s250 & s300 Service Manual

Service
Manual
S250
Page 1 - OSS# 6163357 - All rights reserved by Bobcat Company, a business unit of Ingersoll-Rand - 05/05/2008 - 08:53:45 - Produced by Ken Cook Co. with media1off
S/N 526011001 & Above

S/N 526111001 & Above
S300
S/N 525811001 & Above
S/N 525911001 & Above
INCLUDES HIGH FLOW
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902711 (3-06) Printed in U.S.A. © Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-16261 B-16264

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

B-16272 B-16260 B-16263

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-16271 B-16270 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW14-0805
ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 EVAPORATOR/HEATER UNIT...............................80-01

AIR CLEANER ........................................................ 70-01 EXPANSION VALVE ...............................................80-01
AIR CLEANER SERVICE ....................................... 10-01 FAN GEARBOX.......................................................10-01
AIR CONDITIONING SERVICE.............................. 80-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FLYWHEEL AND HOUSING ............................... 70-01
ALTERNATOR ........................................................ 60-01 FLYWHEEL RPM SENSOR ................................ 60-01
FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
BASIC TROUBLESHOOTING ................................ 80-01 FUEL SYSTEM........................................................10-01
BATTERY ............................................................... 60-01 FUEL TANK .............................................................50-01
BICS™ SYSTEM .................................................... 60-01
BLOWER FAN ........................................................ 80-01
GENERAL AIR CONDITIONING SERVICE
BOBCAT CONTROLLER........................................ 60-01
GUIDELINES .........................................................80-01
BOB-TACH .............................................. 10-01, 50-01
BRAKE .................................................................... 40-01
BRAKE (TWO-SPEED)........................................... 40-01 HEATER COIL.........................................................80-01
BUCKET POSITION VALVE ............................... 20-01 HEATER VALVE .....................................................80-01
HYDRAULIC CONNECTION SPECS ............... SPEC-01
CALIBRATION ........................................................ 60-01 HYDRAULIC CONTROL VALVE
CHAINCASE ........................................................... 40-01 (ADVANCED CONTROL SYSTEM) (ACS) ...........20-01
CHARGE PRESSURE ............................................ 30-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
COMPONENTS ...................................................... 80-01 (ADVANCED CONTROL SYSTEM) (ACS) ...........20-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC CONTROL VALVE
CONDENSER ......................................................... 80-01 (FOOT CONTROL)................................................20-01

CONTROL HANDLE ............................................... 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (FOOT CONTROL)................................................20-01
(ACS) SELECTABLE HAND/FOOT CONTROL ... 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)......20-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 50-01 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
CONTROL PANEL (ADJUSTABLE PINTLES) ....... 50-01 (SELECTABLE JOYSTICK CONTROL) (SJC)......20-01
CONTROL PANEL (NON-ADJUSTABLE PINTLES) .. 50-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CONTROL PANEL HYDRAULIC FLUID SPECIFICATIONS ....... SPEC-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 50-01 HYDRAULIC/HYDROSTATIC FILTER....................20-01
CONTROL PEDALS ............................................... 50-01 HYDRAULIC/HYDROSTATIC SYSTEM .................10-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC PUMP ...............................................20-01
CONTROLLER (SELECTABLE JOYSTICK HYDRAULIC PUMP (CHARGE)..............................20-01
CONTROL) (SJC) ................................................. 60-01 HYDRAULIC PUMP (HI FLOW) ............................20-01
CONVERSIONS ............................................SPEC-01 HYDRAULIC PUMP (SELECTABLE JOYSTICK
COOLING FAN ....................................................... 70-01 CONTROL) (SJC).................................................20-01
CYLINDER (LIFT) ................................................... 20-01 HYDRAULIC PUMP (HI FLOW)
CYLINDER (POWER BOB-TACH) ......................... 20-01 (SELECTABLE JOYSTICK CONTROL) (SJC).....20-01
CYLINDER (TILT) ................................................ 20-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
HYDROSTATIC MOTOR .................................... 30-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 HYDROSTATIC MOTOR (TWO SPEED) ...............30-01
DRIVE BELT ........................................................... 30-01 HYDROSTATIC MOTOR CARRIER .......................30-01
DRIVE COMPONENTS .......................................... 40-01 HYDROSTATIC MOTOR CARRIER
(SELECTABLE JOYSTICK CONTROL) (SJC)......30-01
ELECTRICAL/HYDRAULIC CONTROLS HYDROSTATIC PUMP ....................................... 30-01
REFERENCE ........................................................ 60-01 HYDROSTATIC PUMP
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) ..30-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01 HYDROSTATIC SYSTEM INFORMATION .........30-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENGINE ................................................................. 70-01 INSIDE ACCESS PANEL ........................................50-01
ENGINE COOLING SYSTEM ................................. 10-01 INSIDE ACCESS PANEL
ENGINE LUBRICATION SYSTEM ......................... 10-01 (SELECTABLE JOYSTICK CONTROL) (SJC)......50-01
ENGINE SPECIFICATIONS ..........................SPEC-01 INSTRUMENT PANEL ............................................60-01
ENGINE SPEED CONTROL .................................. 70-01
ENGINE SPEED CONTROL (SELECTABLE
JOYSTICK CONTROL) (SJC)............................... 70-01
EVAPORATOR ....................................................... 80-01
ALPHABETICAL INDEX (CONT’D)
LIFT ARMS ..........................................................50-01

LIFT ARM BY-PASS CONTROL VALVE ............ 20-01
LIFT ARM SUPPORT DEVICE ............................10-01
LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS ............................................................... 60-01
LOADER SPECIFICATIONS (S250) ................. SPEC-01
LOADER SPECIFICATIONS (S300) ................. SPEC-01
LUBRICATING THE LOADER.................................10-01
MAIN RELIEF VALVE (ACS)...............................20-01

MAIN RELIEF VALVE (FOOT CONTROL)..............20-01
MAIN RELIEF VALVE
(SELECTABLE JOYSTICK CONTROL) (SJC)......20-01
MUFFLER................................................................70-01
OIL COOLER (SEAL TO CONNECT) (STC)...........30-01

OPERATOR CAB .........................................10-01, 50-01
OPERATOR SEAT ..................................................50-01
OPERATOR SEAT (SUSPENSION) .......................50-01
POWER BOB-TACH ................................ 10-01, 50-01
POWER BOB-TACH BLOCK ..................................20-01
PRESSURE RELIEF VALVE...................................80-01
PRESSURE SWITCH..............................................80-01
RADIATOR ..............................................................70-01
REAR AUXILIARY DIVERTER................................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ....................................................... 50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START ................................................ 10-01
RPM SENSOR.........................................................70-01
SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR...............................................60-01
SRVICE PC (LAPTOP COMPUTER) ......................60-01
SERVICE SCHEDULE ........................................... 10-01
SPEED SENSOR (SELECTABLE JOYSTICK ........60-01
CONTROL) (SJC)..................................................60-01
STARTER ............................................................... 60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE/PRESSURE.................................80-01
THERMOSTAT ........................................................80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS ... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER ............10-01
TROUBLESHOOTING.............................................70-01
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . X
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 70-01 SERVICE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
S250, S300 Bobcat Loader

I Service Manual
II
Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function

and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers and foot 15. Inspect for fuel, oil or

pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct function of 16. Lubricate the loader.

the work lights

III Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Recommend to the owner
pressure. that all necessary corrections
be made before the machine
is returned to service.
21. Inspect for loose or broken

parts or connections.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.

IV Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or

service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Skid-Steer Loader Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
• The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI SSL-0206 SM

V Service Manual
SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.
Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM

VI Service Manual
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
• The operator cab, engine compartment, and engine

• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI SSL-0206 SM

VII Service Manual
VIII
Service Manual
SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 2
P-48339
The engine serial number is located on the engine block

[Figure 3].
DELIVERY REPORT
Figure 4
P-31226
The loader serial number plate is located on the outside

of the loader frame [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
1. The four digit Model/Engine Combination Module

B-16315
number identifies the model number and engine
combination.
The Delivery Report must be filled out by the dealer and
2. The five digit Production Sequence Number identifies signed by the owner or operator when the Bobcat loader
the order which the loader is produced. is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
4].

IX Service Manual
BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS OPERATOR SEAT

with SEAT BELT
GRAB HANDLES
TILT CYLINDER
+ BUCKET
FRONT AUXILIARY
QUICK COUPLERS
BUCKET STEPS STEPS
● OPERATOR CAB
LIFT CYLINDER (ROPS & FOPS)
SEAT BAR
LIFT ARM
REAR GRILL
LIFT ARM
SUPPORT DEVICE
REAR
LIGHT
REAR DOOR
▼ TAIL LIGHT
* TIRES B-16373
B-16275
▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

* TIRES - Flotation tires ▼ are shown. The Bobcat loader is factory equipped with standard tires.
+ BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective
Structure per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a
standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

X Service Manual
SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Adding The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Cleaning Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
DRIVE
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

ELECTRICAL
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 SYSTEM &
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ANALYSIS
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2
SPECIFICATIONS
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-2
Replacing Hydraulic Fluid And Case Drain Filters . . . . . . 10-120-3
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing The Lift Arm Support Device. . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Continued On Next Page

10-01 Service Manual
SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Procedure For Loader With Attachments Control Harness 10-60-2
Procedure For Loader W/O Attachments Control Harness 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIGHTEN ALL HARDWARD PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION
SPEC-01) UNLESS OTHERWISE SPECIFIED.

LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-31290
Lift the rear of the loader and install jackstands [Figure

B-7023A 10-10-2].
Figure 10-10-3
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
P-31676
Read the Removal & Installation, Disassembly &

Assembly, etc. completely to become familiar with the Lift the front of the loader and put jackstands under the
procedure before beginning [Figure 10-10-1]. axle tubes [Figure 10-10-3].
Always park the loader on a level surface. NOTE: Make sure the jackstands do not touch the
tires.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

10-10-1 Service Manual
LIFT ARM SUPPORT DEVICE Remove the lift arm support device (Item 1) [Figure 10-
20-1] from the storage position.
Installing The Lift Arm Support Device
The operator must stay in the operator seat with the seat
Figure 10-20-1 belt fastened and the seat bar lowered, until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
P-10136
1
P-31290 P-31244
WARNING P-31264
Never work on a machine with the lift arms up unless

Have a second person install the lift arm support device
the lift arms are secured by an approved lift arm
over the rod of one of the lift cylinders [Figure 10-20-2].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
The lift arm support device must be tight against the
to fall and cause injury or death.
W-2059-0598
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].
WARNING
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-1].

LIFT ARM SUPPORT DEVICE (CONT’D)
Installing The Lift Arm Support Device (Cont’d)
Figure 10-20-3
P-31265
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-
20-3].
Removing The Lift Arm Support Device
The operator must be in the operator's seat, with the seat

belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.
Start the engine, raise the lift arms all the way up.
Have a second person remove the lift arm support

device.
Lower the lift arms all the way and stop the engine.
Return the lift arm support device to storage position and

secure with clamping knobs.
Remove the jackstands.

OPERATOR CAB Figure 10-30-2
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.
ROPS/FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.
Level I - Protection from falling bricks, small concrete P-31288 P-31289

blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Loosen the nut (both sides) at the front corner of the
operator cab [Figure 10-30-2].
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Remove the nuts and plates [Figure 10-30-2] (both
or forestry. sides).
Raising The Operator Cab Figure 10-30-3
Figure 10-30-1
P-31267
P-31290
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
Always stop the engine before raising or lowering the mechanism engages [Figure 10-30-3].
cab.
Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing The Lift
Arm Support Device on Page 10-20-1.)
Install jackstands under the rear of the loader frame

[Figure 10-30-1].

OPERATOR CAB (CONT'D) Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Raising The Operator Cab (Cont’d)
Release the latching mechanism (Inset) [Figure 10-30-4]
Advanced Hand Control Only and pull the cab all the way down.
Figure 10-30-5
P-31288 P-31289
WARNING Install the plates and nuts [Figure 10-30-5] (both sides).
Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.

Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
Emergency Exit
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
Figure 10-30-6
and falling objects, and result in injury or death.
W-2069-1299
Lowering The Operator Cab

Figure 10-30-4
N-19386
The front opening on the operator cab and rear window

provide exits.
N-20120 P-31268
REAR WINDOW (If Equipped)
Always stop the engine before raising or lowering the Pull on the tag on the top of the rear window to remove
cab. the rubber cord [Figure 10-30-6].
NOTE: Make sure the seat bar is fully raised or

lowered when lowering the cab. Always use
the grab handles to lower the cab.

OPERATOR CAB (CONT'D) Figure 10-30-9
Emergency Exit (Cont’d)
Figure 10-30-7
P-28359
Push the window out with your foot [Figure 10-30-9] at

P-31269 any corner of the window.
Exit through the front door.

Push the rear window out of the rear of the operator cab.
Exit through the rear of the operator cab [Figure 10-30-

7].
Figure 10-30-8
N-20171
FRONT DOOR (If Equipped)
NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be
used as an emergency exit [Figure 10-30-8].
NOTE: When the special applications kit is installed,

the front door cannot be used for an
emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].

TRANSPORTING THE BOBCAT LOADER Figure 10-40-2
Procedure
Figure 10-40-1
P-31228A P-31230A
P-31915
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. 6595014 P-31916
W-2058-0494
Use the following procedure to fasten the Bobcat loader

A loader with an empty bucket or no attachment must be to the transport vehicle to prevent the loader from moving
loaded backward onto the transport vehicle [Figure 10- during sudden stops or when going up or down slopes
40-1]. [Figure 10-40-2].
Be sure the transport and towing vehicles are of • Lower the bucket or attachment to the floor.
adequate size and capacity (See LOADER
SPECIFICATIONS (S250) on Page SPEC-10-1.) or (See • Stop the engine.
LOADER SPECIFICATIONS (S300) on Page SPEC-11-
1.). • Engage the parking brake.
The rear of the trailer must be blocked or supported (Item • Install chains at the front and rear loader tie down
1) [Figure 10-40-1] when loading or unloading the loader positions (Inset) [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
• Fasten each end of the chain to the transport vehicle.

TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

recommended towing procedure.
• The loader can be lifted onto a transport vehicle.
• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1 & 1/2

times the weight of the loader (See LOADER
SPECIFICATIONS (S250) on Page SPEC-10-1.) or
(See LOADER SPECIFICATIONS (S300) on Page
SPEC-11-1.)

REMOTE START Figure 10-60-2
Procedure For Loader W/O Attachments Control

Harness
Figure 10-60-1
1
1
P-28365
Remove the cap (Item 1) [Figure 10-60-2] from the

loader harness.
P13841
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-60-2].

The tool listed will be need to do the following procedure:
Figure 10-60-3
MEL1563 - Remote Start Tool Kit
The remote start (Item 1) [Figure 10-60-1] is required

when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering 2
linkage.
Lift and block the loader. (See Procedure on Page 10-10-

1.) 1
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)
P-28366
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Connect the remote start tool to the engine harness
Open the rear door of the loader. connector (Item 1) [Figure 10-60-3].
The connector (Item 2) [Figure 10-60-3] from the remote

start harness is not used in the remote start procedure
and should remain capped.
NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Kit will not operate.

REMOTE START (CONT'D) Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Procedure For Loader W/O Attachments Control
Harness (Cont’d) Open the rear door of the loader.
Figure 10-60-5
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working in the engine area 1
it is important to remove the operator panel keys.
W-2357-0899
P-28362
Procedure For Loader With Attachments Control
Harness
Figure 10-60-6
Figure 10-60-4
P-28364
P13841
Disconnect the attachment control harness (Item 1)

The tool listed will be need to do the following procedure: [Figure 10-60-5] & [Figure 10-60-6] from the loader
harness (Item 2) [Figure 10-60-6].
The remote start (Item 1) [Figure 10-60-4] is required

when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering
linkage.

1.)
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)

REMOTE START (CONT'D) Procedure
Procedure for Loader With Attachments Control Figure 10-60-8

Harness (Cont’d)
Figure 10-60-7
1
3 2
P13842
1
P-28363 The remote start tool (Item 1) [Figure 10-60-8] has three
rocker switches.
Connect the remote start tool (Item 1) [Figure 10-60-7] to Figure 10-60-9
the loader harness connector (Item 2) [Figure 10-60-6].
The connector (Item 3) [Figure 10-60-7] on the remote

start harness is not used in the remote start procedure
and should remain capped.
2
NOTE: The key switch on the right-hand side 1
3
operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
N-19541
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the The traction lock switch (Item 1) [Figure 10-60-9] is used
loader can still be started from the operator panel to turn traction lock on or off. Push the switch to the
inside the cab. Placing the key switch of the remote override position. The switch will illuminate to indicate
start tool in the run position disconnects the traction lock OVERRIDE, in this position the wheels are
operator panel key switch from the start circuit. If the able to turn.
service technician will be working in the engine area The maximum flow/variable flow switch (Item 2) [Figure
it is important to remove the operator panel keys. 10-60-9] is used to activate the auxiliary hydraulics.
W-2357-0899 Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-9]
is used to release hydraulic pressure to the rear auxiliary
couplers, and right hand auxiliary. (If so equipped.) To
release pressure; push and hold the switch for three
seconds.

REMOTE START (CONT'D)
Procedure (Cont’d)
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to press the switch
after the engine has stopped.

SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS

■ ■ ■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Tires Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™) details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Fuel Filter Remove the trapped water.
Heater and A/C Filters Clean or replace filters as needed during heating/cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls,
and Steering Levers
Wheel Nuts ❏Check for loose wheel nuts and tighten to 105-115 ft.-lbs. (142-156 Nm)
torque
Parking Brake Check operation.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Engine/Hydro. Drive Belt *Check for wear or damage. Check idler arm stop.
Alternator Belt Check tension and adjust as needed.
Air Condition Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm by-pass control.
(BICS™)
Fuel Filter Replace filter element.
Steering Shaft Grease fittings.
Fan Drive Gearbox Check gear lube level.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter ●Replace the filter element.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^ ❍
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves Adjust the engine valves.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace hydraulic/hydrostatic filter element at the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
❍ When operating under severe conditions, change oil and filter every 250 hours.
■ Or every 12 months.

AIR CLEANER SERVICE If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER /
Replacing Filter Element CODE DISPLAY (Item 2) [Figure 10-80-2].
Figure 10-80-1 Figure 10-80-3
B-16300
P-48340
B-15552
B-15553
OUTER FILTER
It is important to change the air filter element only when Disengage the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner Icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated on See Replacing Filter Element
(Cont'd) on Page 10-80-2.
Figure 10-80-2 1
P-48341
1
Remove the wing nut (Item 1) [Figure 10-80-4] and
remove the outer filter element.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
B-15551 Install a new outer element, and install the wing nut.
Install the dust cover and install the outer wing nut.
Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

AIR CLEANER SERVICE (CONT'D) Figure 10-80-6
Replacing Filter Element (Cont'd)
Figure 10-80-5
1
1
P-48340
Install the new inner element.

P-48342
Install the dust cover and wing nut (Item 1) [Figure 10-
80-6].
INNER FILTER
Only replace the inner filter element under the following

conditions:
• Replace the inner filter element every third time the

outer filter is replaced.
• After the outer element has been replaced, start the

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
Remove the inner filter element (Item 1) [Figure 10-80-

5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.

ENGINE COOLING SYSTEM Figure 10-90-2
Cleaning Cooling System
Figure 10-90-1
P-34868
Lift the overflow tank (Item 1) [Figure 10-90-2] out of its

P-34869 mount bracket.
Remove the cotter pin (Item 2) [Figure 10-90-2] (both

Check the cooling system every day to prevent over- sides) from the oil cooler.
heating, loss of performance or engine damage.
Figure 10-90-3
WARNING
Wear safety glasses to prevent eye injury when any
of the flollowing conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
Remove the rear grill. (See Removal And Installation on

Page 50-60-1.) P-34867
Use air pressure or water pressure to clean the top of the

oil cooler [Figure 10-90-1]. Raise the oil cooler [Figure 10-90-3].
Use air pressure or water pressure to clean the top of the

engine oil cooler.

ENGINE COOLING SYSTEM (CONT’D)
Cleaning Cooling System (Cont’d)
Figure 10-90-4
Access
Cover
P-31691
NOTE: The access cover (both sides) must be in
place to ensure proper air flow through the oil
cooler which will ensure correct cooling for
the engine/hydraulic system [Figure 10-90-4].

ENGINE COOLING SYSTEM (CONT’D)
Checking The Coolant Level

IMPORTANT
Figure 10-90-5
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
MAX
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
MIN
MAX
damage.
P-45106
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
P-62252 I-2124-0497
Open the rear door and raise the rear grill.
Check the coolant level [Figure 10-90-5]. The level

marks are on the outside of the tank. Coolant level must
be between the MIN and MAX marks on the coolant
recovery tank when the engine is cold.
Close the rear door before operating the loader.

ENGINE COOLING SYSTEM (CONT’D) Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
Adding The Coolant
One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34°F (-37°C) freeze protection.
WARNING Use a refractometer to check the condition of propylene
glycol in your cooling system.
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
Fill the tank with the premixed coolant until it is between
the MIN and MAX marks. Install the coolant tank cap.
Figure 10-90-6 Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level in the coolant tank
when cool. Add coolant as needed.
Install the rear grill and close the rear door.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

P-62252 efficiency and may cause serious premature engine
damage.
Open the rear door and remove the rear grill. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Remove the coolant tank cap (Item 1) [Figure 10-90-6]. boiling point and freeze protection of the system.
Mix the coolant in a separate container. (See Capacities Always add a premixed solution. Adding full strength
on Page SPEC-10-4.) or (See Capacities on Page concentrated coolant can cause serious premature
SPEC-11-4.) engine damage.
I-2124-0497
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
The following is one suggested blending guideline which

should prevent fuel gelling problems:
Temp. F° (C°) No. 2 No. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B-15526
We recommend an operator contact their fuel supplier for

local recommendations. Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
Filling The Fuel Tank free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap [Figure 10-100-1].
WARNING Fuel Filter
Stop and cool the engine before adding fuel. NO Figure 10-100-3
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
Figure 10-100-1
2
P-48343
1
(See SERVICE SCHEDULE on Page 10-70-1.) for the

recommended service interval when to remove the water
from the fuel filter.
P-31254
Loosen the drain (Item 1) [Figure 10-100-3] at the

Remove the fuel fill cap (Item 1) [Figure 10-100-1]. bottom of the filter element to drain any water from the
filter.
(See SERVICE SCHEDULE on Page 10-70-1.) for the

recommended service interval when to replace the fuel
filter.
To replace the fuel filter element, use a filter wrench to

remove the filter element (Item 2) [Figure 10-100-3].
FUEL SYSTEM (CONT'D)
Fuel Filter (Cont’d)
Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter, and
hand tighten. Remove the air from the fuel system.
Removing Air From The Fuel System
Figure 10-100-4
P-48343
After replacing the fuel filter element or when the fuel

tank has run out of fuel, the air must be removed from the
fuel system prior to starting the engine.
Loosen the air vent plug (Item 1) [Figure 10-100-4] at the

top of the fuel filter.
Figure 10-100-5
P-48351
Operate the hand pump (priming bulb) (Item 1) [Figure

10-100-5] until the fuel flows from the air vent plug with
out air bubbles.
Tighten the air vent plug.

ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil Figure 10-110-2
Figure 10-110-1
P-48345
P-48345
(See SERVICE SCHEDULE on Page 10-70-1.), for the
service interval for replacing the engine oil and filter.
Check the engine oil level every day.

Run the engine until it is at operating temperature. Stop
Before starting the engine for the work shift, open the the engine.
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1]. Open the rear door. Remove the drain hose (Item 1)
[Figure 10-110-2] from its storage position. Remove the
Keep the oil level between the marks on the dipstick. cap and drain the oil into container.
Use a good quality motor oil that meets API Service

Classification of CD, CE or better. (See Oil Chart below.)
Oil Chart

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-4
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
P-48347
Remove the filler cap (Item 1) [Figure 10-110-4].

P-48345
Put 14 qts. (13,2 L) of oil in the engine.
Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
WARNING oil as needed if it is not at the top mark on the dipstick.
Always clean up spilled fuel or oil. Keep heat, flames,

sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Remove the oil filter (Item 1) [Figure 10-110-3].
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.
Install and tighten the drain cap on the drain hose.

HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-2
Checking And Adding Fluid
Figure 10-120-1
Sight
Gauge
1
P-4613
P-31692
If fluid is needed, remove the fill cap (Item 1) [Figure 10-

P-31692 120-2].
Add the fluid as needed to bring the level to the center of

Use only recommended fluid in the hydraulic system. the sight gauge.
(See Hydraulic System on Page SPEC-10-3.) or (See
Hydraulic System on Page SPEC-11-3.) Figure 10-120-3
Hydraulic Fluid Chart
P-30011
NOTE: Before installing the fill cap, make sure the

rubber gasket (Item 1) [Figure 10-120-3] is
installed on the fill cap.
To check the reservoir, use the following procedure:
Put the Bobcat loader on a level surface. Lower the lift

arms and tilt the Bob-Tach fully back. Stop the engine.
Check the fluid level at the sight gauge [Figure 10-120-

1]. The fluid level must show in the sight gauge.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)
Hydraulic/Hydrostatic Filter Replacement
Figure 10-120-4
P-34904
correct service interval.
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
Use a filter wrench to remove the filter element (Item 1)

[Figure 10-120-4].
Clean the surface of the filter housing where the element

seal contacts the housing. Put clean oil on the rubber
seal of the filter elements.
Install and hand tighten the filter elements.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-6
Replacing Hydraulic Fluid And Case Drain Filters

1
Figure 10-120-5
1
P-34905
Disconnect the hoses from the hydrostatic motor case

P-31286 drain filter (Item 1) [Figure 10-120-6].
Remove the case drain filter and clean thoroughly with

(See SERVICE SCHEDULE on Page 10-70-1.), for the clean solvent.

service interval.
Install the case drain filter and tighten the hoses.
Replace the fluid if it becomes contaminated or after
major repair. Install the plug in the reservoir drain hose and tighten.
Install the motor cover.
Also clean the hydrostatic motor case drain filter
thoroughly after a major repair.

on Page 10-30-1.)
Remove the left hydrostatic motor cover.
Pull the reservoir drain hose (Item 1) [Figure 10-120-5]

out the motor cover hole. Remove the plug and drain the
fluid into a container.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-8
Replacing Hydraulic Fluid And Case Drain Filters

(Cont’d)
Figure 10-120-7
P-31565
Remove the hoses from the attachments case drain filter

(Item 1) [Figure 10-120-8]. Remove and discard the
1
P-31692 filter.
Install a new filter, tighten the hose fittings and install the
Remove the left side access panel (Item 1) [Figure 10- cover.
120-7].
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-120-1.)
Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the reservoir and add as
needed.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing The Oil
Checking And Adding Oil Remove the front chaincase cover. (See Front
Chaincase Cover Removal And Installation on Page 40-
Figure 10-130-1 30-1.)
Use a vacuum pump to extract the fluid from the chain

case.
P-31287
The chaincase contains the final drive sprockets and

chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See LOADER SPECIFICATIONS
(S250) on Page SPEC-10-1.) or (See LOADER
SPECIFICATIONS (S300) on Page SPEC-11-1.)
To check the chaincase oil level, use the following

procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the

front of the chaincase housing.
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

10-130-2
Service Manual
FAN GEARBOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube 1
Level
P7616

correct service interval.

on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the

lubricant level.
When checking the gearbox lube level, make sure the

level does not go above the center line of the shaft in the
gearbox [Figure 10-140-1]. Use SAE 90W gear lube if
the level is low.

10-140-2
Service Manual
BOB-TACH Figure 10-150-3
Inspection And Maintenance

Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1 In the Attachment
B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
P-21234 If the wedge does not contact the lower edge of the hole
[Figure 10-150-2] and [Figure 10-150-3], the
1 attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4
P-31693
Move the Bob-Tach levers to engage the wedges

[Figure 10-150-1]. The levers and wedges must move
freely.
The wedges must extend through the holes in the

attachment mounting frame (Inset) [Figure 10-150-1].
Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
1
on Page 10-160-1.)
P-31237

10-150-2
Service Manual
POWER BOB-TACH Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
B-15177
Wedges Must Contact

Lower Edge Of Hole
In The Attachment
P-31237
If the wedge does not contact the lower edge of the hole
B-15891A (Item 1) [Figure 10-151-3], the attachment will be loose
and can come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the

1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
P-31233 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-160-1.)

10-151-2
Service Manual
LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1 3
P-31301
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-3].

P-31299 Figure 10-160-4
Lubricate the loader as specified in the SERVICE

SCHEDULE, Contents Page 10-01 for the best
performance of the loader.
Record the operating hours each time you lubricate the

Bobcat loader. 4
Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:

P-31302
1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1].
Figure 10-160-2 4. Lift Arm Link Pivot (Both Sides) [Figure 10-160-4].
Figure 10-160-5
2
P-31300
P-31305
2. Base End Lift Cylinder (Both Sides) [Figure 10-160-
2].
5. Base End Tilt Cylinder (Both Sides) [Figure 10-160-
5].

LUBRICATION OF THE LOADER (CONT'D) Figure 10-160-8
Procedure (Cont'd)
Figure 10-160-6
P-31308
8. Bob-Tach Wedge (Both Sides) [[Figure 10-160-8]

P-31306
Figure 10-160-9
6. Rod End Tilt Cylinder (Both Sides) [Figure 10-160-6].
Figure 10-160-7
9
P-31304
7
9. Stabilizer Bar (Both Sides) [Figure 10-160-9].

P-31307
Figure 10-160-10
7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-7].
10
P-31303
10. Stabilizer Bar (Both Sides) [Figure 10-160-10].

LUBRICATION OF THE LOADER (CONT'D)
Procedure (Cont'd)
Figure 10-160-11
11
P10105
11. 250 Hours: Steering Lever Shaft (three) [Figure 10-

160-11].
Pivot Pins
Figure 10-160-12
P-31309
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-12].
Check that the lock nuts are tightened to 18-20 ft.-lbs.

(24-27 Nm) torque.

10-160-4
Service Manual
TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-170-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Tire Mounting
Tires are to be repaired only by an authorized person

using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
P-31673 lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire

(See SERVICE SCHEDULE on Page 10-70-1.), for the pressure frequently to avoid over inflation.
service interval to check the wheel nuts [Figure 10-170-
1].
When installing wheel nuts, tighten to 160 ft.-lbs. (217

Nm) torque. WARNING
When checking wheel nuts, tighten to 140 ft.-lbs. (190 Do not inflate tires above specified pressure. Failure
Nm) torque . to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
Tire Rotation W-2078-1285
Figure 10-170-2
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
B-9976
Check the tires regularly for wear, damage and pressure.

(See Tires on Page SPEC-10-4.) or (See Tires on Page
SPEC-11-4.)
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].

10-170-2
Service Manual
HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .20-90-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-2 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . .20-90-1 SYSTEM
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-3 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-3

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-2 ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-6
Base Pin Removal And Installation . . . . . . . . . . . . . . . . . . . .20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ENGINE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-5 SERVICE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . 20-120-1 SPECIFICATIONS

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . 20-44-6
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-13
Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-44-27
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-44-25
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-44-32
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-44-31
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . 20-44-12
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . 20-44-29
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-44-28
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-44-18
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-11
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-19
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . 20-44-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-31
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-17
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-16
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-44-14
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-44-15
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-44-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-2
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . 20-41-2
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . . . 20-41-5
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-30
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . 20-41-15
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-41-14
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . . . . 20-41-16
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . 20-41-17
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-41-29
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Lift Spool Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) . 20-43-1

Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-8
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 20-43-29
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-27
BICS™ Valve, Check Valve Removal and Installation . . . . . . . . . . . . . . 20-43-34
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . 20-43-33
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . 20-43-7
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . . 20-43-31
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . . 20-43-30
End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . . . 20-43-14
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-6
Lift Spool and Detent Removal and Installation . . . . . . . . . . . . . . . . . . . . 20-43-15
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . . 20-43-8
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-33
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-11
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . . 20-43-9
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . 20-43-10

Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . 20-43-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-13
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) . 20-40-1

Anti-Cavitation Valve, Lift Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool. . . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Backslide, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-40-9
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . . 20-40-8
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . . 20-40-7
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS™ Valve, Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 20-40-10
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Lift And Tilt Lock Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool And Detent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Lift Spool And Detent Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Lift Spool And Detent Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Lift Spool And Detent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Port-Auxiliary Section Removal And Installation . . . . . . . . . . . . . . . . . . . 20-40-34
Port Relief Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE

JOYSTICK CONTROL) (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . 20-45-6
Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . 20-45-8
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . 20-45-13
Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . 20-45-27
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-45-25
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . 20-45-32
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly20-45-31
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . 20-45-12
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . 20-45-29
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . 20-45-28
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-45-18
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-11
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-19
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . 20-45-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-31
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-17
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . 20-45-14
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . 20-45-15
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . 20-45-15
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-2
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (SELECTABLE
JOYSTICK CONTROL) (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . 20-42-2
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . 20-42-5
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-24
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-42-23
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . 20-42-29
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-42-28
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . 20-42-15
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly20-42-14
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . 20-42-16
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-42-11
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . 20-42-17
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-18
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-30
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-19
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . 20-42-27
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-20
Lift Spool Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-25
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-26
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-20
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-21
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-30
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-22
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Check The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
HYDRAULIC PUMP (CHARGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1

Disassembly And Assembly (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . 20-62-14

High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) . . . . . . . . . . 20-62-7
High Flow Relief Valve Removal and Installation (30 GPM And 40 GPM) . . . 20-62-9
Hydraulic Pump Test (30 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1
Hydraulic Pump Test (40 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-2
Identification (30 GPM) (S/N 526016699 & Below) (S/N 525815599 & Below)20-62-12
Identification (40 GPM) (S/N 526016700 & Above) (S/N 525815600 & Above)20-62-13
Inline Hydraulic Pump Test (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-3
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM) . . . . . . . . . . 20-62-5
Removal And Installation (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . . . 20-62-10
HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . 20-63-1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-4

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC) 20-64-1

Disassembly And Assembly (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . 20-64-15
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) . . . . . . . . . . . 20-64-7
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM) . . . . 20-64-9
Hydraulic Pump Test (30 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-1
Hydraulic Pump Test (40 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-2
Identification (30 GPM) (S/N 525815599 & Below) (S/N 526016699 & Below) 20-64-13
Identification (40 GPM) (S/N 525815600 & Above) (S/N 526016700 & Above)20-64-14
Inline Hydraulic Pump Test (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-3
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM) . . . . . . . . . . . 20-64-5
Removal And Installation (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . . . . 20-64-11
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Tightening Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Additional Inspection For Loaders W/Advanced Hand Controls . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Checking Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

REAR AUXILIARY DIVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
TIGHTEN ALL HARDWARD PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.

HYDRAULIC/HYDROSTATIC SCHEMATIC
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 625814999)
(S/N 525911001 - 525911999)
Printable Version Click Here
(PRINTED FEBRUARY 2005)
V-0383legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BASE 4000 PSI (275 Bar)
17 ONE WAY RESTRICTOR (ACS VALVE ONLY) 34 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
2 FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
18 LOAD CHECK VALVE VALVE (ON/OFF)
3 FILTER - HYDRAULIC (CANISTER) 35
LOAD SHUTTLE VALVE - BLEED OFF
19 RELIEF VALVE - MAIN: 53 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224-231 Bar) 36 PRESSURE BLEED-OFF VALVE
SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers CONTROL VALVE (TWO COIL)
54 ORIFICE WITH 0.025 (0.64 mm)
5 PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL RESTRICTION
CONTROL VALVE WITH 30PSI SPRING
- HYDRAULIC POWERED BOB-TACH 4000 PSI (275 Bar) CONTROL VALVE - REAR AUX
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE 38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION
36-44 PSI (2,5-3,0 Bar)
22 RELIEF/ANTICAVITATION VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
3500 PSI (241 Bar) RESTRICTION
8 CHECK VALVE - BUCKET POSITION 40 RELIEF VALVE - 3300 PSI (227,6 Bar)
23 LIFT BASE ORIFICE (MANUAL VALVE ONLY)
VALVE
41 CHECK VALVE - BICS CONTROL VALVE
9 FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (241 Bar) 43 FILTER - CASE DRAIN (ATTACHMENT)
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (345 Bar) 44 ORIFICE WITH 0.089 (2.26 mm)
RESTRICTION
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH
CONTROL VALVE - UNLOADING 45 VARIABLE CAPACITY DISPLACEMENT
SPOOL 28 RELIEF VALVE - CHARGE: BIDIRECTIONAL HYDROSTATIC PUMP
120 degrees F. (53 degrees C.)Fluid
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle 46 RELIEF VALVE 2000 PSI (138 Bar)
CONTROL VALVE - TILT CONTROL 400 - 460 PSI (27,6 - 31,7 Bar)
13 PILOTED ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL
29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL CONTROL VALVE (TWO COIL)
13.6 GPM (51,5 L/min.) at High
48 RELIEF VALVE - 1200 PSI (83 Bar)
14 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 30 HYDRAULIC Engine
PUMP Idle
. . . . . . . Gear Type 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
20.7 GPM (78.35 L/min.) at High Engine Idle
15 PULL BUTTON ACTIVATED SPRING
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE WITH 300 PSI (20,7 Bar)
ARM BY PASS SPRING WITH 0.016 (0,40 mm) ORIFICE NOTE: Unless otherwise specified
32 SHUTTLE RELIEF VALVE: springs have NO significant
200 PSI (13,8 Bar) pressure value.
Printed in U.S.A. V-0383legend (2-7-05)
(REAR QUICK
FEMALE COUPLERS) MALE
S250 (S/N 526011001 - 526015999) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
33 34
INTEGRATED QUICK COUPLER BLOCK
(PRINTED FEBRUARY 2005) Printable Version Click Here 35
V-0383
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 53
LEFT SIDE LIFT ARM)
MALE
31 37 53
32
FEMALE
P-OUT P-IN T
9 HYDRAULIC FILTER
3 BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS OIL

4 43 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE HYDRAULIC CONTROL VAVLE 10
INLET
26
11
27
24 24
45 25 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
29 TILT CYLINDERS
22 BICS CONTROL VALVE
18
BOB-TACH
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
51 TILT
BOB-TACH
CYLINDER
(OPTIONAL)
SPOOL
DRIVE MOTOR
49 21
9 DR
18
20 LIFT CYLINDERS
17
50
13
48 46 23
A B
54 LIFT
47 44
CYLINDER
PP SPOOL
32 P1 P2
31 5
18 42
19 14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
2 16 41 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0383 (2-7-05)
WITH TWO SPEED VALVE
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
(PRINTED FEBRUARY 2005) Printable Version Click Here
V-0384legend
LEGEND
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BASE 4000 PSI (275,9 Bar)
19 RELIEF VALVE - MAIN: 53 FIXED CAPACITY DISPLACEMENT
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224-231 Bar) 36 BIDIRECTIONAL HYDROSTATIC
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers MOTOR
CONTROL VALVE (TWO COIL)
5 PILOT ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
CONTROL VALVE WITH 30PSI SPRING - 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
HYDRAULIC POWERED BOB-TACH 4000 PSI (275,9 Bar) CONTROL VALVE - REAR AUX 55 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BRAKE
36-44 PSI (2,5-3,0 Bar)
22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - MAKE-UP
39 CHECK VALVE
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) 57 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,4 Bar) CONTROL VALVE - TWO SPEED
8 CHECK VALVE - BUCKET POSITION 40 FILTER (BRAKE)
VALVE 58 FRONT AUXILIARY MANUAL
41 CHECK VALVE - BICS CONTROL VALVE PRESSURE BLEED-OFF VALVE
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 59 FILTER - CASE DRAIN (ATTACHMENT)
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 60 ORIFICE WITH 0.025 (0.64 mm) RESTRICTION
3500 PSI (241,4 Bar) 43
10 PILOTED ACTIVATED DIRECTIONAL ORIFICE WITH 0.089 (2.26 mm)
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH RESTRICTION 61 ORIFICE WITH 0.031 (0.76 mm) RESTRICTION
SPOOL PRESSURE: 5000 PSI (344,8 Bar)
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH CONTROL VALVE - TWO SPEED 62 RELIEF VALVE - 3300 PSI (227,6 Bar)
CONTROL VALVE - UNLOADING DRIVE MOTOR
SPOOL 28 RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid 45 VARIABLE CAPACITY DISPLACEMENT
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC PUMP
400 - 460 PSI (27,6 - 31,7 Bar)
13 PILOTED ACTIVATED DIRECTIONAL 46 RELIEF VALVE 2000 PSI (138 Bar)
29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High 47 SOLENOID ACTIVATED DIRECTIONAL
14 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
PUMP Idle
. . . . . . . Gear Type
20.7 GPM (78.35 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
15 PULL BUTTON ACTIVATED
31 DRIVE MOTOR SHUTTLE VALVE 49 CHECK VALVE WITH 80 PSI (5,5 Bar) SPRING
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS NOTE: Unless otherwise specified
32 SHUTTLE RELIEF VALVE: 50 CHECK VALVE WITH 300 PSI (20,7 Bar) SPRING springs have NO significant
200 PSI (13,8 Bar) WITH 0.016 (0,04 mm) ORIFICE pressure value.
(REAR QUICK
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999) Printable Version Click Here
BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 525911001 - 525911999) TWO SPEED DRIVE MOTOR

V-0384
33 34
31 35
32 36 MALE
38
61 (FRONT AUXILIARY
62 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
P-OUT P-IN T
53
9 HYDRAULIC FILTER

4 59 D
COOLER 8
45
26 26
28
7
6
52 C
INLET
26
11
27
24 24
45 25 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
TWO SPEED VALVE 29 TILT CYLINDERS
18
55 B
40
BOB-TACH
CYLINDER
(OPTIONAL)
40 TWO SPEED DRIVE MOTOR
HYDRAULIC
POWERED A B 12
51 TILT
39 9 BOB-TACH
CYLINDER
(OPTIONAL)
SPOOL
54 49 21
56 53
C DR
18
P D 44 20 LIFT CYLINDERS
17
50
13
48 46 23
39 A B
60 LIFT
47 43
CYLINDER
PP SPOOL
57
P1 P2
A 5
18 42
31 32
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0384 (2-7-05)
WITH HIGH FLOW OPTION
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
V-0385legend
LEGEND
19 RELIEF VALVE - MAIN:
4 SPRING LOADED FILTER BYPASS 53 RELIEF VALVE - 3300 PSI (227 Bar)
3250-3350 PSI (224-231 Bar) 36 SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers CONTROL VALVE (TWO COIL)
54 DUMP VALVE (ON/OFF)
CONTROL VALVE WITH 30PSI SPRING - 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL
HYDRAULIC POWERED BOB-TACH 4000 PSI (275 Bar) CONTROL VALVE - REAR AUX 55 CHECK VALVE
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE 38 ORIFICE WITH 0.140 (3,6 mm)
56 FRONT AUXILIARY MANUAL
36-44 PSI (2,5-3,0 Bar) RESTRICTION
22 RELIEF/ANTICAVITATION VALVE - PRESSURE BLEED-OFF VALVE
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) 57
RESTRICTION FILTER - CASE DRAIN (ATTACHMENT)
3500 PSI (241 Bar)
8 CHECK VALVE - BUCKET POSITION 40 RELIEF VALVE - 3300 PSI (227 Bar)
VALVE 58 ORIFICE WITH 0.025 (0.64 mm)
41 CHECK VALVE - BICS CONTROL VALVE RESTRICTION
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (241 Bar) 43 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 10.2 GPM (37.85 L/min.) at High Engine Idle
SPOOL PRESSURE: 5000 PSI (345 Bar)
44 ORIFICE WITH 0.089 (2,26 mm)
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH RESTRICTION
CONTROL VALVE - UNLOADING
400 - 460 PSI (27,6 - 31,7 Bar)
29 CHARGE PUMP
PUMP Idle
. . . . . . . Gear Type
20.7 GPM (78.35 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (83 Bar)
31 DRIVE MOTOR SHUTTLE VALVE 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
SPRING NOTE: Unless otherwise specified
ARM BY PASS
32 SHUTTLE RELIEF VALVE: 50 CHECK VALVE WITH 300 PSI (20,7 Bar) springs have NO significant
200 PSI (13,8 Bar) SPRING WITH 0.016 (0,40 mm) ORIFICE pressure value.
(REAR QUICK
S250 (S/N 526011001 - 526015999) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 526111001 - 526111999)

S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999) Printable Version Click Here 34
33 INTEGRATED QUICK COUPLER BLOCK
V-0385 35
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 56
LEFT SIDE LIFT ARM)
MALE
31 37 56
32
FEMALE
P-OUT P-IN T
9 HYDRAULIC FILTER

4 57 D
COOLER 8
45
26 26
28
7
6
52 C
INLET
26
11
27
24 24
45 25 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
29 TILT CYLINDERS
OUTLET 18
54
43
53
55
BOB-TACH
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
51 TILT
BOB-TACH
CYLINDER
(OPTIONAL)
SPOOL
DRIVE MOTOR
49 21
9 DR
18
20 LIFT CYLINDERS
17
50 13
48 46 23
A B
58 LIFT
47 44
CYLINDER
PP SPOOL
32 P1 P2
31 5
18 42
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0385 (2-8-05)
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
V-0386legend
LEGEND
19 RELIEF VALVE - MAIN: 53 FIXED CAPACITY DISPLACEMENT
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224-231 Bar) 36 BIDIRECTIONAL HYDROSTATIC
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers MOTOR
CONTROL VALVE (TWO COIL)
5 PILOT ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
CONTROL VALVE WITH 30PSI SPRING - 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
HYDRAULIC POWERED BOB-TACH 4000 PSI (275 Bar) CONTROL VALVE - REAR AUX 55 SOLENOID ACTIVATED DIRECTIONAL
36-44 PSI (2,5-3,0 Bar)
39 CHECK VALVE
3500 PSI (241 Bar) CONTROL VALVE - TWO SPEED
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 60 RELIEF VALVE - 3300 PSI (227 Bar)
10 PILOTED ACTIVATED DIRECTIONAL 61 DUMP VALVE (ON/OFF)
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 10.2 GPM (37.85 L/min.) at HIGH ENGINE IDLE
SPOOL PRESSURE: 5000 PSI (345 Bar) 62 CHECK VALVE
11 PILOTED ACTIVATED DIRECTIONAL 27 44 PILOT ACTIVATED DIRECTIONAL
PRESSURE SWITCH 63 ORIFICE WITH 0.031 (0.76 mm)
CONTROL VALVE - UNLOADING CONTROL VALVE - TWO SPEED
28 DRIVE MOTOR RESTRICTION
SPOOL RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid 64 ORIFICE WITH 0.089 (2.26 mm)
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle 45 VARIABLE CAPACITY DISPLACEMENT RESTRICTION
CONTROL VALVE - TILT CONTROL 400 - 460 PSI (27,6 - 31,7 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 46 RELIEF VALVE 2000 PSI (138 Bar) RESTRICTION
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High 66 RELIEF VALVE - 3300 PSI (227 Bar)
30 HYDRAULIC Engine
PUMP Idle
. . . . . . . Gear Type CONTROL VALVE (TWO COIL)
CONTROL VALVE - BICS CONTROL
20.7 GPM (78.35 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (83 Bar)
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
ARM BY PASS SPRING NOTE: Unless otherwise specified
50 CHECK VALVE WITH 300 PSI (20,7 Bar)
SPRING WITH 0.016 (0,40 mm) ORIFICE
(REAR QUICK
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999) Printable Version Click Here
(S/N 525911001 - 525911999) TWO SPEED DRIVE MOTOR

V-0386
33 34
31 35
32 36 MALE
38
63 (FRONT AUXILIARY
66 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
P-OUT P-IN T
53
9 HYDRAULIC FILTER

4 COOLER 59 D
45 8
26 26
28
7
6
52 C
INLET
26
11
27
24 24
45 25 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
OUTLET 18
55 B 61
40 43
60
62
BOB-TACH
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
51 TILT
39 9 BOB-TACH
CYLINDER
(OPTIONAL)
SPOOL
54 49 21
56 53
C DR
18
P D 44 20 LIFT CYLINDERS
17
50 13
48 46 23
39 A B
65 LIFT
47 64
CYLINDER
PP SPOOL
57
P1 P2
A 5
18 42
31 32
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0386 (2-8-05)
WITH SJC OPTION
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
V-0476legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 Bar)
Capacity . . . . . . . . 21 Qts. (19.9 L) (SCREEN) Spring and 0.016 inch (0,40 mm) orifice
32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 Bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 52 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - Base CONTROL VALVE - HYDRAULIC
4 SPRING LOADED FILTER BYPASS POWERED BOB-TACH
19 RELIEF VALVE - MAIN: 34
VALVE: 45-55 PSI (3,1-3,8 Bar) SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers CONTROL VALVE - Rod 53 FILTER - CASE DRAIN (ATTACHMENT)
5 SOLENOID ACTIVATED DIRECTIONAL 3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BUCKET POSITION 35 LOAD SHUTTLE VALVE - BLEED OFF 54 SOLENOID ACTIVATED DIRECTIONAL
VALVE (ON/OFF) 20 RELIEF VALVE - PORT:
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (276 Bar) 36 PILOT ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED
36-44 PSI (2,5-3,0 Bar) 21 ANTICAVITATION VALVE CONTROL VALVE - (Two Coil) - PRESSURE RELEASE
7 FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE - 37 PILOT ACTIVATED DIRECTIONAL 56 ORIFICE - With 0.089 inch (2,26 mm)
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) CONTROL VALVE - REAR AUXILIARY
VALVE 3500 PSI (241 Bar) 57 DISPLACEMENT CONTROL VALVE
38 ORIFICE - With 0.140 inch (3,6 mm)
9 FIXED CAPACITY DISPLACEMENT 23 RELIEF VALVE - PORT:
58 PUMP SERVO
BIDIRECTIONAL HYDROSTATIC 4000 PSI (276 Bar)
39 RELIEF VALVE - PORT:
MOTOR 24 SOLENOID ACTIVATED DIRECTIONAL 59 PRESSURE CONTROL PILOT VALVE
3000 PSI (207 Bar)
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY (2 COILS) 0 - 0.085 Ampere
CONTROL VALVE - FLOW CONTROL 25 40 ORIFICE - With 0.031 inch (0,79 mm)
RELIEF VALVE - PORT: . . . . . (Optional)
SPOOL 3500 PSI (241 Bar)
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - UNLOADING PRESSURE: 5220 PSI (345 Bar) 42 RESTRICTION
SPOOL
27 PRESSURE SWITCH 43 CHECK VALVE
12 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 44 FRONT AUXILIARY MANUAL
CONTROL VALVE - TILT CONTROL
PRESSURE BLEED-OFF VALVE
CONTROL VALVE - LIFT CONTROL 330 - 360 PSI (22,7 - 24,8 Bar) 45 VARIABLE CAPACITY DISPLACEMENT
29 CHARGE PUMP: BIDIRECTIONAL HYDROSTATIC PUMP
14 SOLENOID ACTIVATED DIRECTIONAL 11.1 GPM (42 L/min) (for each
CONTROL VALVE - BICS CONTROL 46 RELIEF VALVE - 2000 PSI (138 Bar)
pump) at High Engine Idle
15 PULL BUTTON ACTIVATED 47 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT 30 HYDRAULIC PUMP . . . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
ARM BY PASS 20.7 GPM (78,4 L/min) at 48 RELIEF VALVE - 1200 PSI (83 Bar)
High Engine Idle
49 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

WITH SJC OPTION
S250 (S/N 526011001 - 526015999) FEMALE MALE
(S/N 526111001 - 526111999) (REAR QUICK
COUPLERS)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
V-0476 BASE ROD REAR AUX VALVE (OPTIONAL)
DRIVE MOTOR
31 32 INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
55
38
44
MALE (FRONT AUXILIARY
40
9 39 44 LEFT SIDE LIFT ARM)
HYDROSTATIC M2 M1 37
PUMP
26 26 FEMALE
P-OUT P-IN T
28
CHARGE
M3 HYDRAULIC FILTER
INLET
3
BUCKET POSITION VALVE (OPTIONAL)
29
OIL
M4 4 D
COOLER
8
45
CASE
M5 58
DRAIN
7
6
57
Control A
Module
(EDC) 5 C
HYDRAULIC CONTROL VALVE 10
59 X2
X1 27
Control X2 X1 11
Module 59
(EDC)
24 24
25 B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
(OPTIONAL) AUXILIARY
57
SPOOL
M4
M 18
5 TILT CYLINDERS
58 22 BICS CONTROL VALVE
45 HYDRAULIC
POWERED
CHARGE BOB-TACH
29 M3 (OPTIONAL)
INLET M3
26 26
49
CASE
28 DRAIN
A B 12
M2 23 TILT
M1 50 CYLINDER
DR 48 46 SPOOL
51
21
47 56
18
HYD PP
BRAK PUMP 20 LIFT CYLINDERS
E 17
OUTLET P1 P2
VALVE 30 52 13
54
A B
LIFT
CYLINDER
SPOOL
DRIVE MOTOR
9 43
18 42
2 53
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
16 41
31 32
55 15
Printed in U.S.A. LIFT ARM BY PASS VALVE V-0476 (2-8-05)
WITH SJC AND 2 SPEED OPTION
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
V-0477legend
LEGEND
1 RESERVOIR: 18 LOAD CHECK VALVE 34 SOLENOID ACTIVATED DIRECTIONAL 53 FILTER - CASE DRAIN (ATTACHMENT)
Capacity . . . . . . . . 21 Qts. (19.9 L) CONTROL VALVE - Rod
2 FILTER - CASE DRAIN (90 Micron) 19 RELIEF VALVE - MAIN: 54 SOLENOID ACTIVATED DIRECTIONAL
35 LOAD SHUTTLE VALVE - BLEED OFF
at Front Quick Couplers CONTROL VALVE - BRAKE
3 FILTER - HYDRAULIC (CANISTER) 55 HYDRAULIC BRAKE - SPRING APPLIED
3250-3350 PSI (224-231 Bar)
4 SPRING LOADED FILTER BYPASS - PRESSURE RELEASE
20 RELIEF VALVE - PORT: CONTROL VALVE - (Two Coil)
VALVE: 45-55 PSI (3,1-3,8 Bar) 4000 PSI (276 Bar) 56 ORIFICE - With 0.089 inch (2,26 mm)
5 37 PILOT ACTIVATED DIRECTIONAL
SOLENOID ACTIVATED DIRECTIONAL 21 ANTICAVITATION VALVE 57
CONTROL VALVE - REAR AUXILIARY DISPLACEMENT CONTROL VALVE
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF) 22 RELIEF/ANTICAVITATION VALVE - 38 ORIFICE - With 0.140 inch (3,6 mm) 58 PUMP SERVO
6 DIFFERENTIAL PRESSURE SWITCH: PORT (TILT BASE END)
36-44 PSI (2,5-3,0 Bar) 3500 PSI (241 Bar) 39 59 PRESSURE CONTROL PILOT VALVE
RELIEF VALVE - PORT:
7 23 RELIEF VALVE - PORT: 3000 PSI (207 Bar) (2 COILS) 0 - 0.085 Ampere
FLOW DIVIDER ADJUSTMENT VALVE
4000 PSI (275 Bar)
8 40 ORIFICE - With 0.031 inch (0,79 mm) 60 FILTER (BRAKE)
CHECK VALVE - BUCKET POSITION 24 SOLENOID ACTIVATED DIRECTIONAL
VALVE CONTROL VALVE - AUXILIARY 61 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 25 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - MAKE-UP
BI-DIRECTIONAL HYDROSTATIC 3500 PSI (241 Bar) 42 RESTRICTION 62 SOLENOID ACTIVATED DIRECTIONAL
MOTOR
26 RELIEF/REPLENISHING VALVE - HIGH 43 CONTROL VALVE - 2 SPEED
10 PILOTED ACTIVATED DIRECTIONAL CHECK VALVE
PRESSURE: 5220 PSI (345 Bar)
CONTROL VALVE - FLOW CONTROL 63 PILOT ACTIVATED DIRECTIONAL
27 PRESSURE SWITCH 44 FRONT AUXILIARY MANUAL
SPOOL CONTROL VALVE - 2 SPEED
11 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 64 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING 120 degrees F. (53 degrees C.)Fluid 45 VARIABLE CAPACITY DISPLACEMENT
BI-DIRECTIONAL HYDROSTATIC
SPOOL at High Engine Idle BI-DIRECTIONAL HYDROSTATIC PUMP
MOTOR
330 - 360 PSI (22,7 - 24,8 Bar) 46 RELIEF VALVE - 2000 PSI (138 Bar)
CONTROL VALVE - TILT CONTROL 29 CHARGE PUMP:
11.1 GPM (42 L/min) (for each
pump) at High Engine Idle CONTROL VALVE (TWO COIL)
CONTROL VALVE - LIFT CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL 49 CHECK VALVE - With 80 PSI (5,5 Bar)
20.7 GPM (78,4 L/min) at
CONTROL VALVE - BICS CONTROL Spring
High Engine Idle
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 Bar)
DIRECTIONAL CONTROL VALVE - LIFT Spring and 0.016 inch (0,40 mm) orifice
ARM BY PASS 32 SHUTTLE RELIEF VALVE: 51 ORIFICE - With 0.025 inch (0,64 mm)
16 FILTER - BICS CONTROL VALVE 200 PSI (13,8 Bar)
(SCREEN) 33 SOLENOID ACTIVATED DIRECTIONAL 52 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC NOTE: Unless otherwise specified
17 ONE WAY RESTRICTOR CONTROL VALVE - Base
POWERED BOB-TACH springs have NO significant
pressure value.

S250 (S/N 526011001 - 526015999)
FEMALE MALE
(S/N 526111001 - 526111999)
(REAR QUICK
S300 (S/N 525811001 - 525814999) COUPLERS)
(S/N 525911001 - 525911999) Printable Version Click Here
(PRINTED FEBRUARY 2005) WORKING CIRCUITS
V-0477 PILOT CIRCUITS
31 BASE ROD REAR AUX VALVE (OPTIONAL)
DRAIN CIRCUITS
32 COMPONENTS
2 SPEED
DRIVE MOTOR INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
63 38
44
55 64 MALE (FRONT AUXILIARY
40
39 44 LEFT SIDE LIFT ARM)
9
37
M2 M1
26 HYDROSTATIC
26 FEMALE
PUMP
P-OUT P-IN T
CHARGE 28
M3 HYDRAULIC FILTER
INLET
3
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN
7
6
57
Control A
Module
(EDC) 5 C
59 X2
X1 27
Control X2 X1 11
Module 59
(EDC)
24 24
25 B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
57
SPOOL
M4
18
M TILT CYLINDERS
5 45 HYDRAULIC
POWERED
CHARGE BOB-TACH
INLET 29 M3 (OPTIONAL)
TWO SPEED VALVE
26 26
B 49
54
60 CASE
28 DRAIN
A B 12
M2 23 TILT
M1 50 CYLINDER
DR 48 46 SPOOL
51
60 HYD 21
PUMP 47 56
43 18
PP
OUTLET 20 LIFT CYLINDERS
17
P1 P2
61 30 52 13
C
A B
D LIFT
CYLINDER
SPOOL
62 P 9 2 SPEED
DRIVE MOTOR
64
18 42
43
63
A 2 53
19 14
16
T 16 41
55 32 31
15
Printed in U.S.A. V-0477 (2-8-05) LIFT ARM BY PASS VALVE
WITH SJC AND HIGH FLOW OPTION
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
(S/N 525911001 - 525911999)
V-0478legend
LEGEND
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 Bar)
58 PUMP SERVO
3000 PSI (207 Bar)
SPOOL 60 AUXILIARY HYDRAULIC PUMP
3500 PSI (241 Bar)
41 CHECK VALVE - BICS CONTROL VALVE 10.2 GPM (39,7 L/min) at
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH High Engine Idle
SPOOL 61 RELIEF VALVE - PORT:
27 PRESSURE SWITCH 43 CHECK VALVE 3300 PSI (228 Bar)
12 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 44 FRONT AUXILIARY MANUAL 62
CONTROL VALVE - TILT CONTROL DUMP VALVE - ON/OFF
13 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle 63 CHECK VALVE
High Engine Idle
49 CHECK VALVE - With 80 PSI (5,5 Bar)
Spring NOTE: Unless otherwise specified
pressure value.

S250 (S/N 526011001 - 526015999) FEMALE MALE
(S/N 526111001 - 526111999) (REAR QUICK
S300 (S/N 525811001 - 525814999) COUPLERS)

DRIVE MOTOR
33 34
MALE
35
36
55
38
44
40
PUMP
26 26 FEMALE
P-OUT P-IN T
28
CHARGE
M3 HYDRAULIC FILTER
INLET
3
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN
7
6
57
Control A
Module
(EDC) 5 C
59 X2
X1 27
Control X2 X1 11
Module 59
(EDC)
24 24
25 B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
57
SPOOL
M4
M 18
5 TILT CYLINDERS
45 HYDRAULIC
POWERED
CHARGE BOB-TACH
29 M3 (OPTIONAL)
INLET M3
26 26
49
CASE
28 DRAIN
A B 12
M2 23 TILT
M1 50 CYLINDER
DR 48 46 SPOOL
HYD 51
PUMP 21
OUTLET 47 56
18
30 PP
BRAK OUTLET 20 17 LIFT CYLINDERS
E P1 P2
VALVE 62 52 13
60
54 63
61 A B
LIFT
CYLINDER
SPOOL
DRIVE MOTOR
9 43
18 42
2 53
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
16 41
31 32
55 15
WITH SJC, 2 SPEED AND HIGH FLOW OPTION
S250 (S/N 526011001 - 526015999)
(S/N 526111001 - 526111999)
S300 (S/N 525811001 - 525814999)
V-0479legend
LEGEND
3 FILTER - HYDRAULIC (CANISTER) 55 HYDRAULIC BRAKE - SPRING APPLIED -
3250-3350 PSI (224-231 Bar)
4 SPRING LOADED FILTER BYPASS PRESSURE RELEASE
4000 PSI (275 Bar)
8 40 ORIFICE - With 0.031 inch (0,79 mm) 60 AUXILIARY HYDRAULIC PUMP
VALVE 10.2 GPM (39,7 L/min) at
CONTROL VALVE - AUXILIARY 41 CHECK VALVE - BICS CONTROL VALVE HIGH Engine Idle
9 FIXED CAPACITY DISPLACEMENT 25 RELIEF VALVE - PORT: . . . . . (Optional)
BI-DIRECTIONAL HYDROSTATIC 3500 PSI (241 Bar) 42 RESTRICTION 61 RELIEF VALVE - PORT:
MOTOR 3300 PSI (228 Bar)
26 RELIEF/REPLENISHING VALVE - HIGH 43
CONTROL VALVE - FLOW CONTROL 62 DUMP VALVE - ON/OFF
SPOOL
PRESSURE BLEED-OFF VALVE 63 CHECK VALVE
11 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE:
CONTROL VALVE - UNLOADING 120 degrees F. (53 degrees C.)Fluid 45 VARIABLE CAPACITY DISPLACEMENT 64 FILTER (BRAKE)
330 - 360 PSI (22,7 - 24,8 Bar) 65 SOLENOID ACTIVATED DIRECTIONAL
46 RELIEF VALVE - 2000 PSI (138 Bar) CONTROL VALVE - MAKE-UP
47 SOLENOID ACTIVATED DIRECTIONAL 66 SOLENOID ACTIVATED DIRECTIONAL
pump) at High Engine Idle CONTROL VALVE (TWO COIL) CONTROL VALVE - 2 SPEED
14 SOLENOID ACTIVATED DIRECTIONAL 49 CHECK VALVE - With 80 PSI (5,5 Bar) CONTROL VALVE - 2 SPEED
20.7 GPM (78,4 L/min) at
High Engine Idle 68 FIXED CAPACITY DISPLACEMENT
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 Bar) BI-DIRECTIONAL HYDROSTATIC
DIRECTIONAL CONTROL VALVE - LIFT Spring and 0.016 inch (0,40 mm) orifice MOTOR
17 ONE WAY RESTRICTOR CONTROL VALVE - Base
pressure value.

S250 (S/N 526011001 - 526015999) FEMALE MALE
(S/N 526111001 - 526111999) (REAR QUICK
S300 (S/N 525811001 - 525814999) Printable Version Click Here COUPLERS)
(S/N 525911001 - 525911999) WORKING CIRCUITS

REAR AUX VALVE (OPTIONAL) PILOT CIRCUITS
(PRINTED FEBRUARY 2005) 31 BASE ROD DRAIN CIRCUITS
V-0479
32 COMPONENTS
2 SPEED
33 34
MALE
35
36
67 38
44
40
9
37
M2 M1
26 HYDROSTATIC
26 FEMALE
PUMP
P-OUT P-IN T
CHARGE 28
M3 HYDRAULIC FILTER
INLET
3
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN
7
6
57
Control A
Module
(EDC) 5 C
59 X2
X1 27
Control X2 X1 11
Module 59
(EDC)
24 24
25 B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
57
SPOOL
M4
18
M TILT CYLINDERS
5 45 HYDRAULIC
POWERED
CHARGE BOB-TACH
INLET 29 M3 (OPTIONAL)
TWO SPEED VALVE
26 26
B 49
54
64 CASE
28 DRAIN
A B 12
M2 23 TILT
M1 50 CYLINDER
DR 48 46 SPOOL
HYD 51
64 PUMP 21
OUTLET 47 56
43 18
30 PP
OUTLET 20 LIFT CYLINDERS
17
62 P1 P2
65 52 13
C 60
63
61 A B
D LIFT
CYLINDER
SPOOL
66 P 9 2 SPEED
DRIVE MOTOR
68
18 42
43
67
A 2 53
19 14
16
T 16 41
55 32 31
15
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 625815000 & Above)
(S/N 525912000 & Above)
V-0661legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 51 FILTER - CASE DRAIN (ATTACHMENT)
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BASE
17 RELIEF VALVE - PORT: 34 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
4000 PSI (275 Bar) CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 35 VALVE (ON/OFF)
53 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: 36 PRESSURE BLEED-OFF VALVE
3250-3350 PSI (224-231 Bar) SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 Bar)
at Front Quick Couplers CONTROL VALVE (TWO COIL)
CONTROL VALVE WITH 30PSI SPRING 37 PILOT ACTIVATED DIRECTIONAL
- HYDRAULIC POWERED BOB-TACH CONTROL VALVE - REAR AUX
4000 PSI (275 Bar)
6 DIFFERENTIAL PRESSURE SWITCH: 38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION
21 ANTICAVITATION VALVE
36-44 PSI (2,5-3,0 Bar)
22 RELIEF/ANTICAVITATION VALVE - 39 ORIFICE WITH 0.031 (0.76 mm)
PORT (TILT BASE END) RESTRICTION
8 CHECK VALVE - BUCKET POSITION 4000 PSI (275 Bar) 40 RELIEF VALVE - 3300 PSI (227,6 Bar)
VALVE 23 FILTER - BOB-TACH VALVE
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 42
MOTOR RESTRICTION
25 RELIEF VALVE - PORT: . . . . . (Optional)
10 PILOTED ACTIVATED DIRECTIONAL 3100 PSI (214 Bar) 43 ORIFICE WITH 0.025 (0.64 mm)
CONTROL VALVE - FLOW CONTROL RESTRICTION
SPOOL 26 RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (345 Bar) 44 ORIFICE WITH 0.089 (2.26 mm)
11 PILOTED ACTIVATED DIRECTIONAL RESTRICTION
CONTROL VALVE - UNLOADING 27 PRESSURE SWITCH
SPOOL
28 RELIEF VALVE - CHARGE:
CONTROL VALVE - TILT CONTROL at High Engine Idle BIDIRECTIONAL HYDROSTATIC PUMP
400 - 460 PSI (27,6 - 31,7 Bar) 46 RELIEF VALVE 2000 PSI (138 Bar)
CONTROL VALVE - LIFT CONTROL 29 CHARGE PUMP
13.6 GPM (51,5 L/min.) at High 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL HYDRAULIC PUMP . . . . . . . Gear Type
30 Engine Idle 48 RELIEF VALVE - 1200 PSI (83 Bar)
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE SPRING NOTE: Unless otherwise specified
ARM BY PASS
50 CHECK VALVE WITH 300 PSI (20,7 Bar) springs have NO significant
SPRING WITH 0.016 (0,40 mm) ORIFICE pressure value.
200 PSI (13,8 Bar)
(REAR QUICK
S250 (S/N 526016000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 526112000 AND ABOVE)
S300 (S/N 525815000 AND ABOVE)
(S/N 525912000 AND ABOVE)
33 34
V-0661 35
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 53
LEFT SIDE LIFT ARM)
MALE
31 37 53
32
FEMALE
P-OUT P-IN T
9 HYDRAULIC FILTER

4 51 D
COOLER 8
45
26 26
28
7
6
HYDRAULIC CONTROL VAVLE A
52 C
CHARGE
10
INLET
26
27 11
24 24
45 25 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
29 TILT CYLINDERS
22
18
BOB-TACH
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
BOB-TACH
(OPTIONAL) TILT
DRIVE MOTOR CYLINDER
21 SPOOL
49
9 DR 17
18
LIFT CYLINDERS
20
50
13
46
48
A B
43
47 44
PP
LIFT
CYLINDER
23 16 41
31 32 SPOOL
P2 18 42
P1
5
14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
19 COMPONENTS
2 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0661 (2-7-05)
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
(S/N 525912000 & Above)
V-0662legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 51 FILTER - BOB-TACH VALVE
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BASE
17 RELIEF VALVE - PORT: 34 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
4000 PSI (275 Bar) CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3 FILTER - HYDRAULIC (CANISTER) 35 VALVE (ON/OFF)
18 LOAD CHECK VALVE LOAD SHUTTLE VALVE - BLEED OFF
53 FIXED CAPACITY DISPLACEMENT
4 SPRING LOADED FILTER BYPASS 36 BIDIRECTIONAL HYDROSTATIC
19 RELIEF VALVE - MAIN: SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 Bar) MOTOR
3250-3350 PSI (224-231 Bar) CONTROL VALVE (TWO COIL)
5 PILOT ACTIVATED DIRECTIONAL at Front Quick Couplers 54 HYDRAULIC BRAKE - SPRING APPLIED -
CONTROL VALVE WITH 30PSI SPRING - 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
HYDRAULIC POWERED BOB-TACH CONTROL VALVE - REAR AUX 55 SOLENOID ACTIVATED DIRECTIONAL
4000 PSI (275 Bar)
36-44 PSI (2,5-3,0 Bar)
39 CHECK VALVE
4000 PSI (275 Bar) CONTROL VALVE - TWO SPEED
23 RELIEF VALVE - 3300 PSI (227 Bar)
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 60 ORIFICE WITH 0.025 (0.64 mm) RESTRICTION
3100 PSI (214 Bar) 43
10 PILOTED ACTIVATED DIRECTIONAL ORIFICE WITH 0.089 (2.26 mm)
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH RESTRICTION 61 ORIFICE WITH 0.031 (0.76 mm) RESTRICTION
SPOOL PRESSURE: 5000 PSI (345 Bar)
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH CONTROL VALVE - TWO SPEED
CONTROL VALVE - UNLOADING DRIVE MOTOR
400 - 460 PSI (27,6 - 31,7 Bar)
29 CHARGE PUMP
PUMP Idle
. . . . . . . Gear Type
20.7 GPM (78.35 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
31 DRIVE MOTOR SHUTTLE VALVE 49 CHECK VALVE WITH 80 PSI (5,5 Bar) SPRING
32 SHUTTLE RELIEF VALVE: 50 CHECK VALVE WITH 300 PSI (20,7 Bar) SPRING springs have NO significant
200 PSI (13,8 Bar) WITH 0.016 (0,04 mm) ORIFICE pressure value.
(REAR QUICK
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above) Printable Version Click Here
(S/N 525912000 & Above) TWO SPEED DRIVE MOTOR

V-0662
33 34
31 35
32 36 MALE
38
61 (FRONT AUXILIARY
23 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
P-OUT P-IN T
53
9 HYDRAULIC FILTER

4 59 D
COOLER 8
45
26 26
28
7
6
HYDRAULIC CONTROL VAVLE

A
52 C
CHARGE 10
INLET
26
27 11
24 24
45 25 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
TWO SPEED VALVE TILT CYLINDERS
29 18
55 B
40
BOB-TACH 17
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
39 9 BOB-TACH
(OPTIONAL) TILT
CYLINDER
49 21 SPOOL
56 54 53
C DR
18
P D 44 LIFT CYLINDERS
50 20
13
48 46
39 A B
60
47 43
PP
LIFT
57
CYLINDER
51 SPOOL 16 41
A
18 42
31 32 P1 P2
5
14 WORKING CIRCUITS
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
19
2 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0662 (2-7-05)
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
(S/N 525912000 & above)
(PRINTED MARCH 2005)
V-0663legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 44 ORIFICE WITH 0.089 (2,26 mm)
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BASE RESTRICTION
17 RELIEF VALVE - PORT: 34 SOLENOID ACTIVATED DIRECTIONAL 45
2 FILTER - CASE DRAIN (90 Micron) VARIABLE CAPACITY DISPLACEMENT
4000 PSI (275 Bar) CONTROL VALVE - ROD BIDIRECTIONAL HYDROSTATIC PUMP
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 35
LOAD SHUTTLE VALVE - BLEED OFF 46 RELIEF VALVE 2000 PSI (138 Bar)
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: 36 SOLENOID ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 Bar) 3250-3350 PSI (224-231 Bar) CONTROL VALVE (TWO COIL) CONTROL VALVE (TWO COIL)
5 at Front Quick Couplers
PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (83 Bar)
CONTROL VALVE WITH 30PSI SPRING -
HYDRAULIC POWERED BOB-TACH 4000 PSI (275 Bar) CONTROL VALVE - REAR AUX 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
21 ANTICAVITATION VALVE SPRING
6 DIFFERENTIAL PRESSURE SWITCH: 38 ORIFICE WITH 0.140 (3,6 mm)
36-44 PSI (2,5-3,0 Bar) RESTRICTION 50 CHECK VALVE WITH 300 PSI (20,7 Bar)
39 SPRING WITH 0.016 (0,40 mm) ORIFICE
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) ORIFICE WITH 0.031 (0.76 mm)
4000 PSI (275 Bar) RESTRICTION 51 FILTER - BOB-TACH VALVE
8 CHECK VALVE - BUCKET POSITION 23 ORIFICE WITH 0.025 (0.64 mm) 40 RELIEF VALVE - 3300 PSI (227 Bar)
VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
RESTRICTION
41 CHECK VALVE - BICS CONTROL VALVE CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 53 RELIEF VALVE - 3300 PSI (227 Bar)
CONTROL VALVE - FLOW CONTROL 54 DUMP VALVE (ON/OFF)
26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (345 Bar) S250 - S/N 526016000 - 526016699
S250 - S/N 526112000 - 526112199 55 CHECK VALVE
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH S300 - S/N 525815000 - 525815599
CONTROL VALVE - UNLOADING S300 - S/N 525912000 - 525912199
SPOOL 28 RELIEF VALVE - CHARGE: 56 FRONT AUXILIARY MANUAL
120 degrees F. (53 degrees C.)Fluid PRESSURE BLEED-OFF VALVE
CONTROL VALVE - TILT CONTROL S250 - S/N 526016700 & Above 57 FILTER - CASE DRAIN (ATTACHMENT)
400 - 460 PSI (27,6 - 31,7 Bar) S250 - S/N 526112200 & Above
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP S300 - S/N 525815600 & Above
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High S300 - S/N 525912200 & Above
PUMP Idle
. . . . . . . Gear Type
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE
(REAR QUICK
S250 (S/N 526016000 & Above) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 526112000 & Above)

S300 (S/N 525815000 & Above)
(S/N 525912000 & Above) 34
33 INTEGRATED QUICK COUPLER BLOCK
(PRINTED MARCH 2005) Printable Version Click Here
V-0663 35
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 56
LEFT SIDE LIFT ARM)
MALE
31 37 56
32
FEMALE
P-OUT P-IN T
9 HYDRAULIC FILTER
BUCKET POSITION
3 VALVE (OPTIONAL)
A

4 57 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
10
INLET
26 25
27 11
24 24
45 B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
29 TILT CYLINDERS
OUTLET
18
54
43
53
55
BOB-TACH
CYLINDER 17
(OPTIONAL)
HYDRAULIC
POWERED A B 12
BOB-TACH
(OPTIONAL) TILT
49 SPOOL
21
9 DR
18
LIFT CYLINDERS
50 13
48 46
A B
23
47 44
PP
LIFT
CYLINDER
51 16 41
31 32 20 SPOOL
18 42
P1 P2
5
14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
19
15 LIFT ARM BY
PASS VALVE
1
Printed in U.S.A. V-0663 (3-8-05)
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
(S/N 525912000 & Above)
V-0664legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BASE CONTROL VALVE (TWO COIL)
17 RELIEF VALVE - PORT: 34 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (83 Bar)
4000 PSI (275 Bar) CONTROL VALVE - ROD
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 35
LOAD SHUTTLE VALVE - BLEED OFF SPRING
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: 50 CHECK VALVE WITH 300 PSI (20,7 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) 3250-3350 PSI (224-231 Bar) SPRING WITH 0.016 (0,40 mm) ORIFICE
at Front Quick Couplers CONTROL VALVE (TWO COIL) 51 FILTER - BOB-TACH VALVE
CONTROL VALVE WITH 30PSI SPRING - 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
HYDRAULIC POWERED BOB-TACH 4000 PSI (275 Bar) CONTROL VALVE - REAR AUX CONTROL VALVE - BUCKET POSITION
38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION VALVE (ON/OFF)
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE
36-44 PSI (2,5-3,0 Bar) 53 FIXED CAPACITY DISPLACEMENT
22 RELIEF/ANTICAVITATION VALVE - 39 CHECK VALVE BIDIRECTIONAL HYDROSTATIC
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) MOTOR
4000 PSI (275 Bar) 40 FILTER (BRAKE) 54 HYDRAULIC BRAKE - SPRING APPLIED -
8 CHECK VALVE - BUCKET POSITION PRESSURE TO RELEASE
23 RELIEF VALVE - 3300 PSI (227 Bar) 41
VALVE CHECK VALVE - BICS CONTROL VALVE
9 FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL 42 CONTROL VALVE - BRAKE
RESTRICTION
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 56 SOLENOID ACTIVATED DIRECTIONAL
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 43 AUXILIARY HYDRAULIC PUMP CONTROL VALVE - MAKE-UP
3100 PSI (214 Bar) 57 SOLENOID ACTIVATED DIRECTIONAL
S250 - S/N 526016000 - 526016699 CONTROL VALVE - TWO SPEED
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH S250 - S/N 526112000 - 526112199
SPOOL PRESSURE: 5000 PSI (345 Bar) 58 FRONT AUXILIARY MANUAL
S300 - S/N 525815000 - 525815599
11 PILOTED ACTIVATED DIRECTIONAL 27 S300 - S/N 525912000 - 525912199 PRESSURE BLEED-OFF VALVE
PRESSURE SWITCH
CONTROL VALVE - UNLOADING 10.2 GPM (37.85 L/min.) at High Engine Idle 59 FILTER - CASE DRAIN (ATTACHMENT)
120 degrees F. (53 degrees C.)Fluid S250 - S/N 526016700 & Above 60 RELIEF VALVE - 3300 PSI (227 Bar)
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle S250 - S/N 526112200 & Above
CONTROL VALVE - TILT CONTROL 61 DUMP VALVE (ON/OFF)
400 - 460 PSI (27,6 - 31,7 Bar) S300 - S/N 525815600 & Above
13 PILOTED ACTIVATED DIRECTIONAL S300 - S/N 525912200 & Above 62 CHECK VALVE
29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 20.7 GPM (76.8 L/min.) at High Engine Idle
13.6 GPM (51,5 L/min.) at High
63 ORIFICE WITH 0.031 (0.76 mm) RESTRICTION
14 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
PUMP Idle
. . . . . . . Gear Type CONTROL VALVE - TWO SPEED 64 ORIFICE WITH 0.089 (2.26 mm) RESTRICTION
20.7 GPM (78.35 L/min.) at High Engine Idle DRIVE MOTOR
31 DRIVE MOTOR SHUTTLE VALVE 65 ORIFICE WITH 0.025 (0.64 mm) RESTRICTION
45 VARIABLE CAPACITY DISPLACEMENT
ARM BY PASS
32 SHUTTLE RELIEF VALVE: BIDIRECTIONAL HYDROSTATIC PUMP
NOTE: Unless otherwise specified springs have
200 PSI (13,8 Bar) 46 RELIEF VALVE 2000 PSI (138 Bar) NO significant pressure value.
(REAR QUICK
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above) Printable Version Click Here
(S/N 525912000 & Above) TWO SPEED DRIVE MOTOR

V-0664
33 34
31 35
32 36 MALE
38
63 (FRONT AUXILIARY
23 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
P-OUT P-IN T
53
9 HYDRAULIC FILTER
BUCKET POSITION
3 A VALVE (OPTIONAL)

4 59 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE 10
INLET
25
26
27 11
45 24 24
B
A B
26
INLET AUXILIARY
OUTLET
SPOOL
30
OUTLET
OUTLET 18
55 B 61
40 43
60
62
BOB-TACH
CYLINDER 17
(OPTIONAL)
HYDRAULIC
POWERED A B 12
39 9 BOB-TACH
(OPTIONAL)
TILT
CYLINDER
54 53 49 21 SPOOL
56 C DR
18
P D 44 LIFT CYLINDERS
50 20
13
48 46
39 A B
65
47 64
PP
LIFT
57
CYLINDER
51 16 41
A SPOOL
18 42
31 32 P1 P2
5
14 WORKING CIRCUITS
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
19
2
15 LIFT ARM BY
1 PASS VALVE
Printed in U.S.A. V-0664 (3-8-05)
WITH SJC OPTION
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
(S/N 525912000 & Above)
V-0665legend
LEGEND
2 FILTER - CASE DRAIN (90 Micron) 17 FILTER - BOB-TACH VALVE 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 Bar)
58 PUMP SERVO
3000 PSI (207 Bar)
SPOOL 3100 PSI (214 Bar)
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL
27 PRESSURE SWITCH 43 CHECK VALVE
12 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 44 FRONT AUXILIARY MANUAL
High Engine Idle
49 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
pressure value.

WITH SJC OPTION
S250 (S/N 526016000 & Above) FEMALE MALE
(S/N 526112000 & Above) (REAR QUICK
COUPLERS)
S300 (S/N 525815000 & Above)
(S/N 525912000 & Above) Printable Version Click Here
DRIVE MOTOR
33 34
MALE
35
36
55
38
44
40
PUMP
26 26 FEMALE
P-OUT P-IN T
28
CHARGE
M3 HYDRAULIC FILTER
INLET
3
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN
7
6
57
A
Control HYDRAULIC CONTROL VALVE
Module
(EDC) 5 C
59 10
X1 X2 27
25
Control X2 X1 11
Module 59
(EDC)
24 24
B
HYDROSTATIC BOB-TACH A B
PUMP CYLINDER
(OPTIONAL)
AUXILIARY
57
SPOOL
M4
M HYDRAULIC 18
5 TILT CYLINDERS
58 POWERED 22 BICS CONTROL VALVE
45 BOB-TACH
(OPTIONAL)
CHARGE
29 M3
INLET M3
49
26 23
26
CASE
28 DRAIN
50 A B 12
M2 DR
M1 48 46
51
TILT
47 56 CYLINDER
21 SPOOL
PP
17 18
HYD
BRAK PUMP LIFT CYLINDERS
E P1 P2 20
OUTLET 52 13
VALVE 30
54
A B
LIFT
SPOOL 16 41
9 43
18 42
2 53
14 WORKING CIRCUITS
16 PILOT CIRCUITS
19 DRAIN CIRCUITS
COMPONENTS
31 32
55 15
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
(S/N 525912000 & Above)
V-0666legend
LEGEND
3 FILTER - HYDRAULIC (CANISTER) 55 HYDRAULIC BRAKE - SPRING APPLIED
3250-3350 PSI (224-231 Bar)
4 SPRING LOADED FILTER BYPASS - PRESSURE RELEASE
4000 PSI (275 Bar)
8 40 ORIFICE - With 0.031 inch (0,79 mm) 60 FILTER (BRAKE)
VALVE CONTROL VALVE - AUXILIARY 61 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 25 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - MAKE-UP
BI-DIRECTIONAL HYDROSTATIC 3100 PSI (214 Bar) 42 RESTRICTION 62 SOLENOID ACTIVATED DIRECTIONAL
MOTOR
26 RELIEF/REPLENISHING VALVE - HIGH 43 CONTROL VALVE - 2 SPEED
CONTROL VALVE - FLOW CONTROL 63 PILOT ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - 2 SPEED
11 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 64 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING 120 degrees F. (53 degrees C.)Fluid 45 VARIABLE CAPACITY DISPLACEMENT
BI-DIRECTIONAL HYDROSTATIC
MOTOR
330 - 360 PSI (22,7 - 24,8 Bar) 46 RELIEF VALVE - 2000 PSI (138 Bar)
pump) at High Engine Idle CONTROL VALVE (TWO COIL)
14 SOLENOID ACTIVATED DIRECTIONAL 49 CHECK VALVE - With 80 PSI (5,5 Bar)
20.7 GPM (78,4 L/min) at
High Engine Idle
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 Bar)
DIRECTIONAL CONTROL VALVE - LIFT Spring and 0.016 inch (0,40 mm) orifice
17 FILTER - BOB-TACH VALVE CONTROL VALVE - Base
pressure value.

S250 (S/N 526016000 & Above)
FEMALE MALE
(S/N 526112000 & Above)
(REAR QUICK
S300 (S/N 52581500 & Above) COUPLERS)
(PRINTED FEBRUARY 2005) WORKING CIRCUITS
V-0666 PILOT CIRCUITS
31 BASE ROD REAR AUX VALVE (OPTIONAL)
DRAIN CIRCUITS
32 COMPONENTS
2 SPEED
33 34
MALE
35
36
63 38
44
40
9
37
M2 M1
26 HYDROSTATIC
26 FEMALE
PUMP
P-OUT P-IN T
CHARGE 28
M3 HYDRAULIC FILTER
INLET
3
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN
7
6
57
A
Module
(EDC) 5 C
59 27 10
X1 X2 25
Control X2 X1 11
Module 59
(EDC)
24 24
B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
57
SPOOL
M4
HYDRAULIC 18
M TILT CYLINDERS
58 POWERED 22
45 BOB-TACH
(OPTIONAL)
CHARGE
INLET 29 M3
TWO SPEED VALVE 49
26 23
26
B 54
60 CASE
28 DRAIN
A B 12
M2 DR
M1 48 46 50
51
TILT
47 56 CYLINDER
60 HYD 21 SPOOL
PUMP PP
43 18
17
OUTLET LIFT CYLINDERS
P1 P2
30 52 20 13
61 C
A B
D
LIFT
62 P 9 2 SPEED CYLINDER
DRIVE MOTOR SPOOL 16 41
64
18 42
43
63
A 2 53
14
16
T 19
55 32 31
15
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
(S/N 525912000 & Above)
V-0667legend
LEGEND
2 FILTER - CASE DRAIN (90 Micron) 17 FILTER - BOB-TACH VALVE 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 Bar)
58 PUMP SERVO
3000 PSI (207 Bar)
SPOOL 60 AUXILIARY HYDRAULIC PUMP
3100 PSI (214 Bar)
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH S250 - S/N 526016000 - 526016699
CONTROL VALVE - UNLOADING PRESSURE: 5220 PSI (345 Bar) 42 RESTRICTION S250 - S/N 526112000 - 526112199
SPOOL S300 - S/N 525815000 - 525815599
27 PRESSURE SWITCH 43 CHECK VALVE S300 - S/N 525912000 - 525912199
12 PILOTED ACTIVATED DIRECTIONAL 28 10.2 GPM (37.85 L/min.) at High Engine Idle
RELIEF VALVE - CHARGE: 44 FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE S250 - S/N 526016700 & Above
CONTROL VALVE - LIFT CONTROL 330 - 360 PSI (22,7 - 24,8 Bar) 45 S250 - S/N 526112200 & Above
VARIABLE CAPACITY DISPLACEMENT
S300 - S/N 525815600 & Above
14 SOLENOID ACTIVATED DIRECTIONAL S300 - S/N 525912200 & Above
CONTROL VALVE - BICS CONTROL 46 RELIEF VALVE - 2000 PSI (138 Bar) 20.7 GPM (76.8 L/min.) at High Engine Idle
15 PULL BUTTON ACTIVATED 47 SOLENOID ACTIVATED DIRECTIONAL 61 RELIEF VALVE - PORT:
DIRECTIONAL CONTROL VALVE - LIFT 30 HYDRAULIC PUMP . . . . . . . . . Gear Type CONTROL VALVE (TWO COIL) 3300 PSI (228 Bar)
ARM BY PASS 20.7 GPM (78,4 L/min) at 48 RELIEF VALVE - 1200 PSI (83 Bar) 62 DUMP VALVE - ON/OFF
High Engine Idle
49 CHECK VALVE - With 80 PSI (5,5 Bar) 63 CHECK VALVE
Spring
pressure value.

DRIVE MOTOR
33 34
MALE
35
36
55
38
44
40
PUMP
26 26 FEMALE
HYDRAULIC FILTER
P-OUT P-IN T
3
28
CHARGE
M3
INLET
4 BUCKET POSITION
A VALVE (OPTIONAL)
29 OIL
COOLER
M4 D
8
45
M CASE
58
5 DRAIN 6
57

Module
(EDC) 5 C
59 27 10
X1 X2
25
Control X2 X1 11
Module 59
(EDC)
24 24
B
PUMP CYLINDER
(OPTIONAL)
AUXILIARY
57
SPOOL
M4
M HYDRAULIC 18
5 POWERED TILT CYLINDERS
58 22
BOB-TACH BICS CONTROL VALVE
45
(OPTIONAL)
CHARGE
29 M3
INLET M3 49
26 26 23
CASE
28 DRAIN
A B 12
M2 DR 48 46
M1 51 50
TILT
47 56
HYD CYLINDER
PUMP OUTLET PP 21 SPOOL
17 18
30
BRAK OUTLET LIFT CYLINDERS
E P1 P2
VALVE 62 52 20 13
60
54 63
61 A B
LIFT
16 41
9 43 SPOOL
18 42
2 53
14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
19
31 32
55 15
S250 (S/N 526016000 & Above)
(S/N 526112000 & Above)
S300 (S/N 525815000 & Above)
V-0668legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 36 PILOT ACTIVATED DIRECTIONAL 57 DISPLACEMENT CONTROL VALVE
Capacity . . . . . . . . 21 Qts. (19.9 L) at Front Quick Couplers CONTROL VALVE - (Two Coil)
3250-3350 PSI (224-231 Bar) 58 PUMP SERVO
2 FILTER - CASE DRAIN (90 Micron) 37 PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - REAR AUXILIARY 59 PRESSURE CONTROL PILOT VALVE
3 FILTER - HYDRAULIC (CANISTER) 38 ORIFICE - With 0.140 inch (3,6 mm) (2 COILS) 0 - 0.085 Ampere
4000 PSI (275 Bar)
4 SPRING LOADED FILTER BYPASS 21 ANTICAVITATION VALVE
39 RELIEF VALVE - PORT: 60 AUXILIARY HYDRAULIC PUMP
VALVE: 45-55 PSI (3,1-3,8 Bar) 3000 PSI (207 Bar)
5 SOLENOID ACTIVATED DIRECTIONAL PORT (TILT BASE END) 40 ORIFICE - With 0.031 inch (0,79 mm) S250 - S/N 526016000 - 526016699
CONTROL VALVE - BUCKET POSITION 4000 PSI (275 Bar) S250 - S/N 526112000 - 526112199
VALVE (ON/OFF) 41 CHECK VALVE - BICS CONTROL VALVE S300 - S/N 525815000 - 525815599
6 DIFFERENTIAL PRESSURE SWITCH: S300 - S/N 525912000 - 525912199
4000 PSI (275 Bar) 42 RESTRICTION
36-44 PSI (2,5-3,0 Bar) 10.2 GPM (37.85 L/min.) at High Engine Idle
24 SOLENOID ACTIVATED DIRECTIONAL 43 CHECK VALVE
7 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE - AUXILIARY S250 - S/N 526016700 & Above
44 FRONT AUXILIARY MANUAL S250 - S/N 526112200 & Above
8 CHECK VALVE - BUCKET POSITION 25 RELIEF VALVE - PORT: . . . . . (Optional)
VALVE PRESSURE BLEED-OFF VALVE S300 - S/N 525815600 & Above
3100 PSI (214 Bar)
9 45 VARIABLE CAPACITY DISPLACEMENT S300 - S/N 525912200 & Above
FIXED CAPACITY DISPLACEMENT 26 RELIEF/REPLENISHING VALVE - HIGH
BI-DIRECTIONAL HYDROSTATIC PUMP 20.7 GPM (76.8 L/min.) at High Engine Idle
BI-DIRECTIONAL HYDROSTATIC PRESSURE: 5220 PSI (345 Bar)
MOTOR 27 PRESSURE SWITCH 46 RELIEF VALVE - 2000 PSI (138 Bar)
10 PILOTED ACTIVATED DIRECTIONAL 61 RELIEF VALVE - PORT:
28 RELIEF VALVE - CHARGE: 47 SOLENOID ACTIVATED DIRECTIONAL 3300 PSI (228 Bar)
CONTROL VALVE - FLOW CONTROL
SPOOL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL)
62 DUMP VALVE - ON/OFF
at High Engine Idle 48 RELIEF VALVE - 1200 PSI (83 Bar)
330 - 360 PSI (22,7 - 24,8 Bar) 63 CHECK VALVE
CONTROL VALVE - UNLOADING
SPOOL 29 CHARGE PUMP: 49 CHECK VALVE - With 80 PSI (5,5 Bar)
64 FILTER (BRAKE)
11.1 GPM (42 L/min) (for each Spring
CONTROL VALVE - TILT CONTROL pump) at High Engine Idle 50 CHECK VALVE - With 300 PSI (20,7 Bar) 65 SOLENOID ACTIVATED DIRECTIONAL
Spring and 0.016 inch (0,40 mm) orifice CONTROL VALVE - MAKE-UP
13 PILOTED ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type
CONTROL VALVE - LIFT CONTROL 20.7 GPM (78,4 L/min) at 51 ORIFICE - With 0.025 inch (0,64 mm)
CONTROL VALVE - 2 SPEED
High Engine Idle
14 SOLENOID ACTIVATED DIRECTIONAL 67 PILOT ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE 52 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL CONTROL VALVE - 2 SPEED
CONTROL VALVE - HYDRAULIC
15 PULL BUTTON ACTIVATED 32 SHUTTLE RELIEF VALVE: POWERED BOB-TACH 68 FIXED CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT 200 PSI (13,8 Bar) 53 FILTER - CASE DRAIN (ATTACHMENT) BI-DIRECTIONAL HYDROSTATIC
ARM BY PASS MOTOR
16 FILTER - BICS CONTROL VALVE 54 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Base
(SCREEN) CONTROL VALVE - BRAKE
17 FILTER - BOB-TACH VALVE 34 SOLENOID ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED -
CONTROL VALVE - Rod PRESSURE RELEASE NOTE: Unless otherwise specified
18 LOAD CHECK VALVE 35 LOAD SHUTTLE VALVE - BLEED OFF 56 ORIFICE - With 0.089 inch (2,26 mm) springs have NO significant
pressure value.

(S/N 525912000 & Above)

WORKING CIRCUITS
REAR AUX VALVE (OPTIONAL) PILOT CIRCUITS
(PRINTED MARCH 2005) 31 BASE ROD DRAIN CIRCUITS
V-0668
32 COMPONENTS
2 SPEED
33 34
MALE
35
36
67 38
44
40
9
37
M2 M1
26 HYDROSTATIC
26 FEMALE
PUMP
HYDRAULIC FILTER 3
4 P-OUT P-IN T
CHARGE 28
M3
INLET
OIL BUCKET POSITION
COOLER A VALVE (OPTIONAL)
29
M4 6 D
8
45
M CASE
58
5 DRAIN
57 HYDRAULIC CONTROL VALVE
Control
Module
(EDC) 5 C
27
59 10
X1 X2 25
Control X2 X1 11
Module 59
(EDC)
24 24
B
PUMP CYLINDER
(OPTIONAL)
AUXILIARY
57
SPOOL
M4
HYDRAULIC
18
M POWERED TILT CYLINDERS
58 BOB-TACH 22 BICS CONTROL VALVE
5 45 (OPTIONAL)
CHARGE
INLET 29 M3
TWO SPEED VALVE 49
26 26 23
B 54
64 CASE
28 DRAIN
50 A B 12
M2 48 46
M1 51
DR TILT
47 56 CYLINDER
HYD
64 PUMP PP 21 SPOOL
OUTLET
43 18
30 17
OUTLET LIFT CYLINDERS
62 P1 P2 20
65 52 13
C 60
63
61 A B
D
LIFT
66 P 9 2 SPEED CYLINDER
DRIVE MOTOR SPOOL 16 41
68
18 42
43
67
A 2 53
14
16
T 19
55 32 31
15
HYDRAULIC SYSTEM INFORMATION

HYDRAULIC SYSTEM INFORMATION (CONT’D)


Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If the service code appears in the left instrument panel,

refer to the Electrical Service Manual for the probable
cause.
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7

Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
By-pass valve stuck. 12
By-pass valve stem bent or broke. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See LOADER SPECIFICATIONS (S250) on Page SPEC-10-1.) or (See
LOADER SPECIFICATIONS (S300) on Page SPEC-11-1.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.

Tightening Procedure
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
For Tightening Torques For Hydraulic Fittings, Tubelines,

etc., (See HYDRAULIC CONNECTION
SPECIFICATIONS on Page SPEC-40-1.)

CYLINDER (LIFT) Install a cap (Item 1) [Figure 20-20-2] in the hose and
tighten.
Checking
Engage the parking brake. Lower the seat bar. Start the
Figure 20-20-1 engine and push the top (toe) of the lift pedal.
If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2]. Remove the lift cylinder for
repair. Repeat the procedure to check the other lift
cylinder.
1 Removal And Installation
Figure 20-20-3
P-31363
1
Lower the lift arms. Stop the engine. Raise the seat bar.
WARNING
Hydraulic fluid escaping under pressure can have P-31363
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
Disconnect both hydraulic hoses from the cylinder (Item
and possibly death if proper medical treatment by a
1) [Figure 20-20-3]. Cap and plug the fittings and hoses.
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-4
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.
Figure 20-20-2
1
1
2
P-31365
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-4] from the retaining pin on the rod end of the lift
cylinder.
P-31364 Installation: Tighten the retainer bolt and nut to 18-20 ft.-
lbs. (24-27 Nm) torque.

CYLINDER (LIFT) (CONT'D) Figure 20-20-7
Removal And Installation (Cont'd)
Figure 20-20-5
1
P-31368
1
Install a slide hammer (Item 1) [Figure 20-20-7] and

P-31366 remove the base end pivot pin.
Remove the lift cylinder.
Install a slide hammer (Item 1) [Figure 20-20-5] and
remove the retaining pin from the rod end of the cylinder.
Figure 20-20-6
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
W-2103-1285
1
P-31367
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-6] from the pivot pin at the base end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 18-20 ft.-


CYLINDER (LIFT) (CONT'D)
Parts Identification
1. Case 9. Spacer
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. O-ring 13. Seal
6. Nut 14. Plug
7. Seal 15. O-ring
8. O-ring 16. Tapeline
7 4
14 15
TS-1060a
1
13
16
3
11
10
12
14 15
TS-1060b PE1519A

Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise. 3
Figure 20-20-8 P-48038
1 Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

20-10] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-10] on
the piston head, becomes damaged, the
complete piston head must be replaced.
Figure 20-20-11
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-8] from the cylinder case.
2
Figure 20-20-9
4
3 P-48039
2
1 Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-11] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-9].

CYLINDER (LIFT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-20-12 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
1 Figure 20-20-14
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-12] from

the cylinder head.
P7424
Figure 20-20-13
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.

1
Lubricate all O-rings and seals with hydraulic oil during
installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-14].
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-20-13] from the
cylinder head.

Assembly (Cont'd)
Figure 20-20-15
1
2
P7425
Install the rod seal in the head [Figure 20-20-17].

P-48038
Figure 20-20-18
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
20-15] on the cylinder piston.
2
Figure 20-20-16
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 18].
Install the rod seal on the rod seal tool [Figure 20-20-16].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-16] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-16].

CYLINDER (LIFT) (CONT'D)
Assembly (Cont'd)
Figure 20-20-19
1
2 3
P-48036
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.
Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-19].
Tighten the nut (Item 4) [Figure 20-20-19] to 600 ft.-lbs.

(814 Nm) torque.
Figure 20-20-20
P-48035
Put the base end of the hydraulic cylinder in a vise.
Using a spanner wrench, tighten the head (Item 1)

[Figure 20-20-20] until the head is flush with the end of
the cylinder tube assembly.

CYLINDER (TILT) Install a cap (Item 1) [Figure 20-21-2] in the hydraulic
hose and tighten.
Checking
Figure 20-21-1 engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port on the cylinder (Item
2) [Figure 20-21-2], remove the tilt cylinder for repair.
Repeat procedure to check the other tilt cylinder.
Removal And Installation
Figure 20-21-3
P-31369
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar. 1
WARNING P-31371
Hydraulic fluid escaping under pressure can have

Remove the attachment from the Bob-Tach. Roll the
sufficient force to enter a person’s body by
Bob-Tach forward
penetrating the skin. This can cause serious injury
and possibly death if proper medical treatment by a Stop the engine. Raise the seat bar.
physician familiar with this injury is not received
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
immediately.
W-2145-0290
3] from the rod end pivot pin.
Installation: Tighten the retainer nut to 18-20 ft.-lbs. (24-

Disconnect the hose (Item 1) [Figure 20-21-1] which 27 Nm) torque.
goes to the base end of the tilt cylinder.
Figure 20-21-4
Figure 20-21-2
1
2
1
P-31372
P-31370
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

CYLINDER (TILT) (CONT'D) Figure 20-21-7
Figure 20-21-5
1
P-31374
Remove the base end pivot bolt and washer (Item 1)

P-31369 [Figure 20-21-7].
Figure 20-21-8
Disconnect the two hydraulic hoses (Items 1 & 2) [Figure
20-21-5] from the tilt cylinder.
Cap the hoses and plug the fittings on the cylinder.
Figure 20-21-6
P-31375
Slide the cylinder from the base pin and remove the tilt
cylinder from the loader [Figure 20-21-8].
P-31373
Remove the retainer nut (Item 1) [Figure 20-21-6] from

the base end pivot pin.
Installation: Tighten the retainer nut to 190 ft.-lbs. (257,6

Nm) torque.

Base Pin Removal And Installation
Figure 20-21-9
P-31378
1
Check pivot pin and replace as needed [Figure 20-21-
P-31376 11].
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-9]. (See Removal And Installation on
Page 20-21-1.)
Figure 20-21-10
P-31377
Use a 7/8” (.875 mm) shaft (Item 1) [Figure 20-21-10]

and a hammer to remove the tilt cylinder base pin from
the lift arms.

CYLINDER (TILT) (CONT'D)
1. Case 9. O-ring
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. Bushing 13. Seal
6. Nut 14. Plug
7. O-ring 15. O-ring
8. Seal 16. Tubeline TS-1688b
12
9
1
15
10
14
16
11
15 6
3
14
2 13
4
8
TS-1688a PE1520A

Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

Spanner Wrench

cylinder.
Put the base end of the cylinder in a vise.
Figure 20-21-12 P-48073
Remove the seal (Item 1), and O-ring (Item 2) [Figure

20-21-14] from the piston.
1
Figure 20-21-15
2
P-48034
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-12] from the cylinder case.
Figure 20-21-13 P-48039
3 Remove the two O-rings (Item 1) and the back-up washer

2 (Item 2) [Figure 20-21-15] from the cylinder head.
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].

CYLINDER (TILT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-21-16 MEL1396 - Seal Installation Tool

Piston Ring Compressor
Spanner Wrench
1 Figure 20-21-18
P-48040
Remove the wiper seal (Item 1) [Figure 20-21-16] from
the cylinder head.
P7424
Figure 20-21-17


1
installation.
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-21-17] from the
cylinder head.

Assembly (Cont'd)
Figure 20-21-19
P7425

P-48073
Figure 20-21-22
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-19] on the cylinder piston.
2
Figure 20-21-20
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
P-48043 P7427 22].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-21-20] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

21-20].

Assembly (Cont'd)
Figure 20-21-23
1
1
2
P-48070

P-48071
Using a spanner wrench, tighten the head (Item 1)
[Figure 20-21-25] until the head is flush with the end of
NOTE: Clean and dry the threads before installing the the cylinder tube assembly.
nut. Install the new nut from the kit.
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-23].
Tighten the nut (Item 3) [Figure 20-21-23] to 100 ft.-lbs.

(136 Nm) torque.
Figure 20-21-24
P-48088 P-48089
Mark the end of the shaft and nut [Figure 20-21-24].

Tighten the nut an additional 135 degrees or 2-1/4 flats
[Figure 20-21-24].

CYLINDER (POWER BOB-TACH) Figure 20-22-3
Checking
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece or cardboard or wood to find leaks. Do 2
not use your bare hand. Wear safety goggles. If fluid 1
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496 P-31381
Figure 20-22-1 Install a plug in the hose (Item 1) [Figure 20-22-3] and
tighten.
engine.
Push and hold the BOB-TACH "WEDGES UP" Switch

(Front Accessory Panel).
If there is any leakage from the base end cylinder port

(Item 2) [Figure 20-22-3], remove the lift cylinder for
repair.
P-31379
WARNING
Tilt the Bob-Tach forward, so it is parallel to the floor Always clean up spilled fuel or oil. Keep heat, flames,
[Figure 20-22-1]. sparks or lighted tobacco away from fuel and oil.
Figure 20-22-2 explosion or fire which can result in injury or death.
W-2103-1285
P-31380
Disconnect the hose (Item 1) [Figure 20-22-2] from the

power Bob-Tach cylinder base end port.

CYLINDER (POWER BOB-TACH)
Figure 20-22-4
1 1
P-31379
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Install plugs in the hoses and cap on fittings.
Figure 20-22-5
1
1
P-31382
Remove the bolts and washers (Item 1) [Figure 20-22-

5].
Installation: Tighten the bolts to 25-28 ft.-lbs. (34-38

Nm) torque.
Remove the cylinder from the lever pivots.

CYLINDER (POWER BOB-TACH) (CONT'D)
1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
2 3
4
5
6
7
8 9
10
11
12
13
B-16207

CYLINDER (POWER BOB-TACH) (CONT'D) Remove the nut (Item 1) [Figure 20-22-7], piston (Item 2)
[Figure 20-22-7], spacer (Item 3) [Figure 20-22-7], and
Disassembly head (Item 4) [Figure 20-22-7] from the rod.
3 2 1
P16293 P16295
Use the following tools to disassemble the cylinder: Piston: Remove the O-ring (Item 1) [Figure 20-22-8],
and seal (Item 2) [Figure 20-22-8] from the piston (Item
MEL1074 - O-ring Seal Hook 3) [Figure 20-22-8].
Spanner Wrench
Figure 20-22-9
cylinder.
4
Put the base end of the cylinder in a vise.
2
Use a spanner wrench to loosen the head [Figure 20-22-
1
6].
Figure 20-22-7
2 5
4 3 3
1
N-20611
Remove the wiper seal (Item 1) [Figure 20-22-9], and

rod seal (Item 2) [Figure 20-22-9], the back up washer
(Item 3) [Figure 20-22-9], the thin O-ring (Item 4) [Figure
20-22-9], and the thick O-ring (Item 5) [Figure 20-22-9]
from the head.
P16294
Remove the head and rod assembly from the cylinder

[Figure 20-22-7]. Put the rod end in a vise.

CYLINDER (POWER BOB-TACH) (CONT'D) Figure 20-22-11
Assembly
3 1
2
Figure 20-22-10
P16295
Piston: Install the O-ring (Item 1) [Figure 20-22-11] and

P7424 seal (Item 2) [Figure 20-22-11] on the piston (Item 3)
[Figure 20-22-11].
Use the following tools to assembly the cylinder: NOTE: The piston center hole (Item 4) [[Figure 20-22-
11] has a bevel on one end. The bevel goes
MEL1396 - Seal Installation Tool toward the rod.
Piston Ring Compressor Figure 20-22-12
Spanner Wrench


installation.
N-20612
Allow the seal to stretch for 30 seconds before installing it
on the piston.
NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

CYLINDER (POWER BOB-TACH) (CONT'D) Figure 20-22-15
Assembly (Cont'd)
Figure 20-22-13
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) [Figure 20-22-15]
and thick O-ring (Item 3) [Figure 20-22-15] into the
Rotate the handles to collapse the rod seal [Figure 20- groove on the head.
22-13].
NOTE: Clean and dry the threads before installing the
Figure 20-22-14 nut. Install the new nut from the seal kit.
Figure 20-22-16
3
2 4
1
P7425
P16294
Install the wiper seal with the wiper toward the outside of Install the head (Item 1) [Figure 20-22-16], and spacer
the head. (Item 2) [Figure 20-22-16].
Install the piston (Item 3) [Figure 20-22-16].
Lift Cylinder: Grease the piston where the nut contacts

the piston. do not get grease on the threads. Install the
new nut (Item 4) [Figure 20-22-16].
Tighten the nut to 90 ft.-lbs. (122 Nm) torque.

CYLINDER (POWER BOB-TACH) (CONT'D)
Assembly (Cont'd)
Figure 20-22-17
P16293
Tighten the head using a spanner wrench [Figure 20-22-

17].

MAIN RELIEF VALVE Figure 20-30-1
Checking Main Relief

2 1
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
WARNING P-37687
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
steering levers must be in neutral and the parking hydraulic tester to the bottom (female) quick coupler on
brake engaged. Failure to do so can cause injury or the loader.
death.
W-2006-0284
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
WARNING Figure 20-30-2

W-2017-0286
The tools listed will be needed to do the following

procedure:
1
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position. N-18409
NOTE: This procedure is for standard loaders,

loaders equipped with ACS option and Start the engine and run at low idle.
loaders equipped with SJC option. The main
relief valve is located in the same place on all • Press the AUXILIARY HYDRAULICS Button (Item 1)
of the loaders. [Figure 20-30-2] twice and the light beside Maximum
Flow comes on.
To release the hydraulic pressure at the front auxiliary
quick couplers push the couplers into the coupler block
and hold for three seconds.

1.)

MAIN RELIEF VALVE (CONT’D) • Push the front switch (Item 1) [Figure 20-30-3] or
[Figure 20-30-4] to give the front quick couplers a
Checking Main Relief (Cont’d) constant flow of fluid.
Figure 20-30-3 • To release from continuous operation, press the front

switch (Item 1) [Figure 20-30-3] or [Figure 20-30-4]
Right a second time.
Standard & ACS option
Steering
Lever
Watch the flow meter on the hydraulic tester to make
Control
sure the flow is correct. Increase the engine speed to full
RPM.
Refer to Specifications, (Contents Page, SPEC-01) for

both flow and pressure specifications of the hydraulic
system.
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

1 relief valve opens. Check the relief pressure.
P-31833
If the relief pressure is not correct, stop the engine and
Figure 20-30-4 adjust the main relief valve.
SJC Option Only
Right
Steering
1 Lever
Control
P-26697

MAIN RELIEF VALVE (CONT’D)
Adjustment
NOTE: This procedure is for standard loaders,

loaders equipped with ACS option and
relief valve is located in the same place on all
of the loaders.
Figure 20-30-5
1
2
P-37690
NOTE: The right side motor cover if removed may

provide better access to the main relief valve
on some machines.
If the pressure is not correct, adjust the main relief valve.

Loosen the lock nut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Check the
pressure setting of the new relief valve.

MAIN RELIEF VALVE (CONT’D) Figure 20-30-7
IMPORTANT
damage the system.
I-2003-0888
P-37689
on Page 10-30-1.)
Remove the O-rings and back-up washers from the main
Clean the area around the control valve. relief valve [Figure 20-30-7].
NOTE: This procedure is for standard loaders, Clean the main relief valve in clean solvent. Use air
loaders equipped with ACS option and pressure to dry the valve.
relief valve is located in the same place on all Install new O-rings and back-up washers. Install the main
of the loaders. relief valve and tighten [Figure 20-30-7].
Figure 20-30-6 Installation: Tighten the main relief valve to 35-40 ft.-lbs.
(47-54 Nm) torque.
Check the pressure again. (See Checking Main Relief on

Page 20-30-1.)
P-37690
NOTE: The right side motor cover if removed may

provide better access to the main relief valve
on some machines.
The main relief valve (Item 1) [Figure 20-30-6] is located

at the lower front of the control valve below the lift and tilt
spool connections.
Loosen and remove the main relief valve (Item 1) [Figure

20-30-6].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-2
(FOOT CONTROL)
Identification
Figure 20-40-1
P-37098
1 Raise the lift arms and install an approved lift arm

support device.
N-18695
Stop the engine. Raise the seat bar.

The hydraulic control valve (2 piece casting) (foot control) Raise the operator cab. (See Raising The Operator Cab
has a removable BICS™ section (Item 1) [Figure 20-40- on Page 10-30-1.)
1].
Drain the hydraulic reservoir. (See Replacing Hydraulic
The BICS™ section and main control valve are in two Fluid And Case Drain Filters on Page 10-120-3.)
seperate castings.
Remove the control panel. (See Removal And Installation
For identification of the hydraulic control valve (1 piece on Page 50-100-1.)
casting) (foot control), (See Identification on Page 20-43-
1.). Clean area around control valve.
Removal And Installation Open rear door.
The fixed end main valve hose assembly (Item 1) [Figure

20-40-2] is connected to a fixed end fitting on the control
valve. The hose is routed to the upright where the hose is
connected to a fitting that feeds the base end of both lift
cylinders. The hose can only be removed by first
removing it from the tee fitting located at the rear of the
loader.
Cap and plug the hose and fitting.
WARNING
W-2059-0598

(FOOT CONTROL) (CONT’D)
Removal And Installation (Cont’d)

2
Figure 20-40-3
1
1
P-37099
Disconnect the tubeline (Item 1) [Figure 20-40-5] that

goes from the control valve to the hydraulic cooler.
P-34119
Disconnect the charge pressure sender (Item 2) [Figure
20-40-5] from the control valve.
Disconnect the two tubelines (Item 1) [Figure 20-40-3]
from the lift arm by-pass valve. Figure 20-40-6
Cap and plug tubelines and fittings.
Figure 20-40-4 1
1 P-34123
Mark the wire connectors for proper installation.

P-34120
Disconnect the three wire harness connector (Item 1)
[Figure 20-40-6] from auxiliary valve solenoid, and the
At the right fender, remove the two mounting bolts and lift and tilt lock solenoids.
nuts (Item 1) [Figure 20-40-4] from the lift arm by-pass
mount.
Remove the lift arm by-pass valve and tubelines from the
loader.

Figure 20-40-7 1
P-34126
1 Loosen the fixed end main valve hose assembly (Item 1)

[Figure 20-40-9] from the control valve.
P-34124
The hose can be removed from the control valve by

rotating the hose assembly.
Disconnect the harness connector (Item 1) [Figure 20-
40-7] from the BICS™ valve solenoid connector. Cap the hose and plug the fitting.
Disconnect the harness connector (Item 2) [Figure 20- Figure 20-40-10

40-7] from the auxiliary valve solenoid.
Figure 20-40-8
1
2
1
2
P-34127
P-34125 Install a chain hoist (Item 1) [Figure 20-40-10] to the

control valve, and support the control valve.
Disconnect foot control linkage (Item 1) [Figure 20-40-8] Remove the case drain hose (Item 2) [Figure 20-40-10]
from the tilt spool on the control valve. from the control valve to the case drain filter.
Disconnect foot control linkage (Item 2) [Figure 20-40-8] Loosen all the tubeline fittings connected to the control
from the lift spool on the control valve. valve.
Move the control linkages to allow clearance for the

control valve removal.

Figure 20-40-11 1
1 2
P-34130
Disconnect the case drain hose (Item 1) [Figure 20-40-

13] and cap the fitting and plug the hose.
P-34128
Disconnect the two auxiliary tubelines (Item 2) [Figure
Remove the two control valve mount bracket mount bolts
(Item 1) [Figure 20-40-11]. Figure 20-40-14
Remove right side motor cover.
Remove the right rear wheel/tire assembly from the

loader.
Remove the right side pump access cover.

1
Figure 20-40-12
1 P-34131
Disconnect the tilt tubeline (Item 1) [Figure 20-40-14]

from the control valve.
1
Disconnect the lift tubeline (Item 2) [Figure 20-40-14]
P-34129
At the right side motor cover access hose, remove the

two control valve mount bolts (Item 1) [Figure 20-40-12]
from the mounting plate.
Remove the control valve mount bracket from the loader.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS™ Valve, Removal And Installation
Figure 20-40-17
Figure 20-40-15 1
1
1
1 1
1
N-20033
P-34132 Remove the control valve. (See Removal And Installation

on Page 20-40-1.)
Disconnect the tilt tubeline (Item 1) [Figure 20-40-15] To remove the BICS™ valve from the control valve,
from the control valve. loosen and remove the six mounting bolts (Item 1)
[Figure 20-40-17].
Cap and plug the tubeline and fitting.
Figure 20-40-18
Figure 20-40-16
N-20034
P-34133
Remove the BICS™ valve assembly from the top of the

With the chain hoist lift the control valve up and clear of control valve [Figure 20-40-18].
the tubelines [Figure 20-40-16].
Disconnect the hydraulic hose (Item 1) [Figure 20-40-16]

that comes from the back of the gear pump to the bottom
of the control valve.
Remove the control valve from the loader.

BICS™ Valve, Removal And Installation (Cont’d)

3
6
Figure 20-40-19
1
2
5
1 1
4
2 N-20033
Install the six mounting bolts [Figure 20-40-20].
N-20035 The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS]
valve assembly to the control valve. Thoroughly clean
Remove the four large O-rings (Item 1) [Figure 20-40- and dry bolts and threads in valve. Use liquid adhesive
19] and the small O-ring (Item 2) [Figure 20-40-19] from LOCTITE #242 or equivalent.
the top of the control valve.
Step Torque Sequence
Install the four large O-rings (Item 1) [Figure 20-40-19]
and the small O-ring (Item 2) [Figure 20-40-19] on the 1 110-130 in.-lbs.
top of the control valve. (12,4-14,7 Nm)
2 190-210 in.-lbs.
1, 2, 3, 4, 5 & 6
(21,5-23,7 Nm)
3 190-210 in.-lbs.
(21,5-23,7 Nm)
*Torque must be 190-210 in.-labs. (21,5-23,7 Nm) for

every bolt or repeat step 3.

BICS™ Valve, Lift Arm By-Pass Orifice Removal And

Installation
Figure 20-40-21
1
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-22] & [Figure 20-40-
23].
N-20040
Orifice size is 0.078 inch.
Remove the fitting (Item 1) [Figure 20-40-21] from the Reverse the removal procedure to install the lift arm by-
valve. pass orifice.
Figure 20-40-22
N-20041

BICS™ Valve, Check Valve Removal And Installation
Figure 20-40-24
1
P-8956
1
Clean and inspect the screen (Item 1) [Figure 20-40-26]

on the end of the valve.
N-20037
Remove the check valve (Item 1) [Figure 20-40-24].
Installation: Tighten the valve to 20 ft.-labs. (27 Nm)

torque.
Figure 20-40-25
N-18684
Remove the O-rings (Item 1) and back-up ring (Item 2)

from the check valve [Figure 20-40-25].
Install new O-rings and back-up ring on the check valve.
The check valve has a rating of 5-10 PSI.

Backslide, Lock Valve Removal And Installation
Figure 20-40-27
1
1
1
N-20040
Remove the lock valves (Item 1) [Figure 20-40-27],

[Figure 20-40-28] & [Figure 20-40-29] from the BICS™
N-20033 valve.
Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)

Figure 20-40-28 torque.
Figure 20-40-30
2
N-20039
2
2
N-18690
Remove the O-rings (Item 1) and back-up rings (Item 2)

from both the tilt and lift lock valves [Figure 20-40-30].
Install new O-rings (Item 1) and back-up rings (Item 2)

on the tilt and lift lock valves [Figure 20-40-30].
Reverse the removal procedure to install the lock valve.

(FOOT CONTROL) (CONT'D)
BICS™ Valve, Solenoid Removal And Installation

1
Figure 20-40-31
N-20038
Remove the solenoid stem (Item 1) [Figure 20-40-33].
N-20037 Installation: Tighten the solenoid stem to 20 ft.-lbs. (27
Nm) torque.
Remove the mounting nut (Item 1) [Figure 20-40-31] Figure 20-40-34

from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lbs. (6

Nm) torque.
3
Remove the solenoid (Item 2) [Figure 20-40-31]. 2
NOTE: The solenoid resistance is (8-10 ohms).
Figure 20-40-32
1
1
1 N-18694
Remove the O-rings (Item 1) and back-up washers (Item

2) on the stem [Figure 20-40-34].
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any part showing
excessive wear.
N-18693A
NOTE: The screen (Item 3) [Figure 20-40-34] may be
cleaned with solvent. If it is torn or worn
Remove the O-rings (Item 1) [Figure 20-40-32] from replace the solenoid stem.
both ends of the solenoid.
Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.
Install new O-rings and new back-up washers on the

solenoid stem.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
BICS™ Valve, Solenoid Testing
Figure 20-40-35
P9175
Use a test meter to measure coil resistance [Figure 20-

40-35]. Coil wires do not have polarity. Correct
resistance for the auxiliary pressure relief (small) coil is 7-
10 ohm and the other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

Identification Chart H2 H1
Item S250, S300 Loader

A1 Lift Cylinder Base End/Restrictor H3
A2 Tilt Cylinder Base End
C4
A3 Auxiliary Hydraulics
B3 A3
B1 Lift Cylinder Rod End G3 D3
C3
B2 Tilt Cylinder Rod End
G2 B2 A2 E2 D2
B3 Auxiliary Hydraulics
F2 C2
C1 Load Check Valve/Lift Function G1 E1
B1 A1
C2 Load Check Valve/Tilt Function C1
F1
C3 Orificed Load Check Valve/Auxiliary
Function D1
C4 Outlet Fluid Flow
D1 Lift Spool Detent MR
TS-1971
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve - 4000 PSI
E2 Anti-Cavitation/Port Relief Valve - 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 4000 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) - 3500 PSI
MR Main Relief Valve - 3300 PSI

Load Check Valve

2
Figure 20-40-37
1
1 1
1 1
N-18698
2
Loosen the load check plugs (Item 1) [Figure 20-40-38]

from the lift and tilt sections of the control valve.
N-20035
Installation: Always use new O-ring. tighten the plug to

35-40 ft.-lbs. (47-54 Nm) torque.
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve, Removal And Installation on Page Figure 20-40-39
20-40-5.)
Remove the four large O-rings (Item 1) and small O-ring

(Item 2) [Figure 20-40-37]. Always replace these O-rings
before installing the BICS valve assembly.
3
IMPORTANT 1

clean the work area before disassembly and keep all 2
N-20077
damage the system.
I-2003-0888
Remove the load check plugs (Item 1) [Figure 20-40-39].

Mark each valve section, spool and related parts so that
they will be returned to its original valve section during Remove the spring (Item 2) and poppet (Item 3) [Figure
assembly. 20-40-39].
Use bolts to fasten the control valve to a work bench for NOTE: Both load checks poppets, plugs and springs
easier disassembly and assembly procedures. are the same for the lift and tilt.
Loosen the load check plug (Item 2) [Figure 20-40-38]

from the auxilliary section of the control valve.

2 3
4
Load Check Valve (Cont’d) 5
Figure 20-40-40
1
B-6764
1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring
CD-15092
1 Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-42].
N-20078
Installation: Always use new O-rings. sleeve, and glide
ring. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
The auxiliary section uses a load check poppet with an
orifice (Item 1) [Figure 20-40-40]. Port Relief Valve, Tilt Spool
NOTE: For correct port locations and valve Figure 20-40-43

component (See Identification Chart on Page
20-40-12.).
Main Relief Valve
Figure 20-40-41
N-20043
Remove the port relief valve (Item 1) [Figure 20-40-43]

1 from the control valve tilt section.
N-20039
Loosen and remove the main relief valve (Item 1) [Figure

20-40-41].

4
Port Relief Valve, Tilt Spool (Cont’d)
3
Figure 20-40-44
2
4 1
3
2 1. O-ring
1 2. Back-up Washer
3. O-ring
4. Relief Valve
1. O-ring N-18844
2. Back-up Washer
3. O-ring
4. Relief Valve Remove the O-rings and back-up washer from the port
N-18844
Installation: Always use new O-rings and back-up

washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-44]. Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
Installation: Always use new O-rings and back-up Figure 20-40-47

Port Relief Valve, Lift Spool
Figure 20-40-45 1
1
N-20042
Remove the anti-cavitation/port relief valve (Item 1)

[Figure 20-40-47] from the control valve tilt section.
N-20040
Remove the port relief valve (Item 1) [Figure 20-40-45]

from the control valve lift section.

1 2 3 4
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
(Cont’d)
Figure 20-40-48 E-1509a
1. Anti-Cavitation Valve
2. O-ring
3. Back-up Washer
1 4. O-ring
N-18839
Remove the O-rings and back-up washer from the anti-

cavitation valve [Figure 20-40-50].
N-18843 Rubber Boot
Figure 20-40-51
Remove the O-rings (Item 1) [Figure 20-40-48] from the
anti-cavitation/port relief valve.

Anti-Cavitation Valve, Lift Spool 1
Figure 20-40-49
N-20043
Remove the two screws (Item 1) [Figure 20-40-51] on

the rubber boot retainer.
1
Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
11,3 Nm) torque.
N-20043
Remove the lift lock solenoid (Item 1) [Figure 20-40-49].
Remove the anti-cavitation valve (Item 2) [Figure 20-40-

49] from the control valve lift section.

Rubber Boot (Cont’d)

1
Figure 20-40-52
2
2 1
2
2
1
1
N-20021
Remove the lock solenoids (Item 1) [Figure 20-40-53] &

[Figure 20-40-54] from the lift and tilt lock block.
N-20020
Remove the rubber Boot (Item 2) [Figure 20-40-53] &

[Figure 20-40-54]. (See Rubber Boot on Page 20-40-
Remove the rubber boot (Item 1) and retainer (Item 2) 16.)
[Figure 20-40-52].
Figure 20-40-55
Lift And Tilt Lock Block
Figure 20-40-53
N-20022
2
N-20043 Remove the lift and tilt lock block [Figure 20-40-55].
NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)

Lift Spool And Detent Removal
Figure 20-40-56
N-20040
1
Remove the end cap (Item 1) [Figure 20-40-58].
N-20022 Figure 20-40-59
The tool listed will be needed to do the following
procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
1
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
56] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-17.)
2
Figure 20-40-57
N-18971
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-59].
2
1 Remove the washer (Item 2) [Figure 20-40-59].
N-20023
Remove the bushing (Item 1) and O-ring (Item 2) from

the lift spool [Figure 20-40-57].

Lift Spool And Detent Removal (Cont'd)
Figure 20-40-60
2 1
2 N-18974
1 Remove the detent sleeve (Item 1), detent balls (Item 2)

and spring (Item 3) [Figure 20-40-62].
N-18972
Figure 20-40-63
Remove the screws (Item 1) [Figure 20-40-60] from the

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-60].
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and 1
assembly.
I-2012-0284
N-18975
Figure 20-40-61
Remove the spool assembly and seal (Item 1) [Figure
N-18973
Put a rag around the detent assembly [Figure 20-40-61].

This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.

Lift Spool And Detent Disassembly 2
Figure 20-40-64
3 1
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-66] over the

centering spring.
N-18930
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-66] from the centering
Remove the spool seal (Item 1) [Figure 20-40-64] from spring, as it is under spring pressure.
the linkage end of the valve.
NOTE: The centering spring (Item 3) [Figure 20-40-66]
Figure 20-40-65 is orange on all large frame loaders.
Figure 20-40-67
P-8988
1
2
N-18916
Clamp the linkage end of the spool in a vise [Figure 20-
40-65].
lost when the detent adapter is removed.
Remove the detent adapter with an allen wrench.
Remove the back-up washer (Item 1) and spool seal

(Item 2) [Figure 20-40-67].

1
Lift Spool And Detent Disassembly (Cont'd) 2
3
Figure 20-40-68
4
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-70].
N-19004
Figure 20-40-71
Remove the detent adapter (Item 1) [Figure 20-40-68]

from the spring assembly.
Figure 20-40-69
N-18918
Remove the stud from the end of the spool [Figure 20-
40-71].
N-19009
Remove spring tool (Item 1) [Figure 20-40-69] from the

spring assembly.

Lift Spool And Detent Disassembly (Cont'd)
Figure 20-40-72
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-72] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS.

Lift Spool And Detent Assembly O-ring
Figure 20-40-73
2
Plastic
1 Plug
0.60 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
N-18961 20-40-75].
Figure 20-40-76
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-73].
Figure 20-40-74
N-18967
Clamp the collar (Item 1) [Figure 20-40-76] in a vice.

N-18963
Install the plastic plug and O-ring in the spool [Figure 20-
40-74].

Lift Spool And Detent Assembly (Cont’d)
Figure 20-40-77
1
2
N-19004
1
3
2 Install the spring tool (Item 1) [Figure 20-40-79] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-80
Apply grease on all the detent component surfaces

before assembly [Figure 20-40-77].
Install the spring (Item 1) [Figure 20-40-77] and detent

balls (Item 2) [Figure 20-40-77] into the adapter (Item 3)
[Figure 20-40-77] and compress with the detent pliers 2
(Item 1) [Figure 20-40-78].
Figure 20-40-78
1
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-80].
N-18968
Install the detent adapter to the collar [Figure 20-40-78].
NOTE: The collar and the detent adapter are held

together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

Figure 20-40-81
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-40-83].
N-19005
Figure 20-40-84
Install the spring assembly to the lift spool hand tight

[Figure 20-40-81].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
1
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-81].
Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm).
Figure 20-40-82
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-84] to the

detent adapter.
CD-15051
Install the detent balls and spring [Figure 20-40-82].

Figure 20-40-85
1
2
N-20040
1
Install the end cap (Item 1) [Figure 20-40-87].
2
N-18972
Install the lift spool assembly in the spool bore [Figure
20-40-85].
Install the detent bonnet (Item 1) [Figure 20-40-85].
Install the mounting screws (Item 2) [Figure 20-40-85].

11,3 Nm) torque.
Figure 20-40-86
N-18971
Install the washer (Item 1) and snap ring (Item 2) [Figure

20-40-86].

Lift Spool And Detent Installation
Figure 20-40-88
1 N-20022
Install the lift and tilt lock block (Item 1) [Figure 20-40-
90]. (See Lift And Tilt Lock Block on Page 20-40-17.)
N-18930
Install the spool seal (Item 1) [Figure 20-40-88] on the

linkage end of the valve.
Figure 20-40-89
1 2
N-18927
Install the bushing (Item 1) [Figure 20-40-89] and O-ring

(Item 2) [Figure 20-40-89] on the linkage end of the lift
spool.

Tilt Spool Removal And Installation
Figure 20-40-91
1
N-20042
1 Remove the screws (Item 1) [Figure 20-40-93] from the

end cap.
N-20022
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
91] from the control valve. (See Lift And Tilt Lock Block Figure 20-40-94
on Page 20-40-17.)
Figure 20-40-92
1 2
N-18816
N-20024 Remove the spool, centering spring, back-up washer and

spool seal [Figure 20-40-94].
Remove the bushing (Item 1) [Figure 20-40-92] and O- Assembly: Always use a new spool seal.
ring (Item 2) [Figure 20-40-92] from the tilt spool.

1
Tilt Spool Disassembly And Assembly 2
3
Figure 20-40-95
4
N-18944
N-18942
Figure 20-40-98
Put the linkage end of the spool in the vice [Figure 20- 2
40-95].
1
Install the spool tool (Item 1) [Figure 20-40-95] over the
centering spring.
Figure 20-40-96
1
1
N-19098 N-18943
Remove the spool seal(s) (Item 1) and the back-up

Assembly: Always use a new spool seal.
N-19014
Remove the bolt (Item 1) [Figure 20-40-96] holding the

centering spring to the spool.

Nm) torque.
Remove spring tool from the spring assembly.

Auxiliary Spool Removal And Installation
Figure 20-40-99
N-18989
1
Remove the spool (Item 1) [Figure 20-40-101].
N-20042 Assembly: Put grease on all the centering spring
component parts.
Remove the screws (Item 1) [Figure 20-40-99] from the Figure 20-40-102
end cap.

Nm) torque.
Figure 20-40-100
1
1
N-20043
Remove the lock solenoid (Item 1) [Figure 20-40-102]

from the tilt lock block.
N-18990
Remove the end cap, O-ring, springs and centering

spring retainer [Figure 20-40-100].
NOTE: If the centering spring retainer (Item 1) [Figure

20-40-100] must be replaced, replace the
retainer on the opposite end also.

Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-103
2
2
N-20075
Remove the centering spring retainer (Item 1) [Figure

1 20-40-105] and springs (Item 2) [Figure 20-40-105].
N-20073
Remove the screws (Item 1) [Figure 20-40-103] from the Assembly: Put grease on all the centering spring
auxiliary bleed block (Item 2) [Figure 20-40-103]. component parts.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3 NOTE: If the centering spring retainer (Item 1) [Figure
Nm) torque. 20-40-105] must be replaced, replace the
Figure 20-40-104
N-20074
Remove the auxiliary bleed block (Item 1) [Figure 20-40-

104] and O-ring.
Assembly: Always use a new O-ring.

Auxiliary Plug Removal And Installation
Figure 20-40-106
N-20031
Remove the plug (Item 1) [Figure 20-40-106] auxiliary
section of the control valve.
Figure 20-40-107
N-20076
Replace the O-rings (Item1) [Figure 20-40-107].
Check the orfice (Item 2) [Figure 20-40-107], to make

sure it is not pluged.

Auxiliary Electric Solenoid Disassembly
Figure 20-40-108
N-20027
Remove the coil (Item 1) [Figure 20-40-110] and end

1 plate (Item 2) [Figure 20-40-110].
N-20025
Remove the nut (Item 1) [Figure 20-40-108] from both Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)
solenoids. torque.
Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm) Figure 20-40-111
torque.
Figure 20-40-109
1
N-18795
2
N-20026 Remove the O-rings (Item 1) [Figure 20-40-111] from

the solenoid stem.
Remove the end plate (Item 1) and housing (Item 2)

[Figure 20-40-109].

Port Relief (Optional)
Port-Auxiliary Section Removal And Installation
Figure 20-40-112
1 2
1
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-113] &

[Figure 20-40-114] and back-up ring (Item 2) [Figure 20-
N-20031 40-113] & [Figure 20-40-114] from the plug or relief
valve.
Remove the plug (Item 1) [Figure 20-40-112] or optional Cleaning And Inspection
port relief valve from the control valve.
Clean all components with clean solvent and dry with
NOTE: Optional port relief (Item 1) [Figure 20-40-112] compressed air.
is 3500 PSI (24129 kPa).
Check the spools for wear or scratches.
Figure 20-40-113
Check that the spools are not loose in their bore.
Plug
Check that the centering springs are not broken.
2 Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.

1
Use new O-rings and back-up rings.
N-18800 Apply oil to all new O-rings and back-up rings before
installation.

(ADVANCED CONTROL SYSTEM) (ACS)
Identification
Figure 20-41-1
N-18695
The hydraulic control valve (2 piece casting) (Advance

Control System) (ACS) has a removable BICS™ section
(Item 1) [Figure 20-41-1].
The BICS™ section and main control valve are in two

seperate castings.
For identification of the hydraulic control valve (1 piece

casting) (Advanced Control System) (ACS), (See
Identification on Page 20-44-1.))

(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
Actuator Removal And Installation (In Loader)
Raise the lift arms and install an approved lift arm

support device. (See Installing The Lift Arm Support 1
Device on Page 10-20-1.)
WARNING
support device. Failure to use an approved lift arm P-37789

W-2059-0598
Remove the by-pass control knob (Item 1) [Figure 20-
41-3] from the lift arm by-pass valve.
Figure 20-41-4
Figure 20-41-2
1
2
1
P-37790
N-22483
Remove the jam nut (Item 1) and the rubber washer
(Item 2) [Figure 20-41-4] from the lift arm by-pass valve.
Remove the access cover (Item 1) [Figure 20-41-2] from
the right side of the loader frame.


(Cont’d)
Figure 20-41-5
1 2
1
1 P-39424
Disconnect the actuator wire connectors (Item 1) [Figure

20-41-7] from the actuators.
P-37791 Figure 20-41-8

from the lift arm by-pass valve.
Disconnect the hydraulic hose (Item 2) [Figure 20-41-5] 1

from the control valve. 1
Cap and plug the fittings and hose.
Figure 20-41-6
1 P-39425
Remove the two actuator mount bolts (Item 1) [Figure

1 20-41-8] from the top actuator.
Installation: Tighten the bolts to 90-100 in.-lbs. (10,2-

11,3 Nm) torque.
P-43928
Remove the two mount bolts (Item 1) [Figure 20-41-6]

from the lift arm by-pass valve/brake valve mounting
bracket.
Move the lift arm by-pass valve/brake valve down into the
fender to allow room for the actuator removal.


(Cont’d)
1
Figure 20-41-9
2
2
P-39428
Slide the actuator (Item 1) [Figure 20-41-11] away from

1 the control valve.
P-39426 With a punch, remove the actuator pin (Item 2) [Figure
20-41-11] from the actuator and spool.
Slide the actuator (Item 1) [Figure 20-41-9] away from Remove the bottom actuator from the loader.
the control valve.
With a punch, remove the actuator pin (Item 2) [Figure

Remove the upper actuator from the loader.
Figure 20-41-10
1
1
P-39427

20-41-10] from the bottom actuator.

11,3 Nm) torque

Actuator Removal And Installation (Out Of Loader)
Figure 20-41-12
3
2
1 1
N-19114
2 1 Remove the actuator (Item 1), the O-ring (Item 2), the
spacer block (Item 3) and O-ring (Item 4) [Figure 20-41-
N-19112 14].
NOTE: There are two types of sealing designs used

Remove the two screws (Item 1) [Figure 20-41-12] on on the actuators and the actuator mounts.
the actuator retainer.
Figure 20-41-15
Installation: Tighten the bolt and nut to 90-100 in.-lbs.
(10,2-11,3 Nm) torque.
EARLIER SEALING STYLE
Pull the actuator (Item 2) [Figure 20-41-12] away from
the control valve.
Figure 20-41-13
1
3
P-51830
1
The earlier style has the O-ring (Item 1) in the actuator

mount (Item 2). The actuator sealing face (Item 3)
[Figure 20-41-15] has a flat face and no O-ring.
N-19113
Use a drift pin and hammer to remove the actuator pin

(Item 1) [Figure 20-41-13] from the actuator and the lift
or tilt spool.


(Cont’d)
Figure 20-41-16
LATER SEALING STYLE
1
2
3
P-51831
The later style has the O-ring (Item 1) in the actuator

sealing face (Item 2). The actuator mount (Item 3)
[Figure 20-41-16] has no O-ring.
NOTE: The later style actuator can replace the earlier

style actuator as long as the actuator mount is
changed to the later style actuator mount.

WARNING
P-37098

Never work on a machine with the lift arms up unless 20-41-17] is connected to a fixed end fitting on the
the lift arms are secured by an approved lift arm control valve. The hose is routed to the right side upright
where the hose is connected to a tee fitting that feeds the

support device can allow the lift arms or attachment base end of both lift cylinders. The hose can only be
to fall and cause injury or death. removed by first removing it from the tee fitting located at
W-2059-0598 the rear of the loader.
Raise the lift arms and install an approved lift arm Cap and plug the hose and fitting.
support device.
Figure 20-41-18

on Page 10-30-1.)

Fluid And Case Drain Filters on Page 10-120-3.) 1
Remove the control panel.(See Removal And Installation

on Page 50-100-1.)
2
Remove the control valve actuators. (See Actuator
Removal And Installation (In Loader) on Page 20-41-2.)
Clean area around control valve. P-39429
Open rear door.

Disconnect the electrical connector (Item 1) [Figure 20-

41-18] from the auxiliary spool solenoid.

41-18] from the BICS valve solenoid.

Figure 20-41-19
P-34126
Loosen the fixed end main valve hose assembly (Item 1)

P-39430
41-19] from the auxiliary spool solenoid. Cap the hose and plug the fitting.
Figure 20-41-20 Figure 20-41-22
2 1
1
P-37099
P-34127
Disconnect the tubeline (Item 1) [Figure 20-41-20] that Install a chain hoist (Item 1) [Figure 20-41-22] to the
goes from the control valve to the hydraulic cooler. control valve, and support the control valve.
Disconnect the charge pressure sender (Item 2) [Figure Loosen all the tubeline fittings connected to the control
20-41-20] from the control valve. valve.
Cap and plug the tubelines and fittings.

1
Figure 20-41-23
1
1
P-34129
Remove the two control valve mount bolts (Item 1)

[Figure 20-41-25] from the mounting plate, at the back
P-43930 side of the control valve.

that comes from the back of the gear pump to the Figure 20-41-26
tubeline at the top of the control valve.
Figure 20-41-24
2
1 1
P-34130
P-43931 Disconnect the case drain hose (Item 1) [Figure 20-41-

Remove the two control valve mount bracket mounting Disconnect the two tubelines (Item 2) [Figure 20-41-26]
bolts (Item 1) [Figure 20-41-24]. from the auxiliary section of the control valve.
Remove the tubeline clamp mount bolt (Item 2) [Figure Cap the fittings and plug the tubelines.
20-41-24].

Figure 20-41-27
P-34131

Figure 20-41-28
P-34132
Disconnect the tilt tubeline (Item 1) [Figure 20-41-28] at

the tee fitting.

BICS™ Valve, Removal And Installation
Figure 20-41-29
1 1
1
1
2
1 1
1
N-20035
1
Remove the four large O-rings (Item 1) and the small O-

ring (Item 2) from the top of the control valve [Figure 20-
N-20033 41-31].
Installation: Install the four large O-rings (Item 1) and

To remove the BICS™ valve from the control valve, the small O-ring (Item 2) on the top of the control valve
loosen and remove the six mounting bolts (Item 1) [Figure 20-41-31].
[Figure 20-41-29].
Figure 20-41-30
N-20034

control valve [Figure 20-41-30].

BICS™ Valve, Removal And Installation (Cont'd)
Figure 20-41-32 1 1
1 1
6
3
1
1 2 1
5 N-23644
4
To remove the BICS™ valve from the control valve,

loosen and remove the six mounting bolts (Item 1)
N-20033 [Figure 20-41-33].
Figure 20-41-34
The chart below lists the correct torque specifications

and tightening sequence when reinstalling the BICS™
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.

1 110-130 in.-lbs.
(12,4-14,7 Nm)
2 190-210 in.-lbs.
1, 2, 3, 4, 5 & 6
(21,5-23,7 Nm)
3* 190-210 in. lbs.
(21,5-23,7 Nm) N-23645
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for Remove the BICS™ valve assembly from the top of the
every bolt or repeat step 3. control valve [Figure 20-41-34].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) The chart below lists the correct torque specifications
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D) and tightening sequence when reinstalling the BICS™
BICS™ Valve, Removal And Installation (Cont’d) and dry bolts and threads in valve. Use liquid adhesive
Figure 20-41-35
1 110-130 in.-lbs.
(12,4-14,7 Nm)
2 190-210 in.-lbs. 1, 2, 3, 4, 5 & 6
(21,5-23,7 Nm)
3* 190-210 in. lbs.
1 1
(21,5-23,7 Nm)
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for

2 every bolt or repeat step 3.
N-23646

41-35].
Install the four large O-rings (Item 1) and the small O-ring
(Item 2) on the top of the control valve [Figure 20-41-35].
Figure 20-41-36
3 6
1 2
5
4
N-23644

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly

And Assembly
Figure 20-41-37
1 N-18685
39].
N-20040
Orifice size is 0.078 inch.
Remove the fitting (Item 1) [Figure 20-41-37] from the Reverse the removal procedure to install the lift arm by-
valve. pass orifice.
Figure 20-41-38
N-20041

BICS™ Valve, Check Valve Disassembly And

Assembly
1
Figure 20-41-40
P-8956
1 Clean and inspect the screen (Item 1) [Figure 20-41-42]

N-20037
Installation: Tighten the valve to 20 ft.-lbs. (27 Nm)

torque.
Figure 20-41-41
N-18684
Remove the O-rings (Item 1) [Figure 20-41-41] and

back-up ring (Item 2) [Figure 20-41-41] from the check
valve.

BICS™ Valve, Lock Valve Disassembly And

Assembly
Figure 20-41-43
1
1
N-20040

valve.
N-23644
Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)
torque.
Figure 20-41-44
N-23647

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) NOTE: The solenoid resistance is (8-10 ohms).
Figure 20-41-48
Assembly (Cont’d)
Figure 20-41-46 1
1
1
N-18693A
2
2
Remove the O-rings (Item 1) [Figure 20-41-48] from
2
N-18690 both ends of the solenoid.
Figure 20-41-49
Install new O-rings (Item 1) and back-up rings (Item 2) on 1

the tilt and lift lock valves [Figure 20-41-46].
BICS™ Valve, Solenoid Disassembly And Assembly
Figure 20-41-47
1
N-20038
2 Installation: Tighten the solenoid stem to 20 ft.-lbs. (27

Nm) torque.
N-20037
Remove the mounting nut (Item 1) [Figure 20-41-47]


Nm) torque.
Remove the solenoid (Item 2) [Figure 20-41-47].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS™ Valve, Solenoid Testing
Figure 20-41-51
(Cont’d)
Figure 20-41-50
3
2
P9175
1
N-18694 41-51]. Coil wires do not have polarity. Correct
2) on the stem [Figure 20-41-50]. Replace the test meter with 12 volt power. You can see
excessive wear.
NOTE: The screen (Item 3) [Figure 20-41-50] may be

replace the solenoid stem.

solenoid stem.

H2 H1
Identification Chart
ITEM S250, S300 Loader ACS Hand Control H3

A1 Lift Cylinder Base End/Restrictor C4
A2 Tilt Cylinder Base End B3 A3 D3
G3
A3 Auxiliary Hydraulics C3 D2
B1 Lift Cylinder Rod End G2 B2 A2 E2
B2 Tilt Cylinder Rod End C2 D1
F2 G1 B1 A1 E1
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function F1 C1
MR
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function TS-2136
D1 Lift Spool Centering Spring
E1 Port Relief Valve – 4000 PSI

E2 Anti–Cavitation/Port Relief Valve – 3500 PSI
F2 Port Relief Valve – 4000 PSI
G1 LIft Spool End
G2 Tilt Spool End
H2 Plug/Port Relief (Optional) – 3500 PSI
MR Main Relief Valve – 3300 PSI

Lift Base End Restrictor
Figure 20-41-52
N-21159
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve, Removal And Installation on
Page 20-41-11.)
Remove the restrictor (Item 1) [Figure 20-41-52] from

the lift section base end port.

Load Check Valve
Figure 20-41-53
1
1 1
1
1
N-19100
2 Loosen the load check valve plugs (Item 1) [Figure 20-

41-54].
N-19099
Installation: Always use new O-ring. Tighten the plug to

35-40 ft.-lbs. (47-54 Nm) torque.
valve. (See BICS™ Valve, Removal And Installation on Figure 20-41-55
Page 20-41-11.)

before installing the BICS™ valve assembly.
1
IMPORTANT
parts clean. Always use caps and plugs on hoses, 3
tubelines and ports to keep dirt out. Dirt can quickly 2
N-19101
damage the system.
I-2003-0888

they will be returned to their original valve section during Remove the spring (Item 2) and poppet (Item 3) [Figure
assembly. 20-41-55].
Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Main Relief Valve
Figure 20-41-57
Load Check Valve (Cont'd)
Figure 20-41-56
N-19034
2
N-19102 Loosen the main relief valve (Item 1) [Figure 20-41-57].
Figure 20-41-58
The auxiliary section (Item 1) uses an orifice load check
poppet (Item 2) [Figure 20-41-56].
N-19035
Remove the main relief valve (Item 1) [Figure 20-41-58].

Main Relief Valve (Cont’d)
Figure 20-41-59
2 3
4 5
B-6764
1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
Installation: Always use new O-rings, sleeve, and glide


Port Relief Valve
Figure 20-41-60
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-62].
N-19000 Figure 20-41-63
4
Figure 20-41-61
3
2
1 1
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844
N-19034 Remove the O-rings and back-up washer from the port
Loosen the port relief valve (Item 1) [Figure 20-41-60] &

[Figure 20-41-61] (Port E1 or F2). (See Identification
Chart on Page 20-41-19.)


Anti-Cavitation Valve/Port Relief Valve
Figure 20-41-64
1
N-18843

N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-41-

64].

Figure 20-41-65
N-18980

[Figure 20-41-65] from the control valve for the tilt
section.

2
1 3 4
Anti-Cavitation Valve
Figure 20-41-67
1
E-1509A
2. O-ring
3. Backup Washer
4. O-ring
N-18839

N-19034
Figure 20-41-68
1
N-19036

67] & [Figure 20-41-68] from the control valve.

Lift Spool Removal
Figure 20-41-70
N-19003

1 cap.
N-19112
Figure 20-41-73
Remove the actuator (Item 1) [Figure 20-41-70] from the

control valve.
Figure 20-41-71
2
N-18983
1
2
Remove the spool assembly (Item 1) [Figure 20-41-73]
and seal from the control valve.
N-19114
Remove the spacer (Item 1) and O-ring (Item 2) from the

lift spool [Figure 20-41-71].

Lift Spool Removal And Installation
Figure 20-41-74
1
1
1
N-19003

end cap.
N-19112
Nm) torque.
Remove the actuators (Item 1) [Figure 20-41-74] from
the control valve. Figure 20-41-77
Figure 20-41-75
2 1
2
1
N-18985
N-18940
Remove the spool assembly (Item 1) [Figure 20-41-77]
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-75] from the tilt spool. Assembly: Always use a new spool seal.

2 1
Lift and Tilt Spool Disassembly And Assembly
3
Figure 20-41-78
4
N-18944A
NOTE: The center spring (Item 3) [Figure 20-41-80] is

orange on all large frame loaders.
N-18942
3), and washer (Item 4) [Figure 20-41-80].
Put the linkage end of the spool in the vise [Figure 20-
41-78]. Figure 20-41-81
Install the spool tool (Item 1) [Figure 20-41-78] over the 2

centering spring.
1
Figure 20-41-79
N-18930 N-18943

N-19014


Nm) torque.

Figure 20-41-82 1
N-18988
1
N-19003 Assembly: Put grease on all the centering spring
component parts.

end cap (both sides).

Nm) torque.
Figure 20-41-83
N-18987
Remove the end cap, O-ring, springs and washer (both

sides) [Figure 20-41-83].

Figure 20-41-85
3 2
1 N-18992
1 Remove the coil (Item 1) and end plate (Item 2) [Figure

20-41-87].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-41-87].
Remove the nut (Item 1) [Figure 20-41-85] from both Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)
solenoids. torque.
Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm) Figure 20-41-88
torque.
Figure 20-41-86
1
N-18795
N-18823 Remove the O-rings (Item 1) [Figure 20-41-88] from the

solenoid valves.

[Figure 20-41-86].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Cleaning And Inspection
Clean all components with clean solvent and dry with
Port-Auxiliary Section Disassembly compressed air.
Figure 20-41-89 Check the spools for wear or scratches.
Check that the load check valve seats are not worn.
Check the rubber boots and retainers

1

N-18996
Apply oil to all new O-rings and back-up rings before
installation.
Remove the plug (Item 1) [Figure 20-41-89] or optional
NOTE: Optional port relief (Item 1) [Figure 20-41-89]

is either 2500 PSI or 3000 PSI depending on
the option used.
Figure 20-41-90
2
1
1
N-18843
Remove the O-rings (Item 1) [Figure 20-41-90] &

[Figure 20-41-90] and back-up ring (Item 2) [Figure 20-
41-90] & [Figure 20-41-90] from the plug.

(SELECTABLE JOYSTICK CONTROL) (SJC)
Identification
Figure 20-41-1
N-18695
The hydraulic control valve (2 piece casting) (Selectable

Joystick Control) (SJC) has a removable BICS™ section
(Item 1) [Figure 20-41-1].
The BICS™ section and main control valve are in two

seperate castings.

casting) (Selectable Joystick Control) (SJC), (See
Identification on Page 20-45-1.)

(CONT’D)
Raise the lift arms and install an approved lift arm 1

support device. (See Installing The Lift Arm Support
WARNING
the lift arms are secured by an approved lift arm P-37789
to fall and cause injury or death. Remove the by-pass control knob (Item 1) [Figure 20-
W-2059-0598 42-3] from the lift arm by-pass valve.
Figure 20-42-4
Figure 20-42-2
1
2
P-37790
N-22483 Remove the jam nut (Item 1) and the rubber washer
(Item 2) [Figure 20-42-4] from the lift arm by-pass valve.
Remove the access cover (Item 1) [Figure 20-42-2] from
the right side of the loader frame.

(CONT'D)

(Cont’d)
Figure 20-42-5
1 2 1
P-39424
1
Disconnect the actuator wire connectors (Item 1) [Figure

20-42-7] from the actuators.
Figure 20-42-8
P-37791

from the lift arm by-pass valve.
1
Disconnect the hydraulic hose (Item 2) [Figure 20-42-5] 1
Cap and plug the fittings and hose.
Figure 20-42-6
P-39425
1

20-42-8] from the top actuator.
1
11,3 Nm) torque.
P-43928

from the lift arm by-pass valve/brake valve mounting
bracket.
Move the lift arm by-pass valve/brake valve down into the
fender to allow room for the actuator removal.

(CONT'D)

(Cont’d)
1
Figure 20-42-9 2
2 P-39428

the control valve.
1
P-39426 20-42-11] from the actuator and spool.
Remove the bottom actuator from the loader.

the control valve.

Remove the upper actuator from the loader.
Figure 20-42-10
1
1
P-39427

20-42-10] from the bottom actuator.

11,3 Nm) torque

(CONT'D)
Figure 20-42-12
3
2
1
N-19114
1
Remove the actuator (Item 1), the O-ring (Item 2), the
2 1 spacer block (Item 3) and O-ring (Item 4) [Figure 20-42-
14].
N-19112
NOTE: There are two types of sealing designs used

on the actuators and the actuator mounts.
Remove the two screws (Item 1) [Figure 20-42-12] on
Figure 20-42-15
Installation: Tighten the bolt and nut to 90-100 in.-lbs.
(10,2-11,3 Nm) torque. EARLIER SEALING STYLE

the control valve.
Figure 20-42-13
1
3
P-51830
1
The earlier style has the O-ring (Item 1) in the actuator
mount (Item 2). The actuator sealing face (Item 3)
[Figure 20-42-15] has a flat face and no O-ring.
N-19113
Use a drift pin and hammer to remove the actuator pin

(Item 1) [Figure 20-42-13] from the actuator and the lift
or tilt spool.


(Cont’d)
Figure 20-42-16
LATER SEALING STYLE
1
2
3
P-51831
The later style has the O-ring (Item 1) in the actuator

sealing face (Item 2). The actuator mount (Item 3)
[Figure 20-42-16] has no O-ring.
NOTE: The later style actuator can replace the earlier

style actuator as long as the actuator mount is
changed to the later style actuator mount.

(CONT'D)
P-37098
WARNING The fixed end main valve hose assembly (Item 1) [Figure
20-42-17] is connected to a fixed end fitting on the
Never work on a machine with the lift arms up unless control valve. The hose is routed to the right side upright
where the hose is connected to a tee fitting that feeds the

support device. Failure to use an approved lift arm base end of both lift cylinders. The hose can only be
support device can allow the lift arms or attachment removed by first removing it from the tee fitting located at
to fall and cause injury or death. the rear of the loader.
W-2059-0598

support device.

on Page 10-30-1.)

Fluid And Case Drain Filters on Page 10-120-3.)
Remove the control panel.(See Removal And Installation

on Page 50-100-1.)
Remove the control valve actuators. (See Actuator

Removal And Installation (In Loader) on Page 20-41-2.)
Clean area around control valve.
Open rear door.

(CONT'D)
Removal And Installation (Cont'd) 2
Figure 20-42-18 1
P-37099
2
P-39429 Disconnect the charge pressure sender (Item 2) [Figure
Cap and plug the tubelines and fittings.
Figure 20-42-21

42-18] from the BICS valve solenoid.
Figure 20-42-19
1
P-34126

P-39430 The hose can be removed from the control valve by

Cap the hose and plug the fitting.

(CONT'D)
1
Figure 20-42-22 2
P-43931
Remove the two control valve mount bracket mounting

bolts (Item 1) [Figure 20-42-24].
P-34127 Remove the tubeline clamp mount bolt (Item 2) [Figure

20-42-24].
Install a chain hoist (Item 1) [Figure 20-42-22] to the
Figure 20-42-25
Loosen all the tubeline fittings connected to the control 1

valve.
Figure 20-42-23
1 1
P-34129

[Figure 20-42-25] from the mounting plate, at the back
side of the control valve.
P-43930

that comes from the back of the gear pump to the
tubeline at the top of the control valve.

(CONT'D)
Figure 20-42-26
1
P-34132
Disconnect the tilt tubeline (Item 1) [Figure 20-42-28] at

the tee fitting.
P-34130 Cap and plug the tubeline and fitting.

Disconnect the case drain hose (Item 1) [Figure 20-42-

from the auxiliary section of the control valve.
Cap the fittings and plug the tubelines.
Figure 20-42-27
P-34131



(CONT'D)
BICS™ Valve, Removal And Installation
Figure 20-42-29
1 1
1
1
2
1 1
1 N-20035
1
ring (Item 2) [Figure 20-42-31] from the top of the control
valve.
N-20033
Installation: Install the four large O-rings (Item 1) and

the small O-ring (Item 2) [Figure 20-42-31] on the top of
the control valve.
[Figure 20-42-29].
Figure 20-42-30
N-20034

control valve [Figure 20-42-30].

(CONT'D)
BICS™ Valve, Removal And Installation (Cont'd)

1 1
Figure 20-42-32
1 1
6
3
1
1
1 2
N-23644
5
4
[Figure 20-42-33].
N-20033
Figure 20-42-34
The chart below lists the correct torque specifications

and tightening sequence when reinstalling the BICS™

1 110-130 in.-lbs.
(12,4-14,7 Nm)
2 190-210 in.-lbs.
1, 2, 3, 4, 5 & 6
(21,5-23,7 Nm)
3* 190-210 in. lbs. N-23645
(21,5-23,7 Nm)

*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for control valve [Figure 20-42-34].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) The chart below lists the correct torque specifications
(SELECTABLE JOYSTICK CONTROL) (SJC) and tightening sequence when reinstalling the BICS™
(CONT'D) valve assembly to the control valve. Thoroughly clean
BICS™ Valve, Removal And Installation (Cont’d)
Figure 20-42-35 Step Torque Sequence
1 110-130 in.-lbs.
(12,4-14,7 Nm)
2 190-210 in.-lbs. 1, 2, 3, 4, 5 & 6
(21,5-23,7 Nm)
3* 190-210 in. lbs.
1 (21,5-23,7 Nm)
1
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for
2
N-23646

42-35].
Install the four large O-rings (Item 1) and the small O-ring
(Item 2) on the top of the control valve [Figure 20-42-35].
Figure 20-42-36
3 6
1 2
5
4
N-23644

(CONT'D)

And Assembly
Figure 20-42-37
N-18685
1
39].
N-20040 Orifice size is 0.078 inch.
Reverse the removal procedure to install the lift arm by-

Remove the fitting (Item 1) [Figure 20-42-37] from the
pass orifice.
valve.
Figure 20-42-38
N-20041

(CONT'D)
BICS™ Valve, Check Valve Disassembly And

Assembly
1
Figure 20-42-40
P-8956
Clean and inspect the screen (Item 1) [Figure 20-42-42]

1
N-20037
Installation: Tighten the valve to 20 ft.-lbs. (27 Nm)

torque.
Figure 20-42-41
N-18684

from the check valve [Figure 20-42-41].

(CONT'D)

Assembly
Figure 20-42-43 1
1
N-20040

valve.
N-23644 Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)
torque.
Figure 20-42-44
Figure 20-42-46
1 1
2
2
N-23647 2
N-18690

Install new O-rings (Item 1) and back-up rings (Item 2) on

the tilt and lift lock valves [Figure 20-42-46].

(CONT'D)

1
Figure 20-42-47
2
N-20038
Installation: Tighten the solenoid stem to 20 ft.-lbs. (27

N-20037 Nm) torque.
Figure 20-42-50

Nm) torque. 3
2
NOTE: The solenoid resistance is (8-10 ohms).
Figure 20-42-48
1
N-18694
1
2) [Figure 20-42-50] on the stem.
excessive wear.
N-18693A NOTE: The screen (Item 3) [Figure 20-42-50] may be

replace the solenoid stem.
both ends of the solenoid.

solenoid stem.

(CONT'D)
BICS™ Valve, Solenoid Testing
Figure 20-42-51
P9175


(CONT'D) H2 H1
H3
ITEM S250, S300 Loader SJC
C4
A1 Lift Cylinder Base End/Restrictor B3 A3
G3 D3
C3 D2
A3 Auxiliary Hydraulics B2 A2
G2 E2
B1 Lift Cylinder Rod End C2 D1
B2 Tilt Cylinder Rod End F2 G1 B1 A1 E1
B3 Auxiliary Hydraulics F1 C1
C1 Load Check Valve/Lift Function MR
C2 Load Check Valve/Tilt Function
TS-2136
C3 Orificed Load Check Valve/Auxiliary Function
D1 Lift Spool Centering Spring
E1 Port Relief Valve – 4000 PSI

E2 Anti–Cavitation/Port Relief Valve – 3500 PSI
F2 Port Relief Valve – 4000 PSI
G1 LIft Spool End
G2 Tilt Spool End
H2 Plug/Port Relief (Optional) – 3500 PSI

(CONT'D)
Lift Base End Restrictor

IMPORTANT
Figure 20-42-52 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
1
they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.
Figure 20-42-54
N-21159

Page 20-41-11.)
Remove the restrictor (Item 1) [Figure 20-42-52] from

the lift section base end port. 1
Load Check Valve
Figure 20-42-53
N-19100
Loosen the load check valve plugs (Item 1) [Figure 20-

1 1
42-54].
Installation: Always use new O-ring. Tighten the plug to

1 35-40 ft.-lbs. (47-54 Nm) torque.
1
N-19099

Page 20-41-11.)

before installing the BICS™ valve assembly.

(CONT'D) Figure 20-42-57
Load Check Valve (Cont'd)
Figure 20-42-55
1
1
N-19034
3
2 Loosen the main relief valve (Item 1) [Figure 20-42-57].
N-19101
Figure 20-42-58
Remove the spring (Item 2) and poppet (Item 3) [Figure

20-42-55].
Figure 20-42-56
N-19035
Remove the main relief valve (Item 1) [Figure 20-42-58].
2
N-19102
The auxiliary section (Item 1) uses an orifice load check

poppet (Item 2) [Figure 20-42-56].

(CONT'D)
Main Relief Valve (Cont’d)

1
Figure 20-42-59
2 3
4 5
B-6764
1. Relief Valve N-19034

2. O-ring
3. Sleeve
4. Glide Ring Loosen the port relief valve (Item 1) [Figure 20-42-60] &
5. O-ring [Figure 20-42-61] (Port E1 or F2). (See Identification
Chart on Page 20-41-19.)
CD-15092

Remove the O-rings, sleeve, and glide ring from the main
Figure 20-42-62
Installation: Always use new O-rings, sleeve, and glide
Port Relief Valve
Figure 20-42-60
N-18981
Remove the port relief valve (Item 1) [Figure 20-42-62].
N-19000

(CONT'D)
Port Relief Valve (Cont’d)
Figure 20-42-63
1
4
3
2
1
1. O-ring N-18980
2. Backup Washer
3. O-ring
4. Relief Valve
[Figure 20-42-65] from the control valve for the tilt
section.
N-18844
Figure 20-42-66
Remove the O-rings and back-up washer from the port
Anti-Cavitation Valve/Port Relief Valve

1
Figure 20-42-64
N-18843

N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-42-

64].


(CONT'D) 2
1 3 4
Anti-Cavitation Valve
Figure 20-42-67
1 E-1509A
2. O-ring
3. Backup Washer
4. O-ring
N-18839

N-19034
Figure 20-42-68
1
N-19036

67] & [Figure 20-42-68] from the control valve.

(CONT'D)
Lift Spool Removal
Figure 20-42-70
N-19003

cap.
1
N-19112 Figure 20-42-73
Remove the actuator (Item 1) [Figure 20-42-70] from the

control valve.
Figure 20-42-71
2 N-18983
1
2 Remove the spool assembly (Item 1) [Figure 20-42-73]
N-19114

20-42-71] from the lift spool.

(CONT'D)
Figure 20-42-74 1
N-19003

end cap.
N-19112 Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the actuators (Item 1) [Figure 20-42-74] from
Figure 20-42-77
the control valve.
Figure 20-42-75
2 1
2
1
N-18985
N-18940 Remove the spool assembly (Item 1) [Figure 20-42-77]

20-42-75] from the tilt spool.

(CONT'D) 1
2
Lift and Tilt Spool Disassembly And Assembly
3
Figure 20-42-78 4
N-18944A
NOTE: The center spring (Item 3) [Figure 20-42-80] is

orange on all large frame loaders.
N-18942 Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-42-80].
Put the linkage end of the spool in the vise [Figure 20-
Figure 20-42-81
42-78].
2
centering spring. 1
Figure 20-42-79
1
1
N-18930 N-18943
Remove the spool seal (s) (Item 1) and the back-up

N-19014 Assembly: Always use a new spool seal.


Nm) torque.

(CONT'D)

1
Figure 20-42-82
N-18988
1
Assembly: Put grease on all the centering spring
N-19003 component parts.

end cap (both sides).

Nm) torque.
Figure 20-42-83
N-18987
Remove the end cap, O-ring, springs and washer (both

sides) [Figure 20-42-83].

(CONT'D)
Figure 20-42-85
3 2
N-18992
1
Remove the coil (Item 1) and end plate (Item 2) [Figure

1 20-42-87].
N-18996 Remove the solenoid valve (Item 3) [Figure 20-42-87].
Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)

Remove the nut (Item 1) [Figure 20-42-85] from both
torque.
solenoids.
Figure 20-42-88
Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)
torque.
Figure 20-42-86
1 N-18795

N-18823 solenoid valves.

[Figure 20-42-86].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Cleaning And Inspection
(CONT'D) Clean all components with clean solvent and dry with
compressed air.
Port-Auxiliary Section Disassembly
Check the spools for wear or scratches.
Figure 20-42-89
Check that the load check valve seats are not worn.
Check the rubber boots and retainers
1 Replace the parts as needed.
N-18996
Apply oil to all new O-rings and back-up rings before
installation.
Remove the plug (Item 1) [Figure 20-42-89] or optional
Figure 20-42-90
2
1
1
N-18843

from the plug [Figure 20-42-90].

(FOOT CONTROL)
Identification IMPORTANT
Figure 20-43-1 When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
1
Figure 20-43-2
1
P-54236
The hydraulic control valve (1 piece casting) (foot control)

(Item 1) [Figure 20-43-1] does not have a removable
BICS™ section.
The BICS™ section and main control valve are in one

casting. P-54497

casting) (foot control), (See Identification on Page 20-40-
support device.
1.)
on Page 10-30-1.)


on Page 50-100-1.)
Open rear door.

WARNING The fixed end main valve hose assembly (Item 1) [Figure
20-43-2] is connected to a fixed end fitting on the control
valve. The hose is routed to the upright where the hose is
connected to a fitting that feeds the base end of both lift
cylinders. The hose can only be removed by first
removing it from the tee fitting located at the rear of the
W-2059-0598
loader.

Figure 20-43-3
1
2
1 P-54487

P-54498
Disconnect the hose (Item 2) [Figure 20-43-5] that goes
from the control valve to the hydraulic cooler.
Mark all hydraulic hoses and tubelines to aid in
assembly. Figure 20-43-6
Disconnect the three hydraulic hoses (Item 1) [Figure

20-43-3] from the lift arm by-pass valve.
3
Cap and plug the hoses and fittings.
Figure 20-43-4
1
1 P-54500
Mark the four wire connectors for proper installation.
Disconnect the wire harness connectors (Item 1) from the

BICS™ valve solenoid, (Item 2) from auxiliary valve
P-54499 solenoid and (Item 3) [Figure 20-43-6] from the lift and
tilt lock solenoids.
At the right fender, remove the two mounting bolts and

nuts (Item 1) [Figure 20-43-4] from the lift arm by-pass
mount.
Remove the lift arm by-pass valve and mount from the
loader.

Figure 20-43-7 1
P-54489

2 [Figure 20-43-9] from the control valve.
P-54486

43-7] from the auxiliary valve solenoid. Cap the hose and plug the fitting.
Disconnect the charge pressure sender wire connector Figure 20-43-10

(Item 2) [Figure 20-43-7] from the charge pressure
sender.
Figure 20-43-8
1
P-54490
2

P-54488 control valve, and support the control valve.
Loosen all the tubeline fittings connected to the control

Disconnect foot control linkage (Item 1) [Figure 20-43-8] valve.
from the tilt spool on the control valve.
Disconnect foot control linkage (Item 2) [Figure 20-43-8]

from the lift spool on the control valve.
Move the control linkages to allow clearance for the

control valve removal.

Figure 20-43-11
1
1
P-62619

[Figure 20-43-13] located on the outside of the frame.
P-62618
Installation: Torque the bolts (Item 1) [Figure 20-43-13]
to 90-100 ft. lbs. (123-135 Nm).
NOTE: Lifting chains were removed for photo clarity
Figure 20-43-14
Remove the tubeline clamp mount bolt and clamp (Item
1) [Figure 20-43-11].
NOTE: Removing the tubeline clamp will help provide

added clearance for removing the valve.
Figure 20-43-12
P-54494

1 20-43-14] from the control valve.
P-54492

1) [Figure 20-43-12].

loader.

Figure 20-43-15
P-54495


Figure 20-43-16
P-54496


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-43-17
J2 C3
C2 J4
D5 B3
E3 E3
G1 G2
F2
A3
D3
B2
D4 A2 E2
F4
A1 D2
E1
F1 F3 B1 H3
H2
D1 J3
MR H1 C1
J1 MS1937
ITEM S250-S300 LOADER

ITEM S250-S300 LOADER
A1 Lift Cylinder Base End
E1 Lift Spool Detent
E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End
E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check/BICS™ Valve F4 Tilt Spool Lock Solenoid
Lift
G1 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function
G2 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function
H1 BICS™ Valve Solenoid
D1 Anti-Cavitation Valve
Lift (Rod End) H2 BICS™ Lock Valve (Tilt)
D2 Port Relief/Anti-Cavitation Valve – 4000 PSI H3 BICS™ Lock Valve (Lift)
Lift (Base End)
J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 4000 PSI
Tilt (Base End) J2 Outlet Fluid Flow (Return to Tank)
D4 Port Relief/Anti-Cavitation Valve – 4000 PSI J3 Lift Arm By-Pass Orifice
Tilt (Rod End) J4 Drain (Case)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) MR Main Relief Valve – 3300 PSI
3500 PSI (Optional)

BICS™ Valve, Lift Load Check Valve Removal And

Installation
Figure 20-43-18 1
1 3
P-54292
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-43-20].
P-54237 Check the load check valve (Item 3) [Figure 20-43-20].
Remove the charge tubeline (Item 1) [Figure 20-43-18]

from the BICS valve fitting on the top of the lift load check
valve.
Figure 20-43-19
P-54238
Remove the lift load check valve (Item 1) [Figure 20-43-

19] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 55-65 ft.-lbs. (75-88 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Anti-Cavitation Valve (Lift, Rod End)
Figure 20-43-23
Load Check Valve Removal And Installation (Tilt &
Auxiliary)
Figure 20-43-21
2
1
1
P-51692
At the back side of the control valve, remove the lift

P-54243
section anti-cavitation valve (Item 1) [Figure 20-43-23].
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-43-21].
At the front side of the control valve locate the auxiliary

WARNING
section load check valve (Item 2) [Figure 20-43-21].
NOTE: The tilt and auxiliary load check valves are clean the work area before disassembly and keep all
interchangeable. parts clean. Always use caps and plugs on hoses,
Figure 20-43-22 damage the system.
I-2003-0888
Figure 20-43-24
4
1
3
2
P-51453
1
P-51693
20-43-22].
Check the orifice (Item 3) [Figure 20-43-22] in the Installation: Always use new O-ring (Item 1) [Figure 20-
poppet to be sure it is not plugged.
43-24] on the anti-cavitation valve plug. Tighten the plug
Installation: Install a new O-ring (Item 4) on the plug and to 38-45 ft.-lbs. (52-61 Nm) torque.
lightly lubricate with oil before installing. Tighten the plug
to 38-45 ft.-lbs. (52-61 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Lift, Base End)
Figure 20-43-26
Anti-Cavitation Valve (Lift, Rod End) (Cont’d)
Figure 20-43-25
1
1
3
2
P-51692
P-51453 Loosen the lift circuit port relief/anti cavitation valve (Item
1) [Figure 20-43-26].
Remove the spring (Item 1) and poppet (Item 2) [Figure Figure 20-43-27
20-43-25].
Check the orifice (Item 3) [Figure 20-43-25] in the

Installation: Install a new O-ring (Item 4) [Figure 20-43-

25] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lbs. (52-61 Nm)
torque.
P-51451
Replace the O-ring (Item 1) [Figure 20-43-27] before

installation.
Installation: Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Figure 20-43-30
Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Figure 20-43-28
P-51692
P-51692 Remove the tilt port relief/anti cavitation valve (Item 1)
[Figure 20-43-30] from the rod end of the tilt section.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-43-31
[Figure 20-43-28] from the base end of the tilt section.
Figure 20-43-29
1
P-51694
P-51454 Replace the O-ring (Item 1) [Figure 20-43-31] before

installation.
Replace the O-ring (Item 1) [Figure 20-43-29] before Installation: Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.
installation.
Installation: Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.

Port Relief Valve

1
Figure 20-43-32
P-51696
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-43-34].
P-51692
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-43-32] Figure 20-43-35
from the auxiliary circuit of the control valve.
Figure 20-43-33
P-51640
1
P-51695 Installation: Always use new O-rings (Item 1) [Figure

20-43-35]. Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.
Installation: Always use new O-rings (Item 1) [Figure

20-43-33]. Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.

Plug Removal
Figure 20-43-36
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-43-38].
P-51459
Figure 20-43-39
At the top side of the control valve, remove the plug (Item
1) [Figure 20-43-36].
Figure 20-43-37
P-51462

1 20-43-39]. Tighten to 60 ft.-lbs. (81,3 Nm) torque.
P-51460

20-43-37]. Tighten to 60 ft.-lbs. (81,3 Nm) torque.

Rubber Boot Removal and Installation
Figure 20-43-40
P-51506
Remove the three screws (Item 1) [Figure 20-43-40] on

the rubber boot retainer plate.
Installation: Tighten the screws to 90-100 in.-lbs. (10-

11,3 Nm) torque.
Figure 20-43-41
1
2
P-51701
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-43-41].

End Cap/Spool Lock Block Removal and Installation
Figure 20-43-42
1 1
P-51699
1
Remove the four end cap/spool lock block mount screws

(Item 1) [Figure 20-43-44].
P-51697
11,3 Nm) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-43-42] from the Remove the rubber boots and retainer plate from the lift
end cap/spool lock block. and tilt spools.
Figure 20-43-43 Figure 20-43-45
1
P-54244
P-54245
Disconnect the tube line (Item 1) [Figure 20-43-43] from Remove the end cap/spool lock block (Item 1) [Figure
the end cap/spool lock block. 20-43-45] from the control valve.

Lift Spool and Detent Removal and Installation

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
Remove the end cap/spool lock block from the control

valve.
Figure 20-43-46
P-54246
Remove the end cap (Item 1) [Figure 20-43-48].
1 Figure 20-43-49
P-54245
1
Remove the O-ring (Item 1) [Figure 20-43-46]. 2
Installation: Replace the O-ring, and lubricate the o-ring

lightly with grease or oil before installation of the end cap/
P-51514
spool lock block.
Figure 20-43-47 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-43-49].
Remove the washer (Item 2) [Figure 20-43-49].
P-51512



(Cont'd)
Figure 20-43-50
1 P-51516

1 lost when the detent sleeve is removed.
2
P-51515
Figure 20-43-52

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-43-50].
Installation: Lubricate the screws and tighten to 90-100

in.-lbs. (10-11,3 Nm) torque.
2 1
3
WARNING
The detent assembly has small springs and balls. Do 2 P-51517
not lose these parts during disassembly and
assembly.
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-43-52].


(Cont'd)
Figure 20-43-53
P-8988

1 43-55].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-43-56
Remove the lift spool assembly and seal (Item 1) [Figure
20-43-53] from the control valve. 2
Figure 20-43-54
1
3
1
N-18915

P-51519 centering spring.
NOTE: Be careful when removing the detent adapter

Remove the lift spool seal (Item 1) [Figure 20-43-54] (Item 2) [Figure 20-43-56] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.

Lift Spool and Detent Removal and Installation 1

(Cont'd)
Figure 20-43-57
N-19009
Remove spring tool (Item 1) [Figure 20-43-59] from the

1 spring assembly.
2
N-18916 Figure 20-43-60
Put a rag around the detent assembly [Figure 20-43-57]. 1

2
lost when the detent adapter is removed. 3
Remove the detent adapter with an Alan wrench.

4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-43-57].
Figure 20-43-58
1
N-18919A
N-19004
Remove the detent adapter (Item 1) [Figure 20-43-58]

from the spring assembly.


(Cont'd)
2
Figure 20-43-61
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-43-63].
N-18918 Figure 20-43-64
Remove the stud from the end of the spool [Figure 20-
43-61].
Figure 20-43-62
N-18963
1
Install the plastic plug and O-ring in the spool [Figure 20-
43-64].
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-43-62] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS.


(Cont'd)
2
Figure 20-43-65
O-ring
1 3
2
N-18958
Plastic
Plug
0.60 inch Apply grease on all the detent component surfaces
(15,2 mm)
before assembly [Figure 20-43-67].
B-14712 Install the spring (Item 1) [Figure 20-43-67] and detent
balls (Item 2) [Figure 20-43-67] into the adapter (Item 3)
[Figure 20-43-67] and compress with the detent pliers
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-43-68].
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-43-65]. Figure 20-43-68
Figure 20-43-66
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-43-68].
Clamp the collar (Item 1) [Figure 20-43-66] in a vice. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.


(Cont'd)
Figure 20-43-69
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-43-71].
N-19004 Remove the spring tool.
Check the alignment of the detent adapter and the

Install the spring tool (Item 1) [Figure 20-43-69] over the washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm).
Figure 20-43-70
NOTE: The adapter must fit in the center of the
Figure 20-43-72
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-43-70].
CD-15051
Install the detent balls and spring [Figure 20-43-72].


(Cont'd)
Figure 20-43-73
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-43-75].
N-19007 Install the detent bonnet (Item 1) [Figure 20-43-75].

Hold the detent balls in place with the detent pliers
[Figure 20-43-73]. Installation: Lubricate the screws and tighten to 90-100
in.-lbs. (10-11,3 Nm) torque.
Figure 20-43-74
Figure 20-43-76
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-43-74] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-43-76].


(Cont'd)
Figure 20-43-77
1
P-51512
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-43-79] on the lift spool.
P-54246 Figure 20-43-80
Figure 20-43-78
1
P-51511
Install the O-ring (Item 1) [Figure 20-43-80] on the

control valve.
P-51520



(Cont'd)
Figure 20-43-81
2
1
P-51697
3
Use an Ohm meter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 5.5 ±.28 Ohms.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap/spool lock block (Item 1) and the (Item 2) lock solenoids and tighten to 38-45 ft.-lbs. (52-61
mount screw (Item 2) [Figure 20-43-81]. Nm) torque [Figure 20-43-83].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-43-81].

11,3 Nm) torque.
Figure 20-43-82
P-54244
Connect the tubeline (Item 1) [Figure 20-43-82].

Tilt Spool Removal and Installation
Remove the lift and tilt end cap/spool lock block. (See
End Cap/Spool Lock Block Removal and Installation on
Page 20-43-14.)
2
Figure 20-43-84
P-51543
Remove the spool centering block (Item 1) [Figure 20-

1 2
43-86] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-43-

86] and lubricate the o-ring lightly with grease or oil
before installation of the end cap/spool lock block.
P-51521
Figure 20-43-87
Remove the spacer (Item 1) and O-ring (Item 2) from the

tilt spool [Figure 20-43-84].
Figure 20-43-85
2 P-51544
1
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-43-87].
2 P-54247

from the spool centering block.
Remove the three screws (Item 2) [Figure 20-43-85]

Installation: Tighten the bolt to 90-100 in.-lbs. (10-11,3

Nm) torque.

Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-43-88
3
4
1
N-18944A
N-18942
Figure 20-43-91
Put the linkage end of the spool in the vice [Figure 20-
43-88]. 2
1
centering spring.
Figure 20-43-89
1
1
P-51545 N-18943

N-19014


Nm) torque.

Figure 20-43-92
1
2
1
1
2 P-51547

20-43-94] from the auxiliary spool.
2 P-54247
Figure 20-43-95
Remove the two tubelines (Item 1) [Figure 20-43-92]


Installation: Tighten the bolt to 90-100 in.-lbs. (10-11,3

2
Nm) torque.
1
Remove the spool centering block from the control valve.
Figure 20-43-93
P-51549
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-43-95] from the auxiliary spool.
2 NOTE: If the centering spring retainer (Item 2) [Figure
1 20-43-95] must be replaced, replace the
P-51546

Note: If the centering spring retainer (Item 2) [Figure


Figure 20-43-96
1
2
P-51550
Figure 20-43-97
P-51551

Auxiliary Solenoid Disassembly and Assembly
Figure 20-43-98
1
P-51703
P-51702 Installation: Tighten the stem to 10-14 ft.-lbs. (14-19

Nm) torque.
Remove the nut (Item 1) [Figure 20-43-98] from both Figure 20-43-101
solenoids.
Installation: Tighten the nut to 48-72 in.-lbs. (5-8 Nm)

torque.
Figure 20-43-99
1
2
2
P-51555

the solenoid stem.
P-51553 Check and clean the screen (Item 2) [Figure 20-43-101].
Remove the nut (Item 1) and solenoid coil (Item 2)

[Figure 20-43-99].
Use an Ohm meter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.9 ±.25 Ohms.

BICS™ Valve Solenoid Disassembly And Assembly
Figure 20-43-102 1
1
2
P-54249
P-54248 Installation: Lubricate the O-rings and tighten the stem
Remove the nut (Item 1) [Figure 20-43-102] from the Figure 20-43-105
solenoid stem.
Installation: Tighten the nut to 53 in.-lbs. (6 Nm) torque.
Remove the solenoid coil (Item 2) [Figure 20-43-102]. 3

2
Figure 20-43-103
N-18694

[Figure 20-43-105] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-43-105] may be
cleaned with solvent. If it is torn or worn it
Use an Ohm meter to measure the solenoid coil needs to be replaced.
resistance.
The correct resistance for the coil is 9.79 ±.29 Ohms. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-43-103] &

[Figure 20-43-105] and new back-up rings (Item 2)
[Figure 20-43-105] on the solenoid stem.

BICS™ Valve, Lock Valve Removal And Installation
Figure 20-43-106 1
1
1
2
1 1
2
2
2
P-51564

from the lift lock valve, and replace with new [Figure 20-
P-54250 43-108].
Figure 20-43-109
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) is for the lift circuit [Figure 20-43-
106].
Figure 20-43-107
1 P-51705
Locate the tilt circuit lock valve (Item 1) [Figure 20-43-

109].
P-54251
Remove the lift lock valve (Item 1) [Figure 20-43-107]

from the back of the control valve.
Installation: Lightly lubricate the lock valve o-rings and



(Cont’d)
1
Figure 20-43-110
1
1
1
2
2
2
2
P-51564
1

from the tilt lock valve, and replace with new [Figure 20-
43-112].
P-51697
Remove the lift spool lock solenoid (Item 1) [Figure 20-

43-110].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

43-110].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 38-45 ft.-lbs. (52-61 Nm) torque.
Figure 20-43-111
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-43-111]

from the front of the control valve.


Figure 20-43-115
And Assembly
Figure 20-43-113
P-51707
1
Remove the main relief valve (Item 1) [Figure 20-43-
P-54252 115].
Figure 20-43-116
valve.
Figure 20-43-114
1
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-43-116].
Installation: Always use new O-rings. Tighten to 38-45

Check the lift arm by-pass orifice (Item 1) [Figure 20-43- ft.-lbs. (52-61 Nm) torque.
114].
NOTE: This orifice is not removable from the valve

casting.

BICS™ Valve, Check Valve Removal and Installation
Figure 20-43-117
1
P-54239
Check the fitting screen (Item 1) [Figure 20-43-119].
P-54237 Figure 20-43-120
from the fitting on the top of the lift load check valve.
Figure 20-43-118
P-54240
Inspect the fitting check valve (Item 1) [Figure 20-43-

120].
P-54238
Remove the BICS check valve fitting (Item 1) [Figure 20-

43-118] from the top of the lift load check valve.

tighten to 20-24 ft.-lbs (27-33 Nm) torque.

(ADVANCED CONTROL SYSTEM) (ACS)
Identification
Figure 20-44-1
P-54336
The hydraulic control valve (1 piece casting) (ACS) (Item

1) [Figure 20-44-1] does not have a removable BICS™
section.

casting.

casting), (See Identification on Page 20-41-1.)

(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
WARNING P-54497
Never work on a machine with the lift arms up unless The fixed end main valve hose assembly (Item 1) [Figure
the lift arms are secured by an approved lift arm 20-44-2] is connected to a fixed end fitting on the control
support device. Failure to use an approved lift arm valve. The hose is routed to the upright where the hose is
support device can allow the lift arms or attachment connected to a fitting that feeds the base end of both lift
to fall and cause injury or death. cylinders. The hose can only be removed by first
W-2059-0598 removing it from the tee fitting located at the rear of the
loader.
Figure 20-44-3
IMPORTANT
damage the system.
I-2003-0888 1

support device.

P-54569

on Page 10-30-1.) Remove the tubeline clamp (Item 1) [Figure 20-44-3]
located on the inside of the left upright.

on Page 50-100-1.)
Remove the lift arm by-pass valve. (See Removal And

Installation on Page 20-50-1.)
Open rear door.

Figure 20-44-4
2
P-54486

P-54570
Disconnect the charge pressure sender wire connector

Mark the two wire connectors for proper installation. sender.
Disconnect the wire harness connector (Item 1) from the Figure 20-44-7
BICS™ valve solenoid and (Item 2) from auxiliary valve
solenoid [Figure 20-44-4].
Figure 20-44-5
1
2
2
P-54487

P-54564 goes from the control valve to the hydraulic cooler.

Disconnect the lift and tilt actuator electrical connectors from the control valve to the gear pump.
(Item 1) and (Item 2) [Figure 20-44-5] from the control
valve.

Figure 20-44-8
P-54492

1) [Figure 20-44-10].
P-54489
Loosen the fixed end main valve hose assembly (Item 1) Remove the right rear wheel/tire assembly from the
[Figure 20-44-8] from the control valve. loader.
The hose can be removed from the control valve by Remove the right side pump access cover.
Figure 20-44-11
Figure 20-44-9
P-54494
P-54572 Disconnect the two auxiliary tubelines (Item 1) [Figure



valve.

Figure 20-44-12
1
P-62619
2
P-54573
Installation: Torque the bolts (Item 1) [Figure 20-44-14]

to 90-100 ft. lbs. (123-135 Nm).
from the control valve. Figure 20-44-15

from the control valve. (If equipped with Bucket
Positioning Valve.)

Figure 20-44-13
1
1
P-62618

1) [Figure 20-44-15] from the mounting plate.

P-54496 added clearance for removing the valve.


WARNING 1

W-2059-0598
P-54564
Figure 20-44-16
Unplug the actuator connectors (Item 1) [Figure 20-44-
17] from the loader harness.
1
Figure 20-44-18
N-23246

P-54587
Stop the engine. Raise the seat bar. Remove the two screws (Item 1) [Figure 20-44-18] from
Remove the access cover (Item 1) [Figure 20-44-16]
from the right side of the loader frame. Installation: Tighten the bolts to 90-100 in.-lbs. (10,2-
11,3 Nm) torque.
Mark the actuator wiring harness connectors for proper
installation.


(Cont’d)
Figure 20-44-19
1
2
P-54568
2
1 Inspect the O-ring (Item 1) [Figure 20-44-20] on the face

of the actuator, and replace as needed.
P-54566 Check the linkage pin (Item 2) [Figure 20-44-20] and

replace as needed.

the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure

Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
and Tilt Calibration Procedure (Selectable
Joystick Control) (SJC) on Page 60-160-1.)

Actuator Removal And Installation (Out of Loader)
Figure 20-44-21
P-54339
Using a drift pin and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-44-23] from the actuator
and the tilt spool.
P-54337 Remove the actuator and linkage pin from the valve.
Figure 20-44-24
from the tilt actuator.
Installation: Tighten the mounting bolts to 90-100 in.-lbs.

(10,2-11,3 Nm) torque.
Figure 20-44-22
P-54340
1 Inspect the O-ring (Item 1) [Figure 20-44-24] on the face

Check the linkage pin (Item 2) [Figure 20-44-24] and

P-54338 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-44-

22] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
44-22].


(Cont’d)
Figure 20-44-25
1 1
P-54343

linkage pin (Item 1) [Figure 20-44-27] from the actuator
1 and the tilt spool.
P-54341
Remove the actuator and linkage pin from the valve.
Remove the two mount bolts (Item 1) [Figure 20-44-25] Figure 20-44-28
from the lift actuator.

(10,2-11,3 Nm) torque.
Figure 20-44-26
P-54340
Inspect the O-ring (Item 1) [Figure 20-44-28] on the face

1 of the actuator, and replace as needed.
P-54342 Check the linkage pin (Item 2) [Figure 20-44-28] and

replace as needed.

44-26].


(Cont’d)
Figure 20-44-29
1 2
P-51738
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-44-29] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-44-29].

(10,2-11,3 Nm) torque (Item 1) [Figure 20-44-29]

Figure 20-44-30
J2
C2 J4 C3
D5 B3 E3
E3
G1 G2
D3
B2 A3
D4 E2
F2
A2
D1 A1
E1 D2
H2 B1
F1 H3
MR C1
H1
J3
J1
MS1972
ITEM S250-S300 LOADER ITEM S250-S300 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check/BICS™ Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS™ Valve Solenoid
H2 BICS™ Lock Valve (Tilt)
D1 Anti-Cavitation Valve H3 BICS™ Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 4000 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm By-Pass Orifice
D3 Port Relief/Anti-Cavitation Valve – 4000 PSI J4 Drain (Case)
Tilt (Base End)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)


Installation
Figure 20-44-31 1
1 3
P-54292

P-54344 Check the load check valve (Item 3) [Figure 20-44-33].

valve.
Figure 20-44-32
P-54355



(ADVANCED CONTROL SYSTEM) (ACS)(CONT’D)
Figure 20-44-36
Auxiliary)
Figure 20-44-34
2
1
1
P-51742

P-54345
load check valve (Item 1) [Figure 20-44-34].
At the front side of the control valve locate the auxiliary

WARNING
section load check valve (Item 2) [Figure 20-44-34].
NOTE: The tilt and auxiliary load check valves are clean the work area before disassembly and keep all
interchangeable. parts clean. Always use caps and plugs on hoses,
Figure 20-44-35 damage the system.
I-2003-0888
4 Figure 20-44-37
1
3
2
P-51453
1
20-44-35].
P-51452

Always use new O-ring (Item 1) [Figure 20-44-37] on the
Installation: Install a new O-ring (Item 4) [Figure 20-44- anti-cavitation valve plug.
35] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lbs. (52-61 Nm)
torque.

Figure 20-44-39
Figure 20-44-38
1
1
3
2
P-51742
P-51453 Loosen the lift circuit port relief/anti cavitation valve (Item
1) [Figure 20-44-39].
Remove the spring (Item 1) and poppet (Item 2) [Figure Figure 20-44-40
20-44-38].

Installation: Install a new O-ring (Item 4) on the plug and

P-51451

installation.
Installation: Lightly lubricate with oil and tighten to 38-45

ft.-lbs. (52-61 Nm) torque.

Figure 20-44-43
Figure 20-44-41
P-51742
P-51742 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-44-43] from the rod end of the tilt section.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-44-44
Figure 20-44-42
1
P-51455
P-51454 Replace the O-ring (Item 1) [Figure 20-44-44] before

installation.
Replace the O-ring (Item 1) [Figure 20-44-42] before Installation: Lightly lubricate with oil and tighten to 38-45
installation. ft.-lbs. (52-61 Nm) torque.


Port Relief Valve

1
Figure 20-44-45
P-51743

P-51742
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-44-45] Figure 20-44-48
Figure 20-44-46
P-51640
1
P-51801 Installation: Always use new O-rings (Item 1) [Figure

20-44-48]. Lightly lubricate with oil and tighten to 38-45

Plug Removal
Figure 20-44-49
1
P-51461

(Item 1) [Figure 20-44-51].
P-51459
Figure 20-44-52
1) [Figure 20-44-49].
Figure 20-44-50
P-51462

1 20-44-52]. Tighten to 60 ft.-lbs. (81,3 Nm) torque.
P-51460


End Cap Block Removal And Installation
Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (In Loader) on
Page 20-44-6.)
Figure 20-44-53
2
P-54346
Disconnect the tube line (Item 1) [Figure 20-44-53] from

the end cap block.
Remove the two end cap block mount screws (Item 1)

[Figure 20-44-53].

11,3 Nm) torque.
Figure 20-44-54
P-54347
Remove the end cap block (Item 1) [Figure 20-44-54]


The tool listed will be needed to do the following 1

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-44-55
1
P-54348
Remove the two screws (Item 1) [Figure 20-44-57] from

1 the lift spool end cap.

in.-lbs. (10,2-11,3 Nm) torque.
Figure 20-44-58
P-51746
Remove the O-ring (Item 1) [Figure 20-44-55].
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
Figure 20-44-56 1
P-51749
Remove the lift spool end cap (Item 1) [Figure 20-44-58]

2 from the control valve.
1
P-51747


Lift Spool Removal And Installation (Cont'd)
Figure 20-44-59
P-51772
1 Clamp the linkage end of the spool in a vise [Figure 20-

44-61].
P-51770
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-44-62
Figure 20-44-60
P-51773
P-51771 Install the spring tool (Item 1) [Figure 20-44-62] over the
centering spring.
Remove the lift spool seal (Item 1) [Figure 20-44-60]

from the linkage end of the valve.


2
1
Figure 20-44-63
P-51771 P-51775

N-190146
Remove the bolt (Item 1) [Figure 20-44-63] holding the Figure 20-44-66

Nm) torque. 1
Figure 20-44-64
2
3
3 3
4 1 P-51749
Install the lift spool assembly (Item 1) [Figure 20-44-66]

in the spool bore.
P-51776 Install the mounting screws (Item 3) [Figure 20-44-66].

Inspect the adapter (Item 1), collar (Item 2), spring (Item in.-lbs. (10,2-11,3 Nm) torque.


1
Figure 20-44-67
P-51746

control valve.
P-51777
Installation: Replace the O-ring, lubricate lightly with oil
or grease before installation of the end cap block.
linkage end of the valve. Figure 20-44-70
Figure 20-44-68
1
3 2
1
2
2
P-54346
P-51747
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-44-70].
20-44-68] on the lift spool. Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
11,3 Nm) torque.
Connect the tubeline (Item 1) [Figure 20-44-70] to the

end cap block.
Install the lift and tilt actuators to the control valve.

Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-44-18.)
Figure 20-44-71 2
P-51780

1 2

73] and lubricate lightly with oil/grease before installation
P-51778 of the end cap block.
Figure 20-44-74
Figure 20-44-72
1
1
2
1
P-51781
2 Remove the tilt spool, centering spring, back-up washer

P-54348 and spool seal (Item 1) [Figure 20-44-74].

Disconnect the two tubelines (Item 1) [Figure 20-44-72].


Nm) torque.

Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-44-75
3
4
1
N-18944A
N-18942
Figure 20-44-78
Put the linkage end of the spool in the vice [Figure 20-
44-75]. 2
1
centering spring.
Figure 20-44-76
1
1
P-51545 N-18943

N-19014


Nm) torque.

Figure 20-44-79
2
1
1
1
2 P-51783
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

P-54349
Figure 20-44-82



Nm) torque.
1
Figure 20-44-80 2
P-51784


2
1
P-51782



Figure 20-44-83
1
2
P-51785
Figure 20-44-84
P-51786
Remove the auxiliary spool (Item 1) [Figure 20-44-84].

Auxiliary Solenoid Disassembly And Assembly
Figure 20-44-85 1
P-54350
P-51552 Installation: Tighten the stem to 10-14 ft.-lbs. (14-19

Nm) torque.
Remove the nut (Item 1) [Figure 20-44-85] from both Figure 20-44-88
solenoids.

torque.
Figure 20-44-86
1
2
2
P-51555

solenoid stem.
P-51553 Check and clean the screen (Item 2) [Figure 20-44-88].

[Figure 20-44-86].

resistance.
The correct resistance for the coil is 4.9 ± .25 Ohms.

Figure 20-44-89
2
P-54352
P-54351 Installation: Lubricate the O-rings and tighten the stem
Remove the nut (Item 1) [Figure 20-44-89] from the Figure 20-44-92
solenoid stem.

2
Figure 20-44-90
1
1
N-18694


N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-44-92] may be
cleaned with solvent. If it is torn or worn it
Use an Ohm meter to measure the solenoid coil needs to be replaced.
resistance.
The correct resistance for the coil is 9.79 ± .29 Ohms. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-44-90] & [Figure

20-44-92] and new back-up rings (Item 2) [Figure 20-44-
92] on the solenoid stem.

Figure 20-44-93 1
1
1
2 1
1
2
2
2
P-51564

[Figure 20-44-95] from the lift lock valve, and replace
P-54353 with new.
Figure 20-44-96
circuit and (Item 2) [Figure 20-44-93] is for the lift circuit.
Figure 20-44-94
1 P-51792

P-54354 from the back of the control valve.

Remove the lift lock valve (Item 1) [Figure 20-44-94] tighten to 20-24 ft.-lbs. (27-33 Nm) torque.



(Cont’d)
Figure 20-44-97
1
1
1
1
2
2
2
P-51564

[Figure 20-44-97] from the tilt lock valve, and replace
with new.

Figure 20-44-100
And Assembly
Figure 20-44-98
P-51794

P-54344 100].
Figure 20-44-101
valve.
Figure 20-44-99
1
1
P-51463

P-51437 [Figure 20-44-101].

Check the lift arm by-pass orifice (Item 1) [Figure 20-44- ft.-lbs. (52-61 Nm) torque.
99].

casting.

Figure 20-44-102
1
P-54239
P-54344 Figure 20-44-105
Figure 20-44-103
1
1
P-54240

105].
P-54355
Remove the BICS™ check valve fitting (Item 1) [Figure

20-44-103] from the top of the lift load check valve.
Installation: Lubricate the o-ring and tighten the valve to

20-24 ft.-lbs. (27-33 Nm) torque.

Identification
Figure 20-45-1
P-54336
The hydraulic control valve (1 piece casting) (SJC) (Item

1) [Figure 20-45-1] does not have a removable BICS™
section.

casting.

casting), (See Identification on Page 20-41-1.)

(CONT’D)
P-54497
WARNING
Never work on a machine with the lift arms up unless 20-45-2] is connected to a fixed end fitting on the control
the lift arms are secured by an approved lift arm valve. The hose is routed to the upright where the hose is
support device. Failure to use an approved lift arm connected to a fitting that feeds the base end of both lift
support device can allow the lift arms or attachment cylinders. The hose can only be removed by first
to fall and cause injury or death. removing it from the tee fitting located at the rear of the
W-2059-0598 loader.
Figure 20-45-3
IMPORTANT
damage the system. 1
I-2003-0888

support device.
Stop the engine. Raise the seat bar. P-54569
Raise the operator cab. (See Raising The Operator Cab Remove the tubeline clamp (Item 1) [Figure 20-45-3]
on Page 10-30-1.) located on the inside of the left upright.

on Page 50-100-1.)
Remove the lift arm by-pass valve. (See Removal And

Open rear door.

(CONT’D)
Figure 20-45-4
1
2
P-54486

P-54570 Disconnect the charge pressure sender wire connector

sender.
Mark the two wire connectors for proper installation.
Figure 20-45-7
Disconnect the wire harness connector (Item 1) from the
BICS™ valve solenoid and (Item 2) from auxiliary valve
solenoid [Figure 20-45-4].
Figure 20-45-5
1
2
P-54487

P-54564

from the control valve to the gear pump.
Disconnect the lift and tilt actuator electrical connectors
(Item 1) and (Item 2) [Figure 20-45-5] from the control
valve.

(CONT’D)
Figure 20-45-8
1
1
P-54492

1) [Figure 20-45-10].
P-54489 Remove right side motor cover.

loader.
Figure 20-45-11
Figure 20-45-9
P-54494

P-54572 20-45-11] from the control valve.


valve.

(CONT’D)
Figure 20-45-12
1
3
P-62619
2 Remove the two control valve mount bolts (Item 1)

P-54573 Installation: Torque the bolts (Item 1) [Figure 20-45-14]

to 90-100 ft. lbs. (123-135 Nm).
Figure 20-45-15

from the control valve. (If equipped with Bucket
Positioning Valve.)

Figure 20-45-13 1
1 P-62618

1) [Figure 20-45-15] from the mounting plate.

added clearance for removing the valve.
P-54496


(CONT’D)
WARNING 1

W-2059-0598 P-54564
Figure 20-45-16 Unplug the actuator connectors (Item 1) [Figure 20-45-

17] from the loader harness.
Figure 20-45-18
N-23246

support device. (See Installing The Lift Arm Support P-54587

Stop the engine. Raise the seat bar. the actuator retainer.
Remove the access cover (Item 1) [Figure 20-45-16] Installation: Tighten the bolts to 90-100 in.-lbs. (10,2-
from the right side of the loader frame. 11,3 Nm) torque.
Mark the actuator wiring harness connectors for proper
installation.

(CONT'D)

(Cont’d)
Figure 20-45-19
1
2
P-54568
2


the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure

Remove the actuator from the hydraulic control valve.

when replacing a lift or tilt actuator. (See Lift
and Tilt Calibration Procedure (Selectable
Joystick Control) (SJC) on Page 60-160-1.)

(CONT’D)
Figure 20-45-21
1
1
P-54339

1
and the tilt spool.
Remove the actuator and linkage pin from the valve.
P-54337
Figure 20-45-24
from the tilt actuator.

(10,2-11,3 Nm) torque.
Figure 20-45-22
1
P-54340


replace as needed.
P-54338

45-22].

(CONT’D)

(Cont’d)
Figure 20-45-25
1
1
P-54343

and the tilt spool.
1
P-54341 Remove the actuator and linkage pin from the valve.
Figure 20-45-28
from the lift actuator.

(10,2-11,3 Nm) torque.
Figure 20-45-26
1
P-54340

1

45-26].

(CONT’D)

(Cont’d)
Figure 20-45-29
1 2
P-51738
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-45-29] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-45-29].

(10,2-11,3 Nm) torque (Item 1) [Figure 20-45-29]

(CONT’D)
Figure 20-45-30
J2
C2 J4 C3
D5 B3 E3
E3
G1 G2
D3
B2 A3
D4 E2
F2
A2
D1 A1
E1 D2
H2 B1
F1 H3
MR C1
H1
J3
J1
MS1972
ITEM S250-S300 LOADER ITEM S250-S300 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check/BICS™ Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS™ Valve Solenoid
H2 BICS™ Lock Valve (Tilt)
D1 Anti-Cavitation Valve H3 BICS™ Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 4000 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm By-Pass Orifice
D3 Port Relief/Anti-Cavitation Valve – 4000 PSI J4 Drain (Case)
Tilt (Base End)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

(CONT’D)

Installation
1
Figure 20-45-31
3
1
P-54292

Check the load check valve (Item 3) [Figure 20-45-33].
P-54344

valve.
Figure 20-45-32
P-54355



(CONT’D) Figure 20-45-36
Auxiliary)
Figure 20-45-34
2 1
1
P-51742


P-54345
load check valve (Item 1) [Figure 20-45-34]. WARNING
At the front side of the control valve locate the auxiliary When repairing hydrostatic and hydraulic systems,
section load check valve (Item 2) [Figure 20-45-34]. clean the work area before disassembly and keep all
NOTE: The tilt and auxiliary load check valves are tubelines and ports to keep dirt out. Dirt can quickly
interchangeable. damage the system.
I-2003-0888
Figure 20-45-35
Figure 20-45-37
4
1
3
2
P-51453
1
Remove the spring (Item 1) and poppet (Item 2) [Figure P-51452

20-45-35].

Always use new O-ring (Item 1) [Figure 20-45-37] on the
anti-cavitation valve plug.

Figure 20-45-38
1 1
3
2
P-51742
Loosen the lift circuit port relief/anti cavitation valve (Item
P-51453 1) [Figure 20-45-39].
Figure 20-45-40
20-45-38].


P-51451

installation.


Figure 20-45-41
P-51742
Remove the tilt port relief/anti cavitation valve (Item 1)

P-51742 [Figure 20-45-43] from the rod end of the tilt section.
Figure 20-45-44
Remove the tilt port relief/anti cavitation valve (Item 1)
Figure 20-45-42
1 P-51455

P-51454 installation.

Replace the O-ring (Item 1) [Figure 20-45-42] before ft.-lbs. (52-61 Nm) torque.
installation.


(CONT’D)
Port Relief Valve 1
Figure 20-45-45
P-51743

P-51742 Remove the auxiliary port relief valve.
Figure 20-45-48
Remove the port relief plug (Item 1) [Figure 20-45-45]
Figure 20-45-46
P-51640
1
P-51801 20-45-48]. Lightly lubricate with oil and tighten to 38-45

(CONT’D)
Plug Removal
Figure 20-45-49
1
P-51461

(Item 1) [Figure 20-45-51].
P-51459 Figure 20-45-52
1) [Figure 20-45-49].
Figure 20-45-50
P-51462

1
P-51460


(CONT’D)
End Cap Block Removal And Installation
Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (In Loader) on
Page 20-45-6.)
Figure 20-45-53
1
2
P-54346
Disconnect the tube line (Item 1) [Figure 20-45-53] from

the end cap block.
Remove the two end cap block mount screws (Item 1)

[Figure 20-45-53].

11,3 Nm) torque.
Figure 20-45-54
P-54347
Remove the end cap block (Item 1) [Figure 20-45-54]


(CONT’D)

1
procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-45-55
1
P-54348

the lift spool end cap.
1

Figure 20-45-58
P-51746
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
1
Figure 20-45-56
P-51749
Remove the lift spool end cap (Item 1) [Figure 20-45-58]

2
1
P-51747


(CONT’D)
Figure 20-45-59
P-51772

1
45-61].
P-51770 NOTE: Protect spool before clamping in vise.
Figure 20-45-62
Remove the lift spool assembly and seal (Item 1) [Figure
Figure 20-45-60
1
P-51773

P-51771 centering spring.
Remove the lift spool seal (Item 1) [Figure 20-45-60]

from the linkage end of the valve.

(CONT’D)
Lift Spool Removal And Installation (Cont'd) 2

1
Figure 20-45-63
P-51771 P-51775

N-190146 Assembly: Always use a new spool seal.
Figure 20-45-66
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3 1

Nm) torque.
Figure 20-45-64
2
3
3
3
2
P-51749
4 1
Install the lift spool assembly (Item 1) [Figure 20-45-66]

in the spool bore.

P-51776


(CONT’D)

1
Figure 20-45-67
P-51746

control valve.
P-51777 Installation: Replace the O-ring, lubricate lightly with oil
or grease before installation of the end cap block.
Figure 20-45-70
Figure 20-45-68
1 3 2
1
2 2
P-54346
P-51747 Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-45-70].
20-45-68] on the lift spool.
11,3 Nm) torque.
Connect the tubeline (Item 1) [Figure 20-45-70] to the

end cap block.
Install the lift and tilt actuators to the control valve.

(CONT’D)
Remove the end cap block. (See End Cap Block

2
Figure 20-45-71
P-51780

1 2 Installation: Replace the O-ring (Item 2) [Figure 20-45-

73] and lubricate lightly with oil/grease before installation
of the end cap block.
P-51778
Figure 20-45-74
Figure 20-45-72
2
1
P-51781
Remove the tilt spool, centering spring, back-up washer

2 and spool seal (Item 1) [Figure 20-45-74].
P-54348

Disconnect the two tubelines (Item 1) [Figure 20-45-72].


Nm) torque.

(CONT’D)
Tilt Spool Removal And Installation (Cont'd) 2 1
Figure 20-45-75 3
N-18944A
N-18942 Figure 20-45-78
Put the linkage end of the spool in the vice [Figure 20- 2
45-75]. 1

centering spring.
Figure 20-45-76
1
1
P-51545 N-18943

N-19014


Nm) torque.

(CONT’D)
Figure 20-45-79
1
P-51783
2

2
P-54349 Figure 20-45-82



Nm) torque. 1

2
Figure 20-45-80
P-51784


1
P-51782



(CONT’D)
Figure 20-45-83
1
2
P-51785

Figure 20-45-84
P-51786
Remove the auxiliary spool (Item 1) [Figure 20-45-84].

(CONT’D)
Auxiliary Solenoid Disassembly And Assembly

1
Figure 20-45-85
1
P-54350
Installation: Tighten the stem to 10-14 ft.-lbs. (14-19

P-51552 Nm) torque.
Figure 20-45-88
Remove the nut (Item 1) [Figure 20-45-85] from both
solenoids.

torque.
Figure 20-45-86
1
2
P-51555

solenoid stem.
Check and clean the screen (Item 2) [Figure 20-45-88].

P-51553

[Figure 20-45-86].

resistance.

(CONT’D)
Figure 20-45-89
1
2 P-54352
Installation: Lubricate the O-rings and tighten the stem
P-54351 to 20-24 ft.-lbs. (27-33 Nm) torque.
Figure 20-45-92
Remove the nut (Item 1) [Figure 20-45-89] from the
solenoid stem.

3
Figure 20-45-90
1
1
N-18694

N-18693A Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-45-90] from NOTE: The screen (Item 3) [Figure 20-45-92] may be
both ends of the solenoid coil. cleaned with solvent. If it is torn or worn it
needs to be replaced.
resistance. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-45-90] & [Figure
20-45-92] and new back-up rings (Item 2) [Figure 20-45-
92] on the solenoid stem.

(CONT’D)

1
Figure 20-45-93
1
1
1
2
1 2
2
2
P-51564

[Figure 20-45-95] from the lift lock valve, and replace
with new.
P-54353
Figure 20-45-96
circuit and (Item 2) [Figure 20-45-93] is for the lift circuit.
Figure 20-45-94
P-51792
1

P-54354

Remove the lift lock valve (Item 1) [Figure 20-45-94]


(CONT’D)

(Cont’d)
Figure 20-45-97
1
1
1
1
2
2
2
P-51564

[Figure 20-45-97] from the tilt lock valve, and replace
with new.

And Assembly
Figure 20-45-98
P-51794

100].
P-54344
Figure 20-45-101
valve.
Figure 20-45-99
1
1
P-51463

[Figure 20-45-101].
P-51437

Check the lift arm by-pass orifice (Item 1) [Figure 20-45-
99].

casting.

(CONT’D)
Figure 20-45-102 1
P-54239
Figure 20-45-105
P-54344

Figure 20-45-103
1
1
P-54240

105].
P-54355
Remove the BICS™ check valve fitting (Item 1) [Figure

20-45-103] from the top of the lift load check valve.
Installation: Lubricate the o-ring and tighten the valve to

20-24 ft.-lbs. (27-33 Nm) torque.

LIFT ARM BY-PASS CONTROL VALVE
Inspecting
WARNING
Figure 20-50-1
W-2059-0598
1

on Page 10-30-1.)
P-31822 Hold the by-pass control knob (Item 1) [Figure 20-50-1]

and loosen the jam nut on the by-pass valve shaft.
Raise the lift arms 6 feet (2 m) off the ground. Stop the Figure 20-50-2
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm By-
Pass Control Knob until the lift arms slowly lower.
Additional Inspection For Loaders W/Advanced Hand

2
Controls
1
Sit in the operator's seat and fasten the Seat Belt. Lower
the Seat Bar, start the engine and press the green
PRESS TO OPERATE Button.
Raise the lift arms about 6 feet (2 meters) off the ground.
Turn the key OFF and wait for the engine to come to a
complete stop.
P-31823
Turn the key ON. Press the green PRESS TO OPERATE

Button, move the left hand control toward the operator. Remove the by-pass control knob. Remove the jam nut
The lift arms should not lower. (Item 1) [Figure 20-50-2] from the valve shaft.
Move the right hand control away from the operator. The Remove the rubber washer (Item 2) [Figure 20-50-2].
bucket (or attachment) should not tilt forward.

LIFT ARM BY-PASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-50-5
Figure 20-50-3
2
1
2
1
P13656
P-34060
Remove the by-pass valve (Item 1) [Figure 20-50-5]
from the valve block. Inspect the by-pass valve for
Disconnect the two hydraulic tubelines (Item 1) [Figure damage and replace if necessary.
20-50-3] and cap and plug the lines.
Installation: Tighten the valve to 33-37 ft.-lbs. (45-50
Remove the two mounting bolts (Item 2) [Figure 20-50- Nm) torque.
3].
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
Installation: Tighten the mounting bolts to 180-200 in.- the valve block for damage and replace if necessary.
Remove the lift arm by-pass valve.
Figure 20-50-4
P13653
Remove the two bolts (Item 1) [Figure 20-50-4] to

replace the by-pass valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm by-

pass valve in the loader.

HYDRAULIC PUMP Figure 20-60-1
Check The Output Of The Hydraulic Pump
The tools listed will be needed to do the following 2

procedure:
MEL1563 - Remote Start Tool 1

WARNING
P-43930
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
tubeline on the control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-2
1.)

2
1
WARNING
P-34851
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-60-2] from
Raise the operator cab. (See Raising The Operator Cab the tester to the OUTLET hose (Item 1) [Figure 20-60-1]
on Page 10-30-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-2] from the tester to the tubeline (Item 2) [Figure
Open the rear door of the loader. 20-60-1] on the control valve.
Connect the remote start tool. (See REMOTE START on

Page 10-60-1.)
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT'D) Removal And Installation
Check The Output Of The Hydraulic Pump (Cont'd)
Figure 20-60-3
EXAMPLE: TESTER
CONNECTION
Reservoir
WARNING
Hydraulic Pump Never work on a machine with the lift arms up unless
Out In Hydraulic Control support device. Failure to use an approved lift arm
Valve support device can allow the lift arms or attachment
W-2059-0598
1
BH-196
Sample tester connection shown[Figure 20-60-3]]. Stop the engine. Raise the seat bar.
Start the engine and run at low idle RPM. Make sure the Lift and block the rear of the loader. (See Procedure on
tester is connected correctly. If no flow is indicated on the Page 10-10-1.)
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full Raise the operator cab. (See Raising The Operator Cab
RPM*. on Page 10-30-1.)
Warm the fluid to 140°F. (60°C.) by turning the restrictor Drain the hydraulic fluid from the reservoir. (See
control (Item 1) [Figure 20-60-3] on the tester to about Replacing Hydraulic Fluid And Case Drain Filters on
1000 PSI (6895 kPa). DO NOT exceed system relief Page 10-120-3.)
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM. Open the rear door of the loader.
Push the maximum/variable flow switch (on the remote Remove the Power Bob-Tach block if equipped. (See
start tool) to engage the front auxiliary hydraulics, the Removal And Installation on Page 20-110-1.)
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X 100

FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*Refer to SPECIFICATIONS Contents Page SPEC-01 for

system relief pressure and full RPM.

HYDRAULIC PUMP (CONT'D) Figure 20-60-6
Removal And Installation (Cont’’d)
Figure 20-60-4
2 P-43936
Remove the two mounting bolts (Item 1) [Figure 20-60-

P-43934 6] from the hydraulic pump.
Installation: Tighten the mounting bolts to 27-37 ft.-lbs.

Disconnect and cap the hose from the outlet fitting (Item (37-50 Nm) torque.
1) [Figure 20-60-4] of the hydraulic pump.
Figure 20-60-7
Disconnect and cap the hose from the outlet fitting (Item
2) [Figure 20-60-4] of the hydraulic charge pump.
Figure 20-60-5
1 1
P-26348 P-43938
Remove the hydraulic pump from the hydrostatic pump

P-43933 [Figure 20-60-7].

Disconnect the two inlet hoses (Item 1) [Figure 20-60-5]
from the front of the hydraulic pump. Installation: Use a new O-ring when installing the
hydraulic pump.

HYDRAULIC PUMP (CONT'D)
Identification
6
14 18
10 11 17
6
15 16
5
3 4
2
7
6
13
12
10 11
8 9
1. Auxiliary Pump End Section 5 6
3 4
2. Pre-Load Seal 2
3. Load Seal
4. Section Seal
5. Wear Plate 1
6. Pins
7. Drive Gear (Auxiliary Pump)
8. Idler Gear (Auxiliary Pump)
9. Auxiliary Pump Center Section
10. Wear Plate
11. Section Seal
12. Spline Shaft
13. Auxiliary Pump End Section
14. Drive Gear (Charge Pump)
15. Idler Gear (Charge Pump)
16. Charge Pump Center Section
17. Charge Pump End Section
18. Bolts (8)
B-21259

Disassembly And Assembly
IMPORTANT 1

clean the work area before disasembly and keep all
damage the system.
I-2003-0888
P-39138
Figure 20-60-8
Set the pump on end, and remove the pump end section
(Item 1) [Figure 20-60-9] from the charge pump.
Figure 20-60-10
1 1
1
1
P-39126
1 2
Mark the pump sections for correct assembly [Figure 20-
60-8].
P-39139
Remove the eight pump housing bolts (Item 2) [Figure
20-60-8].
Remove the wear plate (Item 1) and the section seal
Installation: Tighten the eight bolts (Item 1) [Figure 20- (Item 2) [Figure 20-60-10].
60-8] to 45-50 ft.-lbs (60-67 Nm) torque.

Disassembly And Assembly (Cont'd)
Figure 20-60-11
4
1
2
P-39142
1 NOTE: Inspect the charge pump center section (Item

P-39140 1) [Figure 20-60-13]. If excessive wear or
damage is visible, the pump must be
replaced.
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-60-11] and replace as needed. Figure 20-60-14
NOTE: Position the wear plate (Item 1) [Figure 20-60-

11] inlets and traps as shown with the bronze
side toward the gears.
1
NOTE: Inspect the pump end section (Item 3) and
bushings (Item 4) [Figure 20-60-11]. If
excessive wear or damage is visible, the
pump must be replaced.
Figure 20-60-12
P-39143
Remove the idler gear (Item 1) [Figure 20-60-14] from

the charge pump.
P-39141
Remove the charge pump center section (Item 1) [Figure

20-60-12] from the auxillary pump.

Figure 20-60-15
P-39146
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-

P-39144 17]. If excessive wear or damage is visible, the
NOTE: Inspect the idler gear (Item 1) [Figure 20-60- Figure 20-60-18
15]. If excessive wear or damage is visible, the
Figure 20-60-16
3
P-39147
Remove the wear plate (Item 1) and section seal (Item 2)

P-39145 [Figure 20-60-18] from the front section of the charge
pump.
Remove the drive gear (Item 1) [Figure 20-60-16] from Remove the locating pins (Item 3) [Figure 20-60-18]
the charge pump. from the front section of the charge pump.

Figure 20-60-19
P-39150
1
Remove the Pre-load seal (Item 1) [Figure 20-60-21]

P-39148 from the front section of the charge pump.
Figure 20-60-22
2) [Figure 20-60-19] and replace as needed.

Figure 20-60-20
1
2
P-39151
1
Inspect the load seal (Item 1) and the Pre-load seal (Item
P-39149
[Figure 20-60-20]Remove the load seal (Item 1) from

the front section of the charge pump.

Figure 20-60-23
2
1
P-39216
Remove the wear plate (Item 1) [Figure 20-60-25] &

P-39152 [Figure 20-60-26] and section seal (Item 2) [Figure 20-
60-25] & [Figure 20-60-26] from the pump section.
Inspect the pump center section and bushings (Item 1) Figure 20-60-26
[Figure 20-60-23]. If excessive wear or damage is
visible, the pump must be replaced.
3
Figure 20-60-24
4
1
2
P-39217
NOTE: Position wear plate (Item 1) [Figure 20-60-26]

P-39215 inlets and traps as shown with bronze side
toward gears.
Remove the pump center section (Item 1) [Figure 20-60- NOTE: Inspect the pump center section (Item 3) and
24] from the pump sections. bushings (Item 4) [Figure 20-60-26]. If

Figure 20-60-27 1
P-39220
Remove the idler gear (Item 1) [Figure 20-60-29] &

P-39218 [Figure 20-60-30].
Figure 20-60-30
Remove the pump section (Item 1) [Figure 20-60-27]
from the pump end section.
Figure 20-60-28
P-39221
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

P-39219 30]. If excessive wear or damage is visible, the
NOTE: Inspect the pump section (Item 1) [Figure 20-

60-28]. If excessive wear or damage is visible,
the pump must be replaced.

Figure 20-60-31
1
1
P-39224
Remove the spline shaft (Item 1) [Figure 20-60-33] from

P-39222 the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-60-

Remove the drive gear (Item 1) [Figure 20-60-31] from 33]. If excessive wear or damage is visible, the
the pump end section. pump must be replaced.
Figure 20-60-32 Figure 20-60-34
1
1
3
P-39223 P-39225
NOTE: Inspect the drive gear (Item 1) [Figure 20-60- Remove the wear plate (Item 1) and section seal (Item 2)
32]. If excessive wear or damage is visible, the [Figure 20-60-34].
Remove the locating pins (Item 3) [Figure 20-60-34].


1
Figure 20-60-35
P-26672
P-26670
1
2
P-39227
Remove the pre-load seal (Item 1) [Figure 20-60-37].

P-39226
Figure 20-60-38
2) [Figure 20-60-35].
1
inlets and traps as shown with bronze side
toward gears.
Figure 20-60-36
2
P-39229
P-26670
1 NOTE: Inspect the pump end section (Item 1) and

P-39228
Remove the load seal (Item 1) [Figure 20-60-36].

HYDRAULIC PUMP (CHARGE) Figure 20-61-1

procedure:
1
MEL1563 - Remote Start Tool
6661247 - Filter Assembly
17 KB 1212 - Elbow Fitting
15 KB 1212 - Straight Fitting
15 KB 0812 - Reducer Fitting
P-43640
WARNING Remove the three mount bolts (Item 1) [Figure 20-61-1]

from the right side access panel. Remove the panel.
Figure 20-61-2
W-2017-0286 2

1.) 3 4
Raise the lift arms and install an approved lift arm 1
WARNING P-39250

the lift arms are secured by an approved lift arm Assemble the filter assembly (Item 1), elbow fitting (Item
support device. Failure to use an approved lift arm 2), straight fitting (Item 3) and the reducer fitting (Item 4)
support device can allow the lift arms or attachment [Figure 20-61-2].
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.

on Page 10-30-1.)
Open the rear door of the loader.

Page 10-60-1.)

HYDRAULIC PUMP (CHARGE) (CONT'D) Figure 20-61-5
Check The Output Of The Hydraulic Pump (Cont’d)
Figure 20-61-3
P-37694
1
1
Disconnect the OUTLET hose (Item 1) [Figure 20-61-5]
P-39247 from the charge pump, that goes to the back side of the
hydrostatic pump.
Determine the proper direction of oil flow through the filter Figure 20-61-6
housing (Item 1) [Figure 20-61-3] and [Figure 20-61-4].
Figure 20-61-4
3 P-39249
2
P-39248 Remove the OUTLET fitting (Item 1) [Figure 20-61-6]

from the charge pump.
Install the fitting (15KB 1212-Straight Fitting) (Item 2)

[Figure 20-61-4] in the filter housing inlet.
Install the fitting (15KB 0812-Reducer Fitting) (Item 3)

[Figure 20-61-4] in the filter housing outlet.

HYDRAULIC PUMP (CHARGE) (CONT'D) Figure 20-61-9
Figure 20-61-7
1 P-39253
Connect the outlet fitting on the hydraulic filter (Item 1)

P-39251 [Figure 20-61-9] to the hose that was remove from the
charge pump and routes to the back side of the
hydrostatic pump.
Install the elbow fitting 17KB 1212 (Item 1) [Figure 20-
61-7] into the OUTLET of the charge pump. Figure 20-61-10
Figure 20-61-8
P-39254
P-39252
Connect the outlet hose on the hydraulic tester (Item 1)
[Figure 20-61-10] to the inlet fitting on the hydraulic filter
Connect the Inlet hose from the hydraulic tester (Item 1) assembly.
[Figure 20-61-8] to the OUTLET fitting of the charge
pump.

HYDRAULIC PUMP (CHARGE) (CONT’D) *Refer to the Hydraulic Schematics for pump flow and
RPM.
Figure 20-61-11
See Hydraulic Pump Removal and Installation (See
HYDRAULIC PUMP on Page 20-60-1.) or (See
HYDRAULIC PUMP (HIGH FLOW) on Page 20-62-1.)
See Hydraulic Pump Dissassembly and Assembly (See

HYDRAULIC PUMP on Page 20-60-1.) or (See
HYDRAULIC PUMP (HIGH FLOW) on Page 20-62-1.)
P-39255
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-61-11].
IMPORTANT
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor

control (Item 1) on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Turn the restrictor down to system operating pressure.

DO NOT EXCEED SYSTEM RELIEF PRESSURE. (2000
PSI) The high pressure flow must be at least 80% of free
flow.
HIGH PRESSURE FLOW (GPM)
%= X 100
FREE FLOW (GPM)


HYDRAULIC PUMP (HIGH FLOW) Warm the fluid to 140°F. (60°C.) by turning the restrictor
control clockwise on the tester so it reads about a 1000
Hydraulic Pump Test (30 GPM) PSI (69 bar).
The tools listed will be needed to do the following NOTE: DO NOT EXCEED 3300 PSI.
procedure:
Turn the restrictor control (Item 2) [Figure 20-62-1] on
MEL10103 - Hydraulic Tester the tester counterclockwise to obtain free flow, the flow
MEL10106 - Hydraulic Test Kit should be at 20 GPM. Start turning the restrictor
clockwise, causing more restriction on the flow. The GPM
NOTE: Machines with (S/N 526016699 and Below) or should drop off slightly until the pressure reaches
(S/N 525815599 and Below) with the high flow approximately 2800 PSI. At approximately 2800 PSI the
option will have the (30 GPM). Machines with flow should start decreasing rapidly until the pressure
(S/N 526016700 and Above) or (S/N 525815600 reaches 3250-3300 PSI. At 3250-3300 PSI the flow
and Above) with the high flow option will have should be at 0 GPM. Turn the restrictor (Item 2) [Figure
the (40 GPM). 20-62-1] counter clockwise to free flow. Shut the front
auxiliary hydraulics off.
Figure 20-62-1 If flow and pressure specs are not obtained, go to the
Inline Standard Hydraulic Pump Test. (See Inline
Hydraulic Pump Test (Standard) on Page 20-62-3.) If
1 flow and pressure specs are obtained continue on to the
next paragraph.
With the engine running at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
RPM*.

control on the tester to about 1000 PSI (69 bar).
2 NOTE: DO NOT EXCEED 3300 PSI.

P-16903 P-37687 the tester counter clockwise, to obtain free flow, the flow
should be at 20 GPM. Press the High Flow button. The
flow should increase to 30 GPM. Start turning the
NOTE: When testing the hydraulic flow of a machine restrictor clockwise, causing more restriction on the flow.
hoses must be at least 3/4 inch in diameter The GPM should drop off slightly until the pressure
and connected directly to the hydraulic tester reaches approximately 3100 PSI. At approximately 3100
without using any type of “quick coupler” on PSI the flow should start decreasing rapidly until the
the connection to the tester. Also make sure pressure reaches 3250-3350 PSI. At 3250-3350 PSI the
your hydraulic tester is capable of at least 50 flow should be at 0 GPM. Turn the restrictor control (Item
GPM. 2) [Figure 20-62-1] counter clockwise to free flow. Shut
the front auxiliary hydraulics off.
Install a hydraulic tester (Item 1) [Figure 20-62-1] onto
If the specs from above are reached, the high flow
the front auxiliary quick couplers.
hydraulic pump is OK.
This procedure will require a operator in the cab and one
If the flow and pressure were not obtained, go to the
operator running the tester.
Inline High Flow Hydraulic Pump Test (See Inline
Start the engine and run at low idle RPM. Press the Front Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)
Auxiliary button. Engage the front auxiliary with the on Page 20-62-5.)
*(See LOADER SPECIFICATIONS (S250) on Page
SPEC-10-1.) for system relief pressure and full RPM.
RPM*.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Warm the fluid to 140°F. (60°C.) by turning the restrictor
control clockwise on the tester so it reads about a 1000
Hydraulic Pump Test (40 GPM) PSI (69 bar).
The tools listed will be needed to do the following NOTE: DO NOT EXCEED 3300 PSI.
procedure:
MEL10103 - Hydraulic Tester the tester counterclockwise to obtain free flow, the flow
MEL10106 - Hydraulic Test Kit should be at 20 GPM. Start turning the restrictor
NOTE: Machines with (S/N 526016699 and Below) or should drop off slightly until the pressure reaches
(S/N 525815599 and Below) with the high flow approximately 2800 PSI. At approximately 2800 PSI the
option will have the (30 GPM). Machines with flow should start decreasing rapidly until the pressure
(S/N 526016700 and Above) or (S/N 525815600 reaches 3250-3300 PSI. At 3250-3300 PSI the flow
and Above) with the high flow option will have should be at 0 GPM. Turn the restrictor (Item 2) [Figure
the (40 GPM). 20-62-2] counter clockwise to free flow. Shut the front
auxiliary hydraulics off.
Hydraulic Pump Test (Standard) on Page 20-62-3.) If
1 flow and pressure specs are obtained continue on to the
next paragraph.
RPM*.

2 NOTE: DO NOT EXCEED 3300 PSI.

P-16903 P-37687 the tester counter clockwise, to obtain free flow, the flow
should be at 20 GPM. Press the High Flow button. The
flow should increase to 40.5 GPM. Start turning the
NOTE: When testing the hydraulic flow of a machine restrictor clockwise, causing more restriction on the flow.
hoses must be at least 3/4 inch in diameter The GPM should drop off slightly until the pressure
and connected directly to the hydraulic tester reaches approximately 3100 PSI. At approximately 3100
without using any type of “quick coupler” on PSI the flow should start decreasing rapidly until the
the connection to the tester. Also make sure pressure reaches 3250-3350 PSI. At 3250-3350 PSI the
your hydraulic tester is capable of at least 50 flow should be at 0 GPM. Turn the restrictor control (Item
GPM. 2) [Figure 20-62-2] counter clockwise to free flow. Shut
the front auxiliary quick couplers.
If the flow and pressure were not obtained, go to the
Inline High Flow Hydraulic Pump Test (See Inline
Start the engine and run at low idle RPM. Press the Front Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)
Auxiliary button. Engage the front auxiliary with the on Page 20-62-5.)
RPM*.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-62-3
Inline Hydraulic Pump Test (Standard)
The tools listed will be needed to do the following 2

procedure:

1
WARNING
of the frame before running the engine for service. P-43930
W-2017-0286 At the control valve, disconnect the standard (auxiliary)
pump OUTLET hose (Item 1) [Figure 20-62-3] from the
tube line.
1.) Figure 20-62-4

2
WARNING 1

W-2059-0598
P-34851

on Page 10-30-1.) NOTE: When testing the hydraulic flow of a machine
hoses must be at least 3/4 inch in diameter
and connected directly to the hydraulic tester
without using any type of “quick coupler” on
the connection to the tester. Also make sure
your hydraulic tester is capable of at least 50
GPM.

the tester to the OUTLET hose (Item 1) [Figure 20-62-3]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-62-4] from the tester to the tube line (Item 2) [Figure
20-62-3] which goes to the control valve.
Lower the cab down.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Record the flow (GPM) at 2700 PSI, this is the high
pressure flow. The high pressure flow must be at least
Inline Hydraulic Pump Test (Standard) (Cont'd) 80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X 100

FREE FLOW (GPM)
IMPORTANT
position before you start the engine. *Refer to SPECIFICATIONS Contents Page SPEC-01 for
I-2024-0284 system relief pressure and full RPM.
Figure 20-62-5
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In Hydraulic Control
Valve
BH-196
Sample tester connection shown [Figure 20-62-5].

RPM*.

control (Item 1) [Figure 20-62-5] on the tester clockwise
to about 1000 PSI (69 bar).
NOTE: DO NOT EXCEED 3300 PSI.
Open the restrictor control and record the free flow

(GPM) at full RPM.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Inline Hydraulic Pump Test (High Flow) (30 GPM And
40 GPM) Figure 20-62-7

procedure:

1
WARNING
2
fall or move and cause injury or death. P-43954
W-2017-0286
Remove the left side access cover.


1.) Disconnect the high flow pump OUTLET hose (Item 1)
from the fitting (Item 2) [Figure 20-62-7] on the tube line.
Figure 20-62-6
Figure 20-62-8
1
2 1
P-34847
Install a jumper hose (Item 1) [Figure 20-62-6] onto the

front auxiliary quick couplers. P-34851

support device. (See Installing The Lift Arm Support NOTE: When testing the hydraulic flow of a machine
Device on Page 10-20-1.) hoses must be at least 3/4 inch in diameter
WARNING your hydraulic tester is capable of at least 50
GPM.
the lift arms are secured by an approved lift arm Connect the INLET hose (Item 1) [Figure 20-62-8] from
support device can allow the lift arms or attachment 20-62-8] from the tester to the fitting (Item 2) [Figure 20-
to fall and cause injury or death. 62-7] on the tube line.
W-2059-0598
Lower the cab down.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Pump Adjustment (See High Flow Relief Adjustment
Procedure (30 GPM And 40 GPM) on Page 20-62-7.) If
Inline Hydraulic Pump Test (High Flow) (30 GPM And the pressure readings are correct, continue on to the next
40 GPM) (Cont’d) paragraph.

(GPM) at full RPM.
IMPORTANT Record the flow (GPM) at 2500 PSI, this is the high
80% of free flow.
I-2024-0284 %= X 100
FREE FLOW (GPM)
Figure 20-62-9
EXAMPLE: TESTER
CONNECTION *Refer to SPECIFICATIONS Contents Page SPEC-01 for
Reservoir
Hydraulic Pump
Valve
BH-196

Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to full RPM*.

control (Item 1) [Figure 20-62-9] clockwise on the tester
Turn the restrictor control clockwise on the tester to 3300

PSI and the flow should go to zero GPM. If the pressure
readings are not obtained go to the High Flow Relief

High Flow Relief Adjustment Procedure (30 GPM And

40 GPM)

procedure:
MEL10103 - Hydraulic Tester 1
WARNING 2
of the frame before running the engine for service. P-43954
W-2017-0286 Remove the left side access cover.
Disconnect the high flow pump OUTLET hose (Item 1)

Lift and block the loader. (See Procedure on Page 10-10- from the fitting (Item 2) [Figure 20-62-11] on the tube
1.) line.
Remove the right rear tire. Figure 20-62-12

Figure 20-62-10
2
1
P-34851
P-34847
Install a jumper hose (Item 1) [Figure 20-62-10] onto the front NOTE: When testing the hydraulic flow of a machine
auxiliary quick couplers. hoses must be at least 3/4 inch in diameter
Raise the lift arms and install an approved lift arm without using any type of “quick coupler” on
support device. (See Installing The Lift Arm Support the connection to the tester. Also make sure
Device on Page 10-20-1.) your hydraulic tester is capable of at least 50
GPM.

WARNING the tester to the OUTLET hose (Item 1) [Figure 20-62-
11] of the pump. Connect the OUTLET hose (Item 2)
[Figure 20-62-12] from the tester to the tube line (Item 2)
Never work on a machine with the lift arms up unless [Figure 20-62-11].
support device. Failure to use an approved lift arm Lower the cab down.
W-2059-0598

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Figure 20-62-15

40 GPM) (Cont’d)
Figure 20-62-13
1 1
1
P-45445
2 P-45457
Remove the six access cover mounting bolts (Item 1) and With the hoses connected correctly, increase the engine
the cover (Item 2) [Figure 20-62-13] from the frame. speed to full RPM*.
Figure 20-62-14 Warm the fluid to 140°F. (60°C.) by turning the restrictor
control clockwise on the tester to about 1000 PSI (69
bar).
P-45443 Turn the restrictor control clockwise on the tester to

causing more restriction on the flow. The GPM should
drop off slightly until the pressure reaches approximately
3100 PSI. At approximately 3100 PSI the flow should
start decreasing rapidly until the pressure reaches 3250-
3350 PSI. At 3250-3350 PSI the flow should be at 0
GPM. Turn the restrictor counter clockwise to free flow.
Shut the front auxiliary hydraulics off.
1 If the specs from above are reached, the pump is OK.

P-45443 If the pump is unable to reach 3300 PSI the relief screw
(Item 1) [Figure 20-62-15] will need to be turned
clockwise a 1/4 turn and retested with the procedure
Remove the plug (Item 1) [Figure 20-62-14] from the above. (1/4 turn equals approximately 200 PSI.)
bottom of the relief valve at the pump.
NOTE: If the relief screw has been turned in 1/4 turn
This procedure will require a operator in the cab and one and the pressure remains the same, go to the
operator running the tester. relief valve removal and installation section.
(See Removal And Installation on Page 20-30-
4.) If relief valve has been checked and is OK,
go to the high flow pump disassembly and
assembly section. (See Disassembly And
Assembly (30 GPM And 40 GPM) on Page 20-
62-14.)
If the pump reaches 3300 PSI and there is flow, the relief
screw must be turned counter clockwise 1/4 turn and
retested with the procedure above.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Installation: Tighten the relief valve to 30-35 ft.-lbs. (41-
47 Nm) torque.
High Flow Relief Valve Removal and Installation (30
GPM And 40 GPM) Figure 20-62-18
1 1
WARNING
fall or move and cause injury or death. 2
W-2017-0286

1.)
P-45459
Remove the right rear tire.
Figure 20-62-16 Inspect the relief valve and replace the two o-rings (Item
If the relief valve is bad, it must be replaced as a

1 complete unit.
Figure 20-62-19
1
1
2
P-45457
1
Remove the six access cover mount bolts (Item 1) and
the access cover (Item 2) [Figure 20-62-16] from the
frame.
Figure 20-62-17
P-45469
Inspect the o-ring (Item 1) [Figure 20-62-19] on the plug

for damage and replace as needed.
P-45443
Remove the relief valve (Item 1) [Figure 20-62-17] from

the pump.

Removal And Installation (30 GPM And 40 GPM)
1
2 4
WARNING P-45446
Never work on a machine with the lift arms up unless At the back side of the gear pump, disconnect and cap
the lift arms are secured by an approved lift arm the hose from the outlet fitting (Item 1) of the standard
support device. Failure to use an approved lift arm flow pump. Disconnect and cap the hose (Item 2) from
the charge pump. Disconnect and cap the hoses from the
High Flow pump outlet fitting (Item 3) and the low
to fall and cause injury or death. pressure hose (Item 4) [Figure 20-62-20].
W-2059-0598
Figure 20-62-21
Device on Page 10-20-1.) 2
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.) 4
Raise the operator cab. (See Raising The Operator Cab 3

on Page 10-30-1.)
1
Drain the hydraulic fluid from the reservoir. (See
Replacing Hydraulic Fluid And Case Drain Filters on
2
Page 10-120-3.)
Open the rear door of the loader. P-62866
Remove the hoses from the Power Bob-Tach block. (If so

equipped.) (See Removal And Installation on Page 20- At the front side of the gear pump, disconnect and cap
110-1.) the three hoses (Item 1) from the inlet fittings (Item 2) of
the hydraulic pump [Figure 20-62-21].
NOTE: Machines with (S/N 526016700 and Above) or

(S/N 525815600 and Above) will have a dual
inlet gear pump (40 GPM). Machines below the
serial number will have a single inlet gear
pump (30 GPM).
Disconnect the inlet hose (Item 3) from the second inlet

fitting (Item 4) [Figure 20-62-21].

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

(Cont’d)
Figure 20-62-22
P-43958
At the right side access hole, disconnect the electrical

connector (Item 1) [Figure 20-62-22] from the high flow
pump solenoid.
Figure 20-62-23
P-43956

23] from the hydraulic pump.

(37-50 Nm) torque.
Remove the hydraulic pump from the hydrostatic pump.
Installation: Use a new O-ring when installing the

hydraulic pump.

Identification (30 GPM) (S/N 526016699 & Below) (S/N

525815599 & Below)

2. Section Seal
3. Pre-Load Seal
4. Load Seal
5. Wear Plate
6. Pin
9. Pump Center Section (Auxiliary Pump)
22
10. Pump End Section (Auxiliary Pump)
11. Spline Shaft
13. Idler Gear (Charge Pump) 24
14. Pump Center Section (Charge Pump) 20
23
15. Pump End Section (Charge Pump)
16. Drive Gear (HI-Flow Pump) 25
17. Idler Gear (Hi-Flow Pump)
18. Pump Center Section (Hi-Flow Pump) 5
16
19. Pump End Section (Hi-Flow Pump) 6
11
6
12 5 21
11 23
2 25 19
5
2 6 17 18 24
3 4
15
6 2 26
13
5 14
2
3 4
27
28
7
6
2 10
5
20. Bolt (4) 8
5 9
21. Bolt (4) 6
22. Relief Valve 3 4
2
23. O-Ring
24. O-Ring 1
25. Back-up Washer
26. Valve
27. Coil
28. Nut
B-22288

Identification (40 GPM) (S/N 526016700 & Above) (S/N

525815600 & Above)

2. Section Seal
3. Pre-Load Seal
4. Load Seal
5. Wear Plate
6. Pin
9. Pump Center Section (Auxiliary Pump) 22
11. Spline Shaft
24 20
13. Idler Gear (Charge Pump)
14. Pump Center Section (Charge Pump) 23
15. Pump End Section (Charge Pump) 25
16. Drive Gear (HI-Flow Pump) 5
17. Idler Gear (Hi-Flow Pump) 16
6
18. Pump Center Section (Hi-Flow Pump) 11

19. Pump End Section (Hi-Flow Pump)
6
12 5 21
11 23 19
2 25
5 17
2 6 18 24
3 4
2 15
6 26
5
13 14
3 4 2
27
28
7
6
2 10
5
8
5 9
6
20. Bolt (4) 3 4
2
21. Bolt (4)
22. Relief Valve 1
23. O-Ring
24. O-Ring
25. Back-up Washer
26. Valve
27. Coil
28. Nut B-22288B

Disassembly And Assembly (30 GPM And 40 GPM) 2
Mark the pump sections for correct assembly.
NOTE: Disassembly and Assembly procedure is the

same for both gear pumps (30 GPM and 40
GPM). 1
The visual difference between the two gear

pumps is one pump has a dual inlet pump (40
GPM) and one pump has a single inlet pump
(30 GPM).
P-45461
IMPORTANT NOTE: Mark the pump housing (Item 1) [Figure 20-62-

25] for proper installation of the solenoid
When repairing hydrostatic and hydraulic systems, valve cartridge.
parts clean. Always use caps and plugs on hoses, Remove the valve cartridge (Item 1) [Figure 20-62-25].
damage the system. Installation: Tighten the solenoid valve to 35-40 ft.-lbs
I-2003-0888 (47-54 Nm).
Figure 20-62-26
Figure 20-62-24
P-45462
P-45460
Inspect the o-ring (Item 1) [Figure 20-62-26] and replace

Remove the solenoid nut (Item 1) [Figure 20-62-24].
as needed.
Inspect the o-ring and back-up washer (Item 2) [Figure
Installation: Tighten the solenoid nut to 48-72 in lbs (5-8 20-62-26] and replace as needed.
Nm)

Disassembly And Assembly (30 GPM And 40 GPM)

(Cont'd)
Figure 20-62-27
1 2
P-45469
Inspect the o-ring (Item 1) [Figure 20-62-29] on the relief

valve adjustment plug for damage and replace as
P-45470
needed.
Figure 20-62-30
NOTE: Mark the pump housing (Item 1) [Figure 20-62-
27] for proper installation of the relief valve.

the pump
Installation: Tighten the relief valve to 30-35 ft.-lbs (41-

47 Nm) torque.
1
Figure 20-62-28
1
1
P-45463
1
Mark the pump sections for proper installation.
Remove the eight bolts (Item 1) [Figure 20-62-30].

2
Installation: Tighten the assembly bolts to 45-50 ft.-lbs
(60-67 Nm).
P-45459
Inspect the relief valve and replace the two o-rings (Item
1) and back-up washer (Item 2)[Figure 20-62-28].


(Cont'd)
Figure 20-62-31 1
P-39171
Remove the pump center section (Item 1) [Figure 20-62-

33] & [Figure 20-62-34] from the pump.
P-39169
Figure 20-62-34
[Figure 20-62-31] from the pump end section.
Figure 20-62-32
1
P-39172
3
1
2 NOTE: Inspect the pump center section (Item 1)
[Figure 20-62-34]. If excessive wear or
P-39170 damage is visible, the pump must be
replaced.

toward gears.



(Cont'd)
Figure 20-62-35
P-39175
Remove the drive gear (Item 1) [Figure 20-62-37] &

[Figure 20-62-38].
P-39173
Figure 20-62-38

[Figure 20-62-36].
Figure 20-62-36
P-39176

P-39174 pump must be replaced.



(Cont'd)
Figure 20-62-39
1 1
P-39179
2 Remove the load seal (Item 1) [Figure 20-62-41].
P-39177
Figure 20-62-42
[Figure 20-62-40] and section seal (Item 2) [Figure 20-
62-39] & [Figure 20-62-40] from the pump center
section.
Figure 20-62-40
1 P-39180
2 Remove the pre-load seal (Item 1) [Figure 20-62-42].
Figure 20-62-43
P-39178

toward gears.
P-39151
Inspect both seals [Figure 20-62-43].


3
(Cont'd)
Figure 20-62-44
4
2 1
P-39183

P-39181 toward gears.
NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-62- bushings (Item 4) [Figure 20-62-46]. If
44] from the pump sections. excessive wear or damage is visible, the
Figure 20-62-45
Figure 20-62-47
1
1
2
P-39182
P-39184

62-45] & [Figure 20-62-46] from the pump section. Remove the spline shaft (Item 1) [Figure 20-62-47].

from the pump.


(Cont'd)
Figure 20-62-48
P-39144
1
Figure 20-62-51
NOTE: Inspect the charge pump center section (Item
1) [Figure 20-62-48]. If excessive wear or
replaced.
Figure 20-62-49 1
P-39145
Remove the drive gear (Item 1) [Figure 20-62-51] from

the charge pump.
P-39143

the charge pump.


(Cont'd)
Figure 20-62-52
1 1
P-39148
2 )[Figure 20-62-54] and replace as needed.
P-39146

NOTE: Inspect the drive gear (Item 1) [Figure 20-62- side toward the gears.
pump must be replaced. Figure 20-62-55
Figure 20-62-53
1
1
2
P-39149
P-39147
Remove the load seal (Item 1) [Figure 20-62-55] from
the front section of the charge pump.
[Figure 20-62-53] from the front section of the charge
pump.
Remove the locating pins (Item 3) [Figure 20-62-53]

from the front section of the charge pump.


(Cont'd)
Figure 20-62-56
1
P-39152
Inspect the pump center section and bushings (Item 1)

P-39150
Figure 20-62-59
from the front section of the charge pump.
Figure 20-62-57
1
1
P-39215
2
Remove the pump center section (Item 1) [Figure 20-62-

P-39151
59] from the pump sections.


(Cont'd) 1
Figure 20-62-60
P-39218
2
from the pump end section.
P-39216
Figure 20-62-63
Remove the wear plate (Item 1) [Figure 20-62-60] & 1

62-60] & [Figure 20-62-61] from the pump section.
Figure 20-62-61
P-39219
1
NOTE: Inspect the pump section (Item 1) [Figure 20-
62-63]. If excessive wear or damage is visible,
2 the pump must be replaced.
P-39217

toward gears.


HYDRAULIC (HIGH FLOW) PUMP (CONT'D) Figure 20-62-66

(Cont'd)
Figure 20-62-64
1
1
P-39222

the pump end section.
P-39220
Figure 20-62-67
[Figure 20-62-65].
Figure 20-62-65
P-39223

the pump end section.
P-39221
NOTE: Inspect the idler gear (Item 1) [Figure 20-62- pump must be replaced.


(Cont'd)
Figure 20-62-68
2
1
1
P-39226
2) [Figure 20-62-70].
P-39224

Remove the spline shaft (Item 1) [Figure 20-62-68] from toward gears.
the end of the drive gear.
Figure 20-62-71
NOTE: Inspect the spline shaft (Item 1) [Figure 20-62-
pump must be replaced. 1
Figure 20-62-69
P-26670
3
1
P-39228
2
3
P-39225

[Figure 20-62-69].
Remove the locating pins (Item 3) [Figure 20-62-69].


(Cont'd)
Figure 20-62-72
P-26672
P-26670
P-39227
Remove the pre-load seal (Item 1) [Figure 20-62-72].
Figure 20-62-73
P-39229P-
26673


HYDRAULIC PUMP (SELECTABLE JOYSTICK Figure 20-63-1
CONTROL) (SJC)

2
procedure:
MEL1563 - Remote Start Tool 1

WARNING
P-43930

Disconnect the OUTLET hose (Item 1) [Figure 20-63-1]
that comes from the gear pump, and connects to the
W-2017-0286
tubeline on the top of the control valve.
Figure 20-63-2
1.)

WARNING
support device can allow the lift arms or attachment P-34851

W-2059-0598
Raise the operator cab. (See Raising The Operator Cab of the pump. Connect the OUTLET hose (Item 2) [Figure
on Page 10-30-1.) 20-63-2] from the tester to the tubeline (Item 2) [Figure
20-63-1] on the top of the control valve.

Page 10-60-1.)
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (SELECTABLE JOYSTICK Removal And Installation
CONTROL) (SJC) (CONT'D)
Figure 20-63-3
EXAMPLE: TESTER
CONNECTION
Reservoir
WARNING
Hydraulic Pump the lift arms are secured by an approved lift arm
Out
In Hydraulic Control support device can allow the lift arms or attachment
Valve to fall and cause injury or death.
W-2059-0598
1
BH-196

Sample tester connection shown[Figure 20-63-3].
Start the engine and run at low idle RPM. Make sure the Page 10-10-1.)
tester, the hoses are connected wrong. With the hoses Raise the operator cab. (See Raising The Operator Cab
connected correctly, increase the engine speed to full on Page 10-30-1.)
RPM*.
Drain the hydraulic fluid from the reservoir. (See
Warm the fluid to 140°F. (60°C.) by turning the restrictor Replacing Hydraulic Fluid And Case Drain Filters on
control (Item 1) [Figure 20-63-3] on the tester to about Page 10-120-3.)
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free Open the rear door of the loader.
flow (GPM) at full RPM.
Remove the right rear tire. (See TIRE MAINTENANCE
Push the maximum/variable flow switch (on the remote on Page 10-170-1.)
start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control Remove the two right side access panels.
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI) Remove the Power Bob-Tach block if equipped. (See
and flow (GPM). The high pressure flow must be at least Removal And Installation on Page 20-110-1.)
80% of free flow.

%= X 100
FREE FLOW (GPM)


Removal And Installation (Cont’’d)
Figure 20-63-4
1
P-48150

P-48149

(37-50 Nm) torque.
Disconnect and cap the hose from the outlet fitting (Item
1) [Figure 20-63-4] of the hydraulic pump. Figure 20-63-7
Figure 20-63-5
1
2
1
1
P-48152
P-48151
At the bottom side of the gear pump, remove the two
pump bolts (Item 1) [Figure 20-63-7] from pump support
Disconnect the two inlet hoses (Item 1) [Figure 20-63-5] bracket.
from the front of the hydraulic pump.
Remove the pump support bracket (Item 2) [Figure 20-
63-7] from the loader.
Remove the hydraulic pump from the hydrostatic pump

[Figure 20-63-7].
Remove the O-ring (Item 1) from the hydraulic gear

pump.
Installation: Use a new O-ring when installing the

hydraulic pump.
(See Disassembly And Assembly on Page 20-60-5.), for

the proper procedure.
HYDRAULIC PUMP (SELECTABLE JOYSTICK
Identification
12
13
13
12
3 11
8
7
9
10
5 7
4
1 3
1. Shaft Seal 2
2. Pump End Section
3. Pre-Load Seal
4. Load Seal
5. Section Seal
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Pump Center Section
11. Pump End Section
12. Bolts (4)
13. Bolts (4) B-22285

IMPORTANT 1

clean the work area before disasembly and keep all
damage the system.
I-2003-0888
P-48187
Figure 20-63-8
Set the pump on end, and remove the pump end section
(Item 1) [Figure 20-63-9] from the charge pump.
Figure 20-63-10
1
1
1 1 1
P-48186
2
Mark the pump sections for correct assembly [Figure 20-

63-8]. P-48188
Remove the eight pump housing bolts (Item 2) [Figure

20-63-8]. Remove the wear plate (Item 1) and the section seal
(Item 2) [Figure 20-63-10].
Installation: Tighten the eight bolts (Item 1) [Figure 20-
63-8] to 45-50 ft.-lbs (60-67 Nm) torque.

Figure 20-63-11
4 1
2 P-39142
NOTE: Inspect the charge pump center section (Item

1) [Figure 20-63-13]. If excessive wear or
1
P-48189 damage is visible, the pump must be
replaced.
Inspect the wear plate (Item 1) and the section seal (Item Figure 20-63-14

1
Figure 20-63-12
P-48191

the pump.
P-48190
Remove the charge pump center section (Item 1) [Figure

20-63-12] from the auxillary pump.

Figure 20-63-15
1
P-48193

Figure 20-63-18
Figure 20-63-16 3
1
1
P-48194

[Figure 20-63-18] from the front section of the pump.
P-48192
from the front section of the pump.
the pump.

Figure 20-63-19
P-48196
1
from the front section of the pump.
P-39148
Figure 20-63-22
2)[Figure 20-63-19] and replace as needed.

Figure 20-63-20
1
2
P-39151
1
P-48195
Remove the load seal (Item 1) [Figure 20-63-20] from

the front section of the pump.

HYDRAULIC PUMP (SELECTABLE JOYSTICK
Figure 20-63-23
P-48197
Inspect the pump end section and bushings (Item 1)

Figure 20-63-24
P-48198
Replace the end section shaft seal (Item 1) [Figure 20-

63-24].

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE Warm the fluid to 140°F. (60°C.) by turning the restrictor
JOYSTICK CONTROL) (SJC) control clockwise on the tester so it reads about a 1000
PSI (69 bar).
Hydraulic Pump Test (30 GPM)
procedure: Turn the restrictor control (Item 2) [Figure 20-64-1] on
the tester counterclockwise to obtain free flow, the flow
MEL10103 - Hydraulic Tester should be at 20 GPM. Start turning the restrictor
should drop off slightly until the pressure reaches
NOTE: Machines with S/N 525815599 & Below or S/N approximately 2800 PSI. At approximately 2800 PSI the
526016699 & Below with the high flow option flow should start decreasing rapidly until the pressure
will have the (30 GPM). reaches 3250-3300 PSI. At 3250-3300 PSI the flow
should be at 0 GPM. Turn the restrictor (Item 2) [Figure
Machines with S/N 525815600 & Above or S/N 20-64-1] counter clockwise to free flow. Shut the front
526016700 & Above with the high flow option auxiliary hydraulics off.
will have the (40 GPM).
If flow and pressure specs are not obtained, go to the
Figure 20-64-1 Inline Standard Hydraulic Pump Test. (See Inline
1 Hydraulic Pump Test (Standard) on Page 20-64-3.) If
flow and pressure specs are obtained continue on to the

next paragraph.
RPM*.

2 control on the tester to about 1000 PSI (69 bar).

P-16903 P-37687

NOTE: When testing the hydraulic flow of a machine the tester counter clockwise, to obtain free flow, the flow
hoses must be at least 3/4 inch in diameter should be at 20 GPM. Press the High Flow button. The
and connected directly to the hydraulic tester flow should increase to 30 GPM. Start turning the
without using any type of “quick coupler” on restrictor clockwise, causing more restriction on the flow.
the connection to the tester. Also make sure The GPM should drop off slightly until the pressure
your hydraulic tester is capable of at least 50 reaches approximately 3100 PSI. At approximately 3100
GPM. PSI the flow should start decreasing rapidly until the
pressure reaches 3250-3350 PSI. At 3250-3350 PSI the
Install a hydraulic tester (Item 1) [Figure 20-64-1] onto flow should be at 0 GPM. Turn the restrictor control (Item
the front auxiliary quick couplers. 2) [Figure 20-64-1] counter clockwise to free flow. Shut
operator running the tester. If the specs from above are reached, the high flow
trigger on the right handle. Make sure the tester is If the flow and pressure were not obtained, go to the
connected correctly. If no flow is indicated on the tester, Inline High Flow Hydraulic Pump Test (See Inline
the hoses are connected wrong. With the hoses Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)
connected correctly, increase the engine speed to full on Page 20-64-5.)
RPM.

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE Warm the fluid to 140°F. (60°C.) by turning the restrictor
JOYSTICK CONTROL) (SJC) (CONT’D) control clockwise on the tester so it reads about a 1000
PSI (69 bar).
Hydraulic Pump Test (40 GPM)
procedure: Turn the restrictor control (Item 2) [Figure 20-64-2] on
the tester counterclockwise to obtain free flow, the flow
should be at 20 GPM. Start turning the restrictor
MEL10106 - Hydraulic Test Kit clockwise, causing more restriction on the flow. The GPM
should drop off slightly until the pressure reaches
NOTE: Machines with S/N (525815599 & Below) or (S/ approximately 2800 PSI. At approximately 2800 PSI the
N 526016699 & Below) with the high flow flow should start decreasing rapidly until the pressure
option will have the (30 GPM). reaches 3250-3300 PSI. At 3250-3300 PSI the flow
should be at 0 GPM. Turn the restrictor (Item 2) [Figure
Machines with (S/N 525815600 & Above) or (S/ 20-64-2] counter clockwise to free flow. Shut the front
N 526016700 & Above) with the high flow auxiliary hydraulics off.
option will have the (40 GPM).
1 Hydraulic Pump Test (Standard) on Page 20-64-3.) If
flow and pressure specs are obtained continue on to the
next paragraph.
RPM*.

2

P-16903 P-37687

NOTE: When testing the hydraulic flow of a machine the tester counter clockwise, to obtain free flow, the flow
hoses must be at least 3/4 inch in diameter should be at 20 GPM. Press the High Flow button. The
and connected directly to the hydraulic tester flow should increase to 40.5 GPM. Start turning the
without using any type of “quick coupler” on restrictor clockwise, causing more restriction on the flow.
the connection to the tester. Also make sure The GPM should drop off slightly until the pressure
your hydraulic tester is capable of at least 50 reaches approximately 3100 PSI. At approximately 3100
GPM. PSI the flow should start decreasing rapidly until the
pressure reaches 3250-3350 PSI. At 3250-3350 PSI the
the front auxiliary quick couplers. flow should be at 0 GPM. Turn the restrictor control (Item
2) [Figure 20-64-2] counter clockwise to free flow. Shut
This procedure will require a operator in the cab and one the front auxiliary hydraulics off.
Start the engine and run at low idle RPM. Press the Front hydraulic pump is OK.
trigger on the right handle. Make sure the tester is If the flow and pressure were not obtained, go to the
connected correctly. If no flow is indicated on the tester, Inline High Flow Hydraulic Pump Test (See Inline
the hoses are connected wrong. With the hoses Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)
on Page 20-64-5.)
RPM.

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE Figure 20-64-3
JOYSTICK CONTROL) (SJC) (CONT’D)
Inline Hydraulic Pump Test (Standard)

2
procedure:

MEL10106 - Hydraulic Test Kit 1
WARNING
Put jackstands under the front axles and rear corners P-43930

At the control valve, disconnect the standard (auxiliary)
W-2017-0286
pump OUTLET hose (Item 1) [Figure 20-64-3] from the
tubeline.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-64-4
1.)

WARNING
to fall and cause injury or death. P-34851
W-2059-0598
NOTE: When testing the hydraulic flow of a machine

Raise the operator cab. (See Raising The Operator Cab hoses must be at least 3/4 inch in diameter
on Page 10-30-1.) and connected directly to the hydraulic tester
your hydraulic tester is capable of at least 50
GPM.

20-64-4] from the tester to the tubeline (Item 2) [Figure
20-64-3] which goes to the control valve.
Lower the cab down.

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE Record the flow (GPM) at 2700 PSI, this is the high
JOYSTICK CONTROL) (SJC) (CONT’D) pressure flow. The high pressure flow must be at least
80% of free flow.
Inline Hydraulic Pump Test (Standard) (Cont'd)
%= X 100
FREE FLOW (GPM)
IMPORTANT A low percentage may indicate a failed pump.

I-2024-0284 system relief pressure and full RPM.
Figure 20-64-5
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve
BH-196

RPM*.

control (Item 1) [Figure 20-64-5] on the tester clockwise

(GPM) at full RPM.

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE Raise the operator cab. (See Raising The Operator Cab
JOYSTICK CONTROL) (SJC) (CONT’D) on Page 10-30-1.)
Inline Hydraulic Pump Test (High Flow) (30 GPM And Figure 20-64-7
40 GPM)

procedure:

1
WARNING
Put jackstands under the front axles and rear corners 2
Failure to use jackstands can allow the machine to P-43954
W-2017-0286
Remove the left side access cover.

1.)
[Figure 20-64-7] from the fitting (Item 2) [Figure 20-64-
7] on the tubeline.
Figure 20-64-6
1 Figure 20-64-8
2 1
P-34847
Install a jumper hose (Item 1) [Figure 20-64-6] onto the

front auxiliary quick couplers.
P-34851

support device. (See Installing The Lift Arm Support NOTE: When testing the hydraulic flow of a machine
Device on Page 10-20-1.) hoses must be at least 3/4 inch in diameter
WARNING your hydraulic tester is capable of at least 50
GPM.
Never work on a machine with the lift arms up unless Connect the INLET hose (Item 1) [Figure 20-64-8] from
the lift arms are secured by an approved lift arm the tester to the OUTLET hose (Item 1) [Figure 20-64-7]
support device. Failure to use an approved lift arm of the pump. Connect the OUTLET hose (Item 2) [Figure
support device can allow the lift arms or attachment 20-64-8] from the tester to the fitting (Item 2) [Figure 20-
64-7] on the tubeline.
W-2059-0598
Lower the cab down.

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE Turn the restrictor control clockwise on the tester to 3300
JOYSTICK CONTROL) (SJC) (CONT’D) PSI and the flow should go to zero GPM. If the pressure
readings are not obtained go to the High Flow Relief
Inline Hydraulic Pump Test (High Flow) (30 GPM And Pump Adjustment (See High Flow Relief Adjustment
40 GPM) (Cont’d) Procedure (30 GPM And 40 GPM) on Page 20-64-7.) If
the pressure readings are correct, continue on to the next
paragraph.
IMPORTANT Open the restrictor control and record the free flow
(GPM) at full RPM.
Record the flow (GPM) at 2500 PSI, this is the high
I-2024-0284
80% of free flow.
Figure 20-64-9 HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
EXAMPLE: TESTER
CONNECTION
Reservoir A low percentage may indicate a failed pump.
Hydraulic Pump
Valve
BH-196

speed to full RPM*.

control (Item 1) [Figure 20-64-9] clockwise on the tester
to about 1000 PSI (6895 kPa).


40 GPM)

procedure:
1
WARNING
2

P-43954
W-2017-0286 Remove the left side access cover.

1.) from the fitting (Item 2) [Figure 20-64-11] on the tubeline.
Remove the right rear tire. Figure 20-64-12

Figure 20-64-10
2
1
P-34851
P-34847
NOTE: When testing the hydraulic flow of a machine

Install a jumper hose (Item 1) [Figure 20-64-10] onto the front hoses must be at least 3/4 inch in diameter
auxiliary quick couplers. and connected directly to the hydraulic tester
Raise the lift arms and install an approved lift arm without using any type of “quick coupler” on
support device. (See Installing The Lift Arm Support the connection to the tester. Also make sure
Device on Page 10-20-1.) your hydraulic tester is capable of at least 50
GPM.

WARNING the tester to the OUTLET hose (Item 1) [Figure 20-64-
11] of the pump. Connect the OUTLET hose (Item 2)
[Figure 20-64-12] from the tester to the tubeline (Item 2)
Never work on a machine with the lift arms up unless [Figure 20-64-11] at the control valve.
Lower the cab down.
W-2059-0598


40 GPM) (Cont’d)
Figure 20-64-13
1 1
1 P-45445
2 sure the tester is connected correctly. If no flow is
P-45457
Remove the six access cover mounting bolts (Item 1) and speed to full RPM.
the cover (Item 2) [Figure 20-64-13] from the frame.
Figure 20-64-14 control clockwise on the tester to about 1000 PSI (6895
kPa).
Turn the restrictor control clockwise on the tester to

P-45443 causing more restriction on the flow. The GPM should
drop off slightly until the pressure reaches approximately
3100 PSI. At approximately 3100 PSI the flow should
start decreasing rapidly until the pressure reaches 3250-
3350 PSI. At 3250-3350 PSI the flow should be at 0
GPM. Turn the restrictor counter clockwise to free flow.
Shut the front auxiliary hydraulics off.
If the specs from above are reached, the pump is OK.

1 If the pump is unable to reach 3300 PSI stop the engine.
P-45443
The relief screw (Item 1) [Figure 20-64-15] will need to
be turned clockwise a 1/4 turn and retested with the
procedure above. (1/4 turn equals approximately 200
PSI.)
Remove the cap (Item 1) [Figure 20-64-14] from the
pump. NOTE: If the relief screw has been turned in 1/4 turn
and the pressure remains the same, go to the
This procedure will require a operator in the cab and one relief valve removal and installation section.
operator running the tester. (See Removal And Installation on Page 20-30-
4.) If relief valve has been checked and is OK,
go to the high flow pump disassembly and
assembly section. (See Disassembly And
Assembly (30 GPM And 40 GPM) on Page 20-
64-15.)
If the pump reaches 3300 PSI and there is flow stop the
engine. The relief screw must be turned counter
clockwise 1/4 turn and retested with the procedure
above.

High Flow Relief Valve Removal And Installation (30

GPM And 40 GPM)
1
WARNING 1
1
W-2017-0286
2 P-45457

1.) Remove the six access cover mount bolts (Item 1) and
the access cover (Item 2) [Figure 20-64-17] from the
Remove the right rear tire. frame.
Figure 20-64-16 Figure 20-64-18
P-34847 P-45443
Install a jumper hose (Item 1) [Figure 20-64-16] onto the Remove the relief valve (Item 1) [Figure 20-64-18] from
front auxiliary quick couplers. the pump.
Raise the lift arms and install an approved lift arm Installation: Tighten the relief valve to 30-35 ft.-lbs. (41-
support device. (See Installing The Lift Arm Support 47 Nm) torque.
WARNING
W-2059-0598

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE
High Flow Relief Valve Removal And Installation (30

GPM And 40 GPM) (Cont’d)
Figure 20-64-19
1 1
P-45459
If the relief valve is bad, it must be replaced as a

complete unit.
Figure 20-64-20
P-45469
Inspect the o-ring (Item 1) [Figure 20-64-20] on the plug

for damage and replace as needed.

P-48153
WARNING
At the back side of the gear pump, disconnect and cap
Never work on a machine with the lift arms up unless the hose from the outlet fitting (Item 1) of the standard
the lift arms are secured by an approved lift arm flow pump. Disconnect and cap the hose from the High
support device. Failure to use an approved lift arm Flow pump outlet fitting (Item 2) [Figure 20-64-21].
to fall and cause injury or death. Figure 20-64-22
W-2059-0598

1

Page 10-10-1.)
1
on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See P-48154
Replacing Hydraulic Fluid And Case Drain Filters on

Page 10-120-3.)
At the front side of the gear pump, disconnect and cap
the three hoses (Item 1) [Figure 20-64-22] from the inlet
fitting of the hydraulic pump.
Remove the hoses from the Power Bob-Tach block. (If so
equipped.) (See POWER BOB-TACH BLOCK on Page
20-110-1.)


(Cont’d)
Figure 20-64-23
1
1
1
P-48155
1

P-26640 Installation: Tighten the mounting bolts to 27-37 ft.-lbs.
(37-50 Nm) torque.
NOTE: Machines with (S/N 525815600 and Above) or Figure 20-64-26

(S/N 526016700 and Above) will have a dual
inlet gear pump (40 GPM). Machines below the
serial number will have a single inlet gear
pump (30 GPM).
At the front side of the gear pump, loosen the clamps

(Item 1) [Figure 20-64-23] and disconnect the two pump
inlet hoses.
Figure 20-64-24
1
1
P-48156
At the bottom side of the gear pump, remove the two

1
pump bolts (Item 1) [Figure 20-64-26] from pump
support bracket.
Remove the pump support bracket (Item 2) [Figure 20-

64-26] from the loader.
P-43958 Remove the hydraulic pump from the hydrostatic pump.
Remove the O-ring from the hydraulic gear pump.

At the right side access hole, disconnect the electrical
connector (Item 1) [Figure 20-64-24] from the high flow Installation: Use a new O-ring when installing the
pump solenoid. hydraulic pump.
(See Disassembly And Assembly (30 GPM And 40 GPM)

on Page 20-64-15.) for the proper procedure.

Identification (30 GPM) (S/N 525815599 & Below) (S/N
526016699 & Below)
1. Seal
2. Auxliliary Pump End Section
3. Pre-Load Seal
4. Load Seal 19
5. Section Seal
6. Wear Plate
7. Pin
20 17
10. Pump Center Section (Auxiliary Pump) 21 18
12. Spline Shaft 22
13. Drive Gear (HI-Flow Pump)
7 13
15. Pump Center Section (Hi-Flow Pump)
12
17
3 22 16
6
21
6
14 15
5 3 7 20
4
23
24
25
8
7
3 11
17. Bolt (4) 6
18. Bolt (4)
9 10
19. Relief Valve 7
5 6
20. O-Ring 4
21. O-Ring 1 3
22. Back-up Washer
23. Valve 2
24. Coil
25. Nut B-22284

Identification (40 GPM) (S/N 525815600 & Above) (S/N
526016700 & Above)
1. Seal
2. Auxliliary Pump End Section
3. Pre-Load Seal
4. Load Seal 19
5. Section Seal
6. Wear Plate
7. Pin
20 17
10. Pump Center Section (Auxiliary Pump) 21 18
12. Spline Shaft 22
13. Drive Gear (HI-Flow Pump)
7 13
15. Pump Center Section (Hi-Flow Pump)
12
17
3 22 16
6
21
6
14 15
5 3 7 20
4
23
24
25
8
7
3 11
17. Bolt (4) 6
18. Bolt (4)
9 10
19. Relief Valve 7
5 6
20. O-Ring 4
21. O-Ring 1 3
22. Back-up Washer
23. Valve 2
24. Coil
25. Nut B-22284A


1
Mark the pump sections for correct assembly.
NOTE: Disassembly and Assembly procedure is the

same for both gear pumps (30 GPM and 40
GPM).
The visual difference between the two gear

pumps is one pump has a dual inlet pump (40
GPM) and one pump has a single inlet pump
(30 GPM).
P-48218
IMPORTANT Remove the valve cartridge (Item 1) [Figure 20-64-28].
Installation: Tighten the solenoid valve to 35-40 ft.-lbs

(47-54 Nm).
parts clean. Always use caps and plugs on hoses, Figure 20-64-29
damage the system.
I-2003-0888
Figure 20-64-27
1
2
2
1
P-45462
Inspect the o-ring (Item 1) [Figure 20-64-29] and replace

as needed.
P-48217
Inspect the o-ring and back-up ring (Item 2) [Figure 20-
64-29] and replace as needed.
Installation: Tighten the solenoid nut to 48-72 in lbs (5-8

Nm)


(Cont'd)
Figure 20-64-30
1
1 2 P-45469
Inspect the o-ring (Item 1) [Figure 20-64-32] on the relief

valve adjustment plug for damage and replace as
needed.
P-45470
Figure 20-64-33
NOTE: Mark the pump housing (Item 1) [Figure 20-64-

30] for proper installation of the relief valve.

the pump
Installation: Tighten the relief valve to 30-35 ft.-lbs (41-

47 Nm) torque.
Figure 20-64-31
1
1
1 P-48219
Mark the pump sections for proper installation.

2 Remove the eight bolts (Item 1) [Figure 20-64-33].
Installation: Tighten the assembly bolts to 45-50 ft.-lbs

(60-67 Nm).
P-45459
1) and back-up washer (Item 2)[Figure 20-64-31].


(Cont'd)
1
Figure 20-64-34
P-48202
Remove the Hi-flow pump center section (Item 1) [Figure

20-64-36] & [Figure 20-64-37] from the pump.
P-48200 Figure 20-64-37

[Figure 20-64-34] from the Hi-flow pump end section.
Figure 20-64-35 1
P-48203
1
3 NOTE: Inspect the Hi-flow pump center section (Item
2 1) [Figure 20-64-37]. If excessive wear or
P-48201 replaced.

toward gears.
NOTE: Inspect the Hi-flow pump end section (Item 3)

and bushings (Item 4) [Figure 20-64-35]. If


(Cont'd)
Figure 20-64-38
1
1
P-48206
Remove the drive gear (Item 1) [Figure 20-64-40] &

[Figure 20-64-41].
P-48204 Figure 20-64-41

[Figure 20-64-39].
Figure 20-64-39
1
P-48207

P-48205



(Cont'd)
Figure 20-64-42
1
P-48210
2
Figure 20-64-45
P-48208

64-42] & [Figure 20-64-43] from the pump center
section.
Figure 20-64-43
P-48211
1
2 Remove the pre-load seal (Item 1) [Figure 20-64-45].
Figure 20-64-46
P-48209

toward gears.
P-39151
Inspect both seals [Figure 20-64-46].


(Cont'd) 3
4
Figure 20-64-47
2 1
P-48214

toward gears.
P-48212
Remove the pump center section (Item 1) [Figure 20-64- excessive wear or damage is visible, the
47] from the pump sections. pump must be replaced.
Figure 20-64-48 Figure 20-64-50
1
2 1
P-48213
P-48215
Remove the wear plate (Item 1) [Figure 20-64-48] & Remove the spline shaft (Item 1) [Figure 20-64-50].
64-48] & [Figure 20-64-49] from the pump section. Remove the auxilliary pump center section (Item 2)
[Figure 20-64-50] from the pump.


(Cont'd)
Figure 20-64-51
P-39144
1 NOTE: Inspect the idler gear (Item 1) [Figure 20-64-

P-39142
Figure 20-64-54
NOTE: Inspect the auxilliary pump center section

(Item 1) [Figure 20-64-51]. If excessive wear or
replaced.
1
Figure 20-64-52
P-48220

the auxilliary pump.
P-48216

the auxilliary pump.


(Cont'd)
Figure 20-64-55
P-39148
1 Inspect the wear plate (Item 1) and the section seal (Item
P-48221 NOTE: Position the wear plate (Item 1) [Figure 20-64-
55]. If excessive wear or damage is visible, the Figure 20-64-58
Figure 20-64-56
3 1
2
P-48223
P-48222 Remove the load seal (Item 1) [Figure 20-64-58] from

the front section of the auxilliary pump.

[Figure 20-64-56] from the front section of the auxilliary
pump.

from the front section of the auxilliary pump.


(Cont'd)
Figure 20-64-59
P-48197
1
Inspect the pump end section and bushings (Item 1)

P-48224
Figure 20-64-62
Remove the pre-load seal (Item 1) [Figure 20-64-59]

from the front section of the auxilliary pump.
Figure 20-64-60
1
P-48225
2
Remove and replace the pump end section shaft seal
(Item 1) [Figure 20-64-62].
P-39151

HYDRAULIC/HYDROSTATIC FILTER Figure 20-70-2
Housing Removal And Installation
WARNING P-37095
Never work on a machine with the lift arms up unless Loosen the nut (Item 1) [Figure 20-70-2], and remove
the lift arms are secured by an approved lift arm the electrical wire from the filter housing.
support device can allow the lift arms or attachment Figure 20-70-3
W-2059-0598
Figure 20-70-1
1
1
2 P-37096
Remove the hose clamp (Item 1) [Figure 20-70-3].
P-37094 Remove the hose from the filter housing fitting.


on Page 10-30-1.)

70-1] from the filter sender.
Loosen the nut (Item 2) [Figure 20-70-1] and disconnect

the tubeline from the filter block.

HYDRAULIC/HYDROSTATIC FILTER (CONT’D)
Housing Removal And Installation
Figure 20-70-4
P-37097
Remove the four mounting bolts (Item 1) [Figure 20-70-
4].
Installation; Tighten the mount bolts to 25 ft.-lbs (34 Nm)

torque.
Remove the filter assembly from the loader.
Mount Removal And Installation
Figure 20-70-5
N-19609
Remove the two filter bracket mount bolts (Item 1)

[Figure 20-70-5].
Remove the bracket from the loader.

HYDRAULIC FLUID RESERVOIR Remove the hose end cap and drain fluid into a
container.
Fluid Removal


on Page 10-30-1.)
Drain the fluid from the reservoir.
WARNING
on Page 50-100-1.)
Remove bucket position valve. (If so equipped.) (See

Always clean up spilled fuel or oil. Keep heat, flames, Removal And Installation on Page 20-90-2.)
Failure to use care around combustibles can cause Figure 20-80-2

W-2103-1295
1
WARNING
W-2059-0598
P-34063
Figure 20-80-1
from the bucket positon valve mount plate. (If so
equipped.)
Remove the mount plate from the loader. (If so

equipped.)
P-31286
Remove the left side motor cover from the loader frame.
Pull the reservoir drain hose (Item 1) [Figure 20-80-1]

out of the side of the loader frame.

HYDRAULIC FLUID RESERVOIR (CONT'D) Figure 20-80-5
Figure 20-80-3
1
P-34066
Remove the lift pedal linkage mount bolt (Item 1) [Figure

P-34064 20-80-5].
Figure 20-80-6
Loosen the two hose clamps (Item 1) [Figure 20-80-3]
and remove the reservoir fill hose.
Figure 20-80-4
P-34067
2
Remove the crossbar pivot bolt (Item 1) [Figure 20-80-
P-34065 6].
Disconnect the wiring harness connector (Item 1) [Figure

20-80-4]

from the reservoir. Cap the hose and plug the fitting on
the reservoir.

Figure 20-80-7
1
1
P-34070
Rremove the two mount bolts (Item 1) [Figure 20-80-9]

P-34068 from the side panel.
Remove the side panel from the loader.

Remove the linkage pin (Item 1) [Figure 20-80-7] from
the tilt linkage bar, and remove the linkage bar from the Figure 20-80-10
control valve lift spool.
Remove the hairpin clip from the crossmember pin.
Remove the crossmember and lift linkage bar from the

1
pivot, and the loader.
Figure 20-80-8
P-34071
1 Remove the sta-strap (Item 1) [Figure 20-80-10] from

the electrical harness.
Remove the lift tubline (Item 2) [Figure 20-80-10].
P-34069
At the left fender, remove the two mount bolts (Item 1)

[Figure 20-80-8] from the front reservoir mount bracket.
Remove the mount bracket from the loader.

Figure 20-80-11
1 1
P-34072
Remove the drain hose and fitting (Item 1) [Figure 20-

P-34074 80-13] from the bottom of the reservoir
Remove the hydraulic reservoir from the loader.
Remove the hose clamp (Item 1) [Figure 20-80-11] and
remove the inlet hose from the pump fitting. Hydraulic Fluid Screen
NOTE: Removing the inlet hose from the pump Figure 20-80-14
allows the reservoir to be move forward so the
hose clamp and hose can be remove from the
bottom of the reservoir through the left side
motor cover hole.
2
Figure 20-80-12
1
N-19610

on Page 10-30-1.)
P-34073 Remove the two hose clamps (Item 1) [Figure 20-80-14]

and remove the hydraulic fill hose (Item 2) [Figure 20-80-
14] from the hydraulic reservoir.
Slide the reservoir ahead. At the left motor access hole
remove the hose clamp and hose (Item 1) [Figure 20-
80-12] from the bottom of the reservoir.

HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen (Cont’d)
Figure 20-80-15
N-17718A
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-15] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

BUCKET POSITION VALVE Figure 20-90-3
Solenoid Removal And Installation
2 1
Figure 20-90-1
P-26912
Inspect the solenoid stem and replace the O-rings (Item

P-34204 1) [Figure 20-90-3] and the back-up washer (Item 2)
[Figure 20-90-3].
Disconnect the wire harness connector (Item 1) [Figure Solenoid Testing

20-90-1] from the bucket position solenoid.
Figure 20-90-4
Installation: Tighten the solenoid nut to 60 in.-lbs. (6,78

Nm) torque.
Figure 20-90-2
1
2
P9175

90-4]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
P-34205 other coils 5-8 ohms.
Move the solenoid until it touches the tubeline (Item 1) and hear the spool shift.
[Figure 20-90-2].
Remove the solenoid stem and solenoid (Item 2) [Figure

20-90-2] from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30-35 ft.-lbs. (40,8-47,6 Nm)
torque.

BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly
Removal And Installation Figure 20-90-7
Figure 20-90-5
2
N-19069
P-34204
Disconnect the electrical harness (Item 1) [Figure 20-90- Installation: Tighten the nut to 60 in.-lbs. (6,78 Nm)
5]. torque.
Disconnect the two tubelines (Item 2) [Figure 20-90-5]. Figure 20-90-8
Figure 20-90-6
1
1
1 N-19070
P-34206
Remove the solenoid (Item 1) [Figure 20-90-8] and the
solenoid stem (Item 2) [Figure 20-90-8].
Disconnect the three tubelines (Item 1) [Figure 20-90-6]
from the long tee fitting. Installation: Tighen the solenoid stem to 30-35 ft.-lbs.
(40,8-47,6 Nm) torque.
Remove the mounting bolts (Item 2) [Figure 20-90-6]
from the bucket position valve.

BUCKET POSITION VALVE (CONT'D) Figure 20-90-11
Disassembly And Assembly (Cont’d)
Figure 20-90-9
N-18339
1
Remove the plug (Item 1) [Figure 20-90-11], and flow
N-19072 control spool (Item 2) [Figure 20-90-11].
Check the flow control spool for wear, check the O-ring
Remove the flow adjustment valve and O-ring (Item 1) on the plug and replace as needed.
[Figure 20-90-9]
Figure 20-90-12
NOTE: Always install new O-rings before any parts
are installed into the valve. Check the parts
for wear or damage and replace as needed.
Figure 20-90-10
3
N-19042
Remove the tilt cylinder check valve (Item 1) [Figure 20-

1 90-12] spring (Item 2) [Figure 20-90-12] and plug (Item
N-19041 3) [Figure 20-90-12]. Check for wear, check the O-ring
and replace as needed.
Remove the plug (Item 1) [Figure 20-90-10].

BUCKET POSITION VALVE (CONT'D)
Figure 20-90-13
N-19045
Remove the plug [Figure 20-90-13].
Figure 20-90-14
1
N-19046
Remove the plug (Item 1) [Figure 20-90-14], spring (Item

2) [Figure 20-90-14] and unloading spool (Item 3)
[Figure 20-90-14].
Check all parts and replace as needed. Install a new O-

ring on the plug before installing.

REAR AUXILIARY DIVERTER Figure 20-100-3
Removal and Installation
Figure 20-100-1
2
1
1
P-43678
1

P-43683 base end fitting.

Remove the two access cover mount bolts (Item 1) rod end fitting.
[Figure 20-100-1] from the right side acces cover.
Remove the access cover. Disconnect the hose (Item 3) [Figure 20-100-3] from the
pressure outlet fitting.
Mark all wires and hoses for proper installation.
Cap and plug all fittings and hoses.
Figure 20-100-2
Figure 20-100-4
1
P-43681
P-43711
Disconnect the four electrical connectors (Item 1) [Figure

20-100-2] from the diverter solenoids. Disconnect the hose (Item 1) [Figure 20-100-4] from the
pressure inlet fitting.

REAR AUXILIARY DIVERTER (CONT’D) Figure 20-100-7
Removal and Installation (Cont’d)
Figure 20-100-5
1 P-43708

P-43711 from the block.
Remove the diverter valve from the loader.
pressure in fitting.
Figure 20-100-6
P-43693

fitting that goes to tank.

REAR AUXILIARY DIVERTER VALVE (CONT'D)

IMPORTANT
Figure 20-100-8
damage the system.
I-2003-0888
Figure 20-100-10
1
1
1
P-48751
Figure 20-100-9
1 P-48755
Figure 20-100-11
2 2 2
P-48752
1
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-100-8] & [Figure 20-

100-9] are located all over the diverter valve and can be
P-48756
removed for cleanout purposes.
Installation: Put oil on O-rings and back-up Remove the shuttle valve (Item 1) [Figure 20-100-10] &
washers.Tighten to 10 ft.-lbs. (13,6 Nm) torque. [Figure 20-100-11] from diverter valve and inspect the
O-rings and back-up washers (Item 2) [Figure 20-100-
11] for damage.
Installation: Put oil on the O-rings and back-up washers.

Tighten to 10-12 ft.-lbs. (14-16 Nm) torque.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-100-14
Figure 20-100-12
P-48753
1
Figure 20-100-15
P-48755
Figure 20-100-13 1
2
2
2
1
P-48754
Remove the relief valve (Item 1) [Figure 20-100-14] &

P-48757 [Figure 20-100-15] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20-
100-15] for damage.
Remove the differential sensing valve (Item 1) [Figure
20-100-12] & [Figure 20-100-13] from diverter valve and Installation: Put oil on O-ring and back-up washers.
inspect the O-rings and back-up washers (Item 2) Tighten to 20-25 ft.-lbs. (27-34 Nm) torque.
[Figure 20-100-13] for damage.
Installation: Put oil on O-ring and back-up washers.


Figure 20-100-16
1
P-48761
NOTE: Before removing the solenoid coils mark the

P-48759 coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-100-18] from the

Figure 20-100-17 solenoid valve stems.

torque.
1
2
P-48760
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nut (Item 1) [Figure 20-100-16] & [Figure

20-100-17] from the solenoid valve stem.

torque.
Remove the spacer (Item 2) and solenoid valve coils

(Item 3) [Figure 20-100-17].

Figure 20-100-19 1
P-48763A
Figure 20-100-22
P-48762
Figure 20-100-20
1 2
2 2
1 1 P-48764
Remove the solenoid valve stem (Item 1) [Figure 20-

P-48763 100-21] & [Figure 20-100-22] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-100-22] for
damage.
Remove the solenoid valve stem (Item 1) [Figure 20-
100-19] & [Figure 20-100-20] and inspect the O-rings Installation: Put oil on O-rings and back-up washers.
and back-up washers (Item 2) [Figure 20-100-20] for Tighten to 30-35 ft.-lbs. (41-47 Nm) torque.
damage.
Installation: Put oil on O-rings and back-up washers.


Figure 20-100-23
P-48765

P-48765
Installation: Tighten the plug to 10 ft.-lbs. (13,6 Nm)
torque.
Figure 20-100-26
Installation: Tighten the plug to 38 ft.-lbs. (51,5 Nm)
torque.
Figure 20-100-24
P-48786
1 Remove the orifice (Item 1) [Figure 20-100-26].

P-48766
Installation: Tighten the orifice to 3.3 ft.-lbs. (4,5 Nm)
torque.
Remove and inspect the orifice (Item 1) [Figure 20-100-
24] for dirt and debris.
Installation: Tighten the orifice to 22 ft.-lbs. (29,8 Nm)

torque.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Solenoid Testing
Disassembly And Assembly (Cont'd) Figure 20-100-28
Figure 20-100-27
P9137
P-48758
Remove the plugs (Item 1) [Figure 20-100-27]. resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.
Installation: Tighten the plug to 14 ft.-lbs. (19 Nm) Replace the test meter with 12 volt power. You can see
torque. and hear the spool shift.
Inspection
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.

POWER BOB-TACH BLOCK Raise the operator cab. ((See Raising The Operator Cab
on Page 10-30-1.)
WARNING Disconnect and cap the two electrical solenoid
connectors (Item 1) [Figure 20-110-1] from the loader
Never work on a machine with the lift arms up unless electrical harness.
Figure 20-110-2
to fall and cause injury or death. 1
W-2059-0598
2
2
2
P-48590
IMPORTANT Disconnect and cap the outlet hose (Item 1) [Figure 20-
110-2] from block.
clean the work area before disassembly and keep all Mark the hydraulic hoses for proper installation.
tubelines and ports to keep dirt out. Dirt can quickly Disconnect and cap the hose (Item 2) [Figure 20-110-2]
from block.
damage the system.
I-2003-0888 Figure 20-110-3
Figure 20-110-1
1
1
1 1
P-48591
P-26244
3].
1.) Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
(34-38 Nm) torque.
support device. (See Installing The Lift Arm Support Remove the power Bob-Tach block.

POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-5
Figure 20-110-4
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-110-5].
Check the O-ring (Item 4) [Figure 20-110-5] on the plug
Clean the block (Item 1) [Figure 20-110-4] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct
assembly. Figure 20-110-6
Installation: Tighten the plug to 25-30 ft.-lbs. (34-40,6

Nm) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-110-6].
Installation: Tighten the plug to 12-14 ft.-lbs. (16,3-19

Nm) torque.

Figure 20-110-7
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-110-9].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting

Remove the check valve (Item 1) [Figure 20-110-7]. will be altered.
Installation: Oil the check valve and O-rings and tighten Figure 20-110-10
the check valve to to 20-25 ft.-lbs. (27,1-34 Nm) torque.
Figure 20-110-8
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-110-10], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-110-
(Item 2) [Figure 20-110-8]. 10] to 12-14 ft.-lbs. (16,3-19 Nm) torque.
Check the O-rings and back up washers (Item 3) [Figure

20-110-8] on the check valve and piston assembly and
replace as needed.

Figure 20-110-11 3
2
1
P-48106
Remove the first solenoid coil (Item 1), spacer (Item 2)

P-48664 and the second solenoid coil (Item 3) [Figure 20-110-
13].
Remove the orifice screw (Item 2) located behind the NOTE: Remember the solenoid coil orientation for
plug (Item 1) [Figure 20-110-10]. ease of installation.
Installation: Tighten the orifice screw (Item 2) [Figure Figure 20-110-14

20-110-10] to 6-8 ft.-lbs. (8,1-10,8 Nm) torque.
Figure 20-110-12
1 1
P-48386
P-48127 Remove the the solenoid stem (Item 1) [Figure 20-110-

14].
NOTE: This plug is a zero leak plug and should not be Installation: Tighten the solenoid stem to to 20-25 ft.-lbs.
removed. If removed damage may occur and (27,1-34 Nm) torque.
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-110-12].
Installation: Tighten the solenoid valve stem nut to 15-

45 in.-lbs. (1,7-5,1 Nm) torque.

Figure 20-110-15
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-17].
Installation: Tighten the screened orifice plug to to 11-

Remove the armature rod assembly (Item 1) [Figure 20- 12 ft.-lbs. (14,9-16,3 Nm) torque.
110-15].
Figure 20-110-18
Figure 20-110-16
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 110-18] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
110-16].
Check the O-ring (Item 2) [Figure 20-110-18] and
NOTE: If the solenoid stem is damaged (Item 1) check replace as needed.
the armature assembly (Item 2) for damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-110-
16].

20-110-6
Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Removal and Installation Figure 20-120-2
IMPORTANT 1

clean the work area before disassembly and keep all 2
tubelines and ports to keep dirt out. Dirt can quickly 4
damage the system.
3
I-2003-0888
Figure 20-120-1
P-34661
2 Figure 20-120-3
6 2
4
5 3
P-31242
Disconnect the auxiliary hoses (Item 1) [Figure 20-120-

1] and drain hose (Item 2) [Figure 20-120-1] from the P-34760
coupler block.
Remove the two mounting bolts (Item 3) [Figure 20-120- Remove the male coupler (Item 1) [Figure 20-120-2] &
1]. [Figure 20-120-3].
Installation: Tighten the male coupler (Item 1) [Figure

20-120-2] & [Figure 20-120-3] to 59 ft.-lbs. (80 Nm)
Remove the drain coupler (Item 2) [Figure 20-120-2] &
[Figure 20-120-3].
Installation: Tighten the drain coupler (Item 2) [Figure

Remove the female coupler (Item 3) [Figure 20-120-2] &
[Figure 20-120-3].
Installation: Tighten the female coupler (Item 3) [Figure

Remove the fittings (Item 4) [Figure 20-120-2] & [Figure
20-120-3] check the O-rings (Item 5) [Figure 20-120-3]
Remove the springs (Item 6) [Figure 20-120-3].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-120-6
(CONT’D)

1
Figure 20-120-4
1
2
P-34665
Check the O-rings (Item 1) [Figure 20-120-6] back-up O-

rings (Item 2) [Figure 20-120-6] for damage and replace
P-34663 as needed.
Figure 20-120-7
Check the O-ring (Item 1) [Figure 20-120-4] for damage
1
Figure 20-120-5
P-34664
Check the O-rings (Item 1) [Figure 20-120-7] back-up O-

P-34701 rings (Item 2) [Figure 20-120-7] for damage and replace
as needed.
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-120-5] for damage and replace as
needed.

HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Setting Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 HYDROSTATIC
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 SYSTEM
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-2
Tensioner Pulley Tension Spring . . . . . . . . . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
HYDROSTATIC MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . 30-22-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-4
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK

CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23-3
HYDROSTATIC MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . 30-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-12
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Hydraulic Pump Removal And Installation. . . . . . . . . . . . . 30-40-8
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-4
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-40-3

HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) . . . . 30-41-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-39
Charge Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-25
Charge Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-26
Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-23
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-28
Hydrostatic Pump Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-35
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-13
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-11
Pump Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . 30-41-51
Pump Controller Removal And Installation . . . . . . . . . . . . . . . . . . . 30-41-1
Pump Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-48
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-18
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9
Shaft Seal And Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-21
Shaft Seal And Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . 30-41-19
System Check Relief Valves (High Pressure Relief, Charge Check & By-
Pass Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-15
HYDROSTATIC SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER (SEAL TO CONNECT) (STC) . . . . . . . . . . . . . . . . . . . . 30-60-1

Hydraulic Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . 30-60-1

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01)
UNLESS OTHERWISE SPECIFIED.

HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If the service code appears in the left instrument panel,

refer to the Electrical Service Manual for the probable
cause.
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.

HYDROSTATIC SYSTEM INFORMATION (CONT'D) The functions of the replenishing valves are:
Replenishing Valve Function 1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
IMPORTANT 30-10-1].
2. To keep high pressure fluid out of the low pressure

When repairing hydrostatic and hydraulic systems, side of the hydrostatic circuitry; Function 2 [Figure
clean the work area before disassembly and keep all 30-10-1].
damage the system.
I-2003-0888
Figure 30-10-1
CHARGE OIL
Valve Moves for Charge
FUNCTION 1 Oil Replacement
Valve Stays on Seat to

Hold High Pressure for Drive
FUNCTION 2 B-2804

HYDROSTATIC MOTOR Disconnect the high pressure hoses (Item 2) [Figure 30-
20-1].
Figure 30-20-2
1
1
1 2
1
1
1
WARNING
Never work on a machine with the lift arms up unless N-17876

Remove the ten mounting bolts (Item 1) [Figure 30-20-

2].
W-2059-0598
Installation: Tighten the mounting bolts to 110 ft.-lbs.
(149,2 Nm) torque.
Figure 30-20-1
NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
the cam ring to the motor, and do not have to
be removed, to remove the motor from the
loader.
1 Remove the motor/cam ring section from the loader.
Figure 30-20-3
2
N-17874
1

1.)

P5405

on Page 10-30-1.) Remove the piston/roller section (Item 1) [Figure 30-20-
3] from the loader, if it was not removed with the motor/
Remove the motor cover. cam ring.
Mark the hoses for correct installation.
To remove the motor carrier. (See Removal and
Disconnect the case drain hose (Item 1) [Figure 30-20- Installation on Page 30-22-1.)
1].

HYDROSTATIC MOTOR (CONT'D)
1. Distributor 16. Bolt

2. Spring 17. Plug
3. Seal 18. O-ring
4. O-ring 19. Spring
5. Plug 20. Shim
6. O-ring 21. Poppet
7. Spring 22. O-ring
8. Washer 23. Seal
9. Spool 24. O-ring
10. Spring 25. Seal
11. Rear Housing 26. O-ring
12. Plug 27. Cam 3
13. O-ring 28. Roller 3
14. O-ring 29. Piston 2
1
15. Stop Pin 30. Block
4
5
4 6
8 7
9
10
11
12
13
23
25
15
28
29 14
16
22 16
24 21
20
19
18
26
17
27
30
B-17125

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-6
Disassembly 1
Figure 30-20-4
N-17863
Remove the cam ring (Item 1) [Figure 30-20-6] from the

N-17861 motor housing.
Figure 30-20-7
Remove the piston/roller section (Item 1) [Figure 30-20-
4] from the motor. 1
Figure 30-20-5
N-17864
Remove the stop pin (Item 1) [Figure 30-20-7] from the

N-17860 rear motor housing.
Remove the two cam ring mounting bolts (Item 1)

[Figure 30-20-5].

HYDROSTATIC MOTOR (CONT'D) Remove the two O-rings, that are located under the
seals.
Disassembly (Cont'd)
Figure 30-20-10
IMPORTANT
1
damage the system.
I-2003-0888
1
Figure 30-20-8
N-17869
1 2
Remove the nine springs (Item 1) [Figure 30-20-10] from
the distributor.
Figure 30-20-11
N-17865
Use a brass drift punch, thru the stop pin hole (Item 1)
[Figure 30-20-8] to remove the distributor (Item 2)
[Figure 30-20-8].
1
Figure 30-20-9
N-17870
Remove the two seals (Item 1) [Figure 30-20-11] from

the distributor.
Remove the two O-rings, that are located under the

1 seals.
N-17866
Remove the two seals (Item 1) [Figure 30-20-9] from the

housing.

Figure 30-20-12
2 1
P5765
1 2 3 4
Apply low air pressure to each port in the cylinder block

N-17872 to remove the roller (Item 1) [Figure 30-20-14] and
piston/ring assembly (Item 2) [Figure 30-20-14].
Remove the plug (Item 1) [Figure 30-20-12] spring (Item NOTE: Put all the roller/piston assembly back in their
2) [Figure 30-20-12] shim (Item 3) [Figure 30-20-12] original position.
and poppet (Item 4) [Figure 30-20-12].
Inspection
Inspect all parts and replace as needed.
Figure 30-20-15
Figure 30-20-13
2 3 4 2 1
N-17870
N-17871
Clean all parts in clean solvent and use air pressure to

Remove the plug (Item 1) [Figure 30-20-13] springs dry them. DO NOT use cloth or paper because small
(Item 2) [Figure 30-20-13] spool (Item 3) [Figure 30-20- pieces of material can get into the system and cause
13] and washer (Item 4) [Figure 30-20-13]. damage.
Inspect all parts and replace as needed. Before the motor is assembled, check the following
items:
Check the distributor surface for scratches [Figure 30-

20-15].

HYDROSTATIC MOTOR (CONT'D) Assembly
Inspection (Cont'd)
Figure 30-20-16
IMPORTANT
damage the system.
I-2003-0888
Figure 30-20-18
P5753
2 1
Check the cam ring inside surface for wear and scratches
[Figure 30-20-16].
Figure 30-20-17
P5765
NOTE: Always use new O-rings and seals when

assembling the hydrostatic motor.
Install the roller (Item 1) [Figure 30-20-18] in the piston

(Item 2) [Figure 30-20-18].
Dip the roller/piston assembly into oil and install into the
bore in the cylinder.
P5759
Repeat for each roller/piston assembly.
Check the cylinder block surface for scratches [Figure
30-20-17].
Check all the roller/piston assembly for scratches and

wear [Figure 30-20-17].

Assembly (Cont'd)
Figure 30-20-19
1 2 3 1 4
N-17871
1
Install the spring (Item 1) [Figure 30-20-21] spool (Item
N-17870 2) [Figure 30-20-21] washer (Item 3) [Figure 30-20-21]
and spring into the rear housing.
Install new O-rings and seals (Item 1) [Figure 30-20-19] Replace the O-ring (Item 4) [Figure 30-20-21] on the
on the distributor. plug.
Figure 30-20-20 Install the plug into the rear housing and tighten to 18-22
ft-lbs. (25-30 Nm) torque.
Figure 30-20-22
N-17869
4 3 2 1
Put grease on the springs (Item 1) [Figure 30-20-20] to

N-17872
hold them in place.
Install the springs into the distributor. Install the poppet (Item 1) [Figure 30-20-22] the shim
(Item 2) [Figure 30-20-22] spring (Item 3) [Figure 30-20-
22] into the rear housing.
Replace the O-ring (Item 4) [Figure 30-20-22] on the

plug.
Install the plug into the rear housing and tighten to 9-11
ft-lbs. (12-15 Nm) torque.

Assembly (Cont'd)
Figure 30-20-23
N-17862
Lightly smear grease on the O-ring.

N-17866
Install he O-ring (Item 1) [Figure 30-20-25] on the rear
housing.
Install the two O-rings into the housing.
Figure 30-20-26
Install the two seals (Item 1) [Figure 30-20-23] into the
housing, over the top of the O-rings, with minimum
distortion.
Lightly smear grease over the seals.
Figure 30-20-24 1
2 3
N-17863
1
Install the cam ring (Item 1) [Figure 30-20-26] on the
rear housing and align the mounting bolt holes.
N-17868
Install the stop pin (Item 1) [Figure 30-20-24] and tighten

Install the distributor (Item 2) [Figure 30-20-24] into the

housing.
Align the distributor hole (Item 3) [Figure 30-20-24] with

the stop pin. When aligned correctly, the distributor can
be depressed slightly.

HYDROSTATIC MOTOR (CONT'D)
Assembly (Cont'd)
Figure 30-20-27
N-17860
Install the two cam ring mounting bolts (Item 1) [Figure

30-20-27] and tighten to 50 ft.-lbs. (67,8 Nm) torque.
Figure 30-20-28
N-17861
Install the piston/roller section (Item 1) [Figure 30-20-28]

in the motor.
Install the motor on the loader and tighten the mount

bolts to 110 ft.-lbs. (149,2 Nm) torque.
NOTE: Before operating the hydrostatic motor, make

sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS] brake locked,
engine running, stroke the steering lever until
oil comes out of the case drain port.

HYDROSTATIC MOTOR (TWO-SPEED) Remove the motor cover from the loader.
Removal And Installation Mark the hoses for correct installation.
Figure 30-21-2
WARNING 1
the lift arms are secured by an approved lift arm N-22484

to fall and cause injury or death. Disconnect the hydraulic hose (Item 1) [Figure 30-21-2]
W-2059-0598 that goes to the two-speed port on the two-speed/brake
block.
Figure 30-21-1 Disconnect the hydraulic hose (Item 2) [Figure 30-21-2]

that goes to the brake port on the two-speed/brake block.

that goes to the make-up port on the two-speed/brake
block.
Figure 30-21-3
1 1
1
N-22483

1.)

Device on Page 10-20-1.) N-22485

on Page 10-30-1.) Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]
that goes to the case drain filter.
Remove the motor cover mount bolts (Item 1) [Figure

30-21-1].

HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D) Figure 30-21-6
Figure 30-21-4
1
2
1
2
N-22487
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

N-22486 21-6] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold
Remove the hydraulic fitting (Item 1) [Figure 30-21-4] the cam ring to the motor and do not have to
from the motor. be remove for motor removal.
Remove the eight flange bolts (Item 2) [Figure 30-21-4] Remove the motor from the loader.
from the high pressure hoses on the motor.
Figure 30-21-7
Installation: Install the lower collar to the motor and
connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 25 ft.-lbs.
(34 Nm) torque.
Figure 30-21-5 1
N-22535

7] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lbs. (149
N-22488 Nm) torque.
Remove the hydraulic fitting (Item 1) [Figure 30-21-5]

from the motor.

HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D)
8
7
6
5
4
3
29
2 28
27 30
9
17
16 18 25
25 26
15
31
38
33
10
32
11 37
35 36
21 34
19
22 24
20 48
14
23
47
13 46
12 49
45
44
43
42
41
40
39
B-16392

Parts Identification (Cont’d)
Ref. Description
1. Motor
2. Distributor
3. Spring
4. Seal/O-ring
5. Seal/O-ring
6. Seal/O-ring
7. Seal/O-ring
8. Seal/O-ring
9. Bushing
10. Roller
11. Piston
12. Block
13. Cam
14. Quad Ring
15. Plug
16. O-ring
17. Locating Pin
18. Housing
19. Shim
20. O-ring
21. Poppet
22. Spring
23. Plug
24. Bolt
25. Spring
26. Spool
27. Washer
28. O-ring
29. Plug
30. Housing
31. Quad Ring
32. Snap Ring
33. Snap Ring
34. Spool
35. Spring
36. Washer
37. Quad Ring
38. Bolt
39. Shaft
40. Brake Disc-Outer
41. Brake Disc-Inner
42. Seal
43. Piston
44. O-ring
45. Washer
46. Washer
47. Gasket
48 Cover
49. Bolt

Disassembly
Figure 30-21-8 2
1 3
N-22491
Remove the cover plate from the brake housing.

N-22489
Remove the cover plate gasket (Item 1) [Figure 30-21-
10].
NOTE: Mark the motor, brake and motor carrier
housings for proper alignment for ease of Remove the disk spring washer (Item 2) [Figure 30-21-
assembly [Figure 30-21-8]. 10] and the disk spring (Item 3) [Figure 30-21-10] from
the brake housing.
Drain the oil from the motor casing.
NOTE: Mark the top side of the disk spring for proper
Figure 30-21-9 installation.
Figure 30-21-11
1
2
1
N-22490
N-22493
Remove the twelve mounting bolts (Item 1) [Figure 30-
21-9] from the brake cover plate.
Remove the piston from the brake housing (Item 1)
NOTE: Unscrew the bolts alternately, one turn at a [Figure 30-21-11].
time to release the preload on the end cap.
NOTE: The use of air pressure through the brake line
connection (Item 2) [Figure 30-21-11] will aid
in piston removal.

Figure 30-21-12
1
1 2
N-22496
Remove the O-ring (Item 1) [Figure 30-21-14] from the

N-22494 brake housing.
Figure 30-21-15
Remove the eight mounting bolts (Item 1) [Figure 30-21-
12] from the brake housing.
1
Remove the brake housing (Item 2) [Figure 30-21-12]
from the rear housing.
Figure 30-21-13
1
2
N-22497
Remove the seal (Item 1) [Figure 30-21-15] from the

brake housing.
N-22495
Remove the brake disks (Item 1) [Figure 30-21-13] from

the brake shaft.

housing.

Figure 30-21-16
1
1 2
N-22502

N-22499 housing.
Installation: Tighten the plug to 18-22 ft.-lbs. (25-30 Nm)

Remove the two-speed spool spool (Item 1) [Figure 30- torque.
21-16] from the housing assembly.
Remove the plugs (Item 2) [Figure 30-21-18] from the
Figure 30-21-17 housing.
Installation: Tighten the plugs to 9-11 ft.-lbs. (12-15 Nm)

torque.
1
Figure 30-21-19
1
2
4
3
N-22501
Inspect the spool (Item 1) [Figure 30-21-17], the spring

(Item 2) [Figure 30-21-17] washer (Item 3) [Figure 30-
21-17] and the snap ring (Item 4) [Figure 30-21-17], and
N-22503
replace as needed.
NOTE: The spool (Item 1) [Figure 30-21-17] is marked Remove the flushing spool assembly (Item 1) [Figure 30-
with either an A or B. The spool must be 21-19] from the housing.
replaced with a spool with the same mark.

Figure 30-21-20
1 1
2 4 3
N-22506
Remove the poppet assembly (Item 1) [Figure 30-21-22]

N-22504 from the housing.
Figure 30-21-23
Remove the spring (Item 1) [Figure 30-21-20], washer
(Item 2) [Figure 30-21-20], and and rear spring (Item 3)
[Figure 30-21-20] from the spool (Item 4) [Figure 30-21-
20].
Inspect all parts and replace as needed.
Figure 30-21-21
1
2
3
N-22507
1 Inspect the poppet (Item 1) [Figure 30-21-23], shim

(Item 2) [Figure 30-21-23] and spring (Item 3) [Figure
30-21-23] for wear and replace as needed.
N-22505

housing.
Installation: Tighten the plug to 9-11 ft.-lbs. (12-15 Nm)

torque.

Figure 30-21-24
1 1
N-22511
Remove the roller/piston assembly (Item 1) [Figure 30-

N-22508 21-26] from the cylinder block.
NOTE: Put all roller/piston assembles back in the

Loosen the two (8 mm) cam ring mount bolts (Item 1) original bore.
[Figure 30-21-24].
Figure 30-21-27
Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Remove the cam ring mount bolts, and remove the cam 1
ring from the housing.
Figure 30-21-25
N-22512
2
Remove the brake shaft (Item 1) [Figure 30-21-27] from

the housing.
N-22509
Remove the cylinder block (Item 1) [Figure 30-21-25]

from the housing.

housing.

Figure 30-21-28
N-22516
NOTE: The distributor removal, is best accomplished

N-22513 by lifting the housing (Item 1) [Figure 30-21-
30] 2-3 inches above a wooden surface, and
dropping the housing [Figure 30-21-30].
NOTE: The snap ring end of the shaft (Item 1) [Figure
30-21-28] goes up toward the cam ring end of Figure 30-21-31
the motor.
1
Figure 30-21-29
N-22521
N-22515 Remove the locating pin (Item 1) [Figure 30-21-31] from

the distributor.
Remove the distributor (Item 1) [Figure 30-21-29] from

the housing.

Figure 30-21-32
1
2
N-22519
Remove the six seals (Item 1) [Figure 30-21-34], and six

N-22522 back-up O-rings (Item 2) [Figure 30-21-34] from the
distributor.
Remove the twelve springs (Item 1) [Figure 30-21-32]

from the distributor.
Figure 30-21-33
N-22523
Remove the bushing (Item 1) [Figure 30-21-33] from the

distributor, if worn or scratched.

Inspection
Figure 30-21-35
N-22510
Check the cam ring inside surface for wear and scratches
N-22498 [Figure 30-21-37].
Figure 30-21-38
Clean all parts in clean solvent and use air pressure to
dry them. Do Not use cloth or paper because small
pieces of material can get into the system and cause
damage. 3
Before the motor is assembled, check the following 1

items:
Check the brake piston (Item 1) [Figure 30-21-35] and

seal (Item 2) [Figure 30-21-35] and replace as needed.
Figure 30-21-36 2
N-22526
Check all rollers (Item 1) [Figure 30-21-38], pistons (Item

2) [Figure 30-21-38] and piston rings (Item 3) [Figure
NOTE: Put all roller/piston assembly back in their

original position.
N-22520
Check the surfaces of the distributor for wear and

scratches [Figure 30-21-36].

HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D) Assembly
Inspection (Cont'd) Figure 30-21-40
Figure 30-21-39
N-22511
N-22514
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.

Check the brake shaft (Item 1) [Figure 30-21-39] for
wear and replace as needed. Dip the roller/piston assembly (Item 1) [Figure 30-21-40]
in oil and replace back its original bore.
Check the brake shaft snap ring (Item 2) [Figure 30-21-
39] and replace as needed. Repeat procedure for each roller/piston assembly.
Figure 30-21-41
N-22518
Apply a small amount of grease to the locating pin (Item

1) [Figure 30-21-41] and install the locating pin in the
housing

Assembly (Cont'd)
Figure 30-21-42
1
1
N-22515
Install the distributor (Item 1) [Figure 30-21-44] in the

N-22525 housing.
Figure 30-21-45
Install a new bushing (Item 1) [Figure 30-21-42] in the
distributor if the old bushing was removed.
Figure 30-21-43
N-22516
Align the locating pin (Item 1) [Figure 30-21-45] in the

N-22522 housing with the alignment hole in the distributor, an tap
the distributor in place with a rubber mallet.
Install new O-rings and seals on the distributor [Figure

30-21-43].
NOTE: When installing seals, apply a light coating of

oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals, allow
30 minutes for the seals to set on the
distributor before installing the distributor in
the housing.
Using a small amount of grease, install the twelve springs

into the distributor valve (Item 1) [Figure 30-21-43].

Assembly (Cont'd)
1
Figure 30-21-46
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

N-22513 21-48] to the brake shaft.
Install the cam ring to the rear housing and start the
Install the brake shaft (Item 1) [Figure 30-21-46] in the mount bolts and finger tighten.
housing.
Figure 30-21-49
Figure 30-21-47
1 1
N-22508
N-22512
Turn the motor so that it sets on the cam ring, and

Apply a light coating of grease, and install the O-ring cylinder block [Figure 30-21-49].
(Item 1) [Figure 30-21-47] to the housing.
NOTE: Be careful when turning or moving the motor
so the cylinder block stays in the motor
housing.
Tighten the two cam ring mounting bolts to 26-29 ft.-lbs.

(35-39 Nm) torque.

Assembly (Cont'd)
Figure 30-21-50
1
1 2
N-18348
Measure the thickness of the individual brake disc's

N-22499 [Figure 30-21-52] to determine the amount of wear on
each disc.
Install a new O-ring on the housing assembly (Item 1) The normal thickness of the individual brake disc is .039
[Figure 30-21-50] and lightly smear with grease. in. (1 mm).
Install the two speed spool (Item 2) [Figure 30-21-50]. If the individual disc's thickness is .037 in. (0,95 mm) or
less, replace the complete disc pack.
Figure 30-21-51
Figure 30-21-53
1
1 2
N-22496
N-22529
Install a new O-ring on the housing assembly (Item 1)

[Figure 30-21-51] and lightly smear with grease. Install the brake housing (Item 1) [Figure 30-21-53] on
the motor housing and align the marks.
Install the eight mounting bolts (Item 2) [Figure 30-21-

53] and tighten evenly to 52-57 ft.-lbs. (70-77 Nm)
torque.

Assembly (Cont'd)
Figure 30-21-54
N-22533
Install the brake seal (Item 1) [Figure 30-21-56].

N-22530
Figure 30-21-57
Install the brake disc pack starting with an outer disc

(Item 1) [Figure 30-21-54] and alternating with an inner
disc, throughout the pack.
Figure 30-21-55
1
N-22498
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-57].
N-22532
End the disc pack with an outer disc (Item 1) [Figure 30-
21-55].

Assembly (Cont'd)
Figure 30-21-58
2
1
1
N-22534
With the motor in a hydraulic press and the

N-22493 predetermined amount of pressure applied on the
piston, use a straight edge, and measure the distance
from the top of the brake housing (Item 1) [Figure 30-21-
Install the piston (Item 1) [Figure 30-21-58] in the brake 59] to the top of the piston (Item 2) [Figure 30-21-59].
housing.
Record the measurement to three decimal places.
NOTE: If the brake pack was not replaced, the
procedure described below for determining Remove the motor from the hydraulic press.
brake washer thickness, need not be
preformed. Figure 30-21-60
Install the motor assembly in a hydraulic press. Apply a

downward force of 4500 lbs. (20 Kn), on the brake piston
[D].
2
NOTE: The 4500 lbs. of force, is NOT the amount of 1
pressure required by the press. It is the
amount of downward force applied by the
press.
The amount of force applied to the brake piston, by the

press, is determined by the diameter of the piston on the
press cylinder and the PSI applied to the press piston.
Determine the diameter of the piston on the press N-22492

cylinder d and use the following formula to determine the
PSI of pressure to apply to the press cylinder piston.
Install the brake plate (Item 1) [Figure 30-21-60].
1432
Install the end plate gasket (Item 2) [Figure 30-21-60].
)
) d = 6 in. 3 (Squared) = 9 1432 = 159 PSI
2 9
Example: d = 6 in. (152 mm) piston diameter of the

press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.

Assembly (Cont'd)
Figure 30-21-61
N-22491
The correct washer thickness must be determined before

the washer (Item 1) [Figure 30-21-61] can be installed.
Use the recorded measurement obtained in [Figure 30-

21-59]. Plus the thickness of the gasket (Item 2) [Figure
30-21-60], which is .012 in. (0,3 mm). Minus the
thickness of the brake plate (Item 1) [Figure 30-21-60],
which is .281 in. (7,15 mm).
Select a washer, or combination of washers to suit the

calculated thickness within ± .006 in. (0,15 mm).
Install the proper brake washer or washers.
Figure 30-21-62
N-22490
Install the brake end cover (Item 1) [Figure 30-21-62].
Install the twelve end cover mount bolts and tighten

evenly to 10-12 ft.-lbs. (14-16 Nm) torque.

HYDROSTATIC MOTOR CARRIER If the motor carrier is removed from the right side,
remove the lift arm by-pass valve, (See Removal And
Removal and Installation Installation on Page 20-50-1.) and remove the hydraulic
control valve. (See Removal And Installation on Page 20-
40-1.)
Remove the six mounting bolts (Item 1) [Figure 30-22-1]

from the carrier.
Installation: Tighten the mounting bolts to 330 ft.-lbs.

(447 Nm) torque.
Slide the motor carrier toward the rear and remove the
rear drive chain.
WARNING Figure 30-22-2


to fall and cause injury or death. 1
W-2059-0598
Figure 30-22-1
P5467

1.) P5489
Raise the lift arm and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on NOTE: For easier access for the motor carrier
Page 10-20-1.) coming out and going into the chaincase, tie
the front drive chain to the chaincase with a
Raise the operator cab. (See Raising The Operator Cab wire [Figure 30-22-2].
on Page 10-30-1.)
Slide the motor carrier out of the chaincase far enough to
Remove the fluid from the chaincase. (See CHAINCASE install a chain and chain hoist to the carrier [Figure 30-
on Page 40-30-1.) 22-2].
Remove the front axle. (See Axle, Sprocket And Remove the case drain filter (Item 1) [Figure 30-22-2]
Bearings Removal And Installation on Page 40-20-3.) from the hydraulic reservoir.

HYDROSTATIC MOTOR CARRIER (CONT’D)
Removal and Installation (Cont’d)
Figure 30-22-3
P5488
NOTE: Be careful not to damage the tee fitting (Item

1) [Figure 30-22-3] at the hydraulic reservoir. If
may be necessary to remove the tee fitting for
easier removal and installation of the motor
carrier from the loader.
Pull the motor carrier out of the chaincase [Figure 30-22-

3].
Lift the motor carrier out of the loader [Figure 30-22-3].

HYDROSTATIC MOTOR CARRIER (CONT'D)
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring
1
2
3
4
5
6
16 7
TS-1227A

HYDROSTATIC MOTOR CARRIER (CONT'D) Put a small amount of pressure on the shaft to release
the pre-load on the snap ring.
Disassembly
Figure 30-22-6
Figure 30-22-4
1 1
P5756
P5760
Remove the snap ring (Item 1) [Figure 30-22-6] and
Remove the large O-ring from the groove (Item 1) washer from the shaft.
[Figure 30-22-4] in the housing.
Figure 30-22-7
Figure 30-22-5
P5766
P5768
Use a hydraulic press to remove the shaft from the

Put the motor carrier in a hydraulic press [Figure 30-22- housing [Figure 30-22-7].
5].

HYDROSTATIC MOTOR CARRIER (CONT'D) Assembly
Disassembly (Cont’d) Figure 30-22-10
Figure 30-22-8
P5764
P5761
The tool listed will be needed to the following procedure:
Install the bearing puller tool under the bearing flange, MEL1431 - Seal Driver Tool
use the hydraulic press to remove the bearing from the
shaft [Figure 30-22-8]. Install the first seal (Item 1) [Figure 30-22-10] into the
housing with the seal lip facing away from you.
Figure 30-22-9
Use the tool (Item 2) [Figure 30-22-10] as shown in the
figure.
Figure 30-22-11
2
1
2
P5763
Remove the two seals (Item 1) [Figure 30-22-9] from the

housing.
P5762
Check the bearing cup (Item 2) [Figure 30-22-9] (both

sides) and replace as needed. Install the second seal (Item 1) [Figure 30-22-11] into the
housing with the seal lip facing toward you.

figure.

HYDROSTATIC MOTOR CARRIER (CONT'D) Figure 30-22-13
Assembly (Cont’d)
Figure 30-22-12
1
1
P5769
Install the shaft/bearing assembly into the housing.

P5767
Install the bearing (Item 1) [Figure 30-22-13] using the
tool (Item 2) [Figure 30-22-13] (MEL1431).
Install the bearing on the shaft [Figure 30-22-12].
After the bearing is seated. Install the washer and snap
Use a pipe (Item 1) [Figure 30-22-12] with O.D. that ring on the shaft.
seats on the I.D. of the bearing.
It may be necessary to use the tool to push the washer
and snap ring down into position because of the pre-load
on the bearings.

HYDROSTATIC MOTOR CARRIER (SELECTABLE Figure 30-23-2
JOYSTICK CONTROL) (SJC)
Figure 30-23-1
1
1
P5467

1.)
Raise the lift arm and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)

on Page 10-30-1.)
P5489
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.)
Slide the motor carrier toward the rear and remove the
Remove the front axle. (See Axle, Sprocket And rear drive chain.
Bearings Removal And Installation on Page 40-20-3.)
NOTE: For easier access for the motor carrier
If the motor carrier is removed from the right side, coming out and going into the chaincase, tie
remove the lift arm by-pass control valve. (See Removal the front drive chain to the chaincase with a
And Installation on Page 20-50-1.) and remove the wire [Figure 30-23-2].
hydraulic control valve. ((See Removal And Installation
on Page 20-40-1.) Slide the motor carrier out of the chaincase far enough to
install a chain and chain hoist to the carrier [Figure 30-
Remove the six mounting bolts (Item 1) [Figure 30-23-1] 23-2].
from the carrier.
NOTE: When installing the motor carrier into the
Installation: Tighten the mounting bolts to 330 ft.-lbs. loader, use caution to protect the wheel speed
(447 Nm) torque. washer from damage.

HYDROSTATIC MOTOR CARRIER (SELECTABLE
JOYSTICK CONTROL) (SJC) (CONT'D)
1 2 3 4 6
5
4
3 7
8
PE-1395A
Ref. Description
1. Snap Ring
2. Spacer
3. Bearing
4. Race
5. Seal
6. Housing
7. Speed Washer
8. Shaft

HYDROSTATIC MOTOR CARRIER (SELECTABLE Put the motor carrier in a hydraulic press [Figure 30-23-
JOYSTICK CONTROL) (SJC) (CONT'D) 4].
Disassembly Put a small amount of pressure on the shaft to release

the pre-load on the snap ring.
Figure 30-23-3
Figure 30-23-5
1
P5760
P-28155
Remove the large O-ring from the groove (Item 1)

[Figure 30-23-3] in the housing. Remove the snap ring (Item 1) [Figure 30-23-5] and
washer from the shaft.
Figure 30-23-4
Figure 30-23-6
P5766
Use a hydraulic press, remove the shaft from the housing

P-28154
[Figure 30-23-6].

Disassembly (Cont’d)
Figure 30-23-7
2
P-28158
Use the hydraulic press to remove the bearing from the

shaft [Figure 30-23-9].
P-28156
Figure 30-23-10
NOTE: The bearing (Item 1) [Figure 30-23-7] and the

wheel speed washer (Item 2) [Figure 30-23-7],
must both be replaced, due to damage to the
wheel speed washer from removing the
bearing.
1
Figure 30-23-8
P-28162
Remove the wheel speed washer (Item 1) [Figure 30-23-

10] from the shaft.
P-28157
Install the bearing puller tool (Item 1) [Figure 30-23-8]

under the bearing flange, between the bearing and the
speed washer.

HYDROSTATIC MOTOR CARRIER (SELECTABLE Assembly
Figure 30-23-12
Figure 30-23-11
2
2 1
P5764
P-28164 The tool listed will be needed to the following procedure:

MEL1431 - Seal Driver Tool

Remove the two seals (Item 1) [Figure 30-23-11] from
the housing. Install the first seal (Item 1) [Figure 30-23-12] into the
housing with the seal lip facing away from you.
Check the bearing cup (Item 2) [Figure 30-23-11] (both
sides) and replace as needed. Use the tool (Item 2) [Figure 30-23-12] as shown in the
figure.
Figure 30-23-13
P5762
Install the second seal (Item 1) [Figure 30-23-13] into the

housing with the seal lip facing toward you.

figure.

Assembly (Cont'd)
Figure 30-23-14
P-28160
The wheel speed washer, has three alignment pins (Item

1) [Figure 30-23-16].
P-28159
Figure 30-23-17
Check the new wheel speed washer with a straight edge,

to be sure it is square [Figure 30-23-14].
If the washer is more than .080 (2,03 mm) out of square,

it must be replaced.
Figure 30-23-15
1 P-28162
Install the wheel speed washer on the shaft [Figure 30-

23-17].
P-28162
Inspect the wheel speed washer for damage to the

magentic surface (Item 1) [Figure 30-23-15].
NOTE: Do not contact the magnetic surface of the

wheel speed washer (Item 1) [Figure 30-23-
15], with a magnet. This may cause damage to
the magnetic surface.

Assembly (Cont'd)
Figure 30-23-18
1
1
P-28161
Align the three pins (Item 1) [Figure 30-23-18] in the

sprocket.
Figure 30-23-19
P-5769
1
Install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) [Figure 30-23-20] using the

tool (Item 2) [Figure 30-23-20] (MEL1431).
After the bearing is seated. Install the washer and snap

ring on the shaft.
It may be necessary to use the tool to push the washer

P-28163
and snap ring down into position because of the pre-load
on the bearings.
Install the bearing on the shaft [Figure 30-23-19].
Use a pipe (Item 1) [Figure 30-23-19] with O.D. that

seats on the I.D. of the bearing.
Seat the bearing on the shaft, down against the wheel

speed washer.
NOTE: The wheel speed washer should be tight on

the shaft.

CHARGE PRESSURE Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Testing
Figure 30-30-3
Figure 30-30-1
2 4
1 3
P-43924
P-43196

The tools needed to check charge pressure, hydraulic from the charge pressure sender.
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
guage (1000 PSI) (Item 3) and adapter fitting (P/N 93F-5) Figure 30-30-4
(Item 4) [Figure 30-30-1].
Figure 30-30-2
3
2
P-43925
P-43197 Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-30-4].
Connect the guage (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-30-2].
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to

the adapter fitting. Tighten all connections.
Raise the loader lift arms and install an approved lift arm
Place the loader on jackstands. (See Procedure on Page

10-10-1.)

CHARGE PRESSURE (CONT’D)
Testing (Cont’d)
Figure 30-30-5
1 P-43926
Install the hose (Item 1) [Figure 30-30-5], that was
disconnected from the charge pressure sender, to the T
fitting.
Install the hose (Item 2) [Figure 30-30-5], that is

attached to the pressure gauge, to the T fitting.
Tighten the hydraulic fittings
Start the loader and run at an idle and allow the hydraulic
fluid to warm to 140 degrees Farenheit.
The charge pressure at high idle, with the fluid

temperature of 140 degree Farenheit is 400-460 PSI
(27.6-31.7 Bar) with the pump in neutral.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 330-360
PSI (22.8 - 24.8 Bar) at 140 F (60 C) fluid @
High idle.

CHARGE PRESSURE (CONT’D) Figure 30-30-8
Figure 30-30-6
1
P-39003
Remove the sender (Item 1) [Figure 30-30-8] from the

P-37704 hydraulic control valve.
Installation: Tighten the charge pressure sender to 7.4-

Disconnect the wire (Item 1) [Figure 30-30-6] from the 8.1 ft.-lbs. (10-11 Nm) torque.
sender.
Figure 30-30-7
P-37705
Remove the charge pressure line (Item 1) [Figure 30-30-

7].

CHARGE PRESSURE (CONT'D) Figure 30-30-10
Setting Charge Pressure
IMPORTANT
damage the system.
I-2003-0888
N-17231
Figure 30-30-9
Remove the plug, spring and poppet [Figure 30-30-10].

1
Check the poppet and spring for wear or damage.
Figure 30-30-11
P-43856
If the charge pressure is not correct loosen the charge 1

relief valve plug (Item 1) [Figure 30-30-9].
Assemble: Always use a new O-ring. Tighten the plug to N-19568

30-50 ft.-lbs. (41-68 Nm) torque.
There are several different thickness of the shims (Item

1) [Figure 30-30-11] and are used to adjust the charge
pressure.
NOTE: 0.010 inch (0,254 mm) is 8 PSI (55.16 kPa)

increase in pressure.
The charge pressure should be set at 400-460 PSI (27.6-

31.7 Bar) at 140 F (60 C) fluid @ High Idle.
NOTE: If the machine is equipped with SJC option

the charge pressure should be set at 330-360
PSI (22.8 - 24.8 Bar) at 140 F (60 C) fluid @
High idle.

HYDROSTATIC PUMP Figure 30-40-3
Figure 30-40-1
N-15339
1
Remove the nut and washer (Item 1) [Figure 30-40-3]
N-15337 from the hydrostatic pump drive shaft.
Installation: Tighten the nut to 175-200 ft.-lbs. (237-271

Remove the hydrostatic pump/engine assembly from the Nm) torque.
loader. (See Removal And Installation on Page 70-70-1.)
Remove the belt shield clips (Item 1) and belt shield (Item
2) [Figure 30-40-1].
Figure 30-40-2
P-37270
Loosen the stop mounting bolt (Item 1) [Figure 30-40-2].
Loosen the spring tension bolt (Item 2) [Figure 30-40-2].
Remove the drive belt.

HYDROSTATIC PUMP (CONT'D) Figure 30-40-6
Figure 30-40-4
P-37274
1 Remove the two mounting bolts (Item 1) [Figure 30-40-

N-15340 5] and nuts (Item 1) [Figure 30-40-6].
Installation: Tighten the mounting bolts and nuts to 65-
Install the nut on the end of the pump drive shaft (without 70 ft.-lbs. (88-95 Nm) torque. Make sure the key (Item 2)
washer). [Figure 30-40-5] is installed.
Use a puller (Item 1) [Figure 30-40-4] to remove the Figure 30-40-7

pulley from the pump drive shaft.
Figure 30-40-5
1
P-37273
P5658 Remove the mounting bolt (Item 1) [Figure 30-40-7] at

the hydraulic pump end of the pump.
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.

HYDROSTATIC PUMP (CONT'D) Check the O-rings (Item 2 & 3) [Figure 30-40-9] for
damage and replace as needed.
Replenishing/High Pressure Relief Valve
If the high pressure relief valve must be replaced, it must
Figure 30-40-8 be replaced as a complete unit.
The pressure setting for a new high pressure relief valve

is 5000 PSI (34475 kPa).
P-43857
There are four replenishing/high pressure relief valves

(Item 1) [Figure 30-40-8] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps.
(See Replenishing Valve Function on Page 30-10-2.)
NOTE: The two top valves are for the forward drive
loop and the two bottom valves are for the
reverse drive loop.
Figure 30-40-9
N-19566
Remove the high pressure relief valve (Items 1) [Figure

30-40-9] from the pump.
Assemble: Tighten the plug to 30-50 ft.-lbs. (41-68 Nm)

torque.
Check for damage and replace as needed.

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
5 4
8 3
7
6
2
9 1
13 14
10 15
11
12 17
19
21
16
23 18
25 20
27
22
29 24
26
28
38
30 33
36
34 32
31
37
35 46
47 48
40
42 45
39 44
49
41
43
D-2427

Parts Identification (Right Half) (Cont'd)
Ref. Description Ref. Description
1. BOLT 26. RETAINER

2. END CAP 27. RETAINER
3. PLUG 28. PISTON ASSEMBLY
4. O-RING 29. PLATE
5. PLUG 30. SWACHPLATE
6. O-RING 31. PIN
7. O-RING 32. HOUSING
8. RELIEF VALVE 33. PLUG
9. BOLT 34. BEARING
10. GASKET 35. SEAL
11. BEARING 36. O-RING
12. PLUG 37. COVER
13. O-RING 38. BOLT

14. O-RING 39. SHAFT
15. RELIEF VALVE 40. SNAP RING
16. PIN 41. BEARING
17. VALVE PLATE 42. SNAP RING
18. RETAINER 43. SNAP RING
19. WASHER 44. PLUG
20. SPRING 45. O-RING
21. WASHER 46. BEARING
22. BLOCK 47. O-RING
23. RETAINER 48. PLATE
24. PIN 49. BOLT
25. WASHER

Parts Identification (Left Half)
4
17 6
16
11 8
1
14 2
13 10 3
5
12
7
9
15
22
23
18
19 21
20 24
28
30
32 25
26
27
34
29
38 36
31
33
35
47
37
46
39 45
44
48 43
49 42
50 40
51
52 58
41
53
53 52 57
59
55
56
54
D-2428B

Parts Identification (Left Half) (Cont'd)
1. SNAP RING 31. PIN

2. WASHER 32. RETAINER
3. SEAL 33. BLOCK
4. SNAP RING 34. WASHER
5. SNAP RING 35. SPRING
6. BEARING 36. WASHER
7. SNAP RING 37. WASHER
8. KEY 38. VALVE PLATE
9. SHAFT 39. PIN
10. HOUSING 40. GASKET
11. PLUG 41. BEARING
12. O-RING 42. PLUG
13. BEARING 43. POPPET

14. SEAL 44. SPRING
15. O-RING 45. SHIM
16. COVER 46. O-RING
17. BOLT 47. PLUG
18. PIN 48. RELIEF VALVE
19. O-RING 49. O-RING
20. PLUG 50. O-RING
21. BEARING 51. O-RING
22. O-RING 52. PIN
23. PLATE 53. O-RING
24. BOLT 54. COUPLER
25. SWASH PLATE 55. O-RING
26. WEAR PLATE 56. BOLT
27. PISTON ASSEMBLY 57. O-RING
28. PISTON RETAINER 58. O-RING
29. RETAINER 59. RELIEF VALVE
30. WASHER

HYDROSTATIC PUMP (CONT'D) Pump Separation
Hydraulic Pump Removal And Installation Figure 30-40-12
Figure 30-40-10
1
P-43858
1
P-43860
12].
Remove the two pump mounting bolts (Item 1) [Figure
30-40-10] (both sides). Figure 30-40-13

(37-50 Nm) torque.
Remove the hydraulic pump (Item 2) [Figure 30-40-10]

from the hydrostatic pumps.
Figure 30-40-11
N-19570
Separate the two hydrostatic pumps [Figure 30-40-13].
P-43859
Remove the O-ring (Item 1) [Figure 30-40-11] with the

hydraulic pump.

Pump Separation (Cont’d)
Figure 30-40-14
3 1
1
N-19551
2 3
Remove the pump housing end cap (Item 1) [Figure 30-

N-19571 40-16].
Remove the gasket (Item 2) [Figure 30-40-16].

Remove the pump coupler (Item 1) [Figure 30-40-14].
Figure 30-40-17
Remove the large O-ring (Item 2) [Figure 30-40-14].
Remove the two small O-rings (Item 3) [Figure 30-40- 1

14].
Disassembly
Figure 30-40-15
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-40-17].
Check the valve plate for wear. (Both Sides.)
N-19550
Remove the four bolts (Item 1) [Figure 30-40-15] from

the pump housing end cap.

1
Figure 30-40-18
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-40-20] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-40-20] for wear
Check the valve plate locating pin (Item 1) [Figure 30-40- and replace the rotating group as needed.
18] for wear and replace if needed.
Figure 30-40-21
Check the needle bearing (Item 2) [Figure 30-40-18] for
wear and replace if needed.
1
Figure 30-40-19
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-40-

N-17197 21] from the cylinder block.
Remove the rotating group (Item 1) [Figure 30-40-19]

from the pump.

Figure 30-40-22
1
3 3
2
2 1
3 3
3
N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2)

N-17200 and the support washer (Item 3) [Figure 30-40-24] from
the drive shaft end of the pump.
Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-25
2) [Figure 30-40-22] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-40-22] from the

cylinder block. 1
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-40-22] to see if they are

all the same length.
Figure 30-40-23
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

1 30-40-25] from the pump housing.
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-23] from

the pump housing.

Figure 30-40-26 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-40-28] for

N-17240 wear and replace if needed.
Figure 30-40-29
Remove the snap ring (Item 1) [Figure 30-40-26] from
the pump housing and remove the driveshaft and bearing
from the housing.
Figure 30-40-27
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-40-29]

from the lower trunnion cover. Remove the cover.
N-17241
Remove the snap ring (Item 1) [Figure 30-40-27] from

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

Figure 30-40-30
2
2
1
1
1 N-17246
Remove the four mount bolts (Item 1) from the pump

N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-40-32].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-33
[Figure 30-40-30] from the pump housing.
Figure 30-40-31
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-40-

33].
Check the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-31] for wear and replace as needed.

Figure 30-40-34
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-40-36] and replace as needed.
Figure 30-40-37
Inspect the seal (Item 1) [Figure 30-40-34] in the upper
trunnion cover and replace if needed.
Figure 30-40-35
1 N-17251
2
Slide the swashplate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-40-37] from
the swashplate shaft.
Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-40-35] from the pump housing.

Figure 30-40-38
N-17252
Install the swashplate and bearing into the pump housing

N-17252 [Figure 30-40-40].
Figure 30-40-41
Tilt the swashplate (Item 1) [Figure 30-40-38] and
remove the swashplate and lower bearing from the pump
housing.
Assembly
Figure 30-40-39
1
1 2
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-41] on

the swashplate shaft.
N-17253
Install the lower bearing (Item 1) [Figure 30-40-39] on

the swashplate.

Assembly (Cont’d)
Figure 30-40-42
N-17246
Install the linkage bracket (Item 1) [Figure 30-40-44] and

N-17248 the four mounting bolts and tighten to 18-22 ft.-lbs. (24-
30 Nm) torque.
Install the bearing race (Item 2) [Figure 30-40-41] and O-
ring (Item 3) [Figure 30-40-41] as shown in [Figure 30-
40-42].
Figure 30-40-43
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-43]

and cover.

Assembly (Cont’d)
Figure 30-40-45
2
N-17243
Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-40-47].
Install the four mounting bolts and tighten to 18-22 ft.-lbs.

Figure 30-40-46 (24-30 Nm) torque.
Figure 30-40-48
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-40-45] and O-
ring (Item 2) [Figure 30-40-45] at the lower trunnion as
shown in [Figure 30-40-46]. Install the snap ring (Item 1) [Figure 30-40-48] on the
pump shaft.

Assembly (Cont’d)
1
1
Figure 30-40-49
1
1 2 3
1
N-17200
Install the four slipper pins (Item 1) [Figure 30-40-51]

N-17241 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)
Install the bearing and snap ring (Item 1) [Figure 30-40- and install into the ball guide retainer (Item 3) [Figure 30-
49] on the pump shaft. 40-51].
Figure 30-40-50 Figure 30-40-52
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
40-50]. 30-40-52] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-50].

Assembly (Cont’d)
1
2
Figure 30-40-53
N-17194
Replace the needle bearing (Item 1) [Figure 30-40-55]

N-17198 and valve plate locating pin (Item 2) [Figure 30-40-55] in
the charge pump.
Assemble the piston assemblies into the slipper guide . Figure 30-40-56
Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
40-53].
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing. 2
1
Figure 30-40-54
N-17196
The bearing cage (Item 1) [Figure 30-40-56] will

protrude from 0.08-0.10 inch (2,0-2,5 mm) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

N-17197 40-56] will protrude from .165-0.185 inch (4,19-4,70 mm)
from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-40-54].

Assembly (Cont’d)
1 1
Figure 30-40-57
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-59] to 35-45 ft.-
Coat the backside of the valve plate with petroleum jelly Figure 30-40-60
to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-57].
The notch (Item 1) [Figure 30-40-57] on the valve plate

must engage the locating pin.
Figure 30-40-58 1
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-40-60].
Install the large new O-ring (Item 2) [Figure 30-40-60].
N-19551 Install the pump coupler (Item 3) [Figure 30-40-60].
Coat a new end cap gasket (Item 1) [Figure 30-40-58]

with petroleum jelly and install onto the end cap.

Assembly (Cont’d)
Figure 30-40-61
N-19570
Install the two pumps together [Figure 30-40-61].
Figure 30-40-62
1
P-43858
Tighten the four bolts (Item 1) [Figure 30-40-62] to 35-45


HYDROSTATIC PUMP (SELECTABLE JOYSTICK Figure 30-41-3
CONTROL)
Pump Controller Removal And Installation
Figure 30-41-1
1
1
P-26465
Remove the control spool plug (Item 1) [Figure 30-41-3]

at the front side of the pump.
P-26463
Figure 30-41-4
Raise the lift arms and install and approved lift arm
Place the loader on jackstands. ((See Procedure on

Page 10-10-1.)
1
Raise the operator cab. ((See Raising The Operator Cab
on Page 10-30-1.)
Locate the two pump controllers (Item 1) [Figure 30-41-

1] on the hydrostatic pumps.
Figure 30-41-2
P-26469
Do Not remove the spring (Item 1) [Figure 30-41-4],as it

is attached to the control spool.
P-26464
Disconnect the electrical connectors (Item 1) [Figure 30-

41-2] from the loader harness.

CONTROL) (CONT'D)
Pump Controller Removal And Installation (Cont'd)
Figure 30-41-5
1 2
1
P-26472
Use a small amount of grease on a new gasket and

install the gasket on the pump controller (Item 1) [Figure
P-26465 30-41-7].
Be sure the pump surface is clean.
Remove the seven mount bolts (Item 1) [Figure 30-41-5]
from the pump controller. Figure 30-41-8
Remove the controller from the pump.
Remove the controller gasket from the pump.

2 1
Figure 30-41-6
P-26473
Align the summing link pin (Item 1) on the pump with the
bore (Item 2) [Figure 30-41-8] in the pump controller
module.
P-26471
Installation:
Be sure the summing link pin (Item 1) [Figure 30-41-6] is

in the center.

CONTROL) (CONT'D)
Pump Controller Removal And Installation (Cont'd)
Figure 30-41-9
2 1
1 2
P-26469
Be sure the spring (Item 1) [Figure 30-41-11] is properly

attached to the control spool.
P-26465
Figure 30-41-12
Install the pump controller on the hydrostatic pump.
Align the bolt holes.

2
Install the seven mount bolts (Item 1) [Figure 30-41-9].
1
Figure 30-41-10
7
4
3
1
P-26465
2
Install the control spool bore plug (Item 1) [Figure 30-41-
12] in the pump and tighten to 30-70 ft.-lbs. (41-94 Nm)
torque.
5
6 Connect the electrical connectors (Item 1) [Figure 30-41-
P-30692 12] to the loader harness.
NOTE: When a pump controller is replaced the

Tighten the controller mounting bolts to 11-13 ft.-lbs. (15- hydrostatic pumps must be calibrated. (See
17.5 Nm) torque using the tightening pattern [Figure 30- Hydrostatic Pump Calibration on Page 30-41-
41-10] 4.) for the proper procedure.)
NOTE: After tightening all the controller mounting

bolts in the sequence numbered in [Figure 30-
41-10] retorque the mounting bolt number 1 a
second time to 11-13 ft. lbs. (15-17.5 Nm).

CONTROL) (CONT'D)
Hydrostatic Pump Calibration

10-10-1.)
Operator must be in the seat and the seat bar down.
Verify that the wheels are straight.
WARNING
P-26480
Failure to use jackstands can allow the machine to Turn the key (Item 1) [Figure 30-41-13] to the RUN
fall or move and cause injury or death. position or press the RUN/ENTER button (Item 1)
[Figure 30-41-14] for power, without starting the loader.
W-2017-0286
Figure 30-41-15
Figure 30-41-13
P-24800
P-26475
Verify the parking brake (Item 1) [Figure 30-41-15] is

OFF.

CONTROL) (CONT'D)
Hydrostatic Pump Calibration (Cont'd)
Figure 30-41-16
1
P-26479
The warning light (Item 1) [Figure 30-41-18] on the right

console will be ON.
P-26476
Figure 30-41-19
Move the left joystick to the forward position and toward

the side screen [Figure 30-41-16] and hold in position.
Figure 30-41-17
2 38-05
3
P-26476
1 Move the left joystick to the reverse postion and toward

the operator [Figure 30-41-19] and hold in position.
P-26477A
Press the PRESS TO OPERATE LOADER Button (Item

1) [Figure 30-41-17] .
Three audible beeps will sound and an error code (Item

2) [Figure 30-41-17] & (38-05 & 38-07) will be displayed
if the operator presses the PRESS FOR CODES,
(LIGHTS) switch (Item 3) [Figure 30-41-17].

CONTROL) (CONT'D)
Figure 30-41-20
38-05
P-26474
Allow the left joystick to go to the neutral position [Figure

1
30-41-22].
P-26477A
Figure 30-41-23

1) [Figure 30-41-20].
Figure 30-41-21 2 38-98
3
1
P-26477A

1) [Figure 30-41-23].
P-26479
Three audible beeps will sound and the error code (Item
2) (38-98) will be displayed if the operator presses the
The warning light (Item 1) [Figure 30-41-21] on the right PRESS FOR CODES (LIGHTS) switch (Item 3) [Figure
console will continue to be ON. 30-41-23].
Start the engine from the RUN, RUN/ENTER position.

DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.

CONTROL) (CONT'D)
Figure 30-41-24
P-26482
Move and hold the left joystick to the forward position

[Figure 30-41-25] until the forward calibration is
P-34548 completed.
The pump controller will start increasing the electrical

Move the throttle (Item 1) [Figure 30-41-24] to high idle. current to the hydrostatic pumps until it sees a pulse from
the wheel sensors.
NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift The loader wheels will rotate a short distance forward
the seat bar, or return the joystick to the each time it sees a pulse.
neutral position.
The four wheels will then go to Full Speed Forward.
The calibration procedure will stop. Continue holding the joystick in the forward position until
the wheels stop and there is an audible beep. Forward
To return to calibration mode the operator calibration is complete.
must start the complete procedure from the
beginning. NOTE: If the wheels do not stop going in Full Speed
Forward in 2 minutes or less, there was an
error in the calibration procedure. The
WARNING
operator must shut the loader OFF, and start
the calibration procedure from the beginning.

W-2017-0286

HYDROSTATIC PUMP (SELECTABLE JOYSTICK The four wheels will then go to Full Speed Reverse.
CONTROL) (CONT'D) Continue holding the joystick in the reverse position until
the wheels stop and there is an audible beep. Reverse
Hydrostatic Pump Calibration (Cont'd) calibration is complete.
Figure 30-41-26 NOTE: If the wheels do not stop going in Full Speed
Reverse in 2 minutes or less, there was an
error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
The SEAT BAR and LIFT AND TILT lights will remain on.
The 38-98 error code will clear.
Allow the joystick to go to the neutral position.
The calibration procedure is completed.
P-26483 Press the PRESS TO OPERATE LOADER button. Move
the joystick to forward position [Figure 30-41-25] and
check for normal forward wheel rotation.
Move and hold the left joystick to the reverse position
[Figure 30-41-26] until the reverse calibration is
Move the joystick to the reverse position [Figure 30-41-
completed.
26] and check for normal reverse wheel rotation.
The pump controller will start increasing the electrical
Stop the engine, and remove the loader from jackstands.
current to the hydrostatic pumps until it sees a pulse from
the wheel speed sensors.
Start the loader, press the PRESS TO OPERATE
LOADER button and return to normal loader operation.
The loader wheels will rotate a short distance in reverse
each time it sees a pulse.

CONTROL) (CONT'D)
Figure 30-41-27
1
1
2 N-15339
Remove the washer and nut (Item 1) [Figure 30-41-29]

1 from the hysrodstic pump drive shaft.
N-15337
Installation: Tighten the nut to 175-200 ft.-lbs. (237-271

Nm) torque
Remove the hydrostatic pump/engine assembly from the
loader. ((See Removal And Installation on Page 70-70- Figure 30-41-30
1.)
Remove the belt shield clips (Item 1) and belt shield (Item
2) [Figure 30-41-27].
Figure 30-41-28
1
2 1
N-15340
3
Install the nut on the end of the pump drive shaft (without
washer).
P-37270 Use a puller (Item 1) [Figure 30-41-30] to remove the

pulley from the pump drive shaft.
Loosen the stop mounting bolt (Item 1) [Figure 30-41-

28].
Loosen the spring tension bolt (Item 2) [Figure 30-41-

28].
Remove the drive belt (Item 3) [Figure 30-41-28].

CONTROL) (CONT'D)
Figure 30-41-31
2
1
P-28073
1
Remove the mounting bolt (Item 1) [Figure 30-41-33] at
the hydraulic pump end of the pump.
P5658
Remove the hydrostatic pump from the mounting bracket
and drive belt housing.
Figure 30-41-32
P-28072

31] and nuts (Item 1) [Figure 30-41-32].

70 ft.-lbs. (88-95 Nm) torque. Make sure the key (Item 2)
[Figure 30-41-31] is installed.

HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (CONT'D)
Parts Identification (Right Half)
2 5 1
23
24 25
26
20 21 27
19 28 21
22 29 20
18
17 19
17
14 30 18
13 16 33
4 23 16 33
6 15 31 34
7 29 34
8 32
35 36
9
3
39
37
10
11 38
65 42 43 41 40
67 46
69 64 44 45 48
66 47 49
51
68 50
63 64 63
54 5
43 62
15
14 52
71 53
70 72 55
32
74 73
75 31
28
72 27
76 56
26
25 77
23 25 57
59 60 34
24
61 33
58
59
B-16054A

Parts Identification (Right Half) (Cont'd)
1. Pump 40. Link

2. Pump 41. Link
3. Housing 42. Link
4. O-ring 43. Pin
5. Bolt 44. Key
6. Snap Ring 45. Coupler
7. Seal 46. Snap Ring
8. O-ring 47. Geroter
9. Snap Ring 48 Bearing
10. Bearing 49. Cover
11. Shaft 50. O-ring
12. Shaft 51. Gasket
14. Plug 53. Screw
16. Spring 55. Gear Pump
17. Valve 56. Spool
19. Washer 58. Bracket
20. O-ring 59. Screw
21. Valve 60. Screw
22. Nut 61. Nut
23. O-ring 62. Plug
24. Plug 63. Pin
25. Screw 64. Filter
26. Cover 65. Poppet
27. Gasket 66. Spring
28. Ring 67. O-ring
29. O-ring 68. Adjuster
30. Servo 69. Nut
31. Plug 70. Rotating Piece
32. O-ring 71. Valve Plate
33. Plug 72. Bearing
34. O-ring 73. Cam
35. Screw 74. Bearing
36. Screw 75. Swashplate
37. Control 76. Gasket
38. Gasket 77. Cover
39. Screw

Parts Identification (Left Half)
5
2
1
23
22
25
26
23 27
19
28
18 20 21
29
22
17 19
16 18
17
14 30
13 23 33
16
4
29 34 33
6 15 31 34
7 32
8
55 35 36
9
3
39 38
10
11
38
12 65 41 40
42 43 46
67
69 44 45 48
64 47
49
66
68 50 51
62 63
63
43 62
54
15
14
71 52
53
70
72
74 73 32
31
75 28
72 27
56
25 26
76
77 23 25 57
59
60 34
24
61 58
33
59
B-16055A

Parts Identification (Left Half) (Cont’d)
1. Pump 40. Link

2. Pump 41. Link
3. Housing 42. Link
4. O-ring 43. Pin
5. Bolt 44. Key
6. Snap Ring 45. Coupler
7. Seal 46. Snap Ring
8. O-ring 47. Geroter
9. Snap Ring 48 Bearing
11. Shaft 50. O-ring
12. Shaft 51. Gasket
14. Plug 53. Screw
16. Spring 55. Key
17. Valve 56. Spool
19. Washer 58. Bracket
20. O-ring 59. Screw
21. Valve 60. Screw
22. Nut 61. Nut
23. O-ring 62. Plug
24. Plug 63. Pin
25. Screw 64. Filter
26. Cover 65. Poppet
27. Gasket 66. Spring
28. Ring 67. O-ring
29. O-ring 68. Adjuster
30. Servo 69. Nut
31. Plug 70. Rotating Piece
32. O-ring 71. Valve Plate
33. Plug 72. Bearing
34. O-ring 73. Cam
35. Screw 74. Bearing
36. Screw 75. Swashplate
37. Control 76. Gasket
38. Gasket 77. Cover
39. Screw

CONTROL) (CONT'D)
System Check Relief Valves (High Pressure Relief, 3

Charge Check & By-Pass Valve)
Figure 30-41-34
2
1
1
1
1 P-28615
Check the valve seat plug O-rings (Item 1) and back-up

ring (Item 2) [Figure 30-41-36], and replace as needed.
P-28613 Check the valve seat surface (Item 3) [Figure 30-41-36]

for scratches and replace as needed.
There are four system check relief valves (Item 1) Figure 30-41-37
[Figure 30-41-34] in the hydrostatic pump. Two are
located on the back side of each pump half.
Figure 30-41-35
1
1
P-28616
Remove relief valve assembly (Item 1) [Figure 30-41-37]

P-28614 from the pump housing.
Check the conical spring (Item 2) [Figure 30-41-36] to be

Remove the valve seat plug (Item 1) [Figure 30-41-35] sure it is retained on the relief valve. DO NOT REMOVE.
from the pump.

HYDROSTATIC PUMP (SELECTABLE JOYSTICK Charge Relief Valve
CONTROL) (CONT'D)
Figure 30-41-40
System Check Relief Valves (High Pressure Relief,
Charge Check & By-Pass Valve) (Cont'd)
Figure 30-41-38
1 1
P-28613
There are two charge pressure relief valves (Item 1)
P-28617 [Figure 30-41-40].
The charge pressure relief valves are located on the

Install relief valve into the pump housing spring first bottom side of the pumps, with one valve on each pump
[Figure 30-41-38]. section [Figure 30-41-40].
Figure 30-41-39 Figure 30-41-41
1
2
P-28614
P-28625
Install the valve seat plug (Item 1) [Figure 30-41-39] in Mark the plug (Item 1) the lock nut (Item 2) and the
the pump, and tighten to 30-70 ft.-lbs. (40-95 Nm) torque. housing (Item 3) [Figure 30-41-41] for ease of assembly.
Loosen the lock nut.
Loosen the charge pressure plug, and remove the

complete assembly from the pump housing.

CONTROL) (CONT'D)
Charge Relief Valve (Cont'd)
Figure 30-41-42 1
2
P-28627
Install the poppet (Item 1) and spring (Item 2) [Figure 30-

41-44] into the pump housing.
P-28626
Figure 30-41-45
Check and replace the O-ring (Item 1) [Figure 30-41-42].
Figure 30-41-43
2
1
2
3 1
P-28625
Install the plug (Item 1) and its lock nut (Item 2) [Figure
P-28627 30-41-45], align the marks made during disassembly.
Inspect the poppet (Item 1) [Figure 30-41-43] and the

mating seat in the pump housing for damage or foreign
material.
Inspect the spring (Item 2) and the adjustable charge

relief valve (Item 3) [Figure 30-41-43] .

CONTROL) (CONT'D)
Pump Separation 1
Figure 30-41-46
P-28640
2 1
Replace the O-ring (Item 1) [Figure 30-41-48].
P-28638
Remove the two mount bolts (Item 1) [Figure 30-41-46].
(Front and Rear.)
Remove the lifting bracket (Item 2) [Figure 30-41-46]

from the pump.
Figure 30-41-47
P-28639
Separate the two hydrostatic pumps [Figure 30-41-47].

CONTROL) (CONT'D)
Shaft Seal And Shaft Replacement 1
Figure 30-41-49
P-28643

top of the bearing.
P-28641
Figure 30-41-52
Remove the snap ring (Item 1) [Figure 30-41-49].
Figure 30-41-50 1
P-28648
Using a press, remove the old seal (Item 1) [Figure 30-

P-28642 41-52] from the seal carrier.
With the pump shaft up, remove the seal carrier

assembly (Item 1) [Figure 30-41-50] using a screwdriver.

CONTROL) (CONT'D)
Shaft Seal And Shaft Replacement (Cont'd)
Figure 30-41-53
P-28646
Remove the snap ring (Item 1)[Figure 30-41-55] from

the shaft.
P-28644
Figure 30-41-56
Press a new seal into the shaft bearing side of the seal
carrier (Item 1) [Figure 30-41-53].
Figure 30-41-54
P-28753
Remove the roller bearing [Figure 30-41-56] from the

shaft.
P-28645
Inspect the bearing for wear and replace as needed.
Grip the splines or threads of the input shaft and remove

the pump shaft and roller bearing assembly (Item 1)
[Figure 30-41-54].

CONTROL) (CONT'D)
Shaft Seal And Shaft Installation
Figure 30-41-57
P-28646
Install the bearing and snap ring on the shaft [Figure 30-
41-59].
P-28752
Figure 30-41-60
Inspect the shaft [Figure 30-41-57] for wear and replace

as needed.
Figure 30-41-58
P-28645
Install the shaft and roller bearing in the pump housing

[Figure 30-41-60].
P-28754
Inspect the snap ring [Figure 30-41-58] and replace as

needed.

CONTROL) (CONT'D)
Shaft Seal And Shaft Installation (Cont'd)
Figure 30-41-61
P-28648
Lubricate the seal (Item 1) [Figure 30-41-63] with

petroleum jelly.
P-28643
Figure 30-41-64
Install the O-ring (Item 1) [Figure 30-41-61] on top of the

shaft bearing.
2
Figure 30-41-62
1
P-28641
Slide the seal carrier (Item 1) [Figure 30-41-64]

assembly over the shaft and into the housing bore. Press
P-28647 against the O-ring. Hold downward pressure against the
shaft to compress the cylinder block spring while
pressing the seal carrier into place.
Wrap the spline and key way with a thin layer of plastic to
prevent damage to the seal lip during installation [Figure Install the retaining ring (Item 2) [Figure 30-41-64].
30-41-62].
Lubricate the O-ring with petroleum jelly [Figure 30-41-

62].

CONTROL) (CONT'D)
Charge Pump Removal
Figure 30-41-65
P-28669
Remove the old charge pump cover gasket (Item 1)

[Figure 30-41-67].
P-28668
Figure 30-41-68
Position the pump so the auxiliary mounting pad is facing 1

up.
Mark pump housing for proper installation [Figure 30-41-

65].
Figure 30-41-66
2
1 1 P-28670
Remove the alignment pins (Item 1) [Figure 30-41-68].

1
Remove the gerotor cover (Item 2) [Figure 30-41-68].
P-28667
Remove the six auxiliary mount pad mount bolts (Item 1)

[Figure 30-41-66].
Remove the charge pump cover.

CONTROL) (CONT'D)
Charge Pump Removal (Cont'd)
Figure 30-41-69
P-28673
Remove the inner gerotor and drive coupler (Item 1)

[Figure 30-41-71].
P-28671
Figure 30-41-72
Remove the old gerotor cover O-ring (Item 1) [Figure 30-

41-69].
1
Figure 30-41-70
P-28674
1
Remove the retainer ring from the drive coupler (Item 1)

[Figure 30-41-72].
P-28672
Remove the outer gerotor assembly from the pump

housing (Item 1) [Figure 30-41-70].
Remove the gerotor cover alignment pin from the

housing.

CONTROL) (CONT'D)
Charge Pump Removal (Cont'd) 2
Figure 30-41-73
P-28675
1
Inspect the inner gerotor assembly (Item 1) [Figure 30-
2
41-75] for scratches and wear, if it must be replaced,
P-28675 replace both the outer and inner gerotors as a set.
Inspect the drive coupler (Item 2) [Figure 30-41-75] for

Remove the inner gerotor (Item 1) and key (Item 2) wear, and replace as needed.
[Figure 30-41-73] from the drive couple.
Figure 30-41-76
Charge Pump Inspection
2
Figure 30-41-74 1
P-28675A
P-28757 Inspect the gerotor drive key (Item 1) and retainer ring
(Item 2) [Figure 30-41-76], and replace as needed.
Inspect the outer gerotor assembly [Figure 30-41-74] for

scratches and wear, if it must be replaced, replace both
the outer and inner gerotors as a set.

CONTROL) (CONT'D)
Charge Pump Inspection (Cont’d)

2
Figure 30-41-77
1
P-28673
Be sure the pump surface (Item 1) [Figure 30-41-79] is

clean and free of gasket material.
P-28758
Install the drive coupler/inner gerotor in the pump
housing (Item 2) ] [Figure 30-41-79].
Inspect the inside of the gerotor cover (Item 1) [Figure
30-41-77] for scratches and foreign material, replace as Figure 30-41-80
needed.
Charge Pump Installation
Figure 30-41-78 2
1
4
2 P-28672
3
Install the outer gerotor (Item 1) and gerotor cover
1
alignment pin (Item 2) [Figure 30-41-80].
P-28675
Install the key (Item 1) in the drive coupler (Item 2)

[Figure 30-41-78] .
Install the inner gerotor (Item 3) and the retaining ring

(Item 4) [Figure 30-41-78] on the drive coupler.
Lubricate the gerotor assembly with clean oil.

CONTROL) (CONT'D)
1
Charge Pump Installation (Cont'd)
Figure 30-41-81
1 1
P-28670
Install the charge pump cover locating pins (Item 1)

[Figure 30-41-83].
P-28671
Figure 30-41-84
Install the new O-ring (Item 1) [Figure 30-41-81] on the

gerotor cover.
Figure 30-41-82
1
2 P-28669
Install a new charge pump cover gasket (Item 1) [Figure

30-41-84]
P-28676A
.
Install the gerotor cover over the gerotor assembly (Item

1) and align the pin in the cover (Item 2) [Figure 30-41-
82].

CONTROL) (CONT'D)
Charge Pump Installation (Cont'd)
Figure 30-41-85
1
1
P-28678
1
Press down on the swashplate with the handle of a clean

rubber mallet (Item 1) [Figure 30-41-87] and remove the
P-28667 side cover.
Figure 30-41-88
Align the charge pump cover on the alignment pins.
Install the six cover bolts (Item 1) [Figure 30-41-85] and
1
Disassembly
Figure 30-41-86
P-28679
1
Remove the gasket (Item 1) [Figure 30-41-88] from side
cover.
P-28677
Separate the two hydrostatic pumps. (See Pump

Separation on Page 30-40-18.)
Remove the charge pump. (See Charge Pump Removal

on Page 30-41-23.)
Remove the shaft and shaft seal. (See Shaft Seal And
Shaft Replacement on Page 30-41-19.)
Remove the six side cover bolts (Item 1) [Figure 30-41-

86].

CONTROL) (CONT'D)
Figure 30-41-89 1
P-28683
2
Remove the swash plate needle bearing assembly (Item

1) [Figure 30-41-91]. It may be necessary to rotate the
P-28680 servo piston, so the bearing can be removed.
Figure 30-41-92
Lift the swash plate (Item 1) and remove cylinder block
(Item 2) [Figure 30-41-89].
Figure 30-41-90
1
1
P-28684
Remove the valve plate timing pin (Item 1) [Figure 30-

P-28682 41-92].
Remove the swash plate (Item 1) [Figure 30-41-90].

CONTROL) (CONT'D)
Figure 30-41-93
P-28687
Remove the control spool plug (Item 1) [Figure 30-41-

95].
P-28685
Figure 30-41-96
Remove the valve plate (Item 1) [Figure 30-41-93].
Figure 30-41-94
1 1
P-26469
Do Not remove the spring (Item 1) [Figure 30-41-96], as

P-28686 it is attached to the control spool.
Remove the electrical displacement control from the

Remove the seven mounting bolts from the electrical pump.
displacement control (Item 1) [Figure 30-41-94].

CONTROL) (CONT'D)
Figure 30-41-97
P-28698
Remove control spool and spring (Item 1) [Figure 30-41-

99].
P-28688
Figure 30-41-100
Move the control spool and summing link (Item 1)

[Figure 30-41-97] until the summing link disconnects
from the control spool.
Figure 30-41-98
P-28691
1 Remove the linkage pivot bolt (Item 1) [Figure 30-41-

100].
P-28689
Remove the summing link (Item 1) [Figure 30-41-98].

CONTROL) (CONT'D)
1
Figure 30-41-101
2
1
2
1
P-28700
Remove the five servo cover mount bolts (Item 1)

[Figure 30-41-103] from the servo cover that does NOT
P-28692 have the servo piston neutral adjustment tie bolt.
Remove the cover (Item 2) [Figure 30-41-103] and
Slide the control feedback link (Item 1) toward the servo gasket.
piston and disengage it from the neutral adjustment link
(Item 2) [Figure 30-41-101]. Figure 30-41-104
Remove the control feedback link.
Figure 30-41-102
P-28701
Remove the servo piston adjustment seal nut (Item 1)

P-28694 [Figure 30-41-104] and discard.
NOTE: Once a servo adjustment seal nut has been

Remove the neutral adjustment link (Item 1) [Figure 30- removed, it should be discarded and replaced
41-102] from the pump housing. with new, to insure a proper seal.

CONTROL) (CONT'D)
1
Figure 30-41-105
1
1
P-28705
Remove the servo cover (Item 1) [Figure 30-41-107]

from the servo piston.
P-28703
Figure 30-41-108
Remove the five servo piston cover mount bolts (Item 1)

[Figure 30-41-105]. 1
Figure 30-41-106
1
P-28706
Remove the piston seals (Item 1) [Figure 30-41-108]

and O-rings located under the seals, from the servo
P-28704 piston.
Remove the servo cover and servo piston (Item 1)

[Figure 30-41-106] from the pump.

CONTROL) (CONT'D)
Figure 30-41-109 1
1
1 P-28744
Remove the three holddown pins (Item 1) and retainer

P-28681
Inspection: Rotating Group
Remove the piston assemblies and slipper retainer (Item

1) [Figure 30-41-109] from the cylinder block.
Figure 30-41-110
P-28743
Remove the ball guide (Item 1) [Figure 30-41-110].

CONTROL) (CONT'D)
Inspection
2
Figure 30-41-112
1
P-28747
Check the piston slippers (Item 1) [Figure 30-41-114] for

any excess wear or damage.
P-28745
Check the pistons (Item 2) [Figure 30-41-114] for any

discoloration, due to excessive heat.
Inspect the cylinder block surface, that runs against the
valve plate (Item 1) [Figure 30-41-112] for nicks or burrs. Figure 30-41-115
Figure 30-41-113
1 1
1
P-28750
P-28746
Check the pump housing and housing piston bore (Item
1) [Figure 30-41-115] for piston seal fragments,
Check the cylinder bores (Item 1) [Figure 30-41-113] for scratches or damage.
grooves or scratches.

CONTROL) (CONT'D)
Inspection (Cont'd)
Figure 30-41-116
1
1
P-28755
Check the swashplate surface (Item 1) [Figure 30-41-

118] for scratches or damage.
P-28706
Check the swashplate bearing surface (Item 2) [Figure
30-41-118] for wear.
Check the surface of the servo piston (Item 1) [Figure
30-41-116] for scratches or damage. Figure 30-41-119
Figure 30-41-117
P-28756
P-28751
Check the swashplate needle bearing (Item 1) [Figure
30-41-119] and replace as needed, as this bearing is a
Check the valve plate for wear. Run a finger nail over the serviceable part.
diameter of the sealing land surface (Item 1) [Figure 30-
41-117]. It should be free of deep groves.

CONTROL) (CONT'D)
Inspection (Cont'd)
1
Figure 30-41-120
P-28699
Check the control spool and spring (Item 1) [Figure 30-

41-122] for wear and replace as needed.
P-28767
Figure 30-41-123
Check the pump housing swashplate needle bearing

(Item 1) [Figure 30-41-120] for wear. If this bearing
needs to be changed, the complete pump housing must 1
be replaced, as the bearing is a non-serviceable part.
Figure 30-41-121
P-28690
Check the summing link (Item 1) [Figure 30-41-123] for

wear and replace as needed.
P-28679
Check the pump side cover swashplate needle bearing

(Item 1) [Figure 30-41-121] for wear. If this bearing
needs to be changed, the complete pump side cover
must be replaced, as the bearing is a non-serviceable
part.

CONTROL) (CONT'D)
Inspection (Cont'd)
Figure 30-41-124
P-28695
Check the neutral adjustment link (Item 1) [Figure 30-41-

126] for wear and replace as needed.
P-28696
Figure 30-41-127
Check the linkage pivot bolt (Item 1) [Figure 30-41-124]

for wear and replace as needed.
Figure 30-41-125
P-28697
1
Check the complete linkage assembly for wear [Figure
30-41-127].
P-28693
Check the control feedback link (Item 1) [Figure 30-41-

125] for wear and replace as needed.

CONTROL) (CONT'D)
Assembly
Figure 30-41-128
P-28787
Install a new O-ring (Item 1) [Figure 30-41-129] and new

piston ring (Item 2) [Figure 30-41-129] on the tie bolt end
P-28789 of the servo piston (Item 1) [Figure 30-41-130].
Lubricate the piston ring with a liberal amount of

Position the pump housing so the charge pump face is hydraulic oil.
pointing downward [Figure 30-41-128].
Figure 30-41-131
Figure 30-41-129
2
1
P-28786
P-28788
Install the servo piston in the corresponding housing bore

in the pump housing [Figure 30-41-131] .
Install the non-tie bolt end of the servo piston into the
housing first [Figure 30-41-131] .
Be sure the cavity for the servo piston/swashplate needle

bearing (Item 1) [Figure 30-41-131] faces the center of
the housing.

HYDROSTATIC PUMP (SELECTABLE JOYSTICK Install a new servo cover gasket (Item 1) [Figure 30-41-
CONTROL) (CONT'D) 133] .
Assembly (Cont'd) Figure 30-41-134
Figure 30-41-132
P-28783
P-28785
Spin the servo cover down as far as possible and slide
the piston back in the housing so the servo cover is
Push the servo piston through the housing far enough holding the gasket against the housing [[Figure 30-41-
that the other O-ring and piston seal may be installed 134].
(Item 1) [Figure 30-41-132].
Install the five servo cover mount bolts and finger tighten.
NOTE: Do not let the tie bolt end of the piston ring
pass completely through its bore. This will Figure 30-41-135
cause damage to the new piston rings earlier
installed.
1 1
Install the new O-ring and piston ring.
Lubricate the piston ring with a liberal amount of

hydraulic oil.
1
Figure 30-41-133 1
1
1
P-28782
Install the second servo cover gasket and cover. Install

the five mount bolts (Item 1) [Figure 30-41-135] and
tighten to 11-13 ft.-lbs. 15-17,5 Nm) torque.
P-28784
Push the servo piston back through the bore so the tie
bolt sticks back out of the housing and the piston is
almost flush with the housing [Figure 30-41-133].

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-136
1
1
1
P-28780
1 1
Install the control spool and spring (Item 1) [Figure 30-

41-138] into the pump housing.
P-28701
Figure 30-41-139
Tighten the tie bolt end, mount bolts (Item 1) [Figure 30-
41-136] to 11-13 ft.-lbs. 15-17,5 Nm) torque.
Install a new adjustment seal nut (Item 2) [Figure 30-41-

136] and tighten until the sealing face touches the servo
cover. 1
NOTE: The pump neutral adjustment must be made

to the pump after it is installed in the loader.
(See Pump Neutral Adjustment on Page 30-41-
48.) 2
Figure 30-41-137
P-28763
Install the center pin on the control feedback link (Item 1)

into the bore in the neutral adjustment link (Item 2)
[Figure 30-41-139].
P-28781
Rotate the pump housing so that the control face is

accessible [Figure 30-41-137].

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-140
1 2
1
3
P-28776
The neutral adjustment link (Item 1) should mate and

engage the neutral adjustment screw (Item 2), and both
P-28778 links should align with the pivot screw hole (Item 3)
[Figure 30-41-142].
Figure 30-41-141 Figure 30-41-143
1
2
P-28777
P-28775
Install the end of the feedback link containing the hole Install the linkage pivot screw (Item 1) [Figure 30-41-
(Item 1) [Figure 30-41-140] into the serrvo piston slot 143] and tighten to 6-11 ft.-lbs. (8-15 Nm) torque.
(Item 2) [Figure 30-41-141].

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-144
1
P-28772
Shift the control spool to the center of the housing until

the summing link pin (Item 1) [Figure 30-41-146] is
P-28774 located in the center.
Figure 30-41-147
Install the summing link (Item 1) [Figure 30-41-144] on to
the feedback link pin.
Figure 30-41-145
P-28771
Install a new gasket (Item 1) [Figure 30-41-147] on the

P-28773 pump housing controller face.
Move the control spool (Item 1) until the summing link

(Item 2) [Figure 30-41-145] lines up with the flat spot on
the control spool.

CONTROL) (CONT'D)
Assembly (Cont'd)
1
Figure 30-41-148
P-28687
Install the control spool bore plug (Item 1) [Figure 30-41-

150] and tighten to 30-70 ft.-lbs (41-94 Nm) torque.
P-28769
Figure 30-41-151
Install the control module on the pump housing.
NOTE: The pin on the summing link (Item 1) must

engage the bore (Item 2) [Figure 30-41-148] on
the control module for proper control
operation.
Figure 30-41-149
1
P-28768
1 Install the valve plate timing pin (Item 1) [Figure 30-41-

151] and allow it to stick out roughly 1/16 Inch, (1,588
mm) beyond the interface of the pump housing side
cover.
P-28770
Install the seven controller mount bolts (Item 1) [Figure

30-41-149] and tighten to 11-13 ft.-lbs. (15-17.5 Nm)
torque.

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-152
P-28766
2
Install the swashplate needle bearing (Item 1) [Figure

30-41-154] on the swashplate, so the letters on the
P-28684 bearing face the swashplate.
Figure 30-41-155
Install the pump valve plate (Item 1) and engage the
valve plate timing pin (Item 2) [Figure 30-41-152].
Lubricate the top surface of the valve plate with a coating

of hydraulic fluid. 1
Figure 30-41-153
P-28765
Install the swashplate and needle bearing into the servo

piston cavity (Item 1) [Figure 30-41-155].
P-28767
Be sure the servo piston cavity (Item 1) [Figure 30-41-

153] is facing the center of the pump.

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-156
P-28743
Install the ball guide (Item 1) [Figure 30-41-158] on the

hold down pins.
P-28748
Figure 30-41-159
Lightly coat all parts with hydraulic oil, before installing

the cylinder block.
Place the retainer ring (Item 1) [Figure 30-41-156] in the

cylinder block, so that it sits approximately 1/8 inch
(3,175 mm) below the surface.
Figure 30-41-157
P-28681
Install the slipper retainer, containing the slippers and

1 pistons [Figure 30-41-159].
Apply a liberal amount of hydraulic oil to the top and

bottom of the slippers and cylinder block.
P-28749
Install the three hold down pins (Item 1) [Figure 30-41-

157], making sure they are setting squarely in the
grooves.

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-160
P-28764
Install a new gasket (Item 1) [Figure 30-41-162] on the

side cover.
P-28682
Figure 30-41-163
Figure 30-41-161
1
1
P-28779
P-28680
Press down on the swashplate, with a clean rubber
mallet.
Lift the the end of the swashplate (Item 1) [Figure 30-41-
160] and insert the cylinder block assembly (Item 1) Install the side cover/swashplate bearing assembly (Item
[Figure 30-41-161]. 1) [Figure 30-41-163] into the pump housing .
Visually center the cylinder block assembly over the

valve plate [Figure 30-41-161].

CONTROL) (CONT'D)
Assembly (Cont'd)
Figure 30-41-164
1
P-28791
The pump neutral adjustment sets the position of the

servo piston and pump swashplate relative to the
P-28677 controlling mechanism.
Align the holes and the gasket, and install the six 10-10-1.)
mounting bolts(Item 1) [Figure 30-41-164] and tighten to
11-13 ft.-lbs (15-17,5) Nm torque. Raise the lift arms, and install an approved lift arm
Install the shaft assembly into the pump housing. (See Device on Page 10-20-1.)
Shaft Seal And Shaft Installation on Page 30-41-21.)
Install the charge pump. (See Charge Pump Removal on on Page 10-30-1.)
Page 30-41-23.)
Pump Neutral Adjustment Page 10-60-1.)
Figure 30-41-165 Connect a hydraulic hose between port M4 (Item 1)

[Figure 30-41-165] on the back side of the hydrostatic
pump, and port M5 (Item 1) [Figure 30-41-166] on the
front side of the hydrostatic pump, to equalize the
1 pressures on both ends of the servo piston.
P-28790

CONTROL) (CONT'D)
Pump Neutral Adjustment (Cont’d)
Figure 30-41-167
P-28790
1 Loosen the pump neutral adjustment lock nut (Item 1)

[Figure 30-41-169].
P-28791
Start the loader using the remote start tool and run at an
idle.
M1 port on the front side of the pump, and install a 7500 Figure 30-41-170
PSI pressure gauge.
Figure 30-41-168
1 P-28790
P-28791 Turn the adjustment screw (Item 1) [Figure 30-41-170]

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
Remove the plug (Item 1) [Figure 30-41-168] from the screw.
M2 port on the front side of the pump, and install a 7500
PSI pressure gauge.

CONTROL) (CONT'D)
Pump Neutral Adjustment (Cont’d)
Figure 30-41-171
P-28790
1 While holding the adjustment screw (Item 1) in position,

tighten the seal lock nut (Item 2) [Figure 30-41-173] to
P-28790 21-37 ft.-lbs. (28-51 Nm) torque.
Shut loader OFF.
Turn the adjustment screw (Item 1) [Figure 30-41-171]
counterclockwise, until the other gauge registers an Remove the hydraulic hose from the M4 and M5 ports on
increase in system pressure. Mark the position of the the pump. Install the plugs and tighten.
adjustment screw.
Remove the pressure gauges from the M1 and M2 ports
Figure 30-41-172 on the pump. Install the plugs and tighten.
NOTE: This pump is equipped with an EDC

Controller. The Controller Neutral Adjustment
procedure must be performed, before running
the loader. (See Pump Controller Neutral
Adjustment on Page 30-41-51.)
P-28790

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

CONTROL) (CONT'D)
Pump Controller Neutral Adjustment
Figure 30-41-174
1
1
P-28790
Remove the M4 plug (Item 1) [Figure 30-41-175] and

install a 500 PSI pressure gauge.
P-26464
Figure 30-41-176
The pump controller neutral adjustment, aligns the pump

swashplate and the control spool so that a zero angle
control setting provides a zero degree swashplate
setting. This adjustment should be performed whenever
any part of the control or swashplate mechanisms are
adjusted or removed or after the pump neutral setting is
adjusted.
Place the loader on jackstands. (See Procedure on Page 1

10-10-1.)
Raise the lift arms, and install an approved lift arm

support device. ((See Installing The Lift Arm Support
P-28791

on Page 10-30-1.) Remove the M5 plug (Item 1) [Figure 30-41-176] and
install a 500 PSI pressure gauge.
Page 10-60-1.)
Disconnect the pump controllers (Item 1) [Figure 30-41-

174] from the loader wiring harness.

CONTROL) (CONT'D)
Pump Controller Neutral Adjustment (Cont’d)
Figure 30-41-177
1
P-28791

counterclockwise, until the other gauge registers an
P-28791 increase in system pressure. Mark the position of the
adjustment screw.
Loosen the control spool neutral adjustment seal lock nut Figure 30-41-180
(Item 1) [Figure 30-41-177].
Start the loader using the remote start tool and run at an
idle.
Figure 30-41-178
1
P-28791

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
P-28791 pressures.

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SELECTABLE JOYSTICK
CONTROL) (CONT'D)
Pump Controller Neutral Adjustment (Cont'd)
Figure 30-41-181
P-28791
While holding the adjustment screw (Item 1) [Figure 30-

41-181] in position, tighten the seal lock nut (Item 2)
[Figure 30-41-181] to 10-18 ft.-lbs. (14-24 Nm) torque.
Shut loader OFF.
Remove the pressure gauges from the M4 and M5 ports

on the pump. Install the plugs and tighten.
Connect the pump controller wire connector to the loader

wiring harness.

30-41-54
Service Manual
DRIVE BELT Adjustment
Shield Removal And Installation Figure 30-50-3
Figure 30-50-1
1
1
2
P-34915
P-34906
The drive belt idler arm stop is located on the left side of
the engine block.

Stop the engine.
Remove the engine air cleaner. (See AIR CLEANER on
Open the rear door. Page 70-40-1.)
There are three belt shield holddown clips. Loosen the bolt (Item 1) [Figure 30-50-3] and slide the
stop (Item 2) [Figure 30-50-3] against the idler arm.
Remove the three belt shield holddown clips (Item 1) Tighten the bolt.
[Figure 30-50-1].
There is no adjustment for the spring, just make sure the
Figure 30-50-2 spring bolt (Item 3) [Figure 30-50-3] is tight.
Replacement
Remove the engine air cleaner. (See AIR CLEANER on

Page 70-40-1.)
Loosen the stop mounting bolt (Item 1) [Figure 30-50-3].
Loosen the spring tension bolt (Item 3) [Figure 30-50-3].
P-34907
Remove the belt shield (Item 1) [Figure 30-50-2] from

the drive belt housing.

DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
Replacement (Cont’d) Figure 30-50-6
Figure 30-50-4
2
1 1
P-34915
P-34265
Remove the belt shield. (See Replacement on Page 30-
50-1.)
Remove the fan drive belt from the tension pulley (Item 1)
[Figure 30-50-4]. Remove the engine air cleaner. (See AIR CLEANER on
Page 70-40-1.)
Figure 30-50-5
Remove the stop mounting bolt (Item 1) [Figure 30-50-
6].
Remove the stop (Item 2) [Figure 30-50-6].
Figure 30-50-7
P-34914
1
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley [Figure 30-50-5].
Remove the drive belt [Figure 30-50-5].

P-34916
Remove the spring tension bolt (Item 1) [Figure 30-50-

7].

DRIVE BELT (CONT'D) Figure 30-50-10
Tensioner Pulley Removal And Installation (Cont'd)

1
Figure 30-50-8
1
2
P5560
Remove the pulley/arm assembly (Item 1) [Figure 30-50-

P-34917 10] from the engine housing.
Remove the arm bushing (Item 2) [Figure 30-50-10].

Remove the end cap (Item 1) [Figure 30-50-8] from the Check for wear and replace as needed.
tension pulley arm.
Figure 30-50-11
Figure 30-50-9
P5553
P-34918
Check the arm seal (Item 1) [Figure 30-50-11]. Replace

Remove the mounting bolt (Item 1) [Figure 30-50-9] from the seal as needed.
the tension pulley arm.

DRIVE BELT (CONT'D) Tensioner Pulley Tension Spring
Tensioner Pulley Removal And Installation (Cont'd) Figure 30-50-14
Figure 30-50-12
P5551
P5561
Remove the base end bolt (Item 1) [Figure 30-50-14]
from the spring block.
Remove the pulley mounting bolt [Figure 30-50-12].
Remove the tension spring from the engine housing.
Figure 30-50-13
Figure 30-50-15
P5559
P5563
Disassembly the pulley and bearings as shown in figure

[Figure 30-50-13]. Remove the end block (Item 1) [Figure 30-50-15] (both
ends) from the spring.
Check the parts for wear and replace as needed.
Check the spring for wear and etc. Replace the spring as
needed.
Check the spring end blocks for wear and replace as

needed.

OIL COOLER (SEAL TO CONNECT) (STC) Figure 30-60-2
Hydraulic Oil Cooler Removal And Installation
1
IMPORTANT
damage the system.
I-2003-0888
P-37018
Figure 30-60-1
Install tool MEL1613 or MEL 1640 (Item 1) [Figure 30-

1 60-2] to the outside of the rubber sleeve.
NOTE: MEL 1613 is used on standard machines. MEL

1640 is used on machines equipped with 40
1 GPM high flow option or machines equipped
with the SJC option.
Slide the rubber sleeve in toward the radiator.
Figure 30-60-3
P-37017
1
Raise and remove the rear grill.
Drain the coolant from the radiator and remove the

radiator coolant tank.
Remove the two radiator coolant tank mount bolts (Item

1) [Figure 30-60-1].
P-37019
Remove the mount from the loader.
The connector will release from the radiator [Figure 30-

60-3].
Repeat the procedure for the other hose and fitting on the
cooler.
NOTE: When installing the cooler hoses, the fittings

should make a clicking sound when pushed
together.

OIL COOLER (SEAL TO CONNECT) (STC) (CONT’D)
Hydraulic Oil Cooler Removal And Installation

(Cont’d)
Figure 30-60-4
P-37020
Remove the clip (Item 1) [Figure 30-60-4]. (Both sides.)
Lift the oil cooler from the mount and remove it from the
loader.

DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-11-2
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-11-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Chaincase Cover Removal And Installation . . . . . . . 40-30-1
Rear Chaincase Cover Removal And Installation . . . . . . . 40-30-1
DRIVE
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 SYSTEM
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1
Axle, Sprocket And Bearings Removal And Installation . . 40-20-3
Drive Chain Removal And Installation . . . . . . . . . . . . . . . . 40-20-7

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION
SPEC-01) UNLESS OTHERWISE SPECIFIED.

BRAKE Figure 40-10-2
Disc Removal And Installation

1
2 2
WARNING P-34231
Never work on a machine with the lift arms up unless Remove the crossmember pivot bolt (Item 1) [Figure 40-
the lift arms are secured by an approved lift arm 10-2].
support device can allow the lift arms or attachment Remove the bolts and nuts (Item 2) [Figure 40-10-2]
to fall and cause injury or death. and remove pivot mount from the crossmember.
W-2059-0598
Figure 40-10-3
Figure 40-10-1
2 1
2
1
P-34125
P-34230
Disconnect the linkage from the control valve tilt spool
(Item 1) [Figure 40-10-3].
support device. Disconnect the crossmember from the control valve lift
spool (Item 1) [Figure 40-10-3].
Raise the operator cab.
Disconnect the wiring connector (Item 1) [Figure 40-10-

1] at the traction lock solenoid.

from the traction lock mount, and remove the traction lock
solenoid and mount bracket from the loader.

BRAKE (CONT'D) Figure 40-10-6
Disc Removal And Installation (Cont'd)
Figure 40-10-4
1
1
P-34234
Remove the fourteen center cover mounting bolts (Item

P-34232 1) [Figure 40-10-6].
Remove the center chaincase cover/guide assembly.
Remove the nut and bolt (Item 1) [Figure 40-10-4] that
attaches the lift linkage to the crossmember. Installation: Replace the chaincase cover gasket.
Tighten the bolts to 16-20 ft.-lbs. (22-27 Nm) torque.
Remove the crossmember from the pivot .
Figure 40-10-7
Figure 40-10-5
1 1
P7799
P-34233
Remove the two nuts (Item 1) [Figure 40-10-7] from the

Installation: Check the nylon bushing (Item 1) [Figure disc bolts.

BRAKE (CONT'D) Figure 40-10-10
Disc Removal And Installation (Cont'd)
Figure 40-10-8
1
P7865
Remove the disc (Item 1) [Figure 40-10-10] from the

P7801 shaft.
Figure 40-10-11
Remove the two disc bolts (Item 1) [Figure 40-10-8]
from the disc.
Figure 40-10-9 3
3
1
2
P13003
Installation: Bolting the disc to the snap ring provides

P7800 proper disc alignment. Disc and shaft are shown
removed for photo clarity. The snap ring end gap (Item 1)
[Figure 40-10-11] must be between the disc bolts (Item
A snap ring pliers with 905 tips are needed for removing 2) [Figure 40-10-11] and sprocket teeth (Item 3) [Figure
the brake disc snap ring. 40-10-11] after the brake disc is installed on the shaft.
Pull the disc away from snap ring.
Remove the snap ring (Item 1) [Figure 40-10-9] from the

end of the carrier shaft.

BRAKE (TWO-SPEED) Figure 40-11-3
Block Removal And Installation
Figure 40-11-1
1
1
2 P-34092
Disconnect the two hydraulic hoses (Item 1) [Figure 40-

P-34096 11-3] from the brake/two speed block.
Figure 40-11-4
1.)
Raise the operator cab. ((See Raising The Operator Cab 1

on Page 10-30-1.)
Remove the steering shock (Item 1) [Figure 40-11-1].

2
Mark all hydraulic hoses for proper installation.
Disconnect the two hydraulic hoses (Item 2) [Figure 40-

11-1] from the brake/two speed block.
Figure 40-11-2
P-34093
1 Disconnect the wire harness connector (Item 1) [Figure

40-11-4] from the brake solenoid.
Disconnect the wire harness connector (Item 2) [Figure

40-11-4] from the two speed solenoid.
1
P-34091
Disconnect the four hydraulic hoses (Item 1) [Figure 40-

11-2] from the brake/two speed block.

BRAKE (TWO-SPEED) (CONT'D) Block Disassembly And Assembly
Block Removal And Installation (Cont'd) Figure 40-11-7
Figure 40-11-5
1
1
1
1
1
P-34097
P-34094
Mark all hydraulic hoses and fittings for proper
installation.
40-11-5] from the make-up valve solenoid. Remove the hydraulic fittings (Item 1) [Figure 40-11-7]
from the block.
Figure 40-11-6
Figure 40-11-8
P-34095
P-34098

6] from the valve. Remove the check valves (Items 1 & 2) [Figure 40-11-8]
from the two-speed valve.
Remove the brake/two-speed block from the loader.
NOTE: The check valves (Items 1 & 2) [Figure 40-11-
8] are interchangable.

BRAKE (TWO-SPEED) (CONT’D) Figure 40-11-11
Block Disassembly And Assembly (Cont'd)
Figure 40-11-9
P-34112
Use a test meter and test the solenoid (Item 1) [Figure

N-22580 40-11-11] for resistance.
The resistance value for the solenoid coil can be found

Check the back-up washers (Item 1) [Figure 40-11-9] on the electrical schematic. (See ELECTRICAL SYSTEM
and O-rings (Item 2) [Figure 40-11-9] for wear and INFORMATION on Page 60-10-1.)
replace as needed.
Figure 40-11-12
Figure 40-11-10
2
1 P-34111
P-34099
Use a test meter and test the brake solenoid (Item 1)

Loosen the electrical solenoid nut (Item 1) [Figure 40-11- [Figure 40-11-12] for resistance.
10] from the make-up valve solenoid.
Remove the brake solenoid nut (Item 2) [Figure 40-11- on the electrical schematic. (See ELECTRICAL SYSTEM
10] from the brake solenoid. INFORMATION on Page 60-10-1.)
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49

Nm) torque.

BRAKE (TWO-SPEED) (CONT'D) Figure 40-11-15
Figure 40-11-13
P-34105A
1 2
Assembly: Always install new O-rings. Tighten the
P-34101 solenoid valve to 20 ft.-lbs. (27,1 Nm) torque.
Check the O-rings [Figure 40-11-15] and replace as
Remove the solenoid valve (Item 1) [Figure 40-11-13] needed.
from the block.
Figure 40-11-16
Remove the brake solenoid (Item 2) [Figure 40-11-13]
from the block.
Figure 40-11-14
1
1 P-34102
Remove the plugs (Item 1) [Figure 40-11-16] from the

N-22584 brake/two-speed block.
Assembly: Always install new O-rings and back-up

washers [Figure 40-11-14]. Tighten the solenoid valve to
20 ft.-lbs. (27,1 Nm) torque.

BRAKE (TWO-SPEED) (CONT'D) Figure 40-11-19
Figure 40-11-17 1
N-22610
Use a test meter and test the solenoid (Item 1) [Figure

1 P-34103 40-11-19] for resistance.

Check the O-ring (Item 1) [Figure 40-11-17] on the plugs on the electrical schematic. (See ELECTRICAL SYSTEM
and replace as needed. INFORMATION on Page 60-10-1.)
Figure 40-11-18 Replace the O-rings (Item 2) [Figure 40-11-19].
Figure 40-11-20
P-34104
N-22611
Remove the two speed solenoid nut (Item 1) [Figure 40-
11-18].
Assembly: Always install new O-rings. Tighten the
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49 solenoid valve to 20 ft.-lbs. (27,1 Nm) torque.
Nm) torque.
Check the O-rings [Figure 40-11-20] and replace as
needed.

DRIVE COMPONENTS
Axle Seal Removal And Installation

WARNING
Figure 40-20-1
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
2 W-2186-0395
Remove the hub from the axle.
Figure 40-20-3
1
2
1
P4850

1.)
Remove the tire/wheel assembly.
Installation: Tighten the wheel nuts to 105-115 ft.-lbs.

(142-155 Nm) torque.
P4848
Remove the bolts (Item 1) [Figure 40-20-1] and plate.

Remove the key (Item 1) [Figure 40-20-3] from the axle.
Installation: Tighten the bolts to 175-190 ft.-lbs. (240-
260 Nm) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1]

across from each other.
Figure 40-20-2
P4849
Install puller (Item 1) [Figure 40-20-2] on the wheel hub.

DRIVE COMPONENTS (CONT'D)
Axle Seal Removal And Installation
Figure 40-20-4
P4817
Install a slide hammer (Item 1) [Figure 40-20-4] with a
screw tip end into the axle seal.
Remove the axle seal.

procedure:
MEL1407 - Seal Installation Tool
Figure 40-20-5
P4814
Place the seal with the lip facing in [Figure 40-20-5].
Use a hammer, install the new axle seal until the tool is
flush with the edge of the axle tube [Figure 40-20-5].

DRIVE COMPONENTS (CONT'D) Lift and block the loader. (See Procedure on Page 10-10-
1.)
Axle, Sprocket And Bearings Removal And
Installation Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
procedure: Remove the front panel/steering lever assembly. (See
MEL1242 - Port-a-Power
MEL1202B - Axle Bearing Service Set Remove the front cover. (See Front Chaincase Cover
NOTE: The procedure shown for removal and
installation of the axle, sprocket and bearings Remove the fluid from the chaincase. (See CHAINCASE
is for a front axle. This procedure will be the on Page 40-30-1.)
same for the rear axle.
Remove the axle sprocket bolt (Item 1) [Figure 40-20-6]
and backing washer (Item 2) [Figure 40-20-6].
Installation: Tighten the axle sprocket bolt to 475-525

Figure 40-20-7
WARNING
support device. Failure to use an approved lift arm 1
W-2059-0598 2
P4850
Figure 40-20-6
Remove the bolts (Item 1) [Figure 40-20-7] and plate.
Installation: Tighten the bolts to 175-190 ft.-lbs. (240-

260 Nm) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-7]

2 across from each other.
P4810


DRIVE COMPONENTS (CONT'D) Figure 40-20-10

Installation (Cont'd)
1
Figure 40-20-8
P5406
1
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
P4849 procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Install a puller (Item 1) [Figure 40-20-8] on the wheel
hub. Remove the sprocket (Item 1) [Figure 40-20-10] and
inner bearing (Item 2) [Figure 40-20-10].
Installation: Pack the inner and outer bearing with

WARNING grease before installing them.
Figure 40-20-11
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395
1
Remove the hub from the axle.
Figure 40-20-9
P-4170
A bearing puller (Item 1) [Figure 40-20-11] is needed to

do the following procedure:
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-11].
P4809
NOTE: Hold the axle during removal because it will
slide freely after the bearing is removed from
Install a Port-a-Power ram between the two sprockets the mounting surface.
[Figure 40-20-9].


0.858 inch.
Figure 40-20-12 (21,8 mm)
Diameter
.3125 inch.
(7,93 mm)
2.440 inch.
(61,9 mm)
Diameter
MC-2165
Use the tools provided in the MEL1202B Axle Bearing

Service Set. A slide hammer is also needed.
P-4171
Use the dimensions shown in figure [Figure 40-20-14] to

make a bearing cup removal tool.
Press the splined end of the axle free from the bearing
[Figure 40-20-12]. Figure 40-20-15
Figure 40-20-13
1
1
P4812
P-4175
Use the long driver handle (Item 1) [Figure 40-20-15]
and the bearing cup removal tool (shown in figure
Installation: Put the spline end of the axle shaft into the [Figure 40-20-14]) to remove the inner bearing cup.
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation because it

will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-

20-13] that contacts inner race of the bearing only.
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-13].


Figure 40-20-16
Bearing Cup
Tool
P4816
Use the slide hammer to remove the bearing cup from

Recess the axle tube [Figure 40-20-18].
MC-2164
Figure 40-20-19
The bearing cup removal tool must fall into the recess
behind the bearing cup, drive the cup out of the axle tube 2
[Figure 40-20-16].
1
Figure 40-20-17
P5468
Use the bearing cup installation tool (Item 1) [Figure 40-

20-19] and (Item 1) [Figure 40-20-20].
P5637 Put the inner cup (Item 2) [Figure 40-20-19] in the axle
tube.
To remove the outer bearing, install a bearing cup Install the long treaded rod (Item 2) [Figure 40-20-20]
removal tool (shown in figure [Figure 40-20-14]) on the into the axle tube and through the installation tool (Item
slide hammer. 1) [Figure 40-20-19].
Install the slide hammer/tool assembly behind the Install the nut (Item 3) [Figure 40-20-19].
bearing cup [Figure 40-20-17].

DRIVE COMPONENTS (CONT'D)

Figure 40-20-20
P4811
Install the installation tool (Item 1) [Figure 40-20-20] on

the threaded rod. Install the nut.
Hold the inside nut (Item 3) [Figure 40-20-19] with a

wrench and tighten the outside nut [Figure 40-20-20].
Tighten the nut until the bearing cup is seated.
Remove the installation tool and threaded rod.
Figure 40-20-21
P4813
To install the outer bearing cup, install the bearing cup

installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-21].

DRIVE COMPONENTS (CONT'D) Remove the front and rear chaincase cover. (See
CHAINCASE on Page 40-30-1.)
Drive Chain Removal And Installation
Remove the rear axle. (See Axle, Sprocket And Bearings
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.)
NOTE: It is necessary to remove the rear axle and

drive chain if the front chain has to be
removed.
WARNING
W-2059-0598
Figure 40-20-22
Front Drive
Chain
Rear Drive
Chain
P5478


1.)

on Page 10-30-1.)
Remove the front panel/steering lever assembly. (See

Remove the center chaincase cover. (See CHAINCASE

on Page 40-30-1.)

CHAINCASE Figure 40-30-2
Front Chaincase Cover Removal And Installation
Figure 40-30-1
1
2
1
P5676

P5382 support device. (See Installing The Lift Arm Support
Remove the control panel. (See Removal And Installation Raise the operator cab. (See Raising The Operator Cab
on Page 50-100-1.) on Page 10-30-1.)
Remove the mounting bolts from the front chaincase Remove the mounting bolts from the rear chaincase
cover (Item 1) [Figure 40-30-1]. cover (Item 1) [Figure 40-30-2].
Remove the cover. Remove the cover (Item 2) [Figure 40-30-2].
Rear Chaincase Cover Removal And Installation
WARNING
W-2059-0598

MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Steering Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE

HAND/FOOT CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Control Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . 50-111-5
Control Handle Removal And Installation . . . . . . . . . . . . . . . . . . . 50-111-4
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-7
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . . 50-111-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . 50-111-1
MAIN FRAME
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC) . 50-112-1

Lever Assembly Removal (Right & Left) . . . . . . . . . . . . . . . . . . . . 50-112-3
Joystick Boot Removal (Right & Left) . . . . . . . . . . . . . . . . . . . . . . 50-112-3
Joystick Removal (Right & Left). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
Joystick Testing (Right & Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
CONTROL PANEL (NON-ADJUSTABLE PINTLES) . . . . . . . . . . . . . 50-100-1

Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
CONTROL PANEL (ADJUSTABLE PINTLES) . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-12
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-6
Linkage Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-16
Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 50-101-11
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-4
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-4
CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) . . 50-102-1

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

MAIN FRAME (CONT’D)
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Foot Pedal Linkage Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 50-91-2
Foot Pedal Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
INSIDE ACCESS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) . 50-121-1

Panel Removal (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-4
Panel Removal (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Installation Of Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-5
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Stabilizer Bar Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . 50-20-3
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Seat Belt Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-31-5
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . 50-41-5
Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-3

MAIN FRAME (CONT’D)
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Door Latch and Catch Adjustment . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . . . . 50-10-3



SEAT BAR Figure 50-10-3
Figure 50-10-1
1 1
P-31288 P-31289
Loosen the nut (both sides) at the front corner of the

N-19225 operator cab [Figure 50-10-3].
Remove the nuts and plates [Figure 50-10-3] (both

Raise the seat bar (Item 1) [Figure 50-10-1]. sides).
N-18463 P-31267
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2] Lift on the grab handle and bottom of the operator cab
from the cab harness. slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].
Lower the seat bar.

SEAT BAR (CONT'D) Assembling Components
Removal And Installation (Cont'd) Figure 50-10-7
Figure 50-10-5
5 6
4
7
1
3
8
1 9
2
10
N-19383
N-18572
Figure 50-10-8
Remove the seat bar mounting nuts (Item 1) [Figure 50-
10-5] (both sides).
4 5 9 8
Installation: Tighten the nuts to 28 ft.-lbs. (38 Nm)
torque. 6
3
Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
2 10
Figure 50-10-6
1
1
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Seat Bar Mount (Item 1)

Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
N-19224 Seat Bar (Item 4)
Magnetic Busing Assembly (Item 5)
Remove the seat bar (Item 1) [Figure 50-10-6] from the Pivot Bushing (Item 6)
operator cab. Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Reverse the above procedure to install the seat bar into Sensor Mounting Bolt (Item 9)
the operator cab. Mounting Nut (Item 10)
Installation: Tighten the mounting bolt (Item 2) [Figure

50-10-7] & [Figure 50-10-8] to 50-70 in.-lbs. (5,6-7,9
Nm) torque.

SEAT BAR (CONT'D) Compression Spring Disassembly And Assembly
Assembling Components (Cont'd) Figure 50-10-11
Figure 50-10-9 1
4 5
6
3 7
N-19222
1
N-19340
Turn the bolt (Item 1) [Figure 50-10-11] & [Figure 50-10-
12] out of the clevis.
Figure 50-10-10
Assembly: Apply LOCTITE #518 adhesive to the bolt
threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
4 5 NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
3 affected parts before the application of
6
2 LOCTITE #518.
Figure 50-10-12
7
8 7
1
5 6
4
N-19220
3
Assemble the parts as shown for the right side of the seat 2
bar pivot assembly [Figure 50-10-9] & [Figure 50-10- 1 N-19384
10].
Seat Bar Mount (Item 1) Disassemble and assemble the seat bar compression
Mounting Nut (Item 2) spring and parts as shown in Fig. [Figure 50-10-12].
Pivot Bushing (Item 3) Bolt (Item 1)
Spacer Bushing (Item 4) Bushing (Item 2)
Seat Bar (Item 5) Spring (Item 3)
Keyed Plastic Bushing (Item 6) Bushing (Item 4)
Mounting Bolt (Item 7) Clevis (Item 5)
Retaining Pin (Item 6)
Installation: Tighten the mounting bolt (Item 7) [Figure Bushing (Item 7)
50-10-9] & [Figure 50-10-10] to 50-70 in.-lbs. (5,6-7,9 Pin (Item 8)
Nm) torque.
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open. 1
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
P-31546
Install a chain (Item 1) [Figure 50-20-2] from the

operator cab to the loader main frame to prevent the cab

1 from tipping forward when the gas cylinder(s) are
removed.
Figure 50-20-3
P-31545
Remove the operator cab stop (Item 1) [Figure 50-20-1]. 2

(Both sides.)
NOTE: Be careful not to break the rear window (if so

equipped) when the cab is raised after the cab
stops are removed. 1

on Page 50-20-1.)
P-31547
Remove the bolt (Item 1) [Figure 50-20-3] from the gas

cylinder mounting bracket.
Loosen the mount bolt (Item 2) [Figure 50-20-3].

Gas Cylinder Removal And Installation (Cont'd)
Figure 50-20-4
1
2
1
1
P-31549
Installation: Mount the gas cylinder to the cab pivot pin

P-31548 [Figure 50-20-5]. Install the front mount bolt (Item 1)
[Figure 50-20-6]. Use a locking pliers and turn the mount
bracket to allign the bracket with the hole (Item 2)
Turn the mounting bracket forward to relieve any [Figure 50-20-6]. Install the bolt and tighten the mount
remaining tension on the gas cylinder [Figure 50-20-4]. bolts to 15-20 ft.-lbs. (20,3-27,1 Nm) torque.
Remove the mount bolt (Item 1) [Figure 50-20-4].
Figure 50-20-5
N-19719
Remove the retainer clip (Item 1) [Figure 50-20-5] from

the top pivot pin.
Remove the gas cylinder from the cab.
Repeat the procedure for the opposite side.

OPERATOR CAB (CONT'D) Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly Figure 50-20-9
Figure 50-20-7
2 P-31289
1
P1008
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-9] (both sides).

Remove the clevis (Item 1) [Figure 50-20-7] and washer
(Item 2) [Figure 50-20-7] from the end of the gas Installation: Tighten the nut to 40-50 ft.-lbs. (54-68 Nm)
cylinder. torque.
Remove the gas cylinder from the outer housing. Raise the operator cab. (See Raising The Operator Cab
on Page 50-20-1.)
Figure 50-20-8
Figure 50-20-10
P1006
P-31550
Assembly: Install a replacement cylinder inside the

cylinder housing. Disconnect the two wiring harness connectors (Item 1 &
2) [Figure 50-20-10].
Apply a small amount of LOCTITE on the threads of the
cylinder rod [Figure 50-20-8]. Remove the tie-straps (Item 3) [Figure 50-20-10] from
the wiring harness.
Reinstall the washer and clevis on the cylinder rod.

Figure 50-20-11
1
P-31546
P-31551
Install a chain (Item 1) [Figure 50-20-13] from the
operator cab to the loader main frame to prevent the cab
Disconnect the electrical connector (Item 1) [Figure 50- from tipping forward when the gas cylinders are
20-11]. removed.
Figure 50-20-12 Remove both gas cylinders. (See Gas Cylinder Removal
And Installation on Page 50-20-1.)
P-31552
Remove the mount bolt (Item 1) [Figure 50-20-12] from

the wire harness mount bracket (Item 2) [Figure 50-20-
12] and ground strap (Item 3) [Figure 50-20-12].
Remove the tie-straps from the wiring harness.
Position the wiring harness, so that it does not get

damaged when the cab is removed.

Figure 50-20-14
P-31554
Move the operator cab forward a small amount for

P-31553 clearance at the pivot mounting brackets [Figure 50-20-
16].
Connect a sling and chain hoist to the operator cab grab Install the pivot bolt, washer and nut (Item 1) [Figure 50-
handles and lower (or raise) the operator cab when the 20-16] in the cab pivot (both sides).
gas cylinders are disconnected [Figure 50-20-14].
Install the sling under the pivot bolt and pivot of the
Figure 50-20-15 operator cab [Figure 50-20-16].
Figure 50-20-17
1
2
P-31545
P-31555
Remove the operator cab stop (Item 1) [Figure 50-20-
15].
Connect the slings (Items 1 & 2) [Figure 50-20-17] to a
Remove the nut (Item 2) [Figure 50-20-15] from the pivot chain hoist.
bolt (both sides).
Remove the operator cab from the loader [Figure 50-20-
Installation: Tighten the pivot bolt and nut to 25-35 ft.- 17].
Remove the pivot bolt (both sides).

OPERATOR SEAT Seat Belt Removal And Installation
Figure 50-30-1
1 1
2
1
N-20729
N-20729
on Page 10-30-1.)
on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation
(Items 1 & 2) [Figure 50-30-3] and peel back or cut
Remove the four seat mounting nuts (Item 1) [Figure 50- insulation to gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27

Nm) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Items 1 & 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54

ft.-lbs. (73 Nm) torque. Tighten nut (Item 2) [Figure 50-
P-31288 P-31289 30-4] to 34 ft.-lbs. (46 Nm) torque.
Repeat for other half of seat belt and guide.

Lower the cab and install one of the mounting washer
and nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.

OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Figure 50-31-1
2
N-20974
NOTE: Assure seat tethers are securely fastened to

N-20647 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)
Remove the four seat mounting nuts (Item 1) [Figure 50-

31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27

Nm) torque.
Figure 50-31-2
1 N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P-31288 P-31289
Lower the cab and install one of the mounting washer

and nut [Figure 50-31-2].
NOTE: With the seat removed the cab will raise.

seat.

OPERATOR SEAT (SUSPENSION) (CONT'D) Seat Belt Removal and Installation
Slide Rail Removal And Installation Figure 50-31-6
Figure 50-31-5
1
1
1
2 2
1
1
N-20974
1
N-18587
Remove the nut (Item 1) [Figure 50-31-6] from the seat
belt mount.
Raise the operator cab. ((See Raising The Operator Cab
on Page 10-30-1.) Remove the seat belt.
Remove the operator seat. (See Removal And Installation: Tighten the mounting nuts to 58 to 62 ft.-lbs.
Installation on Page 50-31-1.) (78.6 to 84 Nm) torque.
Remove the two slide rail mounting bolts (Item 1) [Figure

50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the

bottom of the seat frame.

seat slide rail.

OPERATOR SEAT (SUSPENSION) (CONT'D) Figure 50-31-9
Cushion Removal And Installation
Figure 50-31-7
N-18580
Inspect the seat ride adjustment [Figure 50-31-9].

P-43119
seat back.
Remove the clips (Item 1) [Figure 50-31-7] from the seat
cushion.
Figure 50-31-8
P-43120
Lift and remove the seat cushion (Item 1) [Figure 50-31-

8] from the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT'D) Shock Removal And Installation
Back Removal And Installation Figure 50-31-12
Figure 50-31-10
1
2
P-43118
N-18583
on Page 10-30-1.)
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-10] and tilt the seat back all the way forward. Remove the operator seat. (See Removal And
Figure 50-31-11
Remove the seat shock mounting bolts (Item 1) [Figure
50-31-12] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-12].

seat shock.
1 1
N-18578
Remove the two mounting screws (Item 1) [Figure 50-

31-11] from the seat back and remove the back.

seat back.

OPERATOR SEAT (SUSPENSION) (CONT’D) Installation: Be sure tether strap (Item 3) [Figure 50-31-
14] is on the seat belt stud behind the seat belt retractor.
3-Point Seat Belt Removal And Installation
Figure 50-31-15
on Page 10-30-1.)
Remove the operator seat. (See Removal And

Figure 50-31-13
OUTSIDE OF CAB
P16131
Remove the mounting bolt (Item 1) [Figure 50-31-15]

3 Figure 50-31-16
P16285
1 2
Remove the end release buckle (Item 2) [Figure 50-31- P16126

13].
Installation: Be sure tether strap (Item 3) [Figure 50-31-

13] is on the seat belt stud behind the end release
buckle.
Figure 50-31-14
INSIDE OF CAB
P16128
Remove the shoulder harness retractor (Item 1) [Figure

2 50-31-16].
Installation: Line up the bolt (Item 1) [Figure 50-31-15]

1 with the mounting bracket (Item 2) [Figure 50-31-16] on
the inside of the cab.
3 Installation: Be sure tether strap (Item 3) [Figure 50-31-

14] is on the seat belt stud behind the seat belt retractor.
P16284
Remove the mounting bolt (Item 1) [Figure 50-31-15]
Remove the mounting nut (Item 1) [Figure 50-31-14].
Remove the seat belt retractor (Item 2) [Figure 50-31-

14]

BOB-TACH Figure 50-40-3
Figure 50-40-1
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-40-3] from the

P-31400 Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.
Remove the retainer nut (Item 1) [Figure 50-40-1] and

bolt from the tilt cylinder rod end pin (both sides).

Figure 50-40-2
1
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].
P-31401
Remove the pivot pin (Item 1) [Figure 50-40-2] from the

tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).

BOB-TACH (CONT'D) Figure 50-40-7
Figure 50-40-5
P-31406
1
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
P-31405 the Bob-Tach pin.
Figure 50-40-8
Check and replace O-ring (Item 1) [Figure 50-40-5] on
the grease plug.
Figure 50-40-6
1
1
P-31407
With a 7/8” (.875 mm) drift (Item 1) [Figure 50-40-8] and

P-31403 a hammer, drive the pivot pin out of the lift arm & Bob-
Tach.
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-

Tach pivot pin retaining bolt (both sides).
Installation: Tighten the retainer nut and bolt to 190 ft.-

lbs. (258 Nm) torque.

BOB-TACH (CONT’D) Figure 50-40-11
Bob-Tach Lever And Wedge
Figure 50-40-9
P-31410
Use a punch and hammer, remove the roll pin (Item 1)

P-31408 [Figure 50-40-11] from the Bob-Tach wedge and spring
clevis.
Tilt the Bob-Tach forward, so it is parallel to the floor. Put Remove the spring/clevis (Item 2) [Figure 50-40-11]
blocks (approximately 3 inches) under each side of the assembly.
Bob-Tach [Figure 50-40-9].
Figure 50-40-12
Tach lever pivot bolt.
NOTE: Removal procedure is shown for the left side.

Right side procedure is the same.
1
Figure 50-40-10
P-31411
2
3
Remove the wedge (Item 1) [Figure 50-40-12] out of the
bottom of the Bob-Tach
Always replace bent or broken wedges.

P-31409
Remove the lever mounting washer (Item 1) [Figure 50-

40-10], spring (Item 2) [Figure 50-40-10] and lever (Item
3) [Figure 50-40-10].

torque.

BOB-TACH (CONT’D)
Bob-Tach Lever And Wedge (Cont’d)
Figure 50-40-13
2 3 4
1
P5345
If the bolt (Item 1) [Figure 50-40-13], handle pivot (Item
2) [Figure 50-40-13], spring (Item 3) [Figure 50-40-13]
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as

needed,
Reverse the removal procedure to install the Bob-Tach

lever and wedge.

POWER BOB-TACH Figure 50-41-3
Figure 50-41-1
P-31401
2 1 2
Remove the pivot pin (Item 1) [Figure 50-41-3] from the
P-31379 tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1]. Figure 50-41-4
Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove the hoses from the cylinder fittings.

the cylinder (both ends).
Remove the cylinder from the Bob-Tach.

1
Figure 50-41-2
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

Bob-Tach pivot pin grease plug (both sides).
P-31400
Remove the retainer nut and bolt (Item 1) [Figure 50-41-

2] from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer nut to 18-20 ft.-lbs. (24-

27 Nm) torque.

POWER BOB-TACH (CONT'D) Figure 50-41-7
Figure 50-41-5
P-31403
1
P-31404 Tach pivot pin retaining bolt (both sides).
Installation: Tighten the retainer nut and bolt to 190 ft.-
Use a grease gun and pump grease into the pivot pin lbs. (258 Nm) torque.
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides). Figure 50-41-8
Figure 50-41-6
1
P-31406
P-31405
the Bob-Tach pivot pin (both sides).
Check and replace the O-ring (Item 1) [Figure 50-41-6]
on the grease plug.

POWER BOB-TACH (CONT’D) Figure 50-41-11
Figure 50-41-9
P-31408
1
Remove the lever mounting nut (Item 1) [Figure 50-41-
P-31407 11].

With a 7/8” (.875 mm) drift (Item 1) [Figure 50-41-9] and torque.
a hammer, drive the pivot pin out of the lift arm and Bob-
Tach (both sides). Figure 50-41-12
Remove the Bob-Tach from the loader.
Power Bob-Tach Lever And Wedge
Figure 50-41-10
1
P-31409
1
1 Remove the washer and spring, (Item 1) [Figure 50-41-
12] and the lever assembly (Item 2) [Figure 50-41-12].
P-31379
Remove the washers and bolts (Item 1) [Figure 50-41-

10] (both ends of the cylinder).

Nm) torque.
Remove the cylinder from the lever pivots.

POWER BOB-TACH (CONT'D) Figure 50-41-15
Power Bob-Tach Lever And Wedge (Cont'd)
Figure 50-41-13 4
1
3 2
2
N-20625
If the bolt (Item 1) [Figure 50-41-15], handle pivot (Item

P-31410 2) [Figure 50-41-15], spring (Item 3) [Figure 50-41-15],
or clevis (Item 4) [Figure 50-41-15] are damaged, put the
assembly in a vise.
Use a punch and hammer to remove the roll pin (Item 1)
[Figure 50-41-13] from the Bob-Tach Wedge and spring Remove the bolt and replace the damaged parts as
clevis. needed.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
Figure 50-41-14
P-31411
Remove the wedge (Item 1) [Figure 50-41-14] out of the

bottom of the Bob-Tach.
Always replace bent or broken wedges.

POWER BOB-TACH (CONT'D)
Pivot Pin Bushing And Seal Replacement
Figure 50-41-16
2 1
N-18557
Remove the Power Bob-Tach. (See Removal And

Use a seal pick to remove seal (Item 1) [Figure 50-41-

16] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-16]

with a driver tool and hammer.

LIFT ARMS Installation: Tighten the retainer bolt to 18-20 ft.-lbs.
(24-27 Nm) torque.
Stabilizer Bar Removal And Installation
.
Figure 50-50-1
Figure 50-50-3
2
1
P-31412
P-31413

on Page 10-30-1.) Remove the stabilizer bar, rear pivot pin (Item 1) [Figure
50-50-3]
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time. Remove the stabilizer bar from the loader.
Remove the retainer bolt (Item 1) [Figure 50-50-1] and Figure 50-50-4
nut from the front stabilizer bar pivot pin.

Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
Figure 50-50-2 1
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

1 stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-31414

the stabilizer bar rear pivot pin at the lift arm.

LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation
Figure 50-50-5
P-31562
Remove the lift arm pivot pin (Item 1) [Figure 50-50-7]

P-31415 (both sides).
Figure 50-50-8
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].
Figure 50-50-6
2
P-31563
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
P-31416 8] (both sides).
Remove the lift arm link from the loader.

6] from the lift arm pivot pin (both sides).

6] from the lift arm link pivot pin (both sides)
Installation: Tighten retainer bolt and nut to 18-20 ft.-lbs.

(24-27 Nm) torque.

LIFT ARMS (CONT'D) Disconnect the hydraulic hose (Item 1) [Figure 50-50-10]
from the filter that goes to the case drain on the auxiliary
Removal And Installation hydraulic coupler.
Figure 50-50-9 Cap and plug the hose and filter fittings.
Figure 50-50-11
1
P-31564 2
P-31572
WARNING Pull the hose (Item 1) [Figure 50-50-11] up and out of

the upright to allow for lift arm removal.
Lift arms must be fully lowered before removing the
Mark the auxiliary hydraulic hoses and tubelines for
stabilizer link pins. Even with the approved lift arm
proper installaion.
support installed, the lift arms and links can
suddenly move if both link pins are removed with the
Disconnect the two auxiliary hydraulic hoses (Item 2)
lift arms raised.
W-2358-0999
[Figure 50-50-11].
Figure 50-50-12
on Page 10-30-1.)
Remove the left side access panel (Item 1) [Figure 50-

50-9].
Figure 50-50-10
1
2
P-31566
At the right side of the loader, mark the two tilt hoses and
tubelines. Disconnect the two tilt hoses (Item 1) [Figure
50-50-12] from the tubelines.
P-31565

Figure 50-50-13
P-31571
Position the front sling in the middle of the Bob-Tach as

P-31567 shown in (Item 1) [Figure 50-50-15].
Support the lift arms with the chain hoist.
Install slings and a chain (Item 1) [Figure 50-50-13] on
the lift arms and connect to a chain hoist. Figure 50-50-16
Figure 50-50-14
P-31568
P-31570
With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-16]. (Both sides.)
NOTE: Be sure the slings on the lift arms are in a
position to balance the lift arms when being
remove. See (Item 1) [Figure 50-50-14].

Figure 50-50-17
1
2
P-31569
Install pivot pin retainer bolt and nut (Item 1) [Figure 50-
P-31569 50-19] (both sides).

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (24-27 Nm) torque.
17] from the lift arm pivot pin (both sides).
Figure 50-50-20
Remove the lift arm pivot pin (Item 2) [Figure 50-50-17]
(both sides).
Using the chain hoist, remove the lift arms from the
loader.
Installation Of Lift Arms
Figure 50-50-18
P-31561
Remove the chain hoist and lift slings from the lift arms.
Support the front of the lift arms with a floor jack.
P-31570
Install lift arms.
Install the lift arm pivot pin (Item 1) [Figure 50-50-18].

(Both sides.)

LIFT ARMS (CONT'D)
Installation Of Lift Arms (Cont’d)
Figure 50-50-21
P-31560
Reposition the lift straps and lower cab [Figure 50-50-
21].
Move the lift arms and link toward the rear of the
machine, using the chain hoist and floor jack until
stabilizer bar pins line up.
Figure 50-50-22
P-31414
Install the stabilizer pins (Item 1) [Figure 50-50-22] (both

sides).
Install the stabilizer pin retainer bolt and nut (Item 2)

[Figure 50-50-22] (both sides).

(24-27 Nm) torque.

REAR GRILL Figure 50-60-3
Figure 50-60-1
P-31558
Lift and pull the rear grill and remove it from the loader
P-31556 [Figure 50-60-3].
Figure 50-60-4
Open the rear door (Item 1) [Figure 50-60-1].
Figure 50-60-2
2
1
P-31559
P-31557 Installation: Insert the tab on the rear grill (Item 1)

[Figure 50-60-4] into the notch (Item 2) [Figure 50-60-4]
on the loader frame. (Both sides.)
Lift the rear grill assembly (Item 1) [Figure 50-60-2] over
the muffler.

REAR DOOR Connect a chain hoist (Item 2) [Figure 50-70-2] to the
lifting chain.
Figure 50-70-3
Figure 50-70-1
1
1 3
P-43360
N-19674
Remove the top and bottom door hinge mounting bolts

Disconnect the light harness connector (Item 1) [Figure (Item 1) [Figure 50-70-3] and nuts.
50-70-1] from the engine harness.
NOTE: Install the door stop (Item 2) and the door stop
Remove both rear lights (Item 2) [Figure 50-70-1] from retainer (Item 3) [Figure 50-70-3] in the top
the door. (See Rear Removal And Installation on Page hinge as shown.
60-60-1.)
Figure 50-70-2 28 ft.-lbs. (34-38 Nm) torque.
Lift the door away from the loader frame and put the door
flat on the floor.
2
Installation: Reverse the removal procedure to install
the rear door.
P-34588
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.

REAR DOOR (CONT’D) Door Latch and Catch Adjustment
Striker Removal and Installation
Figure 50-70-4
WARNING
1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-31126
Remove the two striker mount bolts (Item 1) [Figure 50-
70-4].
Remove the striker assembly from the loader. 1
Striker Disassembly and Assembly

P-31126
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 2
3 Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P-31320
Installation: Tighten the mounting bolts (Item 1) [Figure
50-70-6] to 90-100 ft.-lbs. (125-135 Nm) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Close the rear door.
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-5].
Check the parts for wear and replace as needed.
Installation: Reverse the removal procedure to install

the rear door striker.

REAR DOOR (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-9] from

P-31125 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.
Remove the bolt and nut (Item 2) [Figure 50-70-7] from

the latch.
Figure 50-70-8
P-31127
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.
Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

FUEL TANK Figure 50-80-3
Figure 50-80-1
1
P-51908
Disconnect the fuel fill hose (Item 1) [Figure 50-80-3].

P1616
Figure 50-80-4
Remove the cover (Item 1) [Figure 50-80-1] which is

installed over the drain plug.
Figure 50-80-2
1
P-51907
Disconnect the tank vent hose (Item 1) [Figure 50-80-4].
P1619 Remove the engine/hydrostatic pump assembly from the

loader. (See Removal And Installation on Page 70-70-1.)
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.
Check the drain plug and replace if necessary.

FUEL TANK (CONT'D) Figure 50-80-7

1
Figure 50-80-5
P-37360

P-37358 50-80-7] from the fuel level sender.
Lift the fuel tank and remove it from the loader frame
Remove the bolts (Item 1) [Figure 50-80-5] from the [Figure 50-80-7].
battery hold down plate.
Fuel Level Sender
Remove the hoedown plate from the loader.
Figure 50-80-8
Figure 50-80-6
1
1
P-37363
P-37359
Disconnect the wire harness connector from the fuel level

Remove the two mounting bolts (Item 1) [Figure 50-80- sender.
6] from the battery hold down plate.
Loosen the fuel level sender in fuel tank.
Remove the hold down plate from the loader.
Remove the fuel level sender (Item 1) [Figure 50-80-8].

CONTROL PEDALS Pedal Adjustment
Removal And Installation After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal and the valve spool
Figure 50-90-1 must travel full stroke without hitting the floor panel.
1
WARNING
Adjust locking tabs on pedal control linkage so the at
lift and tilt control pedals are locked in neutral when
the seat bar is up.
W-2104-1285
P-31714
Remove the bolt and nut (Item 1) [Figure 50-90-1] from

the pedal linkage.
Installation: Tighten the bolt and nut to 21-25 ft.-lbs. (28-

34 Nm) torque.
Check the rubber bushing in the pedal for wear and

replace as needed.
Figure 50-90-2
P-31715

2].
Remove the pedal assembly from the loader.

CONTROL PEDALS (ACS) Figure 50-91-3
Foot Sensor Removal And Installation
Figure 50-91-1
2 1
P-21936
P-21927
Remove the two bolts (Item 1) [Figure 50-91-3] from the

1
P-21938 foot sensor shield.
Installation: Tighten the bolts to 80-90 in.-lbs. (9,0-10,2

Pull the pin (Item 1) [Figure 50-91-1] holding the foot Nm) torque.
pedal linkage to the sensor.
Figure 50-91-4
Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.
Figure 50-91-2 1
P-21924
Remove foot lock solenoid (Item 1) [Figure 50-91-4].

P-21935
Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35-40 ft.-lbs. (47-54 Nm)
Tilt the foot pedal up and remove the two nuts (Item 1) lubed torque.
[Figure 50-91-2].
Remove the two bolts (Item 2) [Figure 50-91-4] from the
Remove the foot pedal and sensor assembly from the bracket and sensor assembly.
loader.
Nm) torque.
Remove the sensor assembly
NOTE: The calibration must be followed when
replacing handle sensor, foot pedal sensor,
actuator or ACS Controller. (See
CALIBRATION on Page 60-160-1.)
CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Linkage Disassembly And Assembly
Foot Pedal Removal And Installation Figure 50-91-7
Figure 50-91-5
2
1
P-21931
1
P-21940
linkage (Item 2) [Figure 50-91-7] to the side of the foot
Remove the pin (Item 1) [Figure 50-91-5] holding the pedal.
linkage to the sensor.
Figure 50-91-8
Figure 50-91-6
3
P-21935
2
3
1
P-21932
P-21934
Remove the spacer (Item 1) [Figure 50-91-8], linkage

Tip the foot pedal up [Figure 50-91-6] and remove the (Item 2) [Figure 50-91-8], and nut (Item 3) [Figure 50-
two nuts (Item 1) [Figure 50-91-6]. 91-8] from the foot pedal.
Remove the foot pedal assembly.

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the engine speed control (Item 1) [Figure 50-
100-1]. (See Removal And Installation on Page 70-20-1.)
WARNING Loosen the jam nut from the by-pass control knob (Item
2) [Figure 50-100-1].
Remove the control knob, jam nut, and rubber washer.
Figure 50-100-2
W-2017-0286
WARNING P-37874
Never work on a machine with the lift arms up unless Disconnect the control harness connector (Item 1)
the lift arms are secured by an approved lift arm [Figure 50-100-2] from the right side steering lever.
support device can allow the lift arms or attachment Figure 50-100-3
W-2059-0598
Figure 50-100-1
2
1
2 N-19862
2
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-3].
N-19802
Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-100-3].
Installation: Tighten the steering linkage mounting bolts

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Figure 50-100-6
(CONT'D)

1
Figure 50-100-4
1
1
1
1
1 1
P-37876
1 Remove the six control panel mounting bolts (Item 1)

1 [Figure 50-100-6] from the left side of the control panel.
P-37875
Remove the side panel mount bolts (Item 2) [Figure 50-
100-6].
Remove the four control panel mounting bolts (Item 1)
[Figure 50-100-4] from right side of the control panel. Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque. Figure 50-100-7
Figure 50-100-5
1 P-37878
P-37877
Remove the fuse cover mount bolts (Item 1) [Figure 50-
100-7].
Remove the electrical connectors (Item 1) [Figure 50-
100-5] from the left handle. (If so equipped.) Remove the fuse cover from the loader.

25-28 ft.-lbs. (34-38 Nm) torque.
Remove the control panel from the loader.

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Loosen both U-bolts (Item 1) [Figure 50-100-9] at the
(CONT'D) steering lever (both sides).
Shock Removal And Installation Remove the steering cross shaft mounting bolts (Item 2)
[Figure 50-100-9] (both sides).
Figure 50-100-8
Installation: Tighten the mounting bolts to 180-200 in.-
Shaft Disassembly And Assembly
Figure 50-100-10
3
1 3
3
1
2
P-4069

from the end of the shock connected to the steering
linkage.
2
N-17639
from the other end of the shock connected to the bracket
on the control panel. Remove the steering cross shaft from the control panel.
Installation: Tighten the mounting bolts to 25-28 ft.-lbs. Disassemble the right and left steering shafts from the
(34-38 Nm) torque. cross shaft assembly.
NOTE: Some loaders may have a sleeve (Item 1),
Shaft Removal And Installation between the bearing (Item 2) and the bell
crank (Item 3) [Figure 50-100-10].
Figure 50-100-9
N-17643
NOTE: The steering shaft can be removed without

removing the control panel from the loader.
Photo [Figure 50-100-9] shows the control
panel removed for clarity purpose only.

(CONT'D)
Shaft Disassembly And Assembly (Cont'd)
Figure 50-100-11 1
2
2
3
4
P13774
NOTE: Some loaders may have a spacer (Item 1),

3 between the bearing (Item 2) and the bell
N-17640 crank (Item 3) [Figure 50-100-13].
Check the fiber washer (Item 4) [Figure 50-100-13] and
Check the bearings (Item 1) [Figure 50-100-11] for wear replace all worn parts.
Check the fiber washers (Item 2) [Figure 50-100-11] for

Replace the wave washer (Item 3) [Figure 50-100-11] if

worn.
Figure 50-100-12
2
P13773
Check the end bearing (Item 1) [Figure 50-100-12] and

fiber washer (Item 2) [Figure 50-100-12] and replace as
needed.

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Lift and block the loader. (See Procedure on Page 10-10-
(CONT'D) 1.)
Linkage Removal And Installation Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
WARNING
Open the access covers (both sides).
Remove the nut (Item 1) from the end of the centering

Put jackstands under the front axles and rear corners spring shoulder bolt (Item 2) [Figure 50-100-14].
Failure to use jackstands can allow the machine to Remove the shoulder bolt/spring assembly.
W-2017-0286 Installation: Tighten the centering spring shoulder bolt
and a NEW lock nut to 25-28 ft.-lbs. (34-38 Nm) torque.

Figure 50-100-15
WARNING
to fall and cause injury or death. P-39283
W-2059-0598
Slide the plate (Item 1) [Figure 50-100-15] to the right

Figure 50-100-14
and remove it from the two guide pins.
NOTE: The two guide bushings will be loose and can

fall out of the plate as soon as it is removed
from the guide pins.
2
P-39282


CONTROL PANEL (NON-ADJUSTABLE PINTLES) The centering plate/centering spring assembly consists
(CONT'D) of the following parts [Figure 50-100-17]:
Linkage Removal and Installation (Cont'd) ITEM DESCRIPTION

1 Bolt
Figure 50-100-16 2 Washer
3 Sleeve
4 Bushing
5 Spring
4
2
Figure 50-100-18
1
2
3
N-17608
The centering plate/centering spring assembly consists
of the following parts [Figure 50-100-16]:
ITEM DESCRIPTION
N-17607
1 Centering Spring Assembly
2 Guide Bushings
3 Lock Nut Check the wear on the centering blocks (Item 1) [Figure
4 Centering Plate 50-100-18].
Figure 50-100-17 Figure 50-100-19
2
1 5
3
N-17606
N-17735
If the centering blocks need replacement, remove the

bolts (Item 1) [Figure 50-100-19]. Remove the centering
blocks.
Installation: Tighten the centering block bolts to 25-28


(CONT'D)
Linkage Removal and Installation (Cont'd)
Figure 50-100-20
1 1 2
1
1
1
N-17727
Remove the linkage bar (Item 1) [Figure 50-100-22] from

the pintle arm. remove the torsion bushing (Item 2)
N-17726 [Figure 50-100-22] from the pintle arm.
Figure 50-100-23
Check the surface of the four pintle cams (Item 1)
[Figure 50-100-20].
If worn replace the cam.

1
Nm) torque.
2
Figure 50-100-21
1 N-17728
Remove the nuts (Item 1) [Figure 50-100-23] from both

shock absorber ball joint ends.
Installation: Tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)

torque.
Disconnect the shock absorbers from the linkage bars.
N-17726
Remove the nuts (Item 2) [Figure 50-100-23] from the
linkage bar mounting bolt. The bolts are threaded into the
Remove the linkage bar nut (Item 1) [Figure 50-100-21] linkage bars, remove the bolts.
from the torsion bushing.
The bolt is threaded into the linkage bar, remove the bolt Nm) torque, then tighten the nuts to 21-25 ft.-lbs. (28-33
Nm) torque.
from underneath the pintle arm.
The torsion bushings can now be removed from the
Installation: Tighten the bolt to 11-13 ft.-lbs. (21-25 Nm) steering bell cranks.
torque, then tighten the nut (Item 1) [Figure 50-100-21] The linkage and the centering plate must be readjusted
to 21-25 ft.-lbs. (28-33 Nm) torque. for neutral after the components have been reassembled.
(See Linkage Neutral Adjustment on Page 50-100-8.)

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Place the loader on jackstands. (See Procedure on Page
(CONT'D) 10-10-1.)
Linkage Neutral Adjustment Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
WARNING
Connect the remote start tool. (MEL 1563) (See
REMOTE START on Page 10-60-1.)
Put jackstands under the front axles and rear corners Pre-load tension in the torsion bushings must be
of the frame before running the engine for service. removed before adjusting the steering linkage.
fall or move and cause injury or death. Loosen the nut (Items 1) (three to four turns), then loosen
W-2017-0286 the bolt. The bolt is threaded into the linkage bar (Item 2)
[Figure 50-100-24]. The bolt must be loosened enough
to allow the torsion bushing to turn freely between the
steering bellcrank and the linkage bar.
Figure 50-100-25
1
WARNING
Never work on a machine with the lift arms up unless 2
support device can allow the lift arms or attachment P-39281
W-2059-0598
Loosen the nut (three to four turns), then loosen the bolt
Figure 50-100-24 at the linkage bar (Items 1). The bolt is threaded into the
linkage bar (Items 2) [Figure 50-100-25]. The bolt must
be loosened enough to allow the torsion bushing to turn
freely between the pintle arm and the linkage bar.
2
1
N-17728


(CONT'D)
Linkage Neutral Adjustment (Cont'd)
Figure 50-100-26
P-45087
Figure 50-100-29
P-45084

control panel. (Both sides.)
Figure 50-100-27
2
3
1
N-17619
1
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3)
[Figure 50-100-29].
P-45085
With an Alan wrench turn the loader drift adjustment bolt

(Item 1) [Figure 50-100-27] counterclockwise until it is
flush with the bottom side of the nut (Item 1) [Figure 50-
100-28]. (Both sides.)
NOTE: This allows the steering lever to be move to

the full forward position without hitting the
adjustment bolt.

(CONT'D)
Figure 50-100-30
1
1
N-19812
3
2 1
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
32] on each steering linkage bar.
N-17620
Move the right side steering lever forward and install a
15/16 inch (24 mm) thick spacer (Item 1) between the
centering plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-30].
This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
speed.
Remove the 3/8 inch (10 mm) thick spacer (Item 1)

[Figure 50-100-29].
Figure 50-100-31
N-17616
Check that the pintle arm mounting bolt (Item 1) is tight,

25-28 ft.-lbs. (34-38 Nm) torque and that there is no play
between the pintle arm and the square pump shaft. Also
check that the cam mounting bolts (Item 2) [Figure 50-
100-31] are tight, 45-50 ft.-lbs. (62-68 Nm) torque.

(CONT'D)
Figure 50-100-33
N-17620
Remove the spacer (Item 1) [Figure 50-100-34].
N-17730
Move the left side steering lever to the full forward

position, then pull forward on the left side rear linkage bar
until the pintle arm is rotated to the front as far as
possible. Use a clamping plier and clamp the two linkage
bars together [Figure 50-100-33].
Tighten the nuts and bolts to 25-28 ft.-lbs. (34-38 Nm)

torque.
Check the lever movement to make sure that the pintle

arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the procedure for the right side steering linkage

bar.
After both sides of the linkage bars have been adjusted,

the feel of both levers at full stroke should be the same.
Readjust the linkage if necessary.

(CONT'D)
Figure 50-100-35
N-17621
Adjust the left side centering block first (Item 1) [Figure

50-100-37].
N-17732
Start the engine, using the remote start tool, and run the
loader at high RPM.
Figure 50-100-36
Figure 50-100-38
1
1
N-17734
N-19581
Loosen the four bolts (Item 1) [Figure 50-100-35] &

[Figure 50-100-36] holding the two centering blocks. On the remote start tool, move the traction lock override
Move the right side centering block to the right as far as switch (Item 1) [Figure 50-100-38] to the OFF position so
possible. the traction function is unlocked. The wheels are now
able to turn.
NOTE: Bolt holes are slotted for pintle arm centering
adjustment. Move the left hand steering lever until the tires do not turn
(neutral position).
Move the left side centering block to the left until it

contacts both pintle cams and the steering lever is still in
the neutral position.

(CONT'D)
Figure 50-100-39
1
P-39281
Tighten the two linkage bar bolts to 221-25 ft.-lbs. (28-33

Nm) torque, then tighten the two nuts to 21-25 ft.-lbs. (28-
N-17618 33 Nm) torque at the pintle levers (Items 1) [Figure 50-
100-40].
Adjust the right side centering block (Item 1) [Figure 50- Figure 50-100-41
100-39].
Move the right side steering lever until the tires do not
turn (neutral position).
Move the right side centering block to the left until it

contacts both pintle cams and the steering lever is still in
1
the neutral position [Figure 50-100-39].
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
N-17728
If the levers do not return to neutral and the tires do not
come to a complete stop, repeat the adjustment
procedure again. Tighten the two linkage bar bolts to 21-25 ft.-lbs. (28-33
Nm) torque, then tighten the two nuts to 21-25 ft.-lbs. (28-
Stop the engine. 33 Nm) torque at the steering cross shaft (Item 1)
[Figure 50-100-41].
Remove the remote start tool from the loader.
Remove the loader from the jackstands.

CONTROL PANEL (NON-ADJUSTABLE PINTLES)
(CONT'D)
Figure 50-100-42
P-37574
Push the control lever to full stroke and turn drift
adjustment bolt (Item 1) [Figure 50-100-42] clockwise
until it touches the U-bolt holding the control lever.
Repeat steps on the other control lever.
With operator in the seat and seat belt fastened, start the
loader.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 10 ft. of

“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-42] clockwise.
If the drift is excessive to the right, turn the left

adjustment bolt clockwise.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition only move each bolt a maximum of

one turn for each test drive. This will help
prevent over correction and excess reduction
in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.

CONTROL PANEL (ADJUSTABLE PINTLES)
Description
Figure 50-101-1
P-54658
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”. Earlier designs use
loader [Figure 50-101-1]. a “spring return” adjustment, later designs use a “thread
return” adjustment.
The steering levers are attached to pivoting bellcranks
that pivot on a steering shaft and plastic bushings. The The steering system returns the levers to their starting
bellcranks have grease fittings. position by means of the centering spring and the
returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts.
NOTE: Torsion bushings need to be replaced if torn
The bellcranks are attached to steering linkage bars with or rotating in the housing. Loosen torsion
rubber torsion bushings pressed into the bellcranks. bushing bolts slightly before adjustments are
Bellcranks mount to the control panel. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
Steering linkage bars are a two-piece design. Steering been made first.
linkage bars are adjustable in length for “full travel Sequence of steering adjustments:
adjustment”.
1. Set neutral of pintle arms, “creep”
Steering linkage bars attach to the pintle arms where a 2. Set full travel at steering linkage bars
rubber torsion bushing is pressed into the pintle arms. 3. Set drift at drift adjustment bolts
CONTROL PANEL (ADJUSTABLE PINTLES) Figure 50-101-2
(CONT'D)
1
2
3
P-37789
WARNING Raise the lift arms and install an approved lift arm
Never work on a machine with the lift arms up unless Device on Page 10-20-1.)
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising The Operator Cab
support device can allow the lift arms or attachment on Page 10-30-1.)
W-2059-0598 Remove the engine speed control. (See Removal And
Loosen the jam nut (Item 1) from the lift arm by-pass
WARNING control knob (Item 2) [Figure 50-101-2].
Remove the control knob (Item 2), jam nut (Item 1) and
Put jackstands under the front axles and rear corners rubber washer (Item 3) [Figure 50-101-2].
Failure to use jackstands can allow the machine to Figure 50-101-3
W-2017-0286
P-48277
Disconnect the control harness connectors (Item 4)

[Figure 50-101-2] & [Figure 50-101-3] from the control
levers.

(CONT'D)
Figure 50-101-4
2
2 1
P-37875
Figure 50-101-7
1 1
P-51130
1
Scribe a mark across the top of the steering linkage bars 1
(Item 1) [Figure 50-101-4] which are connected to the
steering shaft on the control panel.
1
Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-101-4].
1
Installation: Align the marks on the steering linkage 1
bars. Tighten the steering linkage mounting bolts to 35-
40 ft.-lbs. (47,5-54,2 Nm) torque.
P-37876
Figure 50-101-5
Remove the control panel mounting bolts (Item 1)

[Figure 50-101-6] & [Figure 50-101-7] from both sides
of the control panel.
2
15-20 ft.-lbs. (20-27 Nm) torque.
1 Remove the control panel from the loader.
1 Reverse the removal procedure to install the control

panel.
P-37878
Remove the fuse/relay mounting bolts (Item 1) [Figure

50-101-5].
Remove the fuse/relay cover (Item 2) [Figure 50-101-5].

CONTROL PANEL (ADJUSTABLE PINTLES) Shaft Removal And Installation
(CONT’D)
NOTE: The steering shaft can be removed without
Shock Removal And Installation removing the control panel from the loader.
Photo [Figure 50-101-9] shows the control
Figure 50-101-8 panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-101-8].
1 Remove the steering shock mounting nuts (Item 2)

[Figure 50-101-8].
3
Figure 50-101-9
P-48275
from the end of the shock connected to the steering
3
linkage.
Remove the mounting nut (Item 2) [Figure 50-101-8] 1 2

from the other end of the shock connected to the bracket
P-48278
on the control panel.
Installation: Tighten the mounting bolts to 25-28 ft.-lbs. Remove Control Handle Lever (Item 1) [Figure 50-101-
(34-38 Nm) torque. 9]. (See Lever Removal And Installation on Page 50-110-
1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

101-9] from both sides of the control panel.
Installation: Tighten the pivot bolts to 25-28 ft.-lbs. (34-

38 Nm) torque.
Remove the steering shaft from the control panel.

(CONT’D)
Shaft Disassembly And Assembly 1
Figure 50-101-10
1
2 1
2
1
P-26331
To remove the steering shaft mounting bracket (Item 3)

3 [Figure 50-101-9], remove the three mounting bolts
N-17640 (Item 1) [Figure 50-101-12] from the front of the control
panel.
Disassemble the right and left steering bellcranks Remove the steering shaft mounting bracket.
from the cross shaft assembly.
Check the bearings (Item 1) [Figure 50-101-10] for wear (20-27 Nm) torque.
Check the fiber washers (Item 2) [Figure 50-101-10] for

Replace the wave washer (Item 3) [Figure 50-101-10] if

worn.
NOTE: The bellcranks should pivot freely on the

cross shaft when assembled correctly.
Figure 50-101-11
2
P13773
Check the end bearing (Item 1) and fiber washer (Item 2)

and replace as needed [Figure 50-101-11].

(CONT’D)
Linkage Removal And Installation
WARNING 2
2
Never work on a machine with the lift arms up unless the lift
arms are secured by an approved lift arm support device.
Failure to use an approved lift arm support device can allow
the lift arms or attachment to fall and cause injury or death.
W-2059-0598 1 1
P-51130
WARNING Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-101-13] which are connected to the
Put jackstands under the front axles and rear corners steering shaft on the control panel.
Failure to use jackstands can allow the machine to Remove the four steering linkage mounting bolts (Item 2)
fall or move and cause injury or death. [Figure 50-101-13].
W-2017-0286
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 35-
Raise the lift arms and install an approved lift arm 40 ft.-lbs. (47,5-54,2 Nm) torque.
Device on Page 10-20-1.) NOTE: After removal and installation of the linkage,
the linkage neutral adjustment procedure
Lift and block the loader. (See Procedure on Page 10-10- must be performed. (See Linkage Neutral
1.) Adjustment on Page 50-101-12.)

(CONT’D)
Linkage Removal And Installation (Cont’d) 7

6 8
Figure 50-101-14 3 1 4
2
5
2
P-48630
The centering plate/centering spring assembly consists

of the following parts:
2
P-48631
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering 1 Bolt
spring shoulder bolt (Item 2) [Figure 50-101-14]. 2 Bushings
3 Washer
Remove the bolt/spring assembly.
4 Bushing Spacer
Installation: Tighten the centering spring bolt and a 5 Spring
NEW lock nut to 25-28 ft.-lbs. (34-38 Nm) torque.
6 Lock Nut
Figure 50-101-15 7 Centering Plate
8 Guide Bushings
P-48632
Slide the centering plate (Item 1) [Figure 50-101-15] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operators seat.

(CONT’D)
SPRING RETURN STYLE
Linkage Removal And Installation (Cont’d)
Figure 50-101-17
1
4 1
2 3
2
1
1 P-48626
2
18] from the pintle.
P-48629
Installation: Tighten the bolts to 35-40 ft.-lbs. (47,5-54,2
Nm) torque.
Check the wear on the centering blocks (Item 1) [Figure
50-101-17]. Loosen the creep adjustment bolt (Item 2) [Figure 50-
101-18].
If the centering blocks need replacement, remove the
bolts (Item 2) [Figure 50-101-17]. Remove the centering Remove the pintle arm (Item 3) from the pintle base (Item
blocks. 4) [Figure 50-101-18].
Installation: Tighten the centering block bolts to 35-40 Figure 50-101-19

ft.-lbs. (47,5-54,2 Nm) torque.
NOTE: The washers go between the bolts and the SPRING RETURN STYLE
centering plate.
NOTE: If the centering blocks are worn, they can be 1

removed and rotated 180 degrees and
reinstalled.
3 4
P-48625
NOTE: When installing the pintle arm (Item 1) onto

the pintle base (Item 2) align the rear of pintle
arm (engine side) (Item 3) into the spring (Item
4) [Figure 50-101-19]. (Spring Return Style
Only)

(CONT’D)
SPRING RETURN STYLE
1
Figure 50-101-20
THREAD RETURN STYLE 3
2
2
P-48621
3
Remove and inspect the spring (Item 1) [Figure 50-101-
22]. Spring return style only.
P-54617
Figure 50-101-23

20] from the pintle. THREAD RETURN STYLE
Installation: Tighten the bolts to 35-40 ft.-lbs. (47,5-54,2

Nm) torque. 3
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-101-20].
Figure 50-101-21
1 2
P-54615
2
Loosen the bolt (Item 2) [Figure 50-101-22] and [Figure
50-101-23].
4
3
Remove the pintle base (Item 3) [Figure 50-101-22] and
[Figure 50-101-23].
2
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-101-21].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering control lever (Item 4) for damage and replace as
needed [Figure 50-101-21].
NOTE: The washers (Item 2) [Figure 50-101-21] are

hardened, and should only be replaced
through Bobcat Parts.

(CONT’D)
Figure 50-101-24
3
1
P-48659
NOTE: When installing the pintle base (Item 1) onto
the pump shaft the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
50-101-24].
Installation: Install the pintle base (Item 1) onto the

pump shaft (Item 2) [Figure 50-101-24]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 35-40 ft.-lbs. (47,5-54,2 Nm) torque.
NOTE: After installing the linkage onto the

hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
(See Linkage Neutral Adjustment on Page 50-
101-12.)

(CONT’D)
Pintle Arm Disassembly and Assembly 1
Figure 50-101-25
2 4
3 2
2
P-54626
3
Remove the base pintle (Item 1) [Figure 50-101-26] from
the pump shaft.
1
P-54624 Remove the retaining bolt (Item 2), adjusting screw (Item
3) and neoprene dampener (Item 4) from the base pintle

[Figure 50-101-26].
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3) Inspect parts for wear and damage, replace as needed
for damage [Figure 50-101-25]. [Figure 50-101-26].
Inspect the torsion bushing (Item 3) [Figure 50-101-25] NOTE: Anti-sieze should be used on the adjusting
for damage and replace as needed. screw to prevent corrosion and allow free
movement while adjusting.
Installation: Tighten the nuts to 35-40 ft.-lbs. (47,5-54,2
Nm) torque. Figure 50-101-27
1 3
2
P-48619
Using a bushing driver (Item 1) remove the torsion

bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-101-27].
Installation: Install the torsion bushing (Item 2) [Figure

50-101-27] into the pintle arm using the same procedure
as the removal.
NOTE: When the torsion bushing is installed, the

amount of bushing on each side of the pintle
arm should be the same.
(CONT’D)
Linkage Neutral Adjustment

1
The following tool listed will be needed to do the following
procedure:
Connect the remote start tool to the engine harness. (See


1.)
P-48448
Figure 50-101-28
3 Loosen the bolt/nut (Item 1) [Figure 50-101-29] only until

the tension is released from the torsion bushing.
Figure 50-101-30
2
1
P-48450
2
Tool that may assist in the neutral adjustment [Figure

50-101-28].
P-54612
To make this tool use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-101-28] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-101-30].
A steering centering block (Item 3) [Figure 50-101-28] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-101-30] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

(CONT’D)
Linkage Neutral Adjustment (Cont’d)
Figure 50-101-31
2
P16121
Using the remote start tool, turn the key (Item 1) [Figure
2 50-101-33] to the run position.
P-54614
Move the traction lock override switch (Item 2) [Figure

50-101-33] so the traction function is unlocked. (The
Loosen the two bolts (Item 1) holding the right centering traction lock override switch light will be ON.) On a
block. Move the right hand centering block (Item 2) standard loader the wedge brake will unlock.
[Figure 50-101-31] until both pintle cams contact the
centering block. NOTE: When the engine is started, the wheels/tracks
may begin to move.
NOTE: The left centering block is not adjustable. By
adjusting the right centering block the left NOTE: In loaders equipped with manual steering and
centering block will also become aligned hydraulic brake, the steering levers may have
properly. to be moved during engine start-up to reduce
the amount of creep. This reduction in creep
Figure 50-101-32 will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key (Item 1) [Figure
50-101-33] and start the engine and run at low idle.
1 Tighten bolts (Item 3) [Figure 50-101-32] to 35-40 ft.-lbs.

(47,5-54,2 Nm).
2 NOTE: Check for slack between centering blocks and

pintle cams. If there is excessive slack repeat
above steps [Figure 50-101-31] & [Figure 50-
101-32].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-101-28] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-101-
32] around both centering blocks.
Lock the C-Clamp in place.

(CONT’D)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-101-34
1 1
2
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
NOTE: This procedure is shown for neutral
adjustment on the left side of the loader. The
P-48632 procedure is the same for the right side
neutral adjustment.
Loosen the left pump pintle adjustment lock bolts
(Item 1). (The right pump pintle adjustment lock bolts are
counterclockwise until forward creep is seen.
(Item 2) [Figure 50-101-34].) Loosen the bolts enough to
allow free movement between the pintle arm and the
pintle base.
counterclockwise to a point between forward and reverse
where there is zero creep.
NOTE: If the bolts are too loose or too tight, the
neutral adjustment may be affected.
Stroke the left steering lever to forward and allow the
lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.

(CONT’D)
Figure 50-101-36
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-101-36] to 35-40 ft.-lbs. (47,5-54,2 Nm).
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-101-36] to 35-40 ft.-lbs. (47,5-54,2 Nm).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels/

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

101-36] at a time and apply loctite 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 35-40 ft.-lbs. (47,5-54,2 Nm). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre applied
loctite.
Remove the loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Page 50-101-16.)

(CONT’D)
Linkage Travel Adjustment

2
NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
adjustment procedure, check the torsion 1
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.
2
1
WARNING
P-48448
Never work on a machine with the lift arms up unless the lift
arms are secured by an approved lift arm support device.
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
Failure to use an approved lift arm support device can allow
(Item 2). The bolt (Item 2) [Figure 50-101-37] must be
the lift arms or attachment to fall and cause injury or death.
W-2059-0598
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm Figure 50-101-38
1
WARNING
2
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10- P-54613
1.)
Raise the operator cab. (See Raising The Operator Cab Loosen the nut (Item 1) only until the tension is released
on Page 10-30-1.) from the torsion bushing (Item 2) [Figure 50-101-38].
Pre-load tension in the torsion bushings must be The bolt must be loose enough to allow the torsion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-101-38] to turn freely
between the torsion bushing and the linkage bar.

(CONT’D)
Linkage Travel Adjustment (Cont’d)
Figure 50-101-39
2
1 3
P-51132
Move the right side steering lever forward and install a

15/16 inch (24 mm) thick spacer (Item 1) between the
P-37574 center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-101-41].
Remove access plug from the top of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-101-39] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 inch (10 mm) thick spacer.
Figure 50-101-40 Figure 50-101-42
3 2
2
4
1
3
1
P-51131
P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, check that the base pintle
3/8 inch (10 mm) thick spacer (Item 1) between the pintle arm mounting bolt (Item 1) and both of the upper pintle
arm cam (Item 2) and the centering block (Item 3) mount bolts (Item 2) and tighten to 35-40 ft.-lbs. (48-54
[Figure 50-101-40]. Nm) torque. There should be no play between the pintle
arm and the square pump shaft.
Also check that the cam mounting nuts (Item 4) [Figure

50-101-40] are tight, 35-40 ft. lbs. (48-54 Nm) torque.

(CONT'D)
Linkage Travel Adjustment (Cont'd)
Figure 50-101-43
1 1
1
P-51132
Remove the spacer (Item 1) [Figure 50-101-45].
P-51130
Disconnect the remote start tool. (See REMOTE START
on Page 10-60-1.)
Loosen the two bolts and nuts (Item 1) [Figure 50-101-
43] on each steering linkage bar. Figure 50-101-46
Figure 50-101-44 2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35-40
ft.-lbs. (47,5-54,2 Nm) [Figure 50-101-46].
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
pintle arm is rotated to the front as far as possible
[Figure 50-101-44]. Use a locking plier, clamp the two
linkage bars together.
Installation: Tighten the nuts and bolts to 35-40 ft.-lbs.

(47,5-54,2 Nm) torque.
Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

(CONT'D)
Linkage Travel Adjustment (Cont'd)

1
Figure 50-101-47
1 P-37574
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-101-48] in until it
P-48448 touches the U-bolt holding the control lever.
Repeat steps on the other control lever.

Tighten the two bolts and nuts (Items 1 & 2) [Figure 50-
101-47] to 35-40 ft.-lbs. (47,5-54,2 Nm) torque at the Drive the loader forward and check for drift.
steering bell cranks.
The traditional benchmark for drift is less than 10 ft. of
“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-101-48] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.

50-101-20
Service Manual
CONTROL PANEL (SELECTABLE JOYSTICK Remove the lift arm by-pass control knob and washer
CONTROL) (SJC) (Item 1) [Figure 50-102-1].
2
WARNING
Put jackstands under the front axles and rear corners 1
W-2017-0286
P-31824
Remove the control panel mount bolt (Item 1) [Figure 50-

102-2].

from the engine speed control.
WARNING Remove the engine speed control linkage from the

engine speed control lever, and remove the lever from
the loader.
Figure 50-102-3
W-2059-0598
Figure 50-102-1
1
P-26234
Remove the two control panel mount bolts (Item 1)

[Figure 50-102-3].
P-31822 Installation: Tighten the control panel mounting bolts to

25-28 ft.-lbs. (34-38 Nm) torque.

support device. ( Contents Page 10-01.)
Raise the operator cab. ( Contents Page 10-01.)

CONTROL PANEL (SELECTABLE JOYSTICK Figure 50-102-6
CONTROL) (SJC) (CONT’D)
Figure 50-102-4
P-26237
Remove the two side panel mount bolts (Item 1) [Figure

50-102-6], to allow clearance for the removal of the
P-26235 control panel.
Remove the fuse cover mount bolts (Item 1) [Figure 50- 25-28 ft.-lbs. (34-38 Nm) torque.
102-4].
Figure 50-102-7
Remove the fuse cover.
Figure 50-102-5
P-26227
P-26236 Disconnect the right joystick wire harness connector

(Item 1) [Figure 50-102-7].
Remove the control panel mount bolt (Item1) [Figure 50-

102-5] from the left side of the control panel.
Remove the two side panel mount bolts (Item 2) [Figure

50-102-5], to allow clearance for the removal of the cotrol
panel.

25-28 ft.-lbs. (34-38 Nm) torque.

CONTROL PANEL (SELECTABLE JOYSTICK Figure 50-102-10
Figure 50-102-8
1 1
P-26240

from the foot rests.
P-26238
Figure 50-102-11
Disconnect the left joystick wire harness connector (Item

1 1
1) [Figure 50-102-8].
Figure 50-102-9
1
1
P-26241
Remove the front four mount bolts (Item 1) [Figure 50-

102-11] from the foot rests.
P-26239
Remove the foot rests from the loader.
Remove the two control panel mount bolts (Item 1)

[Figure 50-102-9].
Remove the control panel from the loader.

CONTROL PANEL (SELECTABLE JOYSTICK
Figure 50-102-12
1
1
P-26242
from the lower fill panel.
Remove the panel from the loader.

CONTROL HANDLE Steering Lever Boot
Lever Removal And Installation Figure 50-110-2
Figure 50-110-1
2
1 3
2
1
P-26797
P-26798
To replace the rubber boot (Item 1) [Figure 50-110-2] on
the control panel, remove the steering lever. (See above

Disconnect the electrical connectors (Item 1) [Figure 50- procedure.)
110-1] from the control lever.
Drill out the four rivets (Item 2) [Figure 50-110-2] located
Remove the nuts from the two U-bolts (Item 2) [Figure on the flange of the rubber boot and remove the old boot.
50-110-1] used to mount the control lever.
Install the new boot and reinstall the steering lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 3) [Figure 50-110-1] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-2] on the front of the control panel.
Installation: Tighten the u-bolts so the lever can not be

moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.

50-110-2
Service Manual
CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL Figure 50-111-3
Components Identification
Figure 50-111-1
1 1
1
P-21864
Loosen the nuts (Item 1) [Figure 50-111-3].


moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-111-4
2
P16572
Control Handle (Item 1) [Figure 50-111-1].
Figure 50-111-2
1 P-21837
Tilt the control handle (Item 1) [Figure 50-111-4] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-4].
P-21879
Handle Sensor (Item 1) [Figure 50-111-2].

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See

CONTROL HANDLE (ADVANCED CONTROL Figure 50-111-7
CONTROL (CONT’D)
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-5
1 P-21860
Remove the handle lock solenoid connector (Item 1)

[Figure 50-111-7] from the clip.
2
P-21836 NOTE: Pry out with a small screwdriver and push the
connector down.
Figure 50-111-8
111-5] from the handle sensor connector.[Figure 50-
111-5].
1
111-5] from the handle lock solenoid connector.
5
Figure 50-111-6 2
4
1
1 P-21862
Remove one of the two mounting screws (Item 1) B from

the handle sensor.
Installation: Tighten screws to 32-38 in.-lbs. (3,6-4,3

P-21861 Nm) torque.
While removing the mounting pin (Item 2) [Figure 50-

Remove the handle sensor connector (Item 1) [Figure
111-8] from the handle sensor, remove the one plastic
50-111-6] from the clip.
spacer (Item 3) [Figure 50-111-8], the spring (Item 4)
[Figure 50-111-8] and washer (Item 5) [Figure 50-111-
NOTE: Pry out with a small screwdriver and push the
8].
connector down.

CONTROL HANDLE (ADVANCED CONTROL Check the spacer (Item 2) [Figure 50-111-10] and
SYSTEM) (ACS) SELECTABLE HAND/FOOT screws (Item 3) [Figure 50-111-10], mounting pin (Item
CONTROL (CONT'D) 4) [Figure 50-111-10], spring (Item 5) [Figure 50-111-
10], washer (Item 6) [Figure 50-111-10], bolt/nut (Item 7)
Handle Sensor Removal And Installation (Cont'd)
[Figure 50-111-10], stop strap (Item 8) [Figure 50-111-
10] and replace as needed.
Figure 50-111-9
Figure 50-111-11
1
P-21863
1
P-21880
EARLIER VERSION HAND CONTROLS ONLY:

CURRENT VERSION HAND CONTROLS:
Remove the top mounting bolt (Item 1) [Figure 50-111-
9]from the handle sensor.
Remove one of the two mounting screws (Item 1) [Figure
50-111-11] from the handle sensor.
NOTE: Be careful not to loose the recessed nut on
the other side of the handle.
Installation: Tighten bolt to 32-38 in.-lbs. (3,6-4,3 Nm)
torque.
Installation: Tighten bolt to 32-38 in.-lbs. (3,6-4,3 Nm)
torque.
Figure 50-111-10
7
7
3
1
4
3 8
5 6
2 P-21791
Remove the handle sensor (Item 1) [Figure 50-111-10]

from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-111-10]

can only be replaced as a complete assembly.

CONTROL (CONT'D)
2 3
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-12
1
P-21799
4
3
Installation: When installing the handle sensor into the
6 control handle, check the routing of the switch handle
2 5 wire harness (Item 1) [Figure 50-111-13] & [Figure 50-
P-21882 111-14] to assure proper return of the control handle to
neutral and minimize harness movement.
Remove the handle sensor (Item 1) [Figure 50-111-12]
NOTE: Route wires (Item 2) [Figure 50-111-13] &
from the handle assembly.
[Figure 50-111-14] as shown away from stop
strap (Item 3) [Figure 50-111-13] & [Figure 50-
NOTE: The handle sensor (Item 1) [Figure 50-111-12]
111-14] to avoid wire damage.
can only be replaced as a complete assembly.
Check the spacers (Item 2) [Figure 50-111-12], and
when replacing handle sensor, foot pedal
screws (Item 3) [Figure 50-111-12], mounting pins (Item
sensor, actuator or ACS Controller. (See
4) [Figure 50-111-12], spring (Item 5) [Figure 50-111-
12], washer (Item 6) [Figure 50-111-12], stop strap (Item
Control Handle Removal And Installation
Figure 50-111-13
Figure 50-111-15
P-21878
P-21879
Remove the handle sensor (Item 1) [Figure 50-111-15].

(See Handle Sensor Removal And Installation on Page
50-111-1.)

SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D)
Control Handle Removal And Installation (Cont’d)
Figure 50-111-16 1
2
1
2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) [Figure 50-111-18] and remove the allen head screws
(Item 2) [Figure 50-111-18] from the handle assembly.
P16534
Installation: Tighten the allen head screws to 35 in.-lbs.

(4 Nm) torque.
Remove the switch handle (Item 1) [Figure 50-111-16].
(See Switch Handle Removal on Page 60-130-7.)
Control Handle Disassembly And Assembly
Figure 50-111-17
Figure 50-111-19
2
1
N-17384
N-17394
Remove the rubber handle cover (Item 1) [Figure 50-

Remove the handle sleeve (Item 1) [Figure 50-111-19]
111-17] from the handle.
and bushings (Item 2) [Figure 50-111-19] from the
handle.
Check all parts for wear and replace as needed.

SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D)
Control Handle Disassembly And Assembly (Cont’d)

1
Figure 50-111-20
N-22658
1
Figure 50-111-23
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-20] that

connects the handle to the handle sensor unit for wear,
replace as needed.
Control Lever Removal And Installation

18.25”
Figure 50-111-21
1
N-18417
1
1
Loosen the two u-clamps (Item 1) [Figure 50-111-22]
nuts.

1 moved either right or left when seated in the operator
seat. Control lever end (Item 2) [Figure 50-111-22]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
N-22667 18.25 inches [Figure 50-111-23].
Remove the control lever from the cross shaft and control
Disconnect the electrical connectors (Item 1) [Figure 50-
panel.
111-21] from the control lever switch handle.
Remove the electrical connectors from the control lever

switch handle. (See CONTROL HANDLE (ADVANCED
CONTROL SYSTEM) (ACS) SELECTABLE HAND/
FOOT CONTROL on Page 50-111-1.)

CONTROL HANDLE (ADVANCED CONTROL Install the new boot and reinstall the control lever. (See
SYSTEM) (ACS) ADVANCED HAND CONTROL CONTROL HANDLE on Page 50-110-1.)
(CONT'D)
Control Lever Removal And Installation
Figure 50-111-24
1
P13734
The control lever (Item 1) [Figure 50-111-24] must be

replaced as a complete unit.
The connector clip (Item 2) [Figure 50-111-24] can be

replaced separately from the control lever.
Control Lever Boot
Figure 50-111-25
1
N-22659
To replace the rubber boot (Item 1) [Figure 50-111-25]

on the control panel, remove the control lever. (See
Lever Removal And Installation on Page 50-110-1.)
Drill out the four rivets (Item 2) [Figure 50-111-25]

located on the flange of the rubber boot and remove the
old boot.

50-111-8
Service Manual
CONTROL HANDLE (SELECTABLE JOYSTICK At the back side of the control panel, locate the left
CONTROL) (SJC) joystick wire connector (Item 1) [Figure 50-112-2].
Joystick Testing (Right & Left) Figure 50-112-3
Figure 50-112-1
1
1 3
P-28312
P-28301
Disconnect the joystick harness connector (Item 1) from

the loader wiring harness (Item 2) [Figure 50-112-3].
procedure: Install the test harness (Item 3) [Figure 50-112-3]
between the two connectors.
MEL1608-Joystick Test Harness [Figure 50-112-1]
MEL1563-Remote Start Tool Turn the remote start key to ON position without starting
Multimeter the loader.
Figure 50-112-2 Check the voltage between pin 3 and pin 5 on the joystick
test harness (Item 3) [Figure 50-112-3].
The voltage should be between 2.45 and 2.55 volts.
Figure 50-112-4
1
P-28311

P-28310

on Page 10-30-1.) Repeat the procedure at the right joystick wiring harness
connector (Item 1) [Figure 50-112-4]. (If needed.)
Connect the remote start tool to the loader. (See

CONTROL HANDLE (SELECTABLE JOYSTICK Figure 50-112-7
Joystick Removal (Right & Left)
Figure 50-112-5
1
P-26222
Remove the two outside joystick mount bolts (Item 1)

[Figure 50-112-7].
P-26220
Figure 50-112-8


on Page 10-30-1.)
Roll the joystick rubber boot (Item 1) [Figure 50-112-5]

down from the joystick handle.
Figure 50-112-6
1 P-26223
Remove the joystick from the rubber boot [Figure 50-

112-8].
P-26221
Remove the two inside joystick mount bolts (Item 1)

[Figure 50-112-6].

CONTROL HANDLE (SELECTABLE JOYSTICK Lever Assembly Removal (Right & Left)
Figure 50-112-11
Joystick Removal (Right & Left) (Cont'd)
Figure 50-112-9
1
1
P-26226
P-26224 Raise the lift arms and install an approved lift arm

Disconnect the electrical harness (Item 1) [Figure 50-
112-9] from the joystick. Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the joystick from the loader.
Remove the joystick. (See Joystick Removal (Right &
Joystick Boot Removal (Right & Left) Left) on Page 50-112-2.)
Figure 50-112-10 Remove the joystick boot. (See Joystick Boot Removal
(Right & Left) on Page 50-112-3.)
Remove the joystick wiring grommet (Item 1) [Figure 50-

112-11]
Figure 50-112-12
P-26225 1

Raise the operator cab. (See Raising The Operator Cab P-26227
on Page 10-30-1.)
Remove the joystick. (See Joystick Removal (Right & Disconnect the joystick wiring harness connector (Item 1)
Left) on Page 50-112-2.) [Figure 50-112-12].
Remove the joystick boot from the control lever assembly

[Figure 50-112-10].

CONTROL HANDLE (SELECTABLE JOYSTICK Figure 50-112-15
Lever Assembly Removal (Right & Left) (Cont'd)
Figure 50-112-13
P-26230
Remove the two control lever mounting bolts (Item 1)

[Figure 50-112-15].
P-26228
Figure 50-112-16
Remove the wiring harness grommet (Item 1) [Figure

50-112-13] from the lower steering lever assembly.
Figure 50-112-14
P-26231
Remove the control lever from the loader [Figure 50-

112-16].
P-26229
Remove the wiring harness (Item 1) [Figure 50-112-14]

from the control lever assembly.

INSIDE ACCESS PANEL Removal And Installation (Right)
Removal And Installation (Left) Figure 50-120-3
Figure 50-120-1
P-37470
P-37102
3] from the front access panel.

1] from the front access panel. Remove the front access panel from the loader.
Remove the front access panel from the loader. Figure 50-120-4
Figure 50-120-2
1 1 1
1
1 1
1
1
1 P-37471
Remove the eight mount bolts (Item 1) [Figure 50-120-4]

P-37103 from the rear access panel.
Remove the throttle lever assembly from the access

Remove the eight mount bolts (Item 1) [Figure 50-120-2] panel.
from the rear access panel.
Remove the rear access panel from behind the steering
Remove the rear access panel from behind the steering panel, remove the panel from the loader.
panel, remove the panel from the loader.

50-120-2
Service Manual
INSIDE ACCESS PANEL (SELECTABLE JOYSTICK Figure 50-121-3
CONTROL) (SJC)
Panel Removal (Right)
Figure 50-121-1
1
1
P-34546
Disconnect the foot operated speed control linkage (Item

1) [Figure 50-121-3] from the hand operated speed
P-34544 control lever arm.
Remove the foot operated speed control assembly from

Raise the lift arms and install an approved lift arm the loader.
Device on Page 10-20-1.) Figure 50-121-4

on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 50- 2

121-1], from the right side foot rest.
Remove the foot rest, from the loader.

1
Figure 50-121-2
1 P-34547
2 Loosen the two mount bolts (Item 1) [Figure 50-121-4]

from the front inside access panel.

the front inside access panel.
Remove the inside access panael from the loader.

P-34545

the foot operated speed control assembly.
Loosen the two mount bolts (Item 2) [Figure 50-121-2]

from the foot operated speed control assembly.

Panel Removal (Right) (Cont’d)
Figure 50-121-5
2
1 P-34553
Lift the speed control pin (Item 1) [Figure 50-121-7] from

the notch (Item 2) [Figure 50-121-7] in throttle cable.
P-34548
Figure 50-121-8

from the hand operated speed control lever.
Figure 50-121-6
P-34549
At the bottom right side of the control panel, remove the

keeper and pin (Item 1) [Figure 50-121-8] that connects
P-34551 the speed control linkage arm to the speed control cable.
Lift slightly on the speed control handle and move it

toward the front of the loader [Figure 50-121-6].

Panel Removal (Right) (Cont’d)
Figure 50-121-9 1
1
2 P-34554
Remove the five mount bolts (Item 1) [Figure 50-121-11]

from the access panel.
P-34550

the lever assembly. Move the lever assembly a slight
Remove the mount bolt and nut (Item 1) [Figure 50-121- amount toward the center of the loader, to allow
9] from the speed control linkage arm. clearance for the panel to be removed.
Remove the speed control linkage arm (Item 1) [Figure Remove the panel from the loader.
50-121-9] from the access panel.
Figure 50-121-10
P-34555
At the bottom right side of the control panel, behind the

lift arm by-pass valve, remove the two bolts and nuts
(Item 1) [Figure 50-121-10] that mount the engine speed
cable to the access panel.

Panel Removal (Left)
Figure 50-121-12
1
1
1
1
1 2
1 1
1
P-34653
Remove the nine mount bolts (Item 1) [Figure 50-121-

14]
P-34651
the lever assembly. Move the lever assembly a slight
Raise the lift arms and install an approved lift arm amount toward the center of the loader, to allow
support device. (See Installing The Lift Arm Support clearance for the panel to be removed.
Remove the inside access panel from the loader.
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 50-

121-12], from the left foot rest.
Remove the foot rest from the loader.
Figure 50-121-13
1
1
P-34652

13].
Remove the front access panel from the loader.

ELECTRICAL SYSTEM & ANALYSIS
ADVANCED CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . .60-130-1

ACS Controller Removal And Installation . . . . . . . . . . . . . .60-130-6
Actuators Disassembly And Assembly . . . . . . . . . . . . . . .60-130-13
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-1
Controller, Connector And Wire Identification . . . . . . . . . . .60-130-4
Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . . .60-130-19
Foot Lock Solenoid Removal And Installation . . . . . . . . . .60-130-18
Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-17
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . .60-130-16
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . . .60-130-15
Handle Lock Solenoid Disassembly And Assembly. . . . . .60-130-15
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-7
Handle Lock Solenoid Removal And Installation . . . . . . . .60-130-14
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . .60-130-10
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-8
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1 ELECTRICAL
Alternator Regulator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-6 SYSTEM &
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-3 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-4
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-3
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . .60-30-5
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . .60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . .60-20-4

ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Additional Inspection For Loaders With Advanced Controls System (ACS) or
Selectable Joystick Control (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED -
Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) . . . . . 60-100-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . 60-100-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . 60-100-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift and Tilt Calibration Procedure (Selectable Joystick Control) (SJC). 60-160-1
Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC) . . . . 60-160-3
Calibration Procedure (Advanced Control System) (ACS) . . . . . . . . . . 60-160-8
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . 60-71-1

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . . . . 60-140-1

Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK

CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . 60-50-10
Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Front Accessory Panel Removal And Installation . . . . . . . . . . . . 60-50-12
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option And Field Accessory Panels (If Equipped) . . . . . . . . . . . . . 60-50-8
Passwords (Deluxe). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Right Panel (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . 60-50-2
Standard Panel Removal And Installation (Right Side) . . . . . . . . . 60-50-9
Standard & Deluxe Panel Removal And Installation (Left Side) . 60-50-11
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-4

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting The Service PC To Remote Start Tool . . . . . . . . . . . 60-150-1
SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC) . . . 60-80-1

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description Of The Control System (Two Speed) . . . . . . . . . . . . 60-120-3
Inspecting The Control System (Two Speed) . . . . . . . . . . . . . . . 60-120-3
Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . 60-120-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1


PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
WIRING SCHEMATIC
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V 7.7 ohm
GROUND
B B 2430 2370 2 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
(Without Option)
PWM
6733137 REAR BASE 2380 2 2
C414
HIGH FLOW BICS HYDRAULIC LOCK
A A 4440
G
C
D
E
B
A
K
E
F
F
J
7.5 ohm
C415
12V
C420
7.5 ohm A A 4460 A A 4460 B B 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
S250 (S/N 526011001 - 526015999) 12V B B 2460 B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
(S/N 526111001 - 526111999)
C423
C418
A A
C441
TWO SPEED 7.5 ohm 4350 9.8 ohm A A 4420 4330 1 1 3.3 ohm
12V
S300 (S/N 525811001 - 525814999) SOLENOID 12V B B 2350 B B 2420 2330 2 2 PWM FRONT BASE
C419
4340 1
(S/N 525911001 - 525911999)
CAB 6727178
C437
TWO SPEED 5 ohm A A 4390
2340 2
2340
Printable Version Click Here (PRINTED FEBRUARY 2005) MAKE-UP 12V B B 2360
DIVERTER
A
C106
3600 A
C416
SPEED
4450 A A
V-0387 7.5 ohm
3610 B B SENSOR MAIN
WORKLIGHTS
12V FRAME
RED = RED YELLOW TIE STRAP 2450 B B
FRONT
RNG = ORANGE
BLK = BLACK
2530 GROUNDS UNSWITCHED POWER 1000-1999 RED
LBL = LIGHT BLUE
SWITCH
BRAKE
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT
2480 DBL = DARK BLUE
1930
SWITCHED POWER 1000-1999 RNG
2000
GROUND 2000-2999 BLK LGN = LIGHT GREEN ENGINE
C104 C405 C406

2460 DGN = DARK GREEN
MONITORING 3000-3999 LBL 3210 B B COOLANT
C435
REAR AUX RELIEF SEE J1 t
RIGHT
2450 HYDRAULIC 4000-4999 LGN YEL = YELLOW SENDER 2760 B B
7 3200 A A
C417
ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK 4480 A A C 500-3000 ohm
2440 2400
LIGHTS 6000-6999 PNK WHT = WHITE
9.8 ohm 6120 A A
2480 B B 12V
2430 ACCESSORIES 7000-7999 WHT BRN = BROWN
SEAT
CAB
ENGINE 8000-8999 TAN TAN = TAN
C434
2340 3700 A A BAR 6110 A A
LEFT
COMMUNICATION 9000-9999 PUR PUR = PURPLE AIR FILTER
4330
4360
4340
4410
4440
4430
12
4420
2770
GRY = GRAY SEE J1 B 3710 B B SWITCH B
3300
2330 2750 B
2110
3700
3600
3200
4350
4450
4460
4390
4480
C476
2520 3110 B B 3110 B FUEL
B
2100 SENDER - +8
3100 A A 3100 A A 30-270 ohm
2910
2920 2900
2360 J1 J2 C
C
C 2930
A
WIRES CONNECT BY LETTER SOME CONNECTOR
6 31 18 29 J1 J2 32
2420 ACROSS CONNECTORS BODIES NOT SHOWN 26 12 221 41 3 21 10 38 48 8 18 2770
2750
2740
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2410 A B FOR DRAWING CLARITY 2760
SPOOL SPARE COOLANT PWM +8V ENG SPEED 28 3100
11 LOCK ANALOG 1
FRONT
ROD
COMPUTER
GROUND
SYSTEM
Tx
LH AUX
RIGHT
L HAND
SERIAL IN TEMP SIGNAL SUPPLY SIGNAL
2380 2390 B A
1 2 3 4 5 6 7 8 9 10
2370 2900 9100 4810 9210 4300 N K G L B R P S F E D C M A J H
4360 4330 3200 3600
2200 R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
11 9110 D C408
2000 7 9210 E
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2240
+ 9110 4440 1200 9200 4820 3700 4310 4920 23 9400 F
A
2350
A PWM RH SKI 42 9410 G
3910
STATUS LH SKI
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE
C
A FRONT
BASE
REAR
ROD IN
COMPUTER
POWER
SEAT BAR
+8v DOWN
OPEN
FUEL
SENDER SIGNAL DOWN
PRESSURE SENDER
C 23 24 25
J2 26 29 30
0.5 - 7.5 V
- C 21 22 27 28
3210 B
3400 A A 3400 15 1900 3900 P05 4830 4320 4930
4430 9400 3100
B B 4340
2800 3420 E E 3420 47 BUCKET SEATBAR LH SKI RH SKI
35 3910
KEY/ENTER
OPEN POSITION OPEN GROUND UP OPEN GROUND OPEN UP
3610 HYDRAULIC 3410 F F 3410 3010 23 SWITCH
45 3920
C102
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE 25 3900 A
SENDER
B B 3310 D D 3310 4420 9350 3910 4840 2110 4940
B 34
2600 500-3000 ohm A A 3300 C C 3300 C HYD LOCK
SOLENOID
STATUS
OUT
FLOAT HEADLIGHT SEATBAR BRAKE SW
OPEN
HYDRAULIC
9350 C407
2300 SEE J2 SEE J2 SWITCH SIGNAL IN TEMP OPEN OPEN
14 1200 SEE FUSE/RELAY CENTER
2110 41 42 43 44 45 46 47 48 49 50 THIS PAGE
HYDRAULIC OIL 3 24 1900
FILTER SWITCH
3430 B B 3430 4410 9410 4640 9340 3920 4500 3300
2740 RESERVED HYD FILTER RESERVED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN TWO SPEED TWO SPEED SPARE RELAY
BLINKER PULL / 963
(AC INPUT) SIGNAL SWITCH (BOOTSTRAP)
HYDRAULIC FILTER 6717247 5 9100

MAKE-UP OUTPUT 1
2730
2120 1 2 3 4 5 6 7 8 9 10
2720 23
15 9200
3430 4910 4390 6410 8510 4110
2710 RESERVED STARTER UNSWITCHED CAN HYD CHARGE TRACTION HIGH FLOW /
44 9340
RIGHT REAR WKLT FUEL RELAY
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V LOCK HOLD
ENGINE OIL A A 3500 3500 37 BLINKER 900 LOAD RELAY HOLD
4 2900
C107
PRESSURE 11 12 13 14 15 16 17 18 19 20
C 40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 4200 4460 6210
- 6510 8800
B 30 4930
0.5-7.5 V B B 3510 TRAVEL
SPARE
DIGITAL 2
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 F&R AUX
RELIEF
RESERVED UNSWITCHED
(SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
21 24 25
22 23
3010 9600 4730
P01 26 27 28 29 30
19 4310
4150 4470 1120 4450 8210
TWO SPEED 29 4320
FUEL PULL UNSWITCHED CAN GLOW PLUG FUEL PULL
SOLENOID ENG OIL MARKER
FEEDBACK BATTERY (3) SELECT OPEN FEEDBACK
PRESS +8v GROUND LT RELAY RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4640
4350 8150 1130 9700 8550 3500 6320 8110
2100
SWITCH PWR / ATTACHMENT +5V 36 4840
HANDLE RESERVED HYD CHARGE ENG OIL
ACC RELAY SUPPLY SPARE RESERVED
KEY INPUT PRESS SIGNAL
POWER (CAN SHIELD) OUTPUT 2 PRESS SIGNAL HORN (FAN OUTPUT) 26 4830
41 42 43 44 45 46 47 48 49 50 16 4820
8000 9800 3420 3520
1400 7200
HOLD PULL
J1 6 4810
15 ohm B B 8820 A A 8800
FUEL
D3
E3
C C 2800 25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 17 41 J2
SHUTOFF 8 48 4
0.5 ohm A A 8120 B B 8100
J1
4730
8250
8210
8150
8110
1130
1120
1110
8000
6320
6210
8550
8510
4110
4150
9800
9500
9600
9700
7200
4200
1400
8800
6510
6410
2100
4910
1480
4810
4820
4830
4840
4640
STARTER
4300
4320
4310
4920
4930
4940
4230
2530
1490
2520
4240
4910
M R
C109
1015 8250
S B B
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
8200
A A
Traction Lock C410 C409
C110
1020 B B 1020
G
H
C
D
G
E
D
C
H
F
K
J
J
1015 A 10.9 ohm
BAT A 1800 4200 A A HOLD
C425
C
YEL/LGN
C
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
2200
WHT
ALTERNATOR
WHT
PUR
DGN
YEL
RGN
DBL
RGN
LGN
2015 4100 B B PULL 0.3 ohm
TAILGATE / WORKLIGHTS 6716419

F F
RIGHT + -
WORKLIGHT
2620 6200 2600 B B 2600
6200
FLOAT
6210 6200 H H PWM
SHIFT
SKI CTRL
SIDE
C103
TWO SPD
SKI CTRL
DETENT
LEFT 6310
A A
FLOW
2630 6210 6310
WORKLIGHT
E E 6400
RIGHT 6500
2610 6320 D D
TAILLIGHT
G 6600
2650 G
LEFT 7100 SEE CAB LEFT HANDLE
A TO OPTIONS RIGHT HANDLE
C404
TAILLIGHT
2640 6330 7100 C C CONNECTOR
BACKUP B (BACKUP ALARM
ALARM SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT A
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
C488
N 6300
TO OPTIONS
C 4275
(ACCESSORY C411 C412
CONNECTOR) E 4550
S 1700 TO OPTIONS TO OPTIONS
(ACCESSORY (ACCESSORY
A 1140 CONNECTOR) CONNECTOR)
1740
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11
25A TO OPTIONS
1130
1120
1110
4110
4150
4100
8010
6320
6310
8500
8510
8550
8200
8210
6300
6200
6210
8150
8110
8100
6000
1700 1055 (ACS CONNECTOR)

4220 M
M
J
C489
TO OPTIONS B 2720 7200

GLOW J
(ACCESSORY 1720 SWITCHED MARKER REAR FUEL 4275 L
A 1720 87A 87 86 87A 87 86 PLUG 87A 87 86 STARTER 86 87 87A
25A
CONNECTOR) POWER 87A 87 86 LIGHT 87A 87 86 LIGHT 87A 87 86 PULL TRACTION L
LOCK P
(COMPUTER)
(ATTACHMENT) 6410 P
FUSE 10
FUSE 4
30 85 30 85 30 85 30 85 30 85 30 85 85 30 N
25A 6510 N
1730 4550 K
1050
2010
2000
1330
2030
2020
2060
2050
1360
1060
2040
2030
1030
2060
1320
2020
2010
1350
2050
2040
K
9720 E
C492
(HEATER E
) FUSE 2 9620 D
FUSE 1 FUSE 3 FUSE 6 FUSE 5 D
15A 15A 30A 30A S
25A G 9410 S
120
9420
1140 R
F 9400 R
G
E9520
9210 G
MAINFRAME HARNESS 6730292 1150 1160
1070 2240
C
H C
H
RELAY GROUNDS 2000-2060 FUSE 9 FUSE 12 1740 B
ARE CONNECTED IN SERIES
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A
F
B
A
D 9110 F
1080
1040
FUSE 5 FUSE 1 FUSE 9

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
LIGHT POWER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT FUSE 10
FUEL PULL FR & MK LT ATTCHMNT
30A 15A 25A

1050
FUSE 7 FUSE 3 FUSE 11 - 1300
G
C
D
A
B
+
E
F
REAR LT ALT & KITS
100A 1060
15A
FUSE 8 FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
FUSE 12
25A
1010 1030 C426 TO OPTIONS
(ATTACHMENT
COMPUTER ACS 1310 ACD & REMOTE
START CONNECTOR CONTROL)
25A 25A 1040
BATTERY 1080 V-0387 (2-7-05)

Printed in U.S.A.
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
WIRING SCHEMATIC
CLOCK/LATCH
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
SYSTEM Tx
LIFT SPOOL LOCK
12V
GROUND
B B 2430 2370 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START
START J
OPEN
1
DATA
4380
DATA B
(With ACS Option) 6733137 REAR BASE 2380 2
C414
A A 4440
G
C
D
E
K
A
B
A
K
E
F
F
J
7.5 ohm
C415
12V
C420
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
(S/N 526111001 - 526111999) BUCKET POSITIONING FRONT ROD
C423
C418
A A
C441
12V
S300 (S/N 525811001 - 525814999) SOLENOID 12V B B 2350 B B 2420 2330 2 2 PWM FRONT BASE
C419
4340 1
(S/N 525911001 - 525911999)
CAB 6727178
C437
TWO SPEED 5 ohm A A 4390
2340 2
2340
MAKE-UP 12V B B
Printable Version Click Here (PRINTED FEBRUARY 2005) 2360
DIVERTER
A
C106
3600 A A
C416
SPEED
4450 A A
V-0388 7.5 ohm
3610 B
B B SENSOR MAIN
WORKLIGHTS
RED = RED YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
RNG = ORANGE
BLK = BLACK
2530 GROUNDS UNSWITCHED POWER 1000-1999 RED
LBL = LIGHT BLUE
SWITCH
BRAKE
1930
2000
GROUND 2000-2999 BLK LGN = LIGHT GREEN
2460 DGN = DARK GREEN ENGINE
C104 C405 C406

MONITORING 3000-3999 LBL
C435
REAR AUX RELIEF SEE J1 3210 B B COOLANT
RIGHT
2450 HYDRAULIC 4000-4999 LGN YEL = YELLOW 2760 B B
7 t SENDER
C417
ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK 4480 A A C 3200 A A
2440 2400
LIGHTS 6000-6999 PNK WHT = WHITE
9.8 ohm 500-3000 ohm 6120 A A
2480 B B 12V
2430 ACCESSORIES 7000-7999 WHT BRN = BROWN
SEAT
CAB
C434
2340 3700 A A BAR 6110 A A
LEFT
4330
4360
4340
4410
12
4440
4430
4420
2770
GRY = GRAY SEE J1 B 3710 B B SWITCH B
3300
2330 2750 B
2110
3700
3200
3600
4350
4450
4460
4390
4480
C476
2520 3110 B B 3110 B FUEL
B
2100 SENDER - +8
3100 A A 3100 A A 30-270 ohm
2910
2920 2900
2360 J1 J2 C
C
C 2930
A
2420 6 31 18 29 26 J1 J2 32 12 221 41 3 21 10
10 38 48 8 18 2770
ACROSS CONNECTORS BODIES NOT SHOWN 2740 2750
3910
3920
3900
9350
1200
1900
2740
9100
9200
9340
2900
6100
4500
2410 A B FOR DRAWING CLARITY 2760
SPARE COOLANT ENG SPEED 28 3100
11 SPOOL
LOCK ANALOG 1
FRONT COMPUTER SYSTEM LH AUX L HAND
TEMP SIGNAL
PWM +8V
SUPPLY SIGNAL
2380 2390 B A ROD GROUND Tx RIGHT SERIAL IN
1 2 3 4 5 6 7 8 9 10
2370 4810 N K G L B R P S F E D C M A J H
4360 4330 2900 9100 9210 3200 4300 3600
2200 11 D
R HAND
SERIAL IN
REAR SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
9110
C408
2000 BASE
7 9210 E N K G L B R P S F E D C M A J H
11 12 13 14 15 16 17 18 19 20
2240 1200 9200 4820 3700 4310 4920 23 9400 F
+ 9110 4440
A
2350 42 9410 G
A PWM RH SKI
3910
A
9350
1200
1900
2740
9100
9200
9340
2900
6100
3920
3900
4500
HYDRAULIC CHARGE FRONT REAR STATUS COMPUTER SEAT BAR LH SKI
OPEN
FUEL
SIGNAL DOWN
C BASE ROD IN POWER +8v DOWN SENDER
PRESSURE SENDER
C C 23 24 25
J2 26 29 30
0.5 - 7.5 V
- 21 22 27 28
3210 B
3400 A A 3400 15 P05
B 9400 1900 3900 4830 3100 4320 4930
B 4340 4430
2800 3420 E E 3420 47 BUCKET RH SKI
35 3910
KEY/ENTER SEATBAR LH SKI
POSITION OPEN
3610 HYDRAULIC 3410 F F 3410 3010 23 OPEN OPEN SWITCH GROUND UP GROUND OPEN UP
45 3920
C102
2300 31 32 33 34 35 36 37 38 39 40
C477
3510 TEMPERATURE 25 3900 A
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940
2110
B 34
2600 500-3000 ohm A A 3300 C C 3300 C HYD LOCK
SOLENOID
STATUS
FLOAT HEADLIGHT SEATBAR BRAKE SW
OPEN
HYDRAULIC
9350 C407
2300 SEE J2 SEE J2 OUT SWITCH SIGNAL IN TEMP OPEN OPEN
14 1200 SEE FUSE/RELAY CENTER
2110 41 42 43 44 45 46 47 48 49 50 THIS PAGE
HYDRAULIC OIL 3 24 1900
FILTER SWITCH
3430 B B 3430 4410 9410 4640 9340 3920 4500 3300
2740 GLOW PLUG TRACTION LOCK 46 4500
RESERVED
OPEN
HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT
(BOOTSTRAP) BLINKER RELAY PULL / 963
HYDRAULIC FILTER 6717247

(AC INPUT) SIGNAL
2730 SWITCH MAKE-UP OUTPUT 1
5 9100
2120 1 2 3 4 5 6 7 8 9 10
2720 23 15 9200
3430 4910 4390 6410 8510 4110
2710 STARTER UNSWITCHED CAN
44 9340
RESERVED HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
FEEDBACK BATTERY (1) HIGH
ENGINE OIL A A 3500 3500 37 (hall) PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD 4 2900
C107
PRESSURE C 11 12 13 14 15 16 17 18 19 20
C 3520 3520 49 40 4940
SENDER C 8250 1110 9500 3400
- 6510 4200 4460 6210 8800
B 4930
0.5-7.5 V B B 3510 TRAVEL
30
SPARE
DIGITAL 2
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 F&R AUX
RELIEF
RESERVED UNSWITCHED
(SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY 20 4920
21 24 25
22 23
3010 9600 4730
P01 26 27 28 29 30
19 4310
4150 4470 1120 4450 8210
29 4320
TWO SPEED FUEL PULL UNSWITCHED CAN GLOW PLUG
ENG OIL MARKER FUEL PULL
SOLENOID FEEDBACK BATTERY (3) OPEN FEEDBACK
SELECT
PRESS +8v GROUND LT RELAY RELAY 9 4300
31 32 33 34 35 36 37 38 39 40 4640
4350 8150 1130 9700 8550 3500 2100 6320 8110
36 4840
SWITCH PWR / ATTACHMENT +5V ENG OIL
HANDLE RESERVED HYD CHARGE RESERVED
ACC RELAY SUPPLY SPARE
POWER (CAN SHIELD) KEY INPUT
OUTPUT 2 PRESS SIGNAL HORN
PRESS SIGNAL
(FAN OUTPUT) 26 4830
41 42 43 44 45 46 47 48 49 50 16 4820
8000 9800 3420 7200 3520
1400
HOLD PULL
J1 6 4810
15 ohm B B 8820 A A 8800
FUEL
D3
E3
C C 2800 25 42 39 19
36 9
12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 17 41 J2
SHUTOFF 8 48 4
0.5 ohm A A 8120 B B 8100
J1
4730
8250
8210
8150
8110
1130
1120
1110
8000
6320
6210
8550
8510
4110
4150
9800
9500
9600
9700
4200
1400
6510
6410
8800
2100
4300
4320
4310
4920
4930
4940
4230
2530
7200
1490
1480
4810
4820
4830
4840
4640
4910
4910
2520
4240
STARTER
M R
C109
1015 8250
G
D
C
H
B
K
F
J
B
G
H
C
D
B
A
F
K
J
S
8200
A A
C410 C409
C409
Traction Lock
G
D
C
H
B
K
C110
J
G
H
C
D
E
K
F
J
1020 B B 1020
1015 A A 1800 10.9 ohm
A
WHT/RED
WHT/BLK
WHT/LGN
A
A
YEL/LGN
4200 HOLD
B
BAT
YEL/RED
A
B
WHT
C425
DGN
YEL
LGN
RGN
WHT
PUR
RGN
DBL
2200 C C C465 C466
ALTERNATOR
A
B
A
2015
B
4100 B B PULL 0.3 ohm
TAILGATE / WORKLIGHTS 6716419
F F + - HANDLE
RIGHT HANDLE LOCK
FLOAT
2620 6200 2600 B
SKI CTRL
SHIFT
B 2600 LOCK
SIDE
WORKLIGHT PWM
H 6200
6210 6200 H LEFT HANDLE
TWO SPD
SKI CTRL
DETENT
C103
FLOW
LEFT 6310
2630 6210 6310 A A AHC LIFT HORN RIGHT
WORKLIGHT
E 6400 HALL SENSOR TURN SIGNAL
E HANDLE
RIGHT 6500 AHC TILT
2610 6320 D D
B
C
A
TAILLIGHT HALL SENSOR
6600
RNG/WHT
RNG/DBL
2650 G G
LEFT SEE CAB C450
DGN
BRN
YEL
7100 A TO OPTIONS
C404
2640 6330 7100 C C
B
C
A
TAILLIGHT CONNECTOR
A
C
B
BACKUP B (BACKUP ALARM
ALARM SWITCH) C407 C449
C
B
D
E
B
A
B
C
A
A
J 2730
C411
B
C412
C
C469
A
P 6600
6000
C472
A
C
B
M 6500
TO OPTIONS TO OPTIONS
C
B
A
L 6400 (ACCESSORY (ACCESSORY
4750
1610
2750
CONNECTOR) CONNECTOR)
1510
F 4730
2650
4650
D 4235
C488
N 6300 13 ohm
TO OPTIONS TILT ACTUATOR LIFT ACTUATOR
C 4275 12V
(ACCESSORY
CONNECTOR) FOOT PEDAL LOCK
E 4550 M M
S 1700
A 1140
DGN
RED
RED
DGN
RED
RED
BLK
BLK
BLK
BLK
1740
H 1150
A B A B
R
C467 C468
B A B
A B
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
G
C428 C429
4270
2500
4280
2510
K (ALTERNATOR
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
1800 & KITS)
FUSE 11
4670
1530
1630
4770
2670
2770
4690
4680
4790
4780
25A
1130
1120
1110
4110
4150
4100
8010
6320
6310
8500
8510
8550
8200
8210
6300
6200
6210
8150
8110
8100
6000
1700 1055 M 4220

4220 M
J J
C489
TO OPTIONS B 2720 7200

(ACCESSORY SWITCHED MARKER REAR GLOW FUEL 4275 L L 4275
1720
A 1720 87A 87 86 87A 87 86 PLUG 87A 87 86 STARTER 86 87 87A
25A
CONNECTOR) POWER 87A 87 86 LIGHT 87A 87 86 LIGHT 87A 87 86 PULL TRACTION
LOCK P A 1170
(COMPUTER)
(ATTACHMENT) 6410
FUSE 10 N
FUSE 4
30 85 30 85 30 85 30 85 30 85 30 85 85 30 N
4680
4260
4220
4780
2270
2260
4790
4690
1190
1180
25A 6510
1730 4550 K K 4550
1050
2010
2000
1330
2030
2020
2060
2050
1360
1060
2040
2030
1030
2060
1320
2020
2010
1350
2050
2040
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
) FUSE 2
C492
FUSE 1 FUSE 3 FUSE 6 FUSE 5
25A
15A 15A 30A 30A S S 4550 C GREY
G 9410 9420
120
1140 R R 9720 F J3
F 9400
G G 9620 E
E9520
9210
MAINFRAME HARNESS 6730292 1150 1160
2240
C
H
C
H
9520
2240
9520
2250
D
J1
1070 G
RELAY GROUNDS 2000-2060 FUSE 9 FUSE 12 1740 B B 1740 2280 H
ARE CONNECTED IN SERIES
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A
F
F
P
1740
1500
B
A
J2
D 9110 BLACK
A B C D K G F H
1080
1040
J E
4750
4650
4670
4770
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
LIGHT POWER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT FUSE 10
FUEL PULL FR & MK LT ATTCHMNT
A A 1620
C470
30A 15A 25A
1050 TILT C C 4760
FUSE 7 FUSE 3 FUSE 11 - 1300 PEDAL
B
G
C
D
A
B
+
E
B
F
REAR LT
2760
ALT & KITS
100A 1060
15A
FUSE 8 FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
FUSE 12
25A
1010 1030 C426 TO OPTIONS
A A 1520
(ATTACHMENT
ACS HARNESS 6733292
C471
COMPUTER ACS 1310 ACD & REMOTE
CONTROL) LIFT C C 4660
25A START CONNECTOR
25A 1040 PEDAL
B B 2660
BATTERY 1080 V-0388 (2-7-05)
Printed in U.S.A.
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER F
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
WIRING SCHEMATIC
CLOCK/LATCH
CLOCK/LATCH A
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1 1
SYSTEM Rx
SYSTEM Rx K
SYSTEM Tx H
SYSTEM Tx
LIFT SPOOL LOCK 7.7 ohm
12V
GROUND
B B 2430 2370 2 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
C422
START
START
OPEN
1
DATA
4380 1
DATA B
7.7 ohm
(With SJC Option)

PWM
6733137 REAR BASE 2380 2 2
C414
A A 4440
G
C
D
E
K
A
B
E
F
J
7.5 ohm
C415
12V
C420
2920
9350
1220
1920
9120
9220
9300
9310
9330
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
2930
9320
(S/N 526111001 - 526111999) BUCKET POSITIONING FRONT ROD
C423
C418
A A
C441
S300 (S/N 525811001 - 525814999) SOLENOID 12V B B 2350 12V
B B 2420 2330 2 2 PWM FRONT BASE
C419 C106
4340 1
(S/N 525911001 - 525911999)
CAB 6727178
C437
TWO SPEED 5 ohm A A 4390 2340
2340 2
MAKE-UP 12V B B 2360
Printable Version Click Here (PRINTED FEBRUARY 2005) DIVERTER
3600 A
A A
C416
SPEED
4450 A A
V-0389 7.5 ohm
3610 B
B B SENSOR MAIN
WORKLIGHTS
RED = RED YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
RNG = ORANGE
UNSWITCHED POWER 1000-1999 RED BLK = BLACK
2530 GROUNDS LBL = LIGHT BLUE
SWITCH
BRAKE
1930
2000
GROUND 2000-2999 BLK LGN = LIGHT GREEN ENGINE
C104 C405 C406

2460
MONITORING 3000-3999 LBL DGN = DARK GREEN
SEE J1
3210 B B COOLANT
C435
REAR AUX RELIEF t
RIGHT
2450 HYDRAULIC 4000-4999 LGN YEL = YELLOW SENDER 2760 B B
7 3200 A A
C417
ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK 4480 A A C 500-3000 ohm
2440 2400 9.8 ohm 6120 A A
LIGHTS 6000-6999 PNK WHT = WHITE 12V
2430 ACCESSORIES 7000-7999 WHT BRN = BROWN 2480 B B
SEAT
CAB
A A
C434
2340 3700 BAR 6110 A A
LEFT
4330
4360
4340
12
4410
4440
4430
4420
2770
GRY = GRAY SEE J1 B 3710 B B SWITCH
3300
2330 B B
2110
2750
3700
3200
3600
4350
4450
4460
4390
4480
C476
2520 3110 B B 3110 B FUEL
B
2100 SENDER - +8
3100 A A 3100 A A 30-270 ohm 2910
J1 J2 2920 2900
2360 C
C
C 2930
A
2420 ACROSS CONNECTORS BODIES NOT SHOWN 6 31 18 29 26 J1 J2 32 12 22 1 41 3 21 10

s250 &amp; s300 Service Manual

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Service

S/N 526011001 & Above

CORRECT CORRECT CORRECT

B-10731a B-16261 B-16264

WRONG WRONG WRONG

B-16272 B-16260 B-16263

B-16271 B-16270 B-6589

ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 EVAPORATOR/HEATER UNIT...............................80-01

CONDENSER ......................................................... 80-01 (FOOT CONTROL)................................................20-01

LIFT ARMS ..........................................................50-01

MAIN RELIEF VALVE (ACS)...............................20-01

OIL COOLER (SEAL TO CONNECT) (STC)...........30-01

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

S250, S300 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function

4. The seat bar must be 12. Safety treads must be in good

6. Machine signs must be 14. Check hydraulic fluid level,

7. Steering levers and foot 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

S250, S300 Bobcat Loader

21. Inspect for loose or broken

S250, S300 Bobcat Loader

correct function after adjustments, repairs or

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

S250, S300 Bobcat Loader

The dealer and owner/operator review the recommended

S250, S300 Bobcat Loader

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

S250, S300 Bobcat Loader

Always use the serial number of the loader when Figure 3

Loader Serial Number

The engine serial number is located on the engine block

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module

S250, S300 Bobcat Loader

FRONT LIGHTS OPERATOR SEAT

▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

S250, S300 Bobcat Loader

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Continued On Next Page

S250, S300 Bobcat Loader

s250 & s300 Service Manual

s250 & s300 Service Manual