this point the loader spool
must be returned to the neutral position, allowing
pump flow to enter the open center passage.
HS01D077

8000-15
HS01D078

8000-16
Loader Spool Actuated to Lower Oil flow entering the open center passage from the
B1 port can be used to operate the bucket or flows
Loader out the power beyond port to auxiliary circuits. If the
Shifting the loader spool inward blocks the oil flow bucket or auxiliary circuit is actuated, the circuit will
through the open center, sending pump flow through function until the loader cylinders come to the end of
the load check and on to the A1 port. Oil from the A1 their travel. Once the loader cylinders reach the end
por t enters the rod end of the loader cylinders, of their travel, oil flow is diverted to the main relief
lowering the loader frame. Oil returning from the valve and all functions stop. At this point the loader
base end of the loader cylinders enters the control spool must be returned to the neutral position,
valve at the B1 port. Oil flow entering the B1 port allowing pump flow to enter the open center passage.
enters the series passage, passing through the
circuit check valve and on to the open center
passage.
HS01D079

8000-17
HS01D080

8000-18
Loader Spool Actuated To Raise, spool shifted inward, oil returning from the loader
cylinders provides oil flow to operate the bucket
Bucket Spool To Rollback cylinders. Oil flows through the load check valve, and
Shifting the loader spool outward blocks the oil flow exits the control valve at the A2 port, flowing on to the
through the open center, sending pump flow through rod end of bucket cylinders. Oil returning from the
the load check valve and on to the B1 port. Oil from base end of the bucket cylinders enters the control
the B1 por t enters the base end of the loader valve at the B2 port. Oil from the B2 port flows to the
cylinders, raising the loader frame. Oil returning from return oil passage, exiting the control valve. Oil
the rod end of the loader cylinders enters the control exiting the control valve flows on to the hydraulic
valve at the A1 port, and flows to the open center return filter, cooler, and reservoir.
passage for use by the bucket circuit. With the bucket
HS01D081

8000-19
HS01D082

8000-20
Loader Spool Actuated To Lower, 6. The loader spool is now shifted inward to lower
the loader. Oil flow, at main relief pressure
Bucket Spool To Rollback setting, flows from the A1 port to the rod end of
A combination of spool position and sequence of the loader cylinders. At the same time the return
events will be used to explain the function of the oil from the base end of the loader cylinders is
check valve in the B1 series passage. The following returning through the B1 port. Oil returning at the
series of events must occur to seat the check valve: B1 port normally passes through the B1 series
passage check valve and on to the open center.
1. Bucket spool shifted inward, sending oil to curl However, with bucket spool shifted and bucket
(rollback) the bucket or auxiliary circuit actuated. cylinders at the end of their travel, open center
2. Bucket cylinders have reached the end of their flow is blocked. The B1 series passage check is
travel, bucket fully curled or loader circuit seated, at system operating pressure (main relief
deadheaded. valve setting).
3. Bucket spool or auxiliary spool position remains 7. Oil flow returning from base end of the loader
unchanged with bucket fully curled. Pump flow is cylinders cannot pass through the check valve,
now going over the main relief valve. and the loader downward movement stops.
4. Pressure in the open center passage is now at NOTE: If the B1 series passage check valve is not
main relief valve setting. used, and the loader spool is feathered to the down
position, the loader may tend to raise instead of
5. Check valve in the B1 passage is seated. lower, under the conditions described above. This is
SERVICE NOTE: If the condition just described were caused by the difference in the working areas of the
to occur, it may be possible that the B1 check valve is loader cylinders, base versus rod end.
leaking or stuck in the open position.
HS01D083

8000-21
HS01D084

8000-22
Loader Spool Actuated To Float A1 and B1 ports to the return passage of the control
valve. With the rod and base ends of the loader
In the float position the loader spool is shifted inward cylinders connected together, the loader frame and
to the detent position. The loader spool is held in this bucket can follow the contour of the ground (float). In
position by a ball type detent assembly. The float the float position, oil from the hydraulic pump flows
position allows the rod end and base end of the through the open center of the control valve and out
loader cylinders to connect to the return passage of the power beyond port to the auxiliary circuits. Oil
the control valve. The A1 and B1 ports are connected leaving the control valve from the return port is sent
together by a drilled passage in the center of the to the filter, cooler, and reservoir.
loader spool. The same drilled passage connects the
HS01D085

8000-23
HS01D086

8000-24
SPOOL LOCK SOLENOIDS

Two spool lock solenoids are par t of the loader The tip of the spool lock solenoid is extended by a
control valve assembly. The solenoids lock the loader spring as the solenoid is not activated. The tip of the
and bucket spools in the neutral position. The loader solenoid engages the spool to secure it in the neutral
and bucket spools are locked in the neutral position position. When the operator is in the operators seat
when the operator seat bar is raised, the operator is with the lap bar down, power is supplied to each of
not in the seat, or the machine is shut off. Each spool the solenoids to allow the spools to actuate. The
lock solenoid is positioned above an undercut area of loader spool lock solenoid is equipped with an
the spool when the spool is in the neutral position. override stem at the top to allow the loader spool to
be unlocked manually in case of a malfunction.
Caution: Use extreme caution when using this
manual override feature. Overriding the interlock will
allow the lift spool to be actuated resulting in loader
arm movement.

8000-25
HS01D087

8000-26
AUXILIARY CIRCUIT
The Auxiliar y circuit controls the operation of The auxiliary circuit can receive oil flow from the
attachments connected to the auxiliary hydraulic open center or return flow from the loader lift circuit, if
circuit. The auxiliary control valve receives oil flow the loader lift circuit is operating. Return flow from the
from the power beyond port of the loader control auxiliary circuit is ported to the return passage of the
valve. auxiliary valve to the hydraulic filter.

8000-27
HS01D070

8000-28
AUXILIARY CONTROL VALVE

The units are equipped with an auxiliary hydraulic The oil is routed through plumbing on the left rear
system. The pump supply will flow from the loader loader frame, through the loader pivot point. The
control valve to the auxiliary control valve, rather than auxiliary quick disconnect couplers are located at the
going directly back to the filter and oil cooler. The left side of the loader frame crossbar. The main relief
auxiliary valve will be supplied with oil only if the valve in the loader valve also limits the maximum
bucket spool is in neutral and the loader lift spool is pressure available to the auxiliary circuit. Return oil
either in neutral or the loader lift circuit is still able to from the auxiliary valve joins the return oil from the
flow oil (cylinder not at the end of travel). The single loader valve and returns to the oil cooler.
spool auxiliary control valve is located at the left rear
Service Tip: Many times the auxiliary valve control
of the machine mounted to the inside of the reservoir.
spool will remain in the engaged position after
The auxiliary valve is actuated by a pedal located at
attachments have been removed. The spool being
the operators feet. A cable interconnects the pedal
engaged while attempting to start the unit can give
and the valve spool. This valve controls the flow to
the symptom of a defective fuel delivery system and
the hydraulic couplers on the loader frame near the
cause a no-start condition. Make sure the auxiliary
bucket.
pedal is not in the locked position.

8000-29
HS01D088
1. INLET 5. WORK PORT “A”

2. OUTLET 6. WORK PORT “B”
3. SPOOL 7. QUICK DISCONNECTS
4. LOAD CHECK VALVE
AUXILIARY CONTROL VALVE

8000-30
HIGH FLOW HYDRAULICS

The high flow hydraulic system is an option used to the loader control main relief valve. The loader
increase the flow capacity of the existing hydraulic control main relief valve is set at 207 bar (3000 psi),
system. The combined flow is accomplished by while the relief in the high flow control valve is set at
connecting the power beyond port of the auxiliary 220 bar (3200 psi). The high flow control valve is
control valve to the high flow system. actuated by a three-position rocker switch in the left
control handle. The switch controls forward, reverse
Increased flow is accomplished using a fixed
and neutral. The forward switch position is a
displacement gear pump mounted in the accessory
maintained position while reverse is momentary.
drive port of the engine. The gear pump is driven by
the engine camshaft. System flow is bi-directional. High flow plumbing is incorporated into the right
The control valve also has a main relief valve to loader arm with flat faced male and female quick
protect the high flow pump if the open center of the disconnects. The male flat coupler is the forward
loader control valve is blocked (loader or bucket direction or oil flow out to the attachment. All return
spool actuated). With the open center blocked, flow oil goes through the return filter and oil cooler.
from the high flow pump would not have access to

8000-31
HS01D089
HIGH FLOW HYDRAULICS

8000-32
FILTER RESTRICTION INDICATOR

The filter restriction indicator is a differential pressure The restriction indicator activates an indicator light
switch that senses both the inlet and outlet pressure when the preset differential is reached. Through the
of the filter. The pressure on the inlet side of the keyswitch, power is fed to a filter indicator light in the
element is ported to the outboard, non-spring end of instrument cluster. To activate the light, the restriction
the nylon piston. The pressure on the downstream indicator completes the circuit to ground when the
side of the element is ported to the inboard, spring filter becomes plugged. A wire connects the light in
end of the nylon piston. The sensing spring forces the instrument cluster to the electrical connection of
the nylon piston towards the inlet area until the the indicator switch. The restr iction indicator
pressure differential across the element is greater electrical connection is insulated from filter head and
than the strength of the spring. When the filter inlet can only complete the circuit to ground when the
pressure exceeds the outlet pressure by the strength grounding washer on the inboard end of the sensing
of the spring, the piston moves inward until it piston contacts the ledge in the filter head.
contacts a ledge in the filter head. The pressure
switch should close to activate the filter light at 40 psi
differential pressure.

8000-33
HS01D090
FILTER RESTRICTION INDICATOR

8000-34
BI-DIRECTIONAL SELF-LEVELING (BDSL) SYSTEM
Bucket Self-Leveling Functional Overview of the

The Bi-Directional Self-Leveling (BDSL) system is an Bi-Direction Self-Level Loader
option on the Skid Steers. The function of the bucket Control Valve
self-leveling circuit is to maintain the bucket in the
“level” position as the loader frame is raised and NOTE: The following discussion refers to the integral
lowered. If self-leveling is not used, and the bucket is BDSL loader control valve assembly as installed on
fully rolled back at ground level, spillage can occur the 60XT model. The separate BDSL valve on the
from the rear of the bucket as the loader frame is 70XT model functions similarly.
raised. The Bi-Direction Self-Level control valve assembly is
Without this option, maintaining a level bucket without a two spool valve, open center configuration, with oil
spillage requires manual operation of the bucket ported in a series/parallel flow path. The valve is
control by the operator as the loader frame is raised. Case manufactured, and has the following functions
However, installing the bi-directional leveling system in addition to all of the functions of the standard
automatically levels the bucket as the loader frame is loader valve discussed earlier:
raised and lowered. This system is designed to level The Flow Divider/Combiner Cartridge splits the
the bucket in both the raise and lower mode. loader cylinder rod end oil flow to divert oil to either
The bi-directional self-leveling control valve is a two the base end or rod end of the bucket cylinder to
spool control valve that replaces the standard loader maintain the bucket position as the loader either
control valve on the 60XT model. The integral BDSL raises or lowers.
Valve has all of the same components as the One Counterbalance Valve holds the bucket
standard valve with the addition of a self-leveling flow cylinder in position until oil flow is forced into the
divider cartridge, a counterbalance valve for both the cylinder to maintain the bucket position and the other
raise and lower directions and an on-off solenoid maintains pressure in the lowering circuit.
control valve. On the 70XT, the bi-directional
self-leveling valve is a separate manifold block. The Self Level Solenoid Valve is ported between
the flow divider and the bucket cylinder ports. When
The on-off solenoid can be activated in three different this solenoid valve is activated, the self leveling
ways. A self-leveling on-off selector switch is located function is turned off. The self leveling function is off
on the right front ROPS post. Activating this switch when the loader valve is in float or when the bucket
keeps the self-leveling system from functioning at spool is activated off the neutral position.
any time. The self-leveling system also turns off any
time that the loader spool is in the float position. A The Float Switch is mounted to the top of the loader
ball switch located on the loader spool centering spool spring end cover. This is a normally open ball
spring cover controls this feature. The self-leveling switch that is activated when the loader spool is
system also turns off any time that the bucket spool is placed in the float position. This switch then activates
activated to either the rollback or dump position. A the self level solenoid valve to cancel the self leveling
micro-switch mounted at the control end of the bucket function.
spool controls this function. The Bucket Spool Switch is a normally open micro-
switch mounted at the clevis end of the bucket spool.
This switch closes as the bucket spool is shifted
inward or outward to the bucket rollback or dump
positions. This switch activates the self level solenoid
valve to cancel the self leveling function.
The Self-Leveling On-Off Switch is a normally open
switch located on the right front ROPS post to cancel
the function of the system. When selected, it
activates the on-off solenoid in the control valve.

8000-35
HS01D091

8000-36
Loader Raise & Bucket B. The bucket leveling flow exits the flow divider
cartridge and goes through the on-off solenoid
Self-Leveling valve to the bucket dump circuit of the loader
To prevent spillage over the back of the bucket or valve. This oil provides a pilot signal to open
keep the attachment level, the leveling circuit keeps the raise counterbalance valve, and is also
the bucket level as the loader is raised. ported to the circuit relief valve and to the
base (dump) end of the bucket cylinders. This
As the loader is raised with the bucket rolled back flow will perform the following functions:
from the full dump position, the following will happen:
● The leveling flow exits the loader valve at
1. The loader control valve lift spool will be the “B2” port. This flow goes to the base
activated to send pump flow to the base end of end of the bucket cylinder, causing it to
the lift cylinders. extend to keep the bucket level.
2. The oil returning from the rod end of the lift ● For the bucket cylinder to move, some oil
cylinders enters the “A1” port of the loader valve. must escape from the rod end. The raise
This flow is directed to the flow divider cartridge. counterbalance valve allows for the gradual
The flow divider cartridge splits the flow between release of this oil. A pilot signal from the
the tank and the base end of the bucket cylinder, “B2” port passage must be present to shift
to keep the bucket level. the raise counterbalance valve into a
A. The flow divider cartridge sends the flow not position to allow flow from the rod end of
required to position the bucket back through the bucket cylinder. As the counterbalance
the loader control valve lift spool. This return valve is shifted, oil from the rod end of the
flow is then directed to the next section of the bucket cylinder flows through the on-off
control valve or out the loader control power solenoid valve. This oil then combines with
beyond port. the remainder of the oil from the flow
divider cartridge returning to the lift spool
area of the loader control valve. This return
flow is then directed to the next section of
the control valve or out the loader control
power beyond port.

8000-37
HS01D092

8000-38
Loader Raise-Bucket At Full Dump B. The bucket leveling flow exits the flow divider
cartridge and goes through the on-off solenoid
As the loader is raised with the bucket at full dump, valve to the bucket dump circuit of the loader
the following will happen: valve. This oil provides a pilot signal to open
1. The loader control valve lift spool will be the raise counterbalance valve, pressurizes
activated to send pump flow to the base end of the base end of the bucket cylinders and is
the lift cylinders. ported to the bucket dump circuit relief valve.
2. The oil returning from the rod end of the lift 3. With the bucket in the full dump position, the oil
cylinders enters the “A1” port of the loader valve. directed to the base end of the bucket cylinder
This flow is directed to the flow divider cartridge. has no place to go.
The flow divider cartridge splits the flow between 4. The flow available to the base end “B2” port of
the tank and the base end of the bucket cylinder, the loader valve is also connected to the bucket
to keep the bucket level. dump circuit relief valve. With no other place to
A. The flow divider cartridge sends the flow not flow, the bucket leveling oil flows over the relief
required to position the bucket back through valve into the “out” port passage of the loader
the loader control valve lift spool. This return valve.
flow is then directed to the next section of the 5. This flow exits the loader valve and flows back
control valve or out the loader control power through the filter and oil cooler to the reservoir.
beyond port.

8000-39
HS01D093

8000-40
Loader Lower & Bucket 3. For the bucket cylinders to move to allow for
self-leveling, some oil must escape from the
Self-Leveling base end. The amount of oil returning from the
To prevent spillage over the front of the bucket or base end of the bucket cylinders enters the “B2”
keep the attachment level, the leveling circuit keeps port of the loader valve. This flow is directed
the bucket level as the loader is lowered. through the On-Off solenoid valve to the flow
divider car tridge. The flow divider car tridge
As the loader is lowered with the bucket not fully regulates the amount of oil coming from the base
rolled back, the following will happen: end of the bucket cylinder, to keep the bucket
1. The loader control valve lift spool will be level. This oil returning from the base end of the
activated to send pump flow to the self-leveling bucket cylinder combines with the pump supply
flow divider/combiner cartridge and through the oil flowing through the flow divider cartridge to
O n - O f f S o l e n o i d va l ve a n d t h e l o w e r the rod end of the loader lift cylinder.
counterbalance valve to the rod end of the lift 4. Oil returning from the base ends of the loader lift
cylinders. cylinders enters the loader control valve through
2. The pump supply oil flowing through the flow the “B1” port and flow through the loader lift
divider cartridge will flow to the rod end of the spool. This return oil then flows to the lower
loader lift cylinder causing it to lower. This oil will counterbalance valve. The lower counterbalance
combine with the oil returning from the base end valve receives an opening signal from the pump
of the bucket cylinders. supply oil flowing to the flow divider cartridge.
The only way for oil to exit the base end of the
loader lift cylinders is to have pump pressure to
the loader lower circuit. Oil flow through the lower
counterbalance valve is then directed to the next
section of the control valve or out the loader
control valve power beyond port.

8000-41
HS01D094

8000-42
Loader In Float 2. The loader spool will port the pump supply flow
through the spool to be available to the bucket
With the loader spool in float, the following will spool or the power beyond port of the loader
happen: valve.
1. The float switch in the loader lift spool end cover 3. The loader spool will connect both the loader
will close, activating the Self-Leveling On-Off raise and lower ports together and also to the
Solenoid valve. This then connects the two ports return port of the loader valve. This will allow the
of the flow divider cartridge to each other turning loader to lower to the ground and then to follow
the self-leveling function off. the contour of the ground as the machine travels.

8000-43
HS01D095

8000-44
Loader Raise & Bucket Dump A. The flow divider cartridge sends the flow not
required to position the bucket back through
Self-Leveling Off the loader control valve lift spool. This return
A nor mally open bucket spool microswitch is flow is then directed to the bucket section of
mounted at the clevis end of the bucket spool. This the control valve to dump the bucket.
switch closes as the bucket spool is shifted inward or B. The bucket leveling flow exits the flow divider
outward to the bucket rollback or dump positions. car tridge and goes to the on-off solenoid
This switch activates the self level solenoid valve to valve. The on-off solenoid is activated by the
cancel the self leveling function. microswitch at the bucket spool clevis. This oil
As the loader is raised with the bucket spool engaged combines with the flow from the opposite side
to the dump position, the following will happen: of the flow divider and is then directed to the
bucket section of the control valve to dump the
1. The microswitch at the clevis end of the bucket bucket.
spool would close to activate the self-leveling
On-Off Solenoid Valve. The solenoid valve will 4. The oil returning from the loader cylinders
then turn off the self-leveling system. through the loader lift spool is sent to the bucket
control spool. With the bucket actuated to the
2. The loader control valve lift spool will be dump position, the following will occur:
activated to send pump flow to the base end of
the lift cylinders through the B1 port of the loader A. The oil returning from the loader circuit is sent
valve. through the B2 port to the base end of the
bucket dump cylinders.
3. The oil returning from the rod end of the lift
cylinders enters the “A1” port of the loader valve. B. The oil from the rod end of the bucket
This flow is directed to the flow divider cartridge. cylinders returns through the A2 port of the
The flow divider cartridge splits the flow between loader valve to the bucket spool. This oil flows
the tank and the self-leveling flow that would go to the outlet port the loader valve to the filter,
to the base end of the bucket cylinder, to keep cooler and then to the reservoir.
the bucket level.

8000-45
HS01D096

8000-46
BI-DIRECTIONAL SELF-LEVELING SYSTEM TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE POSSIBLE SOLUTION
Bucket does not On-Off switch on right front ROPS post Turn On-Off switch to the ON position.
self-level at all. turned to OFF position.
Bad bucket spool microswitch or out of Adjust, repair or replace the bucket spool
adjustment. microswitch.
Bad float switch in the end cover of the Repair or replace the float switch.
loader lift spool.
On-Off Solenoid Valve stuck in the OFF Check the On-Off Solenoid Valve.
position.
Bucket Self-Levels when Bad On-Off switch or bad wiring. Check power supply to the On-Off switch,
the On-Off switch on the check the On-Off switch and the wiring
right front ROPS post is between the switch and the On-Off
in the OFF position. Solenoid in the loader valve.
Bad On-Off Solenoid Valve in the loader Check function of the On-Off Solenoid
valve. valve.
Bucket does not maintain Bucket self-leveling is designed to work Run engine at high idle.
level while raising or optimally at high idle.
lowering at engine Bucket self-leveling works best when lift Fully stroke the lift spool.
speeds other than high spool is fully stroked.
idle.
Bucket does not maintain Flow divider cartridge stuck. Check flow divider cartridge for free
level while raising at high operation.
idle. Incorrect flow divider cartridge installed. Check flow divider cartridge for correct
part number.
Raise counterbalance valve stuck. Check raise counterbalance valve for
free operation.
Bucket does not maintain Flow divider cartridge stuck. Check flow divider cartridge for free
level while lowering at operation.
high idle. Incorrect flow divider cartridge installed. Check flow divider cartridge for correct
part number.
Lower counterbalance valve stuck. Check lower counterbalance valve for
free operation.
Excessive bucket drift in Bad bucket cylinder packing. Repack cylinder.
the dump direction. Raise counterbalance valve stuck. Check Raise counterbalance valve for
free operation.
Bad A2 Port circuit relief/ Anti-Cavitation Check A2 Port circuit relief/
check valve. Anti-Cavitation check valve.
Excessive loader control valve bucket Check for bucket circuit leakage.
spool port leakage. Replace loader valve.
Excessive bucket drift Bad bucket cylinder packing. Repack cylinder.
towards the roll back Bad B2 Port circuit relief/ Anti-Cavitation Check B2 Port circuit relief/
direction. check valve. Anti-Cavitation check valve.
Bad A1 Port circuit relief/ Anti-Cavitation Check A1 Port circuit relief/
Bad B1 Port circuit relief/ Anti-Cavitation Check B1 Port circuit relief/
Excessive loader control valve port Check for bucket circuit leakage.
leakage. Replace loader valve.

8001
Section
8001
HYDRAULIC SYSTEM TROUBLESHOOTING
CASE CORPORATION
700 State Street
8001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRESSURE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FLOWMETER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test No. 1 - Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test No. 2 - Loader Circuits and Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
METRIC MEASURE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
U.S. MEASURE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8001-3
SPECIFICATIONS
Hydraulic Pump
Manufacturer ................................................................................................................................... Sauer-Danfoss
Type.................................................................................................................................................................Gear
Displacement ................................................................................................................................. 38 cc (2.32 in3)
Flow at 2000 RPM...................................................................................................................72.2 L/min (19 gpm)
Loader Control Valve Relief Pressure Settings
Main Relief Pressure ............................................................................................ 20,700 kPa (207 bar) (3000 psi)
Circuit Relief Pressure - Port A1................................................................................. 26,200 kPa (3800 psi)
Circuit Relief Pressure - Port B1................................................................................. 21,374 kPa (3100 psi)
Circuit Relief Pressure - Port A2 ....................................................................................... 26,200 kPa (3800 psi)
Circuit Relief Pressure - Port B2 ....................................................................................... 21,374 kPa (3100 psi)
Cycle Times With Rated Load In Bucket
Loader Raising Time ........................................................................................................................... 4.1 seconds
Loader Lowering Time........................................................................................................................ 3.2 seconds
Bucket Dump Time (full rollback to full dump) ..................................................................................... 2.4 seconds
Bucket Rollback Time.......................................................................................................................... 1.9 seconds
Bucket Float Time ................................................................................................................................ 12 seconds
SPECIAL TOOLS
B785789M B877895
OEM-1239 (CAS-10280) FLOWMETER CAS-100900 HAND PUMP
B797157M B009638M
CAS-1808 FLOWMETER FITTING KIT CAS-1804 PRESSURE TEST FITTING KIT

8001-4
PRESSURE CHECKS
Loader Main Relief 3. Use a pressure gauge with a capacity of at least

276 bar (4000 psi). Connect the pressure gauge
NOTE: Flat face couplers are not included with the to one of the auxiliary hydraulic couplers on the
CAS-1808 Flowmeter Fitting Kit or the CAS-1804 left hand loader arm.
Pressure Test Fitting Kit. The part numbers for the
auxiliary hydraulic couplers are 393395A1 (male 4. Run the engine at full throttle. Actuate the
coupler) and 393394A1 (female coupler). a u x i l i a r y hy d ra u l i c f l ow c o n t r o l p e d a l t o
pressurize the hydraulic line which has the
1. Park the machine on a level surface. Lower the pressure gauge. Record the indication on the
loader bucket to the floor. pressure gauge. Then retur n the auxiliar y
2. The oil must be at operating temperature. To heat hydraulic flow control pedal to the Neutral
the oil, do the following steps: position and decrease the engine speed to low
idle. Stop the engine.
A. With the engine running at full throttle, hold
the bucket control lever in the ROLLBACK 5. Compare the indication with the specification on
position for 10 seconds. page 3. If the indication is not correct, see page 8
for the location of the main relief valve. Adjust the
B. Put the bucket control lever in the NEUTRAL main relief valve. Then do the pressure check
position for 10 seconds. again to make sure that the setting is correct.
C. Repeat steps A and B until the temperature of
the oil is 52°C (125°F) or the side of the
reservoir is very warm.
TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP

1. Park the machine on a level surface. 9. Operate the hand pump to fill the hose of the
hand pump with oil. Then tighten the
2. Lower all attachments to the floor.
connections.
3. Stop the engine.
10. Operate the hand pump and read the pressure
4. Move the control levers in all directions to release gauge. Record the highest indication. Check the
any circuit pressure. pressure several times to make sure that the
indications are correct.
5. The best way to connect the hand pump is
directly to the control valve. Disconnect the tube 11. Compare the indication with the specification on
from the port of the control valve and connect the page 3. If the indication is not correct, replace the
hand pump to the port. By connecting directly to circuit relief valve.
the control valve, you avoid the possibility of a
NOTE: The circuit relief valves for the loader circuit
bad reading because of cylinder movement.
are not adjustable and must be replaced if they do
6. Remove all dirt and grease from the connecting not meet the specification.
point.
12. Repeat this test after installing a new circuit relief
7. Connect the hose of the hand pump to the valve.
c o n n e c t i n g p o i n t , bu t d o n o t t i g h t e n t h e
connection.
8. Make sure that the hand pump is filled with oil.
The temperature of the oil must be at least 21°C
(70°F).

8001-5
FLOWMETER TESTS
7. Make sure that the pressure valve is opened
WARNING: Two persons are required to completely. Adjust the engine speed to 2000
! perform the flowmeter tests for safety to r/min (rpm) and read the flow gauge. Write the
avoid possible injury. One person must be indication on line 1 on the check sheet.
seated in the operators seat with the Seat 8. Slowly close the pressure valve on the flowmeter
Bar down when the engine is running. The until the pressure gauge indicates 97 bar (1400
second person is to control the flowmeter psi). Keep the engine running at 2000 r/min
and take the readings. CSM118 (r pm). Read the flow gauge and write the
indication on line 2 on the check sheet.
General Information 9. Slowly close the pressure valve on the flowmeter

until the pressure gauge indicates 124 bar (1800
The flowmeter measures the volume, pressure, and psi). Keep the engine running at 2000 r/min
temperature of the hydraulic oil as the hydraulic oil (r pm). Read the flow gauge and write the
flows through the flowmeter. indication on line 3 on the check sheet.
Test No. 1 will indicate whether or not there are 10. Slowly close the pressure valve on the flowmeter
problems in the line between the reservoir and the until the pressure gauge indicates 152 bar (2200
gear pump and whether or not the gear pump is psi). Keep the engine running at 2000 r/min
working within acceptable standards of efficiency. (r pm). Read the flow gauge and write the
Test No. 2 will indicate whether or not there are indication on line 4 on the check sheet.
problems in the loader hydraulic circuits. 11. Open the pressure valve completely. Decrease
There is a check sheet at the end of this section. You the engine speed to low idle and stop the engine.
can make copies of the check sheet to record the test
results. Understanding the Results
NOTE: Use an accurate tachometer to adjust and 1. If the output at minimum pressure was less than
maintain engine speeds during these tests. the specification for Gear Pump Flow to Loader
(Machine in Neutral) shown on page 3, the
Test No. 1 - Gear Pump problem can be a restr iction between the
reservoir and the gear pump, or the problem can
1. Park the machine on a level surface. Lower the be a badly worn or damaged gear pump.
loader bucket to the floor. Stop the engine.
2. If the output at minimum pressure was more than
2. See the illustration on the next page. Disconnect the specification on page 3, there are no
t h e h o s e f r o m t h e e l b ow a t Te s t Po i n t 1 problems between the reservoir and the gear
(7/8-14 JIC). Install a plug in the hose. Connect pump. However, the gear pump can be worn or
the flowmeter inlet hose to the elbow. damaged and still have good flow at minimum
pressure.
3. Put the flowmeter outlet hose into the hydraulic
reservoir. Use wire to fasten the flowmeter outlet 3. Loss of output at 152 bar (2200 psi) indicates
hose below the surface of the hydraulic oil. that the gear pump is worn or damaged. To
determine the efficiency of the gear pump, divide
4. Make sure that the oil level in the hydraulic
the flow indication from line 4 by the flow
reservoir is correct.
indication from line 1. This answer multiplied by
5. Make sure that the pressure valve of the 100 is the percent efficiency of the gear pump. If
flowmeter is opened completely. the efficiency of the gear pump is less than 75%,
repair or replace the gear pump. If the efficiency
6. The oil must be at operating temperature. If the
of the gear pump is more than 75%, the pump is
oil is not at operating temperature, run the engine
good.
at full throttle and close the pressure valve of the
flowmeter until the pressure gauge indicates 103 NOTE: The flow at the other pressures will be used
bar (1500 psi). Continue to run the engine at full in the remaining tests.
throttle until the temperature of the oil is 52°C
( 1 2 5 ° F ) . T h e n o p e n t h e p r e s s u r e va l ve
completely.

8001-6
3 4
5
7 6
HI01E020
1. FROM HYDRAULIC RESERVOIR 3. RETURN FILTER 5. LOADER CONTROL VALVE 7. HYDRAULIC EQUIPMENT PUMP
2. TO OIL COOLER 4. TANDEM PUMPS 6. TEST POINT 1

8001-7
Test No. 2 - Loader Circuits and 10. Start the engine and run the engine at 2000 r/min
(rpm).
Main Relief Valve
11. Hold the bucket control lever in the ROLLBACK
1. Park the machine on a level surface. Lower the position and close the pressure valve on the
loader bucket to the floor. Stop the engine. flowmeter until the pressure gauge indicates 124
2. See the illustration above. Disconnect the bar (1800 psi). Adjust the engine speed to keep
flowmeter inlet hose from the elbow at Test Point the engine running at 2000 r/min (rpm). Read the
1 (7/8-14 JIC). Remove the plug which you flow gauge and write the indication on line 7 on
installed in the hose to the loader control valve the check sheet.
(Test No. 1 - step 2) and reconnect the hose to 12. Hold the bucket control lever in the DUMP
the elbow. Connect the flowmeter inlet hose to position and adjust the pressure valve on the
the tee. Leave the flowmeter outlet hose in the flowmeter until the pressure gauge indicates 124
hydraulic reservoir as in Test No. 1 - Gear Pump. bar (1800 psi). Adjust the engine speed to keep
3. Make sure that the oil level in the hydraulic the engine running at 2000 r/min (rpm). Read the
reservoir is correct. flow gauge and write the indication on line 8 on
4. The oil must be at operating temperature. If the the check sheet.
oil is not at operating temperature, run the engine 13. Hold the lift control lever in the LIFT position and
at full throttle. Hold the auxiliary hydraulic flow adjust the pressure valve on the flowmeter until
control pedal in the ON position and close the the pressure gauge indicates 124 bar (1800 psi).
pressure valve of the flowmeter until the pressure Adjust the engine speed to keep the engine
gauge indicates 103 bar (1500 psi). Continue to running at 2000 r/min (rpm). Read the flow
run the engine at full throttle until the gauge and write the indication on line 9 on the
temperature of the oil is 52°C (125°F). check sheet.
5. Continue to hold the auxiliary hydraulic flow 14. Hold the lift control lever in the LOWER position
control pedal in the ON position. Continue to run and adjust the pressure valve on the flowmeter
the engine at full throttle. Slowly close the until the pressure gauge indicates 124 bar (1800
pressure valve. As the pressure increases, the psi). Adjust the engine speed to keep the engine
flow indication will decrease slowly. As you running at 2000 r/min (rpm). Read the flow
continue to close the pressure valve, you will gauge and write the indication on line 10 on the
reach a point at which the flow indication begins check sheet.
to decrease rapidly. This is the point at which the
main relief valve star ts to open. Read the Auxiliary Circuits
pressure gauge and write the indication on line 5 NOTE: Both of the loader control valve spools must
on the check sheet. be in the NEUTRAL position during the following test.
6. Continue to close the pressure valve until the NOTE: If the auxiliary hydraulic circuit is connected
indication of the flow gauge is zero. This is the to an attachment using a hydraulic motor, this flow
point at which the main relief valve is completely test does not apply.
open. Read the pressure gauge and write the
indication on line 6 on the check sheet. 15. Push down one side of the auxiliary hydraulic
flow control pedal and adjust the pressure valve
7. Open the pressure valve completely. Decrease on the flowmeter until the pressure gauge
the engine speed to low idle and stop the engine. indicates 124 bar (1800 psi). Adjust the engine
8. If the pressure setting of the main relief valve is speed to keep the engine running at 2000 r/min
not as specified on page 3, try to adjust the main (r pm). Read the flow gauge and write the
relief valve. See page 8 for the location of the indication on line 11 of the check sheet.
main relief valve. If the main relief valve cannot 16. Push down the opposite side of the auxiliary
be adjusted to the correct setting, you must hydraulic flow control pedal and adjust the
replace the main relief valve. pressure valve on the flowmeter until the
9. If you adjusted, repaired, or replaced the main pressure gauge indicates 124 bar (1800 psi).
relief valve, repeat steps 5 through 7. Adjust the engine speed to keep the engine
If the completely open pressure (step 6) is as running at 2000 r/min (rpm). Read the flow
specified, but the pressure at which the main relief gauge and write the indication on line 12 of the
valve begins to open (step 5) is 183 bar (2400 psi) or check sheet.
less, the main relief valve is damaged and must be 17. Open the pressure valve completely. Decrease
replaced before you do further testing. the engine speed to low idle and stop the engine.

8001-8
Understanding the Results 21. Leakage in the lift circuits can be caused by any
of the following problems:
18. If the flow indication for a circuit was
approximately the same as the flow indication at A. Damaged or worn packing in one or both of
the same pressure in Test No. 1, the circuit is the lift cylinders.
good. B. Damaged or worn spool or spool bore in the
19. If the flow indication for a circuit was more than loader control valve.
3.8 L/min (one gpm) less than the flow indication C. Defective circuit relief valves.
at the same pressure in Test No. 1, there is
D. Inadequate control spool travel.
leakage in that circuit.
22. Leakage in the auxiliary circuits can be caused
20. Leakage in the bucket circuits can be caused by
by any of the following problems:
any of the following problems:
A. Inadequate control spool travel.
A. Damaged or worn packing in one or both of
the bucket cylinders. B. Damaged or worn packing in one or both of
the cylinders.
B. Damaged or worn spool or spool bore in the
loader control valve. C. Damaged or worn spool or spool bore in the
loader control valve.
C. Self-leveling valve (if equipped) is sticking or
has worn spools. 23. If the flow indication for every circuit tested was
more than 3.8 L/min (one gpm) less than the flow
D. Defective circuit relief valves.
indication at the same pressure in Test No. 1,
E. Inadequate control spool travel. there is leakage at a point common to the entire
system. A probable cause is a damaged or worn
main relief valve or seals.

8001-9
1 9 9
1
7
2
10 10
3 8
10 8
4
4
7 6
5
8 8
10
3 3
6 7 2
1. Inlet
2. Lift Spool
3. To Lift Cylinders 8
5 10
4. Bucket Spool 5
5. To Bucket Cylinders
4
6. Power Beyond
7. Return
8. Circuit Relief Valve
9. Main Relief Valve
10. Load Check Valve
HI01E017

8001-10
METRIC MEASURE CHECK SHEET

Owner _______________________________________________ Date _________ Hours ________________
Model _________________________________________ Product Identification Number___________________
Oil Temperature: At start of test ______ °C. At end of test ______ °C.
Test No. 1 - Gear Pump

1. _________ L/min at min. pressure at 2000 r/min 3. _________ L/min at 124 bar at 2000 r/min
2. _________ L/min at 97 bar at 2000 r/min 4. _________ L/min at 152 bar at 2000 r/min
The efficiency of the gear pump is line 4 divided by line 1.
Test No. 2 - Loader Circuits and Main Relief Valve

5. Main relief valve begins to open at ________ bar 9. Lift ______________________ L/min at 124 bar
6. Main relief valve completely open at _______ bar 10. Lower ____________________ L/min at 124 bar
7. Rollback __________________ L/min at 124 bar 11. Auxiliary __________________ L/min at 124 bar
8. Dump ____________________ L/min at 124 bar 12. Auxiliary __________________ L/min at 124 bar
U.S. MEASURE CHECK SHEET

Owner _______________________________________________ Date _________ Hours ________________
Model _________________________________________ Product Identification Number___________________
Oil Temperature: At start of test ______ °F. At end of test ______ °F.
Test No. 1 - Gear Pump

1. _________ gpm at min. pressure at 2000 rpm 3. _________ gpm at 1800 psi at 2000 rpm
2. _________ gpm at 1400 psi at 2000 rpm 4. _________ gpm at 2200 psi at 2000 rpm
The efficiency of the gear pump is line 4 divided by line 1.
Test No. 2 - Loader Circuits and Main Relief Valve

5. Main relief valve begins to open at ________ psi 9. Lift _______________________ gpm at 1800 psi
6. Main relief valve completely open at _______ psi 10. Lower ____________________ gpm at 1800 psi
7. Rollback __________________ gpm at 1800 psi 11. Auxiliary __________________ gpm at 1800 psi
8. Dump ____________________ gpm at 1800 psi 12. Auxiliary __________________ gpm at 1800 psi

Section
8005
8005

8005-2
TABLE OF CONTENTS
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DUAL SELF-LEVELING CONTROL VALVE 60XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BI-DIRECTIONAL SELF LEVELING VALVE 70XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8005-3
CONTROL VALVE
Disassembly STEP 3
NOTE: The photos in the following procedures
may be different from your machine. The
procedure is the same.
STEP 1
BD01J012
Loosen and remove the counterbalance cartridge.
STEP 4
BD01J010
Loosen and remove the solenoid assembly.
STEP 2
BD01J014
Loosen and remove the cap.
STEP 5
BD01J011
Remove the other solenoid assembly.
BD01J019
Loosen and remove the bolts and washers from the

end cap.

8005-4
STEP 6 STEP 9
BD01J020 BD01J023
Remove the end cap. Loosen the relief valve plug.
STEP 7 STEP 10
BD01J021 BD01J024
Loosen the relief valve. Remove the relief valve plug.
STEP 8 STEP 11
BD01J022 BD01J025
Remove the relief valve from the valve body. Remove the relief valve assembly.
STEP 12
Repeat steps 9 through 11 for the other relief valves.

8005-5
STEP 13 STEP 16
0BD01J026 BD01J029
Loosen the check valve plug. Remove the poppet from the valve port.
STEP 14 STEP 17
BD01J027
BD01J034
Remove the check valve plug from the valve body.
Remove the spool from the valve body.
STEP 15
STEP 18
BD01J028
BD01J035
Remove the spring from the valve port.
Remove the loader lift spool from the valve body.

8005-6
STEP 19 STEP 22
1
1 1 2
1
BD01J038 BD01J042
1. O-RING 1. O-RING
2. BACKUP RING
Remove the O-ring from the relief valve plug.
Remove the O-rings and backup ring from the relief
valve. STEP 23
STEP 20 1
BD01J043
1. O-RING
BD01J040 Remove the O-ring from the check valve plug.
1. O-RING
Remove the O-ring from the solenoid valves. STEP 24

STEP 21
2
1 2
1
1 2
BD01J044
Remove the retainer and O-ring from the spool.

BD01J041
1. O-RING
2. BACKUP RING
Remove the O-rings and backup rings from the

counterbalance cartridge.

8005-7
STEP 25 STEP 28
BD01J045 BD01J048
Remove the retainer and O-ring from the float spool. Install the CAS-1147-2 and compress the spool
spring. Remove the stud from the spool.
STEP 26
STEP 29
4 5
3
2
1
BD01J046
Using CAS-1147-2 compress the spring and remove BD01J049
the snap ring from the spool. 1. STUD 4. RETAINER

2. RETAINER 5. SPOOL
STEP 27 3. SPRING
Remove the first spring retainer, spring, and the
second spring retainer from the float spool.
5
3 4
2
1
BD01J047
1. SNAP RING 4. RETAINER

3. SPRING
Remo ve th e first retainer, spring, and secon d
retainer from the spool.

8005-8
STEP 30 STEP 33
Remove the O-ring from the top plug.
2 STEP 34
1
1 2
3
4
BD01J050
1. PLUG
2. SWITCH
NOTE: The switch (2) will be replaced with a plug on BD01J054

non dual self-leveling control valves. 1. RELIEF VALVE PLUG 3. SPRING
Remove the plugs (1 and 2) from the spool cover. 2. O-RING 4. DETENT BALL
Remove the O-ring, spring, and detent ball from the
STEP 31 plug.
STEP 35
1
BD01J052
1. O-RING
Remove the O-ring from the plugs. BD01J055
Remove the O-ring from the spool port in the valve

STEP 32 body.
STEP 36
BD01J051
1. PLUG
Remove the other plug from the cover. BD01J057
Remove the spool seal from the spool port.

8005-9
STEP 37 2. Inspect the spools and spool bores for wear and
Repeat steps 35 through 36 for the other spool port. damage. Use new parts as required.
3. Inspect the spool assemblies for wear and
STEP 38 damage. Use new parts as required.
4. Inspect the check valve springs and poppets for
wear and damage. Use new parts as required.
5. Inspect the solenoid valves for wear and
damage. Use new parts as required.
6. Inspect the pilot operated relief valve for wear
and damage. Use new parts as required.
7. Inspect the parts of the lock rod assembly for
8. Inspect the valve body for wear, damage and
corrosion. Use new parts as required.
BD01J058
Remove the O-ring for the float spool cover.
Inspection
1. Clean all parts in cleaning solvent. Use a lint free
cloth or air dry the parts.
NOTE: The parts must be clean and free of
contamination before assembly.

8005-10
1
1
2 2 1
6
6
2
5
1 5 1
6
1 5
2 2
1
2
2
4
4
4
7
4 8
2
3
2
BC01J003
1. PLUG 4. RELIEF VALVE 7. HEX SOCKET PLUG
2. O-RING 5. VALVE POPPET 8. COUNTERBALANCE CARTRIDGE
3. BACKUP RING 6. SPRING 9. RELIEF VALVE
EXPLODED VIEW OF THE CONTROL VALVE

8005-11
11
2
7
2
8
3
10
9
3 2
5 2
18 3
17
16
13 2
2 15
14
4
17 15 5
19 12 2 1
13 2
3 3
11
2 2
5 6
3
BC01J004
1. LOADER LIFT SPOOL 6. STUD 11. OIL SEAL 16. PLUG
2. O-RING 7. SPOOL 12. COVER 17. PLUG
3. RETAINER 8. RETAINING RING 13. PLUG ASSEMBLY 18. CAP
4. WASHER 9. SOLENOID ASSEMBLY 14. DETENT SPRING 19. BOLT
5. SPRING 10. LOCK SPOOL ASSEMBLY 15. BALL
EXPLODED VIEW OF THE CONTROL VALVE

8005-12
Assembly STEP 42
1
STEP 39 2
3
4
BD01J054
1. RELIEF VALVE PLUG 3. SPRING

2. O-RING 4. DETENT BALL
BD01J058
Install a new O-ring into the loader lift port. Install a new O-ring onto the plug. Install the spring
and detent ball into the relief valve plug.
STEP 40
STEP 43
BD01J056
BD01J052
Install a new seal into the spool port. 1. O-RING
Install a new O-ring onto the plugs.

STEP 41
STEP 44
BD01J055
Install a new O-ring into the spool ports.

BD01J051
NOTE: Repeat step 40 to 41 for the other spool port. 1. PLUG ASSEMBLY
Install the plug onto the float spool cover.

8005-13
STEP 45 STEP 47
BD01J050 BD01J046
1. SWITCH
Install the two spring retainers and spring into the
2. PLUG ASSEMBLY
CAS-1147-2 and compress the spring. Install the
NOTE: The switch (2) will be replaced with a plug on spring assembly onto the spool and install the snap
non dual self-leveling control valves. ring.
Install the plugs onto the spool cover.
STEP 48
STEP 46
BD01J045
BD01J048
Install the retainer and a new O-ring onto the spool.
CAS-1147-2 and compress the spring. Install the STEP 49
spring assembly onto the spool and install the stud.
BD01J044
Install the retainer and a new O-ring onto the spool.

8005-14
STEP 50 STEP 52
1 1 2
2 1
2
1 2
3 4
BD01J043 BD01J041
1. O-RING
1. CHECK VALVE PLUG 3. SPRING
2. BACKUP RING
2. O-RING 4. POPPET
Install a new O-ring onto the plug. In sta ll ne w O -r in g s a n d ba c ku p ring o n to th e
counterbalance cartridge. Repeat step 52 for the
STEP 51 other relief valve.
1 2 STEP 53
3 1
BD01J042
1. RELIEF VALVE PLUG 3. RELIEF VALVE ASSEMBLY

2. O-RING BD01J040
1. O-RING
Install a new O-ring on the plug.
Install a new O-ring onto the solenoid valve.
STEP 54
1 2
1
BD01J038
1. O-RING
2. BACKUP RING
Install new O-rings and backup ring onto the relief

valve.
8005-15
STEP 55 STEP 58
BD01J035 BD01J028
Lubricate the loader lift spool with clean oil and install Install the spring into the valve port.
the spool into the valve body.
STEP 59
STEP 56
BD01J027
BD01J034
Lubricate the other spool with clean oil and install

into the valve body.
STEP 57
BD01J025
Install the plug into the valve port. Tighten the plug
37 to 64 Nm (327 to 566 pound-inches).
STEP 60
BD01J029
Repeat steps 57 through 59 for the other check
Install the poppet into the valve port.
valves.

8005-16
STEP 61 STEP 64
BD01J025 BD01J022
Install the relief valve assembly.
STEP 62
BD01J021
Install the relief valve onto the valve body. Tighten

the relief valve 47 to 54 Nm (416 to 478
BD01J024 pound-inches).
BD01J023
Install the relief valve plug. Tighten the plug 37 to 64

STEP 63
Repeat steps 61 through 62 for the other relief
valves.

8005-17
STEP 65 STEP 67
BD01J020 BD01J012
Install the counterbalance cartridge. Tighten 78 to 85

STEP 68
BD01J019
Install the float spool cover. Install the bolts.
STEP 66
BD01J011
BD01J014
Install the spool end cap. Tighten the cap 27 to 41 BD01J010
Nm (239 to 363 pound-inches). Install the solenoid valves onto the valve body.

8005-18
NOTES

8005-19
DUAL SELF-LEVELING CONTROL VALVE 60XT
Disassembly STEP 4
STEP 1
BD01J013
Remove the counterbalance valve cartridge.

BD01J010
Loosen and remove the solenoid assembly. STEP 5
STEP 2
BD01J014
Loosen and remove the cap.
BD01J011 STEP 6
Remove the other solenoid assembly.
STEP 3
BD01J015
Loosen and remove the nut from the solenoid valve.
BD01J012
Loosen and remove the counterbalance cartridge.

8005-20
STEP 7 STEP 10
BD01J016 BD01J019
Remove the solenoid from the cartridge. Loosen and remove the bolts from the end cap.
STEP 8 STEP 11
BD01J017
BD01J020
Loosen the solenoid cartridge.
Remove the end cap.
STEP 9
STEP 12
BD01J018
BD01J021
Remove the cartridge from the valve body.
Loosen the relief valve.

8005-21
STEP 13 STEP 16
BD01J022 BD01J025
Remove the relief valve from the valve body. Remove the relief valve assembly.
STEP 14 STEP 17
Repeat steps 14 through 16 for the other relief
valves.
STEP 18
BD01J023
Loosen the relief valve plug.
STEP 15
0BD01J026
Loosen the check valve plug.
STEP 19
BD01J024
Remove the relief valve plug.
BD01J027
Remove the check valve plug from the valve body.

8005-22
STEP 20 STEP 23
BD01J028 BD01J031
Remove the spring from the valve port. Remove the flow control cartridge from the valve
body.
STEP 21
STEP 24
BD01J029
Remove the poppet from the valve port. BD01J032
Loosen the plug assembly.
STEP 22 STEP 25
BD01J030
BD01J033
Loosen the flow control cartridge. Remove the plug assembly from the valve body.

8005-23
STEP 26 STEP 29
1 1 1
2 2
1
2 2
2
1 2
BD01J034 BD01J037
1. O-RING
Remove the spool from the valve body.
2. BACKUP RING
STEP 27 Remove the O-rings and backup rings from the

solenoid cartridge.
STEP 30
1 1 2
1
BD01J035
Remove the loader lift spool from the valve body.
STEP 28 1. O-RING
BD01J038
1 1 2. BACKUP RING
2 2 1 Remove the O-rings and backup ring from the relief

valve.
2 2 1
2 2
BD01J036
1. O-RING
2. BACKUP RING
Remove the O-rings and backup rings from the flow

control cartridge.

8005-24
STEP 31 STEP 34
1
1
2 1
2
BD01J039 BD01J042
1. O-RING 1. O-RING
2. BACKUP RING
Remove the O-ring from the relief valve plug.
Remove the O-rings and backup rings from the plug
assembly.
STEP 35
STEP 32 1
BD01J043
1. O-RING
Remove the O-ring from the plug.

BD01J040
1. O-RING
Remove the O-ring from the solenoid valve.

STEP 36
STEP 33
2
1 2
1
1 2
BD01J044
Remove the retainer and O-ring from the spool.

BD01J041
1. O-RING
2. BACKUP RING
Remove the O-rings and b ackup ring from the

counterbalance cartridge.

8005-25
STEP 37 STEP 40
BD01J045 BD01J048
Remove the retainer and O-ring from the float spool. Install the CAS-1147-2 and compress the spool
spring. Remove the stud from the spool.
STEP 38
STEP 41
4 5
3
2
1
BD01J046
Using CAS-1147-2 compress the spring and remove BD01J049
the snap ring from the spool. 1. STUD 4. RETAINER

STEP 39 3. SPRING
Remove the first spring retainer, spring, and the
second spring retainer from the float spool.
5
3 STEP 42
4
2
1 1
BD01J047
1. SNAP RING 4. RETAINER

3. SPRING
Remove the first retainer, spring, and second retainer BD01J050
1. SWITCH
from the spool.
2. PLUG ASSEMBLY
Remove the switch and plug from the spool cover.

8005-26
STEP 43 STEP 46
1
2
3
1 4
BD01J051 BD01J054
1. PLUG
Remove the other plug from the cover. 2. O-RING 4. DETENT BALL
Remove the O-ring, spring, and detent ball from the
STEP 44 plug.
STEP 47
1
BD01J052
1. O-RING
Remove the O-ring from the plug. BD01J055
Remove the O-ring from the spool port in the valve

STEP 45 body.
STEP 48
BD01J053
1. O-RING
Remove the O-ring from the switch. BD01J057
Remove the spool seal from the spool port.
STEP 49
Repeat steps 47 through 48 for the other spool port.

8005-27
STEP 50 2. Inspect the spools and spool bores for wear and
3. Inspect the spool assemblies for wear and
4. Inspect the check valve springs and poppets for
5. Inspect the solenoid valves for wear and
6. Inspect the pilot operated relief valve for wear
and damage. Use new parts as required.
7. Inspect the parts of the lock rod assembly for
BD01J058
Remove the O-ring for the float spool cover. 8. Inspect the valve body for wear, damage and
corrosion. Use new parts as required.
Inspection
1. Clean all parts in cleaning solvent. Use a lint free
cloth or air dry the parts.
NOTE: The parts must be clean and free of
contamination before assembly.

8005-28
1
1
2
2
4
4 1 1
2 2 1
1 1
9 2
2 11
2
6
7 2
6
5 4
4 5
12
13
10
2
2 3
14
BC01J003
1. PLUG 6. SPRING 10. FLOW CONTROL CARTRIDGE
2. O-RING 7. COUNTERBALANCE VALVE 11. COUNTERBALANCE CARTRIDGE
3. BACKUP RING CARTRIDGE 12. SOLENOID VALVE
4. RELIEF VALVE 8. PLUG ASSEMBLY 13. SPECIAL NUT
5. VALVE POPPET 9. HEX SOCKET PLUG 14. RELIEF VALVE
EXPLODED VIEW OF DUAL SELF-LEVELING CONTROL VALVE

8005-29
10 11
9 2
5 8 3
3
18 2 2 7
17 2
3
16
13
2 14
15
4 13
19 15 5
12 2
11
2
1
2
3 3
2 5
3
17 6
BC01J004
1. LOADER LIFT SPOOL 6. STUD 11. OIL SEAL 16. SWITCH
2. O-RING 7. SPOOL 12. COVER 17. PLUG
3. RETAINER 8. RETAINING RING 13. PLUG ASSEMBLY 18. CAP
4. WASHER 9. SOLENOID ASSEMBLY 14. DETENT SPRING 19. BOLT
5. SPRING 10. LOCK SPOOL ASSEMBLY 15. BALL
EXPLODED VIEW OF DUAL SELF-LEVELING CONTROL VALVE

8005-30
Assembly STEP 54
1
STEP 51 2
3
4
BD01J054

2. O-RING 4. DETENT BALL
BD01J058
Install a new O-ring into the loader lift port. Install a new O-ring onto the plug. Install the spring
and detent ball into the relief valve plug.
STEP 52
STEP 55
BD01J056
BD01J053
Install a new seal into the spool port. 1. O-RING
Install the O-ring onto the switch.

STEP 53
STEP 56
BD01J055
Install a new O-ring into the spool ports.

BD01J052
NOTE: Repeat step 52 to 53 for the other spool port. 1. O-RING
Install a new O-ring onto the plug.

8005-31
STEP 57 STEP 60
BD01J051 BD01J046
1. PLUG ASSEMBLY
Install the plug onto the float spool cover. CAS-1147-2 and compress the spring. Install the
spring assembly onto the spool and install the snap
STEP 58 ring.
1 STEP 61
BD01J050
1. SWITCH
2. PLUG ASSEMBLY
BD01J045
Install the switch and plug onto the spool cover. Install the retainer and a new O-ring onto the spool.
STEP 59 STEP 62
BD01J048 BD01J044
Install the two spring retainers and spring into the Install the retainer and a new O-ring onto the spool.
CAS-1147-2 and compress the spring. Install the
spring assembly onto the spool and install the stud.

8005-32
STEP 63 STEP 65
1 1 2
2 1
2
1 2
3 4
BD01J043 BD01J041
1. O-RING
1. CHECK VALVE PLUG 3. SPRING
2. BACKUP RING
2. O-RING 4. POPPET
Install a new O-ring onto the plug. In sta ll ne w O -r in g s a n d ba c ku p ring o n to th e
counterbalance cartridge. Repeat step 65 for the
STEP 64 other relief valve.
1 2 STEP 66
3 1
BD01J042
1. RELIEF VALVE PLUG 3. RELIEF VALVE ASSEMBLY

2. O-RING BD01J040
1. O-RING
Install a new O-ring on the plug.
Install a new O-ring onto the solenoid valve.
STEP 67
2 1
2
BD01J039
1. O-RING
2. BACKUP RING
Install new backup rings and O-ring onto the plug

assembly.
8005-33
STEP 68 STEP 70
1
1 2
2
2 1 2
1 2 1 2
1 2
BD01J038 BD01J036
1. O-RING 1. O-RING
2. BACKUP RING 2. BACKUP RING
Install new O-rings and backup ring onto the relief Install new O-rings and backup rings onto the flow
valve. control cartridge.
STEP 69 STEP 71
1 1 2 2
1 1
2
2
2
1 2
BD01J037 BD01J035
1. O-RING
Lubricate the float spool with clean oil and install the
2. BACKUP RING
spool into the valve body.
Install new O -rings an d b ackup rin gs on to the
solenoid cartridge. STEP 72
BD01J034
Lubricate the other spool with clean oil and install

into the valve body.

8005-34
STEP 73 STEP 74
BD01J033 BD01J031
BD01J032 BD01J030
Install the plug assembly into the valve body. Tighten Install the flow control valve into the valve body.
the plug 23 to 34 Nm (204 to 301 pound-inches). Tighten 121 to 135 Nm (140 to 220 pound-feet).
STEP 75
BD01J029
Install the poppet into the valve port.

8005-35
STEP 76 STEP 79
BD01J028 BD01J025
Install the spring into the valve port. Install the relief valve assembly.
STEP 77 STEP 80
BD01J024
BD01J027
BD01J023
BD01J025
Install the plug into the valve port. Tighten the plug Install the relief valve plug. Tighten the plug 37 to 64
37 to 64 Nm (327 to 566 pound-inches). Nm (327 to 566 pound-inches).
STEP 78 STEP 81
Repeat steps 75 through 77 for the other check Repeat steps 79 through 80 for the other relief
valves. valves.

8005-36
STEP 82 STEP 83
BD01J022 BD01J020
BD01J021 BD01J019
Install the relief valve onto the valve body. Tighten Install the float spool cover. Install the bolts.
the relief valve 47 to 54 Nm (416 to 478
pound-inches).

8005-37
STEP 84 STEP 86
BD01J018 BD01J015
Install the nut onto the solenoid cartridge. Tighten the

nut 5 to 8 Nm (44 to 71 pound-inches).
STEP 87
BD01J017
Install the solenoid cartridge. Tighten the cartridge 65

STEP 85 BD01J014
Install the spool end cap. Tighten the cap 27 to 41

STEP 88
BD01J016
Install the solenoid onto the cartridge.
BD01J013


8005-38
STEP 89 STEP 90
BD01J012 BD01J011

BD01J010
Install the solenoid valves onto the valve body.

8005-39
BI-DIRECTIONAL SELF LEVELING VALVE 70XT
Disassembly STEP 6
STEP 1
Remove the flow control cartridge (2) from the valve
(1).
STEP 2
2
3 3 3 8
9 10
9
BS01M109
8. CHECK VALVE
9. O-RING
10. BACKUP RING
4 Remove the O-rings (9) and backup ring (10) from

4 4
3 the check valve (8).
2. FLOW CONTROL CARTRIDGE

BS01M106
STEP 7
3. O-RING Remove the piston (11) from the check valve (8) port
4. BACKUP RING on the valve (1).
Remove the O-rings (3) and backup rings (4) from
the flow control cartridge (2). STEP 8
13 13
STEP 3
Remove the counterbalance valve (5) from the valve 11
(1).
STEP 4
5 7 7 7
12
BS01M108
11. PISTON
12. O-RING
13. BACKUP RING
Remove the O-ring (12) and backup rings (13) from

6 the piston (11).
6 6
5. COUNTERBALANCE VALVE
BS01M107
STEP 9
6. O-RING Loosen and remove th e n ut (14) on to p of the
7. BACKUP RING solenoid coil (15).
the counterbalance vale (5). STEP 10
Remove the solenoid coil (15) from the solenoid
STEP 5 valve cartridge (16).
Remove the check valve (8) from the valve (1).
8005-40
STEP 11 STEP 13
Remove the solenoid cartridge (16) from the valve Remove the check valve (19) from the valve (1).
(1).
STEP 14
STEP 12
15
17 18 14
18 16
18 17
18 19 20 20 21
18 17
18 17 17 17 BS01M109
19. CHECK VALVE
BS01M110
20. O-RING
14. NUT 16. SOLENOID 17. O-RING 21. BACKUP RING
15. SOLENOID COIL CARTRIDGE 18. BACKUP RING
Remove the O-rings (20) and backup ring (21) from
Remo ve th e O-rings (17) from the ends of the
the check valve (19).
solenoid coil (15) and the solenoid cartridge (16).
Remove the backup rings (18) from the solenoid
cartridge.

8005-41
BD01M044
16
19
BD01M043
1. BI-DIRECTIONAL SELF LEVELING VALVE 70XT 5. COUNTER BALANCE VALVE 16. SOLENOID CARTRIDGE
2. FLOW CONTROL CARTRIDGE 8. CHECK VALVE 19. CHECK VALVE

8005-42
Assembly STEP 18
STEP 15
3 3 3
15
18 14
18
17 16
18 17
3 4 4 4
2
BS01M106
18 17 18 18 17 2. FLOW CONTROL CARTRIDGE
17 17 3. O-RING
BD01M110 4. BACKUP RING
14. NUT 16. SOLENOID 17. O-RING
Install new O-rings (3) and backup rings (4) onto the
15. SOLENOID COIL CARTRIDGE 18. BACKUP RING
flow control cartridge (2) and install into the valve (1).
Install new O-rings (16) and backup rings (17) onto
the solenoid cartridge (15). Install the solenoid STEP 19
cartridge into the valve (21).
STEP 16 7
Place new O-rings (16) on both sides of the solenoid
coil (14). Place the solenoid coil onto the solenoid
cartridge (15) and install the nut (13). Tighten the nut
15 to 23 Nm (133 to 204 pound-inches).
STEP 17
6 6 6
5 7 7
BS01M107
5. COUNTERBALANCE VALVE
6. O-RING
7. BACKUP RING
Install new O-rings (6) and backup rings (7) onto the
counterbalance valve (5). Install the counterbalance
valve onto the valve (1).
19 20 21
20
BS01M109
19. CHECK VALVE
20. O-RING
21. BACKUP RING
Install new O-rings (19) and backup ring (20) onto

the check valve (18). Install the check valve into the
valve (1).

8005-43
STEP 20 STEP 22
11 10
8 9
13 12 13 9
BS01M108 BS01M109
11. PISTON 8. CHECK VALVE
12. O-RING 9. O-RING
13. BACKUP RING 10. BACKUP RING
Install a new O-ring (12) and backup rings (13) onto Install new O-rings (9) and backup rings (10) onto the
the piston (11). check valve (8). Install the check valve onto the valve
(1).
STEP 21
Install the piston (11) into the check valve (8) port on
the valve (1).

8005-44
NOTES

Section
8006
CYLINDERS
8006

8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Retaining Screw - Tube to Gland Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOADER LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOADER BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BACKHOE SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BACKHOE BOOM AND DIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BACKHOE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BACKHOE FOLD DOWN STABILIZER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BACKHOE VERTICAL STABILIZER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

8006-3
SPECIFICATIONS
Piston Bolt Torque
Loader Lift Cylinder .......................................................................................240 to 300 Nm (175 to 225 pound-feet)
Loader Bucket Cylinder .................................................................................650 to 830 Nm (480 to 615 pound-feet)
Packing Gland Torque
Loader Lift Cylinder ............................................................................................. 407 ± 68 Nm (300 ± 50 pound-feet)
Loader Bucket Cylinder ....................................................................................... 407 ± 68 Nm (300 ± 50 pound-feet)
Backhoe Boom (125) Torque
Piston Rod Bolt..............................................................................................365 to 460 Nm (270 to 340 pound-feet)
Cylinder Gland ...............................................................................................135 to 542 Nm (100 to 400 pound-feet)
Backhoe Bucket (125) Torque
Backhoe Dipper (125) Torque
Piston Rod Bolt.......................................................................................... 1180 to 1250 Nm (870 to 920 pound-feet)
Backhoe Bucket, Boom and Dipper (125) Torque
Backhoe Fold Down Stabilizer (125) Torque
Backhoe Vertical Stabilizer (125) Torque
Piston Rod Bolt................................................................................................122 to 135 Nm (90 to 100 pound-feet)
SPECIAL TOOLS
1040L93
CAS-1456 GLAND WRENCH. NOT SHOWN IN USE.
GENERAL
Retaining Screw - Tube to Gland 3. When assembling new parts, tighten gland to
torque specified. Drill a hole 3.73 to 3.86 mm
Procedure (0.147 to 0.152 inch) diameter and 11 mm (7/16
1. When assembling original parts, align tube and inch) deep. Drill half in the tube and half in the
gland after tightening. gland. Make sure hole does not align within 12
mm (1/2 inch) of hole for gland wrench.
2. Install screw. If holes do not align, see step 3.

8006-4
LOADER LIFT CYLINDER
Disassembly 7. Inspect the gland (15) for rust or corrosion. Clean

and remove rust or corrosion from the gland (15).
NOTE: Refer to illustration on page 5. Use new parts as required.
Clean the outside of the cylinder. If the hoses were 8. Inspect the gland end of the tube (1) for sharp
removed with the cylinder, remove the hoses from edges that may cut the gland O-ring (9). Remove
the cylinder. sharp edges.
1. Fasten the tube (1) in a vise or other holding
equipment. Be careful not to damage the tube. Assembly
2. Use a wrench to loosen the gland (15) in the tube NOTE: If a new gland (15) is being installed, put the
(1). part number of the cylinder on the new gland (15),
refer to the illustration on page 5.
3. Pull the piston rod (7) straight out of the tube (1)
to prevent damage to the tube. 1. Lubricate the rod (7) and the cylinder bore (1)
with hydraulic oil prior to assembly.
4. Fasten the piston rod (7) end in a vise. Place a
padded support below the piston rod (7) near the 2. Lubricate a new wear ring (12) and install in the
piston (4) to prevent damage to the piston rod gland (15).
(7).
3. Lubricate a new seal (11) and install in the gland
5. Loosen and remove the nut (3) and the washer (15).
(2) that connects the piston (4) on the piston rod
4. Lubricate a new seal (10) and install in the gland
(7).
(15). The seal is to be installed so that the lips
6. Remove the piston (4) from the piston rod (7). are toward the big end of the gland (15).
7. Remove the seal (5) and wear ring (6) from the 5. Lubricate a new backup ring (8) and install in the
piston (4). groove on the outside of the gland (15). Install
the backup ring (8) with the flat side toward the
8. Remove the gland (15) and spacer (18) from the
large end if the gland (15).
piston rod (7).
6. Lubricate a new O-ring (9) and install in the
9. Remove the O-ring (9), backup ring (8), seals (10
groove next to the backup ring (8) on the outside
and 11), and wear ring (12) from the gland (15).
of the gland (15). The O-ring (9) must be toward
the small end of the gland (15).
Inspection
7. Fasten the piston rod (7) end in the vise.
1. Clean the piston (4), gland (16), piston rod (7),
tube (1), washer (2), nut (3), and spacer (18) in 8. Remove any marks and sharp edges on the
cleaning solvent, refer to the illustration on page chamfered end of the piston rod (7).
5. 9. Lubricate the bore of the gland (15) with clean
2. Discard the seals, wear rings and O-rings that hydraulic oil.
were removed from the piston (4) and gland (15). 10. Push the gland (15) onto the piston rod (7). If the
3. Inspect the inside of the tube (1) for deep gland (15) will not slide easily onto the piston rod
grooves or other damage. If there is damage to (7), use a soft hammer to drive the gland (15)
the tube (1), use new parts as required. onto the piston rod (7).
4. Inspect the piston rod (7) to make sure it is 11. Install the spacer (18) onto the piston rod (7).
straight. If the piston rod is damaged, use new 12. Place a support below and near the end of the
parts as required. piston rod (7). Use a shop cloth between the
5. Remove small scratches on the inside of the support and the piston rod (7) to prevent damage
tube (1) with emery cloth of medium grit. Use the to the piston rod.
emery cloth with a rotary motion. 13. Install the piston (4) onto the end of the piston
6. Inspect the bushings (16) in the piston rod end rod (7).
and the bushings (17) in the tube end. If the 14. Install the washer (2) onto the piston rod (7).
bushing(s) are worn or damaged, use new parts
as required.
8006-5
15 5
8 9 6
4
10
2
11
12 18
3
13 13
14
16 7 17
1
BS01K225
1. TUBE 7. PISTON ROD 13. GREASE FITTING

2. WASHER 8. BACKUP RING 14. ROD END
3. LOCK NUT 9. O-RING 15. GLAND
4. PISTON 10. SEAL 16. BUSHING
5. SEAL 11. SEAL 17. BUSHING
6. WEAR RING 12. WEAR RING 18. SPACER
CROSS SECTION VIEW OF LIFT CYLINDER

8006-6
NOTE: Refer to illustration on page 7. 20. Push the tube (1) straight onto the piston (4).
15. Clean the threads on the end of the piston rod (7) 21. Start the tube (1) onto the piston rod (7)
using Loctite cleaning solvent. Allow to dry. Apply assembly. Push the tube (1) onto the piston rod
Loctite 242 to the piston rod threads, 1/4 inch (7) until the compression tool is clear of the
from the end of the piston rod. piston rod (7). Be careful not to damage the wear
ring (6) and the seal (5).
NOTE: Do not apply Loctite 242 to the first 1/4 inch
of the piston rod (3) threads. 22. When the piston (4) is in the smooth part of the
tube (1), start the gland (15) into the tube (1).
16. Install the nut (3) and tighten to 240 to 300 Nm
(175 to 225 pound-feet). A torque multiplier can 23. Lubricate the new O-ring (9) on the gland (15)
be used to tighten the nut. with clean hydraulic oil.
17. Lubricate a new wear ring (6) with clean 24. Tighten the gland (15) to 407 Nm ± 68 Nm (300
hydraulic oil and install in the end groove on the pound-feet ± 50 pound-feet).
outside of the piston (4).
25. If hoses were removed with the cylinder, install
18. Lubricate a new seal (5) with clean hydraulic oil new O-rings, if equipped, on the hose fittings.
and install in the center groove on the outside of Lubricate the new O-rings with clean hydraulic oil
the piston (4). and install the hoses.
19. Lubricate the inside of the tube (1) and the piston
(4) with clean hydraulic oil. Use a piston ring
compression tool to hold the new wear ring (6) in
place.

8006-7
15 5
8 9 6
4
10
2
11
12 18
3
13 13
14
16 7 17
1
BS01K225
1. TUBE 7. PISTON ROD 13. GREASE FITTING

2. WASHER 8. BACKUP RING 14. ROD END
3. LOCK NUT 9. O-RING 15. GLAND
4. PISTON 10. SEAL 16. BUSHING
5. SEAL 11. SEAL 17. BUSHING
6. WEAR RING 12. WEAR RING 18. SPACER
CROSS SECTION VIEW OF LIFT CYLINDER

8006-8
LOADER BUCKET CYLINDER
Disassembly Inspection
NOTE: Refer to illustration on page 9. 1. Clean the piston (4), gland (14), piston rod (8),
tube (1), hardened washer (2), and bolt (3) in
1. Clean the outside of the cylinder. If the hoses
cleaning solvent, refer to illustration on page 9.
were removed with the cylinder, remove the
hoses. 2. Discard the seals, wear rings and O-rings that
were removed from the piston (4) and gland (14).
2. Clamp the tube (1) in a vise or other holding
equipment. Be careful not to damage the tube. 3. Illuminate the inside of the tube (1). Inspect the
inside of the tube (1) for deep grooves or other
3. Use a wrench to loosen the gland (14) from the
damage. If there is damage to the tube (1), use
tube (1).
4. Inspect the piston rod (8) to make sure it is
to prevent damage to the tube.
straight. If the piston rod is damaged, use new
5. Clamp the piston rod end (12) in a vise. Place a parts as required.
padded support below the piston rod (8) near the
5. Remove small scratches on the inside of the
piston (4) to prevent damage to the piston rod.
tube (1) with emery cloth of medium grit. Use the
6. Loosen and remove the bolt (3) and the washer emery cloth with a rotary motion.
(2) that connects the piston (4) to the piston rod
6. Inspect the bushings in the piston rod end (12)
(8). Use a torque multiplier for the bolts that have
a n d th e b u s h i n g s i n t h e t u b e e n d . I f t h e
a high torque value.
bushing(s) are worn or damaged, use new parts
7. Remove the piston (4) from the piston rod (8). as required.
8. Remove the seal (6) and wear ring (7) from the 7. Inspect the gland (14) for rust or corrosion. Clean
piston (4). and remove rust or corrosion from the gland (14).
Use new parts as required.
9. Remove the O-ring (13), backup ring (5), seal
(11), seal (10), and seal (9) from the gland. 8. Inspect the gland end of the tube (1) for sharp
ed ge s tha t may cu t the glan d O -ring (1 3).
Remove sharp edges.

8006-9
14 5 13 6 7
4
11 10 9
2
3
12
15
8
1
BS01K223
1. TUBE 6. SEAL 11. SEAL
2. HARDENED WASHER 7. WEAR RING 12. PISTON ROD END
3. BOLT 8. PISTON ROD 13. O-RING
4. PISTON 9. SEAL 14. GLAND
5. BACKUP RING 10. SEAL 15. GREASE FITTING
CROSS SECTION VIEW OF BUCKET CYLINDER

8006-10
Assembly 14. Clean the threads on the end of the piston rod (8)
and the threads of the bolt (3) using Loctite
NOTE: If a new gland (14) is being installed, put the cleaning solvent. Allow all the parts to dry. Apply
part number of the cylinder on the new gland (14), Loctite 242 to the piston rod (8) threads, 1/4 inch
refer to the illustration on page 11. from the open end of the piston rod (8). Apply 1/2
1. Lubricate all components with hydraulic oil. inch of Loctite 242 on the piston rod (8) threads.
2. Lubricate seal (9) with clean hydraulic oil and NOTE: Do not apply Loctite 242 to the first 1/4 inch
install in the gland (14). of the piston rod (8) threads.
3. Lubricate seal (10) with clean hydraulic oil and 15. Install the bolt (3).
install in the gland (14). Install the seal so that 16. Torque the bolt to 650 to 830 Nm (480 to 615
the lips are toward the small end of the gland. pound-feet). A torque multiplier can be used to
4. Lubricate a new seal (11) with clean hydraulic oil tighten the bolt (3).
and install in the gland (14). The wiper lips must 17. Lubricate a new seal (6) with clean hydraulic oil
be toward the large end of the gland. and install in the center groove on the outside of
5. Lubricate a new backup ring (5) with clean the piston (4).
hydraulic oil and install in the groove on the 18. Lubricate a new wear ring (7) with clean
outside of the gland (14). Install the ring with the hydraulic oil and install in the end groove on the
flat side toward the large end if the gland. opposite end of the piston (4).
6. Lubricate a new O-ring (13) with clean hydraulic 19. Lubricate the inside of the tube (1) and the piston
oil and install in the groove next to the backup (4) with clean hydraulic oil. Use a piston ring
ring (5) on the outside of the gland (14). compression tool to hold the new wear ring (7) in
7. Fasten the piston rod end (12) in the vise. place.
8. Remove any marks and sharp edges on the 20. Push the tube (1) straight onto the piston (4).
chamfer at the end of the piston rod (8). 21. Start the tube (1) onto the piston rod (8)
9. Lubricate the bore of the gland (14) with clean assembly. Push the tube (1) onto the piston rod
hydraulic oil. (8) until the compression tool is pushed off the
piston rod (8). Be careful not to damage the wear
10. Push the gland (14) onto the piston rod (8). If the ring (7) and the seal (6).
gland will not slide easily onto the piston rod (8),
a soft hammer may be used. 22. When the piston (4) is in the smooth part of the
11. Place a support below and near the end of the
piston rod (8). Use a shop cloth between the 23. Lubricate the new O-ring (13) on the gland (14)
support and the piston rod to prevent damage to with clean hydraulic oil.
the piston rod. 24. Tighten the gland (14) to 407 Nm ± 68 Nm (300
12. Install the piston (4) onto the end of the piston pound-feet ± 50 pound-feet).
rod (8). 25. If hoses were removed with the cylinder, install
13. Install the washer (2) onto the bolt (3). new O-rings, if equipped, on the hose fittings.
Lubricate the new O-rings with clean hydraulic oil
NOTE: Refer to illustration on page 9. and install the hoses.

8006-11
14 5 13 6 7
4
11 10 9
2
3
12
15
8
1
BD01J189
1. TUBE 6. SEAL 11. SEAL
2. HARDENED WASHER 7. WEAR RING 12. PISTON ROD END
3. BOLT 8. PISTON ROD 13. O-RING
4. PISTON 9. SEAL 14. GLAND
5. BACKUP RING 10. SEAL 15. GREASE FITTING
CROSS SECTION VIEW OF BUCKET CYLINDER

8006-12
BACKHOE SWING CYLINDER
Disassembly 10. Inspect the inside of the tube (4) for deep
grooves and other damage . If there is any
NOTE: Refer to illustration on page 13. damage, a new tube (4) must be used.
NOTE: The cylinders for the Model 125 Backhoe are 11. Remove small scratches on the piston rod (1) or
shown, others are similar. inside the tube (4) with emery cloth of medium
1. Remove the dirt and grease from the cylinder. If grit. Use the emery cloth with a rotary motion.
the hoses were removed with the cylin der, 12. Inspect the relief valves (3). If the relief valves (3)
remove the hoses from the cylinder. are damaged, use a new relief valve (3) as
2. Fasten the pivot plate of the piston rod (1) in a required.
vise. Be careful not to damage the piston rod.
Assembly
3. Drive the tubes (4) off the piston rod (1).
13. Install new O-rings (7) on the relief valves (3).
4. Remove the wiper (6), backup ring (5), and
O-ring (2) from each tube (4). Discard the parts 14. Lubricate the O-rings (7) on the relief valves (3)
that were removed. with clean hydraulic oil.
5. Remove the relief valves (3) from the end of the 15. Install the relief valves (3) in the piston rod (1).
piston rod (1).
16. Install a new O-ring (2), backup ring (5), and
6. Remove and discard the O-rings (7) from the wiper (6) in each tube (4). Use a suitable driver
relief valves (3). to drive or press the wiper (6) into the tube (4).
17. Lubricate the wiper (6) and the O-ring (2) in each
Inspection tube (4), and the piston rod (1) before installing
7. Clean all parts in cleaning solvent. the tubes (4).
8. Inspect the piston rod (1) for grooves and other 18. Install the tubes (4) on the piston rod (1) so that
wear that will damage the new wipers (6) and the fittings will be on top when the swing cylinder
O-rings (2). is installed.
9. Check to make sure that the piston rod (1) is

straight. If bent install a new piston rod.

8006-13
2
5
4 6
7
1
3
7
3
5
2
4
BD01J191
1. PISTON ROD 3. RELIEF VALVE 5. BACKUP RING 7. O-RING
2. O-RING 4. TUBE 6. WIPER
NOTE: The swing cylinder for the Model 125 Backhoe is shown. Other models are similar.
BACKHOE SWING CYLINDER

8006-14
BACKHOE BOOM AND DIPPER CYLINDER
Disassembly 19. Inspect the gland (6) for rust or corrosion. Clean
1. Remove the dirt and grease from the cylinder. 20. Inspect the gland end of the tube (16) for sharp
2. Fasten the tube (16) in a vise with soft jaws or edges that may cut the gland O-ring (9). Remove
other holding equipment. sharp edges.
3. Remove the screw (15) from the gland (6). Assembly

4. Use a wrench to loosen and remove the gland
21. Lubricate a new narrow seal (7) with clean
(6).
hydraulic oil and install in the gland (6).
22. Lubricate a new wide seal (5) with clean
to prevent damage to the tube.
hydraulic oil and install in the gland (6). The wide
6. Fasten the piston rod (3) eye in a vise and put a seal (5) is to be installed so that the lips are
support under the piston rod near the piston (11). toward the small end of the gland (6).
Use a shop cloth between the support and piston
23. Lubricate a new wiper (4) with clean hydraulic oil
rod to prevent damage to the piston rod.
and install in the gland (6). The lips of the wiper
7. Remove the seal (10), ring (1), and wear ring (4) must be toward the large end of the gland (6).
(12) from the piston (11).
24. Lubricate a new backup ring (8) with clean
8. Loosen and remove the bolt (14) and washer hydraulic oil ad install in the groove on the
(13) from the piston rod (3). outside of the gland (6). Install the backup ring
(8) with the flat side toward the large end if the
9. Remove the piston (11) from the piston rod (3).
gland (6).
10. Remove the gland (6) from the piston rod (3).
25. Lubricate a new O-ring (9) with clean hydraulic
11. Remove the O-ring (9) and backup ring (8) from oil and install in the groove on the outside of the
the outside diameter of the gland (6). gland (3). The O-ring (9) must be toward the
small end of the gland (6).
12. Remove the bushing (2) from the inside diameter
of the gland (6). 26. Install a new bushing (2) in the inside diameter of
the gland (6).
13. Remove the wiper (4), wide seal (5), and the
narrow seal (7) from the gland (6). 27. Fasten the piston rod (3) eye in the vise.
28. Remove any marks and sharp edges on the
Inspection chamfer at the end of the piston rod (3).
14. .Clean the piston (11), gland (6), piston rod (3), 29. Lubricate the bore of the gland (6) and the piston
tube (16), washer (13), and bolt (14) in cleaning rod (3) with clean hydraulic oil.
solvent.
30. Push the gland (6) onto the piston rod (3). If the
15. Discard the bushing (2), wiper (4), wide seal (5), gland (6) will not slide easily onto the piston rod,
narrow seal (7), O-ring (9), backup ring (8), wear use a soft hammer to drive the gland onto the
ring (12 ), ring (1 ), and sea l (10) that we re piston rod.
removed from the piston (11) and the gland (6).
31. Place a support below and near the end of the
16. Inspect the inside of the tube (16) for deep piston rod (3) to prevent damage to the piston
grooves or other damage. If there is damage to rod (3).
the tube (16), use new parts as required.
32. Install the piston (11) onto the piston rod (3).
17. Inspect the piston rod (3) to make sure it is
straight. If the piston rod (3) is damaged, use 33. Install the washer (13) onto the bolt (14).
new parts as required. 34. Clean the threads on the end of the piston rod (3)
18. Remove small scratches on the inside of the and the threads of the bolt (14) using Loctite
tube (16) with emery cloth of medium grit. Use cleaning solvent. Allow all the parts to dry. Apply
the emery cloth with a rotary motion. Loctite 242 to the first six threads on the bolt
(14).

8006-15
15
16
11
12
1
13 10
5 4
14 7
6
8
9
996L93
1. RING 5. WIDE SEAL 9. O-RING 13. WASHER
2. BUSHING 6. GLAND 10. SEAL 14. BOLT
3. PISTON ROD 7. NARROW SEAL 11. PISTON 15. SCREW
4. WIPER 8. BACKUP RING 12. WEAR RING 16. TUBE
NOTE: The boom, bucket, and dipper cylinder for the Model 125 Backhoe is shown. Other models are similar.
BOOM AND DIPPER CYLINDER

8006-16
NOTE: Refer to illustration on page 15 or 17. 41. When the piston (11) is in the smooth part of the
tube (16), start the gland (6) into the tube.
35. Install the bolt (14), refer to Specifications for the
correct torque. 42. Lubricate the new O-ring (9) on the gland (6) with
clean hydraulic oil.
36. Lubricate a new wear ring (12) with clean
hydraulic oil and install on top of the piston (11). 43. Tighten the gland (6). Refer to Specifications for
proper torque.
37. Lubricate a new ring (1) with clean hydraulic oil
and install in the center groove on the outside of 44. See General on page 3 for the tube to gland
the piston (11). retaining screw procedure.
38. Lubricate a new seal (10) with clean hydraulic oil 45. If hoses were removed with the cylinder, install
and install on top of the ring (1) on the outside of new O-rings, if equipped, on the hose fittings.
the piston (11). Lubricate the O-rings with clean hydraulic oil and
install the hoses.
39. Lubricate the inside of the tube (16) and the
piston (11) with clean hydraulic oil.
40. Start the tube (16) onto the piston rod (3)
assembly. Push the tube (16) onto the piston
rod.

8006-17
8
10 12
1 15 6 9 16 11
1 14
4
3 5 7 2
13
1028L93
1. RING 5. WIDE SEAL 9. O-RING 13. HARDENED WASHER
2. BUSHING 6. GLAND 10. SEAL 14. BOLT
3. PISTON ROD 7. NARROW SEAL 11. PISTON 15. SCREW
4. WIPER 8. BACKUP RING 12. WEAR RING 16. TUBE
NOTE: The boom, bucket, and dipper cylinder for NOTE: The torque for the screw (15) is 2.25 Nm (20
the Model 125 Backhoe is shown. Other models are lb inch).
similar.
CROSS SECTION VIEW OF BOOM AND DIPPER CYLINDER

8006-18
BACKHOE BUCKET CYLINDER
Disassembly 18. Inspect the gland (3) for rust or corrosion.Clean

1. Remove the dirt and grease from the cylinder. 19. Inspect the gland end of the tube (14) for sharp
2. Fasten the tube (14) in a vise with soft jaws or edges that may cut the gland O-ring (6). Remove
other holding equipment. sharp edges.
3. Remove the screw (12) from the gland (3). Assembly

4. Use a wrench to loosen and remove the gland
20. Lubricate a new seal (4) with clean hydraulic oil
(3).
and install in the gland (3). The buffer seal (4) is
5. Pull the piston rod (13) straight out of the tube to be installed so that the lips are toward the
(14) to prevent damage to the tube. small end of the gland (3).
6. Fasten the piston rod (13) eye in a vise and put a 21. Lubricate a new seal (2) with clean hydraulic oil
support under the piston rod near the piston (8). and install in the gland (3). The seal (2) is to be
Use a shop cloth between the support and piston installed so that the lips are toward the small end
rod to prevent damage to the piston rod. of the gland (3).
7. Remove the backup ring (10), seal (5) and ring 22. Lubricate a new wiper (1) with clean hydraulic oil
(9) from the piston (8). and install in the gland (3). The lips of the wiper
(1) must be toward the large end of the gland (3).
8. Remove the gland (3) from the piston rod (13).
9. Remove the O-ring (6) and backup ring (7) from
hydraulic oil ad install in the groove on the
the outside diameter of the gland (3).
outside of the gland (3). Install the backup ring
10. Remove the bushing (18) from the inside (7) with the flat side toward the large end of the
diameter of the gland (3). gland (3).
11. Remove the wiper (1), seal (2), and the seal (4) 24. Lubricate a new O-ring (6) with clean hydraulic
from the gland (3). oil and install in the groove next to the backup
ring (7) on the outside of the gland (3). The
Inspection O-ring (6) must be toward the small end of the
gland (3).
12. .Clean the piston (8), gland (3), piston rod (13),
tube (14) washer (16), and screw (12) in cleaning 25. Install a new bushing (18) in the inside diameter
solvent. of the gland (3).
13. Discard the wiper (1), seal (2), seal (4), O-ring 26. Fasten the piston rod (13) eye in the vise.
(6), backup ring (7), backup ring (10), seal (5) 27. Remove any marks and sharp edges on the
and ring (9) that were removed from the piston chamfer at the end of the piston rod (13).
(8) and the gland (3).
28. Lubricate the bore of the gland (3) and the piston
14. Inspect the inside of the tube (14) for deep rod (13) with clean hydraulic oil.
grooves or other damage. If there is damage to
the tube, use new parts as required. 29. Push the gland (3) onto the piston rod (13). If the
gland (3) will not slide easily onto the piston rod,
15. Remove small scratches on the inside of the use a soft hammer to drive the gland onto the
tube (14) with emery cloth of medium grit. Use piston rod.
the emery cloth with a rotary motion.
30. Place a support below the piston rod (13) to
16. Inspect the piston rod (13) to make sure it is prevent damage to the piston rod.
straight. If the piston rod (13) is damaged, use
new parts as required. 31. Install the piston (8) onto the piston rod (13).
17. Inspect the bushings (15) if they are worn or 32. Install the washer (16) onto the bolt (11).
damaged, use new parts as required.

8006-19
17
15 15
13
1
2
4
3
18
7 12
6
8
11 9
5
10
16
15 14
17
15
BS01J192
1. WIPER 6. O-RING 11. BOLT 16. WASHER
2. SEAL 7. BACKUP RING 12. SCREW 17. GREASE FITTING
3. GLAND 8. PISTON 13. PISTON ROD 18. BUSHING
4. SEAL 9. RING 14. TUBE
5. SEAL 10. BACKUP RING 15. BUSHING
NOTE: The stabilizer cylinder for the Model 125 Backhoe is shown. Other models are similar.
BACKHOE BUCKET CYLINDER

8006-20
NOTE: Refer to illustration on page 19. 38. Lubricate the inside of the tube (14) and the
piston (8) with clean hydraulic oil.
33. Clean the threads on the end of the piston rod
(13) and the threads of the bolt (11) using Loctite 39. Start the tube (14) onto the piston rod (13)
cleaning solvent. Allow all the parts to dry. Apply assembly. Push the tube (14) onto the piston rod.
Loctite 242 to the first six threads on the bolt.
40. When the piston (8) is in the smooth part of the
34. Install the bolt (11), refer to Specifications for the tube (14), start the gland (3) into the tube.
correct torque.
41. Lubricate the new O-ring (6) on the gland (3) with
35. Lubricate a new ring (9) with clean hydraulic oil clean hydraulic oil.
and install on top of the piston (8).
42. Tighten the gland (3). Refer to Specifications for
36. Lubricate a new seal (5) with clean hydraulic oil proper torque.
and install on top of the ring (9) on the outside of
43. See General on page 3 for the tube to gland
the piston (8).
retaining screw procedure.
44. If hoses were removed with the cylinder, install
hydraulic oil and install on the outer groove on
new O-rings, if equipped, on the hose fittings.
the outside of the piston (8).
BACKHOE FOLD DOWN STABILIZER CYLINDER
Disassembly 7. Fasten the piston rod yoke (20) in a vise and put
a support under the piston rod (12) near the
NOTE: Refer to illustration on page 21. piston (8). Use a shop cloth between the support
NOTE: The cylinders for the Model 125 Backhoe are and piston rod to prevent damage to the piston
shown, others are similar. rod.
1. Remove the dirt and grease from the cylinder. 8. Use the CAS-1456 gland wrench to loosen and
remove the piston (8) or the piston rod yoke (20).
2. Remove the fitting from the gland (17) and end The piston rod yoke and the piston are tightened
cap (1). Make a mark on each end of the tube (6) to the same torque value, see Specifications for
to show the location of the ports. torque values.
3. Remove the cover for the lock wire (5) that holds 9. Remove the gland (17) from the piston rod (12).
the gland (17).
10. Remove the wiper (19), seal (18), O-ring (13),
4. Use a brass rod in the port of the gland (17) or a backup ring (14), and the dust seal (15) from the
chain wrench to rotate the gland for removal of gland (17).
the lock wire (5). Use a screwdriver to lift the end
of the lock wire out of the slot. 11. Repeat Steps 2 through 6 to remove the end cap
(1).
Inspection
12. Clean the piston (8), gland (17), end cap (1)
piston rod (12), and the tube (6) in cleaning
solvent.
13. Discard the O-rings (2, 9, 11, 13), backup rings
(3, 10, 14), dust seals (4, 15) wear ring (7), wiper
(19), and the seal (18) that were removed from
the piston (8) and the gland (17).
B860488J 14. Inspect the inside of the tube (6) for deep
5. Pull the piston rod (12) straight out of the tube (6) grooves or other damage. If there is damage to
to prevent damage to the tube. the tube (6), use new parts as required.
6. If the gland (17) will not come out of the tube (6), 15. Inspect the piston rod (12) to make sure it is
cut the O-ring (2) a nd backup ring (3 ) an d straight. If the piston rod (12) is damaged, use
remove these parts through the slot. new parts as required.

8006-21
20
6
19
12 18
17
2
16
11
3
10
15
4
5 14
9
13
8
1
7
BS01J193
1. END CAP 6. TUBE 11. O-RING 16. LOCK RING
2. O-RING 7. WEAR RING 12. ROD 17. GLAD
3. BACKUP RING 8. PISTON 13. O-RING 18. SEAL
4. DUST SEAL 9. O-RING 14. BACKUP RING 19. WIPER
5. LOCK WIRE 10. BACKUP RING 15. DUST SEAL 20. CLEVIS
BACKHOE FOLD DOWN STABILIZER CYLINDERS

8006-22
NOTE: Refer to illustration on page 23. 29. Push the gland (17) onto the piston rod (12).
16. Remove small scratches on the inside of the 30. Place a support below and near the end of the
tube (6) with emery cloth of medium grit. Use the piston rod (12) to prevent damage to the piston
emery cloth with a rotary motion. rod (12).
17. Inspect the gland (17) for rust or corrosion. Clean 31. Lubricate a new O-ring (11) with clean hydraulic
and remove the rust and corrosion from the oil and install in the inside diameter of the piston
gland (17). Use new parts as required. (8) on the piston rod (12) side.
18. Inspect both ends of the tube (6) for sharp edges 32. Install the piston (8) on the end of the piston rod
that may cut the gland (17), the end cap (1), and (12).
O-rings (2, 9,13). Remove sharp edges.
33. Use a CAS-145 gland wrench to tighten the
piston (8) or piston rod yoke (20) to a torque of
Assembly 310 to 350 Nm (230 to 260 pound-feet).
NOTE: If a new gland (17) or end cap (1) is being 34. Lubricate a new wear ring (7) with clean
used, write the part number of the cylinder on the hydraulic oil and install in the inner groove on the
new gland (17) or end cap (1). outside of the piston (8).
19. Lubricate a new seal (18) with clean hydraulic oil 35. Lubricate a new O-ring (9) with clean hydraulic
and install in the gland (17). The seal (18) is to oil and install on the outer groove on the outside
be installed so that the lips are toward the inside of piston (8).
of the gland (17).
20. Lubricate a new wiper (19) with clean hydraulic hydraulic oil and install on top of the O-ring (9) on
oil and install in the gland (17). The lips of the the outside of the piston (8).
wiper (19) must be toward the large end of the
gland (17). 37. Lubricate the inside of the tube (6) and the piston
(8) with clean hydraulic oil.
21. Install a new dust seal (4,15) on the end cap (1)
and the gland (17). 38. Start the tube (6) on the piston rod (12)
assembly. Push the tube (6) onto the piston rod
22. Lubricate a new backup ring (3, 14) with clean (12).
hydraulic oil and install on the end cap (1) and
the gland (17). 39. When the piston (8) is in the smooth part of the
23. Lubricate a new O-ring (2, 13) with clean
hydraulic oil and install on the end cap (1) and 40. Lubricate the bore of the tube (6) at the end
the gland (17). where the gland (17) is to be installed.
24. Lubricate the bore of the tube (6) at the end 41. Install the gland (17) in the tube (6).
where the end cap (1) is to be installed. 42. Engage the internal tab on the lock ring (16) with
25. Install the end cap (1) in the tube (6). a hole in the gland (17). Use the brass rod or
chain wrench to rotate the gland (17) to pull the
26. Engage the internal tab on the lock ring (5) with a lock ring (16) into the tube (6). Make sure that
hole in the end cap (1). Use the brass rod or the port is aligned with the mark on the tube (6).
chain wrench to rotate the end cap (1) to pull the
lock ring (5) into the tube (6). Make sure that the 43. If hoses were removed with the cylinder, install
port is aligned with the mark on the tube (6). new O-rings, if equipped, on the hose fittings.
Lubricate the new O-rings with clean hydraulic oil
27. Fasten the piston rod yoke (20) in the vise. and install the hoses.
28. Lubricate the bore of the gland (17) and the
piston rod (12) with clean hydraulic oil.

8006-23
20
6
19
12 18
17
2
16
11
3
10
15
4
5 14
9
13
8
1
7
BS01J193
1. END CAP 6. TUBE 11. O-RING 16. LOCK RING
2. O-RING 7. WEAR RING 12. ROD 17. GLAD
3. BACKUP RING 8. PISTON 13. O-RING 18. SEAL
4. DUST SEAL 9. O-RING 14. BACKUP RING 19. WIPER
5. LOCK WIRE 10. BACKUP RING 15. DUST SEAL 20. CLEVIS
BACKHOE FOLD DOWN STABILIZER CYLINDERS

8006-24
BACKHOE VERTICAL STABILIZER CYLINDER
Disassembly 19. Inspect the inside of the inner tube (16) for deep
grooves and other damage . If there is any
NOTE: Refer to illustration on page 25. damage to the outer tube, use new parts as
1. Clean the outside of the cylinder. If the hoses required.
were removed with the cylinder, remove the 20. Remove small scratches on the piston rod (12),
hoses from the cylinder. in ner tu be ( 16), a nd o uter tu be ( 17) u sin g
2. Fasten the closed end of the cylinder in a vise mediu m grit emery cloth. Use in a circular
with soft jaws or other holding equipment. Be motion.
careful not to damage the outer tube (17). 21. Inspect the gland (1) for rust or corrosion.
3. Loosen and remove the gland (1). Remove the rust and corrosion as necessary
from the gland.
4. Pull the piston rod straight out of the inner tube
(16) and outer tube (17). 22. Inspect the gland (1) end of the outer tube (17)
for sharp edges that will cut the gland, O-ring (2)
5. Fasten the piston rod (12) in a vise with soft jaws and backup ring (3).
and put a support under the piston rod near the
piston (8). Use a shop cloth between the support 23. Inspect the piston (8) for damage and wear. If the
and piston rod to prevent damage to the piston piston (8) is damaged or worn, use new parts as
rod. required.
6. Loosen and remove the nut (7). Assembly

7. Remove the piston (8) from the rod (12).
24. Install a new backup ring (14) in the groove at
8. Remove the gland (1) from the piston rod (12). the closed end of the inner tube (16). If the
backup ring (14) is not flat on both sides, the side
9. Remove the backup ring (13), O-ring (9), and
that is not flat must be toward the O-ring (15).
backup ring (10) from the outside of the piston
(8). 25. Install a new O-ring (15) in the groove next to the
backup ring (14). The O-ring must be toward the
10. Remove the O-ring (11) from inside the piston
rod end of the inner tube (16).
(8).
26. Install a new O-ring (4) in the inside diameter of
11. Remove the O-ring (2) and backup ring (3) from
the gland (1). The O-ring (4) must be toward the
the outside of the gland (1).
small end of the gland (1).
12. Remove the O-ring (4), backup ring (5), and
27. Install a new backup ring (5) in the groove next to
wiper (6) from inside the gland (1).
the O-ring (4). If the backup ring (5) is not flat on
13. Remove the outer tube (17) from the inner tube both sides, the side that is not flat must be
(16). toward the O-ring (4).
14. Remove the backup ring (14) and the O-ring (15) 28. Install a new wiper (6) in the gland (1). the lips of
from the inner tube (16). the wiper (6) must be toward the outside of the
gland (1).
Inspection 29. Fasten the piston rod (12) in the vise.
15. Discard the backup rings, O-rings, and the wiper. 30. Remove any marks and sharp edges on the
16. Clean the tubes (16 and 17), piston (8), piston chamfer at the end of the piston rod (12).
rod (12), lock nu t (7), and the gland (1 ) in 31. Lubricate the bore of the gland (1) and the piston
cleaning solvent. rod (12) with clean hydraulic oil.
17. Check to be sure that the piston rod (12) is 32. Put a support below the end of the piston rod
straight. If the piston rod is not straight, use new (12) to prevent damage to the piston rod (12).
parts as required.
33. Install a new O-ring (11) in the groove on the
18. Inspect the inside of the outer tube (17) for deep inside diameter of the piston (8).
grooves and other damage. If there is andy
damage to the outer tube, use new parts as 34. Lubricate the bore of the piston (8) with clean
required. hydraulic oil.

8006-25
15
14
17
8
11
10
9
13
7
16
12
2 6
5
4
1
3
BS01J194
1. GLAND 6. WIPER 11. O-RING 16. INNER TUBE
2. O-RING 7. LOCK NUT 12. ROD 17. OUTER TUBE
3. BACKUP RING 8. PISTON 13. BACKUP RING
4. O-RING 9. O-RING 14. BACKUP RING
5. BACKUP RING 10. BACKUP RING 15. O-RING
BACKHOE VERTICAL STABILIZER CYLINDERS

8006-26
NOTE: Refer to illustration on page 25. 40. Lubricate the O-ring (3) at the closed end of the
inner tube (16) with clean hydraulic oil.
35. Put the piston (8) on the end of the piston rod
(12). 41. Lubricate the inside of the outer tube (17) with
clean hydraulic oil.
36. Install a new lock nut (7) on the end of the piston
rod (12). Tighten the lock nut (7) to 122 to 135 42. Install the outer tube (17) over the inner tube
Nm (90 to 100 pound-feet). (16). Be careful to prevent damage to the O-ring
(15) at the closed end of the inner tube (16).
37. Install the backup ring (10) on the outside of the
piston (8). 43. Lubricate the inside of the inner tube (16).
38. Install the O-ring (9) and backup ring (13) on the 44. Start the gland (1) into the inner tube (16).
piston (8). Tighten the gland (1) to 237 to 271 Nm (175 to
200 pound-feet).
39. Fasten the closed end of the inner tube (16) in
the vise or other holding equipment. Be careful to 45. If the hoses were removed with the cylinder,
prevent damage to the inner tube (16). install new O-rings, if equipped, on the hose
fi tt in g s. L u b r ic a te t h e O - r in g s w i th c le a n
hydraulic oil. Install the hoses.

Section
8008
HIGH FLOW VALVE
8008
CASE CORPORATION
700 State Street Copyright © 2001 Case Corporation
Racine, WI 53404 U.S.A. Printed in U.S.A.
Bur 6-45580 September, 2001
8008-2
TABLE OF CONTENTS
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 8

8008-3
HIGH FLOW VALVE
Disassembly STEP 6
NOTE: Refer to illustration on page 7. Remove the solenoid fitting (7) and collar (42) from
the actuator body (8).
STEP 1
Loosen and remove the nut (1) and washer (2) from STEP 7
the top of the solenoid (3).
7
STEP 2
Remove the coil (3) from the solenoid valve cartridge
(4). 43
STEP 3
Loosen and remove the solenoid valve cartridge (4).
STEP 4 42
43
BS01K081
4
7. FITTING 42. COLLAR 43. O-RING
Remove the O-rings (43) from the solenoid fitting (7)
and collar (42).
STEP 8
5
10
8
5
BS01K097 9
4. SOLENOID CARTRIDGE
5. O-RING BS01K079
Remove the O-rings (5) from the cartridge (4). 8. BODY 9. SCREW 10. WASHER
Remove the four screws (9) and washers (10) from
STEP 5 the actuator body (8).
Repeat steps 1 through 4 for the other solenoid (6).
STEP 9
Remove the actuator body (8) from the valve body
(11).

8008-4
STEP 10 STEP 15
11
14 15
22 21
13 12
21
BS01K078
12. SPOOL ADAPTER 13. PISTON ROD 14. SPACER

SCREW 15. SPRING BS01K082
Loosen the spool adapter screw (12) slightly. 11. VALVE BODY 21. SCREW 22. RETAINER BOOT
Remove the bolts (21) holding the retainer boot (22)
STEP 11 from the valve body (11).
Remove the piston (38) and guide (40) assembly
from the spool adapter screw (12), by sliding the STEP 16
piston rod (13) end out of the spool adapter screw. Remove the retainer boot (22) from the valve body
(11).
STEP 12
Remove the spacer sleeve (14) from the spring (15) STEP 17
assembly.
11
STEP 13
16
25 24 23
BS01K082
12 17 11. VALVE BODY 24. SEAL

18 15 19 23. SEAL RETAINER 25. BACKUP WASHER
20
BS01K077 Remove the special washer (23) from the valve body
16. SPOOL 19. COLLAR
(11).
12. SPOOL ADAPTER
SCREW 17. SPACER 20. SEAL
15. SPRING 18. COLLAR RETAINER STEP 18
Remove the spool adapter screw (12) from the spool Remove the spool (16) from the valve body (11).
(16).
STEP 19
STEP 14 Remove the load check plug (26) from the valve
Remove the spacer (17), collar (18), spring (15), body (11).
collar (19), and seal retainer (20).

8008-5
STEP 20 STEP 26
Remove the poppet (27) and spring (not shown) from Remove the O-rings from the inlet cover (29) and
the load check plug (26). outlet cover (34) sealing surface.
STEP 21 STEP 27
Remove the relief cartridge (28) from the valve cover Remove the solenoid fitting (35) and collar (36) from
(29). the actuator body (8).
STEP 22 STEP 28
26 35
31
37
30 27
30 36
30
BS01K075
26. LOAD CHECK PLUG 30. O-RING

27. POPPET AND SPRING 31. BACKUP RING
the load check plug (26). 37
STEP 23 BS01K081
Remove the poppet and spring (27) from the load 35. SOLENOID FITTING 36. COLLAR 37. O-RING
check plug (26). Remove the O-rings (37) from the fitting (35) and
collar (36).
STEP 24
STEP 29
41 41
38 41
13
39
41 40
28 33 32 39
32
BS01K098
28. RELIEF CARTRIDGE 32. O-RING 33. BACKUP RING BS01K099
Remove the O-rings (32) and backup ring (33) from 13. PISTON ROD 39. RETAINING 40. GUIDE
the relief cartridge (28). 38. PISTON RING 41. O-RING
Remove the piston (38) and piston rod (13) from the
STEP 25 guide (39).
Loosen and remove the three bolts holding the inlet
cover (29), outlet cover (34), and valve body (11)
together.

8008-6
STEP 30 STEP 32
Remove the retaining ring (40) from the piston rod
(13) and remove the piston (38) from the rod. 11
STEP 31
Remove the O-rings (41) from the piston (38) and
guide (39).
25 24 23
BS01K082
11. VALVE BODY 24. SEAL

23. SEAL RETAINER 25. BACKUP WASHER
Remove the seals (24) and backup washers (25)
from both sides of the valve body (11).

8008-7
2 1
35
3
37
4 36
5 6 26
26 26
37
11
11
21
7
16
42
8 41
41 41 13 41
40
22
40 39
38
9 10
14 20
18 12 17 15 19
9 10 32 33
34 28
29 32
BS01K072
1. NUT 10. WASHER 19. COLLAR 28. RELIEF CARTRIDGE 37. O-RING
2. WASHER 11. VALVE BODY 20. SEAL RETAINER 29. INLET COVER 38. PISTON
3. SOLENOID 12. ADAPTER SCREW 21. BOLT 30. O-RING 39. GUIDE
4. CARTRIDGE 13. PISTON ROD 22. RETAINER BOOT 31. BACKUP RING 40. RETAINING RING
5. O-RING 14. SPACER SLEEVE 23. SPECIAL WASHER 32. O-RING 41. O-RING
6. SOLENOID 15. SPRING 24. SEAL 33. BACKUP RING 42. COLLAR
7. SOLENOID FITTING 16. SPOOL 25. BACKUP WASHER 34. OUTLET COVER 43. O-RING
8. ACTUATOR BODY 17. COLLAR 26. LOAD CHECK PLUG 35. SOLENOID FITTING
9. SCREW 18. SPACER 27. POPPET 36. COLLAR
HIGH FLOW VALVE

8008-8
Inspection STEP 41
STEP 33 41 41
Clean all parts in cleaning solvent. Use a lint free 38 41
13
cloth, or air dry the parts.
STEP 34
Inspect all springs and spring collars. Use new parts
as required. 39
41 40
39
STEP 35
Inspect the spool and valve cartridges for damage
and wear. Use new parts as required. BS01K099
13. PISTON ROD 39. RETAINING 40. GUIDE

STEP 36 38. PISTON RING 41. O-RING
Inspect the valve body sections for cracks, corrosion Install new O-rings (41) on the piston (38) and guide
and wear. Use new parts as required. (40).
STEP 37 STEP 42
Check all passaged for damage or obstructions. Install the piston (38) onto the piston rod (13) and
install the retaining ring (39).
STEP 38
Check the solenoid coils for damage or wear. Use STEP 43
new parts as required. Slide the guide (40) onto the piston rod (13).
Assembly STEP 44
STEP 39 35
Install new O-rings onto the inlet cover (29) and
outlet cover (34).
37
STEP 40
Assemble the inlet cover (29), valve body (11), and
outlet cover (34) in the correct order. Install the three
bolts and nuts that secure the covers and body
together. 36
37
BS01K081
35. SOLENOID FITTING 36. COLLAR 37. O-RING

Install new O-rings (37) onto the solenoid fitting (35)
and collar (36). Install the solenoid fitting (35) and
collar (36) onto the actuator body (8).

8008-9
STEP 45 STEP 50
11
25 24 23
BS01K082
28 33 32 11. VALVE BODY 24. SEAL

32 23. SEAL RETAINER 25. BACKUP WASHER
BS01K098
Install new seal (24) and backup washer (25) into the
28. RELIEF CARTRIDGE 32. O-RING 1. BACKUP RING
valve body (11) on the retainer boot (22) side.
Install new O-rings (32) and backup ring (33) onto
the relief cartridge (28). STEP 51
Lubricate the spool (16) with clean oil and install into
STEP 46 the valve body (11). Push the spool just past the
Install the relief cartridge (28) into the valve inlet bores for the backup washer (25) and seal (24).
cover (29).
STEP 52
STEP 47
11
26
31
25 24
23
30 27
30 BS01K082
30 11. VALVE BODY 24. SEAL
BS01K075 23. SEAL RETAINER 25. BACKUP WASHER
26. LOAD CHECK PLUG 30. O-RING Install a new seal (24) and backup washer (25) into
27. POPPET AND SPRING 31. BACKUP RING the valve body (11).
Install new O-rings (30) and backup rings (31) onto
the load check plug (26). STEP 53
Center the spool (16) in the valve body (11).
STEP 48
Place the spring and poppet (27) into the load check STEP 54
plug (26). Install the special washer (23) onto the valve body
(11) at the retainer boot (22) end.
STEP 49
Install the load check plug (26) into the valve body
(11).

8008-10
STEP 55 STEP 57
11
14 15
22 21
13 12
21
BS01K078
12. SPOOL ADAPTER 13. PISTON ROD 15. SPRING

BS01K082 SCREW 14. SPACER
11. VALVE BODY 21. SCREW 22. RETAINER BOOT Slide the spacer (14) over the spring (15). Install the
Install the retainer boot (22), and screws (21) onto piston rod (13) assembly onto the spool adapter
the valve body (11). screw (12) by sliding the piston rod into the screw.
STEP 56 STEP 58
Tighten the spool adapter screw (12) while making
sure the spacer (17) is positioned between the two
collars (18 and 19).
16
STEP 59
Lubricate the piston (38) and guide (40) with clean
oil.
12 17 19 STEP 60
18 15 20
BS01K077
12. SPOOL ADAPTER 16. SPOOL 19. COLLAR 10

SCREW 17. SPACER 20. SEAL 8
15. SPRING 18. COLLAR RETAINER
Apply a small amount of Loctite 242 on the threads of

the spool adapter (12). Install the seal retainer (20),
collar (19), spring (15), collar (18), spacer (17), and
spool adapter screw (12). Tighten the spool adapter 8 8
9
screw only 2 to 3 turns.
BS01K079
NOTE: Do not tighten the screw (12) completely.
8. BODY 10. WASHER 40. GUIDE
9. SCREW 38. PISTON
Carefully slide the actuator body (8) over the piston
(38) and guide (40).
STEP 61
Install the washers (10) and screws (9) into the body
(11).

8008-11
STEP 62 STEP 66
Install the washer (2) and nut (1) onto the solenoid
( 3 ) . Tig h t e n t h e n u t 1 . 7 to 3 . 4 N m ( 1 5 t o 3 0
pound-inches).
STEP 67
Repeat steps 62 through 66 for the other solenoid
(6).
4
STEP 68
7
43
5
42
5
BS01K097
4. SOLENOID CARTRIDGE
5. O-RING
Install new O-rings (5) onto the solenoid cartridge (4).

43
STEP 63
BS01K081
Install the solenoid cartridge (4) onto the actuator
7. FITTING 42. COLLAR 43. O-RING
body (8).
Install new O-rings (43) on the solenoid fitting (7) and
STEP 64 collar (42). Install the collar and fitting onto the
Tighten the solenoid cartridge (4) 20.4 to 27 Nm (180 actuator body (8).
to 240 pound-inches).
STEP 65
Place the solenoid coil (3) onto the cartridge (4).

8008-12
NOTES

8012
Section
8012
D125 BACKHOE CONTROL VALVE -

NORTH AMERICA ONLY
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 7-54690 September, 2001
8012-2
TABLE OF CONTENTS
SEPARATING THE PARTS OF THE BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CIRCUIT RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLING THE PARTS OF THE BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8012-3
SEPARATING THE PARTS OF THE BACKHOE CONTROL VALVE

STEP 1 STEP 4
2
1
3
B9109704M B9109708M
1. 2.4 MM (0.094 INCH)
Remove the nut from the Allen head screw.
2. 1.9 MM (0.073 INCH)
3. 3.5 MM (0.138 INCH)
STEP 5
Put the backhoe control valve on a clean bench.
Remove the five restrictors from the ports shown.
STEP 2
B9109709M
Turn the spool and remove the control stud from the
spool. Also remove the Allen head screw from the
next spool.
B9109705M
Pull up the boots on the control levers. STEP 6

STEP 3
B9109710M
Remove the Allen head screws that fasten the

B9109707M mounting plate to the housing.
Remove the nut from the control stud.

8012-4
STEP 7 STEP 10
B9109711M B9109713M
Re move the mou nting plate and co ntro l leve r Remove the cotter pin and pin from the spool.
assembly. Remove the stabilizer control lever from t he backhoe
control valve.
STEP 8
Repeat steps 2 through 7 to remove the control elver STEP 11
assembly from the other side of the backhoe control Repeat steps 9 and 10 to remove the other stabilizer
valve. control lever.
STEP 9 STEP 12
B9109712M B9109716M
Remove the cotter pin from the bottom of the link. Loosen the Allen head screws from the check valve
assemblies.

8012-5
STEP 13 STEP 16
B9109717M B9109720M
Remove the Allen head screws and check valve Separate the valve sections.
assemblies.
STEP 17
STEP 14
B9109721M
B9109718M Remove the sleeves from the valve section.

Remove the O-rings for the check valve assemblies.
STEP 15
B9109719M
Remove the nuts and bolts that fasten the valve

sections together.

8012-6
2 1
2 2
0
3
15
6
6
16 5
1
1
16
5
4 12
4
A
11 14
8 13 8
10
7
4
10 6
B
B
A
BS97H157
1. KNOB 6. ALLEN HEAD SCREW 11. LEFT STABILIZER CONTROL LEVER
2. BOOT 7. BALL JOINTS 12. RIGHT STABILIZER CONTROL LEVER
3. SWING AND BOOM CONTROL LEVER 8. CONTROL STUD 13. LINK
4. NUT 9. SPACER 14. BELLCRANK
5. PLATE 10. MOUNTING PLATE 15. BUCKET AND DIPPER CONTROL LEVER
16. WAVE WASHER

8012-7
VALVE SECTION STEP 20

The two valve sections are the same except the inlet
section has the main relief valve and two circuit relief
valves. See the illustration on page 11 for the inlet
section. The outlet section has only one circuit relief
valve. See the illustration on page 12 for the outlet
section.
The following procedure shows the disassembly and
assembly of the inlet section.
STEP 18
B9109724M
Pull the spool from the housing. Put an identification

tag on the spool so that the spool can be installed in
the correct bore when the section is assembled.
STEP 21
Repeat steps 18 through 20 to remove the other two
spools.
STEP 22
B9109722M
Remove the Allen head screws from the spool cap.
STEP 19
B9109725M
Loosen the circuit relief valve.
STEP 23
B9109723M
Remove the spool cap.
B9109726M
Remove the circuit relief valve.

8012-8
STEP 24 STEP 27
B9109727M B9109730M
Turn the housing around and loosen the main relief Remove the circuit relief valve.
valve.
STEP 28
STEP 25
B9068703M
B9109728M Remove the O-rings from each end of the spool

Remove the main relief valve. bores.
STEP 26 STEP 29
B9109729 B9109732M
Loosen the other circuit relief valve. Remove the plug for the load check valve.

8012-9
STEP 30
B9109733M
Remove the spring and load check poppet.
STEP 31
Repeat steps 29 and 30 to remove the other plugs
and load check parts.
STEP 32
Fasten the spool in a vise with soft jaws. Loosen the
stud.
STEP 33
B9068907M
Remove the stud, spring seat, spring, and washer

from the spool.
STEP 34
Repeat steps as necessary for the other spools.

8012-10
7 28 9
10 9
11
10 11
7
4 12
12 18
5
7 13
7
6 9 20
7 11
1 7 7
14 15
30 7 22 22
2 14
3 19
7 21
22 8
9
7 18
7
7
29 17
7 16
14 14 12
30
23 14 11
13 7 7
24
9
12 11
25
7
26
10 27
11
20
9 10
BS97H158
1. BOOM SPOOL 9. PLUG 17. SPACER 24. WASHER
2. SWING SPOOL 10. SHIMS 18. SEAT 25. SPRING SEAT
3. LEFT STABILIZER SPOOL 11. SPRING 19. CHECK VALVE BODY 26. STUD
4. FINAL ADJUSTING SCREW 12. POPPET 20. ALLEN HEAD SCREW 27. SPRING CAP
5. LOCK NUT 13. CIRUCIT RELIEF BODY 21. PLUNGER 28. CAP
6. MAIL RELIEF CARTRIDGE 14. BACKUP RING 22. RESTRICTOR 29. HOUSING
7. O-RING 15. LOAD CHECK POPPET 23. SLEEVE 30. PLUG
8. BACKUP RING 16. STEEL BALL

8012-11
11
9
6 12
17
1 2
3
9
4 8 18
5 11
14 9 27
19
8
20
9
8 17
21
9
16
15
9 12
8 6
14 8 11
13 9 9
23 8
12 11
24
9
25
10 26
11
18
8 10
BS97H159
1. RIGHT STABALIZER SPOOL 9. O-RING 16. SPACER 23. ALLEN HEAD
2. DIPPER SPOOL 10. SHIMS 17. SEAL SCREW
3. BUCKET SPOOL NUT 11. SPRING 18. ALLEN HEAD SCREW 24. SPRING SEAT
4. LOCK WASHER 12. POPPET 19. CHECK VALVE BODY 25. STUD
5. WASHER 13. CIRCUIT RELIEF BODY 20. PLUNGER 26. SRPING CAP
6. BOLT 14. BACKUP RING 21. LOAD CHECK POPPET 27. RESTRICTOR
7. INLET SIDE OF BACKHOE 15. STEEL BALL 22. HOUSING
8. PLUG

8012-12
Inspection STEP 38
Clean the parts in cleaning solvent. Inspect the 1 2
housing for cracks, wear in the spool bores, or other
damage. 1
STEP 35
B9068824M
1. O-RING
2. BACKUP RING
Re place the O-ring s a nd ba cku p ring s o n th e

sleeves.
B9068834M
STEP 39
Inspect the spools for wear and damage.
1
STEP 36 2
B9109734M
1. O-RING
2. BACKUP RING
B9068828M Replace the O-rings and backup rings on the main

Inspect the parts of the load check valves. relief valve.
STEP 37
B9068830M
Replace the O-ring on the plug.

8012-13
STEP 40 Assembly
1 Do the reve rse of d isa sse mbly ex cep t for th e
2
following steps. These steps will prevent damage to
1 the spool O-rings.
1. Do not assemble the washer, spring, spring seat
and stud on the spool.
2. Install a new O-ring at the top of the spool bore.
3. Lubricate the spool and install the spool from the
bottom. Push the spool into the bore until the
O-ring can be installed in the bottom. Install a
new O-ring in the groove at the bottom of the
spool bore.
B9068822M
1. O-RING
2. BACKUP RING
Replace the O-rings and backup rings on the main

relief valve.
CHECK VALVE ASSEMBLY
Disassembly STEP 42
NOTE: The components for the check valve
assembly are not the same at both ends so make
sure that the parts are kept in the order that they
were removed.
STEP 41
B9068724M
Remove the plug.
STEP 43
B9068721M
Fasten the check valve assembly in a vise with soft

jaws. Loosen the plug at one end of the check valve
assembly.
B9068727M
Remove the spring.

8012-14
STEP 44 Inspection
1 STEP 45
3
2
4
B9068810M
Replace the O-ring on the seat.

7
STEP 46
5
6
10
2 8
3 B9068813M
Replace the O-ring on the plug.
Assembly
1 STEP 47
BS97H160
Lubricate the poppets, steel ball, spacer, plunger,
1. PLUG 6. BODY
2. O-RING 7. PLUNGER
and O-rings on the seats with clean hydraulic oil.
3. SPRING 8. STEEL BALL Install the plunger, spacer, steel ball, seats, and
4. POPPET 9. SHORT POPPET poppets in the check valve body. The seats must be
5. SEAT 10. SPACER installed with the flat side toward the outside. See the
illustration on this page for correct assembly.
Remove the poppets, steel ball, spacer, plunger, and
seats from the body.

8012-15
STEP 48 STEP 50
B9068727M B9068721
Install the spring on the poppet . Tighten the plug.
STEP 49 STEP 51
Repeat steps 48, 49, and 50 for the other end of the
body.
B9068724M
Lubricate the O-ring with clean hydraulic oil. Install

the plug.

8012-16
MAIN RELIEF VALVE

STEP 52 Most of the parts in the main relief valve are not
available for service. You can replace the O-rings,
5 backup rings, lock nut and adjusting screw. If you
cannot adjust the main relief valve, use a complete
new main relief valve.
4
1
3
1
2
BS97H161
1. O-RING 4. LOCK NUT
2. BACKUP RING 5. ADJUSTING SCREW
3. BODY
CIRCUIT RELIEF VALVE

STEP 53 STEP 54
B9068709M B9068712M
Fasten the circuit relief valve in a vise with soft jaws. Remove the plug.
Loose the plug.

8012-17
STEP 55 STEP 58
B9068815M B9068815M
Separate the parts of the circuit relief valve. Install the poppet, shims, spring, and shims in the
circuit relief body.
STEP 56
STEP 59
B9068819M
Replace the O-ring on the plug. B9068709M
Lubricate the O-ring on the plug. Install the plug in

STEP 57 the body.
1
2
1
B9068819M
1. O-RING
2. BACKUP RING
Replace the O-rings and backup rings on the circuit

relief body.

8012-18
ASSEMBLING THE PARTS OF THE BACKHOE CONTROL VALVE
STEP 60 STEP 63
1 2
1
B9068824M B9109719M
1. O-RING Install the bolts and nuts to fasten the sections
2. BACKUP RING
together. Tighten to a torque of 11 to 14 Nm (96 to
Re place the O -ring s a nd ba ckup ring s o n th e 120 pound-inches.
sleeves.
STEP 64
STEP 61
B9109718M
B9109721M Install new O-rings for the check valve assemblies.

Lubricate the O-rings and backup rings on the
sleeves with clean hydraulic oil. Install the sleeves in STEP 65
the housing.
STEP 62
B9109717M
Install the check valve assemblies.
B9109720M
Put the two sections together.

8012-19
STEP 66 STEP 69
B9109716M B9109711M
Tighten the Allen head screws to a torque of 5 to 8 Install the control lever assembly and bracket on the
Nm (48 to 72 pound-inches). valve.
STEP 67 STEP 70
B9109714M B9109710M
Install the stabilizer control levers in the center two Install the Allen head screws to fasten the bracket in
spools. place.
STEP 68 STEP 71
1
B9109712M B9109709M
Install the cotter pins. 1. ALLEN HEAD SCREW 2. CONTROL STUD
Install the Allen head screw in the ball joint and

spool, then rotate the outer spool and install the
control stud.

8012-20
STEP 72 STEP 75
B9109708M B9109706M
Install and tighten the nut on the Allen head screw. Install the boots.
STEP 73 STEP 76
1 2
3
B9109707M B9109704M
1. 2.4 MM ORIFICE (0.094 INCH)
Install and tighten the nut on the control stud.
STEP 74
Install the restrictors in the correct ports. Install the
Use a similar procedure to install the control lever on
restrictors with the slotted side out.
the other side.

SECTION INDEX
MOUNTED EQUIPMENT

Pedals and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Attachment Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
ROPS Canopy, Seat, Seat Belts, and Operators Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Backhoe (D - 125 Backhoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007

CASE CORPORATION
9001
Section
9001
PEDALS AND LEVERS

9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THROTTLE CONTROL LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Throttle Lever Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hand Throttle Adjustment (Without Foot Throttle Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hand Throttle Adjustment (With Foot Throttle Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Foot Throttle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LOADER CONTROL LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fore/Aft Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader and Bucket Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LAP BAR HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AUXILIARY HYDRAULIC PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DRIVE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking the Drive Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9001-3
SPECIFICATIONS
Number of Teeth on the Flywheel.................................................................................................................159 teeth
Engine Speeds
Low Idle ......................................................................................................................................... 950 r/min (rpm)
High Idle ....................................................................................................................................... 2450 r/min (rpm)
Drive Chain Tension .............................................................................. 3 to 12 mm (1/8 to 1/2 inch) Total Deflection
Loosest Position ....................................................................................................... 40 mm (1-1/2 inch) Maximum
SPECIAL TORQUES
Drive Wheel Nuts...................................................................................................... 135 to 163 Nm (100 to 120 lb-ft)
Axle Mounting Bolts.................................................................................................. 223 to 265 Nm (165 to 195 lb-ft)
Drive Chain Inspection Covers ................................................................................... 125 to 150 Nm (93 to 112 lb-ft)
Drive Chain Retaining Plate Center Bolt .................................................................. 247 to 320 Nm (185 to 235 lb-ft)

9001-4
1
2
4
3
10
5
9
7 7
9 8 8
16
12
14
13
11 15
HI01E006
1. THROTTLE CONTROL LEVER 5. THROTTLE LEVER 9. FRICTION DISC 13. FOOT THROTTLE CABLE
2. NUT 6. THROTTLE LEVER (70XT) 10. RUBBER WASHER 14. CLEVIS
3. WASHER 7. BALL JOINT 11. THROTTLE PIVOT 15. MOUNTING BRACKET
4. THROTTLE ROD 8. JAM NUT 12. FOOT THROTTLE PEDAL 16. LINKAGE CONTROLLER
THROTTLE LEVER

9001-5
THROTTLE CONTROL LINKAGE ADJUSTMENT
Throttle Lever Tension Adjustment Hand Throttle Adjustment (With

The tension adjusting nut (2) for the throttle lever (1) Foot Throttle Option)
is to compress the rubber washer (10) to cause a The adjustment procedure for the hand throttle when
resistance to hold the throttle lever in the position the foot throttle option is present is very similar to the
selected. procedure without the foot throttle.
The tension adjusting nut (2) is not to be so tight the 1. Disconnect the foot throttle cable from the
throttle lever is difficult to move. linkage controller so that the only input to the
controller is from the hand throttle.
Hand Throttle Adjustment (Without
2. Place the hand throttle lever in the rearmost
Foot Throttle Option) position against the rear of the slot in the controls
The 40XT and 60XT Skid Steers currently use a cover.
Bosch "VE" injection pump and the 70XT Skid Steers 3. Verify the throttle lever on the injection pump is in
currently use a Bosch "A" injection pump. They have the low idle position. This is when the throttle
an integrated over-stroke protection device to protect lever is rotated clockwise until it rests on the low
the internals of the pump from excessive throttle idle stop.
lever motion or loading. These designs are more
forgiving of excessive lever stroke and incorrect 4. Adjust the ball joints at each end of the throttle
adjustment. The adjustment for this configuration rod such that the lever rests against the low idle
starts with the low idle adjustment. Note the throttle stop. Because the hand throttle does not directly
rod ball joint that connects to the hand throttle lever control the rod in this configuration, it is not
attaches to the hole farthest from the throttle pivot. possible to have the rod force the injection pump
lever into a slight over-stroke condition. The
1. Place the hand throttle lever in the rearmost return spring is the only direct returning force on
position against the rear of the slot in the controls the rod.
cover.
5. Pull the hand throttle lever forward to the front
2. Verify the throttle lever on the injection pump is in end of the slot and observe the motion of the
the low idle position. This is when the throttle injection pump throttle lever. The lever should
lever is rotated clockwise until it rests on the low rotate counterclockwise until it contacts the high
idle stop. idle stop. The lever should continue to move into
3. Adjust the ball joints at each end of the throttle the over-stroke zone to insure high idle can be
rod such that the lever is held firmly against the achieved and held.
low idle stop. It is acceptable to have the rod 6. Return the hand throttle lever to the low idle
force the injection pump lever into a slight position to ensure the low idle adjustment is still
over-stroke condition. correct.
4. Pull the hand throttle lever forward to the front 7. Tighten the jam nuts on the ball joints to maintain
end of the slot and observe the motion of the the adjustment and verify correct contact with the
injection pump throttle lever. The lever should high and low idle stops on the injection pump.
rotate counterclockwise until it contacts the high
idle stop. The lever should continue to move into 8. Proceed to and complete the foot throttle
the over-stroke zone to insure high idle can be adjustment procedure.
achieved and held.
5. Return the hand throttle lever to the low idle
position to ensure the low idle adjustment is still
correct.
6. Tighten the jam nuts on the ball joints to maintain
the adjustment and verify correct contact with the
high and low idle stops on the injection pump.

9001-6
Foot Throttle Adjustment 3. Lower the foot pedal down until it is setting on the
footrest on the floor plate.
The adjustment of the foot pedal in the foot throttle
option is the last adjustment made to the system. To 4. Move the hand throttle to the full throttle (high
be properly adjusted the hand throttle must be idle) position.
correctly set prior to any foot pedal adjustment. 5. Check the alignment of the clevis pin hole to the
1. At assembly set all cable related adjustments to hole in the linkage controller.
nominal (mid-point) locations. This includes the 6. Adjust the clevis, clevis end bulkhead
ball joint, clevis, bulkhead connections, and connection, and clevis end mounting bracket to
mounting brackets. Assemble the ball joint to the get the clevis pin installed properly.
foot pedal, but DO NOT connect the clevis to the
linkage controller. 7. Move the hand throttle lever back to the low idle
position and verify the foot pedal rises up from
2. Raise and lower the foot pedal to check for the foot rest and the throttle rod returns the
binding with the floor plate. Correct any binding engine to low idle.
problems as needed.

9001-7
CONTROL LOCK ADJUSTMENT PROCEDURE

IMPORTANT: When performing the following NOTE: The photo below shows the ROPS in the
procedure, the loader lift arms must be in the down tilted position for photo clarity.
position with the attachment resting on the ground.
STEP 3
STEP 1
2
1
2
1
BD01J001
1. CONTROL SHIFT BELL CRANK
BD01C102
1. ACCESS DOOR
Reach through the access door opening and place a
2. THUMBSCREWS
finger on the control shift bell crank (1).
Make sure the ROPS is in the operating position.
Remove the two thumbscrews (2) from the access STEP 4
door (1) located on the right rear corner of the ROPS.
Remove the access door (1) from the ROPS.
STEP 2
1
BDO1C168
1. CONTROL LEVER
Have the person sitting in the operators seat move

one of the control levers (1) from the neutral position
BD01C168 inward and outward to the extent of the travel of the
1. RESTRAINT BAR IN OPERATING POSITION
control lever. Check for movement of the control shift
Have another person sit in the operators seat. With bell crank as indicated in the photo in Step 3. If any
the ignition switch in the OFF position, move the movement is detected proceed with Step 6. If no
restraint bar down to the operating position. movement is detected proceed with Step 5.

9001-8
STEP 5 STEP 7
3
2
1
1
2
BD01J007 BD01J003
1. CHASSIS INDEX HOLE 1. ADJUSTMENT BOLT
2. INDEX BOLT 2. CONTROL SHIFT BELL CRANK
3. BRAKE PIVOT INDEX HOLE
Loosen the jam nut on the adjustment bolt (1).
Install a 8 mm diameter by 50 mm long bolt through Tighten the adjustment bolt (1) until there is no free
the index hole in the side of the chassis. If the bolt movement of the control shift bell crank (2). Tighten
will align with the index hole in the brake pivot then the jam nut on the adjustment bolt (1).
the adjustment is correct. Proceed with the Loader
Controls Adjustment Procedure on page 10. If the STEP 8
bolt will not align with the index hole in the brake
pivot, proceed with Step 6. 2
STEP 6
1
BD01J002
1. INDEX BOLT
1 2. BRAKE PIVOT
2 Use acceptable tools to move the brake pivot until
BD01J002 the index bolt can be removed.
1. CHASSIS INDEX HOLE
2. INDEX BOLT
4. BRAKE PIVOT
Remove the attachment from the loader lift arms and

raise the loader lift arms. Install the loader lift arm
support strut. Loosen and remove the two mounting
bolts from the rear of the ROPS and tilt the ROPS
forward. Install a 3/8 inch diameter by 1 3/4 inch long
bolt through the index hole (1) in the chassis. Use
acceptable tools to hold the brake pivot (4) in position
to allow the bolt (2) to align with the index hole (3) in
the brake pivot (4).

9001-9
STEP 9 STEP 10
Lower the ROPS into the operating position. Install
and tighten the two mounting bolts at the rear of the
3
ROPS
1 1
2
BD01J007
1. CHASSIS INDEX HOLE
2. INDEX BOLT
Attach acceptable lifting equipment to the ROPS.

Close the ROPS to the mid point. Re-install the index 2
bolt (2) through the chassis index hole (1) and into
the brake pivot index hole (3).
HS01E002
1. RESTRAINT BAR BRAKE ROD
2. BRAKE PIVOT
STEP 11
Lower the restraint bar. If the restraint bar brake rod
(1) is free to move, loosen the jam nuts on the
restraint bar brake rod (1) and adjust it downward to
contact the brake pivot (2). Raise the restraint bar
an d tigh te n th e re stra in t b ar bra ke ro d ( 1) a n
additional 1 1/2 turns. Tighten the jam nuts on the
restraint bar brake rod (1). Lower the restraint bar
and check for correct operation. If operation is
correct remove the index bolt from the side of the
chassis.
STEP 12
Remove the loader lift arm support strut and lower
the loader lift arms to the ground.
STEP 13
Verify the adjustment is correct by re-testing using
Steps 2 through 4.

9001-10
LOADER CONTROL ADJUSTMENT PROCEDURE
Fore and Aft Adjustment STEP 3
STEP 1
BD01J008
1. FORE AND AFT POSITION CONTROL ROD
BD01J004
Pull the control handle rubber boot up to access the
Make sure the ROPS is in the operating position. control linkage. Loosen the jam nuts on the fore and
Place a 25.4 mm (1.0 inch) bar through the side aft position control rod (1) and turn the control rod (1)
screen on the ROPS in the first row from the front until the proper measurement is obtained. Tighten
and five rows up from the bottom as indicated in the the jam nuts on the control rod (1). Repeat the same
photo above. Slide the bar towards the rear of the p r o c e d u r e f o r th e o p p o s it e c o n t r o l h a n d l e if
machine on both sides until it comes in contact with adjustment is required.
the divider for the next row.
STEP 2
BD01J005
1. 12 MM (0.47 INCHES) +/- 6 TO 8 MM (0.24 TO 0.31 INCHES)
Measure the distance from the edge of the bar to the

handles as shown in the photo above. The distance
should be 12 mm (0.47 inches) +/- 6 mm to 8 mm
(0.24 to 0.31 inches). If the handle position is correct,
proceed with Step 3. If the measurement is not within
the specifications do the following procedure in Step
3.

9001-11
Loader and Bucket STEP 3

Control Adjustment
STEP 1
Make sure the ROPS is in the operating position.
Enter the operators compartment and sit in the
operators seat and pull the restraint bar down to the
operating position. Turn the ignition switch to IGN to
release the loader control spool interlocks.
STEP 2 1
1 BD01J008
1. OUTER CONTROL ROD
Pull the control handle rubber boot up to access the

control linkage. Loosen the jam nuts on the outer
control rod (1) and turn the control rod (1) until the
proper measurement is obtained. Tighten the jam
nu ts on th e c on tro l ro d (1) . R ep ea t th e sa me
p r o c e d u r e f o r th e o p p o s it e c o n t r o l h a n d l e if
adjustment is required.
BD01J006
1. 25 TO 40 MM (0.98 TO 1.57 INCHES)
Move the left control handle to the full forward and

full outward position. Measure the distance between
the handle and the ROPS front post as shown in the
photo above. The clearance should be 25 to 40 mm
(0.98 to 1.57 inches). Repeat the same procedure for
the opposite control handle. If the measurement is
no t with in th e sp ec ifica tion s do t he fo llow in g
procedure.

9001-12
Control Adjustment STEP 3

Restraint Bar Clearance
STEP 1
Make sure the ROPS is in the operating position. 1
Enter the operators compartment and sit in the
operators seat and pull the restraint bar down to the
operating position. Turn the ignition switch to IGN to
release the loader control spool interlocks.
STEP 2
Move the left hand control handle into the float
position and move the handle back to the full reverse BD01J008
1. STRAIGHT TRACKING SET SCREW
position. If the handle does not make contact the
restraint bar while maintaining the float position, the Pull the control handle rubber boot up to access the
adjustment is correct. If the handle makes contact control linkage. Loosen the jam nut on the straight
with the restraint bar, do the following adjustment tracking set screw (1). Loosen the set screw (1) until
procedure. the pump trunnion will act as the stop for the control
lever in the full reverse position. With the handle in
the full reverse position, adjust the set screw (1) until
it makes contact with the ball joint. Tighten the set
screw (1) finger tight only at this point.
STEP 4
Release the control handle. Tighten the set screw (1)
an additional three turns. Tighten the jam nut on the
set screw (1).
STEP 5
Repeat Steps 1 through 4 for the opposite control
handle.

9001-13
3
8
7
2
5
6
HS01E002
1. LAP BAR LINKAGE 4. INSERT ROD 7. CAM PLATE
2. LOADER LINKAGE 5. BRAKE PIVOT 8. CONTACT LINK
3. GROUND DRIVE LINKAGE 6. CONTROL SHIFT CRANK 9. BUCKET LINKAGE
ADJUSTMENT SCREW
LOADER CONTROL LINKAGE

9001-14
7
6
1
5
6
5 3 7
5
6 2
6 5 4
5
6
6
5
5
8
8 6
5
6
10
BC01J097
1. LH CONTROL LEVER (STANDARD) 5. JAM NUT 9. LH FRAME

2. RH CONTROL LEVER (STANDARD) 6. SET SCREW 10. RH FRAME
3. LH CONTROL LEVER (DELUXE) 7. BOOT ADAPTER
4. RH CONTROL LEVER (DELUXE) 8. BALL JOINT
EXPLODED VIEW OF CONTROL HANDLES

9001-15
LAP BAR HEIGHT ADJUSTMENT
HS01E003
1. ADJUST TO 743 MM (29-1/4 IN) 3. LAP BAR
2. ADJUSTING SCREW 4. CROSSMEMBER
1. Measure the distance from the bottom of the 2. Loosen the nut on the adjusting screw (2) on
crossmember (4) of the ROPS frame to the flat each side of the frame and adjust the screw as
spot with the molded seat belt sign on the lap bar needed to obtain the correct measurement.
(3) when the lap bar is in the operating position. Tighten the nuts on the adjusting screws.
This distance (1) must be 743 mm (29-1/4 in).

9001-16
AUXILIARY HYDRAULIC PEDAL
2
1
HI01E001
1. AUXILIARY HYDRAULIC PEDAL 4. AUXILIARY CONTROL CABLE

2. AUXILIARY HYDRAULIC PEDAL LOCK LEVER 5. EQUIPMENT CONTROL VALVE
3. CABLE ADJUSTMENT NUTS
NOTE: Make sure the auxiliary spool in the control valve is in the neutral position. Adjust the cable until the
auxiliary hydraulic pedal is in the horizontal position.

9001-17
DRIVE CHAINS
Checking the Drive Chain Tension

Check the tension of the four drive chains after the
first 250 hours of operation on a new machine or new
chains. Then, check the tension after every 1000
hours of operation.
1. Lower the loader bucket or attachment to the
ground. Turn the key switch to OFF and stop the
engine.
2. Use a jack or hoist and lift the machine. Install
blocks or axle stands under the machine.
1 BD01C252
5. Remove the brake disc.
BD01C103
1. DRIVE CHAIN INSPECTION COVER
3. Clean the area around both drive chain

inspection covers. Loosen and remove the bolts
from the covers and remove the covers from the BD01C253
machine. 6. Rotate the rear wheel in a rearward direction and
hold while you check the deflection of the chain
on the slack side.
NOTE: The deflection of the chains cannot be
measured with accuracy.
7. Move the chain up and down and measure the
deflection as close as possible.
IMPORTANT: If the deflection is more than 40.0 mm
(1.5 inch) total movement for one chain, adjust the
deflection of all chains. See Drive Chain Tension
Adjustment on page 13 of this section.
BD01C261 8. Repeat the procedure for the front wheel while
4. Loosen and remove the center bolt and the moving the front wheel in a forward direction.
retaining plate.

9001-18
BD01C251 BD01C258
9. Install the brake disc, retaining plate and center 11. Apply sealant between gasket, cover and
bolt. chassis.
12. Install the inspection covers. Tighten the
inspection cover bolts to a torque of 125 to 150
Nm (93 to 112 lb-ft).
13. Follow the same procedure for the opposite side
of the machine.
BD01C259
10. Tighten the center bolt to a torque of 247 to 320

Nm (185 to 235 lb-ft).

9001-19
Drive Chain Tension Adjustment
1 1
BD01C265
6. Loosen the axle housing mounting nuts so the

BD01C274
1. AXLE HOUSING axle is free to move forward or rearward.
1. Lower the bucket or attachment to the ground

and stop the engine.
2. Use a jack or hoist and lift the machine. Install
blocks or axle stands under the machine as
sho wn. R ais e lo ad er lift arms a nd eng ag e
support strut. Remove the wheels.
3. Clean the area around each axle housing.
BD01C267
7. Insert a pry bar against the adjusting spud and

the axle housing.
8. Pry against the axle housing until it stops
mov in g . Tigh ten tw o n uts to h o ld th e a xle
housing in place.
BD01C257
4. Remove the inspection covers.
BD01C253
9. Recheck the chain deflection following the

procedure on page 11 of this section.
BD01C261
5. Loosen and remove the center bolt and the

retaining plate.

9001-20
BD01C266 BD01C258
10. When the deflection is 3 to 12 mm (1/8 to 1/2 20. Install the inspection covers. Tighten the
inch), tighten the axle housing mounting nuts to a inspection cover bolts to a torque of 125 to 150
torque of 7 Nm (5 lb-ft). Nm (93 to 112 lb-ft).
11. Repeat the above steps for the remaining drive
chains.
12. Following adjustment of all drive chains, start the
engine and run at low idle.
13. Move the control levers all the way forward for
five seconds. Stop the engine.
14. Check the deflection of all four drive chains. The
d r ive c h a in s a r e c o rr e c tly a d ju s te d if t h e
deflection is 3 to 12 mm (1/8 to 1/2 inch).
15. If required, tighten or loosen the drive chains to
get the correct deflection. BD01C268
21. Install the four wheels and tighten the wheel nuts
16. Tighten the axle housing mounting bolts to a to a torque of 135 to 163 Nm (100 to 120 lb-ft).
torque of 223 to 265 Nm (165 to 190 lb-ft).
22. Remove the blocks or stands and lower the
17. Install the brake disc, retaining plate and center machine to the floor.
bolt.
BD01C259
18. Tighten the center bolt to a torque of 247 to 320

Nm (185 to 235 lb-ft).
19. Apply RTV sealant between gasket, cover and
chassis.

9002
Section
9002
LOADER
60 / 70XT SKID STEER

9002-2
TABLE OF CONTENTS
REPLACING THE CUTTING EDGE ON 60 / 70XT BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacing Welded Cutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacing Bolt-On Cutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WELD SPECIFICATIONS FOR 60 / 70XT BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL OF THE 60 / 70XT LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION OF THE 60 / 70XT LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION OF THE 60 / 70XT LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

9002-3
REPLACING THE CUTTING EDGE ON 60 / 70XT BUCKETS
Replacing Welded Cutting Edges 5. Position a new cutting edge on the bucket. Use
C-clamps to hold the cutting edge in proper
1. Raise the bucket to an acceptable height and position.
place supports to hold the bucket in position.
6. See page 4 for weld specifications for the bucket
2. Use carbon arc rod or an acetylene torch to be ing repa ire d. Use E70 18 w eldin g rod or
remove the welds that hold the cutting edge. Be equivalent welding wire.
careful not to distort the bucket while cutting the
welds. Replacing Bolt-On Cutting Edges
3. When removing the weld at the rear of the cutting
7. Raise the bucket to an acceptable height and
edge, do not cut through the bottom of the
place supports to hold the bucket in position.
bucket.
8. Remove the nuts, plow bolts, and cutting edge
from the bucket.
9. Install the new cutting edge, plow bolts and nuts
to the bucket.
BD01C061
1. CUTTING EDGE TO BE REMOVED
4. After the cutting edge has been removed, use a

grinder to remove any welds or extra metal on
the bucket that will prevent a new cutting edge
from fitting correctly.

9002-4
WELD SPECIFICATIONS FOR 60 / 70XT BUCKETS

60 / 70XT Buckets
1. 86618349 4. 86618352 7. 86618353 10. 86618357 13. 86618360
2. 86618350 5. 86618363 8. 86618354 11. 86618358 14. 86618361
3. 86618351 6. 86618364 9. 86618355 12. 86618359
1 2
3
BT97G325
3. 6 MM (1/4 INCH) GROOVE 6

1. 10 MM (3/8 INCH) FILLET
MM (1/4 INCH) FILLET
(WELD TWICE 1 ROOT PASS 1
(WELD TWICE -WRAP
COVER PASS)
ENDS)
2. 6 MM (1/4 INCH) FILLET (WELD
4 TIMES)
REMOVAL OF THE 60 / 70XT LOADER FRAME

NOTE: Refer to illustration on page 6. 8. Relieve any pressure from the hydraulic system
by turning the key switch to the “on” position and
1. Park the machine on a level surface.
move the hydraulic bypass control lever to the
2. Remove the bucket from the loader frame (1), bypass position and move the loader control
refer to Operators Manual. levers in both directions.
3. Clean any dirt and grease from the hydraulic 9. Tag all hydraulic lines and couplings for use
connections for the bucket and lift cylinders. during assembly procedure.
4. Claean any dirt and grease from the hydraulic 10. Loosen and remove all the hydraulic lines that
connections for the auxiliary hydraulic circuits at pass through both uprights of the chassis.
the rear of the machine.
11. Plug and cap the fittings and couplings to
5. Attach acceptable lifting slings to the loader arms minimize the loss of hydraulic oil and to prevent
(1) on each side of the loader frame towards the con tamina tion from e nte rin g the hyd ra ulic
rear of the machine. system.
6. Attach an acceptable lifting sling to the center of 12. Remove the rubber retaining rings (if equipped)
the tube between the loader arms (1). from the hydraulic couplings on each side of the
uprights and push the hydraulic couplings into
7. Attach the lifting slings to acceptable lifting
the center of the uprights.
equipment.

9002-5
13. Remove the snap ring (10), washer (11), and pin 15. Loosen and remove the bolt (5) and lock nut (6)
(7) from the loader frame (1). Use an acceptable from the right loader arm pivot pin (7). Use
support and attach the lift cylinder to the loader acceptable tools and remove the pivot pin (7).
frame.
16. Follow the procedure in step 14 to remove the
14. Follow the procedure in step 12 and remove the left loader arm pivot pin (7).
left side lift cylinder pivot pin (1).
17. Use lifting equipment and remove the loader
frame (1) from the chassis.

9002-6
2 5
7 14
14
14 13
6 14 14
13
14
1
7
4
5
7
9
3 7
4 5
6
4
12 11 10
8
3
8 4
BC01J007
1. LOADER ARM 6. NUT 11. WASHER
2. BUSHING 7. PIN 12. BUSHING
3. COVER (EUROPEAN) 8. CYLINDER ASSEMBLY 13. CYLINDER ASSEMBLY
4. CLAMP 9. STRUT 14. COVER
5. BOLT 10. RING
60 / 70XT LOADER FRAME

9002-7
5
6
1
7
BC01J
1. FRAME SUPPORT 3. PIN 5. PAD 7. RETAINING RING
2. LOADER FRAME 4. GROMMET 6. PIN
LOADER FRAME SUPPORT

9002-8
INSPECTION OF THE 60 / 70XT LOADER FRAME

NOTE: Refer to the illustration on page 6. 2. Inspect the pins (7) removed from the loader lift
frame (1) for wear, cracks, corrosion, and any
1. Inspect the loader frame (1) for cracks,
other damage. Use new parts as required.
corrosion, and any other damage. Use new parts
as required. 3. Inspect the loader lift pin bushings (2) for wear,
cracks, corrosion, and any other damage. Use
INSTALLATION OF THE 60 / 70XT LOADER FRAME

NOTE: Refer to illustration on page 6. 4. Install the bucket onto the loader frame (1).
1. Installation of the loader frame (1) is the reverse 5. After completing the loader installation, Check
of the removal procedure. th e hy dr au lic o il re se r vo ir le ve l. Sta rt th e
machine and check for proper loader operation.
2. After lowering the loader frame (1) onto the
Check hydraulic lines for leaks.
chassis and install the loader lift cylinder pins (7).
3. Push the hydraulic couplings into the mounting
holes in the chassis uprights. Install the hydraulic
coupling retaining rings.

Section
9003
9003
ATTACHMENT COUPLER

Racine, WI 53404 U.S.A. Bur 6-45360 September, 2001
9003-2
TABLE OF CONTENTS
ATTACHMENT COUPLER (MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ATTACHMENT COUPLER (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9003-3
ATTACHMENT COUPLER (MECHANICAL)
Disassembly 5. Inspect the left handle (2) and the right handle
(3) for wear and damage. Use new parts as
NOTE: Refer to illustration on page 4. required.
1. Loosen and remove the nut (19), bolt (16),
washers (17 and 20), and spacer (18) from the Assembly
left and the right lower pins (21) on the coupler
1. Place the right handle (3) in a vise with soft jaws.
frame (1).
2. Install the pin (7) into the right handle (3).
2. Use acceptable tools and remove the left and the
right lower pins (21) from the coupler frame (1). 3. Place the bolt (6) into the pin (7) and install the
spring guide (8), spring (9) and pin (13) on the
bolt (6).
washers (17 and 20), and spacer (18) from the
left and right upper pins (23) of the coupler frame 4. Prevent pin (13) from turning and tighten the bolt
(1). (6).
4. Use acceptable tools and remove the left and 5. Install the latch pin (14) into the coupler frame
right upper pins (23) from the coupler frame (1). (1). Be sure the tapered side of the latch pin (14)
faces the coupler frame (1).
5. Remove the coupler frame (1) from the loader
arms. 6. Install the right handle (3) onto the coupler frame
(1). Install the pivot pin (10) into the right handle
6. Place the coupler frame (1) on a work bench.
(3) and coupler frame (1).
7. Remove the cotter pin (12) from pin (13) and
7. Install the retaining ring (15) onto the pivot pin
latch pin (14).
(10). Lift the handle (3) until the pin (13) will
8. Remove the retaining ring (15) from the right engage the latch pin (14).
handle pivot pin (10).Remove the pivot pin (10)
8. Install the cotter pin (12) through the latch pin
from the frame (1).
(14) and pin (13).
9. Lift the right handle (3) until the pin (13)
9. Repeat steps 1 through 8 for the left handle (2).
disengages the latch pin (14). Remove the right
handle (3) from the coupler frame (1). Remove 10. Install the coupler frame (1) onto the loader
the latch pin (14) from the coupler frame (1). arms.
10. Place the right handle (3) in a vise with soft jaws. 11. Install the left and right upper pins (23) into the
coupler frame (1).
11. Prevent the pin (13) from turning. Loosen and
remove the bolt (6) from the pin (13). Remove 12. Install the bolts (16), spacers (18), washers (17
the bolt (6), pin (13), spring (9), spring guide (8), and 20), and nuts (19) for the left and right upper
and pin (7) from the right handle (3). pins (23), Tighten the nuts (19).
12. Repeat steps 7 through 11 for the left handle (2). 13. Install the left and right lower pins (21) into the
coupler frame (1).
Inspection 14. Install the bolts (16), spacers (18), washers (17
1. Inspect the coupler frame (1) to be sure it is free and 20), and nuts (19) for the left and right lower
of cracks, corrosion, rust or any other damage. pins (21). Tighten the nuts (19).
2. Inspect the upper pins (23) and the lower pins
(21) for wear, cracks, corrosion or any other
3. Inspect the latch pins (14) for wear and damage.
4. Inspect the bolt (6), pin (13), spring (9), spring
guide (8), and pin (7) for wear and damage. Use

9003-4
3
2
23
4 15
21 7
8
9 12
13
11
19 14
20
22
5
18
17 10
16
1
4
BC01J200
1. COUPLER FRAME 7. PIN 13. PIN 19. LOCK NUT

2. LEFT HANDLE 8. SPRING GUIDE 14. LATCH PIN 20. WASHER
3. RIGHT HANDLE 9. SPRING 15. RETAINING RING 21. PIN
4. GREASE FITTING 10. HANDLE PIVOT PIN 16. BOLT 22. HEX SOCKET PLUG
5. WASHER 11. RETAINING RING 17. WASHER
6. BOLT 12. PIN 18. SPACER
EXPLODED VIEW OF MECHANICAL ATTACHMENT COUPLER

9003-5
ATTACHMENT COUPLER (HYDRAULIC)
Disassembly 3. Inspect the upper cylinder pins (24), cotter pins

(25), and flag rods (35) for wear, cracks, and
NOTE: Refer to illustrations on page 5, 6 and 7. corrosion. Use new parts as required.
1. Loosen and remove the nuts (6), washers (5 and 4. Inspect the latch pins (20) for wear and damage.
7) and bolts (4) from the protective plate (2). Use new parts as required.
Remove the protective plate (2) from the coupler
frame (1). 5. Inspect the cylinders (27) for leaks, wear or any
other damage. Use new parts as required.
2. Loosen and remove the hydraulic hoses (62 and
63) from hoses (49 and 55). Assembly
3. Loosen and remove the hydraulic hoses (31, 34,
1. Install the latch pin (20) into the coupler frame
39, and 45) from the cylinders (27). Plug the
(1).
hoses and cap the fittings on the cylinders (27).
2. Put the cylinder (27) in place on the coupler
frame (1) and engage the cylinder (27) into the
washers (14 and 17), and spacer (15) from the
latch pin (20).
left and the right lower pins (12) of the coupler
frame (1). 3. Put the flag rod (35) into position on the bottom
of the cylinder (27).
5. Use acceptable tools and remove the left and
right lower pins (12) from the coupler frame (1). 4. Install the cotter pin (25) into the latch pin (20).
6. Loosen and remove the nut (16), bolt (13), 5. Install the pin (24) through the coupler frame (1)
washers (14 and 17), and spacer (15) from the and into the top of the cylinder (27).
left and right upper pins (23) of the coupler frame
6. Install the retaining ring (28) an the pin (24).
(1).
7. Repeat step 1 through 6 for the other cylinder
7. Use acceptable tools and remove the left and
(27).
right upper pins (23) from the coupler frame (1).
8. Install the coupler frame (1) onto the loader arm.
8. Remove the coupler frame (1) from the loader
arms. 9. Install the left and right upper pins (23) into the
coupler frame (1).
9. Place the coupler frame (1) on a work bench.
10. Install the bolts (13), spacers (15), washers (14
10. Remove the cotter pin (25) from the latch pin (20)
and 17), and nuts (16) for the left and right upper
an d the flag r od (3 5) o n the bottom o f th e
pins (23). Tighten the nuts (16).
cylinder (27).
11. Install the left and right lower pins (12) into the
11. Remove the retaining ring (28) from the pin (24)
coupler frame (1).
on the top of the cylinder (27). Remove the pin
(24) from the coupler frame (1). 12. Install the bolts (13), spacers (15), washers (14
and 17) and nuts (16) for the left and right lower
12. Remove the latch pin (20) from the cylinder (27)
pins (12). Tighten the nuts (16).
and frame (1).
13. Connect the hydraulic hoses to the cylinders
13. Remove the cylinder (27) from the coupler frame
(27).
(1).
14. Connect the hydraulic hoses (63 and 62) to the
14. Repeat step 10 through 13 for the other cylinder
hydraulic hoses (49 and 55).
(27).
15. Install the protective plate (2) onto the coupler
Inspection frame (1). Install and tighten the bolts (4),
washers (5 and 7), and nuts (6) which fasten the
1. Inspect the coupler frame (1) to be sure it is free protective plate (2) to the coupler frame (1).
of cracks, corrosion, rust or any other damage.
Use new parts as required. 16. Start the engine and run at low idle and check for
leaks.
2. Inspect the upper pins (23) and the lower pins
(12) for wear, cracks, corrosion or any other
9003-6
4
21 23
22 5 3
7
12
11
8 10
6
9
16
17
18 1
15
14
13
22
19 20
BC01J199
1. COUPLER FRAME 7. WASHER 13. BOLT 19. WASHER
2. PROTECTIVE PLATE 8. BOLT 14. WASHER 20. LATCH PIN
3. BRACKET 9. WASHER 15. SPACER 21. HEX SOCKET PLUG
4. BOLT 10. NUT 16. NUT 22. GREASE FITTING
5. WASHER 11. WASHER 17. WASHER 23. PIN
6. NUT 12. PIN 18. WASHER
EXPLODED VIEW OF HYDRAULIC ATTACHMENT COUPLER

9003-7
57
56
61 57 54
55
61
59 51
60 58
50
49 46
55 54 58 41
40 39
38
37
53 31
35
48
47 42
27
49
28 24 26
43 45
34
44
29 30
31
28 27
26
39 30 29
34
32
33 24
25
45
35
32
35 33
25
BC01J197
24. PIN 32. O-RING 40. ADAPTER 48. 90° ELBOW 55. STEP TO
25. COTTER PIN 33. 90° ELBOW 41. O-RING 49. STEP TO COUPLER HOSE
26. RETAINING RING 34. LH ROD END HOSE 42. O-RING COUPLER HOSE 56. NUT
27. COUPLER CYLINDER 35. FLAG ROD 43. WASHER 50. BOLT 57. WASHER
28. RETAINING RING 36. TEE 44. NUT 51. O-RING 58. 90° ELBOW
29. O-RING 37. 90° ELBOW 45. RH ROD END HOSE 52. O-RING 59. O-RING
30. ADAPTER 38. O-RING 46. CHECK VALVE 53. ADAPTER 60. LOCK NUT
31. LH BASE END HOSE 39. RH BASE END HOSE 47. O-RING 54. ADAPTER 61. BOLT
ATTACHMENT COUPLER SYSTEM HYDRAULICS

9003-8
78
67 67 67
62
66 66 75
66 72
70
71 65 65 65 63 73
73
64 64 64
63
69
64
68
69 69
68
62
63
76
62
77
BC01J198
62. VALVE TO LOADER 65. CLAMP 70. WASHER 75. ELBOW
ARM HOSE 66. SPACER 71. NUT 76. RELAY
63. VALVE TO LOADER 67. BAR 72. LOCK NUT 77. STRAP
ARM HOSE 68. BOLT 73. O-RING 78. SWITCH
64. SCREW 69. CLAMP 74. 90° ELBOW
ATTACHMENT COUPLER HYDRAULIC SYSTEM

Section
9004
9004
ROPS CANOPY, SEAT, SEAT BELTS AND OPERATORS
COMPARTMENT
40XT, 60XT, 70XT SKID STEER

9004-2
TABLE OF CONTENTS
POSSIBLE DAMAGE TO THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL OF THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION OF THE ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL OF THE REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION OF THE REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL OF THE SIDE WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION OF THE SIDE WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL OF TOP WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION OF TOP WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL OF THE DOOR FRAME WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION OF THE DOOR FRAME WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL OF THE FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION OF THE FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL OF THE 40XT NON-SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION OF THE SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION OF THE 40XT NON-SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL OF THE 40XT SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION OF THE SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION OF THE 40XT SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9004-3
POSSIBLE DAMAGE TO THE ROPS CANOPY

If the machine has been rolled over or the ROPS After an accident, check for damage to the ROPS
canopy has been damaged (such as hitting an ca n o py, th e o p er a to rs se a t, t he s e at b elt, a ll
overhead object during transport), the ROPS canopy accessories, and wiring in the ROPS canopy. Before
shall be replaced in order to maintain maximum operating the machine again, all damaged parts must
protection. be replaced.
IMPORTANT: Do not weld or try to straighten a
ROPS canopy.
MAINTENANCE AND INSPECTION OF THE ROPS CANOPY
WARNING: Improper ROPS inspection or WARNING: Securely fasten your seat belt.
! maintenance can cause injury or death. Do
! Your machine is equipped with a ROPS cab,
the recommended ROPS inspection shown ROPS canopy or ROPS frame for your
in this manual. If you must replace the protection. The seat belt can help insure your
ROPS, ROPS parts, or ROPS mounting safety if it is used and maintained. Never
hardware, use only the replacement parts wear a seat belt loosely or with slack in the
shown in the Case parts catalog for this belt system. Never wear the belt in a twisted
machine. condition or pinched between the seat
SM029 structural members.
M437
After the first 20 hours of operation and after every

WARNING: Do not modify ROPS in any 500 hours of operation, do the following:
! manner. Unauthorized modifications such as
welding, drilling, cutting or adding 1. Check the operators seat and the mounting parts
attachments can weaken the structure and for the seat belt. Torque the seat belt mounting
reduce protection. Replace ROPS if bolts to 52 to 61 Nm (38 to 45 pound-feet). Use
subjected to roll-over or damage. Do not new parts as required.
attempt to repair. 2. Check for cracks, rust, or holes in the ROPS and
SM026 ROPS parts. Age, weather and accidents can
cause damage to the ROPS and ROPS parts. If
you have any doubt about the ROPS system,
s e e y o u r C a s e d e a l e r. U s e n e w p a r t s a s
WARNING: If you operate this machine
! without a ROPS and the machine rolls over,
required.
you can be injured or killed. Remove the
ROPS only for service or replacement. Do
not operate this machine with the ROPS
removed.
SM027
WARNING: Adding additional weight

! (attachments, etc). to the machine can cause
injury or death. Do not exceed the gross
weight printed on the ROPS label.
SM028

9004-4
REMOVAL OF THE ROPS CANOPY

NOTE: Refer to the illustration on page 5. IMPORTANT: Do not attempt to remove the gas strut
cylinder (1) mounting hardware with the ROPS in the
1. Park the unit on a level surface and remove the
lowered position.
bucket from the unit.
8. With the cab in the tilted position, remove the gas
2. Raise the loader arm and engage the loader arm
cylinder mounting bolt (2), washers (3), and lock
support strut.
nut (5) and gas strut cylinder (1).
3. Stop the engine and remove the key.
9. Remove the electrical harness clamp from under
4. Using a floor jack, raise the unit and place a the floor panel bolt. Loosen the retaining bolt in
suitable jack stand(s) under the unit. the cab harness connector and uncouple the
connector from the socket in the chassis.
5. Remove one of the tires/wheels from the unit.
This will be the side to which the ROPS pivot pin 10. Remove the wire harness retaining clip(s) from
(8) will be removed from. the canopy pivot pin (8).
6. Tilt the cab into the forward position. 11. Remove the lock rings (9) from the pivot pin (8).
7. Use the floor jack to raise the loader arm away 12. Place overhead lift chains or straps in the
from the chassis. It will be necessary to activate sidescreen cutouts (towa rd the rea r of th e
the manual override on the control valve to move cutouts) and remove any slack between the lift
the lift control lever to allow the arms to be and the ROPS.
raised. Raise the loader just high enough to be
13. Drive out the pivot pin (8) and lift the ROPS from
able to clear the ROPS pivot shaft (8) from the
the unit.
unit.
INSTALLATION OF THE ROPS CANOPY

1. Raise the ROPS over the chassis. Lower the 5. Insert the cab wire harness connector into the
ROPS until the pivot pin hole in the ROPS align socket in the chassis kick plate.
with the ROPS ears on the chassis.
6. Install the clamp and bolt into the floorplate.
2. Install the pivot pin (8) through the chassis ear
7. Install the gas strut cylinder (1), with the rod end
and ROPS pivot holes.
facing down, lock nut (5), washers (3), and bolt
3. Inspect the lock rings (9) and replace if (2).
necessary. Install both lock rings (9) in the pivot
8. Install the tire/wheel assembly and torque wheel
pin (8) ring grooves.
nuts to 135 to 163 Nm (100 to 120 pound-feet).
4. Insert the cab wire harness clips over the pivot Refer to Section 6011.
pin (8).
9. Lift the front of the unit with the floor jack and
remove the jack stand(s) from underneath.
Lower the unit to the ground.

9004-5
1
1
2 3
3
5
1
2 6
3
7 4 3
3
5
6
2
8
9
BC01H249
1. GAS STRUT CYLINDER 4. SPACER 7. NUT

2. BOLT 5. LOCK NUT 8. PIVOT PIN
3. WASHER 6. SPACER 9. LOCK RING
ROPS CANOPY - REAR LATCH AND PIVOT

9004-6
3
3
11 12
10
16
7
17 7
11 6
6 14
7
7 15
6
11
6
5
18
7 6
18
5
18 6
9
18 18
18
18
BC01H245
1. FRAME 7. BOLT 13. CYLINDER
2. TRIM 8. PANEL 14. BUSHING
3. COVER 9. THUMB SCREW 15. LOCK RING
4. PLUG 10. CYLINDER 16. BAR
5. PLATE 11. FLANGE NUT 17. MANUAL BOX
6. WASHER 12. BALL STUD 18. SEAL
ROPS CANOPY

9004-7
REMOVAL OF THE REAR WINDOW

NOTE: Refer to illustration on page 7. 6. Remove the brackets (6) from the ROPS frame
(1).
1. Park the machine on a flat, level surface.
7. Inspect the brackets (3) for corrosion and
2. Remove the bolts (2) and knobs (8).
damage. Replace as needed.
3. Remove the retaining brackets (3).
8. Inspect the seal (4) for damage. Replace if
4. Remove the seal (4) and rear window (5). damaged.
5. Remove the bolts (9), washers (10), and flange 9. Inspect brackets (6) for corrosion or damage.
nuts (7) from the brackets (6). Replace as needed.
INSTALLATION OF THE REAR WINDOW

10. Install the brackets (6) on the ROPS frame. 13. Put the retaining brackets (3) in place on the rear
window (5).
11. Install the bolts (9), washers (10), and flange
nuts (7) that secure the brackets (6) to the ROPS 14. Install the knobs (8) and bolts (2) that secure the
frame (1). brackets (3).
12. Put the rear window (5) and seal (4) into place on 15. Fill the gaps between the window brackets and
the brackets (6). the ROPS with sikaflex.
9 10
6
8
5
4
7
3
8
7 10
2 6 9
1
3
2
BC01K072
1. ROPS FRAME 5. SCREEN 8. KNOB
2. BOLT 6. BRACKET 9. BOLT
3. RETAINING BRACKET 7. NUT FLANGE 10. WASHER
4. SEAL
ROPS CANOPY - REAR WINDOW

9004-8
REMOVAL OF THE SIDE WINDOWS

NOTE: Refer to illustration on page 9. 4. The flocked rubber can be remove by lifting it
with a screwdriver midway between the glass
NOTE: Steps 1 through 4 are for removal of the
and the radius. and then pulling it out from under
glass for cleaning only.
the glass. This section of the flocked rubber
1. Close the side window (2). should only be removed from the bottom on the
glass.
2. Locate the midway point between the back of the
glass and the end of the glass frame. Begin 5. Remove the bolts (5) and jam nuts (6).
removing the flocked rubber from the glass
6. Remove the “outside window sub-assembly”.
c h a n n e l b y l i f t i n g i t w i t h a s c r e w d r i v e r.
Approximately 76 mm (3 inches) will be located 7. Remove the bolts (7) and jam nuts (8) from the
under the glass. Slide this portion out in order to window frame (2).
completely remove the flocked rubber back to
8. Remove the bolts (3) and jam nuts (4) from the
the plastic slide stop.
window frame (2).
3. Gently slide the glass to the full open position.
9. Remove the “inside window sub-assembly”.
About 76 mm (3 inches) of the flocked rubber
may also need to be removed from under the 10. Repeat procedure 1 through 9 for the other side.
front portion of the glass. This will allow the glass
11. Inspect the window frames, windows, and seals
to be lowered far enough into the channel so that
for damage. Replace as necessary.
the top of the glass can be tilted out of the frame.
INSTALLATION OF THE SIDE WINDOWS

12. Put the “inside window sub-assembly” in place 19. With the flocked rubber still removed from the
on the inside of the ROPS frame (9). glass, tilt and lower the bottom of the glass into
the rear portion of the open position. Lift up on
13. Install the bolts (3) and jam nuts (4). Tighten 2.26
the front of the glass while guiding it into the top
to 2.82 Nm (20 to 25 inch lbs).
channel. Slide the loose end of the flocked
14. Install the bolts (7) and jam nuts (8). Tighten rubber still remaining on the glass into the
bolts (7) 2.26 to 2.82 Nm (20 to 25 inch lbs). channel and under the glass. If necessary, coat
the end of the flocked rubber with soapy water.
15. Put the “outside window sub-assembly” in place
Smooth out the flocked rubber and make sure
on the ROPS (9).
the entire length is pressed into the channel.
16. Install the bolts (5) and jam nuts (6) on the
20. Slide the glass to the closed position and install
window frame (2). Tighten 1.13 to 1.36Nm (10 to
the rear piece of the flocked rubber in the same
12 inch lbs).
manner. Make sure both pieces of flocked rubber
17. Repeat steps 12 through 16 for the other side. fit together end to end under the glass.
18. Do steps 19 through 21 if the glass was removed 21. Repeat steps 19 through 20 for the other side.
for cleaning.

9004-9
6 8
5 7
5 6
8
7
2
3
4
3 1
4
6
5
7
8 5 6 3
4
7
8
BS01H289
1. LH WINDOW 1. BOLT 3. BOLT 5. BOLT 7. FRAME
2. RH WINDOW 2. JAM NUT 4. JAM NUT 6. JAM NUT
ROPS CANOPY - SIDE WINDOWS

9004-10
REMOVAL OF TOP WINDOW

NOTE: Refer to illustration on page 10. 3. Remove the seal (3) from the ROPS frame (7).
1. Remove the lock nuts (6), washers (5), and bolts 4. Inspect the seal (2) and window (1) for damage.
(4). Replace as necessary.
2. Remove the top window (1). 5. Inspect the seal (3) for damage. Replace if
needed.
INSTALLATION OF TOP WINDOW

6. Put the seal (3) in place on the ROPS frame (7). 8. Install the bolts (4), washers (5), and lock nuts
(6).
7. Put the top window (1) on the ROPS frame (7).
7
1 4
4 5
5
3
2 5
5
6
6
BC01K073
1. TOP WINDOW 3. SEAL 5. WASHER 7. FRAME

2. TOP SEAL 4. BOLT 6. LOCK NUT
ROPS CANOPY - TOP AND SIDE WINDOWS (IF EQUIPPED)

9004-11
NOTES

9004-12
REMOVAL OF THE DOOR FRAME WINDOW

NOTE: Refer to illustration on page 13. 2. Remove the window (4) and seal (3).
1. Remove the bolts (5), washers (6), and lock nut
(7) from the window (4).
INSTALLATION OF THE DOOR FRAME WINDOW

3. Put the seal (3) and window (4) in place on the 4. Install the bolts (5), washers (6), and lock nuts
bracket (43). (8).
REMOVAL OF THE FRONT DOOR

NOTE: Refer to illustration on page 13. 11. Remove the bracket (30).
1. Open the front door (1). 12. Remove the bolts (31), washers (32), and lock
nuts (33).
2. Remove the bolts (25) and lock nuts (23).
13. Remove the bolt (38), washers (39), and lock nut
3. Remove the bracket (24) from the ROPS
(40) on bracket (34).
canopy.
14. Remove the bracket (34) from the machine.
4. Remove the retaining ring (11).
15. Remove the bolts (35), washers (36), and lock
5. Remove the pin (10) from the hinge (9).
nuts (37).
6. Remove the front window (1) from the machine.
16. Remove the bolt (38), washers (39), and lock nut
7. Remove the bolts (15), washers (17), and lock (40) on bracket (41).
nuts (16).
17. Remove the bracket (41) from the machine.
8. Remove the bolts (18), washers (19), and lock
18. Inspect the brackets (30, 34, 41, 43) for
nuts (20).
corrosion or damage. Replace as needed.
9. Remove the bracket (43).
19. Inspect the seals (2, 3, 14, 22, 26) for damage.
10. Remove bolts (27), washers (28), and lock nuts Replace as needed.
(29).
INSTALLATION OF THE FRONT DOOR

1. Place the bracket (41) on the machine. 8. Install the bolts (18), washers (19), lock nuts
(20).
2. Install the bolt (38), washers (39), and lock nut
(40) on bracket (41). 9. Install the bolts (15), washers (17), and lock nuts
(16).
3. Install the bolts (35), washers (36), and lock nuts
(37). 10. Put the front door (1) in place on the machine
and install the pins (10) and retaining rings (11).
4. Put the bracket (34) in place and install the bolt
(38), washers (39), and lock nut (40). 11. Put the bracket (24) in place and install the bolts
(25) and lock nuts (23).
5. Install the bolts (31), washers (32), and lock nuts
(33).
6. Install bracket (30), bolts (27), washers (28), and
lock nuts (29).
7. Put the bracket (43), seal (14, 26), and seals (22)
in place on the machine.

9004-13
6 15
7 3 17 22
4 14
43 19 20
6
17
26 5
16 19
18
29
28
28 21
2
27 24
25 1
23 35
36 41
30 37
32 39 36
40 8
31 11
38 9
12
33 39 13 8
34 42
32 39 10
40
BS01H288
1. FRONT DOOR 12. FLANGE BOLT 23. FLANGE NUT 34. BRACKET
2. SEAL 13. FLANGE NUT 24. BRACKET 35. BOLT
3. SEAL 14. SEAL 25. BOLT 36. WASHER
4. WINDOW 15. BOLT 26. SEAL 37. LOCK NUT
5. BOLT 16. LOCK NUT 27. BOLT 38. BOLT
6. WASHER 17. WASHER 28. WASHER 39. WASHER
7. LOCK NUT 18. BOLT 29. LOCK NUT 40. LOCK NUT
8. WASHER 19. WASHER 30. BRACKET 41. BRACKET
9. HINGE 20. LOCK NUT 31. BOLT 42. GAS STRUT CYLINDER
10. PIN 21. BRACKET 32. WASHER 43. BRACKET
11. RETAINING RING 22. SEAL 33. LOCK NUT
ROPS CANOPY - FRONT DOOR (IF EQUIPPED)

9004-14
3
4
5
2
6
BC01H243
1. FRONT WINDOW (GLASS) 3. WIPER 5. SPACER
2. RESERVOIR 4. FLANGE NUT 6. SEAL
ROPS CANOPY - FRONT DOOR (GLASS)

9004-15
NOTES

9004-16
REMOVAL OF THE 40XT NON-SUSPENSION SEAT

NOTE: Refer to illustration on page 15. 8. Inspect the operator presence switch (2) and
harness (3) for damage. Replace all parts that
are damaged.
2. Raise the loader arm up and engage the lift arm
support strut.
3. Remove the two ROPS mounting bolts from the REMOVAL OF THE SEAT BELT
rear of the ROPS. 1. Remove bolts (4), lock nuts (7) and washers (6).
4. Tile the ROPS forward until the cab hold open 2. Remove the seat belts (5) from the mounts.
latch assembly is engaged.
3. Inspect the seat belt mounts for corrosion or
5. Remove lock nuts (9) from the non-suspension damage.
seat (1).
NOTE: Keep the seat belt clean. Use only soap and
6. Remove the non-suspension seat (1) from the water to wash the seat belt. Dye or other compounds
cab. can cause damage to the seat belt.
7. Inspect the non-suspension seat (1) mounts, on 4. Inspect the seat belts for damage. Replace all
the bottom of the seat, for corrosion or damage. parts that are damaged.
Replace all parts that are damaged.
INSTALLATION OF THE SEAT BELTS

1. Install the seat belts (5), bolts (4), washers (6), 2. Tighten the lock nuts (7) to 52 to 61 Nm (38 to 45
and lock nuts (7) to the mounts. pound-feet).
INSTALLATION OF THE 40XT NON-SUSPENSION SEAT

1. Install the non-suspension seat (1) in the cab. 2. Install the lock nuts (9) on the non-suspension
seat (1) mounts.

9004-17
4 1
5 2
6
7
7 6
5
4 3
BC01H247
1. SEAT 4. BOLT 7. LOCK NUT

2. SWITCH 5. SEAT BELT 8. SEAT PLATE
3. HARNESS 6. WASHER 9. LOCK NUT
NON - SUSPENSION SEAT MOUNTING (IF EQUIPPED)

9004-18
REMOVAL OF THE 40XT SUSPENSION SEAT

NOTE: Make sure that all suspension seat adjusters 9. Inspect the suspension seat mounts, on the
(angle, position, weight, and lumbar adjusters) bottom of the seat, for corrosion or damage.
function correctly before removing the suspension Replace all parts that are damaged.
seat.
10. Inspect the operator presence switch (2) and
NOTE: Refer to illustration on page 17. harness (3) for damage. Replace all parts that
are damaged.
4. Raise the loader arm up and engage lift arm
support strut. REMOVAL OF THE SEAT BELT
5. Remove the two ROPS mounting bolts from the 1. Remove bolts (4), lock nuts (7) and washers (6).
rear of the ROPS.
2. Remove the seat belts (5) from the mounts.
6. Tilt the ROPS forward until the cab hold open
latch assembly is engaged. 3. Inspect the seat belt mounts for corrosion or
damage.
7. Remove lock nuts (9) from the suspension seat
(1). NOTE: Keep the seat belt clean. Use only soap and
water to wash the seat belt. Dye or other compounds
8. Remove the suspension seat (1) from the cab. can cause damage to the seat belt.
4. Inspect the seat belts for damage. Replace all
parts that are damaged.
INSTALLATION OF THE SEAT BELTS

1. Install the seat belts (5), bolts (4), washers (6), 2. Tighten the lock nuts (7) to 52 to 61 Nm (38 to 45
and lock nuts (7) to the mounts. pound-feet).
INSTALLATION OF THE 40XT SUSPENSION SEAT

1. Install the non-suspension seat (1) in the cab. 2. Install the lock nuts (9) on the suspension seat
(1) mounts.

9004-19
4 2
5
5
6
7
5
7
3
6 5
4
BC01H246
1. SEAT 4. BOLT 7. LOCK NUT

2. SWITCH 5. SEAT BELT 8. SEAT PLATE
3. HARNESS 6. WASHER 9. LOCK NUTS
SUSPENSION SEAT MOUNTING (IF EQUIPPED)

9004-20
NOTES

Section
9006
HEATER
40XT, 60XT, 70XT SKID STEER
9006

9006-2
TABLE OF CONTENTS
BASIC HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DELUXE HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

9006-3
BASIC HEATER
Removal Inspection
NOTE: Refer to illustration on page 4 and 5. 1. Inspect the heater (1) for leaks or damage. Use
1. Open the heater shut-off valves (9). Place a drain
tube on the radiator drain valve and drain the 2. Inspect the supply hose (4) and return hose (5)
engine coolant into a clean container. for crac ks or damage. Use new parts as
required.
2. Remove radiator cap to speed-up draining
process. 3. Inspect the seals for any damage. Use new parts
as required.
3. After draining is complete, replace radiator cap,
remove drain tube, close drain valve, and cover
the container to keep contaminates out of the Installation
coolant. 1. Install the heater (1) onto the mounting bracket
4. Close the shut-off valves (9) and loosen the (11) and install the washers (19) and nuts (18)
clamps (3) on the heater supply (4) and return onto the heater (1).
hose (5). 2. Place the heater (1) and mounting bracket (11)
5. Remove the bolts (14) and washers (15) from the onto the floor plate (12).
mounting bracket (11). 3. Connect the wiring harness(16) to the heater (1).
6. Disconnect the wire harness (16) for the blower. 4. Connect the return (5) and supply hose (4) to the
7. Place some shop towels under the hose heater (1).
connections (4 and 5) under the heater (1) to 5. Install the washers (15) and bolts (14) onto the
catch any remaining coolant and loosen the floor plate (12) that secures the mounting bracket
clamps (17). (11) to the floor plate (12).
8. Disconnect the heater hoses (4 and 5) from the 6. Install the heater supply hose (4) and return hose
heater (1). (5) onto the heater shut-off valves (9).
9. Remove the nuts (18) and washers (19) from the 7. Open the shut-off valve (9), remove the radiator
heater (1). ca p a nd fill th e c oo lin g s yste m with clea n
IMPORTANT: Use care when removing the supply coolant. Install the radiator cap on the radiator
and return hose(s) from the heater connection(s). and tighten the cap.
Twist the hose to break the seal between the hose 8. Start the engine and allow the engine to reach
and the connection before attempting to remove the op era ting tempe ratur e. Ch eck the he atin g
hose. If the seal cannot be broken with the twisting system for any leaks. Check the heater (1) for
motion, it may be necessary to cut the hose, before proper operation.
removing the hose from the heater connection.
9. Stop the engine. After the engine has cooled,
10. Remove the shop towels in the heater check the cooling system for proper coolant level.
compartment and clean up any remaining engine
coolant.

9006-4
8
9
5
3
10
3
4
6 6
6 6
11
6 12
BS01F166
1. HEATER 5. HEATER RETURN HOSE 9. SHUT OFF VALVE

2. HEATER MOUNTING BRACKET 6. WIRE TIE 10. BLOWER SWITCH
3. HOSE CLAMP 7. HEATER WIRE HARNESS 11. MOUNTING BRACKET
4. HEATER SUPPLY HOSE 8. WIRE HARNESS CLAMP 12. FLOOR PLATE
BASIC HEATER INSTALLATION

9006-5
13
11
14
15
19
4
18
12 5
17 16
BS01F165
1. HEATER 12. FLOOR PLATE 16. HEATER WIRE HARNESS

4. HEATER SUPPLY HOSE 13. MOUNTING BRACKET SEAL 17. HOSE CLAMP
5. HEATER RETURN HOSE 14. BOLT 18. NUT
11. MOUNTING BRACKET 15. WASHER 19. WASHER
BASIC HEATER INSTALLATION

9006-6
DELUXE HEATER
Removal Inspection
NOTE: Refer to illustration on page 7 and 8. 1. Inspect the heater (1) for leaks or damage. Use
new parts as required, refer to the illustration on
1. Remove any attachments from the loader arm.
page 7.
2. Raise the loader arm up and secure in place
2. Inspect the air ducts for cracks or damage. Use
using the support strut.
3. Tilt the ROPS cab forward.
3. Inspect the supply hose (8) and return hose (7)
4. Open the heater shut-off valves (6). for crac ks or damage. Use new parts as
required.
5. Install a hose on the radiator drain valve and
drain the radiator coolant into a clean container. 4. Inspect the air filter to ensure its clean and free
of damage. If the filter is dirty, wash in a soap
6. Remove the fill cap on the radiator.
and water solution, rinse with clean water and
7. After the radiator is drained install the fill cap and allow to air dry. Use new parts as required.
close the drain valve.
8. Close the heater shut-off valves (6). Installation
9. Loosen the hose clamps (5) on the heater supply 1. Install the heater (1) onto the cab, refer to the
hose (8) and the heater return hose (7). illustration on page 8. Install the bolts (27) from
inside the cab that fasten the heater housing (1)
10. Disconnect the heater supply hose (8) and return to the cab.
hose (7) from the heater shut-off valves (6).
2. Install the nuts (28) onto the heater (1).
IMPORTANT: Use care when removing the supply
and return hose(s) from the heater connection(s). 3. Put the air ducts (17) in place in the cab and
Twist the hose to break the seal between the hose install the washers (19 and 21) and bolts (18 and
and the connection. If the seal cannot be broken it 20) onto the air ducts.
may be necessary to cut the hose. 4. Connect the wiring harness to the heater (1).
11. Drain the coolant from the heater (1). 5. Connect the supply hose (8) and return hose (7)
12. Remove the bolt (11), washers (12 and 13), and to the heater (1).
nut (14) from the hose clamps (10). Remove the 6. Install the lower cover (3) and upper cover (2) on
spring from the clamps (10). the heater (1).
13. Remove the air filter cover (24) and air filter from 7. Install the air filter and air filer cover (24) on the
the heater (1). heater (1).
14. Remove the top cover (2) and bottom cover (3) 8. Connect the heater supply hose (8) and return
from the heater (1). hose (7) to the shut-off valves (6).
15. Remove the bolts (18 and 20) and washers (19 9. Install the bolt (11), washers (12 and 13), and nut
and 21) from the air ducts (17). (14) in clamps (10).
16. Remove the air ducts (17) from the cab. 10. Install the spring (15) onto the hose clamps (10).
17. Place rags under the hoses (7 and 8) on the 11. Open the shut-off valves (6), remove the radiator
heater (1) and disconnect the hoses from the ca p a nd fill th e c oo lin g s yste m with clea n
heater. coolant. Install the radiator cap on the radiator
18. Remove the eight bolts (27) from inside the cab and tighten the cap.
that fasten the heater housing onto the cab. 12. Start the engine and allow the engine to reach
19. Remove the four nuts (28) from the bolt studs on op era ting tempe ratur e. Ch eck the he atin g
the bottom of the heater (1). system for any leaks. Check the heater (1) for
proper operation.
20. Remove the heater (1) from the cab.
13. Stop the engine. After the engine has cooled,
21. Remove shop towels in heater compartment and check the cooling system for proper coolant
clean up any remaining engine coolant. level.
9006-7
17
18
21
19 25
20
22
4
2
9
24 9
1
3 23
10
11
12 10
15
6
5 13 14
6 7
16
5
23
BT97H041
1. HEATER 8. SUPPLY HOSE 15. SPRING 22. GROMMET
2. TOP COVER 9. HOSE CLAMP 16. CLAMP 23. TIE STRAP
3. BOTTOM COVER 10. CLAMP 17. HEATER DUCTS 24. AIR FILTER COVER
4. BACK COVER 11. BOLT 18. BOLT 25. BLOWER SWITCH
5. HOSE CLAMP 12. WASHER 19. WASHER
6. SHUT-OFF VALVE 13. WASHER 20. BOLT
7. RETURN HOSE 14. NUT 21. WASHER
DELUXE HEATER

9006-8
27
26
27
6
27
6
7 8 28
BT97H041
6. SHUT-OFF VALVE 8. SUPPLY HOSE 27. BOLTS

7. RETURN HOSE 26. WIRE HARNESS 28. NUTS
DELUXE HEATER

Section
9007
D125 BACKHOE
40XT, 60XT, 70XT
9007

9007-2
TABLE OF CONTENTS
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PIVOT PIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tooth Shank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tooth Point Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CUTTING EDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bottom Cutting Edge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Side Cutting Edge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9007-3
BACKHOE
1. Park the machine on a level surface and lower 1. Carefully align the machine to the backhoe. Roll
the stabilizers to the ground. the backhoe onto the coupler and engage the
coupler handles.
2. Extend the boom and dipper from the transport
position. The dipper is to be at approximately 90 2. Connect the supply and return hoses.
degree to the boom.
3. Push down the right side of the auxiliary control
3. Lower the boom to put the bucket on the ground. pedal and install the lock lever.
4. Raise the stabilizers. Apply downward pressure NOTE: Carefully check the backhoe for correct
with the boom cylinder to move the backhoe hydraulic function. If stabilizers move opposite to that
against the front of the machine. indicated on the control decal, reverse the supply and
return hoses and check the operation again. Do not
5. Remove and store the tie rods.
operate the backhoe with supply and return lines
6. Raise the backhoe boom to relieve pressure on reversed. Reversed oil flow can damage the valve
the coupler handles. Disengage the handles. and cause unpredictable backhoe movement
possible resulting in serious personal injury.
7. Set the backhoe on the ground using the
machines bucket cylinders and back away. Be 4. Use the combination of the machines bucket
careful not to stretch the supply and return cylinders and backhoe boom cylinder to push the
hoses. coupler against the roll back stops. Do not force
loader arms away from the frame stops.
NOTE: The backhoe must rest on the main frame or
mounting brackets. Do not leave the backhoe raised 5. Secure mounting with the tie rods. Torque the
on the stabilizers. nuts to 68 to 102 Nm (50 to 75 pound-feet).
8. Use the backhoe boom cylinder to tilt the main
frame slightly 2 to 4 degrees toward the boom.
This will make installation of the backhoe and
securing the coupler handles much easier.
9. Before disconnecting the supply and return
hoses, stop the engine and relieve all backhoe
valve spools and the machines auxiliary circuit.
When all pressure has been relieved, disconnect
the supply and return hoses and return the
machines auxiliary valve to neutral.

9007-4
8
6
3
7
2 4
5
8 6
1
BS01K085
1. MOUNTING FRAME 4. RIGHT SIDE HOOK 7. CLEVIS

2. LEFT SIDE HOOK 5. BACKUP BAR 8. BOLT SUPPORT PIN
3. TIE ROD 6. LATCH HANDLE
BACKHOE MOUNTING FRAME

9007-5
4
2
5 3
1 6
7 8
1
BS01K084
1. MOUNTING FRAME 5. HYDRAULIC RETURN LINE

2. CONTROL VALVE SUPPLY LINE 6. TILT CYLINDER(S)
3. CONTROL VALVE RETURN LINE 7. 40XT COUPLER STOP COLLAR(S) (2)
4. HYDRAULIC SUPPLY LINE 8. 60 / 70XT COUPLER STOP COLLAR(S) (2)
BACKHOE MOUNTING FRAME AND HYDRAULIC PLUMBING INSTALLATION

9007-6
BS01K086
1. BACKHOE CONTROL VALVE 3. OUTLET
2. INLET
BACKHOE CONTROL VALVE AND MOUNTING

9007-7
BT97J191
1. BACKHOE SEAT 2. BACKHOE SEAT MOUNT
SEAT MOUNTING

9007-8
1 2
3
4
BI97H965
1. SWING CYLINDER 3. MAIN FRAME 5. GEAR
2. BOOM LATCH 4. BUMPER
BACKHOE SWING CYLINDER INSTALLATION

9007-9
3
6
5
BI97H066
1. STABILIZER (WING TYPE) 3. STABILIZER CYLINDER 5. STABILIZER PAD
2. STABILIZER (VERTICAL) 4. SPACERS (USE AS REQUIRED) 6. COVER
BACKHOE STABILIZER INSTALLATION

9007-10
BI97H067
1. SWING TOWER 3. BOOM CYLINDER
2. PIVOT PIN 4. BOOM
BACKHOE SWING TOWER AND BOOM INSTALLATION

9007-11
5 6
BI97H068
1. BOOM 3. PIVOT PIN 5. DIPPER 7. BUCKET
2. DIPPER CYLINDER 4. BUSHING 6. BUCKET CYLINDER
BACKHOE DIPPER AND BUCKET INSTALLATION

9007-12
1
3
2
6
8
7
BS97H069
1. RIGHT-HAND SIDE CUTTING EDGE 3. LEFT-HAND SIDE CUTTING EDGE 6. BUCKET 610 MM (24 INCH)
2. CENTER CUTTING EDGE 4. BUCKET 330 MM (13 INCH) 7. TOOTH POINT
5. BUCKET 458 MM (18 INCH) 8. TOOTH SHANK
BACKHOE BUCKETS

9007-13
NOTES

9007-14
PIVOT PIN INSTALLATION

The pivot pins are not tapered. The components
must be installed before the pivot pins are installed. If
the pivot pins are driven into the components, the
bushings can be damaged.
BUCKET TEETH
Tooth Shank Replacement 6. Use E-8018-C3 welding rod or equivalent and
weld the tooth shank to the cutting edge.
NOTE: When welding or using a carbon arc rod on
the backhoe, the ground cable from the welder must Tooth Point Replacement
be connected to the component being repaired or
damage to the hydraulic cylinders will result. NOTE: When welding or using a carbon arc rod on
the backhoe, the ground cable from the welder must
1. If the bucket is not removed from the backhoe,
be connected to the component being repaired or
disconnect the wiring from the alternator.
damage to the hydraulic cylinders will result
2. Use a carbon arc rod or an acetylene cutting
1. The tooth point is held in place by pressing the
torch to remove the welds that hold the tooth
sides of the tooth point into a hole in the tooth
shank in place.
shank. Heat the bent area of the tooth point and
3. Use a grinder to remove any welds or extra lift that area out of the hole on both sides of the
material that will prevent the new tooth shank tooth shank.
from fitting correctly.
2. When installing the tooth point, heat the area on
4. See the illustration on page 12 for the correct each side of the tooth point that fits into the hole
location of the tooth shank. in the tooth shank and drive that area into the
hole with a hammer and punch.
5. See the illustration on this page for weld
specifications.
1
4
BS97H07
1. 10 MM (0.39 INCH) FILLET. WELD TWO TIMES 3. 6 MM (0.24 INCH). NO WELD
2. TACK WELD 4. 38 MM (1.50 INCH). NO WELD

9007-15
1 1
BS97H071
1. 330 MM (13 INCH) BUCKET - 146 MM (5-3/4 INCH)
2. 458 MM (18 INCH) BUCKET - 135 MM (3-5/16 INCH)
610 MM (24 INCH) BUCKET - 185 MM (7-5/16 INCH)
BUCKET TEETH LOCATION

9007-16
CUTTING EDGES
Bottom Cutting Edge Replacement Side Cutting Edge Replacement

NOTE: When welding or using a carbon arc rod on NOTE: When welding or using a carbon arc rod on
the backhoe, the ground cable from the welder must the backhoe, the ground cable from the welder must
be connected to the component being repaired or be connected to the component being repaired or
damage to the hydraulic cylinders will result. damage to the hydraulic cylinders will result.
1. If the bucket is not removed from the backhoe, 1. If the bucket is not removed from the backhoe,
disconnect the wiring from the alternator. disconnect the wiring from the alternator.
2. See page 12 and remove the tooth point and 2. Remove all welds that hold the side cutting edge
to o t h s h a n k . U s e a c a r b o n a r c r o d o r a n in place. Use a carbon arc rod or an acetylene
acetylene cutting torch to remove the welds. cutting torch to remove all welds.
3. Remove all welds that hold the bottom cutting 3. Remove the side cutting edge from the bucket.
edge in place. U se a ca rbon arc rod o r a n
4. Use a grinder to remove any welds still on the
acetylene cutting torch to remove the welds.
bucket and any extra metal so that the new side
4. Remove the bottom cutting edge from the bucket. cutting edge will fit the bucket.
5. Use a grinder to remove any welds still on the 5. Put the side cutting edge in place and use
bucket and any extra metal so that the new clamps to hold the side cutting edge in place.
bottom cutting edge will fit the bucket.
6. See the illustration on page 15 for location and
6. Put the new bottom cutting edge in place and weld specifications.
use clamps to hold the bottom cutting edge in
7. Use E-7018 welding rod to weld the side cutting
place.
edge to the bucket.
7. See the illustration and weld specifications on
page 15.
8. Use E-7018 welding rod and weld the bottom
cutting edge to the bucket.
9. Install the tooth shank and tooth points. See
page 12.

9007-17
BS97H072
1. 83.8 MM (3-5/16 INCHES) 4. 6 MM (1/4 INCH FILLET. 60 MM (2-3/8 INCH) LENGTH ON 140 MM (5-1/2
2. 538.7 MM (21-3/16 INCHES) INCH) CENTERS BOTH SIDES, WRAP ENDS
3. 6 MM (1/4 INCH) FILLET, BOTH SIDES 5. 6 MM (1/4 INCH) FILLET

9007-18
NOTES

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components
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@@WN@primary@fuse@block QXN@seat@switch RYN@fuel@sender TPN@horn@switch UQN@brake@release@solenoid VQN@hydraulic@coupler@release@solenoid WQN@foot@heater
@@XN@options@fuse@block QYN@seat@bar@switch SPN@engine@oil@pressure@sensor@HoptionalI TQN@backup@alarm@switch URN@brake@switch VRN@hydraulic@coupler@release@timer WRN@front@electric@control@switch
@@YN@fuel@hold@in@solenoid RPN@lh@instrument@cluster@HVMpin@connectorI SQN@engine@coolant@temperature@sender@HoptionalI TRN@backup@alarm@switch USN@cold@start@switch VSN@self@level@override@switch WSN@auxiliary@electric@switch@CQ
QPN@fuel@timing@heater RQN@rh@instrument@cluster@HXMpin@connectorI SRN@hydraulic@oil@temperature@sender@HoptionalI TSN@backup@alarm UTN@thermostart@coil VTN@self@level@override@solenoid WTN@auxiliary@electric@switch@CR
QQN@fuel@timing@temperature@switch RRN@lh@instrument@cluster@HQPMpin@connectorI SSN@workOroad@light@switch TTN@cab@door@switch
circuit@diagram@legend wire@identification actuators housings contact miscellaneous notes legend

UT xxx
@configurations @symbols QN diagram@shown@with@vehicle@parkedL@ RN sheet@numbers@refer@to@the@number@at@
indicates@constant@power
component connector power@off@and@controls@in@off@or@ the@bottom@center@of@each@blockN
number number indicates neutral@positionN indicates@power@when@key@switch@is@in@on@position
shows@circuit internally@ v p t
crossing MALE FEMALE grounded@ indicates@momentary@power@when@key@switch@is@in@
not@connected SP CAVITY TERMINAL TERMINAL component abbrev @wire@color abbrev @wire@color liquid
level sNpNsNtN sNpNdNtN fuse autoN@reset start@position
DESIGNATION b@ N N N N N N N N @black o@N N N N N N N N @orange lever lever
float pressure hand diode vacuum pressure temperature circuit@breaker
wire@tag twisted indicates released actuated switch switch switch
number @pair x external br N N N N N N N @brown p N N N N N N N N @pink
SHOWS
INTERFACE CAB|FRONT
ground db N N N N N N N @dark@blue
dg N N N N N N N @dark@green
r N N N N N N N N @red
t@ N N N N N N N N tan momentary electrical@schematic
shows
RS
g@N N N N N N N N @gray v@ N N N N N N N N @violet@HpurpleI
maintained
m
VPOWPxt@skid@steer@loaders
circuit shows@page@number INLINE CONNECTION WITH TERMINALS lb@ N N N N N N N @light@blue w@ N N N N N N N @white light manual@reset a‡‡ŒšŒ•”„’@†•–Œˆ™@•‰@š‹Œ™@h ‡˜„›’Œ†@„”‡@e’ˆ†š˜Œ†„’@s†‹ˆ“„šŒ†@†„”@…ˆ@•˜‡ˆ˜ˆ‡@š‹˜•›Š‹@
variable tempN circuit@breaker
lg@N N N N N N N @light@green y@ N N N N N N N N @yellow coil emitting dNpNsNtN dNpNdNtN
connected circuit@is@continued@on ground resistor resistor diode contacts motor lamp
tˆ†‹”Œ†„’@p›…’Œ†„šŒ•”™@dŒ™š˜Œ…›šŒ•”@s ™šˆ“N@t‹ˆ@–„˜š@”›“…ˆ˜@Œ™@VMTTYTPN
hiPQhPPR

60XT 70XT Skid Steer Service Manual

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60XT 70XT Skid Steer Service Manual

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SECTION INDEX

Section Title Section Number

Copyright © 2001 Case Corporation

FLUIDS AND LUBRICANTS

Bur 6-44860 Issued 9-01 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Bur 6-44860 Issued 9-01 Printed in U.S.A.

Engine Oil Selection

Case Multi-Viscosity Engine Oil

See the chart below for recommended viscosity at

Oil Viscosity/Temperature Ranges

Bur 6-44860 Issued 9-01 Printed in U.S.A.

DIESEL FUEL SYSTEM

Specifications for Acceptable No. 2 Diesel Fuel

Bur 6-44860 Issued 9-01 Printed in U.S.A.

Bur 6-44860 Issued 9-01 Printed in U.S.A.

Section Title Section Number

Copyright © 2001 Case Corporation

ENGINE AND RADIATOR REMOVAL AND

CASE CORPORATION Copyright © 2001 Case Corporation

Bur 6-45950 Issued 11-01 Printed in U.S.A.

O p e n t h e h o o d a n d re a r a cc e s s d o o r o n th e If equipped with a heater, open the heater coolant

NOTE: Refer to illustration on page 5. NOTE: Refer to illustration on page 5.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Disconnect the electrical connectors from the rear tail

Tag and disconnect the hoses from the oil cooler on

If equipped with a heater, disconnect the heater STEP 7

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Disco nnect the electrica l connector for the air

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Disconnect the wires (1) from the starter solenoid.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

STEP 28 1. FUEL 2. FUEL RETURN 3. CLAMP 4. CLAMP

Disconnect the wire connector for the fuel injection

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Remove the hose from the hydraulic oil filter.

Disconnect the hydraulic lines shown from the left

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Disconnect the control rods (1) from the tandem STEP 50

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Bur 6-45950 Issued 11-01 Printed in U.S.A.

Section Title Section Number

Copyright © 2001 Case Corporation

Section Title Section Number

Copyright © 2001 Case Corporation

Bur 6-44870 Issued 9-01 Printed in U.S.A.

SAFETY INTERLOCK SYSTEM

258C A BRAKE LAMP

311F 311G 19. Seat Bar Switch

1 9 14 311F 311D 313H (8-Pin Connector)

Circuits Circuits Circuits

Bur 6-44870 Issued 9-01 Printed in U.S.A.

Bur 6-44870 Issued 9-01 Printed in U.S.A.

Bur 6-44880 Issued 9-01 Printed in U.S.A.

Circuit Diagram Legends

Diode Harness Connector With Pin Number:

6 Indicates component number Harness Connector With Pin Number

PRIMARY FUSE BLOCK OPTIONS FUSE BLOCK

2 20 AMPERE 2. Wiper/Heater 6 10 AMPERE 6. Miscellaneous Power

30 AMPERE 3. Backup Alarm/Horn 10 AMPERE 7. Beacon/Front Electrics