SM-s250-s300 6901926 SM 3-06 Bobcat S250 Service Manual

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Dealer Copy -- Not for Resale

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
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

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

SYSTEM
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI
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 . . . . . . . . . . . . 80-01 SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
S250, S300 Bobcat Loader

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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

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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.

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IV Service Manual
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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

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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

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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

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VIII Service Manual
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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-34903
The engine serial number is located on the engine block

[Figure 3].

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

number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies

the order which the loader is produced.

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DELIVERY REPORT
Figure 4
B-16315
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure

4].

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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).

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XII Service Manual
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ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 EVAPORATOR ........................................................80-01

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

CONDENSER ......................................................... 80-01 (SELECTABLE JOYSTICK CONTROL) (SJC) ......20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDRAULIC FLUID RESERVOIR ..........................20-01
(ACS) SELECTABLE HAND/FOOT CONTROL.... 50-01 HYDRAULIC FLUID SPECIFICATIONS ....... SPEC-01
CONTROL HANDLE HYDRAULIC/HYDROSTATIC FILTER ................ 20-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 50-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
CONTROL PANEL .................................................. 50-01 HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596)
CONTROL PANEL (VENDOR P/N 163D1185, 163D1301) ..................20-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 50-01 HYDRAULIC PUMP (BOBCAT P/N 6683236)
CONTROL PEDALS ............................................... 50-01 (VENDOR P/N 163D1298) ....................................20-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC PUMP (CHARGE)..............................20-01
CONTROLLER (SELECTABLE JOYSTICK HYDRAULIC PUMP (HI FLOW)
CONTROL) (SJC) ................................................. 60-01 (BOBCAT P/N 6680295, 6681600)
CONVERSIONS ............................................SPEC-01 (VENDOR P/N 163D1275, 163D1304)..................20-01
COOLING FAN ....................................................... 70-01 HYDRAULIC PUMP (HI FLOW)
CYLINDER (LIFT) ................................................... 20-01 (BOBCAT P/N 6683237)
CYLINDER (POWER BOB-TACH).......................... 20-01
(VENDOR P/N 163D1299) ....................................20-01
CYLINDER (TILT) ................................................ 20-01
HYDRAULIC PUMP (HI FLOW)
DIAGNOSTICS SERVICE CODE ........................ 60-01 (BOBCAT P/N 6684635)
DRIVE BELT ........................................................... 30-01 (VENDOR P/N 163D1372) ....................................20-01
DRIVE COMPONENTS .......................................... 40-01 HYDRAULIC PUMP (SELECTABLE JOYSTICK
CONTROL) (SJC) (BOBCAT P/N 6684386)
ELECTRICAL/HYDRAULIC CONTROLS (VENDOR P/N 163D1357) ....................................20-01
REFERENCE ........................................................ 60-01 HYDRAULIC PUMP (HI FLOW)
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) .....20-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 HYDROSTATIC MOTOR ..................................... 30-01
ENGINE ................................................................. 70-01 HYDROSTATIC MOTOR (TWO SPEED) ................30-01
ENGINE COOLING SYSTEM ................................. 10-01 HYDROSTATIC MOTOR CARRIER ........................30-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 HYDROSTATIC MOTOR CARRIER
ENGINE SPECIFICATIONS ...........................SPEC-01 (SELECTABLE JOYSTICK CONTROL) (SJC) ......30-01
ENGINE SPEED CONTROL .................................. 70-01 HYDROSTATIC PUMP
ENGINE SPEED CONTROL (SELECTABLE ......... 70-01 (S250 S/N 521313912 & BELOW)
JOYSTICK CONTROL) (SJC)............................... 70-01 (S300 S/N 521512099 & BELOW) .................... 30-01
Continued On Next Page
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ALPHABETICAL INDEX (CONT’D)
HYDROSTATIC PUMP SYSTEM CHARGING AND RECLAMATION ...... 80-01

(S250 S/N 521313913 & ABOVE) SYSTEM TROUBLESHOOTING CHART ............... 80-01
(S300 S/N 521512100 & ABOVE) ..................... 30-01
HYDROSTATIC PUMP TEMPERATURE/PRESSURE................................. 80-01
(SELECTABLE JOYSTICK CONTROL) (SJC) . 30-01 THERMOSTAT ........................................................ 80-01
HYDROSTATIC SYSTEM INFORMATION ......... 30-01 TIRE MAINTENANCE ............................................. 10-01
TORQUE SPECIFICATIONS FOR BOLTS ....SPEC-01
INSIDE ACCESS PANEL ........................................50-01 TOWING THE LOADER.......................................... 10-01
INSIDE ACCESS PANEL TRACTION LOCK ................................................... 60-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ......50-01 TRANSPORTING THE BOBCAT LOADER ............ 10-01
INSTRUMENT PANEL.............................................60-01 TROUBLESHOOTING ............................................ 70-01
LIFT AND TILT ACTUATOR CALIBRATION

(SELECTABLE JOYSTICK CONTROL) (SJC) ......60-01
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 (SNAP 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.........................................................60-01
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
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SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

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

Cleaning Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 DRIVE
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

ELECTRICAL
Replacing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 SYSTEM &
ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 SPECIFICATIONS
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid And Case Drain Filters . . . . . . 10-120-2
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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
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
10-01 Service Manual
19 of 1030
SAFETY AND MAINTENANCE (CONT’D)
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
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 For Non-Two-Speeds . . . . . . . . . . . . . . . . . . . . 10-50-1

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

20 of 1030
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, 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-2003-0199
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
21 of 1030

22 of 1030
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].

23 of 1030
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.

24 of 1030
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].

25 of 1030
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.-lb. (54-68 N•m) 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.

26 of 1030
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].

27 of 1030

28 of 1030
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 and • Stop the engine.
LOADER SPECIFICATIONS (S300) on Page SPEC-10-5
for weight of loader.) • 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.

29 of 1030

30 of 1030
TOWING THE LOADER Figure 10-50-2
Procedure For Non-Two-Speeds
Figure 10-50-1
1
P-28038
• Press the TRACTION LOCK OVERRIDE Button

P-28360A (Item 1) [Figure 10-50-2].
• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not

To prevent damage to the loaders hydrostatic system, the more than 25 feet (7,6 meters).
loader must be towed only a short distance at slow

speed. (Example: Moving the loader onto a transport If the electrical system is not functioning, contact your
vehicle). Bobcat loader dealer.
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 and
LOADER SPECIFICATIONS (S300) on Page SPEC-10-
5.
• Turn the key switch to RUN (Item 1) [Figure 10-50-1]

(Standard Panel) OR press the RUN / ENTER Button
(Deluxe).

31 of 1030

32 of 1030
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 LIFTING AND BLOCKING

THE LOADER 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.

33 of 1030
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].
MEL1563 - Remote Start Tool Kit
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.

THE LOADER on Page 10-10-1.)
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.)

34 of 1030
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.

35 of 1030
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.

36 of 1030
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, 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-2003-0199
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.-lb. (142-156 N•m)
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.

37 of 1030

38 of 1030
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-34864
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-34860
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.

39 of 1030
AIR CLEANER SERVICE (CONT'D) Figure 10-80-6
Replacing Filter Element (Cont'd)
Figure 10-80-5
1
1
P-34864
Install the new inner element.

P-34861
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.

40 of 1030
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.

41 of 1030
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].

42 of 1030
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
2
Figure 10-100-1
P-34865
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.

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].
43 of 1030
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-34865
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-34865
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.

44 of 1030
ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil Figure 10-110-2
Figure 10-110-1
1
1
P-34866
P-34866
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
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
TEMPERATURE RANGE ANTICIPATED

BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CD, CF4,CG4)
*Can be used ONLY when available with appropriate diesel rating.

45 of 1030
ENGINE LUBRICATION SYSTEM (CONT’D) Put 12 qts. (11 L) of oil in the engine.
Replacing Oil And Filter (Cont’d) Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
Figure 10-110-3 oil as needed if it is not at the top mark on the dipstick.
P-34866
WARNING

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.
Figure 10-110-4
P-34866
Remove the filler cap (Item 1) [Figure 10-110-4].

46 of 1030
HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-3
Checking And Adding Fluid
Figure 10-120-1
Sight
Gauge
P-4613
P-30011
NOTE: Before installing the fill cap, make sure the

P-31692 rubber gasket (Item 1) [Figure 10-120-3] is
installed on the fill cap.
Use only recommended fluid in the hydraulic system. Figure 10-120-4

(See Specifications on Page SPEC-50-1.)

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.
Figure 10-120-2
1
P-34904
Hydraulic/Hydrostatic Filter Replacement

1
correct service interval.
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
P-31692 Use a filter wrench to remove the filter element (Item 1)

[Figure 10-120-4].
If fluid is needed, remove the fill cap (Item 1) [Figure 10- Clean the surface of the filter housing where the element
120-2]. seal contacts the housing. Put clean oil on the rubber
seal of the filter elements.
Add the fluid as needed to bring the level to the center of
the sight gauge. Install and hand tighten the filter elements.

47 of 1030
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Disconnect the hoses from the hydrostatic motor case
drain filter (Item 1) [Figure 10-120-6].
Replacing Hydraulic Fluid And Case Drain Filters
Remove the case drain filter and clean thoroughly with
Figure 10-120-5 clean solvent.
Install the case drain filter and tighten the hoses.
Install the plug in the reservoir drain hose and tighten.

Install the motor cover.
Figure 10-120-7
P-31286

service interval.

Replace the fluid if it becomes contaminated or after
major repair. 1
P-31692
Also clean the hydrostatic motor case drain filter

thoroughly after a major repair. Remove the left side access panel (Item 1) [Figure 10-
120-7].
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.
Figure 10-120-6
P-34905

48 of 1030
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)
Replacing Hydraulic Fluid And Case Drain Filters

(Cont’d)
Figure 10-120-8
P-31565
Remove the hoses from the attachments case drain filter

(Item 1) [Figure 10-120-8]. Remove and discard the
filter.
Install a new filter, tighten the hose fittings and install the
cover.
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.

49 of 1030

50 of 1030
FINAL DRIVE TRANSMISSION (CHAINCASE) Replacing The Oil
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
P-1616
P-31287
To drain the oil from the chaincase, remove the cover
(Item 1) [Figure 10-130-2] which is installed over the
The chaincase contains the final drive sprockets and drain plug at the rear of the chaincase.
chains and uses the same type of oil as the hydraulic/

hydrostatic system. (See Specifications on Page SPEC- Figure 10-130-3
50-1.)
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.
1
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. P-1619
Remove the drain plug (Item 1) [Figure 10-130-3] and

drain the oil into a container.
Check the drain plug and replace if necessary.

51 of 1030

52 of 1030
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.

53 of 1030

54 of 1030
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

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

55 of 1030

56 of 1030
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.)

57 of 1030

58 of 1030
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 (See SERVICE

SCHEDULE on Page 10-70-1) 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].

59 of 1030
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].

60 of 1030
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.-lb. (24-
27 N•m) torque.

61 of 1030

62 of 1030
TIRE MAINTENANCE Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
Wheel Nuts to the front [Figure 10-170-2].
Figure 10-170-1 It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
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
P-31673 mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
See SERVICE SCHEDULE on Page 10-70-1 for the bead and rim flange must be lubricated with a rubber
service interval to check the wheel nuts [Figure 10-170- lubricant before mounting the tire, avoid excessive

1]. pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
When installing wheel nuts, tighten to 160 ft.-lb. (217 pressure frequently to avoid over inflation.
N•m) torque.
When checking wheel nuts, tighten to 140 ft.-lb. (190

N•m) torque .
WARNING
Tire Rotation
Do not inflate tires above specified pressure. Failure
Figure 10-170-2 to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
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 LOADER SPECIFICATIONS (S250) on Page
SPEC-10-1 and LOADER SPECIFICATIONS (S300) on
Page SPEC-10-5.)

63 of 1030

64 of 1030
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
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . 20-120-1 SPECIFICATIONS

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

65 of 1030
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS). . . . . 20-41-1

Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . . . . . . . . 20-41-4
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-9
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . . . 20-41-11
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . . . . . . 20-41-12
BICS™ Valve, Lock Valve Disassembly And Assembly. . . . . . . . . . . . . . . . . . 20-41-13
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-41-14
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Lift Spool Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18

Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
HYDRAULIC CONTROL VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Anti-Cavitation Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Backslide, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . 20-40-7
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . . . . . . 20-40-6
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS™ Valve, Solenoid Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-40-9
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Lift And Tilt Lock Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Lift Spool And Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Lift Spool And Detent Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Lift Spool And Detent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24
Lift Spool And Detent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Port-Auxiliary Section Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Port Relief Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24

66 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE JOYSTICK CONTROL) (SJC) .20-42-1

Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . .20-42-1
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . . . . . . .20-42-4
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-20
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-21
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-26
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-25
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . . . . .20-42-12
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . . 20-42-11
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . . . . . . . .20-42-13
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-9
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . .20-42-14
BICS™ Valve, Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-15
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-27
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-16
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . .20-42-24
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-17
Lift Spool Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-22
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-23

Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-17
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-18
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-27
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-19
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-5
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-1

Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-4
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596) (VENDOR P/N 163D1185,

163D1301). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-7
Check The Output Of The Hydraulic Pump W/Power Bob-Tach.. . . . . . . . . . .20-60-2
Check The Output Of The Hydraulic Pump W/O Power Bob-Tach . . . . . . . . .20-60-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-6

67 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N 6680295, 6681600) (VENDOR P/N
163D1275, 163D1304) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
High Flow Relief Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . 20-61-6
High Flow Relief Valve Removal and Installation. . . . . . . . . . . . . . . . 20-61-8
Hydraulic Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Inline Hydraulic Pump Test (High Flow) . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Inline Hydraulic Pump Test (Standard). . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
HYDRAULIC PUMP (BOBCAT P/N 6683236) (VENDOR P/N 163D1298)20-62-1

Check The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . 20-62-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-5
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-2
HYDRAULIC PUMP (CHARGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1


HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N 6683237) (VENDOR P/N
163D1299). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-12
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N 6684635) (VENDOR P/N

163D1372). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65-12
HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) (BOBCAT P/

N 6684386) (VENDOR P/N 163D1357) . . . . . . . . . . . . . . . . . . . . . . . . . 20-66-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66-5
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66-2

68 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC)

(BOBCAT P/N 6684387) (VENDOR P/N 163D1358) . . . . . . . . . . . . . . . 20-67-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67-12
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
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-3
Checking The Main Relief Valve At Front Aux. Hyd. . . . . . . . . . . . . 20-31-1
MAIN RELIEF VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Checking The Main Relief Valve At Front Aux. Hyd. . . . . . . . . . . . . 20-30-1
MAIN RELIEF VALVE (SELECTABLE JOYSTICK CONTROL) (SJC) . 20-32-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-3
Checking The Main Relief Valve At Front Auxiliary Hydraulics . . . . 20-32-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-2
POWER BOB-TACH BLOCK (EARLY MODELS) . . . . . . . . . . . . . . . . 20-110-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
POWER BOB-TACH BLOCK (LATER MODELS) . . . . . . . . . . . . . . . . 20-111-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1

69 of 1030
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) . . . . . . . . 20-100-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
REAR AUXILIARY DIVERTER (LATER MOTELS) . . . . . . . . . . . . . . . 20-101-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-8
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-8

70 of 1030
HYDRAULIC/HYDROSTATIC SCHEMATIC
S250 (S/N 521311001 - 521311993)
(S/N 521411001 - 521411028)
S300 (S/N 521511001 - 521511265)
(S/N 5216 No machines built to this schematic)
(PRINTED AUGUST 2003)
Printable Version Click Here V-0186legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 41 CHECK VALVE - BICS CONTROL VALVE
Capacity . . . . . . . . 21 Qts. (19.9 L) (SCREEN) 20.7 GPM (78,35 L/min) at 2750
Engine RPM 42 RESTRICTION
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR
31 DRIVE MOTOR SHUTTLE VALVE CHECK VALVE - AUXILIARY
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 43
32 SHUTTLE RELIEF VALVE:
4 SPRING LOADED FILTER BYPASS 200 PSI (13,8 Bar) 44 FRONT AUXILIARY MANUAL
19 RELIEF VALVE - MAIN: PRESSURE BLEED-OFF VALVE
VALVE: 45-55 PSI (3,1-3,8 Bar)
3250-3350 PSI (224,1-231,0 Bar) 33 SOLENOID ACTIVATED DIRECTIONAL VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL at Front Quick Couplers 45
CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - HYDRAULIC
AUXILIARY ("SV2")
POWERED BOB-TACH 20 RELIEF VALVE - PORT: 46 TWO STAGE RELIEF (1000 PSI/2000 PSI)
6 4000 PSI (275,9 Bar) 34 LOAD SHUTTLE VALVE - BLEED OFF (69/138 Bar)
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar) 21 ANTICAVITATION VALVE
35 PILOT ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE 47 SOLENOID ACTIVATED DIRECTIONAL
22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR CONTROL VALVE (TWO COIL)
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) AUXILIARY - NORMALLY CLOSED
("P2" and "F2") 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
VALVE 3500 PSI (241,4 Bar)
9 FIXED CAPACITY DISPLACEMENT 23 ONE WAY RESTRICTOR 36 PILOT ACTIVATED DIRECTIONAL 49 PRESSURE COMPENSATED FLOW
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - FOR REAR CONTROL
MOTOR 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN 50 CHECK VALVE WITH 0.015 RESTRICTION
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY ("D1" and "P1")
CONTROL VALVE - FLOW CONTROL 25 RELIEF VALVE - PORT: . . . . . (Optional) 37 51 RELIEF VALVE - PORT:
PILOT ACTIVATED DIRECTIONAL
SPOOL 3500 PSI (241,4 Bar) CONTROL VALVE - FOR REAR 4000 PSI (275,9 Bar)
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH AUXILIARY - NORMALLY OPEN 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING PRESSURE: 5000 PSI (344,8 Bar) ("D2" and "P2") CONTROL VALVE - BUCKET POSITION
SPOOL 27 38 VALVE (ON/OFF)
PRESSURE SWITCH FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID 53 FILTER - CASE DRAIN (ATTACHMENT)
12 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE:
CONTROL VALVE - TILT CONTROL 120 degrees F. (53 degrees C.)Fluid 39 SOLENOID ACTIVATED DIRECTIONAL
at 1775 Pump RPM CONTROL VALVE - TO ACTIVATE
13 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1")
390 - 430 PSI (26,9 - 29,6 Bar)
CONTROL VALVE - LIFT CONTROL
29 CHARGE PUMP: 40 PILOT ACTIVATED DIRECTIONAL
14 SOLENOID ACTIVATED DIRECTIONAL 14.0 GPM (53,0 L/min) at 2750 CONTROL VALVE - FOR REAR
CONTROL VALVE - BICS CONTROL Engine RPM AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
15 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-0186legend (8-5-03)

71 of 1030
HYDRAULIC/HYDROSTATIC SCHEMATIC DIVERTER VALVE (OPTIONAL)
S250 (S/N 521311001 - 521311993) 38
(S/N 521411001 - 521411028)
39
S300 (S/N 521511001 - 521511265) PILOT
V-0186 Printable Version Click Here
DRIVE MOTOR
40 36 INTEGRATED QUICK COUPLER BLOCK
MALE MALE F1 D1 MALE
31 32
34 44
(REAR QUICK
COUPLERS) MALE (FRONT AUXILIARY
44 LEFT SIDE LIFT ARM)
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3
53 BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS OIL

4 D
COOLER
45 8
26
28
26
7
6
A
CHARGE INLET OUTLET
52 C
HYDRAULIC CONTROL VAVLE 10
29
43
11
26 27
BOB-TACH Dealer Copy -- Not for Resale

24 24
45 CYLINDER 25 B
(OPTIONAL) A B
26
HYDRAULIC
AUXILIARY
POWERED
SPOOL
BOB-TACH
OUTLET (OPTIONAL)
INLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
47
48 46
A B 12
51 TILT
CYLINDER
49 SPOOL
DRIVE MOTOR
21
DR 50 18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
PP
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0186 (8-5-03)
72 of 1030
WITH TWO SPEED VALVE OPTION
S250 (S/N 521311001 - 521311993)
(S/N 521411001 - 521411028)
S300 (S/N 521511001 - 521511265)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 45 VARIABLE CAPACITY DISPLACEMENT
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) 200 PSI (13,8 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
17 ONE WAY RESTRICTOR 33 SOLENOID ACTIVATED DIRECTIONAL 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
2 FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - BLEED OFF REAR (69/138 Bar)
18 LOAD CHECK VALVE
3 FILTER - HYDRAULIC (CANISTER) AUXILIARY ("SV2") 47 SOLENOID ACTIVATED DIRECTIONAL
19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE (TWO COIL)
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224,1-231,0 Bar) 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - HYDRAULIC 4000 PSI (275,9 Bar) AUXILIARY - NORMALLY CLOSED CONTROL
POWERED BOB-TACH ("P2" and "F2") 50 CHECK VALVE WITH 0.015 RESTRICTION
21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: 36 PILOT ACTIVATED DIRECTIONAL
51 RELIEF VALVE - PORT:
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR
PORT (TILT BASE END)
Dealer Copy -- Not AUXILIARY
for Resale- NORMALLY OPEN 4000 PSI (275,9 Bar)
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (241,4 Bar) ("D1" and "P1") 52 SOLENOID ACTIVATED DIRECTIONAL
23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - BUCKET POSITION
8 CHECK VALVE - BUCKET POSITION 37 PILOT ACTIVATED DIRECTIONAL
VALVE (ON/OFF)
VALVE 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN 53 FIXED CAPACITY DISPLACEMENT
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - AUXILIARY BIDIRECTIONAL HYDROSTATIC
("D2" and "P2")
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) MOTOR
MOTOR 3500 PSI (241,4 Bar) 38 FILTER - DIVERTER VALVE (SCREEN) 54 HYDRAULIC BRAKE - SPRING APPLIED -
INTEGRATED IN SOLENOID PRESSURE TO RELEASE
10 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (344,8 Bar) 39 SOLENOID ACTIVATED DIRECTIONAL 55 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - TO ACTIVATE CONTROL VALVE - BRAKE
27 PRESSURE SWITCH
28 RELIEF VALVE - CHARGE: 56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING 40 PILOT ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.)Fluid CONTROL VALVE - MAKE-UP
SPOOL CONTROL VALVE - FOR REAR
at 1775 Pump RPM 57 SOLENOID ACTIVATED DIRECTIONAL
12 PILOTED ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (26,9 - 29,6 Bar) CONTROL VALVE - TWO SPEED
CONTROL VALVE - TILT CONTROL ("P1" and "F1")
29 CHARGE PUMP 58 FRONT AUXILIARY MANUAL
13 PILOTED ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE
14.0 GPM (53.0 L/min.) at 2750 PRESSURE BLEED-OFF VALVE
CONTROL VALVE - LIFT CONTROL Engine RPM 42 RESTRICTION 59 FILTER - CASE DRAIN (ATTACHMENT)
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - BICS CONTROL 60 FILTER (BRAKE)
20.7 GPM (78.35 L/min.) at 2750
15 PULL BUTTON ACTIVATED Engine RPM 44 PILOT ACTIVATED DIRECTIONAL
NOTE: Unless otherwise specified, springs have
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TWO SPEED
NO significant pressure value.
ARM BY PASS DRIVE MOTOR
V-0187legend (8-5-03)
Printed in U.S.A.
73 of 1030
38
S250 (S/N 521311001 - 521311993)
(S/N 521411001 - 521411028) PILOT
39
S300 (S/N 521511001 - 521511265) TWO SPEED

(S/N 5216 No machines built to this schematic) DRIVE MOTOR

V-0187
INTEGRATED QUICK COUPLER BLOCK
40 36
Printable Version Click Here 31 32 MALE MALE F1 D1 MALE
34 (FRONT AUXILIARY
58
(REAR QUICK LEFT SIDE LIFT ARM)
MALE
COUPLERS)
58
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3

4 D
COOLER
45 8
26 26
28
7
6
52 C
CHARGE OUTLET HYDRAULIC CONTROL VAVLE 10
INLET 29
43
11
27

24 24
45 CYLINDER 25 B
(OPTIONAL)
A B
26 30 26
HYDRAULIC
INLET OUTLET POWERED AUXILIARY
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
BICS CONTROL VALVE
55 B
60
TWO SPEED DRIVE MOTOR
47
60
48 46
54 A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
21
53
C DR 50 18
P D 44 20 LIFT CYLINDERS
P2 17
P1 5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0187 (8-5-03)
74 of 1030
WITH HIGH FLOW OPTION
S250 (S/N 521311001 - 521311993)
(S/N 521411001 - 521411028)
S300 (S/N 521511001 - 521511265)
Printable Version Click Here (PRINTED AUGUST 2003)
V-0188legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 46 TWO STAGE RELIEF: 1000 PSI/2000 PSI
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BLEED OFF REAR (69/138 Bar)
17 ONE WAY RESTRICTOR AUXILIARY ("SV2")
2 FILTER - CASE DRAIN (90 Micron) SOLENOID ACTIVATED DIRECTIONAL
34 47
LOAD SHUTTLE VALVE - BLEED OFF
18 LOAD CHECK VALVE CONTROL VALVE (TWO COIL)
3 FILTER - HYDRAULIC (CANISTER)
35 PILOT ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - FOR REAR
VALVE: 45-55 PSI (3,1-3,8 Bar) 3250-3350 PSI (224,1-231 Bar) AUXILIARY - NORMALLY CLOSED 49 PRESSURE COMPENSATED FLOW
at Front Quick Couplers ("P2" and "F2") CONTROL
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT:
CONTROL VALVE - HYDRAULIC 36 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH 0.015 RESTRICTION
4000 PSI (275,9 Bar)
POWERED BOB-TACH CONTROL VALVE - FOR REAR
21 ANTICAVITATION VALVE AUXILIARY - NORMALLY OPEN 51 RELIEF VALVE - PORT:
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275,9 Bar)
("D1" and "P1")
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE -
37 PILOT ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (241,4 Bar)
Dealer Copy -- Not CONTROL
for ResaleVALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
23 ONE WAY RESTRICTOR VALVE
8 CHECK VALVE - BUCKET POSITION ("D2" and "P2") 53 AUXILIARY HYDRAULIC PUMP
VALVE 24 SOLENOID ACTIVATED DIRECTIONAL 10 GPM (37.85 L/min.)
38 FILTER - DIVERTER VALVE (SCREEN)
CONTROL VALVE - AUXILIARY at 2750
9 FIXED CAPACITY DISPLACEMENT INTEGRATED IN SOLENOID Engine RPM
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 54 FILTER - CASE DRAIN (ATTACHMENT)
39 SOLENOID ACTIVATED DIRECTIONAL
MOTOR 3500 PSI (241,4 Bar) CONTROL VALVE - TO ACTIVATE 55 RELIEF VALVE - 3300 PSI (227,6 Bar)
10 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH REAR AUXILIARY ("SV1")
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (344,8 Bar) 56 DUMP VALVE (ON/OFF)
SPOOL 27 PRESSURE SWITCH CONTROL VALVE - FOR REAR
57 CHECK VALVE
28 RELIEF VALVE - CHARGE: ("P1" and "F1")
CONTROL VALVE - UNLOADING
120 degrees F. (53 degrees C.)Fluid
SPOOL 41 CHECK VALVE - BICS CONTROL VALVE
at 1775 Pump RPM
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (26,9 - 29,6 Bar)
42 RESTRICTION
CONTROL VALVE - TILT CONTROL 29 CHARGE PUMP
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53.0 L/min.) at 2750 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - LIFT CONTROL Engine RPM
44 FRONT AUXILIARY MANUAL
30 HYDRAULIC PUMP . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL PRESSURE BLEED-OFF VALVE
20.7 GPM (78.35 L/min.) at 2750
CONTROL VALVE - BICS CONTROL 45
Engine RPM VARIABLE CAPACITY DISPLACEMENT
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC PUMP NOTE: Unless otherwise specified
DIRECTIONAL CONTROL VALVE - LIFT springs have NO significant
32 SHUTTLE RELIEF VALVE: pressure value.
ARM BY PASS
200 PSI (13,8 Bar)

75 of 1030
38
S250 (S/N 521311001 - 521311993)
(S/N 521411001 - 521411028) Printable Version Click Here 39
PILOT
S300 (S/N 521511001 - 521511265)
(PRINTED AUGUST 2003) DRIVE MOTOR
V-0188
40 36
31 32
34 44
(REAR QUICK
33 35 37
F2 D1
FEMALE
9 FEMALE FEMALE
DRAIN P1 P2
HYDRAULIC FILTER
3

4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
BOB-TACH 27
26
CYLINDER
26 45 (OPTIONAL) 24 24
Dealer Copy 25-- Not for Resale B
A B
HYDRAULIC
POWERED
BOB-TACH AUXILIARY
(OPTIONAL) SPOOL
INLET OUTLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
53
57 47
48 46
55
56 A B 12
49 51 TILT
CYLINDER
SPOOL
DRIVE MOTOR DR 50 21
9 18
P1 P2
5 20 LIFT CYLINDERS
17
PP 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0188 (8-5-03)
76 of 1030
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
S250 (S/N 521311001 - 521311993)
(S/N 521411001 - 521411028)
S300 (S/N 521511001 - 521511265)
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 - BLEED OFF REAR CONTROL VALVE (TWO COIL)
17 ONE WAY RESTRICTOR AUXILIARY ("SV2") 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
34 LOAD SHUTTLE VALVE - BLEED OFF
18 LOAD CHECK VALVE 49 PRESSURE COMPENSATED FLOW
3 FILTER - HYDRAULIC (CANISTER) 35 PILOT ACTIVATED DIRECTIONAL CONTROL
19 RELIEF VALVE - MAIN: CONTROL VALVE - FOR REAR 50 CHECK VALVE WITH 0.015 RESTRICTION
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224-231 Bar) AUXILIARY - NORMALLY CLOSED
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers ("P2" and "F2") 51 RELIEF VALVE - PORT:
5 20 RELIEF VALVE - PORT: 4000 PSI (275,9 Bar)
PILOT ACTIVATED DIRECTIONAL 36 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC 4000 PSI (275,9 Bar) 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
POWERED BOB-TACH 21 ANTICAVITATION VALVE CONTROL VALVE - BUCKET POSITION
AUXILIARY - NORMALLY OPEN
VALVE (ON/OFF)
6 DIFFERENTIAL PRESSURE SWITCH: ("D1" and "P1")
22 RELIEF/ANTICAVITATION VALVE - 53 FIXED CAPACITY DISPLACEMENT
36-44 PSI (2,5-3,0 kPa) PORT (TILT BASE END) Dealer Copy --37NotPILOT
for Resale
ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (241,4 Bar) CONTROL VALVE - FOR REAR MOTOR
23 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN
54 HYDRAULIC BRAKE - SPRING APPLIED -
8 CHECK VALVE - BUCKET POSITION ("D2" and "P2") PRESSURE TO RELEASE
VALVE 24 SOLENOID ACTIVATED DIRECTIONAL
38 FILTER - DIVERTER VALVE (SCREEN) 55 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY CONTROL VALVE - BRAKE
9 FIXED CAPACITY DISPLACEMENT INTEGRATED IN SOLENOID
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 56 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,4 Bar) 39 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - MAKE-UP
MOTOR
26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - TO ACTIVATE
10 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1") 57 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE: 5000 PSI (344,8 Bar)
CONTROL VALVE - FLOW CONTROL CONTROL VALVE - TWO SPEED
SPOOL 27 PRESSURE SWITCH 40 PILOT ACTIVATED DIRECTIONAL
11 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: PRESSURE BLEED-OFF VALVE
AUXILIARY - NORMALLY CLOSED
CONTROL VALVE - UNLOADING 120 degrees F. (53 degrees C.)Fluid ("P1" and "F1") 59 FILTER - CASE DRAIN (ATTACHMENT)
SPOOL at High Engine Idle
390 - 430 PSI (26,9 - 29,6 Bar) 41 CHECK VALVE - BICS CONTROL VALVE 60 RELIEF VALVE - 3300 PSI (227,6 Bar)
12 PILOTED ACTIVATED DIRECTIONAL
29 CHARGE PUMP 42 61 DUMP VALVE (ON/OFF)
CONTROL VALVE - TILT CONTROL RESTRICTION
14.0 GPM (53.0 L/min.) at High
13 PILOTED ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY 62 CHECK VALVE
Engine Idle
CONTROL VALVE - LIFT CONTROL 44 PILOT ACTIVATED DIRECTIONAL 63 FILTER (BRAKE)
30 HYDRAULIC PUMP . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL 20.7 GPM (78.35 L/min.) at High CONTROL VALVE - TWO SPEED 64 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - BICS CONTROL Engine Idle DRIVE MOTOR 10 GPM (37.85 L/min.)
31 DRIVE MOTOR SHUTTLE VALVE 45 VARIABLE CAPACITY DISPLACEMENT At High Engine Idle
15 PULL BUTTON ACTIVATED BIDIRECTIONAL HYDROSTATIC PUMP
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: NOTE: Unless otherwise specified springs
46 TWO STAGE RELIEF 1000 PSI/2000 PSI
ARM BY PASS 200 PSI (13,8 Bar) have NO significant
(69/138 Bar) pressure value.
77 of 1030
38
S250 (S/N 521311001 - 521311993)
PILOT
S300 (S/N 521511001 - 521511265) TWO SPEED
(PRINTED August 2003)
V-0189
40 36
31 32 MALE MALE F1 D2 MALE
34 (FRONT AUXILIARY
58
MALE
COUPLERS)
58
33 35 37
F2 D1
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3

4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
26 43
11
27

24 24
45 CYLINDER 25 B
(OPTIONAL)
A B
26 30 26
HYDRAULIC
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
64 61 BICS CONTROL VALVE
55 B 62
63 60
47
63 TWO SPEED DRIVE MOTOR 48 46
A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
54 21
53
C DR 50 18
P1 P2 17
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0189 (8-5-03)
78 of 1030
S250 (S/N 521311994 - 521312052)
S300 (S/N 521511266 -521511290)
LEGEND
31 DRIVE MOTOR SHUTTLE VALVE 43 CHECK VALVE - AUXILIARY (Item 43
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE
was removed from the loaders at the
4 SPRING LOADED FILTER BYPASS following:
19 RELIEF VALVE - MAIN: 200 PSI (13,8 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) S250 S/N 521312004 And Above
3250-3350 PSI (224,1-231,0 Bar) 33 SOLENOID ACTIVATED DIRECTIONAL S300 S/N 521511270 And Above
5 PILOT ACTIVATED DIRECTIONAL at Front Quick Couplers CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2") 44 FRONT AUXILIARY MANUAL
POWERED BOB-TACH 20 RELIEF VALVE - PORT:
34 PRESSURE BLEED-OFF VALVE
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275,9 Bar) LOAD SHUTTLE VALVE - BLEED OFF
45 VARIABLE CAPACITY DISPLACEMENT
36-44 PSI (2,5-3,0 Bar) 21 ANTICAVITATION VALVE
35 PILOT ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
7 FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR 46 TWO STAGE RELIEF (1000 PSI/2000 PSI)
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) AUXILIARY - NORMALLY CLOSED (69/138 Bar)
VALVE 3500 PSI (241,4 Bar) ("P2" and "F2")
Dealer Copy -- Not for Resale 47 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 23 ONE WAY RESTRICTOR 36 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - FOR REAR
MOTOR 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY ("D1" and "P1")
CONTROL VALVE - FLOW CONTROL 25 RELIEF VALVE - PORT: . . . . . (Optional) 49 PRESSURE COMPENSATED FLOW
SPOOL 3500 PSI (241,4 Bar) CONTROL
26 RELIEF/REPLENISHING VALVE - HIGH AUXILIARY - NORMALLY OPEN 50 CHECK VALVE WITH 0.015 RESTRICTION
CONTROL VALVE - UNLOADING PRESSURE: 5000 PSI (344,8 Bar) ("D2" and "P2") 51 RELIEF VALVE - PORT:
SPOOL 27 PRESSURE SWITCH 38 FILTER - DIVERTER VALVE (SCREEN) 4000 PSI (275,9 Bar)
INTEGRATED IN SOLENOID 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 39 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
CONTROL VALVE - TO ACTIVATE VALVE (ON/OFF)
at 1775 Pump RPM
13 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1") 53 FILTER - CASE DRAIN (ATTACHMENT)
390 - 430 PSI (26,9 - 29,6 Bar)
("P1" and "F1")
ARM BY PASS

pressure value.

79 of 1030
S250 (S/N 521311994 - 521312052) 38
39
S300 (S/N 521511266 - 521511290) PILOT
DRIVE MOTOR
31 32
34 44
(REAR QUICK
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3

4 D
COOLER
45 8
26
28 NOTE 1: Item 43 was removed

26 from the loaders at the following:
S250 S/N 521311204 And Above 7
6 S300 S/N 521511270 And Above
A
CHARGE INLET OUTLET
52 C
29
43
SEE NOTE 1: 11
26 27

24 24
45 CYLINDER 25 B
(OPTIONAL) A B
26
HYDRAULIC
AUXILIARY
POWERED
SPOOL
BOB-TACH
OUTLET (OPTIONAL)
INLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
47
48 46
A B 12
51 TILT
CYLINDER
49 SPOOL
DRIVE MOTOR
21
DR 50 18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
PP
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0343 (8-5-03)
80 of 1030
S250 (S/N 521311994 - 521312052)
S300 (S/N 521511266 - 521511290)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 45 VARIABLE CAPACITY DISPLACEMENT
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC PUMP
17 ONE WAY RESTRICTOR AUXILIARY ("SV2") 46
2 FILTER - CASE DRAIN (90 Micron) TWO STAGE RELIEF 1000 PSI/2000 PSI
34 LOAD SHUTTLE VALVE - BLEED OFF (69/138 Bar)
18 LOAD CHECK VALVE
3 FILTER - HYDRAULIC (CANISTER) 47 SOLENOID ACTIVATED DIRECTIONAL
19 RELIEF VALVE - MAIN: CONTROL VALVE (TWO COIL)
4 SPRING LOADED FILTER BYPASS CONTROL VALVE - FOR REAR
3250-3350 PSI (224,1-231,0 Bar) AUXILIARY - NORMALLY CLOSED 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers ("P2" and "F2")
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT: 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - HYDRAULIC 4000 PSI (275,9 Bar) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
POWERED BOB-TACH CONTROL VALVE - FOR REAR 50 CHECK VALVE WITH 0.015 RESTRICTION
21 ANTICAVITATION VALVE
AUXILIARY - NORMALLY OPEN
6 DIFFERENTIAL PRESSURE SWITCH: ("D1" and "P1") 51 RELIEF VALVE - PORT:
Dealer Copy -- Not for Resale 4000 PSI (275,9 Bar)
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (241,4 Bar) CONTROL VALVE - FOR REAR 52 SOLENOID ACTIVATED DIRECTIONAL
23 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN CONTROL VALVE - BUCKET POSITION
8 CHECK VALVE - BUCKET POSITION ("D2" and "P2") VALVE (ON/OFF)
38 53 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - AUXILIARY FILTER - DIVERTER VALVE (SCREEN)
9 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC
INTEGRATED IN SOLENOID
MOTOR 3500 PSI (241,4 Bar) 39 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
CONTROL VALVE - TO ACTIVATE PRESSURE TO RELEASE
CONTROL VALVE - FLOW CONTROL REAR AUXILIARY ("SV1")
PRESSURE: 5000 PSI (344,8 Bar) 55 SOLENOID ACTIVATED DIRECTIONAL
SPOOL 40 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BRAKE
27 PRESSURE SWITCH
11 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR
28 RELIEF VALVE - CHARGE: AUXILIARY - NORMALLY CLOSED 56 SOLENOID ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.)Fluid ("P1" and "F1") CONTROL VALVE - MAKE-UP
SPOOL
at 1775 Pump RPM 41 CHECK VALVE - BICS CONTROL VALVE 57 SOLENOID ACTIVATED DIRECTIONAL
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (26,9 - 29,6 Bar) CONTROL VALVE - TWO SPEED
CONTROL VALVE - TILT CONTROL
29 CHARGE PUMP 42 RESTRICTION 58 FRONT AUXILIARY MANUAL
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53.0 L/min.) at 2750 PRESSURE BLEED-OFF VALVE
CONTROL VALVE - LIFT CONTROL 43 CHECK VALVE - AUXILIARY (Item 43
Engine RPM
was removed from the loaders at the 59 FILTER - CASE DRAIN (ATTACHMENT)
14 SOLENOID ACTIVATED DIRECTIONAL 30 following:
HYDRAULIC PUMP . . . . . . . Gear Type
CONTROL VALVE - BICS CONTROL S250 S/N 521312004 And Above 60 FILTER (BRAKE)
20.7 GPM (78.35 L/min.) at 2750
Engine RPM S300 S/N 521511270 And Above
15 PULL BUTTON ACTIVATED NOTE: Unless otherwise specified, springs have
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL NO significant pressure value.
ARM BY PASS CONTROL VALVE - TWO SPEED
32 SHUTTLE RELIEF VALVE: DRIVE MOTOR V-0344legend (8-5-03)
Printed in U.S.A. 200 PSI (13,8 Bar)
81 of 1030
WITH TWO SPEED VALVE OPTION Printable Version Click Here 38
S250 (S/N 521311994 - 521312052)
(S/N 5214 No machines built to this schematic) PILOT
39
S300 (S/N 521511266 - 521511290) TWO SPEED


V-0344
40 36
34 (FRONT AUXILIARY
58
MALE
COUPLERS)
58
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3

4 D
COOLER
45 8
26 26
28 NOTE 1: Item 43 was removed

from the loaders at the following: 7
6 S250 S/N 521311204 And Above
S300 S/N 521511270 And Above
52 C
CHARGE OUTLET HYDRAULIC CONTROL VALVE 10
INLET 29
43
SEE NOTE 1: 11
27
BOB-TACH
24 24
45 CYLINDER 25 B
(OPTIONAL)
A B
26 30 26
HYDRAULIC
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
BICS CONTROL VALVE
55 B
60
47
60
48 46
54 A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
53 21
C DR 50 18
P D 44 LIFT CYLINDERS
20 17
P1 P2
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0344 (8-5-03)
82 of 1030
S250 (S/N 521311994 - 521312052)
(S/N 5214 No machines built with this schematic)
S300 (S/N 521511266 - 521511290)
(S/N 5216 No machines built with this schematic)
V-0345legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 45 VARIABLE CAPACITY DISPLACEMENT
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC PUMP
17 ONE WAY RESTRICTOR AUXILIARY ("SV2") 46
2 FILTER - CASE DRAIN (90 Micron) TWO STAGE RELIEF: 1000 PSI/2000 PSI
34 LOAD SHUTTLE VALVE - BLEED OFF (69/138 Bar)
3 18 LOAD CHECK VALVE
FILTER - HYDRAULIC (CANISTER)
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - FOR REAR CONTROL VALVE (TWO COIL)
VALVE: 45-55 PSI (3,1-3,8 Bar) 3250-3350 PSI (224,1-231 Bar) AUXILIARY - NORMALLY CLOSED
at Front Quick Couplers 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
("P2" and "F2")
CONTROL VALVE - HYDRAULIC 36 PILOT ACTIVATED DIRECTIONAL 49 PRESSURE COMPENSATED FLOW
4000 PSI (275,9 Bar)
POWERED BOB-TACH CONTROL VALVE - FOR REAR CONTROL
21 ANTICAVITATION VALVE AUXILIARY - NORMALLY OPEN
6 DIFFERENTIAL PRESSURE SWITCH: 50 CHECK VALVE WITH 0.015 RESTRICTION
("D1" and "P1")
for ResaleVALVE - FOR REAR 4000 PSI (275,9 Bar)
23 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN 52 SOLENOID ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION ("D2" and "P2") CONTROL VALVE - BUCKET POSITION
VALVE 24 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - AUXILIARY INTEGRATED IN SOLENOID 53 AUXILIARY HYDRAULIC PUMP
BIDIRECTIONAL HYDROSTATIC 25 10 GPM (37.85 L/min.)
RELIEF VALVE - PORT: . . . . . (Optional) 39 SOLENOID ACTIVATED DIRECTIONAL
MOTOR at 2750
3500 PSI (241,4 Bar) CONTROL VALVE - TO ACTIVATE Engine RPM
10 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH REAR AUXILIARY ("SV1") 54 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (344,8 Bar)
11 PILOTED ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY CLOSED 56 DUMP VALVE (ON/OFF)
120 degrees F. (53 degrees C.)Fluid 57 CHECK VALVE
at 1775 Pump RPM
42 RESTRICTION
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53.0 L/min.) at 2750 43 CHECK VALVE - AUXILIARY (Item 43
CONTROL VALVE - LIFT CONTROL Engine RPM was removed from the loaders at the
30 HYDRAULIC PUMP . . . . . . . Gear Type following:
14 SOLENOID ACTIVATED DIRECTIONAL S250 S/N 521312004 And Above
20.7 GPM (78.35 L/min.) at 2750
CONTROL VALVE - BICS CONTROL S300 S/N 521511270 And Above
Engine RPM
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE NOTE: Unless otherwise specified
44 FRONT AUXILIARY MANUAL springs have NO significant
32 SHUTTLE RELIEF VALVE: PRESSURE BLEED-OFF VALVE pressure value.
ARM BY PASS
200 PSI (13,8 Bar)

83 of 1030
38
S250 (S/N 521311994 - 521312052)
(S/N 5214 No machined built to this schematic) PILOT
39
S300 (S/N 521511266 - 521511290) Printable Version Click Here

(S/N 5216 No machined built to this schematic)
V-0345
40 36
31 32
34 44
(REAR QUICK
33 35 37
F2 D1
FEMALE
9 FEMALE FEMALE
DRAIN P1 P2
HYDRAULIC FILTER
3

4 D
COOLER
45 8
28
26 26
NOTE 1: Item 43 was removed 7
S250 S/N 521311204 And Above
S300 S/N 521511270 And Above
A
CHARGE INLET OUTLET
52 C
29
43
SEE NOTE 1: 11
27 BOB-TACH
26
CYLINDER
26 45 (OPTIONAL) 24 24
A B
HYDRAULIC
POWERED
BOB-TACH AUXILIARY
(OPTIONAL) SPOOL
INLET OUTLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
53
57 47
48 46
55
56 A B 12
49 51 TILT
CYLINDER
SPOOL
9 18
P1 P2
5 20 LIFT CYLINDERS
17
PP 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0345 (8-5-03)
84 of 1030
S250 (S/N 521311994 - 521312052)
S300 (S/N 521511266 - 521511290)
Printable Version Click Here
V-0346legend
LEGEND
1 RESERVOIR: 18 LOAD CHECK VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 21 Qts. (19.9 L) CONTROL VALVE (TWO COIL)
RELIEF VALVE - MAIN: 35 PILOT ACTIVATED DIRECTIONAL
19 48
2 FILTER - CASE DRAIN (90 Micron) CONTROL VALVE - FOR REAR RELIEF VALVE - 1200 PSI (82,8 Bar)
3250-3350 PSI (224-231 Bar)
at Front Quick Couplers AUXILIARY - NORMALLY CLOSED 49
3 FILTER - HYDRAULIC (CANISTER) PRESSURE COMPENSATED FLOW
20 RELIEF VALVE - PORT: ("P2" and "F2")
CONTROL
4 SPRING LOADED FILTER BYPASS 4000 PSI (275,9 Bar) 36 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH 0.015 RESTRICTION
VALVE: 45-55 PSI (3,1-3,8 Bar) 21 ANTICAVITATION VALVE CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN 51 RELIEF VALVE - PORT:
22 RELIEF/ANTICAVITATION VALVE - ("D1" and "P1") 4000 PSI (275,9 Bar)
POWERED BOB-TACH PORT (TILT BASE END) 37 PILOT ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,4 Bar) CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
6 DIFFERENTIAL PRESSURE SWITCH:
23 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
36-44 PSI (2,5-3,0 kPa)
("D2" and "P2") 53 FIXED CAPACITY DISPLACEMENT
7 FLOW DIVIDER ADJUSTMENT VALVE 24 SOLENOID ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
38 FILTER - DIVERTER VALVE (SCREEN) BIDIRECTIONAL HYDROSTATIC
CONTROL VALVE - AUXILIARY MOTOR
8 CHECK VALVE - BUCKET POSITION INTEGRATED IN SOLENOID
VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) 54 HYDRAULIC BRAKE - SPRING APPLIED -
3500 PSI (241,4 Bar) PRESSURE TO RELEASE
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - TO ACTIVATE
BIDIRECTIONAL HYDROSTATIC 26 RELIEF/REPLENISHING VALVE - HIGH
REAR AUXILIARY ("SV1") 55 SOLENOID ACTIVATED DIRECTIONAL
MOTOR PRESSURE: 5000 PSI (344,8 Bar) CONTROL VALVE - BRAKE
27 40 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL PRESSURE SWITCH
CONTROL VALVE - FLOW CONTROL CONTROL VALVE - FOR REAR CONTROL VALVE - MAKE-UP
SPOOL 28 RELIEF VALVE - CHARGE: AUXILIARY - NORMALLY CLOSED 57 SOLENOID ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.)Fluid ("P1" and "F1") CONTROL VALVE - TWO SPEED
at High Engine Idle 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - UNLOADING 58 FRONT AUXILIARY MANUAL
390 - 430 PSI (26,9 - 29,6 Bar)
SPOOL PRESSURE BLEED-OFF VALVE
29 CHARGE PUMP 42 RESTRICTION
14.0 GPM (53.0 L/min.) at High 59 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - TILT CONTROL 43
Engine Idle CHECK VALVE - AUXILIARY (Item 43
13 PILOTED ACTIVATED DIRECTIONAL was removed from the loaders at the 60 RELIEF VALVE - 3300 PSI (227,6 Bar)
CONTROL VALVE - LIFT CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type following: 61 DUMP VALVE (ON/OFF)
20.7 GPM (78.35 L/min.) at High S250 S/N 521312004 And Above
Engine Idle S300 S/N 521511270 And Above 62 CHECK VALVE
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE
15 PULL BUTTON ACTIVATED 44 PILOT ACTIVATED DIRECTIONAL 63 FILTER (BRAKE)
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: CONTROL VALVE - TWO SPEED
ARM BY PASS 64 AUXILIARY HYDRAULIC PUMP
200 PSI (13,8 Bar) DRIVE MOTOR
16 FILTER - BICS CONTROL VALVE 10 GPM (37.85 L/min.)
33 SOLENOID ACTIVATED DIRECTIONAL 45 VARIABLE CAPACITY DISPLACEMENT At High Engine Idle
(SCREEN) CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC PUMP
17 ONE WAY RESTRICTOR AUXILIARY ("SV2") NOTE: Unless otherwise specified springs
46 TWO STAGE RELIEF 1000 PSI/2000 PSI have NO significant
(69/138 Bar) pressure value.
85 of 1030
38
S250 (S/N 521311994 - 521312052)
(S/N 5214 No machines built to this schematic) PILOT
39
S300 (S/N 521511266 - 521511290) TWO SPEED

V-0346
40 36
34 (FRONT AUXILIARY
58
MALE
COUPLERS)
58
33 35 37
F2 D1
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3

4 D
COOLER
45 8
26 26
28
NOTE 1: Item 43 was removed 7
S250 S/N 521311204 And Above
S300 S/N 521511270 And Above
52 C
INLET 29
26 43
SEE NOTE 1: 11
27

24 24
45 CYLINDER 25 B
(OPTIONAL)
A B
26 30 26
HYDRAULIC
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
55 B 62
63 60
47
A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
54 21
53
C DR 50 18
P1 P2 17
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0346 (8-5-03)
86 of 1030
S250 (S/N 521312053 - 521313912)
(S/N 521411029 - 521411180)
S300 (S/N 521511291 - 521512099)
(S/N 521611001 - 521611029)
V-0347legend
LEGEND
31 DRIVE MOTOR SHUTTLE VALVE 43 FILTER - CASE DRAIN (ATTACHMENT)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE
32 SHUTTLE RELIEF VALVE: 44 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BYPASS 200 PSI (13,8 Bar) PRESSURE BLEED-OFF VALVE
19 RELIEF VALVE - MAIN:
VALVE: 45-55 PSI (3,1-3,8 Bar)
3250-3350 PSI (224,1-231,0 Bar) 33 45 VARIABLE CAPACITY DISPLACEMENT
SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL at Front Quick Couplers BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2") 46 TWO STAGE RELIEF (1000 PSI/2000 PSI)
POWERED BOB-TACH 20 RELIEF VALVE - PORT:
34 (69/138 Bar)
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275,9 Bar) LOAD SHUTTLE VALVE - BLEED OFF
21 ANTICAVITATION VALVE 47 SOLENOID ACTIVATED DIRECTIONAL
36-44 PSI (2,5-3,0 Bar)
35 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR
8 PORT (TILT BASE END) AUXILIARY - NORMALLY CLOSED 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
CHECK VALVE - BUCKET POSITION
VALVE 3500 PSI (241,4 Bar) ("P2" and "F2")
Dealer Copy -- Not for Resale 49 PRESSURE COMPENSATED FLOW
9 FIXED CAPACITY DISPLACEMENT 23 ONE WAY RESTRICTOR 36 PILOT ACTIVATED DIRECTIONAL CONTROL
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - FOR REAR 50
24 SOLENOID ACTIVATED DIRECTIONAL CHECK VALVE WITH 0.015 RESTRICTION
MOTOR AUXILIARY - NORMALLY OPEN
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY ("D1" and "P1") 51 RELIEF VALVE - PORT:
CONTROL VALVE - FLOW CONTROL 25 RELIEF VALVE - PORT: . . . . . (Optional) 37 4000 PSI (275,9 Bar)
PILOT ACTIVATED DIRECTIONAL
SPOOL 3500 PSI (241,4 Bar) CONTROL VALVE - FOR REAR 52 SOLENOID ACTIVATED DIRECTIONAL
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH AUXILIARY - NORMALLY OPEN CONTROL VALVE - BUCKET POSITION
CONTROL VALVE - UNLOADING PRESSURE: 5000 PSI (344,8 Bar) ("D2" and "P2") VALVE (ON/OFF)
SPOOL 27 PRESSURE SWITCH 38 FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
CONTROL VALVE - TILT CONTROL 120 degrees F. (53 degrees C.)Fluid 39 SOLENOID ACTIVATED DIRECTIONAL
at 1775 Pump RPM CONTROL VALVE - TO ACTIVATE
390 - 430 PSI (26,9 - 29,6 Bar)
("P1" and "F1")
ARM BY PASS

pressure value.

87 of 1030
S250 (S/N 521312053 - 521313912) 38
(S/N 521411029 - 521411180)
39
S300 (S/N 521511291 - 521512099) PILOT
(S/N 521611001 - 521611029)
DRIVE MOTOR
31 32
34 44
(REAR QUICK
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3

4 D
COOLER
45 8
26
28
26
7
6
A
CHARGE INLET OUTLET
52 C
29
11
26 27

24 24
45 CYLINDER 25 B
(OPTIONAL) A B
26
HYDRAULIC
AUXILIARY
POWERED
SPOOL
BOB-TACH
OUTLET (OPTIONAL)
INLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
47
48 46
A B 12
51 TILT
CYLINDER
49 SPOOL
DRIVE MOTOR
21
DR 50 18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
PP
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0347 (8-5-03)
88 of 1030
S250 (S/N 521312053 - 521313912)
(S/N 521411029 - 521411180)
S300 (S/N 521511291 - 521512099)
(S/N 521611001 - 521611029)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 45 VARIABLE CAPACITY DISPLACEMENT
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) 200 PSI (13,8 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
17 ONE WAY RESTRICTOR 33 SOLENOID ACTIVATED DIRECTIONAL 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
CONTROL VALVE - BLEED OFF REAR (69/138 Bar)
18 LOAD CHECK VALVE AUXILIARY ("SV2")
3 FILTER - HYDRAULIC (CANISTER) 47 SOLENOID ACTIVATED DIRECTIONAL
19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE (TWO COIL)
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224,1-231,0 Bar) 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR 49 PRESSURE COMPENSATED FLOW
AUXILIARY - NORMALLY CLOSED CONTROL
CONTROL VALVE - HYDRAULIC 4000 PSI (275,9 Bar)
("P2" and "F2") 50 CHECK VALVE WITH 0.015 RESTRICTION
POWERED BOB-TACH 21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: 51 RELIEF VALVE - PORT:
22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR
36-44 PSI (2,5-3,0 Bar) Dealer Copy -- Not AUXILIARY
for Resale- NORMALLY OPEN 4000 PSI (275,9 Bar)
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (241,4 Bar) ("D1" and "P1")
23 ONE WAY RESTRICTOR VALVE 37 CONTROL VALVE - BUCKET POSITION
8 CHECK VALVE - BUCKET POSITION PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR VALVE (ON/OFF)
VALVE 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN 53 FIXED CAPACITY DISPLACEMENT
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - AUXILIARY ("D2" and "P2") BIDIRECTIONAL HYDROSTATIC
MOTOR 3500 PSI (241,4 Bar) 38 FILTER - DIVERTER VALVE (SCREEN) 54 HYDRAULIC BRAKE - SPRING APPLIED -
INTEGRATED IN SOLENOID PRESSURE TO RELEASE
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (344,8 Bar) 39 SOLENOID ACTIVATED DIRECTIONAL 55 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - TO ACTIVATE CONTROL VALVE - BRAKE
27 PRESSURE SWITCH REAR AUXILIARY ("SV1")
28 RELIEF VALVE - CHARGE: 56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING 40 PILOT ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.)Fluid CONTROL VALVE - MAKE-UP
SPOOL CONTROL VALVE - FOR REAR
at 1775 Pump RPM AUXILIARY - NORMALLY CLOSED 57 SOLENOID ACTIVATED DIRECTIONAL
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (26,9 - 29,6 Bar) CONTROL VALVE - TWO SPEED
("P1" and "F1")
CONTROL VALVE - TILT CONTROL
29 CHARGE PUMP 41 58 FRONT AUXILIARY MANUAL
CHECK VALVE - BICS CONTROL VALVE
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53.0 L/min.) at 2750 PRESSURE BLEED-OFF VALVE
CONTROL VALVE - LIFT CONTROL Engine RPM 42 RESTRICTION 59 FILTER - CASE DRAIN (ATTACHMENT)
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type 43 FILTER (BRAKE)
CONTROL VALVE - BICS CONTROL 20.7 GPM (78.35 L/min.) at 2750
15 Engine RPM 44 PILOT ACTIVATED DIRECTIONAL
PULL BUTTON ACTIVATED NOTE: Unless otherwise specified, springs have
DIRECTIONAL CONTROL VALVE - LIFT 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TWO SPEED
DRIVE MOTOR NO significant pressure value.
ARM BY PASS
V-0348legend (8-5-03)
Printed in U.S.A.
89 of 1030
38
S250 (S/N 521312053 - 521313912)
PILOT
S300 (S/N 521511291 - 521512099) TWO SPEED
(S/N 521611001 - 521611029) DRIVE MOTOR

V-0348
40 36
34 (FRONT AUXILIARY
58
MALE
COUPLERS)
58
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3

4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
11
27

24 24
45 CYLINDER 25 B
(OPTIONAL)
A B
26 30 26
HYDRAULIC
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
BICS CONTROL VALVE
55 B
43
47
43
48 46
54 A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
21
53
C DR 50 18
P2 17
P1 5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0348 (8-5-03)
90 of 1030
S250 (S/N 521312053 - 521313912)
(S/N 521411029 - 521411180)
S300 (S/N 521511291 - 521512099)
(S/N 521611001 - 521611029)
V-0349legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 46 TWO STAGE RELIEF: 1000 PSI/2000 PSI
Capacity . . . . . . . . . 21 Qts. (19.9 L) (SCREEN) CONTROL VALVE - BLEED OFF REAR (69/138 Bar)
17 ONE WAY RESTRICTOR AUXILIARY ("SV2")
34 47 SOLENOID ACTIVATED DIRECTIONAL
LOAD SHUTTLE VALVE - BLEED OFF
18 LOAD CHECK VALVE CONTROL VALVE (TWO COIL)
3 FILTER - HYDRAULIC (CANISTER)
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - FOR REAR
VALVE: 45-55 PSI (3,1-3,8 Bar) 3250-3350 PSI (224,1-231 Bar) AUXILIARY - NORMALLY CLOSED 49 PRESSURE COMPENSATED FLOW
at Front Quick Couplers ("P2" and "F2") CONTROL
CONTROL VALVE - HYDRAULIC 36 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH 0.015 RESTRICTION
4000 PSI (275,9 Bar)
POWERED BOB-TACH CONTROL VALVE - FOR REAR
21 ANTICAVITATION VALVE AUXILIARY - NORMALLY OPEN 51 RELIEF VALVE - PORT:
6 DIFFERENTIAL PRESSURE SWITCH: ("D1" and "P1") 4000 PSI (275,9 Bar)
for ResaleVALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
8 CHECK VALVE - BUCKET POSITION ("D2" and "P2") 53 AUXILIARY HYDRAULIC PUMP
VALVE 24 SOLENOID ACTIVATED DIRECTIONAL 10 GPM (37.85 L/min.)
CONTROL VALVE - AUXILIARY at 2750 Engine RPM
9 FIXED CAPACITY DISPLACEMENT INTEGRATED IN SOLENOID
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 54 FILTER - CASE DRAIN (ATTACHMENT)
MOTOR 3500 PSI (241,4 Bar) CONTROL VALVE - TO ACTIVATE
55 RELIEF VALVE - 3300 PSI (227,6 Bar)
10 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH REAR AUXILIARY ("SV1")
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (344,8 Bar) 56 DUMP VALVE (ON/OFF)
at 1775 Pump RPM
42 RESTRICTION
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53.0 L/min.) at 2750 43 CHECK VALVE
CONTROL VALVE - LIFT CONTROL Engine RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type 44 FRONT AUXILIARY MANUAL
14 SOLENOID ACTIVATED DIRECTIONAL PRESSURE BLEED-OFF VALVE
20.7 GPM (78.35 L/min.) at 2750
Engine RPM
31 45 VARIABLE CAPACITY DISPLACEMENT NOTE: Unless otherwise specified
15 PULL BUTTON ACTIVATED DRIVE MOTOR SHUTTLE VALVE
BIDIRECTIONAL HYDROSTATIC PUMP springs have NO significant
32 SHUTTLE RELIEF VALVE: pressure value.
ARM BY PASS
200 PSI (13,8 Bar)

91 of 1030
38
S250 (S/N 521312053 - 521313912)
(S/N 521411029 - 521411180) Printable Version Click Here PILOT
39
S300 (S/N 521511291 - 521512099)

(S/N 521611001 - 521611029)
V-0349
40 36
31 32
34 44
(REAR QUICK
33 35 37
F2 D1
FEMALE
9 FEMALE FEMALE
DRAIN P1 P2
HYDRAULIC FILTER
3

4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
11
27 BOB-TACH
26
CYLINDER
26 45 (OPTIONAL) 24 24
A B
HYDRAULIC
POWERED
BOB-TACH AUXILIARY
(OPTIONAL) SPOOL
INLET OUTLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
53
43 47
48 46
55
56 A B 12
49 51 TILT
CYLINDER
SPOOL
9 18
P1 P2
5 20 LIFT CYLINDERS
17
PP 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0349 (8-5-03)
92 of 1030
S250 (S/N 521312053 - 521313912)
(S/N 521411029 - 521411180)
S300 (S/N 521511291 - 521512099)
(S/N 521611001 - 521611029)
V-0350legend
LEGEND
1 RESERVOIR: 18 LOAD CHECK VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 21 Qts. (19.9 L) CONTROL VALVE (TWO COIL)
RELIEF VALVE - MAIN: 35 PILOT ACTIVATED DIRECTIONAL
19 48
2 FILTER - CASE DRAIN (90 Micron) CONTROL VALVE - FOR REAR RELIEF VALVE - 1200 PSI (82,8 Bar)
3250-3350 PSI (224-231 Bar)
at Front Quick Couplers AUXILIARY - NORMALLY CLOSED 49
3 FILTER - HYDRAULIC (CANISTER) PRESSURE COMPENSATED FLOW CONTROL
20 RELIEF VALVE - PORT: ("P2" and "F2")
4 SPRING LOADED FILTER BYPASS 4000 PSI (275,9 Bar) 36 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH 0.015 RESTRICTION
VALVE: 45-55 PSI (3,1-3,8 Bar) 21 ANTICAVITATION VALVE CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN 51 RELIEF VALVE - PORT:
22 RELIEF/ANTICAVITATION VALVE - ("D1" and "P1") 4000 PSI (275,9 Bar)
POWERED BOB-TACH PORT (TILT BASE END) 37 PILOT ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,4 Bar) CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 kPa)
("D2" and "P2") 53 FIXED CAPACITY DISPLACEMENT
7 FLOW DIVIDER ADJUSTMENT VALVE 24 SOLENOID ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
38 FILTER - DIVERTER VALVE (SCREEN) BIDIRECTIONAL HYDROSTATIC
CONTROL VALVE - AUXILIARY MOTOR
8 CHECK VALVE - BUCKET POSITION INTEGRATED IN SOLENOID
VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) 54 HYDRAULIC BRAKE - SPRING APPLIED -
3500 PSI (241,4 Bar) PRESSURE TO RELEASE
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - TO ACTIVATE
BIDIRECTIONAL HYDROSTATIC 26 RELIEF/REPLENISHING VALVE - HIGH
REAR AUXILIARY ("SV1") 55 SOLENOID ACTIVATED DIRECTIONAL
MOTOR PRESSURE: 5000 PSI (344,8 Bar) CONTROL VALVE - BRAKE
27 40 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL PRESSURE SWITCH
CONTROL VALVE - FLOW CONTROL CONTROL VALVE - FOR REAR CONTROL VALVE - MAKE-UP
SPOOL 28 RELIEF VALVE - CHARGE: AUXILIARY - NORMALLY CLOSED 57 SOLENOID ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.)Fluid ("P1" and "F1") CONTROL VALVE - TWO SPEED
at High Engine Idle 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - UNLOADING 58 FRONT AUXILIARY MANUAL
390 - 430 PSI (26,9 - 29,6 Bar)
SPOOL PRESSURE BLEED-OFF VALVE
29 CHARGE PUMP 42 RESTRICTION
14.0 GPM (53.0 L/min.) at High 59 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - TILT CONTROL 43
Engine Idle AUXILIARY HYDRAULIC PUMP
13 PILOTED ACTIVATED DIRECTIONAL 10 GPM (37.85 L/min.) 60 RELIEF VALVE - 3300 PSI (227,6 Bar)
CONTROL VALVE - LIFT CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type
At High Engine Idle 61 DUMP VALVE (ON/OFF)
20.7 GPM (78.35 L/min.) at High
Engine Idle 44 PILOT ACTIVATED DIRECTIONAL 62 CHECK VALVE
31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TWO SPEED
15 PULL BUTTON ACTIVATED 63 FILTER (BRAKE)
DRIVE MOTOR
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: 45 VARIABLE CAPACITY DISPLACEMENT
ARM BY PASS 200 PSI (13,8 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
CONTROL VALVE - BLEED OFF REAR
17 ONE WAY RESTRICTOR AUXILIARY ("SV2") (69/138 Bar) NOTE: Unless otherwise specified springs
have NO significant
pressure value.
93 of 1030
38
S250 (S/N 521312053 - 521313912)
PILOT
S300 (S/N 521511291 - 521512099) TWO SPEED
(S/N 521611001 - 521611029) DRIVE MOTOR
V-0350
40 36
34 (FRONT AUXILIARY
58
MALE
COUPLERS)
58
33 35 37
F2 D1
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3

4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
26
11
27

24 24
45 CYLINDER 25 B
(OPTIONAL)
A B
26 30 26
HYDRAULIC
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
55 B 62
63 60
47
A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
54 21
53
C DR 50 18
P1 P2 17
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0350 (8-5-03)
94 of 1030
S250 (S/N 521313913 - 521315299)
(S/N 521411181 - 521411321)
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081)
V-0351legend
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 (275,9 Bar)
17 ONE WAY RESTRICTOR (ACS VALVE ONLY) 34 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
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
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers CONTROL VALVE (TWO COIL)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH 4000 PSI (275,9 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)
Dealer Copy --39Not ORIFICE
for Resale
WITH 0.031 (0.76 mm)
RESTRICTION
3500 PSI (241,4 Bar)
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 (241,4 Bar) 43 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - FLOW CONTROL 10.2 GPM (37.85 L/min.) at High Engine Idle
26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (344,8 Bar) 44 FILTER - CASE DRAIN (ATTACHMENT)
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH
CONTROL VALVE - UNLOADING 45 VARIABLE CAPACITY DISPLACEMENT
SPOOL 28 RELIEF VALVE - CHARGE: BIDIRECTIONAL HYDROSTATIC PUMP
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle 46 TWO STAGE RELIEF VALVE 1000/2000
CONTROL VALVE - TILT CONTROL 390 - 430 PSI (26,9 - 29,6 Bar) PSI (69/138 Bar)
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High CONTROL VALVE (TWO COIL)
14 SOLENOID ACTIVATED DIRECTIONAL Engine Idle
CONTROL VALVE - BICS CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78.35 L/min.) at High Engine Idle
15 PULL BUTTON ACTIVATED 49 PILOT ACTIVATED PRESURE CONTROL
31 DRIVE MOTOR SHUTTLE VALVE VALVE
ARM BY PASS NOTE: Unless otherwise specified
32 50 CHECK VALVE WITH 0.015 inch (0,38 mm)
SHUTTLE RELIEF VALVE: springs have NO significant
RESTRICTION
200 PSI (13,8 Bar) pressure value.
95 of 1030
(REAR QUICK
FEMALE COUPLERS) MALE
S250 (S/N 521313913 - 521315299) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 521411181 - 521411321)
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081)
33 34
(PRINTED August 2003) Printable Version Click Here 35
V-0351
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 53
LEFT SIDE LIFT ARM)
MALE
31 37 53
32
FEMALE
POUT PIN T
9 HYDRAULIC FILTER
HYDROSTATIC PUMPS OIL 44

4 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
INLET OUTLET AUXILIARY
SPOOL
30
OUTLET
29 TILT CYLINDERS
BOB-TACH 22
18 BICS CONTROL VALVE
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR
21
9 18
47
20 LIFT CYLINDERS
48 46 17
13
23
49 A B
LIFT
CYLINDER
SPOOL
DR 50
31 32
P1 P2 42
5 18
PP
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
2 16 41 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0351 (8-7--03)
96 of 1030
WITH TWO SPEED VALVE
S250 (S/N 521313913 - 521315299)
(S/N 521411181 - 521411321)
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081)
LEGEND
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 - HYDRAULIC 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
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
Dealer Copy --39NotCHECK
for Resale
VALVE
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 RELIEF VALVE - 3300 PSI (227,6 Bar)
42 RESTRICTION
60 ORIFICE WITH 0.031 (0.76 mm)
3500 PSI (241,4 Bar) 43
10 PILOTED ACTIVATED DIRECTIONAL FILTER - CASE DRAIN (ATTACHMENT) RESTRICTION
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (344,8 Bar) 44 PILOT ACTIVATED DIRECTIONAL
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH CONTROL VALVE - TWO SPEED
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
390 - 430 PSI (26,9 - 29,6 Bar)
13 PILOTED ACTIVATED DIRECTIONAL 46 TWO STAGE RELIEF VALVE 1000/2000
29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL PSI (69/138 Bar)
13.6 GPM (51,5 L/min.) at High
Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL
30 HYDRAULIC PUMP . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
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 PILOT ACTIVATED DIRECTIONAL
ARM BY PASS CONTROL VALVE NOTE: Unless otherwise specified
32 SHUTTLE RELIEF VALVE: springs have NO significant
50 CHECK VALVE WITH 0.015 inch (0,38 mm)
RESTRICTION
97 of 1030
(REAR QUICK
S250 (S/N 521313913 - 521315299) Printable Version Click Here
(S/N 521411181 - 521411321)
BASE ROD REAR AUX VALVE (OPTIONAL)
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081) TWO SPEED DRIVE MOTOR
V-0352
33 34
31 35
32 36 MALE
38
60 (FRONT AUXILIARY
59 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
POUT PIN T
53
9 HYDRAULIC FILTER

4 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
BOB-TACH TILT CYLINDERS
TWO SPEED VALVE 29
CYLINDER 22
(OPTIONAL)
55 B
40
HYDRAULIC
POWERED
BOB-TACH
40 TWO SPEED DRIVE MOTOR (OPTIONAL)
A B 12
39 51 TILT
9
CYLINDER
SPOOL
54 21
56 53
C
18
47 17
48 46 13
23
39
A B
49 LIFT
CYLINDER
SPOOL
57
DR 50
A
18 42
31 32 P1 P2
5
PP 19 WORKING CIRCUITS
14
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0352 (8-7--03)
98 of 1030
S250 (S/N 521313913 - 521315299)
(S/N 521411181 - 521411321)
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081)
V-0353legend
LEGEND
4000 PSI (275,9 Bar)
19 RELIEF VALVE - MAIN: 53 RELIEF VALVE - 3300 PSI (227,6 Bar)
4 SPRING LOADED FILTER BYPASS 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 (275,9 Bar) CONTROL VALVE - REAR AUX 55 CHECK VALVE
36-44 PSI (2,5-3,0 Bar)
22 RELIEF/ANTICAVITATION VALVE - PRESSURE BLEED-OFF VALVE
for Resale
WITH 0.031 (0.76 mm)
RESTRICTION
3500 PSI (241,4 Bar)
VALVE
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY
42 RESTRICTION
SPOOL PRESSURE: 5000 PSI (344,8 Bar) 44 FILTER - CASE DRAIN (ATTACHMENT)
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH
45 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - TILT CONTROL 46 RELIEF VALVE 1000/2000 PSI (69/138 Bar)
390 - 430 PSI (26,9 - 29,6 Bar)
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High CONTROL VALVE (TWO COIL)
14 SOLENOID ACTIVATED DIRECTIONAL Engine Idle
30 HYDRAULIC PUMP . . . . . . . Gear Type 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
15 PULL BUTTON ACTIVATED 49 PRESSURE COMPENSATED FLOW
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE
32 SHUTTLE RELIEF VALVE: 50 CHECK VALVE WITH 0.015 inch (0,38 springs have NO significant
200 PSI (13,8 Bar) mm) RESTRICTION pressure value.
99 of 1030
(REAR QUICK
S250 (S/N 521313913 - 521315299) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 521411181 - 521411321)

S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081) 34
33 INTEGRATED QUICK COUPLER BLOCK
V-0353 Printable Version Click Here 35
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 56
LEFT SIDE LIFT ARM)
MALE
31 37 56
32
FEMALE
POUT PIN T
9 HYDRAULIC FILTER

4 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
29 TILT CYLINDERS
BOB-TACH 22
OUTLET 18 BICS CONTROL VALVE
CYLINDER
54 (OPTIONAL)
43
53 HYDRAULIC
55
POWERED
BOB-TACH
(OPTIONAL)
A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR
21
9 18
47 LIFT CYLINDERS
20 17
48 46
13
23
49 A B
LIFT
CYLINDER
SPOOL
DR 50
31 32
P1 P2 18 42
5
PP
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0353 (8-7-03)
100 of 1030
S250 (S/N 521313913 - 521315299)
(S/N 521411181 - 521411321)
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081)
V-0354legend
LEGEND
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 - HYDRAULIC 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
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
Dealer Copy --39NotCHECK
for Resale
VALVE
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 RELIEF VALVE - 3300 PSI (227,6 Bar)
10 PILOTED ACTIVATED DIRECTIONAL 61 DUMP VALVE (ON/OFF)
CONTROL VALVE - FLOW CONTROL 10.2 GPM (37.85 L/min.) at 2967 PUMP RPM at 91% EFF
SPOOL PRESSURE: 5000 PSI (344,8 Bar) 62 CHECK VALVE
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH CONTROL VALVE - TWO SPEED 63 ORIFICE WITH 0.031 (0.76 mm)
CONTROL VALVE - UNLOADING DRIVE MOTOR RESTRICTION
120 degrees F. (53 degrees C.)Fluid 45 VARIABLE CAPACITY DISPLACEMENT 64 RELIEF VALVE - 3300 PSI (227,6 Bar)
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC PUMP
390 - 430 PSI (26,9 - 29,6 Bar)
13 PILOTED ACTIVATED DIRECTIONAL 46 TWO STAGE RELIEF VALVE 1000/2000
29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL PSI (69/138 Bar)
13.6 GPM (51,5 L/min.) at High
14 SOLENOID ACTIVATED DIRECTIONAL Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
DIRECTIONAL CONTROL VALVE - LIFT 49 PRESSURE COMPENSATED FLOW
32 CONTROL VALVE
200 PSI (13,8 Bar) 50 CHECK VALVE WITH 0.015 inch (0,38 mm) pressure value.
SPRING
101 of 1030
(REAR QUICK
S250 (S/N 521313913 - 521315299)
(S/N 521411181 - 521411321) Printable Version Click Here
S300 (S/N 521512100 - 521512918)
(S/N 521611030 - 521611081) TWO SPEED DRIVE MOTOR
V-0354
33 34
31 35
32 36 MALE
38
63 (FRONT AUXILIARY
64 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
POUT PIN T
53
9 HYDRAULIC FILTER

4 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
TWO SPEED VALVE 29 TILT CYLINDERS
22
BOB-TACH
55 B 61
40 CYLINDER
43
60 HYDRAULIC (OPTIONAL)
62
POWERED
BOB-TACH
(OPTIONAL)
40 TWO SPEED DRIVE MOTOR
A B 12
39 51 TILT
9
CYLINDER
SPOOL
54 21
56 53
C
18
20 17
48 46
13
23
39
49 A B
LIFT
CYLINDER
SPOOL
57 50
DR
A
P1 P2 18 42
31 32 5
PP
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0354 (8-7--03)
102 of 1030
S250 (S/N 521315300 AND ABOVE)
(S/N 521411322 AND ABOVE)
S300 (S/N 521512919 AND ABOVE)
(PRINTED JUNE 2004)
V-0356legend
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 ONE WAY RESTRICTOR (ACS VALVE ONLY) 34 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
CONTROL VALVE - ROD
18 LOAD CHECK VALVE 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
SPRING
19 RELIEF VALVE - MAIN: 50 CHECK VALVE WITH 300 PSI (20,7 Bar) SPRING
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224-231 Bar) 36 SOLENOID ACTIVATED DIRECTIONAL and Orifice
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers CONTROL VALVE (TWO COIL) 0.03 (0,76 mm)
5 PILOT ACTIVATED DIRECTIONAL (S/N 521315300 - 521316165)
CONTROL VALVE WITH 30PSI SPRING - 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL
(S/N 521411322 - 521411558)
HYDRAULIC POWERED BOB-TACH 4000 PSI (275,9 Bar) CONTROL VALVE - REAR AUX
(S/N 521512919 - 521513445)
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE (S/N 521611082 - 521611121)
38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION
36-44 PSI (2,5-3,0 Bar) 0.016 (0.41 mm)
22 RELIEF/ANTICAVITATION VALVE - (S/N 521316166 And Above)
for Resale
WITH 0.031 (0.76 mm) (S/N 521411559 And Above)
RESTRICTION (S/N 521513446 And Above)
3500 PSI (241,4 Bar)
8 CHECK VALVE - BUCKET POSITION 40 RELIEF VALVE - 3300 PSI (227,6 Bar) (S/N 521611122 And Above)
VALVE
41 CHECK VALVE - BICS CONTROL VALVE 51 RELIEF VALVE - PORT:
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 4000 PSI (275,9 Bar)
42 RESTRICTION 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
10 PILOTED ACTIVATED DIRECTIONAL VALVE (ON/OFF)
26 RELIEF/REPLENISHING VALVE - HIGH 53 ORIFICE WITH 0.030 (0.76 mm)
SPOOL PRESSURE: 5000 PSI (344,8 Bar) 44 ORIFICE WITH RESTRICTION: RESTRICTION
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH 0.12 (3.05 mm)
CONTROL VALVE - UNLOADING 54 ORIFICE WITH 0.025 (0.64 mm)
(S/N 521315300 - 521316165)
SPOOL 28 RELIEF VALVE - CHARGE: RESTRICTION
(S/N 521411322 - 521411558)
120 degrees F. (53 degrees C.)Fluid (S/N 521512919 - 521513445) 55 FILTER - CASE DRAIN (ATTACHMENT)
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle (S/N 521611082 - 521611121)
CONTROL VALVE - TILT CONTROL 390 - 430 PSI (26,9 - 29,6 Bar) 0.089 (2.26 mm) 56 FRONT AUXILIARY MANUAL
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP (S/N 521316166 And Above) PRESSURE BLEED-OFF VALVE
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High (S/N 521411559 And Above)
Engine Idle (S/N 521513446 And Above)
14 SOLENOID ACTIVATED DIRECTIONAL (S/N 521611122 And Above)
CONTROL VALVE - BICS CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type
15 45 VARIABLE CAPACITY DISPLACEMENT
PULL BUTTON ACTIVATED
31 DRIVE MOTOR SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC PUMP
32 46 RELIEF VALVE 2000 PSI (138 Bar)
Printed in U.S.A. (For S/M P/N 6901926) V-0356legend (6-10-04)
103 of 1030
(REAR QUICK
S250 (S/N 521315300 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)
S300 (S/N 521512919 AND ABOVE)
33 34
(PRINTED JULY 2004) INTEGRATED QUICK COUPLER BLOCK
V-0356
Printable Version Click Here 35
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 56
LEFT SIDE LIFT ARM)
MALE
31 37 56
32
FEMALE
POUT PIN T
9 HYDRAULIC FILTER

4 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
29 TILT CYLINDERS
22
BOB-TACH
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
BOB-TACH 51 TILT
(OPTIONAL) CYLINDER
SPOOL
DRIVE MOTOR
49 21
9 DR
18
20 LIFT CYLINDERS
17
50 13
48 46 23
53
A B
54 LIFT
47 44
PP CYLINDER
SPOOL
32 P1 P2
31 5
18 42
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
(For S/M P/N 6901926) 1
Printed in U.S.A. V-0356 (6-10-04)
104 of 1030
S250 (S/N 521315300 AND ABOVE)
S300 (S/N 521512919 AND ABOVE)
(PRINTED JUNE 2004)
V-0357legend
LEGEND
1 RESERVOIR: 50 CHECK VALVE WITH 300 PSI (20,7 Bar)
35 LOAD SHUTTLE VALVE - BLEED OFF
Capacity . . . . . . . . . 21 Qts. (19.9 L) SPRING and Orifice
18 LOAD CHECK VALVE 0.03 (0,76 mm)
2 36 SOLENOID ACTIVATED DIRECTIONAL (S/N 521315300 - 521316165)
FILTER - CASE DRAIN (90 Micron)
19 RELIEF VALVE - MAIN: CONTROL VALVE (TWO COIL) (S/N 521411322 - 521411558)
3 FILTER - HYDRAULIC (CANISTER) 3250-3350 PSI (224-231 Bar) (S/N 521512919 - 521513445)
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL (S/N 521611082 - 521611121)
4 SPRING LOADED FILTER BYPASS CONTROL VALVE - REAR AUX 0.016 (0.41 mm)
20 RELIEF VALVE - PORT:
VALVE: 45-55 PSI (3,1-3,8 Bar) (S/N 521316166 And Above)
4000 PSI (275,9 Bar) 38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION
5 PILOT ACTIVATED DIRECTIONAL (S/N 521411559 And Above)
21 ANTICAVITATION VALVE (S/N 521513446 And Above)
CONTROL VALVE WITH 30PSI SPRING -
39 CHECK VALVE (S/N 521611122 And Above)
HYDRAULIC POWERED BOB-TACH 22 RELIEF/ANTICAVITATION VALVE -
6 DIFFERENTIAL PRESSURE SWITCH: PORT (TILT BASE END) 40 FILTER (BRAKE) 51 RELIEF VALVE - PORT:
36-44 PSI (2,5-3,0 Bar) 3500 PSI (241,4 Bar) 4000 PSI (275,9 Bar)
23 LIFT BASE ORIFICE (MANUAL VALVE ONLY) 41 CHECK VALVE - BICS CONTROL VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
Dealer Copy -- Not for Resale CONTROL VALVE - BUCKET POSITION
24 SOLENOID ACTIVATED DIRECTIONAL 42 VALVE (ON/OFF)
8 CHECK VALVE - BUCKET POSITION RESTRICTION
CONTROL VALVE - AUXILIARY 53 FIXED CAPACITY DISPLACEMENT
VALVE
25 RELIEF VALVE - PORT: . . . . . (Optional) 43 ORIFICE WITH RESTRICTION: BIDIRECTIONAL HYDROSTATIC
9 FIXED CAPACITY DISPLACEMENT 3500 PSI (241,4 Bar) 0.12 (3.05 mm) MOTOR
BIDIRECTIONAL HYDROSTATIC (S/N 521315300 - 521316165) HYDRAULIC BRAKE - SPRING APPLIED -
54
MOTOR 26 RELIEF/REPLENISHING VALVE - HIGH (S/N 521411322 - 521411558) PRESSURE TO RELEASE
PRESSURE: 5000 PSI (344,8 Bar) (S/N 521512919 - 521513445)
10 PILOTED ACTIVATED DIRECTIONAL 55 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 27 PRESSURE SWITCH (S/N 521611082 - 521611121) CONTROL VALVE - BRAKE
SPOOL 0.089 (2.26 mm)
28 (S/N 521316166 And Above) 56 SOLENOID ACTIVATED DIRECTIONAL
RELIEF VALVE - CHARGE:
11 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid (S/N 521411559 And Above) CONTROL VALVE - MAKE-UP
CONTROL VALVE - UNLOADING at High Engine Idle (S/N 521513446 And Above) 57 SOLENOID ACTIVATED DIRECTIONAL
SPOOL 390 - 430 PSI (26,9 - 29,6 Bar) (S/N 521611122 And Above) CONTROL VALVE - TWO SPEED
12 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 44 PILOT ACTIVATED DIRECTIONAL 58 FRONT AUXILIARY MANUAL
CONTROL VALVE - TILT CONTROL 13.6 GPM (51,5 L/min.) at High CONTROL VALVE - TWO SPEED PRESSURE BLEED-OFF VALVE
Engine Idle DRIVE MOTOR
13 PILOTED ACTIVATED DIRECTIONAL 59 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - LIFT CONTROL 45 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP 60 ORIFICE WITH 0.025 (0.64 mm)
14 31 HYDRAULIC PUMP . . . . . . . Gear Type RESTRICTION
CONTROL VALVE - BICS CONTROL 46 RELIEF VALVE 2000 PSI (138 Bar) 61 ORIFICE WITH 0.030 (0.76 mm)
15 PULL BUTTON ACTIVATED RESTRICTION
200 PSI (13,8 Bar) 47 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE (TWO COIL) 62 RELIEF VALVE - 3300 PSI (227,6 Bar)
ARM BY PASS 33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BASE 48 RELIEF VALVE - 1200 PSI (82,8 Bar) 63 ORIFICE WITH 0.031 (0.76 mm)
16 FILTER - BICS CONTROL VALVE (SCREEN)
RESTRICTION
34 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified springs have NO
17 ONE WAY RESTRICTOR (ACS VALVE ONLY) 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
CONTROL VALVE - ROD significant pressure value.
SPRING
Printed in U.S.A. (For S/M P/N 6901926) V-0357legend (6-10-04)
105 of 1030
(REAR QUICK
S250 (S/N 521315300 AND ABOVE)
S300 (S/N 521512919 AND ABOVE)
(S/N 521611082 AND ABOVE) TWO SPEED DRIVE MOTOR
(PRINTED JUNE 2004)
V-0357
33 34
31 35
32 36 MALE
38
63 (FRONT AUXILIARY
62 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
POUT PIN T
53
9 HYDRAULIC FILTER

4 D
COOLER 8
45
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
22
55 B
40
BOB-TACH
CYLINDER
(OPTIONAL)
40 TWO SPEED DRIVE MOTOR HYDRAULIC
POWERED A B 12
39 BOB-TACH 51 TILT
9
(OPTIONAL) CYLINDER
SPOOL
54 49 21
56 53
C DR
18
17
50 13
48 46 23
39 61
A B
60 LIFT
47 43
PP CYLINDER
SPOOL
57
P1 P2
A 5
18 42
31 32
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
15
(For S/M P/N 6901926) 1
Printed in U.S.A. V-0357 (6-10-04)
106 of 1030
S250 (S/N 521315300 AND ABOVE)
S300 (S/N 521512919 AND ABOVE)
(PRINTED JUNE 2004)
V-0358legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (82,8 Bar)
49 CHECK VALVE WITH 80 PSI (5,5 Bar)
17 ONE WAY RESTRICTOR (ACS VALVE ONLY) 34 SOLENOID ACTIVATED DIRECTIONAL SPRING
CONTROL VALVE - ROD
18 LOAD CHECK VALVE 50 CHECK VALVE WITH 300 PSI (20,7 Bar)
SPRING and Orifice
19 RELIEF VALVE - MAIN: 0.03 (0,76 mm)
4 SPRING LOADED FILTER BYPASS 3250-3350 PSI (224-231 Bar) 36 SOLENOID ACTIVATED DIRECTIONAL (S/N 521315300 - 521316165)
VALVE: 45-55 PSI (3,1-3,8 Bar) at Front Quick Couplers CONTROL VALVE (TWO COIL) (S/N 521411322 - 521411558)
5 PILOT ACTIVATED DIRECTIONAL (S/N 521512919 - 521513445)
CONTROL VALVE WITH 30PSI SPRING - 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL (S/N 521611082 - 521611121)
HYDRAULIC POWERED BOB-TACH 4000 PSI (275,9 Bar) CONTROL VALVE - REAR AUX 0.016 (0.41 mm)
(S/N 521316166 And Above)
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE 38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION (S/N 521411559 And Above)
36-44 PSI (2,5-3,0 Bar) (S/N 521513446 And Above)
for Resale
WITH 0.031 (0.76 mm) (S/N 521611122 And Above)
RESTRICTION 51 RELIEF VALVE - PORT:
3500 PSI (241,4 Bar)
23 LIFT BASE ORIFICE (MANUAL VALVE ONLY) 4000 PSI (275,9 Bar)
9 FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY VALVE (ON/OFF)
42 RESTRICTION
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 53 RELIEF VALVE - 3300 PSI (227,6 Bar)
26 RELIEF/REPLENISHING VALVE - HIGH 54 DUMP VALVE (ON/OFF)
SPOOL PRESSURE: 5000 PSI (344,8 Bar) 44 ORIFICE WITH RESTRICTION:
11 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH 0.12 (3.05 mm) 55 CHECK VALVE
CONTROL VALVE - UNLOADING (S/N 521315300 - 521316165)
SPOOL 28 RELIEF VALVE - CHARGE: (S/N 521411322 - 521411558) 56 FRONT AUXILIARY MANUAL
120 degrees F. (53 degrees C.)Fluid (S/N 521512919 - 521513445) PRESSURE BLEED-OFF VALVE
12 PILOTED ACTIVATED DIRECTIONAL at High Engine Idle (S/N 521611082 - 521611121)
CONTROL VALVE - TILT CONTROL 390 - 430 PSI (26,9 - 29,6 Bar) 57 FILTER - CASE DRAIN (ATTACHMENT)
0.089 (2.26 mm)
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP (S/N 521316166 And Above)
CONTROL VALVE - LIFT CONTROL 13.6 GPM (51,5 L/min.) at High (S/N 521411559 And Above) 58 ORIFICE WITH 0.025 (0.64 mm)
Engine Idle (S/N 521513446 And Above) RESTRICTION
14 SOLENOID ACTIVATED DIRECTIONAL (S/N 521611122 And Above)
CONTROL VALVE - BICS CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type 59 ORIFICE WITH 0.030 (0.76 mm)
45 VARIABLE CAPACITY DISPLACEMENT RESTRICTION
31 DRIVE MOTOR SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC PUMP
ARM BY PASS 46 RELIEF VALVE 2000 PSI (138 Bar) NOTE: Unless otherwise specified
32 SHUTTLE RELIEF VALVE: springs have NO significant
200 PSI (13,8 Bar) 47 pressure value.
Printed in U.S.A. (For S/M P/N 6901926) CONTROL VALVE (TWO COIL) V-0358legend (6-10-04)
107 of 1030
(REAR QUICK
S250 (S/N 521315300 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

S300 (S/N 521512919 AND ABOVE)
(S/N 521611082 AND ABOVE) 34
33 INTEGRATED QUICK COUPLER BLOCK
(PRINTED JUNE 2004)
V-0358 Printable Version Click Here 35
36 MALE
38
DRIVE MOTOR
39 (FRONT AUXILIARY
40 56
LEFT SIDE LIFT ARM)
MALE
31 37 56
32
FEMALE
POUT PIN T
9 HYDRAULIC FILTER

4 57 D
COOLER
45 8
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
29 TILT CYLINDERS
22
54
43
53
55
BOB-TACH
CYLINDER
(OPTIONAL)
HYDRAULIC
POWERED A B 12
BOB-TACH 51 TILT
(OPTIONAL) CYLINDER
SPOOL
DRIVE MOTOR
49 21
9 DR
18
20 LIFT CYLINDERS
17
50 13
48 46 23
59
A B
58 LIFT
47 44
PP CYLINDER
SPOOL
32 P1 P2
31 5
18 42
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
(For S/M P/N 6901926) 1
Printed in U.S.A. V-0358 (6-10-04)
108 of 1030
S250 (S/N 521315300 AND ABOVE)
S300 (S/N 521512919 AND ABOVE)
(PRINTED JUNE 2004)
LEGEND
1 RESERVOIR: 20 RELIEF VALVE - PORT: 37 PILOT ACTIVATED DIRECTIONAL 57 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 21 Qts. (19.9 L) 4000 PSI (275,9 Bar) CONTROL VALVE - REAR AUX CONTROL VALVE - TWO SPEED
21 ANTICAVITATION VALVE 58 FRONT AUXILIARY MANUAL
38 ORIFICE WITH 0.140 (3,6 mm) RESTRICTION
3 FILTER - HYDRAULIC (CANISTER) PRESSURE BLEED-OFF VALVE
4 SPRING LOADED FILTER BYPASS 39 CHECK VALVE 59 FILTER - CASE DRAIN (ATTACHMENT)
VALVE: 45-55 PSI (3,1-3,8 Bar) 3500 PSI (241,4 Bar) 40 FILTER (BRAKE) 60 RELIEF VALVE - 3300 PSI (227,6 Bar)
23 LIFT BASE ORIFICE (MANUAL VALVE ONLY) 61 DUMP VALVE (ON/OFF)
CONTROL VALVE WITH 30PSI SPRING - 41 CHECK VALVE - BICS CONTROL VALVE
HYDRAULIC POWERED BOB-TACH
24 SOLENOID ACTIVATED DIRECTIONAL 42 62 CHECK VALVE
6 DIFFERENTIAL PRESSURE SWITCH: RESTRICTION
CONTROL VALVE - AUXILIARY
36-44 PSI (2,5-3,0 Bar) 43 AUXILIARY HYDRAULIC PUMP 63 ORIFICE WITH 0.031 (0.76 mm)
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) 10.2 GPM (37.85 L/min.) at High Engine Idle RESTRICTION
3500 PSI (241,4 Bar)
8 CHECK VALVE - BUCKET POSITION 44 PILOT ACTIVATED DIRECTIONAL 64 ORIFICE WITH RESTRICTION:
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - TWO SPEED 0.12 (3.05 mm)
PRESSURE: 5000 PSI (344,8 Bar)
DRIVE MOTOR (S/N 521315300 - 521316165)
9 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR 45 VARIABLE CAPACITY DISPLACEMENT (S/N 521411322 - 521411558)
27 PRESSURE SWITCH BIDIRECTIONAL HYDROSTATIC PUMP (S/N 521512919 - 521513445)
10 PILOTED ACTIVATED DIRECTIONAL (S/N 521611082 - 521611121)
CONTROL VALVE - FLOW CONTROL 28 46 RELIEF VALVE 2000 PSI (138 Bar) 0.089 (2.26 mm)
RELIEF VALVE - CHARGE:
SPOOL (S/N 521316166 And Above)
120 degrees F. (53 degrees C.)
11 PILOTED ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL (S/N 521411559 And Above)
Fluid at High Engine Idle
CONTROL VALVE - UNLOADING SPOOL 390 - 430 PSI (26,9 - 29,6 Bar) CONTROL VALVE (TWO COIL) (S/N 521513446 And Above)
48 RELIEF VALVE - 1200 PSI (82,8 Bar) (S/N 521611122 And Above)
12 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 65 ORIFICE WITH 0.025 (0.64 mm)
CONTROL VALVE - TILT CONTROL 13.6 GPM (51,5 L/min.) at High 49 CHECK VALVE WITH 80 PSI (5,5 Bar)
RESTRICTION
Engine Idle SPRING
13 PILOTED ACTIVATED DIRECTIONAL 66 CHECK VALVE WITH 300 PSI (20,7 Bar)
CONTROL VALVE - LIFT CONTROL 30 HYDRAULIC PUMP . . . . . . . Gear Type 50 CHECK VALVE WITH 300 PSI (20,7 Bar)
SPRING and Orifice
20.7 GPM (78.35 L/min.) at High Engine Idle SPRING
14 SOLENOID ACTIVATED DIRECTIONAL 0.03 (0,76 mm)
51 RELIEF VALVE - PORT: (S/N 521315300 - 521316165)
CONTROL VALVE - BICS CONTROL 31 DRIVE MOTOR SHUTTLE VALVE
4000 PSI (275,9 Bar) (S/N 521411322 - 521411558)
15 PULL BUTTON ACTIVATED 52 SOLENOID ACTIVATED DIRECTIONAL (S/N 521512919 - 521513445)
DIRECTIONAL CONTROL VALVE - LIFT (S/N 521611082 - 521611121)
200 PSI (13,8 Bar) CONTROL VALVE - BUCKET POSITION
ARM BY PASS 0.016 (0.41 mm)
VALVE (ON/OFF)
16 FILTER - BICS CONTROL VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 53 FIXED CAPACITY DISPLACEMENT (S/N 521316166 And Above)
(SCREEN) CONTROL VALVE - BASE (S/N 521411559 And Above)
BIDIRECTIONAL HYDROSTATIC MOTOR
17 LOAD CHECK VALVE (S/N 521513446 And Above)
34 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED - (S/N 521611122 And Above)
18 CONTROL VALVE - ROD PRESSURE TO RELEASE 67 RELIEF VALVE - 3300 PSI (227,6 Bar)
ONE WAY RESTRICTOR (ACS VALVE ONLY)
35 LOAD SHUTTLE VALVE - BLEED OFF 55 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified springs have
19 RELIEF VALVE - MAIN: CONTROL VALVE - BRAKE
36 NO significant pressure value.
3250-3350 PSI (224-231 Bar) SOLENOID ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers CONTROL VALVE (TWO COIL) CONTROL VALVE - MAKE-UP V-0359legend (6-10-04)
109 of 1030
Printed in U.S.A. (For S/M P/N 6901926)
(REAR QUICK
S250 (S/N 521315300 AND ABOVE)
(S/N 521411322 AND ABOVE) Printable Version Click Here
S300 (S/N 521512919 AND ABOVE)
(S/N 521611082 AND ABOVE) TWO SPEED DRIVE MOTOR
(PRINTED JUNE 2004)
V-0359
33 34
31 35
32 36 MALE
38
63 (FRONT AUXILIARY
67 58
LEFT SIDE LIFT ARM)
MALE
37 58
54 44 FEMALE
POUT PIN T
53
9 HYDRAULIC FILTER

4 59 D
COOLER
45 8
26 26
28
7
6
52 C
CHARGE
INLET
26
11
27
24 24
45 25 B
A B
26
SPOOL
30
OUTLET
22
55 B 61
40 43
60
62
BOB-TACH
CYLINDER
(OPTIONAL)
40 TWO SPEED DRIVE MOTOR HYDRAULIC
POWERED A B 12
39 BOB-TACH 51 TILT
9
(OPTIONAL) CYLINDER
SPOOL
54 49 21
56 53
C DR
18
17
50 13
48 46 23
39 66
A B
65 LIFT
47 64
PP CYLINDER
SPOOL
57
P1 P2
A 5
18 42
31 32
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
15
(For S/M P/N 6901926) 1
Printed in U.S.A. V-0359 (6-10-04)
110 of 1030
HYDRAULIC SYSTEM INFORMATION

111 of 1030
HYDRAULIC SYSTEM INFORMATION (CONT’D)

112 of 1030

113 of 1030

114 of 1030
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.)
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.

115 of 1030
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.)

116 of 1030
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.-
lb. (24-27 N•m) torque.

117 of 1030
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.-


118 of 1030
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
TS-1060a
1
13
16
3
11
10
12
14 15
TS-1060b PE1519A

119 of 1030
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].

120 of 1030
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.

121 of 1030
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].

122 of 1030
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.-lb.

(814 N•m) 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.

123 of 1030

124 of 1030
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 Bob-
sufficient force to enter a person’s body by
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.-lb. (24-

Disconnect the hose (Item 1) [Figure 20-21-1] which 27 N•m) 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].

125 of 1030
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.-lb. (257,6

N•m) torque.

126 of 1030
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.

127 of 1030
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
TS-1060a

128 of 1030
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].

129 of 1030
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.

130 of 1030
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].

131 of 1030
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.-lb.

(136 N•m) 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].

132 of 1030
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.

133 of 1030
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.-lb. (34-38 N•m)

torque.
Remove the cylinder from the lever pivots.

134 of 1030
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

135 of 1030
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.

136 of 1030
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.

137 of 1030
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.-lb. (122 N•m) torque.

138 of 1030
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].

139 of 1030

140 of 1030
MAIN RELIEF VALVE (FOOT CONTROL) Connect the OUT port of the hydraulic tester to the male
quick coupler on the loader [Figure 20-30-1].
Checking The Main Relief Valve At Front Aux. Hyd.
Figure 20-30-2
Figure 20-30-1
1 2
B-15551
P-31821
Start the engine and run at low engine idle RPM. Push
The tools listed will be needed to do the following the mode switch (Item 1) [Figure 20-30-2] (on the
procedure: instrument panel) two times to engage the front auxiliary

hydraulics, the lights (Item 2) [Figure 20-30-2] will come
MEL10003 - Hydraulic Tester ON.
MEL10006 - Hydraulic Test Kit
Figure 20-30-3
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to
release the hydraulic pressure at the front auxiliary quick Right
couplers. Steering
Lever
Control
Connect the IN port of the hydraulic tester to the female

IMPORTANT 1 P13254
The hydraulic tester must be in the fully open

position before you start the engine. Press the front switch (Item 1) [Figure 20-30-3] for fluid
I-2024-0284 flow to the quick couplers.
Watch the flow meter on the hydraulic tester to make

sure the flow is correct. Increase the engine speed to full
WARNING RPM.
Record the GPM and refer to the hydraulic schematic for

Put jackstands under the front axles and rear corners the correct GPM for the model and serial number of your
of the frame before running the engine for service. loader. Turn the restrictor control, on the tester, until the
Failure to use jackstands can allow the machine to main relief valve opens. The correct pressure for the
fall or move and cause injury or death. main relief is 3300 PSI (22753 kPa).
W-2017-0286

141 of 1030
MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D) Figure 20-30-6
Figure 20-30-4
CD-15092
1
Remove the O-rings and back-up washers from the main
N-20039 relief valve [Figure 20-30-6].
Clean the main relief valve in clean solvent. Use air

Raise the operator cab. (See Raising The Operator Cab pressure to dry the valve.
on Page 10-30-1.)

Install new O-rings and back-up washers. Install the main
The main relief valve (Item 1) [Figure 20-30-4] is located relief valve and tighten [Figure 20-30-4]. Check the
at the lower front of the control valve. pressure again. (See Checking The Main Relief Valve At
Front Aux. Hyd. on Page 20-30-1.)
Remove the right motor cover.
Adjustment
Clean the area around the control valve.
Figure 20-30-7
Figure 20-30-5
N-19801
N-19800
If the pressure is not correct, adjust the main relief valve.

Loosen and remove the main relief valve (Item 1) [Figure Remove the end cap (Item 2) [Figure 20-30-5].
20-30-5].
Turn the adjusting screw (Item 1) [Figure 20-30-7] in or
Installation: Tighten the main relief valve to 35-40 ft.-lb. out until the pressure is correct. Turning screw in will
(47-54 N•m) torque. 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.
142 of 1030
MAIN RELIEF VALVE (ACS)
Checking The Main Relief Valve At Front Aux. Hyd.

WARNING
Figure 20-31-1
W-2017-0286
Figure 20-31-2
2
1
P-31821
2
The tools listed will be needed to do the following
procedure:

MEL10003 - Hydraulic Tester
B-15551
Turn the key switch to the OFF position, as the engine

stops running, turn the key switch all the way to the left to Start the engine and run at low engine idle RPM. Push
release the hydraulic pressure at the front auxiliary quick the mode switch (Item 1) [Figure 20-31-2] (on the
couplers. instrument panel) two times to engage the front auxiliary
hydraulics, the lights (Item 2) [Figure 20-31-2] will come
Lift and block the loader. (See LIFTING AND BLOCKING ON.
Figure 20-31-3
1
Connect the OUT port of the hydraulic tester to the male
IMPORTANT
Right
The hydraulic tester must be in the fully open Steering
Lever
position before you start the engine. Control
I-2024-0284
P13254
Press the front switch (Item 1) [Figure 20-31-3] for fluid

flow to the quick couplers.

RPM.

143 of 1030
MAIN RELIEF VALVE (ACS) (CONT’D) Figure 20-31-5
Checking The Main Relief Valve At Front Aux. Hyd. 1

(Cont’d)
Record the GPM and refer to the hydraulic schematic for

the correct GPM for the model and serial number of your
loader. Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the
main relief is 3300 PSI (22753 kPa).
If the relief pressure is not correct, stop the engine.

Adjust or replace the main relief valve. (See Adjustment
on Page 20-31-3.)
Removal And Installation N-23264
Figure 20-31-4
Loosen and remove the main relief valve (Item 1) [Figure
20-31-5].
Installation: Tighten the main relief valve to 35-40 ft.-lb.

(47-54 N•m) torque.

Figure 20-31-6
N-20039

on Page 10-30-1.)
The main relief valve (Item 1) [Figure 20-31-4] is located

at the lower front of the control valve. CD-15092

Remove the O-rings and back-up washers from the main
Clean the area around the control valve. relief valve [Figure 20-31-6].

pressure to dry the valve.
Install new O-rings and back-up washers. Install the main

relief valve and tighten [Figure 20-31-4]. Check the
pressure again. (See Checking The Main Relief Valve At
Front Aux. Hyd. on Page 20-31-1.)

144 of 1030
MAIN RELIEF VALVE (ACS) (CONT’D)
Adjustment
Figure 20-31-7
N-23265
If the pressure is not correct, remove the end cap and

adjust the main relief valve [Figure 20-31-5].

Turn the adjusting screw (Item 1) [Figure 20-31-7] in or
out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

pressure setting of the new relief valve.

145 of 1030

146 of 1030
MAIN RELIEF VALVE (SELECTABLE JOYSTICK
CONTROL) (SJC)
Checking The Main Relief Valve At Front Auxiliary WARNING

Hydraulics
Figure 20-32-1 of the frame before running the engine for service.
W-2017-0286
Figure 20-32-2
1 2
P-31821

procedure:
B-15551
Start the engine and run at low engine idle RPM. Push
Turn the key switch to the OFF position, as the engine the mode switch (Item 1) [Figure 20-32-2] (on the
stops running, turn the key switch all the way to the left to instrument panel) two times to engage the front auxiliary
release the hydraulic pressure at the front auxiliary quick hydraulics, the light (Item 2) [Figure 20-32-2] will come
couplers. ON.


Connect the OUT port of the hydraulic tester to the male

WARNING
position before you start the engine.
I-2024-0284

147 of 1030
MAIN RELIEF VALVE (SELECTABLE JOYSTICK Raise the operator cab (See Raising The Operator Cab
CONTROL) (SJC) (CONT'D) on Page 10-30-1.)
Checking The Main Relief Valve At Front Auxiliary

Hydraulics (Cont’d)
Figure 20-32-3 IMPORTANT

When making repairs on 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.
Right I-2003-0284
Steering
1 Lever
Control The main relief valve (Item 1) [Figure 20-32-4] is located
at the lower front of the control valve.
Clean the area around the control valve.

P-26697
Figure 20-32-5
Push the button (Item 1) [Figure 20-32-3] for fluid flow to

the quick couplers.
2
RPM.
There should be 20.0 GPM (75,8 L/min.) free flow. Turn

the restrictor control, on the tester, until the main relief 1
valve opens. The correct pressure for the main relief is
2950-3050 PSI (20340-21030 kPa).
If the relief pressure is not correct, stop the engine.

Adjust or replace the main relief valve. (See Checking
The Main Relief Valve At Front Auxiliary Hydraulics on
Page 20-30-1.) N-23264
Removal and Installation

Loosen and remove the main relief valve (Item 1)[Figure
Figure 20-32-4 20-32-5].
Installation: Tighten the main relief valve to 35-40 ft.-lb.

N-19112

148 of 1030
MAIN RELIEF VALVE (SELECTABLE JOYSTICK Adjustment
CONTROL) (SJC) (CONT'D)
Figure 20-32-7
Removal and Installation (Cont’d)
Figure 20-32-6
N-23265
CD-15092 If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 2) [Figure 20-32-5] .
Remove the O-rings and back-up washers from the main Turn the adjusting screw (Item 1) [Figure 20-32-7] in or
relief valve [Figure 20-32-6].

out until the pressure is correct. Turning screw in will
increase pressure.
pressure to dry the valve. NOTE: If the correct pressure can not be reached,
Install new O-rings and back-up washers. Install the main pressure setting of the new relief valve.
relief valve and tighten [Figure 20-32-4]. Check the
pressure again. (See Removal and Installation on Page
20-30-2.)

149 of 1030

150 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Open rear door.
Removal And Installation The fixed end main valve hose assembly (Item 1) [Figure
20-40-1] 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.
Figure 20-40-2
WARNING
to fall and cause injury or death. 1
W-2059-0598

Figure 20-40-1
P-34119
Disconnect the two tubelines (Item 1) [Figure 20-40-2]

from the lift arm by-pass valve.
1
Cap and plug tubelines and fittings.
Figure 20-40-3
P-37098
Raise the lift arms and install an approved lift arm support
device.
Stop the engine. Raise the seat bar. 1

on Page 10-30-1.)
P-34120
Drain the hydraulic reservoir. (See Fluid Removal on

Page 20-80-1.)
At the right fender, remove the two mounting bolts and
nuts (Item 1) [Figure 20-40-3] from the lift arm by-pass
Remove the control panel. (See Removal And Installation
mount.
on Page 50-100-1.)
Remove the lift arm by-pass valve and tubelines from the
Clean area around control valve.
loader.
151 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-6
(CONT’D)
Removal And Installation (Cont’d)
Figure 20-40-4
2
2
1
P-34124
Disconnect the harness connector (Item 1) [Figure 20-

40-6] from the BICS™ valve solenoid connector.
P-37099
40-6] from the auxiliary valve solenoid.
Disconnect the tubeline (Item 1) [Figure 20-40-4] that
goes from the control valve to the hydraulic cooler.

Figure 20-40-7
Disconnect the charge pressure sender (Item 2) [Figure

20-40-4] from the control valve.
Figure 20-40-5
1
2
1
P-34125
1
Disconnect foot control linkage (Item 1) [Figure 20-40-7]
from the tilt spool on the control valve.
P-34123
Disconnect foot control linkage (Item 2) [Figure 20-40-7]
from the lift spool on the control valve.
Mark the wire connectors for proper installation.
Move the control linkages to allow clearance for the
Disconnect the three wire harness connector (Item 1) control valve removal.
[Figure 20-40-5] from auxiliary valve solenoid, and the
lift and tilt lock solenoids.

152 of 1030
(CONT’D)
Figure 20-40-8
1
P-34128
Remove the two control valve mount bracket mount bolts

(Item 1) [Figure 20-40-10].
P-34126
Remove right side motor cover.
Loosen the fixed end main valve hose assembly (Item 1) Remove the right rear wheel/tire assembly from the
[Figure 20-40-8] from the control valve.

loader.
The hose can be removed from the control valve by Remove the right side pump access cover.
rotating the hose assembly.
Figure 20-40-11
Cap the hose and plug the fitting.
Figure 20-40-9
1 1
2
P-34129
P-34127 At the right side motor cover access hose, remove the
two control valve mount bolts (Item 1) [Figure 20-40-11]
from the mounting plate.
Install a chain hoist (Item 1) [Figure 20-40-9] to the
control valve, and support the control valve. Remove the control valve mount bracket from the loader.
Remove the case drain hose (Item 2) [Figure 20-40-9]

from the control valve to the case drain filter.
Loosen all the tubeline fittings connected to the control

valve.

153 of 1030
(CONT’D)
Figure 20-40-12
1
2
P-34132
Disconnect the tilt tubeline (Item 1) [Figure 20-40-14]

from the control valve.
P-34130
Cap and plug the tubeline and fitting.
Disconnect the case drain hose (Item 1) [Figure 20-40- Figure 20-40-15
12] and cap the fitting and plug the hose.

Disconnect the two auxiliary tubelines (Item 2) [Figure
Figure 20-40-13
1
P-34133
2 With the chain hoist lift the control valve up and clear of
the tubelines [Figure 20-40-15].
P-34131 Disconnect the hydraulic hose (Item 1) [Figure 20-40-15]

that comes from the back of the gear pump to the bottom
of the control valve.
from the control valve. Remove the control valve from the loader.
Disconnect the lift tubeline (Item 2) [Figure 20-40-13]


154 of 1030
(CONT’D)
BICS™ Valve, Removal And Installation
Figure 20-40-16
1 1
1
1
2
1
1
1
N-20035
1
Remove the four large O-rings (Item 1) [Figure 20-40-
18] and the small O-ring (Item 2) [Figure 20-40-18] from
N-20033 the top of the control valve.
Install the four large O-rings (Item 1) [Figure 20-40-18]

Remove the control valve. (See Removal And Installation and the small O-ring (Item 2) [Figure 20-40-18] on the
on Page 20-40-1.)

top of the control valve.
To remove the BICS™ valve from the control valve,

loosen and remove the six mounting bolts (Item 1)
[Figure 20-40-16].
Figure 20-40-17
N-20034
Remove the BICS™ valve assembly from the top of the

control valve [Figure 20-40-17].

155 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) BICS™ Valve, Lift Arm By-Pass Orifice Removal And
(CONT’D) Installation
BICS™ Valve, Removal And Installation (Cont’d) Figure 20-40-20
Figure 20-40-19
3
6
1
1
2
5
4
N-20040
N-20033
Remove the fitting (Item 1) [Figure 20-40-20] from the
valve.
Install the six mounting bolts [Figure 20-40-19].

Figure 20-40-21
The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS]
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.
Step Torque Sequence

1 110-130 in.-lb. 1
(12,4-14,7 N•m)
2 190-210 in.-lb.
1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3 190-210 in.-lb.
(21,5-23,7 N•m)
N-20041
*Torque must be 190-210 in.-labs. (21,5-23,7 N•m) for

every bolt or repeat step 3.

156 of 1030
(CONT’D)
BICS™ Valve, Lift Arm By-Pass Orifice Removal And

Installation (Cont’d)
Figure 20-40-22
N-18684
1
Remove the O-rings (Item 1) [Figure 20-40-24] and
back-up ring (Item 2) [Figure 20-40-24] from the check
valve.
N-18685
Install new O-rings and back-up ring on the check valve.
Using a flat blade screw driver, remove the lift arm by-

The check valve has a rating of 5-10 PSI.
pass orifice (Item 1) [Figure 20-40-21] & [Figure 20-40-
22]. Figure 20-40-25
Orifice size is 0.078 inch.
Reverse the removal procedure to install the lift arm by-

pass orifice.
1
BICS™ Valve, Check Valve Removal And Installation
Figure 20-40-23
P-8956
Clean and inspect the screen (Item 1) [Figure 20-40-25]

on the end of the valve.
1
N-20037
Remove the check valve (Item 1) [Figure 20-40-23].
Installation: Tighten the valve to 20 ft.-labs. (27 N•m)

torque.

157 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Remove the lock valves (Item 1) [Figure 20-40-26],
(CONT’D) [Figure 20-40-27] & [Figure 20-40-28] from the BICS™
valve.
Backslide, Lock Valve Removal And Installation
Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)
Figure 20-40-26 torque.
Figure 20-40-29
1
1
1
2
N-20033
2
2
N-18690
Figure 20-40-27

back-up rings (Item 2) [Figure 20-40-29] from both the tilt
and lift lock valves.
Install new O-rings (Item 1) [Figure 20-40-29] and back-

1 up rings (Item 2) [Figure 20-40-29] on the tilt and lift lock
valves.
Reverse the removal procedure to install the lock valve.
N-20039
Figure 20-40-28
N-20040

158 of 1030
(CONT'D)
BICS™ Valve, Solenoid Removal And Installation

1
Figure 20-40-30
N-20038
Remove the solenoid stem (Item 1) [Figure 20-40-32].
N-20037 Installation: Tighten the solenoid stem to 20 ft.-lb. (27

N•m) torque.
Remove the mounting nut (Item 1) [Figure 20-40-30] Figure 20-40-33

from the solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6
N•m) torque.
3
Remove the solenoid (Item 2) [Figure 20-40-30]. 2
NOTE: The solenoid resistance is (8-10 ohms).
Figure 20-40-31
1
1
1 N-18694

back-up washers (Item 2) [Figure 20-40-33] on the stem.
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 20-40-33] may be
cleaned with solvent. If it is torn or worn
Remove the O-rings (Item 1) [Figure 20-40-31] 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.

159 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Identification Chart
(CONT'D)
Item S250, S300 Loader
BICS™ Valve, Solenoid Testing
A1 Lift Cylinder Base End/Restrictor
Figure 20-40-34 A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
P9175
E1 Port Relief Valve - 4000 PSI
E2 Anti-Cavitation/Port Relief Valve - 3500 PSI
Use a test meter to measure coil resistance [Figure 20-
40-34]. Coil wires do not have polarity. Correct resistance F1 Anti-Cavitation Valve

for the auxiliary pressure relief (small) coil is 7-10 ohm F2 Port Relief Valve - 4000 PSI
and the other coils 5-8 ohms. G1 Lift Spool End
Replace the test meter with 12 volt power. You can see G2 Tilt Spool End
and hear the spool shift. G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
Figure 20-40-35
H2 Plug/Port Relief (Optional) - 3500 PSI
H2 H1
MR Main Relief Valve - 3300 PSI
H3
C4
B3 A3
G3 D3
C3
G2 B2 A2 E2 D2
F2 C2
G1 B1 A1 E1
C1
F1
D1
MR
TS-1971

160 of 1030
(CONT'D)
Load Check Valve

2
Figure 20-40-36
1
1 1
1 1
N-18698
2
Loosen the load check plugs (Item 1) [Figure 20-40-37]

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.-lb. (47-54 N•m) torque.
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve, Removal And Installation on Page

Figure 20-40-38
20-40-5.)

36] and small O-ring (Item 2) [Figure 20-40-36]. Always
replace these O-rings before installing the BICS valve
assembly.
IMPORTANT 1
When repairing hydrostatic and hydraulic systems, 2

N-20077
damage the system.
I-2003-0888
Remove the load check plugs (Item 1) [Figure 20-40-38].
Mark each valve section, spool and related parts so that Remove the spring (Item 2) [Figure 20-40-38] and
they will be returned to its original valve section during poppet (Item 3) [Figure 20-40-38].
assembly.
NOTE: Both load checks poppets, plugs and springs
Use bolts to fasten the control valve to a work bench for are the same for the lift and tilt.
easier disassembly and assembly procedures.
Loosen the load check plug (Item 2) [Figure 20-40-37]
from the auxilliary section of the control valve.

161 of 1030
(CONT'D)
2 3
4
Load Check Valve (Cont’d) 5
Figure 20-40-39
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
N-20078
Installation: Always use new O-rings. sleeve, and glide
ring. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
The auxiliary section uses a load check poppet with an
orifice (Item 1) [Figure 20-40-39].

Port Relief Valve, Tilt Spool
NOTE: For correct port locations and valve Figure 20-40-42

component (See Identification Chart on Page
20-40-10.).
Main Relief Valve
Figure 20-40-40
N-20043
Remove the port relief valve (Item 1) [Figure 20-40-42]

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

20-40-40].

162 of 1030
(CONT'D)
4
Port Relief Valve, Tilt Spool (Cont’d)
3
Figure 20-40-43
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.-lb. (47-54 N•m) torque.
Remove the O-rings and back-up washer from the port

Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
Installation: Always use new O-rings and back-up Figure 20-40-46

Port Relief Valve, Lift Spool
Figure 20-40-44 1
1
N-20042
Remove the anti-cavitation/port relief valve (Item 1)

[Figure 20-40-46] from the control valve tilt section.
N-20040
Remove the port relief valve (Item 1) [Figure 20-40-44]

from the control valve lift section.

163 of 1030
(CONT'D)
1 2 3 4
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
(Cont’d)
Figure 20-40-47 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 20-40-49].
N-18843 Rubber Boot
Figure 20-40-50
Remove the O-rings (Item 1) [Figure 20-40-47] from the

anti-cavitation/port relief valve.

Anti-Cavitation Valve, Lift Spool 1
Figure 20-40-48
N-20043
Remove the two screws (Item 1) [Figure 20-40-50] on

the rubber boot retainer.
1
Installation: Tighten the screws to 90-100 in.-lb. (10,2-
11,3 N•m) torque.
N-20043
Remove the lift lock solenoid (Item 1) [Figure 20-40-48].
Remove the anti-cavitation valve (Item 2) [Figure 20-40-

48] from the control valve lift section.

164 of 1030
(CONT'D)
Rubber Boot (Cont’d)

1
Figure 20-40-51
2
2 1
2
2
1
1
N-20021
Remove the lock solenoids (Item 1) [Figure 20-40-52] &

[Figure 20-40-53] from the lift and tilt lock block.
N-20020
Remove the rubber Boot (Item 2) [Figure 20-40-52] &
[Figure 20-40-53]. (See Rubber Boot on Page 20-40-
Remove the rubber boot (Item 1) [Figure 20-40-51] and 14.)
retainer (Item 2) [Figure 20-40-51].

Figure 20-40-54
Lift And Tilt Lock Block
Figure 20-40-52
N-20022
2
N-20043 Remove the lift and tilt lock block [Figure 20-40-54].
NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)

165 of 1030
(CONT'D)
Lift Spool And Detent Removal
Figure 20-40-55
N-20040
1
Remove the end cap (Item 1) [Figure 20-40-57].
N-20022 Figure 20-40-58
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-
55] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-15.)
2
Figure 20-40-56
N-18971
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-58].
2
1 Remove the washer (Item 2) [Figure 20-40-58].
N-20023
Remove the bushing (Item 1) [Figure 20-40-56] and O-

ring (Item 2) [Figure 20-40-56] from the lift spool.

166 of 1030
(CONT'D)
Lift Spool And Detent Removal (Cont'd)
Figure 20-40-59
2 1
2 N-18974
1 Remove the detent sleeve (Item 1) [Figure 20-40-61],

detent balls (Item 2) [Figure 20-40-61] and spring (Item
N-18972 3) [Figure 20-40-61].
Figure 20-40-62
Remove the screws (Item 1) [Figure 20-40-59] from the
detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-40-59].
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly. 1
I-2012-0284
N-18975
Figure 20-40-60
Remove the spool assembly and seal (Item 1) [Figure

N-18973
Put a rag around the detent assembly [Figure 20-40-60].

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

167 of 1030
(CONT'D)
Lift Spool And Detent Disassembly 2
Figure 20-40-63
3 1
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-65] over the

centering spring.
N-18930
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-65] from the centering
Remove the spool seal (Item 1) [Figure 20-40-63] from spring, as it is under spring pressure.
the linkage end of the valve.

NOTE: The centering spring (Item 3) [Figure 20-40-65]
Figure 20-40-64 is orange on all 800 series loaders.
Figure 20-40-66
P-8988
1
2
N-18916
Clamp the linkage end of the spool in a vise [Figure 20-
40-64].
Put a rag around the detent assembly [Figure 20-40-66].
This will prevent the detent balls and spring from being
lost when the detent adapter is removed.
Remove the detent adapter with an allan wrench.
Remove the back-up washer (Item 1) [Figure 20-40-66]

and spool seal (Item 2) [Figure 20-40-66].

168 of 1030
(CONT'D)
1
Lift Spool And Detent Disassembly (Cont'd) 2
3
Figure 20-40-67
4
N-18919A
Inspect the adapter (Item 1) [Figure 20-40-69], collar

(Item 2) [Figure 20-40-69], spring (Item 3) [Figure 20-
N-19004 40-69], and washer (Item 4) [Figure 20-40-69].
Figure 20-40-70
Remove the detent adapter (Item 1) [Figure 20-40-67]
from the spring assembly.

Figure 20-40-68
N-18918
Remove the stud from the end of the spool [Figure 20-
N-19009 40-70].
Remove spring tool (Item 1) [Figure 20-40-68] from the

spring assembly.

169 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Install the O-ring (Item 1) [Figure 20-40-72] over the
(CONT'D) nipple on the plastic plug (Item 2) [Figure 20-40-72].
Lift Spool And Detent Disassembly (Cont'd) Figure 20-40-73
Figure 20-40-71
N-18963
N-18920
Install the plastic plug and O-ring in the spool [Figure 20-
40-73].
Removal of the plastic plug:

Figure 20-40-74
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 O-ring
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-71] 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. Plastic
Plug
NOTE: DO NOT USE LOCTITE ON THE STUD 0.60 inch
THREADS. (15,2 mm)
Lift Spool And Detent Assembly

B-14712
Figure 20-40-72
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
20-40-74].
2
N-18961

170 of 1030
(CONT'D)
Lift Spool And Detent Assembly (Cont’d)
Figure 20-40-75
N-18968
Install the detent adapter to the collar [Figure 20-40-77].
N-18967 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
Clamp the collar (Item 1) [Figure 20-40-75] in a vice. detent adapter and collar together to prevent

the detent balls and spring from falling out.
Figure 20-40-76
Figure 20-40-78
1
3
2
N-18958
N-19004
Apply grease on all the detent component surfaces

before assembly [Figure 20-40-76]. Install the spring tool (Item 1) [Figure 20-40-78] over the
washer, spring, collar and detent adapter.
Install the spring (Item 1) [Figure 20-40-76] and detent
balls (Item 2) [Figure 20-40-76] into the adapter (Item 3)
[Figure 20-40-76] and compress with the detent pliers
(Item 1) [Figure 20-40-77].

171 of 1030
(CONT'D)
Figure 20-40-79
CD-15051
1
Install the detent balls and spring [Figure 20-40-81].
N-18917 Figure 20-40-82
Install the spool seal (Item 1) [Figure 20-40-79] and

back-up washer (Item 2) [Figure 20-40-79].

Figure 20-40-80
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-40-82].
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-80].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-40-80].
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m).

172 of 1030
(CONT'D)
Figure 20-40-83
1
1
N-18971
Install the washer (Item 1) [Figure 20-40-85] and snap

ring (Item 2) [Figure 20-40-85].
N-19008
Figure 20-40-86
Install the detent sleeve (Item 1) [Figure 20-40-83] to the

detent adapter.

Figure 20-40-84
1
2
N-20040
1
Install the end cap (Item 1) [Figure 20-40-86].
2
N-18972
Install the lift spool assembly in the spool bore [Figure

20-40-84].
Install the detent bonnet (Item 1) [Figure 20-40-84].
Install the mounting screws (Item 2) [Figure 20-40-84].
Installation: Tighten the screws to 90-100 in.-lb. (10,2-

11,3 N•m) torque.

173 of 1030
(CONT'D)
Lift Spool And Detent Installation
Figure 20-40-87
1 N-20022
Install the lift and tilt lock block (Item 1) [Figure 20-40-
89]. (See Lift And Tilt Lock Block on Page 20-40-15.)
N-18930
Tilt Spool Removal And Installation
Install the spool seal (Item 1) [Figure 20-40-87] on the Figure 20-40-90
linkage end of the valve.

Figure 20-40-88
1 2
N-20022
N-18927 Remove the lift and tilt lock block (Item 1) [Figure 20-40-
90] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-15.)
Install the bushing (Item 1) [Figure 20-40-88] and O-ring
(Item 2) [Figure 20-40-88] on the linkage end of the lift
spool.

174 of 1030
(CONT'D)
Tilt Spool Removal And Installation (Cont’d)
Figure 20-40-91
1 2
N-18816
Remove the spool, centering spring, back-up washer and

spool seal [Figure 20-40-93].
N-20024
Assembly: Always use a new spool seal.
Remove the bushing (Item 1) [Figure 20-40-91] and O- Tilt Spool Disassembly And Assembly
ring (Item 2) [Figure 20-40-91] from the tilt spool.

Figure 20-40-94
Figure 20-40-92
N-18942
N-20042
Put the linkage end of the spool in the vice [Figure 20-
Remove the screws (Item 1) [Figure 20-40-92] from the 40-94].
end cap.
Install the spool tool (Item 1) [Figure 20-40-94] over the
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 centering spring.
N•m) torque.

175 of 1030
(CONT'D)
2
Tilt Spool Disassembly And Assembly (Cont’d)
1
Figure 20-40-95
N-19098 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-40-97] and

the back-up washer (Item 2) [Figure 20-40-97].
N-19014
Remove the bolt (Item 1) [Figure 20-40-95] holding the Auxiliary Spool Removal And Installation
centering spring to the spool.

Figure 20-40-98
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
N•m) torque.
Remove spring tool from the spring assembly.
Figure 20-40-96
1
2
3
4
1
N-20042

end cap.
N-18944 Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3

N•m) torque.
Inspect the adapter (Item 1) [Figure 20-40-96], collar

(Item 2) [Figure 20-40-96], spring (Item 3) [Figure 20-
40-96], and washer (Item 4) [Figure 20-40-96].

176 of 1030
(CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-99
1
1
N-20043
Remove the lock solenoid (Item 1) [Figure 20-40-101]

from the tilt lock block.
N-18990
Figure 20-40-102
Remove the end cap, O-ring, springs and centering

spring retainer [Figure 20-40-99].

NOTE: If the centering spring retainer (Item 1) [Figure
20-40-99] must be replaced, replace the
retainer on the opposite end also.

2
Figure 20-40-100
1
N-20073

auxiliary bleed block (Item 2) [Figure 20-40-102].

1 N•m) torque.
N-18989
Remove the spool (Item 1) [Figure 20-40-100].
Assembly: Put grease on all the centering spring

component parts.

177 of 1030
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Auxiliary Plug Removal And Installation
(CONT'D)
Figure 20-40-105
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-103
N-20031
N-20074 Remove the plug (Item 1) [Figure 20-40-105] auxiliary

section of the control valve.
Remove the auxiliary bleed block (Item 1) [Figure 20-40- Figure 20-40-106
103] and O-ring.

Assembly: Always use a new O-ring. 1
Figure 20-40-104
1 N-20076
2 Replace the O-rings (Item1) [Figure 20-40-106].
N-20075 Check the orfice (Item 2) [Figure 20-40-106], to make

sure it is not pluged.
Remove the centering spring retainer (Item 1) [Figure

20-40-104] and springs (Item 2) [Figure 20-40-104].
Assembly: Put grease on all the centering spring

component parts.
NOTE: If the centering spring retainer (Item 1) [Figure

20-40-104] must be replaced, replace the
retainer on the opposite end also.

178 of 1030
(CONT'D)
Auxiliary Electric Solenoid Disassembly
Figure 20-40-107
N-20027
Remove the coil (Item 1) [Figure 20-40-109] and end

1 plate (Item 2) [Figure 20-40-109].
N-20025
Remove the nut (Item 1) [Figure 20-40-107] from both Installation: Tighten valve to 8-12 ft.-lb. (11-16 N•m)
solenoids.

torque.
Installation: Tighten the nut to 8-12 ft.-lb. (11-16 N•m) Figure 20-40-110
torque.
Figure 20-40-108
1
N-18795
2
N-20026 Remove the O-rings (Item 1) [Figure 20-40-110] from the

solenoid stem.
Remove the end plate (Item 1) [Figure 20-40-108] and

housing (Item 2) [Figure 20-40-108].

179 of 1030
(CONT'D)
Port Relief (Optional)
Port-Auxiliary Section Removal And Installation
Figure 20-40-111
1 2
1
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-112] &

[Figure 20-40-113] and back-up ring (Item 2) [Figure 20-
N-20031 40-112] & [Figure 20-40-113] from the plug or relief
valve.
Remove the plug (Item 1) [Figure 20-40-111] 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 20-40-111] compressed air.
is 3500 PSI (24129 kPa).
Check the spools for wear or scratches.
Figure 20-40-112
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.

180 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-2
CONTROL SYSTEM) (ACS)
Actuator Removal And Installation (In Loader)
device. (See Installing The Lift Arm Support Device on 1
Page 20-41-1..)
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-
41-2] from the lift arm by-pass valve.
Stop the engine. Raise the seat bar. Figure 20-41-3
Figure 20-41-1

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

181 of 1030
CONTROL SYSTEM) (ACS) (CONT'D)

(Cont’d)
Figure 20-41-4
1 2
1
1 P-39424
Disconnect the actuator wire connectors (Item 1) [Figure

20-41-6] from the actuators.
P-37791 Figure 20-41-7

Disconnect the hydraulic hose (Item 2) [Figure 20-41-4] 1

from the control valve. 1
Cap and plug the fittings and hose.
Figure 20-41-5
1 P-39425
Remove the two actuator mount bolts (Item 1) [Figure

1 20-41-7]from the top actuator.
Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3

N•m) torque.
P-43928
Remove the two mount bolts (Item 1) [Figure 20-41-5]

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.

182 of 1030

(Cont’d)
1
Figure 20-41-8
2
2
P-39428
Slide the actuator (Item 1) [Figure 20-41-10] away from

1 the control valve.
P-39426 With a punch, remove the actuator pin (Item 2) [Figure

20-41-10] from the actuator and spool.

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 20-41-9
1
1
P-39427

20-41-9] from the bottom actuator.

N•m) torque

183 of 1030
Actuator Removal And Installation (Out Of Loader)
Figure 20-41-11
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 13].

the actuator retainer.

Installation: Tighten the bolt and nut to 90-100 in.-lb.
(10,2-11,3 N•m) torque.
Pull the actuator (Item 2) [Figure 20-41-11] away from

the control valve.
Figure 20-41-12
N-19113
Use a drift pin and hammer to remove the actuator pin

(Item 1) [Figure 20-41-12] from the actuator and the lift
or tilt spool.

184 of 1030
P-37098
WARNING
The fixed end main valve hose assembly (Item 1) [Figure
Never work on a machine with the lift arms up unless 20-41-14] 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
support device. Failure to use an approved lift arm 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 support Cap and plug the hose and fitting.
device.
Stop the engine. Raise the seat bar.

on Page 10-30-1.)

Page 20-80-1.)

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

Removal And Installation (In Loader) on Page 20-41-1.)
Open rear door.

185 of 1030

2
Figure 20-41-15
1
2 P-37099

P-39429

Cap and plug the tubelines and fittings.
Disconnect the electrical connector (Item 1) [Figure 20-
41-15] from the auxiliary spool solenoid. Figure 20-41-18

41-15] from the BICS valve solenoid.
Figure 20-41-16
P-34126
Loosen the fixed end main valve hose assembly (Item 1)

P-39430
The hose can be removed from the control valve by
41-16] from the auxiliary spool solenoid. Cap the hose and plug the fitting.

186 of 1030
Removal And Installation (Cont'd) 1
Figure 20-41-19
2
P-43931
Remove the two control valve mount bracket mounting

bolts (Item 1) [Figure 20-41-21].
P-34127
Remove the tubeline clamp mount bolt (Item 2) [Figure
20-41-21].
control valve, and support the control valve.

Figure 20-41-22

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

[Figure 20-41-22] from the mounting plate, at the back
P-43930 side of the control valve.
Remove the control valve mount bracket from the loader.

Disconnect the hydraulic hose (Item 1) [Figure 20-41-20]
that comes from the back of the gear pump to the
tubeline at the top of the control valve.

187 of 1030
Figure 20-41-23
1
2
P-34132
Disconnect the tilt tubeline (Item 1) [Figure 20-41-25] at

the tee fitting.
P-34130
Disconnect the case drain hose (Item 1) [Figure 20-41- Remove the control valve from the loader.

from the auxiliary section of the control valve.
Cap the fittings and plug the tubelines.
Figure 20-41-24
P-34131



188 of 1030
Figure 20-41-26
1 1
1
1
2
1 1
1
N-20035
1

Installation: Install the four large O-rings (Item 1)

To remove the BICS™ valve from the control valve, [Figure 20-41-28] and the small O-ring (Item 2) [Figure

20-41-28] on the top of the control valve.
[Figure 20-41-26].
Figure 20-41-27
N-20034


189 of 1030
BICS™ Valve, Removal And Installation (Cont'd)
Figure 20-41-29 1 1
1 1
6
3
1
1 2 1
5 N-23644
4

N-20033 [Figure 20-41-30].
Figure 20-41-31

and tightening sequence when reinstalling the BICS™

1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb.
1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
(21,5-23,7 N•m) N-23645
*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for Remove the BICS™ valve assembly from the top of the
every bolt or repeat step 3. control valve [Figure 20-41-31].

190 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED The chart below lists the correct torque specifications
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 20-41-32
1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb. 1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
1 1
(21,5-23,7 N•m)
*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for

2 every bolt or repeat step 3.
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly

And Assembly
N-23646
Figure 20-41-34

the top of the control valve.

and the small O-ring (Item 2) [Figure 20-41-32] on the
Figure 20-41-33 1
3 6
N-20040
1 2 Remove the fitting (Item 1) [Figure 20-41-34] from the

valve.
5
4
N-23644

191 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED BICS™ Valve, Check Valve Disassembly And
CONTROL SYSTEM) (ACS) (CONT'D) Assembly
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly Figure 20-41-37

And Assembly (Cont’d)
Figure 20-41-35
1 1
N-20037
N-20041 Remove the check valve (Item 1) [Figure 20-41-37].
Installation: Tighten the valve to 20 ft.-lb. (27 N•m)

Figure 20-41-36

torque.
Figure 20-41-38
1
2
1
N-18685
N-18684
36]. Remove the O-rings (Item 1) [Figure 20-41-38] and
Orifice size is 0.078 inch. valve.
Reverse the removal procedure to install the lift arm by- Install new O-rings and back-up ring on the check valve.
pass orifice.

192 of 1030
BICS™ Valve, Check Valve Disassembly And

Assembly (Cont’d)
Figure 20-41-39
N-23647
Figure 20-41-42
P-8956

on the end of the valve. 1
BICS™ Valve, Lock Valve Disassembly And

Assembly
Figure 20-41-40
N-20040
Remove the lock valves (Item 1) [Figure 20-41-40],

[Figure 20-41-41] & [Figure 20-41-42] from the BICS™
1 valve.

torque.
N-23644

193 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED Remove the solenoid (Item 2) [Figure 20-41-44].
Assembly (Cont’d) Figure 20-41-45
Figure 20-41-43
1
1
1
2
2 N-18693A
2
N-18690
Remove the O-rings (Item 1) [Figure 20-41-45] from

back-up rings (Item 2) [Figure 20-41-43] from both the tilt Figure 20-41-46

up rings (Item 2) [Figure 20-41-43] on the tilt and lift lock 1
valves.
BICS™ Valve, Solenoid Disassembly And Assembly
Figure 20-41-44
1
N-20038
2 Installation: Tighten the solenoid stem to 20 ft.-lb. (27

N•m) torque.
N-20037
Remove the mounting nut (Item 1) [Figure 20-41-44]


N•m) torque.

194 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED BICS™ Valve, Solenoid Testing
Figure 20-41-48
(Cont’d)
Figure 20-41-47
3
2
P9175
1
N-18694 41-48]. 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.

back-up washers (Item 2) [Figure 20-41-47] on the stem. Replace the test meter with 12 volt power. You can see
and hear the spool shift.
excessive wear.

replace the solenoid stem.

solenoid stem.

195 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED
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
C1 Load Check Valve/Lift Function F1 C1
MR
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
F1 Anti-Cavitation Valve

F2 Port Relief Valve – 4000 PSI
G1 LIft Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H2 Plug/Port Relief (Optional) – 3500 PSI
MR Main Relief Valve – 3300 PSI

196 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED
Lift Base End Restrictor IMPORTANT

Figure 20-41-49 When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
1
Mark each valve section, spool and related parts so that

they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

Figure 20-41-51
N-21159
Remove the BICS™ valve assembly from the control

valve. (See BICS™ Valve, Removal And Installation on

Page 20-41-9.)
Remove the restrictor (Item 1) [Figure 20-41-49] from

the lift section base end port.
1
Load Check Valve
Figure 20-41-50
N-19100
1 1 Loosen the load check valve plugs (Item 1) [Figure 20-

41-51].
1 Installation: Always use new O-ring. Tighten the plug to

1
35-40 ft.-lb. (47-54 N•m) torque.
N-19099

Page 20-41-9.)

replace these O-rings before installing the BICS™ valve
assembly.

197 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED Main Relief Valve
Figure 20-41-54
Load Check Valve (Cont'd)
Figure 20-41-52
1
1
N-19034
3
2
N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-54].
Figure 20-41-55

Remove the spring (Item 2) [Figure 20-41-52] and
poppet (Item 3) [Figure 20-41-52].
Figure 20-41-53
N-19035
Remove the main relief valve (Item 1) [Figure 20-41-55].

2
N-19102
The auxiliary section (Item 1) [Figure 20-41-53] uses an

orifice load check poppet (Item 2) [Figure 20-41-53].

198 of 1030
Main Relief Valve (Cont’d)

1
Figure 20-41-56
2 3
4 5
B-6764
1. Relief Valve
2. O-ring N-19034
3. Sleeve
4. Glide Ring
5. O-ring Loosen the port relief valve (Item 1) [Figure 20-41-57] &
[Figure 20-41-58] (Port E1 or F2). (See Identification
CD-15092 Chart on Page 20-41-16.)

Remove the O-rings, sleeve, and glide ring from the main washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

Figure 20-41-59
Installation: Always use new O-rings, sleeve, and glide
Port Relief Valve
Figure 20-41-57
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-59].
N-19000

199 of 1030
Port Relief Valve (Cont’d)
Figure 20-41-60
4 1
3
2
1
1. O-ring
N-18980
2. Backup Washer
3. O-ring
4. Relief Valve Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-41-62] from the control valve for the tilt
N-18844 section.
Figure 20-41-63

Anti-Cavitation Valve/Port Relief Valve
1
Figure 20-41-61
N-18843

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

61].


200 of 1030
2
1 3 4
Anti-Cavitation Valve
Figure 20-41-64
1
E-1509A
2. O-ring
3. Backup Washer
4. O-ring
N-18839

N-19034
Figure 20-41-65

1
N-19036

64] & [Figure 20-41-65] from the control valve.

201 of 1030
Lift Spool Removal
Figure 20-41-67
N-19003

1 cap.
N-19112
Figure 20-41-70
Remove the actuator (Item 1) [Figure 20-41-67] from the

control valve.

Figure 20-41-68
2
N-18983
1
2
Remove the spool assembly (Item 1) [Figure 20-41-70]
and seal from the control valve.
N-19114
Remove the spacer (Item 1) [Figure 20-41-68] and O-


202 of 1030
Lift Spool Removal And Installation
Figure 20-41-71
1
1
1
N-19003

end cap.
N-19112
N•m) torque.
Remove the actuators (Item 1) [Figure 20-41-71] from
the control valve.

Figure 20-41-74
Figure 20-41-72
2 1
2
1
N-18985
N-18940
ring (Item 2) [Figure 20-41-72] from the tilt spool. Assembly: Always use a new spool seal.

203 of 1030
2 1
Lift and Tilt Spool Disassembly And Assembly
3
Figure 20-41-75
4
N-18944A
NOTE: The center spring (Item 3) [Figure 20-41-77] is

orange on all 800 Series and T200 loaders.
N-18942
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-41-77].
Put the linkage end of the spool in the vise [Figure 20-
41-75].

Figure 20-41-78
Install the spool tool (Item 1) [Figure 20-41-75] over the 2

centering spring.
1
Figure 20-41-76
N-18930 N-18943
Remove the spool seal (s) (Item 1) [Figure 20-41-78]

and the back-up washer (Item 2) [Figure 20-41-78].
N-19014
Remove the bolt (Item 1) [Figure 20-41-76] holding the


N•m) torque.

204 of 1030
Auxiliary Spool Removal And Installation
Figure 20-41-79 1
N-18988
1
N-19003 Assembly: Put grease on all the centering spring

component parts.

end cap (both sides).

N•m) torque.
Figure 20-41-80
N-18987
Remove the end cap, O-ring, springs and washer (both

sides) [Figure 20-41-80].

205 of 1030
Figure 20-41-82
3 2
1 N-18992
1 Remove the coil (Item 1) [Figure 20-41-84] and end

plate (Item 2) [Figure 20-41-84].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-41-84].
solenoids.

torque.
torque.
Figure 20-41-83
1
N-18795

solenoid valves.


206 of 1030
HYDRAULIC CONTROL VALVE (ADVANCED Cleaning And Inspection
Port-Auxiliary Section Disassembly compressed air.
Figure 20-41-86 Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
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 20-41-86] or optional

NOTE: Optional port relief (Item 1) [Figure 20-41-86]
is either 2500 PSI or 3000 PSI depending on
the option used.
Figure 20-41-87
2
1
1
N-18843

back-up ring (Item 2) from the plug.

207 of 1030

208 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE Figure 20-42-2
JOYSTICK CONTROL) (SJC)
Page 10-20-1.)
WARNING

W-2059-0598
Remove the by-pass control knob (Item 1) [Figure 20-
42-2] from the lift arm by-pass valve.
Stop the engine. Raise the seat bar. Figure 20-42-3
Figure 20-42-1

1
2
1
P-37790
N-22483
Remove the jam nut (Item 1) and the rubber washer
(Item 2) [Figure 20-42-3] from the lift arm by-pass valve.
Remove the access cover (Item 1) [Figure 20-42-1] from
the right side of the loader frame.

209 of 1030
JOYSTICK CONTROL) (SJC) (CONT'D)

(Cont’d)
Figure 20-42-4
1 2
1
1 P-39424
Disconnect the actuator wire connectors (Item 1) [Figure

20-42-6] from the actuators.
P-37791 Figure 20-42-7

Disconnect the hydraulic hose (Item 2) [Figure 20-42-4] 1

from the control valve. 1
Cap and plug the fittings and hose.
Figure 20-42-5
1 P-39425

1 20-42-7]from the top actuator.

N•m) 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.

210 of 1030

(Cont’d)
1
Figure 20-42-8
2
2
P-39428

1 the control valve.
P-39426 With a punch, remove the actuator pin (Item 2) [Figure


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 20-42-9
1
1
P-39427

20-42-9] from the bottom actuator.

N•m) torque

211 of 1030
Actuator Removal And Installation (Out Of Loader)
Figure 20-42-11
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 20-42-
N-19112 13].

the actuator retainer.

Installation: Tighten the bolt and nut to 90-100 in.-lb.
(10,2-11,3 N•m) torque.
Pull the actuator (Item 2) [Figure 20-42-11] away from

the control valve.
Figure 20-42-12
N-19113
Use a drift pin and hammer to remove the actuator pin

(Item 1) [Figure 20-42-12] from the actuator and the lift
or tilt spool.

212 of 1030
P-37098
WARNING
The fixed end main valve hose assembly (Item 1) [Figure
Never work on a machine with the lift arms up unless 20-42-14] 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
support device. Failure to use an approved lift arm 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 support Cap and plug the hose and fitting.
device.

on Page 10-30-1.)

Page 20-80-1.)

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

Removal And Installation (In Loader) on Page 20-41-1.)
Open rear door.

213 of 1030

2
Figure 20-42-15
1
2 P-37099

P-39429

Cap and plug the tubelines and fittings.
42-15] from the auxiliary spool solenoid. Figure 20-42-18

42-15] from the BICS valve solenoid.
Figure 20-42-16
P-34126
Loosen the fixed end main valve hose assembly (Item 1)

P-39430
The hose can be removed from the control valve by
42-16] from the auxiliary spool solenoid. Cap the hose and plug the fitting.

214 of 1030
Removal And Installation (Cont'd) 1
Figure 20-42-19
2
P-43931
Remove the two control valve mount bracket mounting

bolts (Item 1) [Figure 20-42-21].
P-34127
Remove the tubeline clamp mount bolt (Item 2) [Figure
20-42-21].
control valve, and support the control valve.

Figure 20-42-22

1
valve.
Figure 20-42-20
1
1
P-34129
Remove the two control valve mount bolts (Item 1)

[Figure 20-42-22] from the mounting plate, at the back
P-43930 side of the control valve.
Remove the control valve mount bracket from the loader.

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

215 of 1030
Figure 20-42-23
P-34132
Disconnect the tilt tubeline (Item 1) [Figure 20-42-25] at

the tee fitting.
P-34130
Disconnect the case drain hose (Item 1) [Figure 20-42- Remove the control valve from the loader.

from the auxiliary section of the control valve.
Cap the fittings and plug the tubelines.
Figure 20-42-24
P-34131



216 of 1030
Figure 20-42-26
1 1
1
1
2
1 1
1
N-20035
1

Installation: Install the four large O-rings (Item 1)

To remove the BICS™ valve from the control valve, [Figure 20-42-28] and the small O-ring (Item 2) [Figure

20-42-28] on the top of the control valve.
[Figure 20-42-26].
Figure 20-42-27
N-20034


217 of 1030
BICS™ Valve, Removal And Installation (Cont'd)
Figure 20-42-29 1 1
1 1
6
3
1
1 2 1
5 N-23644
4

N-20033 [Figure 20-42-30].
Figure 20-42-31

and tightening sequence when reinstalling the BICS™

1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb.
1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
(21,5-23,7 N•m) N-23645
*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for Remove the BICS™ valve assembly from the top of the
every bolt or repeat step 3. control valve [Figure 20-42-31].

218 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE The chart below lists the correct torque specifications
JOYSTICK CONTROL) (SJC) (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 20-42-32
1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb. 1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
1 1
(21,5-23,7 N•m)
*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for

2 every bolt or repeat step 3.
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly

And Assembly
N-23646
Figure 20-42-34

the top of the control valve.

and the small O-ring (Item 2) [Figure 20-42-32] on the
Figure 20-42-33 1
3 6
N-20040
1 2 Remove the fitting (Item 1) [Figure 20-42-34] from the

valve.
5
4
N-23644

219 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE BICS™ Valve, Check Valve Disassembly And
JOYSTICK CONTROL) (SJC) (CONT'D) Assembly
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly Figure 20-42-37

And Assembly (Cont’d)
Figure 20-42-35
1 1
N-20037
N-20041 Remove the check valve (Item 1) [Figure 20-42-37].
Installation: Tighten the valve to 20 ft.-lb. (27 N•m)

Figure 20-42-36

torque.
Figure 20-42-38
1
2
1
N-18685
N-18684
36]. Remove the O-rings (Item 1) [Figure 20-42-38] and
Orifice size is 0.078 inch. valve.
Reverse the removal procedure to install the lift arm by- Install new O-rings and back-up ring on the check valve.
pass orifice.

220 of 1030
BICS™ Valve, Check Valve Disassembly And

Assembly (Cont’d)
Figure 20-42-39
N-23647
Figure 20-42-42
P-8956

on the end of the valve. 1

Assembly
Figure 20-42-40
N-20040
Remove the lock valves (Item 1) [Figure 20-42-40],

[Figure 20-42-41] & [Figure 20-42-42] from the BICS™
1 valve.

torque.
N-23644

221 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE Remove the solenoid (Item 2) [Figure 20-42-44].
Assembly (Cont’d) Figure 20-42-45
Figure 20-42-43
1
1
1
2
2 N-18693A
2
N-18690
Remove the O-rings (Item 1) [Figure 20-42-45] from

back-up rings (Item 2) [Figure 20-42-43] from both the tilt Figure 20-42-46

up rings (Item 2) [Figure 20-42-43] on the tilt and lift lock 1
valves.
Figure 20-42-44
1
N-20038
2 Installation: Tighten the solenoid stem to 20 ft.-lb. (27

N•m) torque.
N-20037


N•m) torque.

222 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE BICS™ Valve, Solenoid Testing
Figure 20-42-48
(Cont’d)
Figure 20-42-47
3
2
P9175
1
N-18694 42-48]. 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.

back-up washers (Item 2) [Figure 20-42-47] on the stem. Replace the test meter with 12 volt power. You can see
excessive wear.

replace the solenoid stem.

solenoid stem.

223 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE
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
C1 Load Check Valve/Lift Function F1 C1
MR
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
F1 Anti-Cavitation Valve

F2 Port Relief Valve – 4000 PSI
G1 LIft Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H2 Plug/Port Relief (Optional) – 3500 PSI
MR Main Relief Valve – 3300 PSI

224 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE
Lift Base End Restrictor IMPORTANT

damage the system.
I-2003-0888
1
Mark each valve section, spool and related parts so that

they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

Figure 20-42-51
N-21159


Page 20-41-9.)
Remove the restrictor (Item 1) [Figure 20-42-49] from

the lift section base end port.
1
Load Check Valve
Figure 20-42-50
N-19100
1 1 Loosen the load check valve plugs (Item 1) [Figure 20-

42-51].
1 Installation: Always use new O-ring. Tighten the plug to

1
35-40 ft.-lb. (47-54 N•m) torque.
N-19099

Page 20-41-9.)

replace these O-rings before installing the BICS™ valve
assembly.

225 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE Main Relief Valve
Figure 20-42-54
Load Check Valve (Cont'd)
Figure 20-42-52
1
1
N-19034
3
2
N-19101 Loosen the main relief valve (Item 1) [Figure 20-42-54].
Figure 20-42-55

poppet (Item 3) [Figure 20-42-52].
Figure 20-42-53
N-19035
Remove the main relief valve (Item 1) [Figure 20-42-55].

2
N-19102
The auxiliary section (Item 1) [Figure 20-42-53] uses an

orifice load check poppet (Item 2) [Figure 20-42-53].

226 of 1030
Main Relief Valve (Cont’d)

1
Figure 20-42-56
2 3
4 5
B-6764
1. Relief Valve
2. O-ring N-19034
3. Sleeve
4. Glide Ring
5. O-ring Loosen the port relief valve (Item 1) [Figure 20-42-57] &
[Figure 20-42-58] (Port E1 or F2). (See Identification
CD-15092 Chart on Page 20-41-16.)

Remove the O-rings, sleeve, and glide ring from the main washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

Figure 20-42-59
Installation: Always use new O-rings, sleeve, and glide
Port Relief Valve
Figure 20-42-57
N-18981
Remove the port relief valve (Item 1) [Figure 20-42-59].
N-19000

227 of 1030
Port Relief Valve (Cont’d)
Figure 20-42-60
4 1
3
2
1
1. O-ring
N-18980
2. Backup Washer
3. O-ring
4. Relief Valve Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-42-62] from the control valve for the tilt
N-18844 section.
Figure 20-42-63

Anti-Cavitation Valve/Port Relief Valve
1
Figure 20-42-61
N-18843

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

61].


228 of 1030
2
1 3 4
Anti-Cavitation Valve
Figure 20-42-64
1
E-1509A
2. O-ring
3. Backup Washer
4. O-ring
N-18839

N-19034
Figure 20-42-65

1
N-19036

64] & [Figure 20-42-65] from the control valve.

229 of 1030
Lift Spool Removal
Figure 20-42-67
N-19003

1 cap.
N-19112
Figure 20-42-70
Remove the actuator (Item 1) [Figure 20-42-67] from the

control valve.

Figure 20-42-68
2
N-18983
1
2
N-19114


230 of 1030
Lift Spool Removal And Installation
Figure 20-42-71
1
1
1
N-19003

end cap.
N-19112
N•m) torque.
Remove the actuators (Item 1) [Figure 20-42-71] from
the control valve.

Figure 20-42-74
Figure 20-42-72
2 1
2
1
N-18985
N-18940
ring (Item 2) [Figure 20-42-72] from the tilt spool. Assembly: Always use a new spool seal.

231 of 1030
2 1
Lift and Tilt Spool Disassembly And Assembly
3
Figure 20-42-75
4
N-18944A
NOTE: The center spring (Item 3) [Figure 20-42-77] is

orange on all 800 Series and T200 loaders.
N-18942
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-42-77].
Put the linkage end of the spool in the vise [Figure 20-
42-75].

Figure 20-42-78
Install the spool tool (Item 1) [Figure 20-42-75] over the 2

centering spring.
1
Figure 20-42-76
N-18930 N-18943
Remove the spool seal (s) (Item 1) [Figure 20-42-78]

and the back-up washer (Item 2) [Figure 20-42-78].
N-19014


N•m) torque.

232 of 1030
Auxiliary Spool Removal And Installation
Figure 20-42-79 1
N-18988
1
N-19003 Assembly: Put grease on all the centering spring

component parts.

end cap (both sides).

N•m) torque.
Figure 20-42-80
N-18987
Remove the end cap, O-ring, springs and washer (both

sides) [Figure 20-42-80].

233 of 1030
Figure 20-42-82
3 2
1 N-18992
1 Remove the coil (Item 1) [Figure 20-42-84] and end

plate (Item 2) [Figure 20-42-84].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-42-84].
solenoids.

torque.
torque.
Figure 20-42-83
1
N-18795

solenoid valves.


234 of 1030
HYDRAULIC CONTROL VALVE (SELECTABLE Check that the spools are not loose in their bore.
Port-Auxiliary Section Disassembly
Check that the load check valve seats are not worn.
Figure 20-42-86
Check the rubber boots and retainers
Apply oil to all new O-rings and back-up rings before

installation.
1
N-18996
Remove the plug (Item 1) [Figure 20-42-86] or optional


NOTE: Optional port relief (Item 1) [Figure 20-42-86]
is either 2500 PSI or 3000 PSI depending on
the option used.
Figure 20-42-87
2
1
1
N-18843
Remove the O-rings (Item 1) [Figure 20-42-87] &

[Figure 20-42-87] and back-up ring (Item 2) [Figure 20-
42-87] & [Figure 20-42-87] from the plug.
Cleaning And Inspection

compressed air.
Check the spools for wear or scratches.

235 of 1030

236 of 1030
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
WARNING
Figure 20-50-1
W-2059-0598
1
device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)

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.

237 of 1030
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.-lb. (45-50
Remove the two mounting bolts (Item 2) [Figure 20-50- N•m) torque.
3].
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
Installation: Tighten the mounting bolts to 180-200 in.-lb. 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.

238 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596) Figure 20-60-1
(VENDOR P/N 163D1185, 163D1301)
Check The Output Of The Hydraulic Pump W/O

Power Bob-Tach

procedure:
1
MEL1563 - Remote Start Tool
MEL10106 - Hydraulic Test Kit 2
WARNING P-34061

Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
from the pump.
W-2017-0286
Figure 20-60-2

Page 10-20-1.) 1
2
WARNING
the lift arms are secured by an approved lift arm P-34062

support device can allow the lift arms or attachment Connect the INLET hose (Item 1) [Figure 20-60-2] from
to fall and cause injury or death. the tester to the OUTLET fitting (Item 2) [Figure 20-60-1]
W-2059-0598
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-2] from the tester to the hose (Item 1) [Figure 20-
Raise the operator cab. (See Raising The Operator Cab 60-1] which was disconnected from the pump.
on Page 10-30-1.)
Open the rear door of the loader.
Connect the remote start tool. (See REMOTE START on IMPORTANT

Page 10-60-1.)
I-2024-0284

239 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596) *See LOADER SPECIFICATIONS (S250) on Page
(VENDOR P/N 163D1185, 163D1301) (CONT'D) SPEC-10-1 and LOADER SPECIFICATIONS (S300) on
Page SPEC-10-5 for system relief pressure and full
Check The Output Of The Hydraulic Pump W/O RPM.
Power Bob-Tach (Cont'd)
Check The Output Of The Hydraulic Pump W/Power
Figure 20-60-3 Bob-Tach.
EXAMPLE: TESTER
CONNECTION The tools listed will be needed to do the following
procedure:
Reservoir
Hydraulic Pump
WARNING
Out In Put jackstands under the front axles and rear corners
Hydraulic Control
Valve of the frame before running the engine for service.

W-2017-0286
1

BH-196 THE LOADER on Page 10-10-1.)
Sample tester connection shown[Figure 20-60-3]].
Page 10-20-1.)
Start the engine and run at low idle RPM. 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*. WARNING
Warm the fluid to 140°F. (60°C.) by turning the restrictor Never work on a machine with the lift arms up unless
control (Item 1) [Figure 20-60-3] on the tester to about the lift arms are secured by an approved lift arm
1000 PSI (6895 kPa). DO NOT exceed system relief support device. Failure to use an approved lift arm
pressure. Open the restrictor control and record the free support device can allow the lift arms or attachment
flow (GPM) at full RPM. to fall and cause injury or death.
W-2059-0598
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics, the Raise the operator cab. (See Raising The Operator Cab
light will come ON. Push the button (on the right control on Page 10-30-1.)
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI) Open the rear door of the loader.
and flow (GPM). The high pressure flow must be at least
80% of free flow. Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
HIGH PRESSURE FLOW (GPM)
%= X 100
FREE FLOW (GPM)
A low percentage may indicate a failed pump.

240 of 1030
(VENDOR P/N 163D1185, 163D1301) (CONT'D)
EXAMPLE: TESTER
Check The Output Of The Hydraulic Pump W/Power CONNECTION
Bob-Tach (Cont’d)
Reservoir
Figure 20-60-4
Hydraulic Pump
1 Out In Hydraulic Control
Valve
1
2
P-26916
BH-196

Sample tester connection shown [Figure 20-60-6].
from the top of the Power Bob-Tach block.
Figure 20-60-5 tester is connected correctly. If no flow is indicated on the
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor

control (Item 1) [Figure 20-60-6] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
2 1 pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
P-34062 go over main relief). Record the highest pressure (PSI)
80% of free flow.
Connect the INLET hose (Item 1) [Figure 20-60-5] from
the tester to the OUTLET fitting (Item 2) [Figure 20-60-4]
on the top of the Power Bob-Tach block. Connect the %= X 100
FREE FLOW (GPM)
OUTLET hose (Item 2) [Figure 20-60-5] from the tester
to the hose (Item 1) [Figure 20-60-4] which was
disconnected from the Power Bob-Tach block.
*See LOADER SPECIFICATIONS (S250) on Page

IMPORTANT SPEC-10-1 and See LOADER SPECIFICATIONS (S300)
on Page SPEC-10-5 for system relief pressure and full
The hydraulic tester must be in the fully open RPM.
I-2024-0284

241 of 1030
P-26243
WARNING
Disconnect and cap the hose from the outlet fitting (Item
Never work on a machine with the lift arms up unless 1) [Figure 20-60-7] of the hydraulic pump.
support device. Failure to use an approved lift arm Figure 20-60-8

W-2059-0598
1
1
Page 10-20-1.)
1
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)

on Page 10-30-1.) P-34121
Drain the hydraulic fluid from the reservoir. (See Fluid Disconnect the three inlet hoses (Item 1) [Figure 20-60-
Removal on Page 20-80-1.) 8] from the front of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See

POWER BOB-TACH BLOCK (EARLY MODELS) on
Page 20-110-1 or See POWER BOB-TACH BLOCK
(LATER MODELS) on Page 20-111-1.)

242 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596) Installation: Use a new O-ring when installing the
(VENDOR P/N 163D1185, 163D1301) (CONT'D) hydraulic pump.
Removal And Installation (Cont’’d) See HYDRAULIC CONTROL VALVE (ADVANCED

CONTROL SYSTEM) (ACS) on Page -1 for the proper
Figure 20-60-9 Hydraulic Pump Disassembly And Assembly procedure.
P-26316
Remove the two mounting bolts (Item 1) [Figure 20-60-

9] from the hydraulic pump.

Installation: Tighten the mounting bolts to 27-37 ft.-lb.
Figure 20-60-10
P-26348 P-26318
Remove the hydraulic pump from the hydrostatic pump

[Figure 20-60-10].
Remove the coupler (Item 1) [Figure 20-60-10] from the

hydraulic pump shaft.
Remove the O-ring (Item 2) [Figure 20-60-10].
Reverse the removal procedure to install the hydraulic

pump.

243 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596)
Identification
15

7
6
14
13
12
11
9 10
7
1 4 5
3
1. Retaining Ring
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. Wear Plate
12. Section Seal
13. Pump End Section
14. Bolt (4)
15. Bolt (4)
B-16050A

244 of 1030
Disassembly And Assembly 1
IMPORTANT
clean the work area before disasembly and keep all
damage the system.
I-2003-0888
P-26353
Figure 20-60-11
Remove the pump end section (Item 1) [Figure 20-60-
12].
2 1 Figure 20-60-13
P-26352

1
1 2
P-26351
2
Mark the pump sections for correct assembly [Figure 20-

60-11]. P-26354
Remove the four smaller pump housing bolts (Item 1)

[Figure 20-60-11].
Remove the four larger pump housing bolts (Item 2)

[Figure 20-60-11].
Installation: Tighten the four smaller bolts (Item 1)

[Figure 20-60-11] to 30 ft.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-60-11] to 54 ft.-
lb. (73,2 N•m) torque.

245 of 1030
Disassembly And Assembly (Cont'd) 1
Figure 20-60-14
3
1 P-26359
NOTE: Inspect the pump center section (Item 1)

2
[Figure 20-60-16]. If excessive wear or
P-26355 damage is visible, the pump must be
replaced.
Remove the wear plate (Item 1) [Figure 20-60-13] & Figure 20-60-17
[Figure 20-60-14] and section seal (Item 2) [Figure 20-

60-13] & [Figure 20-60-14] from the pump end section.
NOTE: Position wear plate (Item 1) [Figure 20-60-14]

inlets and traps as shown with bronze side
toward gears.
1
NOTE: Inspect the pump end section (Item 3) [Figure
20-60-14] and bushings (Item 4) [Figure 20-60-
14]. If excessive wear or damage is visible, the
pump must be replaced.
Figure 20-60-15
P-26389
1
Remove the idler gear (Item 1) [Figure 20-60-17] &
[Figure 20-60-18].
P-26358
Remove the pump center section (Item 1) [Figure 20-60-

15] & [Figure 20-60-16] from the pump end section.

246 of 1030
Disassembly And Assembly (Cont'd)

1
Figure 20-60-18
P-26364
1
P-26362
To remove the drive gear (Item 1) [Figure 20-60-19] from

the pump end section, locate and remove the retaining
P-26390 ring (Item 1) [Figure 20-60-20] from the spline end of the
drive gear.
NOTE: Inspect the idler gear (Item 1) [Figure 20-60- Figure 20-60-21

Figure 20-60-19
P-26392
1
Remove the drive gear (Item 1) [Figure 20-60-21] from
P-26391 the pump end section.
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-


247 of 1030
Figure 20-60-22
P-26396
P-26395
2 Remove the load seal (Item 1) [Figure 20-60-24].
P-26393 Figure 20-60-25
Remove the wear plate (Item 1) [Figure 20-60-22] &

1

60-22] & [Figure 20-60-23] from the pump end section.
Figure 20-60-23
P-26398
1
1
P-26397
2
Remove the pre-load seal (Item 1) [Figure 20-60-25].
P-26394

toward gears.

248 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596)
Figure 20-60-26
P-26374
NOTE: Inspect the pump end section (Item 1) [Figure

20-60-26] and bushings (Item 2) [Figure 20-60-

26] . If excessive wear or damage is visible,
the pump must be replaced.

249 of 1030

250 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N flow should start decreasing rapidly until the pressure
6680295, 6681600) (VENDOR P/N 163D1275, reaches 3250-3300 PSI. At 3250-3300 PSI the flow
163D1304) should be at 0 GPM. Turn the restrictor (Item 2) [Figure
20-61-1] counter clockwise to free flow. Shut the front
Hydraulic Pump Test
auxiliary hydraulics off.
If flow and pressure specs are not obtained, go to the
procedure:
Inline Standard Hydraulic Pump Test. (See Inline
Hydraulic Pump Test (Standard) on Page 20-61-2.) If flow
and pressure specs are obtained continue on to the next
paragraph.
Figure 20-61-1
With the engine running at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
1 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 (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.

Turn the restrictor control (Item 2) [Figure 20-61-1] on
the tester counter clockwise, to obtain free flow, the flow
2 should be at 20 GPM. Press the High Flow button. The
flow should increase to 30 GPM. Start turning the
restrictor clockwise, causing more restriction on the flow.
P-16903 P-31821 The GPM should drop off slightly until the pressure
reaches approximately 2700 PSI. At approximately 2700
PSI the flow should start decreasing rapidly until the
Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
pressure reaches 3250-3300 PSI. At 3250-3300 PSI the
the front auxiliary quick couplers.
flow should be at 0 GPM. Turn the restrictor control (Item
2) [Figure 20-61-1] counter clockwise to free flow. Shut
This procedure will require a operator in the cab and one
the front auxiliary hydraulics off.
operator running the tester.
If the specs from above are reached, the high flow
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
Inline High Flow Hydraulic Pump Test (See Inline
Hydraulic Pump Test (High Flow) on Page 20-61-4.)
RPM*.
SPEC-10-1 or See LOADER SPECIFICATIONS (S300)
on Page SPEC-10-5 for system relief pressure and full
control clockwise on the tester so it reads about a 1000
RPM.
PSI (6895 kPa).

the tester counterclockwise to obtain free flow, the flow
should be at 20 GPM. Start turning the restrictor
clockwise, causing more restriction on the flow. The GPM
should drop off slightly until the pressure reaches
approximately 2800 PSI. At approximately 2800 PSI the

251 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Figure 20-61-2
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304)
Inline Hydraulic Pump Test (Standard)
The tools listed will be needed to do the following 1

procedure:
MEL10103 - Hydraulic Tester 2

WARNING
P-34845
Failure to use jackstands can allow the machine to Disconnect the standard pump OUTLET hose (Item 1)
fall or move and cause injury or death. [Figure 20-61-2] from the tubeline.
W-2017-0286
Figure 20-61-3

Page 10-20-1.) 2
1
WARNING
W-2059-0598
the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
Raise the operator cab. (See Raising The Operator Cab 20-61-3] from the tester to the tubeline (Item 2) [Figure
on Page 10-30-1.) 20-61-2] which goes to the control valve.
Lower the cab down.

252 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Record the flow (GPM) at 2700 PSI, this is the high
6680295, 6681600) (VENDOR P/N 163D1275, pressure flow. The high pressure flow must be at least
163D1304) (CONT'D) 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.
The hydraulic tester must be in the fully open *See LOADER SPECIFICATIONS (S250) on Page
position before you start the engine. SPEC-10-1 or LOADER SPECIFICATIONS (S300) on
I-2024-0284 Page SPEC-10-5 for system relief pressure and full
RPM.
Figure 20-61-4
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Out In Hydraulic Control
Valve
BH-196
Sample tester connection shown [Figure 20-61-4]].

RPM*.

control (Item 1) [Figure 20-61-4] on the tester clockwise
to about 1000 PSI (6895 kPa).
Open the restrictor control and record the free flow

(GPM) at full RPM.

253 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Raise the operator cab. (See Raising The Operator Cab
6680295, 6681600) (VENDOR P/N 163D1275, on Page 10-30-1.)
163D1304) (CONT'D)
Figure 20-61-6
Inline Hydraulic Pump Test (High Flow)

procedure:

1
WARNING
Put jackstands under the front axles and rear corners 2
P-34844
W-2017-0286
Disconnect the high flow pump OUTLET hose (Item 1)

Lift and block the loader. (See LIFTING AND BLOCKING [Figure 20-61-6] from the fitting (Item 2) [Figure 20-61-
THE LOADER on Page 10-10-1.) 6] at the control valve.

2
1
P-34847
P-34851
Install a jumper hose (Item 1) [Figure 20-61-5] onto the

front auxiliary quick couplers. Connect the INLET hose (Item 1) [Figure 20-61-7] from
Raise the lift arms and install an approved lift arm support of the pump. Connect the OUTLET hose (Item 2) [Figure
device. (See Installing The Lift Arm Support Device on 20-61-7] from the tester to the tubeline (Item 2) [Figure
Page 10-20-1.)
20-61-6] at the control valve.
Lower the cab down.

WARNING
W-2059-0598

254 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Turn the restrictor control clockwise on the tester to 3300
6680295, 6681600) (VENDOR P/N 163D1275, PSI and the flow should go to zero GPM. If the pressure
163D1304) (CONT'D) readings are not obtained go to the High Flow Relief
Pump Adjustment ((See High Flow Relief Adjustment
Inline Hydraulic Pump Test (High Flow) (Cont’d)
Procedure on Page 20-61-6.)). If the pressure readings
are correct, continue on to the next paragraph.

IMPORTANT (GPM) at full RPM.
The hydraulic tester must be in the fully open Record the flow (GPM) at 2500 PSI, this is the high
position before you start the engine. pressure flow. The high pressure flow must be at least
I-2024-0284 80% of free flow.

Figure 20-61-8 %= X 100
FREE FLOW (GPM)
EXAMPLE: TESTER
CONNECTION
Reservoir
SPEC-10-1 or LOADER SPECIFICATIONS (S300) on
RPM.

Hydraulic Pump
Valve
BH-196

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 20-61-8] clockwise on the tester

255 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304)
WARNING
High Flow Relief Adjustment Procedure
The tools listed will be needed to do the following the lift arms are secured by an approved lift arm
procedure: support device. Failure to use an approved lift arm
MEL10103 - Hydraulic Tester to fall and cause injury or death.
MEL10106 - Hydraulic Test Kit W-2059-0598
Figure 20-61-10
WARNING
fall or move and cause injury or death. 1
W-2017-0286


2
Remove the right rear tire.
P-34844
Figure 20-61-9

1 [Figure 20-61-10] from the fitting (Item 2) [Figure 20-61-
10] at the control valve.
Figure 20-61-11
2
1
P-34847

front auxiliary quick couplers.
P-34851
Page 10-20-1.)
the tester to the OUTLET hose (Item 1) [Figure 20-61-
10] of the pump. Connect the OUTLET hose (Item 2)
[Figure 20-61-11] from the tester to the tubeline (Item 2)
[Figure 20-61-10] at the control valve.
Lower the cab down.

256 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT’D)
High Flow Relief Adjustment Procedure (Cont’d)
Figure 20-61-12
1
1
1
1
1
P-34919
1
P-37082 sure the tester is connected correctly. If no flow is
Remove the six access cover mounting bolts (Item 1) and

speed to full RPM*.
the cover (Item 2) [Figure 20-61-12] from the frame.
Figure 20-61-13
control clockwise on the tester to about 1000 PSI (6895
kPa).
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
1 2600 PSI. At approximately 2600 PSI the flow should
start decreasing rapidly until the pressure reaches 3250-
3300 PSI. At 3250-3300 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.

P-34846
If the pump is unable to reach 3300 PSI the relief plug

Remove the cap (Item 1) [Figure 20-61-13] from the (Item 1) [Figure 20-61-14] will need to be turned
pump. clockwise a 1/4 turn and retested with the procedure
above. (1/4 turn equals 400 PSI.)
operator running the tester. NOTE: If the relief plug has been turned in 1/4 turn and
the pressure remains the same, go to the
relief valve removal and installation section.
(See MAIN RELIEF VALVE (ACS) on Page 20-
31-1.) If relief valve has been checked and is
OK, go to the high flow pump disassembly
and assembly section. (See Disassembly And
Assembly on Page 20-65-13)
If the pump reaches 3300 PSI and there is flow, the relief
plug must be turned counter clockwise 1/4 turn and
retested with the procedure above.

257 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304)
High Flow Relief Valve Removal and Installation 1

1
WARNING 1
1

W-2017-0286
P-37082

THE LOADER on Page 10-10-1.) Remove the six access cover mount bolts (Item 1) and
the access cover (Item 2) [Figure 20-61-16] from the
Remove the right rear tire. frame.
Figure 20-61-15 Figure 20-61-17

1
P-34847
P-34846
Install a jumper hose (Item 1) [Figure 20-61-15] onto the Remove the cap (Item 1) [Figure 20-61-17] from the
front auxiliary quick couplers. pump.
Page 10-20-1.)
WARNING
W-2059-0598

258 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Adjustment section to finish setting the relief. (Page 20-
6680295, 6681600) (VENDOR P/N 163D1275, 61-6.)
163D1304) (CONT’D)
High Flow Relief Valve Removal and Installation

(Cont’d)
Figure 20-61-18
P-34919

Remove the Relief Plug (Item 1) [Figure 20-61-18] from
the pump.
Figure 20-61-19
P-34696
Inspect the relief valve (Item 1), spring (Item 2), and plug
(Item 3) [Figure 20-61-19] for damage and replace as
needed.
Inspect the relief valve seat in the pump for damage or

wear.
Install the relief valve (Item 1) and spring (Item 2) [Figure

20-61-19] into the pump.
Install the plug (Item 3) [Figure 20-61-19] and turn it in

until it makes contact with the spring. Then turn the plug
one full turn clockwise. Go to the High Flow Relief

259 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)

3
1
P-34855
WARNING Disconnect and cap the hoses from the outlet fitting (Item
1) of the hydraulic pump. Disconnect and cap the hoses
Never work on a machine with the lift arms up unless from the High Flow outlet fitting (Item 2) and the low
the lift arms are secured by an approved lift arm pressure return hose (Item 3) [Figure 20-61-20].
support device can allow the lift arms or attachment Figure 20-61-21

W-2059-0598
Page 10-20-1.)

on Page 10-30-1.)
P-34852
Drain the hydraulic fluid from the reservoir. (See Fluid
Removal on Page 20-80-1.)
Disconnect and cap the hoses from the inlet fitting (Item
Open the rear door of the loader. 1) [Figure 20-61-21] of the hydraulic pump.
Remove the hoses from the Power Bob-Tach block. (If so

equipped.) (See POWER BOB-TACH BLOCK (EARLY
MODELS) on Page 20-110-1 or POWER BOB-TACH
BLOCK (LATER MODELS) on Page 20-111-1.)

260 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Installation: Use a new O-ring when installing the
6680295, 6681600) (VENDOR P/N 163D1275, hydraulic pump.
163D1304) (CONT'D)
Figure 20-61-22
P-34854

61-22] from the high flow solenoid.
Figure 20-61-23
1
P-34849


Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.
Reverse the removal procedure to install the hydraulic

pump.

261 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
Identification
1. Retaining Ring
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 26
10. Pump Section
11. Wear Plate
12. Section Seal 23
13. Spline Shaft 19 22
15. Pre-Load Seal
16. Load Seal
27

24 25
23
18 20 21
17
15 16
8
7
14
13
17. Section Seal 12

18. Wear Plate 11
1
19. Drive Gear 9 10
20. Idler Gear 6 7
4 5
21. Pump Section 3
22. Wear Plate
23. Pins 2
24. Section Seal
26. Bolts (4)
27. Bolts (4)
28 29 30 31 32 33
28. Cap
29. Gasket 34 35
30. Set Screw
31. Spring 36
32. Relief Valve
33. O-Ring
34. Back-up Washer 37
35. O-Ring B-18619
36. Valve 38
37.Coil B-16051A
38. Nut

262 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
Disassembly And Assembly

1
Mark the pump sections for correct assembly.
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly P-34693
damage the system.

I-2003-0888
Remove the valve cartridge (Item 1) [Figure 20-61-25].
Figure 20-61-24 Installation: Tighten the solenoid valve to 35-40 ft.-lbs

(47-54 N•m).
1
Figure 20-61-26

2
P-34692
1
Remove the solenoid nut (Item 1) [Figure 20-61-24].
P-34694
Remove the solenoid (Item 2) [Figure 20-61-24].

Inspect the o-ring (Item 1) [Figure 20-61-26] and replace
Installation: Tighten the solenoid nut to 48-72 in lbs (5-8 as needed.
N•m)
Inspect the o-ring and back-up ring (Item 2) [Figure 20-
61-26] and replace as needed.

263 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
1
2
Figure 20-61-27
3
1
P-34696
Inspect the check valve (Item 1), spring (Item 2) [Figure

20-61-29], and plug (Item 3) [Figure 20-61-29] for
damage and replace as needed.
P-34708
Figure 20-61-30
Remove the cap (Item 1) [Figure 20-61-27].

Installation: Tighten the cap to 13-16 ft.-lbs (18-22 N•m)
after the relief valve has been set.
Figure 20-61-28 1
1
2
P-34699
Remove the eight bolts (Item 1) [Figure 20-61-30].

1
Installation: Tighten the assembly bolts to 45-50 ft.-lbs
(60-67 N•m).
P-34695
Remove the washer (Item 1) [Figure 20-61-28].
Remove the set screw, spring and relief valve (Item 2)

[Figure 20-61-28].
Installation: (See High Flow Relief Adjustment Procedure

on Page 20-61-6.)

264 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)

1
Figure 20-61-31
1
P-26627

33] & [Figure 20-61-34] from the pump center section.
P-34697 Figure 20-61-34
Remove the wear plate (Item 1) and section seal (Item 2)

[Figure 20-61-31] from the pump end section.
Figure 20-61-32
3
1
1 P-26628
NOTE: Inspect the pump center section (Item 1)

2 [Figure 20-61-34]. If excessive wear or
damage is visible, the pump must be
P-34698 replaced.

toward gears.
NOTE: Inspect the pump end section (Item 3) and

bushings (Item 4) [Figure 20-61-32]. If
excessive wear or damage is visible, the

265 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
Figure 20-61-35
P-26631
Figure 20-61-38
P-26629

[Figure 20-61-36].
1
Figure 20-61-36
P-26632
1
Remove the drive gear (Item 1) [Figure 20-61-37] &
[Figure 20-61-38].

P-26630
NOTE: Inspect the idler gear (Item 1) [Figure 20-61-


266 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D) 1
Figure 20-61-39
P-26636
1
1
P-26635
2
Remove the load seal (Item 1) [Figure 20-61-41].
Figure 20-61-42
P-26633
1
Figure 20-61-40

P-26638
1 1
2
P-26637

P-26634

61-39] & [Figure 20-61-40] from the pump center
section.

toward gears.

267 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
3
Figure 20-61-43
4
1 1
2
P-26657

toward gears.
P-26654
NOTE: Inspect the pump center section (Item 3) and


43] from the pump sections.
Figure 20-61-44
Figure 20-61-46
P-26655
P-26659

Remove the pump section (Item 1) [Figure 20-61-46]
from the pump end section.
61-44] & [Figure 20-61-45] from the pump section.

268 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
Figure 20-61-47
1 1
P-26662

P-26660
Figure 20-61-50
NOTE: Inspect the pump section (Item 1) [Figure 20-

61-47]. If excessive wear or damage is visible,
Figure 20-61-48 1
P-26665
1
P-26664
Remove the retaining ring (Item 1) [Figure 20-61-50]

from the spline end of the drive gear.
P-26661

[Figure 20-61-49].

269 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
Figure 20-61-51
1
P-26674
Remove the spline shaft (Item 1) [Figure 20-61-53] from

the end of the drive gear.
P-26663 NOTE: Inspect the spline shaft (Item 1) [Figure 20-61-


the pump end section.
Figure 20-61-54
Figure 20-61-52
1 1
P-26667
P-26666

[Figure 20-61-54]


270 of 1030
6680295, 6681600) (VENDOR P/N 163D1275,
163D1304) (CONT'D)
1
Figure 20-61-55
P-26672
P-26670
2
P-26671
Figure 20-61-58
P-26668
Inspect the wear plate (Item 1) and the section seal (Item 1

2) [Figure 20-61-55].

toward gears.
2
Figure 20-61-56
P-26673
P-26670
1 excessive wear or damage is visible, the
P-26669

271 of 1030

272 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6683236) (VENDOR Figure 20-62-1
P/N 163D1298)
Check The Output Of The Hydraulic Pump

2
procedure:
1
WARNING
P-43930

that comes from the gear pump, and connects to the
W-2017-0286
tubeline on the control valve.
Figure 20-62-2

Page 10-20-1.)
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.) 20-62-2] from the tester to the tubeline (Item 2) [Figure
20-62-1] on the control valve.
Connect the remote start tool. (See REMOTE START on

Page 10-60-1.)
IMPORTANT
I-2024-0284

273 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6683236) (VENDOR Page SPEC-10-5 for system relief pressure and full
P/N 163D1298) (CONT'D) RPM.
Check The Output Of The Hydraulic Pump (Cont'd) Removal And Installation
Figure 20-62-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump WARNING

Out In Hydraulic Control Never work on a machine with the lift arms up unless
Valve the lift arms are secured by an approved lift arm
1 to fall and cause injury or death.

W-2059-0598
BH-196
Sample tester connection shown[Figure 20-62-3]. Page 10-20-1.)
Start the engine and run at low idle RPM. Make sure the Stop the engine. Raise the seat bar.
tester, the hoses are connected wrong. With the hoses Lift and block the rear of the loader. (See LIFTING AND
connected correctly, increase the engine speed to full BLOCKING THE LOADER on Page 10-10-1.)
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor on Page 10-30-1.)
control (Item 1) [Figure 20-62-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief Drain the hydraulic fluid from the reservoir. (See Fluid
pressure. Open the restrictor control and record the free Removal on Page 20-80-1.)
flow (GPM) at full RPM.
start tool) to engage the front auxiliary hydraulics, the Remove the Power Bob-Tach block if equipped. (See
light will come ON. Push the button (on the right control POWER BOB-TACH BLOCK (EARLY MODELS) on
lever) for fluid flow to the quick coupler (fluid pressure will Page 20-110-1 or POWER BOB-TACH BLOCK (LATER
go over main relief). Record the highest pressure (PSI) MODELS) on Page 20-111-1.)
80% of free flow.

%= X 100
FREE FLOW (GPM)


274 of 1030
P/N 163D1298) (CONT'D)
Removal And Installation (Cont’’d)
Figure 20-62-4
P-43936
2

P-43934
1) [Figure 20-62-4] of the hydraulic pump.

Figure 20-62-7
2) [Figure 20-62-4] of the hydraulic charge pump.
Figure 20-62-5
1
1
P-26348 P-43938

[Figure 20-62-7].
P-43933
Remove the O-ring (Item 2) [Figure 20-62-7].
Disconnect the two inlet hoses (Item 1) [Figure 20-62-5] Installation: Use a new O-ring when installing the
from the front of the hydraulic pump. hydraulic pump.

275 of 1030
HYDRAULIC PUMP (BOBCAT P/N 6683236) (VENDOR
P/N 163D1298) (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

276 of 1030
P/N 163D1298) (CONT'D)
1
IMPORTANT
damage the system.
I-2003-0888
P-39138
Figure 20-62-8
Set the pump on end, and remove the pump end section
(Item 1) [Figure 20-62-9] from the charge pump.
Figure 20-62-10
1 1

1
1
P-39126 1 2

62-8]. P-39139
Remove the eight pump housing bolts (Item 2) [Figure

20-62-8]. Remove the wear plate (Item 1) and the section seal
(Item 2) [Figure 20-62-10].
Installation: Tighten the eight bolts (Item 1) [Figure 20-
62-8] to 45-50 ft.-lbs (60-67 N•m) torque.

277 of 1030
P/N 163D1298) (CONT'D)
Figure 20-62-11
4 1
2
P-39142
NOTE: Inspect the charge pump center section (Item

1 1) [Figure 20-62-13]. If excessive wear or
replaced.
Inspect the wear plate (Item 1) and the section seal (Item Figure 20-62-14
2) [Figure 20-62-11] and replace as needed.

NOTE: Position the wear plate (Item 1) [Figure 20-62-
11] inlets and traps as shown with the bronze
side toward the gears. 1

Figure 20-62-12
P-39143
Remove the idler gear (Item 1) [Figure 20-62-14] from

the charge pump.
P-39141
Remove the charge pump center section (Item 1) [Figure

20-62-12] from the auxillary pump.

278 of 1030
P/N 163D1298) (CONT'D)
Figure 20-62-15
P-39146

P-39144 pump must be replaced.
Figure 20-62-18

Figure 20-62-16 3
1
2
P-39147

[Figure 20-62-18] from the front section of the charge
P-39145 pump.
Remove the locating pins (Item 3) [Figure 20-62-18]

Remove the drive gear (Item 1) [Figure 20-62-16] from from the front section of the charge pump.
the charge pump.

279 of 1030
P/N 163D1298) (CONT'D)
Figure 20-62-19
P-39150
1
Remove the Pre-load seal (Item 1) [Figure 20-62-21]
from the front section of the charge pump.
P-39148
Figure 20-62-22
Inspect the wear plate (Item 1) and the section seal (Item

side toward the gears.
Figure 20-62-20
1
2
P-39151
1
Inspect the load seal (Item 1) and the Pre-load seal (Item
P-39149
[Figure 20-62-20]Remove the load seal (Item 1) from

the front section of the charge pump.

280 of 1030
P/N 163D1298) (CONT'D)
Figure 20-62-23
2
1
P-39216

P-39152 62-25] & [Figure 20-62-26] from the pump section.
Figure 20-62-26
Inspect the pump center section and bushings (Item 1)
[Figure 20-62-23]. If excessive wear or damage is

visible, the pump must be replaced. 3
Figure 20-62-24
2
P-39217

P-39215 toward gears.

Remove the pump center section (Item 1) [Figure 20-62- bushings (Item 4) [Figure 20-62-26]. If
24] from the pump sections. excessive wear or damage is visible, the

281 of 1030
P/N 163D1298) (CONT'D)

1
Figure 20-62-27
P-39220

[Figure 20-62-30].
P-39218
Figure 20-62-30


Figure 20-62-28
1
1
P-39221



282 of 1030
P/N 163D1298) (CONT'D)
Figure 20-62-31
P-39224
Remove the spline shaft (Item 1) [Figure 20-62-33] from

P-39222
NOTE: Inspect the spline shaft (Item 1) [Figure 20-62-
Remove the drive gear (Item 1) [Figure 20-62-31] from pump must be replaced.

Figure 20-62-34
Figure 20-62-32
3
P-39225
P-39223

NOTE: Inspect the drive gear (Item 1) [Figure 20-62- [Figure 20-62-34].
pump must be replaced. Remove the locating pins (Item 3) [Figure 20-62-34].

283 of 1030
P/N 163D1298) (CONT'D)
Figure 20-62-35
P-26672
P-26670
1
2
P-39227
P-39226 Figure 20-62-38
2) [Figure 20-62-35]. 1

toward gears.
Figure 20-62-36 2
P-39229
P-26670
1 bushings (Item 2) [Figure 20-62-38]. If
P-39228

284 of 1030
HYDRAULIC PUMP (CHARGE) Figure 20-63-1

procedure:
1
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 20-63-1]

from the right side access panel. Remove the panel.
of the frame before running the engine for service. Figure 20-63-2

W-2017-0286 2

THE LOADER on Page 10-10-1.) 3 4
Raise the lift arms and install an approved lift arm support 1
Page 10-20-1.)
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 20-63-2].
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.)

Page 10-60-1.)

285 of 1030
HYDRAULIC PUMP (CHARGE) (CONT'D) Figure 20-63-5
Check The Output Of The Hydraulic Pump (Cont’d)
Figure 20-63-3
P-37694
1
1
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 20-63-6
housing (Item 1) [Figure 20-63-3] and [Figure 20-63-4].

Figure 20-63-4
3 P-39249
2
P-39248 Remove the OUTLET fitting (Item 1) [Figure 20-63-6]

from the charge pump.
Install the fitting (15KB 1212-Straight Fitting) (Item 2)

[Figure 20-63-4] in the filter housing inlet.
Install the fitting (15KB 0812-Reducer Fitting) (Item 3)

[Figure 20-63-4] in the filter housing outlet.

286 of 1030
HYDRAULIC PUMP (CHARGE) (CONT'D) Figure 20-63-9
Figure 20-63-7
1 P-39253
Connect the outlet fitting on the hydraulic filter (Item 1)

P-39251 [Figure 20-63-9] 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-
63-7] into the OUTLET of the charge pump. Figure 20-63-10

Figure 20-63-8
P-39254
P-39252
Connect the outlet hose on the hydraulic tester (Item 1)
[Figure 20-63-10] to the inlet fitting on the hydraulic filter
Connect the Inlet hose from the hydraulic tester (Item 1) assembly.
[Figure 20-63-8] to the OUTLET fitting of the charge
pump.

287 of 1030
HYDRAULIC PUMP (CHARGE) (CONT’D) Page SPEC-10-5 for system relief pressure and full
RPM.
*Refer to the Hydraulic Schematics for pump flow and
Figure 20-63-11 RPM.
See Hydraulic Pump Removal and Installation (Standard

Removal And Installation on Page 20-60-4 or Hi-Flow
Removal And Installation on Page 20-61-10).
Disassembly and Assembly
See Hydraulic Pump Dissassembly and Assembly

(Standard Disassembly And Assembly on Page 20-60-7
or Hi-Flow Disassembly And Assembly on Page 20-61-
13) .
P-39255
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader

[Figure 20-63-11].
IMPORTANT
I-2024-0284
RPM*.

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.
%= X 100
FREE FLOW (GPM)


288 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N reaches 3250-3300 PSI. At 3250-3300 PSI the flow
6683237) (VENDOR P/N 163D1299) should be at 0 GPM. Turn the restrictor (Item 2) [Figure
Hydraulic Pump Test auxiliary hydraulics off.
The tools listed will be needed to do the following If flow and pressure specs are not obtained, go to the
procedure: Inline Standard Hydraulic Pump Test. (See Inline
MEL10103 - Hydraulic Tester and pressure specs are obtained continue on to the next
MEL10106 - Hydraulic Test Kit paragraph.
Figure 20-64-1 With the engine running at low idle RPM. Press the Front
1
RPM*.


Install a hydraulic tester (Item 1) [Figure 20-64-1] onto pressure reaches 3250-3300 PSI. At 3250-3300 PSI the
the front auxiliary quick couplers. flow should be at 0 GPM. Turn the restrictor control (Item
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) on Page 20-64-4.)
RPM*. *See LOADER SPECIFICATIONS (S250) on Page
Warm the fluid to 140°F. (60°C.) by turning the restrictor Page SPEC-10-5 for system relief pressure and full
control clockwise on the tester so it reads about a 1000 RPM.
PSI (6895 kPa).

flow should start decreasing rapidly until the pressure
289 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)

2
procedure:

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 20-64-2] from the
tubeline.
Lift and block the loader. (See LIFTING AND BLOCKING Figure 20-64-3

Page 10-20-1.) 2
WARNING
to fall and cause injury or death. P-34851
W-2059-0598

Raise the operator cab. (See Raising The Operator Cab the tester to the OUTLET hose (Item 1) [Figure 20-64-2]
on Page 10-30-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-64-3] from the tester to the tubeline (Item 2) [Figure
20-64-2] which goes to the control valve.
Lower the cab down.

290 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D) pressure flow. The high pressure flow must be at least
80% of free flow.
%= X 100
FREE FLOW (GPM)

I-2024-0284 SPEC-10-1 or LOADER SPECIFICATIONS (S300) on
RPM.
Figure 20-64-4
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Valve
BH-196

RPM*.


(GPM) at full RPM.

291 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D) on Page 10-30-1.)
Inline Hydraulic Pump Test (High Flow) Figure 20-64-6

procedure:

WARNING
of the frame before running the engine for service. 2
fall or move and cause injury or death. P-43954
W-2017-0286
Remove the left side access cover.


Figure 20-64-5 [Figure 20-64-6] from the fitting (Item 2) [Figure 20-64-
6] on the tubeline.
1 Figure 20-64-7
2 1
P-34847
Install a jumper hose (Item 1) [Figure 20-64-5] onto the P-34851

device. (See Installing The Lift Arm Support Device on Connect the INLET hose (Item 1) [Figure 20-64-7] from
Page 10-20-1.) the tester to the OUTLET hose (Item 1) [Figure 20-64-6]
20-64-7] from the tester to the fitting (Item 2) [Figure 20-
64-6] on the tubeline.
WARNING Lower the cab down.
W-2059-0598

292 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N readings are not obtained go to the High Flow Relief
6683237) (VENDOR P/N 163D1299) (CONT’D) Pump Adjustment (See High Flow Relief Adjustment
Procedure on Page 20-64-6). If the pressure readings
Inline Hydraulic Pump Test (High Flow) (Cont’d) are correct, continue on to the next paragraph.

(GPM) at full RPM.
IMPORTANT Record the flow (GPM) at 2500 PSI, this is the high
pressure flow. The high pressure flow must be at least
80% of free flow.
I-2024-0284
%= X 100
FREE FLOW (GPM)
Figure 20-64-8
EXAMPLE: TESTER
CONNECTION A low percentage may indicate a failed pump.
Reservoir *See LOADER SPECIFICATIONS (S250) on Page

RPM.

Hydraulic Pump
Valve
BH-196

speed to full RPM*.

Turn the restrictor control clockwise on the tester to 3300

PSI and the flow should go to zero GPM. If the pressure
293 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)

procedure:
WARNING
2
Failure to use jackstands can allow the machine to P-43954

W-2017-0286
Lift and block the loader. (See LIFTING AND BLOCKING Disconnect the high flow pump OUTLET hose (Item 1)
THE LOADER on Page 10-10-1.) [Figure 20-64-10] from the fitting (Item 2) [Figure 20-64-
Remove the right rear tire. 10] on the tubeline.

2
1
P-34847 P-34851
Install a jumper hose (Item 1) [Figure 20-64-9] onto the front

auxiliary quick couplers. Connect the INLET hose (Item 1) [Figure 20-64-11] from
Page 10-20-1.)
Lower the cab down.

WARNING
W-2059-0598

294 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-12
1
1
1
1
1
1 P-34919
P-37082 front auxiliary with the trigger on the right handle. Make
Remove the six access cover mounting bolts (Item 1) and With the hoses connected correctly, increase the engine

speed to full RPM*.
Figure 20-64-13 Warm the fluid to 140°F. (60°C.) by turning the restrictor
kPa).

1 drop off slightly until the pressure reaches approximately
2600 PSI. At approximately 2600 PSI the flow should
P-34846 If the specs from above are reached, the pump is OK.

Remove the cap (Item 1) [Figure 20-64-13] from the
(Item 1) [Figure 20-64-14] will need to be turned
pump.
clockwise a 1/4 turn and retested with the procedure
NOTE: If the relief plug has been turned in 1/4 turn and
Assembly on Page 20-67-13.)

295 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)

1
1
WARNING 1
1
W-2017-0286
P-37082
Remove the six access cover mount bolts (Item 1) and
Remove the right rear tire. the access cover (Item 2) [Figure 20-64-16] from the
frame.
Figure 20-64-15
Figure 20-64-17

1
P-34847
P-34846

front auxiliary quick couplers. Remove the cap (Item 1) [Figure 20-64-17] from the
pump.
Page 10-20-1.)
WARNING
W-2059-0598

296 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N Adjustment section to finish setting the relief. (Page 20-
6683237) (VENDOR P/N 163D1299) (CONT’D) 61-6.)

(Cont’d)
Figure 20-64-18
P-34919
Remove the Relief Plug (Item 1) [Figure 20-64-18] from

the pump.
Figure 20-64-19
P-34696
Inspect the relief valve (Item 1), spring (Item 2), and plug
needed.
Inspect the relief valve seat in the pump for damage or

wear.
Install the relief valve (Item 1) and spring (Item 2) [Figure

20-64-19] into the pump.
Install the plug (Item 3) [Figure 20-64-19] and turn it in

until it makes contact with the spring. Then turn the plug
one full turn clockwise. Go to the High Flow Relief

297 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
1
P-37699
WARNING
Disconnect and cap the hydraulic hose from each of the
Never work on a machine with the lift arms up unless outlet fittings on the High Flow pump (Item 1), the charge
the lift arms are secured by an approved lift arm pump (Item 2) and the standard flow pump (Item 3)
support device. Failure to use an approved lift arm [Figure 20-64-20].
to fall and cause injury or death. Remove the hoses from the Power Bob-Tach block. (If so

W-2059-0598 equipped.) (See POWER BOB-TACH BLOCK (EARLY
Raise the lift arms and install an approved lift arm support BLOCK (LATER MODELS) on Page 20-111-1.)
Page 10-20-1.) Figure 20-64-21

on Page 10-30-1.)
1
Remove the hoses from the Power Bob-Tach block. (If so P-37702

Disconnect and cap the three hoses from the inlet fitting
(Item 1) [Figure 20-64-21] of the hydraulic pump.

298 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-22
P-43958
At the right side access hole, disconnect the electrical

connector (Item 1) [Figure 20-64-22] from the high flow

pump solenoid.
Figure 20-64-23
1
1
P-48155


Remove the hydraulic pump from the loader.

299 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Identification
1. Auxliliary Pump End Section

2. Pre-Load Seal
3. Load Seal
4. Section Seal 20
5. Wear Plate
6. Pin
7. Drive Gear (Auxiliary Pump) 6 16
8. Idler Gear (Auxiliary Pump) 11
9. Pump Center Section (Auxiliary Pump)
10. Pump End Section (Auxiliary Pump)
6
12 5
4 19
5
17
5 18
4 6
2 3
11
4 15 7
6 6

13
14 5
4
2 3
5 4 10
8 9
5
2 3 4
21 22 23 24 25
1
11. Spline Shaft
14. Pump Center Section (Charge Pump)
15. Pump End Section (Charge Pump)
16. Drive Gear (HI-Flow Pump)
17. Idler Gear (Hi-Flow Pump)
18. Pump Center Section (Hi-Flow Pump) 26
27
19. Pump End Section (Hi-Flow Pump)
28
20. Bolt (8)
21. Cap
22. Gasket 29
23. Set Screw
24. Spring
25. Relief Valve
26. O-Ring
27. Back-up Washer 30
28. O-Ring
29. Valve 31
30. Coil
31. Nut
B-21260

300 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)

1
IMPORTANT
P-39165
damage the system.
I-2003-0888

Figure 20-64-24
Installation: Tighten the solenoid valve to 35-40 ft.-lbs
1 (47-54 N•m).
2 Figure 20-64-26

2
P-39164
Remove the solenoid nut (Item 1) [Figure 20-64-24]. 1

P-34694
Installation: Tighten the solenoid nut to 48-72 in lbs (5-8 Inspect the o-ring (Item 1) [Figure 20-64-26] and replace
N•m) as needed.


301 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
1
2
Figure 20-64-27
P-34696
Inspect the check valve (Item 1), spring (Item 2) [Figure

20-64-29], and plug (Item 3) [Figure 20-64-29] for
P-39166 damage and replace as needed.
Figure 20-64-30
Remove the cap (Item 1) [Figure 20-64-27].

Installation: Tighten the cap to 13-16 ft.-lbs (18-22 N•m)
after the relief valve has been set.
Figure 20-64-28
2
1
P-39168
Mark the pump sections for proper installation.

1

P-39167 (60-67 N•m).
Remove the washer (Item 1) [Figure 20-64-28].
Remove the set screw, spring and relief valve (Item 2)

[Figure 20-64-28].
Installation: (See High Flow Relief Adjustment

Procedure on Page 20-64-6.)

302 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-31 1
P-39171

33] & [Figure 20-64-34] from the pump.
P-39169
Figure 20-64-34


Figure 20-64-32
1
3 P-39172
1
2 NOTE: Inspect the pump center section (Item 1)
replaced.

toward gears.


303 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-35
P-39175

[Figure 20-64-38].
P-39173
Figure 20-64-38

[Figure 20-64-36].

Figure 20-64-36
P-39176



304 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-39
1
1
P-39179
2
P-39177 Figure 20-64-42


section.
Figure 20-64-40
1 P-39180
2 Remove the pre-load seal (Item 1) [Figure 20-64-42].
Figure 20-64-43
P-39178

toward gears.
P-39151
Inspect both seals [Figure 20-64-43].

305 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-44
4
2 1
P-39183



Figure 20-64-45
Figure 20-64-47
1
1
2
P-39182
P-39184

[Figure 20-64-46] and section seal (Item 2) [Figure 20- Remove the spline shaft (Item 1) [Figure 20-64-47].
from the pump.

306 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-48
P-39144
1
Figure 20-64-51
1) [Figure 20-64-48]. If excessive wear or

replaced.
Figure 20-64-49 1
P-39145

the charge pump.
P-39143

the charge pump.

307 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-52
1 1
P-39148
2)[Figure 20-64-54] and replace as needed.
P-39146
NOTE: Inspect the drive gear (Item 1) [Figure 20-64- side toward the gears.

pump must be replaced. Figure 20-64-55
Figure 20-64-53
1
1
2
P-39149
P-39147
Remove the load seal (Item 1) [Figure 20-64-55] from
pump.


308 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-56
1
P-39152

P-39150 visible, the pump must be replaced.
Figure 20-64-59

Figure 20-64-57
1
1
2 P-39215

P-39151 59] from the pump sections.

309 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-60
P-39218
2
P-39216
Figure 20-64-63
Remove the wear plate (Item 1) [Figure 20-64-60] & 1


Figure 20-64-61
P-39219
1
2 the pump must be replaced.
P-39217

toward gears.


310 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-64
1
1
P-39222

P-39220
Figure 20-64-67

[Figure 20-64-65].

Figure 20-64-65
P-39223

P-39221
NOTE: Inspect the idler gear (Item 1) [Figure 20-64- pump must be replaced.

311 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-68
2
1
1
P-39226
2) [Figure 20-64-70].
P-39224
Remove the spline shaft (Item 1) [Figure 20-64-68] from toward gears.

Figure 20-64-71
pump must be replaced. 1
Figure 20-64-69
P-26670
3
1
P-39228
2
3
P-39225

[Figure 20-64-69].
Remove the locating pins (Item 3) [Figure 20-64-69].

312 of 1030
6683237) (VENDOR P/N 163D1299) (CONT’D)
Figure 20-64-72
P-26672
P-26670
P-39227

Figure 20-64-73
P-39229P-
26673


313 of 1030

314 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N reaches 3250-3300 PSI. At 3250-3300 PSI the flow
6684635) (VENDOR P/N 163D1372) should be at 0 GPM. Turn the restrictor (Item 2) [Figure
Hydraulic Pump Test auxiliary hydraulics off.
The tools listed will be needed to do the following If flow and pressure specs are not obtained, go to the
procedure: Inline Standard Hydraulic Pump Test. (See Inline
MEL10103 - Hydraulic Tester and pressure specs are obtained continue on to the next
MEL10106 - Hydraulic Test Kit paragraph.
Figure 20-65-1 With the engine running at low idle RPM. Press the Front
1
RPM*.


Install a hydraulic tester (Item 1) [Figure 20-65-1] onto 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
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) on Page 20-65-4.)
RPM*. *See LOADER SPECIFICATIONS (S250) on Page
Warm the fluid to 140°F. (60°C.) by turning the restrictor Page SPEC-10-5 for system relief pressure and full
control clockwise on the tester so it reads about a 1000 RPM.
PSI (6895 kPa).

flow should start decreasing rapidly until the pressure
315 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)

2
procedure:

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 20-65-2] from the
tube line.
Lift and block the loader. (See LIFTING AND BLOCKING Figure 20-65-3

Page 10-20-1.) 2
WARNING
W-2059-0598

Raise the operator cab. (See Raising The Operator Cab the tester to the OUTLET hose (Item 1) [Figure 20-65-2]
on Page 10-30-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-65-3] from the tester to the tube line (Item 2) [Figure
Lower the cab down.

316 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D) pressure flow. The high pressure flow must be at least
80% of free flow.
%= X 100
FREE FLOW (GPM)

I-2024-0284 SPEC-10-1 or LOADER SPECIFICATIONS (S300) on
RPM.
Figure 20-65-4
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Valve
BH-196

RPM*.


(GPM) at full RPM.

317 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D) on Page 10-30-1.)
Inline Hydraulic Pump Test (High Flow) Figure 20-65-6

procedure:

WARNING
W-2017-0286


Figure 20-65-5 [Figure 20-65-6] from the fitting (Item 2) [Figure 20-65-
6] on the tube line.
1 Figure 20-65-7
2 1
P-34847

device. (See Installing The Lift Arm Support Device on Connect the INLET hose (Item 1) [Figure 20-65-7] from
Page 10-20-1.) the tester to the OUTLET hose (Item 1) [Figure 20-65-6]
65-6] on the tube line.
W-2059-0598

318 of 1030
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N readings are not obtained go to the High Flow Relief
6684635) (VENDOR P/N 163D1372) (CONT'D) Pump Adjustment (See High Flow Relief Adjustment
Inline Hydraulic Pump Test (High Flow) (Cont’d) are correct, continue on to the next paragraph.

(GPM) at full RPM.
IMPORTANT Record the flow (GPM) at 2500 PSI, this is the high
pressure flow. The high pressure flow must be at least
80% of free flow.
I-2024-0284
%= X 100
FREE FLOW (GPM)
Figure 20-65-8
EXAMPLE: TESTER
CONNECTION A low percentage may indicate a failed pump.
Reservoir *See LOADER SPECIFICATIONS (S250) on Page

RPM.

Hydraulic Pump
Valve
BH-196

speed to full RPM*.

Turn the restrictor control clockwise on the tester to 3300

PSI and the flow should go to zero GPM. If the pressure
319 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
High Flow Relief Adjustment Procedure WARNING

procedure: Never work on a machine with the lift arms up unless
MEL10103 - Hydraulic Tester support device. Failure to use an approved lift arm
MEL10106 - Hydraulic Test Kit support device can allow the lift arms or attachment
W-2059-0598
WARNING Figure 20-65-10

W-2017-0286
1


2
Figure 20-65-9
P-43954
1 Remove the left side access cover.

[Figure 20-65-10] from the fitting (Item 2) [Figure 20-65-
10] on the tube line.
Figure 20-65-11
P-34847
2
1
Page 10-20-1.)
P-34851

[Figure 20-65-11] from the tester to the tube line (Item 2)
Lower the cab down.

320 of 1030
6684635) (VENDOR P/N 163D1372) (CONT’D)
Figure 20-65-12
1
1
1
P-45445
2 Auxiliary button. Press the High Flow button. Engage the
P-45457 front auxiliary with the trigger on the right handle. Make
Remove the six access cover mounting bolts (Item 1) and With the hoses connected correctly, increase the engine

speed to full RPM*.
Figure 20-65-13 Warm the fluid to 140°F. (60°C.) by turning the restrictor
kPa).

P-45443
1 Shut the front auxiliary hydraulics off.
P-45443 If the specs from above are reached, the pump is OK.
If the pump is unable to reach 3300 PSI the relief (Item 1)

[Figure 20-65-14] will need to be turned clockwise a 1/4
bottom of the relief valve at the pump.
turn and retested with the procedure above. (1/4 turn
equals approximately 200 PSI.)
NOTE: If the relief plug has been turned in 1/4 turn and

321 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
WARNING
1
W-2017-0286
2 P-45457
Remove the six access cover mount bolts (Item 1) and
Remove the right rear tire. the access cover (Item 2) [Figure 20-65-16] from the
frame.
Figure 20-65-15
Figure 20-65-17

1
P-34847
P-45443

front auxiliary quick couplers. Remove the relief valve (Item 1) [Figure 20-65-17] from
the pump.
device. (See Installing The Lift Arm Support Device on Installation: Tighten the relief valve to 30-35 ft.-lb. (41-
Page 10-20-1.) 47 N•m) torque.
WARNING
W-2059-0598

322 of 1030
6684635) (VENDOR P/N 163D1372) (CONT’D)

(Cont’d)
Figure 20-65-18
1 1
P-45459
Inspect the relief valve and replace the two o-rings (Item

1) and washer (Item 2) [Figure 20-65-18].
If the relief valve is bad, it must be replaced as a

complete unit.
Figure 20-65-19
P-45469
Inspect the o-ring (Item 1) [Figure 20-65-19] on the relief

valve adjustment plug for damage and replace as
needed.

323 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
1
2 4
P-45446
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 (Item 2) from
support device. Failure to use an approved lift arm the charge pump. Disconnect and cap the hoses from the
support device can allow the lift arms or attachment High Flow pump outlet fitting (Item 3) and the low
to fall and cause injury or death. pressure hose (Item 4) [Figure 20-65-20].

W-2059-0598
Figure 20-65-21
Page 10-20-1.)
BLOCKING THE LOADER on Page 10-10-1.) 1

on Page 10-30-1.)

P-43957

At the front side of the gear pump, disconnect and cap
the three hoses from the inlet fitting (Item 1) [Figure 20-
65-21] of the hydraulic pump.

324 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-22
P-43958


pump solenoid.
Figure 20-65-23
P-43956


Installation: Use a new O-ring when installing the

hydraulic pump.

325 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Identification
1. Auxiliary Pump End Section

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
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
6

12 5 21
11 23 19
2 25
5
2 6 17 18 24
3 4
2 15 26
6
5
2 13 14
3 4
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-22288

326 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
2
IMPORTANT
P-45461
damage the system.
I-2003-0888
NOTE: Mark the pump housing (Item 1) [Figure 20-65-

Figure 20-65-24 25] for proper installation of the solenoid
valve cartridge.
1 Remove the valve cartridge (Item 1) [Figure 20-65-25].

Installation: Tighten the solenoid valve to 35-40 ft.-lbs
2 (47-54 N•m).
Figure 20-65-26
P-45460
2
1
Installation: Tighten the solenoid nut to 48-72 in lbs (5-8

N•m) P-45462

as needed.
Inspect the o-ring and back-up washer (Item 2) [Figure

20-65-26] and replace as needed.

327 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-27
1 2
P-45469

P-45470 needed.
Figure 20-65-30
27] for proper installation of the relief valve.

Remove the relief valve (Item 2) [Figure 20-65-27] from
the pump
Installation: Tighten the relief valve to 30-35 ft.-lbs (41-

47 N•m) torque.
Figure 20-65-28
1
1
P-45463
1

2
(60-67 N•m).
P-45459
1) and back-up washer (Item 2)[Figure 20-65-28].

328 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-31 1
P-39171

33] & [Figure 20-65-34] from the pump.
P-39169
Figure 20-65-34


Figure 20-65-32
1
3 P-39172
1
2 NOTE: Inspect the pump center section (Item 1)
replaced.

toward gears.


329 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-35
P-39175

[Figure 20-65-38].
P-39173
Figure 20-65-38

[Figure 20-65-36].

Figure 20-65-36
P-39176



330 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-39
1
1
P-39179
2
P-39177 Figure 20-65-42


section.
Figure 20-65-40
1 P-39180
Figure 20-65-43
P-39178

toward gears.
P-39151

331 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-44
4
2 1
P-39183



Figure 20-65-45
Figure 20-65-47
1
1
2
P-39182
P-39184

[Figure 20-65-46] and section seal (Item 2) [Figure 20- Remove the spline shaft (Item 1) [Figure 20-65-47].
from the pump.

332 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-48
P-39144
1
Figure 20-65-51

replaced.
Figure 20-65-49 1
P-39145

the charge pump.
P-39143

the charge pump.

333 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-52
1 1
P-39148
P-39146
NOTE: Inspect the drive gear (Item 1) [Figure 20-65- side toward the gears.

pump must be replaced. Figure 20-65-55
Figure 20-65-53
1
1
2
P-39149
P-39147
pump.


334 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-56
1
P-39152

P-39150 visible, the pump must be replaced.
Figure 20-65-59

Figure 20-65-57
1
1
2 P-39215

P-39151 59] from the pump sections.

335 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-60
P-39218
2
P-39216
Figure 20-65-63
Remove the wear plate (Item 1) [Figure 20-65-60] & 1


Figure 20-65-61
P-39219
1
2 the pump must be replaced.
P-39217

toward gears.


336 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-64
1
1
P-39222

P-39220
Figure 20-65-67

[Figure 20-65-65].

Figure 20-65-65
P-39223

P-39221
NOTE: Inspect the idler gear (Item 1) [Figure 20-65- pump must be replaced.

337 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-68
2
1
1
P-39226
2) [Figure 20-65-70].
P-39224
Remove the spline shaft (Item 1) [Figure 20-65-68] from toward gears.

Figure 20-65-71
pump must be replaced. 1
Figure 20-65-69
P-26670
3
1
P-39228
2
3
P-39225

[Figure 20-65-69].
Remove the locating pins (Item 3) [Figure 20-65-69].

338 of 1030
6684635) (VENDOR P/N 163D1372) (CONT'D)
Figure 20-65-72
P-26672
P-26670
P-39227

Figure 20-65-73
P-39229P-
26673


339 of 1030

340 of 1030
HYDRAULIC PUMP (SELECTABLE JOYSTICK Figure 20-66-1
CONTROL) (SJC) (BOBCAT P/N 6684386) (VENDOR
P/N 163D1357)
Check The Output Of The Hydraulic Pump 2

procedure:
1
WARNING P-43930

of the frame before running the engine for service. Disconnect the OUTLET hose (Item 1) [Figure 20-66-1]
Failure to use jackstands can allow the machine to that comes from the gear pump, and connects to the
fall or move and cause injury or death. tubeline on the top of the control valve.
W-2017-0286
Figure 20-66-2

Page 10-20-1.)
1
WARNING
W-2059-0598
Raise the operator cab. (See Raising The Operator Cab 20-66-2] from the tester to the tubeline (Item 2) [Figure
on Page 10-30-1.) 20-66-1] on the top of the control valve.

Page 10-60-1.) IMPORTANT
I-2024-0284

341 of 1030
HYDRAULIC PUMP (SELECTABLE JOYSTICK *See LOADER SPECIFICATIONS (S250) on Page
CONTROL) (SJC) (BOBCAT P/N 6684386) (VENDOR SPEC-10-1 or LOADER SPECIFICATIONS (S300) on
P/N 163D1357) (CONT'D) Page SPEC-10-5 for system relief pressure and full
RPM.
Figure 20-66-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Out
Hydraulic Pump
In
WARNING
Hydraulic Control
Valve

1 support device can allow the lift arms or attachment
W-2059-0598
BH-196
Sample tester connection shown[Figure 20-66-3]. device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)
tester is connected correctly. If no flow is indicated on the Stop the engine. Raise the seat bar.
connected correctly, increase the engine speed to full Lift and block the rear of the loader. (See LIFTING AND
RPM*. BLOCKING THE LOADER on Page 10-10-1.)
Warm the fluid to 140°F. (60°C.) by turning the restrictor Raise the operator cab. (See Raising The Operator Cab
control (Item 1) [Figure 20-66-3] on the tester to about on Page 10-30-1.)
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free Drain the hydraulic fluid from the reservoir. (See Fluid
flow (GPM) at full RPM. Removal on Page 20-80-1.)
Push the maximum/variable flow switch (on the remote Open the rear door of the loader.
start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control Remove the right rear tire. (See TIRE MAINTENANCE
lever) for fluid flow to the quick coupler (fluid pressure will on Page 10-170-1.)
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least Remove the two right side access panels.
80% of free flow.
Remove the Power Bob-Tach block if equipped. (See
HIGH PRESSURE FLOW (GPM) POWER BOB-TACH BLOCK (EARLY MODELS) on
%= X 100
FREE FLOW (GPM) Page 20-110-1 or POWER BOB-TACH BLOCK (LATER
MODELS) on Page 20-111-1.)

342 of 1030
P/N 163D1357) (CONT'D)
Removal And Installation (Cont’’d)
Figure 20-66-4
1
P-48150


P-48149 (37-50 N•m) torque.
Figure 20-66-7

1) [Figure 20-66-4] of the hydraulic pump.
Figure 20-66-5
2
1 1
1
1
P-48152
At the bottom side of the gear pump, remove the two

pump bolts (Item 1) [Figure 20-66-7] from pump support
P-48151
bracket.
Disconnect the two inlet hoses (Item 1) [Figure 20-66-5] Remove the pump support bracket (Item 2) [Figure 20-
from the front of the hydraulic pump. 66-7] from the loader.

[Figure 20-66-7].
Remove the O-ring (Item 1) from the hydraulic gear

pump.

hydraulic pump.
See Disassembly And Assembly on Page 20-60-7 for the

proper Hydraulic Pump Disassembly And Assembly
procedure.

343 of 1030
HYDRAULIC PUMP (SELECTABLE JOYSTICK
P/N 163D1357) (CONT'D)
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
12. Bolts (4)
13. Bolts (4) B-22285

344 of 1030
P/N 163D1357) (CONT'D)
IMPORTANT
damage the system.
I-2003-0888 P-48187
Figure 20-66-8 Set the pump on end, and remove the pump end section
(Item 1) [Figure 20-66-9] from the charge pump.
Figure 20-66-10

1
1 1
1
P-48186 2

P-48188
66-8].
Remove the eight pump housing bolts (Item 2) [Figure Remove the wear plate (Item 1) and the section seal
20-66-8]. (Item 2) [Figure 20-66-10].
Installation: Tighten the eight bolts (Item 1) [Figure 20-

66-8] to 45-50 ft.-lbs (60-67 N•m) torque.

345 of 1030
P/N 163D1357) (CONT'D)
Figure 20-66-11
3
1
4
P-39142
2

1 damage is visible, the pump must be
P-48189 replaced.
Figure 20-66-14


side toward the gears. 1

Figure 20-66-12
P-48191

the pump.
P-48190
Remove the charge pump center section (Item 1) [Figure

20-66-12] from the auxillary pump.

346 of 1030
P/N 163D1357) (CONT'D)
Figure 20-66-15 1
P-48193

P-39144
Figure 20-66-18

3
Figure 20-66-16
P-48194

[Figure 20-66-18] from the front section of the pump.
P-48192 Remove the locating pins (Item 3) [Figure 20-66-18]

from the front section of the pump.
the pump.

347 of 1030
P/N 163D1357) (CONT'D)
Figure 20-66-19
P-48196
1
from the front section of the pump.
P-39148 Figure 20-66-22


Figure 20-66-20
1
2
P-39151
1
P-48195

the front section of the pump.

348 of 1030
HYDRAULIC PUMP (SELECTABLE JOYSTICK
P/N 163D1357) (CONT'D)
Figure 20-66-23
P-48197
Inspect the pump end section and bushings (Item 1)

visible, the pump must be replaced.
Figure 20-66-24
P-48198
Replace the end section shaft seal (Item 1) [Figure 20-

66-24].

349 of 1030

350 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE flow should start decreasing rapidly until the pressure
JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684387) reaches 3250-3300 PSI. At 3250-3300 PSI the flow
(VENDOR P/N 163D1358) should be at 0 GPM. Turn the restrictor (Item 2) [Figure
Hydraulic Pump Test
auxiliary hydraulics off.
If flow and pressure specs are not obtained, go to the
procedure:
Inline Standard Hydraulic Pump Test. (See Inline
and pressure specs are obtained continue on to the next
paragraph.
Figure 20-67-1
With the engine running at low idle RPM. Press the Front
1 trigger on the right handle. Make sure the tester is
RPM*.


Install a hydraulic tester (Item 1) [Figure 20-67-1] onto
pressure reaches 3250-3300 PSI. At 3250-3300 PSI the
the front auxiliary quick couplers.
flow should be at 0 GPM. Turn the restrictor control (Item
the front auxiliary hydraulics off.
hydraulic pump is OK.
If the flow and pressure were not obtained, go to the
Inline High Flow Hydraulic Pump Test (See Inline
Hydraulic Pump Test (High Flow) on Page 20-67-4.)
RPM*.
control clockwise on the tester so it reads about a 1000
RPM.
PSI (6895 kPa).


351 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE Figure 20-67-2
JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684387)
(VENDOR P/N 163D1358) (CONT’D)

2
procedure:

WARNING
P-43930
Failure to use jackstands can allow the machine to At the control valve, disconnect the standard (auxiliary)
fall or move and cause injury or death. pump OUTLET hose (Item 1) [Figure 20-67-2] from the
W-2017-0286 tubeline.
Figure 20-67-3

Page 10-20-1.)
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.) 20-67-3] from the tester to the tubeline (Item 2) [Figure
Lower the cab down.

352 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE Record the flow (GPM) at 2700 PSI, this is the high
JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684387) pressure flow. The high pressure flow must be at least
(VENDOR P/N 163D1358) (CONT’D) 80% of free flow.
%= X 100
FREE FLOW (GPM)
The hydraulic tester must be in the fully open *See LOADER SPECIFICATIONS (S250) on Page
position before you start the engine. SPEC-10-1 or LOADER SPECIFICATIONS (S300) on
I-2024-0284 Page SPEC-10-5 for system relief pressure and full
RPM.
Figure 20-67-4
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Valve
BH-196

RPM*.


(GPM) at full RPM.

353 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE Raise the operator cab. (See Raising The Operator Cab
JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684387) on Page 10-30-1.)
Figure 20-67-6
Inline Hydraulic Pump Test (High Flow)

procedure:

1
WARNING
2
W-2017-0286

THE LOADER on Page 10-10-1.) Disconnect the high flow pump OUTLET hose (Item 1)

Figure 20-67-5 6] on the tubeline.
1 Figure 20-67-7
2 1
P-34847

Raise the lift arms and install an approved lift arm support Connect the INLET hose (Item 1) [Figure 20-67-7] from
device. (See Installing The Lift Arm Support Device on the tester to the OUTLET hose (Item 1) [Figure 20-67-6]
Page 10-20-1.)
67-6] on the tubeline.

W-2059-0598

354 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE Turn the restrictor control clockwise on the tester to 3300
JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684387) PSI and the flow should go to zero GPM. If the pressure
(VENDOR P/N 163D1358) (CONT’D) readings are not obtained go to the High Flow Relief
Pump Adjustment (See High Flow Relief Adjustment
Inline Hydraulic Pump Test (High Flow) (Cont’d)
are correct, continue on to the next paragraph.

IMPORTANT (GPM) at full RPM.
The hydraulic tester must be in the fully open Record the flow (GPM) at 2500 PSI, this is the high
position before you start the engine. pressure flow. The high pressure flow must be at least
I-2024-0284 80% of free flow.

Figure 20-67-8 %= X 100
FREE FLOW (GPM)
EXAMPLE: TESTER
CONNECTION
Reservoir
RPM.

Hydraulic Pump
Valve
BH-196

speed to full RPM*.


355 of 1030
HYDRAULIC PUMP (HI FLOW) (SELECTABLE

WARNING
The tools listed will be needed to do the following Never work on a machine with the lift arms up unless
procedure: the lift arms are secured by an approved lift arm
MEL10103 - Hydraulic Tester support device can allow the lift arms or attachment
MEL10106 - Hydraulic Test Kit to fall and cause injury or death.
W-2059-0598
WARNING Figure 20-67-10

W-2017-0286
1

Figure 20-67-9 2
P-43954
1

10] on the tubeline.
Figure 20-67-11
P-34847
2
1
Install a jumper hose (Item 1) [Figure 20-67-9] onto the front
auxiliary quick couplers.
Page 10-20-1.)
P-34851

Lower the cab down.

356 of 1030
Figure 20-67-12
1 1
1
P-45445
2 front auxiliary with the trigger on the right handle. Make
P-45457 sure the tester is connected correctly. If no flow is
Remove the six access cover mounting bolts (Item 1) and

speed to full RPM*.
Figure 20-67-13
kPa).
P-45443 Turn the restrictor control clockwise on the tester to

1
If the specs from above are reached, the pump is OK.
P-45443

Remove the cap (Item 1) [Figure 20-67-13] from the (Item 1) [Figure 20-67-14] will need to be turned
pump. clockwise a 1/4 turn and retested with the procedure
operator running the tester. NOTE: If the relief plug has been turned in 1/4 turn and
31-1) If relief valve has been checked and is

357 of 1030

1
WARNING 1
1
W-2017-0286
2 P-45457

THE LOADER on Page 10-10-1.) Remove the six access cover mount bolts (Item 1) and
the access cover (Item 2) [Figure 20-67-16] from the
Remove the right rear tire. frame.
Figure 20-67-15 Figure 20-67-17

1
P-34847
P-45443
Install a jumper hose (Item 1) [Figure 20-67-15] onto the Remove the relief valve (Item 1) [Figure 20-67-17] from
front auxiliary quick couplers. the pump.
Raise the lift arms and install an approved lift arm support Installation: Tighten the relief valve to 30-35 ft.-lb. (41-
device. (See Installing The Lift Arm Support Device on 47 N•m) torque.
Page 10-20-1.)
WARNING
W-2059-0598

358 of 1030

(Cont’d)
Figure 20-67-18
1 1
P-45459

1) and washer (Item 2) [Figure 20-67-18].
If the relief valve is bad, it must be replaced as a

complete unit.
Figure 20-67-19
P-45469

needed.

359 of 1030
P-48153
WARNING At the back side of the gear pump, disconnect and cap
the hose from the outlet fitting (Item 1) of the standard
Never work on a machine with the lift arms up unless flow pump. Disconnect and cap the hose from the High
the lift arms are secured by an approved lift arm Flow pump outlet fitting (Item 2) [Figure 20-67-20].

W-2059-0598
Page 10-20-1.) 1
BLOCKING THE LOADER on Page 10-10-1.) 1

on Page 10-30-1.)
P-48154
At the front side of the gear pump, disconnect and cap
Open the rear door of the loader. the two hoses (Item 1) [Figure 20-67-21] from the inlet
fitting of the hydraulic pump.

360 of 1030
Figure 20-67-22
1
1
1
P-48156
At the bottom side of the gear pump, remove the two

pump bolts (Item 1) [Figure 20-67-24] from pump
support bracket.
P-43958
Remove the pump support bracket (Item 2) [Figure 20-

67-24] from the loader.

pump solenoid.
Remove the O-ring from the hydraulic gear pump.
Figure 20-67-23
hydraulic pump.
See Disassembly And Assembly on Page 20-60-7 for the

proper Hydraulic Pump Disassembly And Assembly
procedure.
1
1
P-48155



361 of 1030
Identification
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)
14. Idler Gear (Hi-Flow Pump) 18
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 6 7
20. O-Ring 4 5
21. O-Ring 1 3
22. Back-up Washer
23. Valve 2
24. Coil
25. Nut B-22284

362 of 1030
Disassembly And Assembly 1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly P-48218
damage the system.

I-2003-0888
Figure 20-67-25 Installation: Tighten the solenoid valve to 35-40 ft.-lbs

(47-54 N•m).
1
Figure 20-67-27

2
P-48217
Remove the solenoid nut (Item 1) [Figure 20-67-25]. 1

P-45462

Installation: Tighten the solenoid nut to 48-72 in lbs (5-8 as needed.
N•m)

363 of 1030
Figure 20-67-28
1 2 P-45469

needed.
P-45470
Figure 20-67-31

28] for proper installation of the relief valve.
Remove the relief valve (Item 2) [Figure 20-67-28] from

the pump
Installation: Tighten the relief valve to 30-35 ft.-lbs (41-

47 N•m) torque.
Figure 20-67-29
1
1 P-48219
1

2
(60-67 N•m).
P-45459
1) and back-up washer (Item 2)[Figure 20-67-29].

364 of 1030

1
Figure 20-67-32
P-48202
Remove the Hi-flow pump center section (Item 1) [Figure

20-67-34] & [Figure 20-67-35] from the pump.
P-48200 Figure 20-67-35

[Figure 20-67-32] from the Hi-flow pump end section.
Figure 20-67-33 1
P-48203
1
3 NOTE: Inspect the Hi-flow pump center section (Item
2 1) [Figure 20-67-35]. If excessive wear or
P-48201 replaced.

toward gears.
NOTE: Inspect the Hi-flow pump end section (Item 3)

and bushings (Item 4) [Figure 20-67-33]. If

365 of 1030
Figure 20-67-36
1
1
P-48206

[Figure 20-67-39].
P-48204 Figure 20-67-39

[Figure 20-67-37].
Figure 20-67-37
1
P-48207

P-48205


366 of 1030
(VENDOR P/N 163D1358) (CONT’D))
Figure 20-67-40
P-48210
2
Figure 20-67-43
P-48208

section.
Figure 20-67-41
P-48211
1
Figure 20-67-44
P-48209

toward gears.
P-39151

367 of 1030
Figure 20-67-45 4
2 1
P-48214

toward gears.
P-48212


Figure 20-67-46
Figure 20-67-48
1
2
1
P-48213
P-48215

Remove the spline shaft (Item 1) [Figure 20-67-48].
Remove the auxilliary pump center section (Item 2)
[Figure 20-67-48] from the pump.

368 of 1030
Figure 20-67-49
P-39144
1 NOTE: Inspect the idler gear (Item 1) [Figure 20-67-

P-39142
Figure 20-67-52
NOTE: Inspect the auxilliary pump center section

(Item 1) [Figure 20-67-49]. If excessive wear or
replaced.
1
Figure 20-67-50
P-48220

the auxilliary pump.
P-48216

the auxilliary pump.

369 of 1030
Figure 20-67-53
P-39148
1 Inspect the wear plate (Item 1) and the section seal (Item
P-48221 NOTE: Position the wear plate (Item 1) [Figure 20-67-


Figure 20-67-56
Figure 20-67-54
3 1
2
P-48223
P-48222 Remove the load seal (Item 1) [Figure 20-67-56] from

the front section of the auxilliary pump.
[Figure 20-67-54] from the front section of the auxilliary
pump.

from the front section of the auxilliary pump.

370 of 1030
Figure 20-67-57
P-48197
1
Inspect the pump end section and bushings (Item 1)

visible, the pump must be replaced.
P-48224
Figure 20-67-60
Remove the pre-load seal (Item 1) [Figure 20-67-57]

from the front section of the auxilliary pump.
Figure 20-67-58
1
P-48225
2
Remove and replace the pump end section shaft seal

(Item 1) [Figure 20-67-60].
P-39151

371 of 1030

372 of 1030
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.
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.
Page 10-20-1.)

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.

373 of 1030
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
N•m) 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.

374 of 1030
HYDRAULIC FLUID RESERVOIR Remove the hose end cap and drain fluid into a
container.
Fluid Removal
Page 10-20-1.)

on Page 10-30-1.)
Drain the fluid from the reservoir.

on Page 50-100-1.)
WARNING
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.

375 of 1030
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.

376 of 1030
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.

377 of 1030
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.

378 of 1030
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.

379 of 1030

380 of 1030
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.-lb. (6,78

N•m) 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.
Replace the test meter with 12 volt power. You can see
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.-lb. (40,8-47,6 N•m)
torque.

381 of 1030
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.-lb. (6,78 N•m)
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.-lb.
(40,8-47,6 N•m) torque.
Remove the mounting bolts (Item 2) [Figure 20-90-6]
from the bucket position valve.

382 of 1030
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].

383 of 1030
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.

384 of 1030
REAR AUXILIARY DIVERTER VALVE (EARLY Figure 20-100-3
MODELS)
Figure 20-100-1 1
P-34744
1 Disconnect the pilot hose (Item 1) [Figure 20-100-3]

from the fitting on the diverter block.
P-34722
Figure 20-100-4
Remove the three mount bolts (Item 1) [Figure 20-100-1]

and remove the left side access panel.

Figure 20-100-2 1
1 P-34715
1
Disconnect the tubeline (Item 1) [Figure 20-100-4] from
the fitting on the “F2” port.
P-34751
Disconnect the two electrical connectors (Item 1) [Figure
20-100-2] from the diverter block.

385 of 1030
REAR AUXILIARY DIVERTER VALVE (EARLY
MODELS) (CONT’D)
Figure 20-100-5
P-34739


386 of 1030
REAR AUXILIARY DIVERTER VALVE (EARLY Figure 20-100-7
MODELS) (CONT’D)
Disassembly and Assembly
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888 2
N-0529
Figure 20-100-6
Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [Figure 20-100-7].
Remove the shuttle check valve from block port SH1

(Item 2) [Figure 20-100-7].

Figure 20-100-8
2
1 3
1 5
N-0527 2
2
Clean the diverter block to remove dirt before
disassembly. Block ports are labeled for correct
assembly. 3
2 1
Remove the logic cartridge valves from block ports LC1 N-0528
and LC2 (Item 1) [Figure 20-100-6].
Remove the nuts (Item 1) [Figure 20-100-8], seal

washers (Item 2) [Figure 20-100-8], and solenoid valve
coils (Item 3) [Figure 20-100-8].
Remove the diverter control solenoid valve (Item 4)

[Figure 20-100-8] from port SV1. Remove the pressure
relieving solenoid valve (Item 5) [Figure 20-100-8] from
block port SV2.
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 block cavities for contamination. Wash

block in clean solvent. Use air pressure to dry.

387 of 1030
REAR AUXILIARY DIVERTER VALVE (EARLY
MODELS) (CONT’D)
Solenoid Testing
Figure 20-100-9
P9137

100-9]. Coil wires do not have polarity. Correct resistance

is 6-9 ohms.
Assembly
Put oil on O-rings and back-up washers.
Tighten the Logic cartridge valves (Item 1) [Figure 20-

100-6] to 65 ft.-lb. (88 N•m) torque.
Tighten the pilot check valves (Item 1) [Figure 20-100-7],

and shuttle check valve (Item 2) [Figure 20-100-7] to 35
ft.-lb. (47 N•m) torque.
Tighten the solenoid valves (Items 4 & 5) [Figure 20-

100-8] to 12 ft.-lb. (16,3 N•m) torque. Install the sealing
washers (Item 2) [Figure 20-100-8] and coils (Item 3)
[Figure 20-100-8]. Tighten the nuts (Item 1) [Figure 20-
100-8] to 10 in.-lb. (1,13 N•m) torque.

388 of 1030
REAR AUXILIARY DIVERTER (LATER MOTELS) Figure 20-101-3
Figure 20-101-1
2
1
1
P-43678
1

P-43683 base end fitting.

Remove the two access cover mount bolts (Item 1) rod end fitting.
[Figure 20-101-1] from the right side acces cover.

Remove the access cover. Disconnect the hose (Item 3) [Figure 20-101-3] from the
pressure out port.
Mark all wires and hoses for proper installation.
Cap and plug all fittings and hoses.
Figure 20-101-2
Figure 20-101-4
1
P-43681
P-43711
Disconnect the four electrical connectors (Item 1) [Figure

20-101-2] from the diverter solenoids. Disconnect the hose (Item 1) [Figure 20-101-4] from the
pressure in fitting.

389 of 1030
REAR AUXILIARY DIVERTER (LATER MODELS) Figure 20-101-7
(CONT’D)
Figure 20-101-5
P-43708
1

from the block.
P-43711
Remove the diverter valve from the loader.

pressure in fitting.

Figure 20-101-6
P-43693

fitting that goes to tank.

390 of 1030
REAR AUXILIARY DIVERTER (LATER MODELS)
(CONT'D)
Disassembly And Assembly IMPORTANT

damage the system.
I-2003-0888
Figure 20-101-10
1
1 1
P-48751
Figure 20-101-9

P-48755
1
Figure 20-101-11
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 20-101-8] & [Figure 20-

101-9] are located all over the diverter valve and can be P-48756
removed for cleanout purposes.

Remove the shuttle valve (Item 1) [Figure 20-101-10] &
Installation: Put oil on O-rings and back-up
[Figure 20-101-11] from diverter valve and inspect the
washers.Tighten to 10 ft.-lb. (13,6 N•m) torque.
O-rings and back-up washers (Item 2) [Figure 20-101-
11] for damage.
Installation: Put oil on the O-rings and back-up washers.

Tighten to 10-12 ft.-lb. (14-16 N•m) torque.

391 of 1030
(CONT'D)
Figure 20-101-12
P-48753
1
Figure 20-101-15
P-48755
1
Figure 20-101-13

2
2
2
1
P-48754
Remove the relief valve (Item 1) [Figure 20-101-14] &

[Figure 20-101-15] from the diverter valve and inspect
P-48757 the O-rings and back-up washers (Item 2) [Figure 20-
101-15] for damage.
Remove the differential sensing valve (Item 1) [Figure Installation: Put oil on O-ring and back-up washers.
20-101-12] & [Figure 20-101-13] from diverter valve and Tighten to 20-25 ft.-lb. (27-34 N•m) torque.
inspect the O-rings and back-up washers (Item 2)
[Figure 20-101-13] for damage.
Installation: Put oil on O-ring and back-up washers.


392 of 1030
(CONT'D)
Figure 20-101-16 1
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
P-48759
Remove the nuts (Item 1) [Figure 20-101-18] from the
solenoid valve stems.
Figure 20-101-17

Installation: Tighten the nut to 4-6 ft.-lb. (5-8 N•m)
torque.
1
2
P-48760
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nut (Item 1) [Figure 20-101-16] & [Figure

20-101-17] from the solenoid valve stem.

torque.
Remove the spacer (Item 2) and solenoid valve coils

(Item 3) [Figure 20-101-17].

393 of 1030
(CONT'D)

1
Figure 20-101-19
P-48763A
Figure 20-101-22
P-48762
Figure 20-101-20

1 2
2 2 P-48764
1 1
Remove the solenoid valve stem (Item 1) [Figure 20-

101-21] & [Figure 20-101-22] and inspect the O-rings
P-48763 and back-up washers (Item 2) [Figure 20-101-22] for
damage.
Remove the solenoid valve stem (Item 1) [Figure 20- Installation: Put oil on O-rings and back-up washers.
101-19] & [Figure 20-101-20] and inspect the O-rings Tighten to 30-35 ft.-lb. (41-47 N•m) torque.
and back-up washers (Item 2) [Figure 20-101-20] for
damage.
Installation: Put oil on O-rings and back-up washers.


394 of 1030
(CONT'D)
Figure 20-101-23
P-48765
P-48765 Installation: Tighten the plug to 10 ft.-lb. (13,6 N•m)

torque.
Remove the plug (Item 1) [Figure 20-101-23]. Figure 20-101-26

Installation: Tighten the plug to 38 ft.-lb. (51,5 N•m)
torque.
Figure 20-101-24
P-48786
Remove the orifice (Item 1) [Figure 20-101-26].

1
P-48766 Installation: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m)
torque.
Remove and inspect the orifice (Item 1) [Figure 20-101-

24] for dirt and debris.
Installation: Tighten the orifice to 22 ft.-lb. (29,8 N•m)

torque.

395 of 1030
REAR AUXILIARY DIVERTER (LATER MODELS) Solenoid Testing
(CONT'D)
Figure 20-101-28
Figure 20-101-27
P9137
P-48758 Use a test meter to measure coil resistance [Figure 20-

101-28]. Coil wires do not have polarity. Correct
resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.
Remove the plugs (Item 1) [Figure 20-101-27].

Installation: Tighten the plug to 14 ft.-lb. (19 N•m) and hear the spool shift.
torque.
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.

396 of 1030
POWER BOB-TACH BLOCK (EARLY MODELS) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Page 20-80-1.)
WARNING Disconnect and cap the two electrical solenoid

connectors (Item 1) [Figure 20-110-1] from the loader
electrical harness.
the lift arms are secured by an approved lift arm Figure 20-110-2
to fall and cause injury or death. 1
W-2059-0598
2 2

2 P-26908
IMPORTANT Disconnect and cap the outlet hose (Item 1) [Figure 20-
110-2] from block.
When repairing hydrostatic and hydraulic systems, Mark the hydraulic hoses for proper installation.
clean the work area before disassembly and keep all Disconnect and cap the hose (Item 2) [Figure 20-110-2]
parts clean. Always use caps and plugs on hoses, from block.
Figure 20-110-3
damage the system.
I-2003-0888
Figure 20-110-1 1
1 1
P-26909

3].
P-26244
Lift and block the loader. (See LIFTING AND BLOCKING (34-38 N•m) torque.
Remove the power Bob-Tach block.
Page 10-20-1.)
397 of 1030
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-110-6
(CONT'D)
Figure 20-110-4
P-26105
2
P-26100 Installation: Tighten the plug to 120 in.-lb. (13,6 N•m)

torque.
Clean the block (Item 1) [Figure 20-110-4] to remove dirt Figure 20-110-7
before disassembly. Block ports are labeled for correct

assembly.
Installation: Tighten the plug to 46 ft.-lb. (62,4 N•m)

torque.
Figure 20-110-5
2
1
3
P-26107
Remove the spring (Item 1) [Figure 20-110-7] and check

ball (Item 2) [Figure 20-110-7].
2
Check the O-ring (Item 3) [Figure 20-110-7] on the plug
1 and replace as needed.
3
P-26103

compensator (Item 2) [Figure 20-110-5].


398 of 1030
(CONT'D)
Figure 20-110-8
P-26113
1 Remove the plug (Item 1) [Figure 20-110-10] & [Figure

20-110-11].
P-26109
Installation: Tighten the plug to 32 in.-lb. (3,6 N•m)
torque.
Remove the pressure reducing valve plug (Item 1)
[Figure 20-110-8] & [Figure 20-110-9].

Figure 20-110-11
Installation: Tighten the pressure reducing valve plug to

to 46 ft.-lb. (62,4 N•m) torque.
Figure 20-110-9
P-26208
3
1
2
3 P-26114
2
1
4 and replace as needed.
5
P-26112
Check the O-ring (Item 3) [Figure 20-110-11] and
replace as needed.
Remove the relief piston (Item 2) [Figure 20-110-9],
spring (Item 3) [Figure 20-110-9], ball seat spring guide
(Item 4) [Figure 20-110-9].
Check the O-ring (Item 5) [Figure 20-110-9] on the

pressure reducing valve plug and replace as needed.
NOTE: The relief valve seat (Item 6) [Figure 20-110-9]

is a non-serviceable part. If seat is damaged,
order a new power Bob-Tach block from
Bobcat parts.

399 of 1030
(CONT'D)
Figure 20-110-12
P-26120
Remove the stem (Item 1) [Figure 20-110-14].
P-26116 Installation: Tighten the stem to 20 ft.-lb. (27,1 N•m)

torque.
Remove the nut (Item 1) [Figure 20-110-12] & [Figure Figure 20-110-15
20-110-13].

Installation: Tighten the nut to 5 ft.-lb. (6,8 N•m) torque. 1
Figure 20-110-13
4
3
2
2
1
P-26122
Check the O-rings and back-up washers (Item 1) [Figure

20-110-15] and replace as needed.
P-26117
Installation: Put oil on O-rings and back-up washers.
Remove the first coil (Item 2) [Figure 20-110-13], spacer Check the O-ring (Item 2) [Figure 20-110-15] and
(Item 3) [Figure 20-110-13] and the second coil (Item 4) replace as needed.
[Figure 20-110-13].
NOTE: Remember the coil orientation for ease of

installation.

400 of 1030
(CONT'D)
Figure 20-110-16
P-26125
Remove the plug (Item 1) [Figure 20-110-18] & [Figure

20-110-19].
1
P-26123
torque.
20-110-17].

Figure 20-110-19

torque.
Figure 20-110-17
2
1
3 P-26127
2
1
Remove the pilot piston (Item 2) [Figure 20-110-19].
3 P-26309 Check the O-ring (Item 3) [Figure 20-110-19] and
replace as needed.
Remove the dowel pin shuttle (Item 2) [Figure 20-110-

17].

replace as needed.

401 of 1030
(CONT'D)
Figure 20-110-20
P-26130

20-110-23].
P-26128
torque.
20-110-21].

Figure 20-110-23

torque.
Figure 20-110-21
2
1
P-26132
1
Remove the orifice (Item 2) [Figure 20-110-23] with a 5/
32 inch allen wrench.
2 P-26129
Installation: Tighten the orifice to 5 ft.-lb. (6,8 N•m)
torque.
replace as needed.

402 of 1030
(CONT'D)
Figure 20-110-24
3
2
1
4
P-26136
Remove the relief spring (Item 2) [Figure 20-110-26].
P-26133 Remove the ball seat spring guide (Item 3) [Figure 20-
110-26].
Make sure orifice is clean and not plugged [Figure 20- Check the O-ring (Item 4) [Figure 20-110-26] and
110-24].

replace as needed.
Figure 20-110-25 Figure 20-110-27
1
P-26134
P-26137
Remove the plug (Item 1) [Figure 20-110-25] & [Figure Remove the plug (Item 1) [Figure 20-110-27].
20-110-26].
Installation: Tighten the plug to 198 in.-lb. (22,4 N•m) torque.
torque.

403 of 1030
(EARLY MODELS) (CONT'D)
Figure 20-110-28
1
1 P-26141

2 replace as needed.
P-26139
Figure 20-110-31
Remove the dowel pin orifice (Item 1) [Figure 20-110-

28].

replace as needed.
Figure 20-110-29
1
P-26141
1

torque.
P-26140

20-110-30].

torque.

404 of 1030
POWER BOB-TACH BLOCK (EARLY MODELS)
(CONT'D)
Figure 20-110-32
2
1
3
P-26143
Remove the flow control spring (Item 1) [Figure 20-110-

32].

Remove the flow control (Item 2) [Figure 20-110-32].

replace as needed.

405 of 1030

406 of 1030
POWER BOB-TACH BLOCK (LATER MODELS) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Page 20-80-1.)
WARNING Disconnect and cap the two electrical solenoid

connectors (Item 1) [Figure 20-111-1] from the loader
electrical harness.
Never work on a machine with the lift arms up unless Figure 20-111-2
support device can allow the lift arms or attachment 1
W-2059-0598 2
2
2
P-48590

IMPORTANT Disconnect and cap the outlet hose (Item 1) [Figure 20-
111-2] from block.
Mark the hydraulic hoses for proper installation.
When repairing hydrostatic and hydraulic systems, Disconnect and cap the hose (Item 2) [Figure 20-111-2]
clean the work area before disassembly and keep all from block.
Figure 20-111-3
damage the system.
I-2003-0888
1
1
Figure 20-111-1
P-48591

3].
P-26244 Installation: Tighten the mounting bolts to 25-28 ft.-lb.

Lift and block the loader. (See LIFTING AND BLOCKING Remove the power Bob-Tach block.
Page 10-20-1.)

407 of 1030
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-111-5
(CONT'D)
Figure 20-111-4
3
1
4
2 1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
spool (Item 3) [Figure 20-111-5].
P-48115
Clean the block (Item 1) [Figure 20-111-4] to remove dirt
before disassembly. Block ports are labeled for correct

Figure 20-111-6
assembly.
Installation: Tighten the plug to 25-30 ft.-lb. (34-40,6

N•m) 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 20-111-6].
Installation: Tighten the plug to 12-14 ft.-lb. (16,3-19

N•m) torque.

408 of 1030
(CONT'D)
Figure 20-111-7
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-111-9].
P-48382 NOTE: Do not remove plugs. If the plugs are removed

the internal pressure relieving spring setting
will be altered.
Remove the check valve (Item 1) [Figure 20-111-7].

Figure 20-111-10
Installation: Oil the check valve and O-rings and tighten
the check valve to to 20-25 ft.-lb. (27,1-34 N•m) torque.
Figure 20-111-8
2
1
P-48384
3
Remove the plug (Item 1) [Figure 20-111-10], inspect the
P-48119 O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-111-

Inspect the check valve (Item 1) and piston assembly 10] to 12-14 ft.-lb. (16,3-19 N•m) torque.
(Item 2) [Figure 20-111-8].
Check the O-rings and back up washers (Item 3) [Figure

20-111-8] on the check valve and piston assembly and
replace as needed.

409 of 1030
(CONT'D)

3
Figure 20-111-11
2
2
1
P-48106
Remove the first solenoid coil (Item 1), spacer (Item 2)

and the second solenoid coil (Item 3) [Figure 20-111-13].
P-48664
NOTE: Remember the solenoid coil orientation for
ease of installation.
Remove the orifice screw (Item 2) located behind the
plug (Item 1) [Figure 20-111-11].

Figure 20-111-14
Installation: Tighten the orifice screw (Item 2) [Figure

20-111-11] to 6-8 ft.-lb. (8,1-10,8 N•m) torque.
Figure 20-111-12
1
2 P-48386
Remove the the solenoid stem (Item 1) [Figure 20-111-

14].
P-48127
Installation: Tighten the solenoid stem to to 20-25 ft.-lb.
(27,1-34 N•m) torque.
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 20-111-12].
Installation: Tighten the solenoid valve stem nut to 15-

45 in.-lb. (1,7-5,1 N•m) torque.

410 of 1030
(CONT'D)
Figure 20-111-15 1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-
111-17].
P-48175
Installation: Tighten the screened orifice plug to to 11-12
ft.-lb. (14,9-16,3 N•m) torque.
Remove the armature rod assembly (Item 1) [Figure 20-
111-15].

Figure 20-111-18
Figure 20-111-16
2
2
1
1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-111-
18] for damage replace as needed. If the screened orifice
Inspect the solenoid stem (Item 1), armature assembly plug is blocked replace with a new plug.
(Item 2) and the spool (Item 3) for damage [Figure 20-
111-16]. Check the O-ring (Item 2) [Figure 20-111-18] and
replace as needed.
NOTE: If the solenoid stem is damaged (Item 1) check
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 20-111-
16].

411 of 1030

412 of 1030
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

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.-lb. (80 N•m)
Remove the drain coupler (Item 2) [Figure 20-120-2] &
[Figure 20-120-3].
Installation: Tighten the drain coupler (Item 2) [Figure

20-120-2] & [Figure 20-120-3] to 37 ft.-lb. (50 N•m)
Remove the female coupler (Item 3) [Figure 20-120-2] &
[Figure 20-120-3].
Installation: Tighten the female coupler (Item 3) [Figure
20-120-2] & [Figure 20-120-3] to 59 ft.-lb. (80 N•m)
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].

413 of 1030
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

needed.

414 of 1030
HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Sender Removal And Installation. . . . . . . . . . . . . . . . . . . . 30-30-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1 HYDROSTATIC
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-2 SYSTEM
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
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . 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 (S250 S/N 521313912 & BELOW) (S300 S/N

521512099 & BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-16
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-4
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-40-1
415 of 1030
HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC PUMP (S250 S/N 521313913 & ABOVE) (S300 S/N

521512100 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . 30-41-3
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . 30-41-4
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6
Hydraulic Pump Removal And Installation . . . . . . . . . . . . . . . . 30-41-8
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-15
HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) 30-

42-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-39
Charge Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-25
Charge Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-26
Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-23
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-28

Hydrostatic Pump Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-35
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . 30-42-13
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . 30-42-11
Pump Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . 30-42-51
Pump Controller Removal And Installation . . . . . . . . . . . . . . . 30-42-1
Pump Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-48
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-18
Shaft Seal And Shaft Installation . . . . . . . . . . . . . . . . . . . . . . 30-42-21
Shaft Seal And Shaft Replacement . . . . . . . . . . . . . . . . . . . . 30-42-19
System Check Relief Valves (High Pressure Relief, Charge Check &
By-Pass Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42-15
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

416 of 1030
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.

417 of 1030
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

418 of 1030
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
support device can allow the lift arms or attachment Remove the ten mounting bolts (Item 1) [Figure 30-20-
to fall and cause injury or death. 2].
W-2059-0598
Installation: Tighten the mounting bolts to 110 ft.-lb.

(149,2 N•m) 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
Page 10-20-1.)
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
Installation on Page 30-22-1.)
Disconnect the case drain hose (Item 1) [Figure 30-20-
1].

419 of 1030
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
6

4
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

420 of 1030
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].

421 of 1030
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.

422 of 1030
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].

423 of 1030
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].

424 of 1030
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-lb. (25-30 N•m) 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-lb. (12-15 N•m) torque.

425 of 1030
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

to 7-9 ft.-lb. (10-12 N•m) torque.
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.

426 of 1030
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.-lb. (67,8 N•m) 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.-lb. (149,2 N•m) 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.

427 of 1030

428 of 1030
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
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
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

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.
Page 20-80-1.)
Remove the motor cover mount bolts (Item 1) [Figure

30-21-1].

429 of 1030
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.-lb.
(34 N•m) torque.
Figure 30-21-5 1
N-22535
Installation: Replace the O-ring (Item 1) [Figure 30-21-

7] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lb. (149
N-22488 N•m) torque.
Remove the hydraulic fitting (Item 1) [Figure 30-21-5]

from the motor.

430 of 1030
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

431 of 1030
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D)
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

432 of 1030
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.

433 of 1030
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.

434 of 1030
Figure 30-21-16
1
1 2
N-22502

N-22499 housing.
Installation: Tighten the plug to 18-22 ft.-lb. (25-30 N•m)

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.-lb. (12-15 N•m)

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.

435 of 1030
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.-lb. (12-15 N•m)

torque.

436 of 1030
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.

437 of 1030
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.

438 of 1030
Figure 30-21-32
1
2 1
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.

439 of 1030
HYDRAULIC MOTOR (TWO-SPEED) (CONT'D) Figure 30-21-37
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].

440 of 1030
HYDRAULIC 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

441 of 1030
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].

442 of 1030
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 (Item 1) [Figure

30-21-49] to 26-29 ft.-lb. (35-39 N•m) torque.

443 of 1030
Assembly (Cont'd)
Figure 30-21-50
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.-lb. (70-77 N•m) torque.

444 of 1030
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].

445 of 1030
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 lb. (20 Kn), on the brake piston
[D].
2
NOTE: The 4500 lb. 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].
1432
) d = 6 in.
2 ) 3 (Squared) = 9
9
= 159 PSI
Example: d = 6 in. (152 mm) piston diameter of the

press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.

446 of 1030
HYDRAULIC MOTOR (TWO-SPEED) (CONT'D)
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.-lb. (14-16 N•m) torque.

447 of 1030

448 of 1030
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 -5.)
Remove the six mounting bolts (Item 1) [Figure 30-22-1]

from the carrier.
Installation: Tighten the mounting bolts to 330 ft.-lb.

(447 N•m) torque.
Slide the motor carrier toward the rear and remove the
rear drive chain.
Figure 30-22-2
WARNING
support device can allow the lift arms or attachment 1
W-2059-0598

Figure 30-22-1
P5467
Lift and block the loader. (See LIFTING AND BLOCKING P5489
Raise the lift arm and install an approved lift arm support NOTE: For easier access for the motor carrier
device. (See Installing The Lift Arm Support Device on coming out and going into the chaincase, tie
Page 10-20-1.) the front drive chain to the chaincase with a
wire [Figure 30-22-2].
on Page 10-30-1) Slide the motor carrier out of the chaincase far enough to
install a chain and chain hoist to the carrier [Figure 30-
Remove the fluid from the chaincase. (See FINAL DRIVE 22-2].
TRANSMISSION (CHAINCASE) on Page 10-130-1.)
Remove the case drain filter (Item 1) [Figure 30-22-2]
Remove the front axle. (See DRIVE COMPONENTS on from the hydraulic reservoir.
Page 40-20-1.)

449 of 1030
HYDROSTATIC MOTOR CARRIER (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].

450 of 1030
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

451 of 1030
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].

452 of 1030
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.

453 of 1030
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.

454 of 1030
HYDROSTATIC MOTOR CARRIER (SELECTABLE Figure 30-23-2
JOYSTICK CONTROL) (SJC)
Figure 30-23-1
1
1
P5467

Raise the lift arm and install an approved lift arm support
Page 10-20-1.)

on Page 10-30-1.)
P5489
Remove the fluid from the chaincase. (See FINAL DRIVE
TRANSMISSION (CHAINCASE) on Page 10-130-1.)
Slide the motor carrier toward the rear and remove the
Remove the front axle. (See DRIVE COMPONENTS on rear drive chain.
Page 40-20-1.)
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 LIFT ARM the front drive chain to the chaincase with a
BY-PASS CONTROL VALVE on Page 20-50-1.) and wire [Figure 30-23-2].
remove the hydraulic control valve. (See HYDRAULIC
CONTROL VALVE (ADVANCED CONTROL SYSTEM) Slide the motor carrier out of the chaincase far enough to
(ACS) on Page -1.) install a chain and chain hoist to the carrier [Figure 30-
23-2].
Remove the six mounting bolts (Item 1) [Figure 30-23-1]
from the carrier. NOTE: When installing the motor carrier into the
loader, use caution to protect the wheel speed
Installation: Tighten the mounting bolts to 330 ft.-lb. washer from damage.
(447 N•m) torque.

455 of 1030
HYDROSTATIC MOTOR CARRIER (SELECTABLE
1 2 3 4 6
5
4
3 7

PE-1395A
Ref. Description
1. Snap Ring
2. Spacer
3. Bearing
4. Race
5. Seal
6. Housing
7. Speed Washer
8. Shaft

456 of 1030
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].

457 of 1030
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.

458 of 1030
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.

459 of 1030
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.

460 of 1030
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.

461 of 1030

462 of 1030
CHARGE PRESSURE
Sender Removal And Installation
Figure 30-30-1
P-34263
Disconnect the charge pressure sender wiring harness

(Item 1) [Figure 30-30-1].

Figure 30-30-2
P-34264
Disconect the charge pressure hose (Item 1) [Figure 30-

30-2] from the sending unit.
Disconnect the fitting (Item 2) [Figure 30-30-2] from the

control valve and remove the charge pressure sender
from the loader.

463 of 1030

464 of 1030
HYDROSTATIC PUMP (S250 S/N 521313912 & Check the O-rings (Items 1 & 2) [Figure 30-40-2] for
BELOW) (S300 S/N 521512099 & BELOW) damage and replace as needed.
NOTE: This hydrostatic pump is internally charged, If the high pressure relief valve must be replaced, it must
by a charge pump section inside of the pump. be replaced as a complete unit.
This hydrostatic pump has attached gear
pumps (Bobcat P/N 6678224, 6681596) The pressure setting for a new high pressure relief valve
(Vendor P/N 163D1185, 163D1301) (Bobcat P/ is 5000 PSI (34475 kPa).
N 6680295, 6681600) (Vendor P/N 163D1275,
163D1304) Charge Pressure Relief Valve
Replenishing/High Pressure Relief Valve Figure 30-40-3
Figure 30-40-1
1

N-17230
N-17227
Loosen the charge relief valve plug (Item 1) [Figure 30-
40-3].
There are four replenishing/high pressure relief valves
(Item 1) [Figure 30-40-1] in the hydrostatic pump. Two Figure 30-40-4
are located at the top of the pump and two at the bottom
of the pump.
See Replenishing Valve Function on Page 30-10-2 for

valve function.
Figure 30-40-2
N-17231
2 Remove the plug, spring and poppet [Figure 30-40-4].
N-17228
Remove the high pressure relief valve from the pump

[Figure 30-40-2].

465 of 1030
HYDROSTATIC PUMP (S250 S/N 521313912 & Figure 30-40-7
BELOW) (S300 S/N 521512099 & BELOW) (CONT'D)
Charge Pressure Relief Valve (Cont’d)
Figure 30-40-5 2
P-37270
Loosen the stop mounting bolt (Item 1) [Figure 30-40-7].
N-17232 Loosen the spring tension bolt (Item 2) [Figure 30-40-7].
Remove the drive belt.

There are several different thickness of the shims (Item
1) [Figure 30-40-5] and they are used to adjust the

Figure 30-40-8
charge pressure.
The charge pressure should be set at 390-430 PSI

(2688-2964 kPa).
Figure 30-40-6
1
1
N-15339
2
Remove the nut and washer (Item 1) [Figure 30-40-8]

from the hydrostatic pump drive shaft.
1
Installation: Tighten the nut to 175-200 ft.-lb. (237-271
N•m) torque.
N-15337
Remove the hydrostatic pump/engine assembly from the

loader. (See Hydraulic Pump Removal on Page 30-40-8.)
Remove the belt shield clips (Item 1) [Figure 30-40-6]

and belt shield (Item 2) [Figure 30-40-6].

466 of 1030
Figure 30-40-9
P-37274

1 10] and nuts (Item 1) [Figure 30-40-11].
N-15340
Installation: Tighten the mounting bolts and nuts to 65-
70 ft.-lb. (88-95 N•m) torque. Make sure the key (Item 2)
Install the nut on the end of the pump drive shaft (without [Figure 30-40-10] is installed.
washer).

Figure 30-40-12
Use a puller (Item 1) [Figure 30-40-9] to remove the
pulley from the pump drive shaft.
Figure 30-40-10
P-37273
1
Remove the mounting bolt (Item 1) [Figure 30-40-12] at

P5658 the hydraulic pump end of the pump.
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.

467 of 1030
HYDROSTATIC PUMP (S250 S/N 521313912 &
Parts Identification (Right Half)
8 3 5
7
6 4
2
9
1
13
14
10 15
12
11
19

21
16
23 18 17
25 20
27
29 22
24
26
28
38
30 33
36
34
32
31
37
35
45
43 42
44
39 46
47
40 48
49
41
D-2427

468 of 1030
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. Swashplate
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
21. Washer 46. Bearing

22. Block 47. O-ring
23. Retainer 48 Plate
24. Pin 49. Bolt
25. Washer

469 of 1030
Parts Identification (Left Half)
4
17
16 6
11 8
14 13 1
2
12 10 3
5
7
15 9
22
23

18
19 21
26
24
20 28
30
32 25
23
34 27
36 29
38 31 47
46
33 45
35 44
37 52 43
48
39 42
49 67
51 40
50
53
41
54
58 5655 65
60
61
64
55 54
66
57
59 63
62
D-2377

470 of 1030
Parts Identification (Left Half) (Cont'd)
1. Snap Ring 35. Spring

2. Washer 36. Washer
3. Seal 37. Washer
4. Snap Ring 38. Valve Plate
5. Snap Ring 39. Pin
6. Bearing 40. Gasket
7. Snap Ring 41. Bearing
8. Key 42. Plug
9. Shaft 43. Poppet
10. Housing 44. Spring
11. Plug 45. Shim
13. Bearing 47. Plug
14. Seal 48 Plug
16. Cover 50. O-ring
17. Bolt 51. O-ring
18. Pin 52. Relief Valve
19. O-ring 53. Plug
20. Plug 54. Pin
21. Bearing 55. O-ring

22. O-ring 56. Pin
23. Plate 57. Gerotor
24. Bolt 58. Spacer
25. Swash Plate 59. O-ring
26. Wear Plate 60. O-ring
27. Piston Assembly 61. Pin
28. Piston Retainer 62. Coupler
29. Retainer 63. Bolt
30. Washer 64. O-ring
31. Pin 65. O-ring
32. Retainer 66. Relief Valve
33. Block 67. O-ring
34. Washer

471 of 1030
HYDROSTATIC PUMP (S250 S/N 521313912 & Disassembly
Figure 30-40-15
Hydraulic Pump Removal
Figure 30-40-13
1
2
1
N-17230
2
N-17226 Figure 30-40-16
Remove the standard flow hydraulic pump (Item 1)

[Figure 30-40-13] from the hydrostatic pumps, by 1

removing the two mounting bolts (Item 2) [Figure 30-40-
13].
Figure 30-40-14
N-17233

15] & [Figure 30-40-16].
1
2
N-17229
Remove the O-ring (Item 1) [Figure 30-40-14] and

coupler (Item 2) [Figure 30-40-14] with the hydraulic
pump.

472 of 1030
Figure 30-40-17
N-17236
Figure 30-40-20
N-17234
Separate the two hydrostatic pumps [Figure 30-40-17].

Figure 30-40-18
2
2
N-17237
1
Remove the gerotor assembly (Item 1) [Figure 30-40-19]
& [Figure 30-40-20] from the charge pump.
N-17235
Charge Pump Disassembly
Remove the two O-rings (Item 1) [Figure 30-40-18] from

the groves in the gerotor spacer on the charge pump.

charge pump housing end cap.

473 of 1030
Charge Pump Disassembly (Cont’d) 1
Figure 30-40-21
1 2
3
3 N-17191
Mark the charge pump (Item 1) [Figure 30-40-23] case

and the pump case (Item 2) [Figure 30-40-23] for proper
installation.
4
N-17185 Mark the trunnion cover (Item 3) [Figure 30-40-23] and
pump case for proper installation.

Inspect the gerotor spacer (Item 1) [Figure 30-40-21] the Figure 30-40-24
gerotor assembly (Item 2) [Figure 30-40-21], drive
coupling (Item 3) [Figure 30-40-21] and drive pin (Item 4)
[Figure 30-40-21] for wear and replace as needed.
Figure 30-40-22
2
1
2 N-17192
2
Remove the charge pump (Item 1) [Figure 30-40-24]

from the hydrostatic shaft end pump.
N-17186
Remove the locating pin (Item 1) [Figure 30-40-22] from

the pump end cap.
NOTE: The charge pump rotation is determined by

the position of the gerotor spacer and
locating pin (Item 1) [Figure 30-40-22] in the
pump end cap, and must be noted for proper
installation.

22] from the charge pump.

474 of 1030
Figure 30-40-25
N-17197
1
Remove the rotating group (Item 1) [Figure 30-40-27]
from the pump.
N-17193
Figure 30-40-28
Check the valve plate (Item 1) [Figure 30-40-25] for wear

and remove from charge pump.

Figure 30-40-26
1
2
N-17198
2
Remove the slipper guide and pistons (Item 1) [Figure
30-40-28] from the cylinder block.
N-17194
Check the pistons (Item 2) [Figure 30-40-28] for wear
Check the valve plate locating pin (Item 1) [Figure 30-40-
26] for wear and replace if needed.
Check the needle bearing (Item 2) [Figure 30-40-26] for

wear and replace if needed.

475 of 1030
Figure 30-40-29
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-31] from

the pump housing.
N-17199
Figure 30-40-32
Remove the ball guide retainer (Item 1) [Figure 30-40-

29] from the cylinder block.

Figure 30-40-30
3
3 1
2
1
3 2
3
3
N-17481
Remove the driveshaft key (Item 1) [Figure 30-40-32]

the snap ring (Item 2) [Figure 30-40-32] and the support
N-17200 washer (Item 3) [Figure 30-40-32] from the drive shaft
end of the pump.
Check the ball guide retainer (Item 1) [Figure 30-40-30]

and washer (Item 2) [Figure 30-40-30] for wear and
replace as needed.
Remove the four slipper holddown pins (Item 3) [Figure

Check the cylinder block for wear and replace as needed.

476 of 1030
Figure 30-40-33
N-17241
1
Remove the snap ring (Item 1) [Figure 30-40-35] from
the driveshaft and remove the bearing.
N-17239
Figure 30-40-36
Use a seal puller and remove the seal (Item 1) [Figure

30-40-33] from the pump housing.

Figure 30-40-34
N-17242
Check the bearing for wear and replace if worn.

1
N-17240 Check the pump shaft (Item 1) [Figure 30-40-36] for

the pump housing and remove the driveshaft and bearing
from the housing.

477 of 1030
Figure 30-40-37
N-17245
1 1 Check the bearing race (Item 1) [Figure 30-40-39] and

O-ring (Item 2) [Figure 30-40-39] for wear and replace
N-17243 as needed.
Figure 30-40-40
Remove the four mount bolts (Item 1) [Figure 30-40-37]
from the lower trunnion cover. Remove the cover.

Figure 30-40-38
2
2
1
1
1
N-17246

N-17244 from the pump housing and remove the steering bracket
(Item 2) [Figure 30-40-40].

bearing race (Item 2) [Figure 30-40-38] from the pump
housing.

478 of 1030
Figure 30-40-41
2
1
N-17248
1
N-17247 housing.
Figure 30-40-44
Remove the upper trunnion cover (Item 1) [Figure 30-40-
41].

Figure 30-40-42
N-17249
1
Inspect the bearing race (Item 1) [Figure 30-40-44] and

N-17250 O-ring (Item 2) [Figure 30-40-44] and replace as
needed.
Inspect the seal (Item 1) [Figure 30-40-42] in the upper

trunnion cover and replace if needed.

479 of 1030
HYDROSTATIC PUMP (S250 S/N 521313912 & Assembly
Figure 30-40-47
Figure 30-40-45 1
1
N-17253
N-17251 Install the lower bearing (Item 1) [Figure 30-40-47] on

the swashplate.
Slide the swashplate from side to side and remove the Figure 30-40-48
tapered roller bearing (Item 1) [Figure 30-40-45] from

the swashplate shaft.
Figure 30-40-46
N-17252
Install the swashplate and bearing into the pump housing

N-17252 [Figure 30-40-48].
Tilt the swashplate (Item 1) [Figure 30-40-46] and

remove the swashplate and lower bearing from the pump
housing.

480 of 1030
Assembly (Cont'd)
Figure 30-40-49
1
1
2 N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-51]

3 and cover.
N-17249
Figure 30-40-52
Figure 30-40-50

1
N-17246
N-17248
Install the steering bracket (Item 1) [Figure 30-40-52]
and the four mounting bolts and tighten to 18-22 ft.-lb.
Install the tapered bearing (Item 1) [Figure 30-40-49] on (24-30 N•m) torque.
Install the bearing race (Item 2) [Figure 30-40-49] and O-

ring (Item 3) [Figure 30-40-49] as shown in [Figure 30-
40-50].

481 of 1030
Assembly (Cont'd)
Figure 30-40-53
N-17243
2
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-40-55].
N-17245
Install the four mounting bolts and tighten to 18-22 ft.-lb.
Figure 30-40-54

Figure 30-40-56
N-17244 1
N-17242

ring (Item 2) [Figure 30-40-53] at the lower trunnion as Install the snap ring (Item 1) [Figure 30-40-56] on the
shown in [Figure 30-40-54]. pump shaft.

482 of 1030
1
Assembly (Cont'd) 1
Figure 30-40-57
1 3
2
1
N-17200
1
Install the four slipper pins (Item 1) [Figure 30-40-59]

into the cylinder block.
N-17241
Apply a small amount of grease to the washer (Item 2)
[Figure 30-40-59] and install into the ball guide retainer
Install the bearing and snap ring (Item 1) [Figure 30-40- (Item 3) [Figure 30-40-59].
57] on the pump shaft.

Figure 30-40-60
Figure 30-40-58
1
N-17199
N-17240
Install the ball guide retainer and washer (Item 1) [Figure

Install the pump shaft into the pump housing [Figure 30- 30-40-60] onto the slipper holddown pins.
40-58].
Install the snap ring (Item 1) [Figure 30-40-58].

483 of 1030
Assembly (Cont'd)
Figure 30-40-61
2
1
N-17194
Replace the needle bearing (Item 1) [Figure 30-40-63]

and valve plate locating pin (Item 2) [Figure 30-40-63] in
N-17198 the charge pump.
Figure 30-40-64
Assemble the piston assemblies into the slipper guide
[Figure 30-40-61]. Lubricate the pistons and cylinder

block bores and insert the piston assemblies into the
cylinder bores [Figure 30-40-61].
Figure 30-40-62
2
1
N-17196
1 The bearing cage (Item 1) [Figure 30-40-64] will

protrude from 0.08-0.10 inch (2,0-2,5 mm) from the
surface of the charge pump.
N-17197
The valve plate locating spring pin (Item 2) [Figure 30-
40-64] will protrude from 1.65-0.185 inch (4,19-4,70 mm)
Lay the pump housing on its side and install the cylinder from the surface of the charge pump.
block, piston assembly (Item 1) [Figure 30-40-62] into
the housing.
Place the pump on a work surface with the end cap

opening up [Figure 30-40-62].

484 of 1030
Assembly (Cont'd)
Figure 30-40-65
N-17191
Align the marks on the charge pump with the pump

housing and install the charge pump [Figure 30-40-67].
N-17193
When the charge pump is properly installed, the cylinder
block spring will hold the charge pump end cap away
Coat the backside of the valve plate with petroleum jelly from the housing approximately .125 inch (3 mm).
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-40-65]. Figure 30-40-68
The notch (Item 1) [Figure 30-40-65] on the valve plate

must engage the locating pin.
Figure 30-40-66
1
1
1
1
N-17186
1
Install the four mounting bolts (Item 1) [Figure 30-40-68]
and tighten evenly to 35-45 ft.-lb. (47-61 N•m) torque.
N-17192
Coat a new end cap gasket (Item 1) [Figure 30-40-66]

with petroleum jelly and install onto the charge pump.

485 of 1030
Assembly (Cont'd)
Figure 30-40-69 2
N-17188
Charge Pump Assembly
N-17186 Apply petroleum jelly to the gerotor drive pin (Item 1)

[Figure 30-40-71] and install the gerotor pin into the
drive coupler (Item 2) [Figure 30-40-71].
Install the locating pin (Item 1) [Figure 30-40-69] in the
pump end cap.

NOTE: The gerotor drive coupler (Item 2) [Figure 30-
40-71] must be installed with the longer
NOTE: The charge pump rotation is determined by portion down toward the rear of the pump.
the position of the gerotor space and locating
pin (Item 1) [Figure 30-40-69] in the pump end Figure 30-40-72
cap.
Prior to assembly, lubricate the gerotor assembly with 2

clean hydraulic oil.
Figure 30-40-70
1
1
N-17189
Install the coupler and drive pin into the gerotor, be sure
the pin engages the gerotor slot (Item 1) [Figure 30-40-
72].
N-17187
Install the gerotor spacer (Item 2) [Figure 30-40-72] into
the pump end cap.
Install the gerotor assembly (Item 1) [Figure 30-40-70]
into the pump housing.

486 of 1030
Assembly (Cont'd)
Charge Pump Assembly (Cont’d)
Figure 30-40-73
N-17234
Charge Pump
1
Slide the two sections of the pumps together [Figure 30-
40-75].
N-17190

A spanner wrench may be used in the two holes (Item 1)
[Figure 30-40-73] to slightly rotate the gerotor spacer to
align with the locating pin.
When the spacer is properly installed the surface of the

gerotor spacer and pump face are flush [Figure 30-40-
73].
Figure 30-40-74
2
1
3
N-17235
Install the two large O-rings (Item 1) [Figure 30-40-74]

into the gerotor cap.
Install the two smaller O-rings (Item 2) [Figure 30-40-74]

in the pump housing end cap.
Install the two aligning pins into the alignment holes (Item
3) [Figure 30-40-74] in the pump.

487 of 1030
Assembly (Cont'd)
Charge Pump (Cont’d)
Figure 30-40-76
N-17233

Figure 30-40-77
N-17230
Install the four mounting bolts (Item 1) [Figure 30-40-76]

& [Figure 30-40-77] and tighten to 35-45 ft.-lb. (47-61
N•m) torque.
Check for proper internal assembly by slowly rotating the

pump shaft while tightening the mount bolts.

488 of 1030
ABOVE) (S300 S/N 521512100 & ABOVE)
NOTE: This hydrostatic pump is externally charged,

from a section of the attached gear pumps.
(Bobcat P/N 6683236) (Vendor P/N 163D1298).

1
Figure 30-41-1
N-15339
Remove the nut and washer (Item 1) [Figure 30-41-3]

2 from the hydrostatic pump drive shaft.
Installation: Tighten the nut to 175-200 ft.-lb. (237-271

N•m) torque.
1

N-15337
Remove the hydrostatic pump/engine assembly from the

loader. (See Hydraulic Pump Removal And Installation
on Page 30-41-8.)
Remove the belt shield clips (Item 1) [Figure 30-41-1]

and belt shield (Item 2) [Figure 30-41-1].
Figure 30-41-2
P-37270
Loosen the spring tension bolt (Item 2) [Figure 30-41-2].
Remove the drive belt.

489 of 1030
ABOVE) (S300 S/N 521512100 & ABOVE) (CONT'D)
Figure 30-41-4
P-37274

1 5] and nuts (Item 1) [Figure 30-41-6].
N-15340
Install the nut on the end of the pump drive shaft (without [Figure 30-41-5] is installed.
washer).

Figure 30-41-7
Figure 30-41-5
P-37273
1

P5658 the hydraulic pump end of the pump.


490 of 1030
HYDROSTATIC PUMP (S250 S/N 521313913 & Check for damage and replace as needed.
Check the o-rings (Item 2 & 3) [Figure 30-41-9] for
Replenishing/High Pressure Relief Valve damage and replace as needed.
Figure 30-41-8 If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
1 The pressure setting for a new high pressure relief valve

is 5000 PSI (34475 kPa).
N-19565
There are four replenishing/high pressure relief valves

(Item 1) [Figure 30-41-8] 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 for

valve function.)
NOTE: The two top valves are for the forward drive
loop and the two bottom valves are for the
reverse drive loop.
Figure 30-41-9
N-19566
Remove the high pressure relief valve (Items 1) [Figure

30-41-9] from the pump.
Assemble: Tighten the plug to 30-50 ft.-lb. (41-68 N•m)

torque.

491 of 1030
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

492 of 1030
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

493 of 1030
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

494 of 1030
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

495 of 1030
HYDROSTATIC PUMP (S250 S/N 521313913 & Pump Separation
Figure 30-41-12
Hydraulic Pump Removal And Installation
Figure 30-41-10 1
1 1
N-19569
P-39279 Remove the four mounting bolts (Item 1) [Figure 30-41-

12].
Remove the two pump mounting bolts (Item 1) [Figure Figure 30-41-13
30-41-10] (both sides).

Remove the hydraulic pump (Item 2) [Figure 30-41-10]

from the hydrostatic pumps.
Figure 30-41-11
2 N-19570
1
N-21969

coupler (Item 2) [Figure 30-41-11] with the hydraulic
pump.

496 of 1030
Pump Separation (Cont’d)
Figure 30-41-14
1
3
1 N-19551
2 3
Remove the pump housing end cap (Item 1) [Figure 30-
41-16].
N-19571
Remove the gasket (Item 2) [Figure 30-41-16].
Remove the pump coupler (Item 1) [Figure 30-41-14]. Figure 30-41-17

Remove the large O-ring (Item 2) [Figure 30-41-14].
1
Remove the two small O-rings (Item 3) [Figure 30-41-
14].
Disassembly
Figure 30-41-15
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-41-17].
Check the valve plate for wear. (Both Sides.)
N-19550
Remove the four bolts (Item 1) [Figure 30-41-15] from

the pump housing end cap.

497 of 1030
Disassembly (Cont’d) 1
Figure 30-41-18
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194
Check all the pistons (Item 2) [Figure 30-41-20] for wear
and replace the rotating group as needed.
Check the valve plate locating pin (Item 1) [Figure 30-41-
18] for wear and replace if needed.

Figure 30-41-21
Check the needle bearing (Item 2) [Figure 30-41-18] for

1
Figure 30-41-19
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-41-

21] from the cylinder block.
N-17197
Remove the rotating group (Item 1) [Figure 30-41-19]

from the pump.

498 of 1030
Figure 30-41-22
1
3 3 2
2 1
3 3
3
N-17481
Remove the driveshaft key (Item 1) [Figure 30-41-24]

the snap ring (Item 2) [Figure 30-41-24] and the support
N-17200 washer (Item 3) [Figure 30-41-24] from the drive shaft
end of the pump.
Check the ball guide retainer (Item 1) [Figure 30-41-22] Figure 30-41-25
and washer (Item 2) [Figure 30-41-22] for wear and

replace as needed.
Remove the four pins (Item 3) [Figure 30-41-22] from the

1
cylinder block.
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-41-22] to see if they are

all the same length.
Figure 30-41-23
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-41-25] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-41-23] from

the pump housing.

499 of 1030
1
Figure 30-41-26
1 N-17242
Check the pump shaft (Item 1) [Figure 30-41-28] for

N-17240
Figure 30-41-29

the pump housing and remove the driveshaft and bearing

from the housing.
Figure 30-41-27
1 1
N-17243
1
from the lower trunnion cover. Remove the cover.
N-17241

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

500 of 1030
Figure 30-41-30
2
1
1
N-17246
1

from the pump housing and remove the linkage bracket
N-17244 (Item 2) [Figure 30-41-32].
Figure 30-41-33

housing.
Figure 30-41-31
1
1
N-17247
2
Remove the upper trunnion cover (Item 1) [Figure 30-41-

33].
N-17245
Check the bearing race (Item 1) [Figure 30-41-31] and

O-ring (Item 2) [Figure 30-41-31] for wear and replace
as needed.

501 of 1030
Figure 30-41-34
N-17249
1
Inspect the bearing race (Item 1) [Figure 30-41-36] and

O-ring (Item 2) [Figure 30-41-36] and replace as
N-17250 needed.
Figure 30-41-37
Inspect the seal (Item 1) [Figure 30-41-34] in the upper
trunnion cover and replace if needed.

Figure 30-41-35
1 N-17251
2
Slide the swashplate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-41-37] from

housing.

502 of 1030
Figure 30-41-38
N-17252
Install the swashplate and bearing into the pump housing

[Figure 30-41-40].
N-17252
Figure 30-41-41
Tilt the swashplate (Item 1) [Figure 30-41-38] and

remove the swashplate and lower bearing from the pump

housing.
Assembly
Figure 30-41-39 1
2
1
N-17249
Install the tapered bearing (Item 1) [Figure 30-41-41] on

N-17253
Install the lower bearing (Item 1) [Figure 30-41-39] on

the swashplate.

503 of 1030
Assembly (Cont’d)
Figure 30-41-42
N-17246
Install the linkage bracket (Item 1) [Figure 30-41-44] and

the four mounting bolts and tighten to 18-22 ft.-lb. (24-30
N-17248 N•m) torque.

ring (Item 3) [Figure 30-41-41] as shown in [Figure 30-

41-42].
Figure 30-41-43
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-41-43]

and cover.

504 of 1030
Assembly (Cont’d)
Figure 30-41-45
2 N-17243
Align the marks on the lower trunnion cover and pump

housing as shown in [Figure 30-41-47].
N-17245
Install the four mounting bolts and tighten to 18-22 ft.-lb.
Figure 30-41-46

Figure 30-41-48
N-17244
N-17242

ring (Item 2) [Figure 30-41-45] at the lower trunnion as Install the snap ring (Item 1) [Figure 30-41-48] on the
shown in [Figure 30-41-46]. pump shaft.

505 of 1030
Assembly (Cont’d) 1
1
Figure 30-41-49
1
1 2 3
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-41-51]

into the cylinder block.
N-17241
Apply a small amount of grease to the washer (Item 2)
[Figure 30-41-51] and install into the ball guide retainer
Install the bearing and snap ring (Item 1) [Figure 30-41- (Item 3) [Figure 30-41-51].
49] on the pump shaft.

Figure 30-41-52
Figure 30-41-50
1
N-17199
N-17240
Install the ball guide retainer and washer (Item 1) [Figure

Install the pump shaft into the pump housing [Figure 30- 30-41-52] onto the slipper holddown pins.
41-50].
Install the snap ring (Item 1) [Figure 30-41-50].

506 of 1030
Assembly (Cont’d) 1
2
Figure 30-41-53
N-17194
Replace the needle bearing (Item 1) [Figure 30-41-55]

and valve plate locating pin (Item 2) [Figure 30-41-55] in
N-17198 the charge pump.
Figure 30-41-56
Assemble the piston assemblies into the slipper guide
[Figure 30-41-53]. Lubricate the pistons and cylinder

block bores and insert the piston assemblies into the
cylinder bores [Figure 30-41-53].
Lay the pump housing on its side and install the cylinder 2
block, piston assembly into the housing. 1
Figure 30-41-54
N-17196
The bearing cage (Item 1) [Figure 30-41-56] 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-

41-56] will protrude from .165-0.185 inch (4,19-4,70 mm)
N-17197 from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-41-54].

507 of 1030
Assembly (Cont’d) 1 1
Figure 30-41-57
N-19550
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-41-59] to 35-45 ft.-
N-17193 lb. (47-61 N•m) torque.
Figure 30-41-60
Coat the backside of the valve plate with petroleum jelly
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-41-57].
The notch (Item 1) [Figure 30-41-57] on the valve plate

must engage the locating pin.
1
Figure 30-41-58
3
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-41-60].
Install the large new O-ring (Item 2) [Figure 30-41-60].
Install the pump coupler (Item 3) [Figure 30-41-60].

N-19551
Coat a new end cap gasket (Item 1) [Figure 30-41-58]

with petroleum jelly and install onto the end cap.

508 of 1030
Assembly (Cont’d)
Figure 30-41-61
N-19570
Install the two pumps together [Figure 30-41-61].

Figure 30-41-62
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-41-62] to 35-45

ft.-lb. (47-61 N•m) torque.

509 of 1030

510 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK Disconnect the electrical connectors (Item 1) [Figure 30-
CONTROL) (SJC) 42-2] from the loader harness.
NOTE: This hydrostatic pump is internally charged, Figure 30-42-3

by a charge pump section inside of the pump.
This hydrostatic pump has attached gear
pumps (Bobcat P/N 6684386) (Vendor P/N
163D1357) (Bobcat P/N 6684387) (Vendor P/N
163D1358)
Pump Controller Removal And Installation
Figure 30-42-1
1
P-26465
Remove the control spool plug (Item 1) [Figure 30-42-3]

at the front side of the pump.

Figure 30-42-4
P-26463
Raise the lift arms and install and approved lift arm
support device. (See Installing The Lift Arm Support
Device on Page 10-20-1.)
1
Place the loader on jackstands. (See TRANSPORTING
THE BOBCAT LOADER on Page 10-40-1.)

on Page 10-30-1.)
Locate the two pump controllers (Item 1) [Figure 30-42-

1] on the hydrostatic pumps. P-26469
Figure 30-42-2
Do Not remove the spring (Item 1) [Figure 30-42-4],as it
is attached to the control spool.
P-26464

511 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK Figure 30-42-7
Pump Controller Removal And Installation (Cont'd)
Figure 30-42-5
1 1
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 30-42-7].
Be sure the pump surface is clean.

Remove the seven mount bolts (Item 1) [Figure 30-42-5]
from the pump controller.

Figure 30-42-8
Remove the controller from the pump.
Remove the controller gasket from the pump.

2 1
Figure 30-42-6
P-26473
Align the summing link pin (Item 1) [Figure 30-42-8] on

the pump with the bore (Item 2) [Figure 30-42-8] in the
pump controller module.
P-26471
Installation:
Be sure the summing link pin (Item 1) [Figure 30-42-6] is

in the center.

512 of 1030
Pump Controller Removal And Installation (Cont'd)
Figure 30-42-9
1 1
1 1
P-26469
Be sure the spring (Item 1) [Figure 30-42-11] is properly

attached to the control spool.
P-26465
Figure 30-42-12
Install the pump controller on the hydrostatic pump.

Align the bolt holes.
2
Install the seven mount bolts, (Item 1) [Figure 30-42-9]
and tighten to 11-13 ft.-lb. (15-17.5 N•m) torque. 1
Figure 30-42-10
7
4
3
P-26465
1 (8)
2 Install the control spool bore plug (Item 1) [Figure 30-42-
12] in the pump and tighten to 30-70 ft.-lb. (41-94 N•m)
torque.
5 Connect the electrical connectors (Item 2) [Figure 30-42-

6 12] to the loader harness.
P-30692
NOTE: When a pump controller is replaced the
hydrostatic pumps must be calibrated. (See
Tighten the controller mounting bolts to 11-13 ft.-lb. (15- Hydrostatic Pump Calibration on Page 30-40-
17.5 N•m) torque using the tightening pattern [Figure 30- 4 for the proper procedure.)
42-10]

513 of 1030
Hydrostatic Pump Calibration
WARNING
W-2017-0286
Place the loader on jackstands. (See TRANSPORTING P-26480

Operator must be in the seat and the seat bar down.
Turn the key (Item 1) [Figure 30-42-14] to the RUN
Figure 30-42-13
position or press the RUN/ENTER button (Item 1)
[Figure 30-42-15] for power, without starting the loader.
The Control Pattern ISO Switch (Item 1) [Figure 30-42-

13] will start flashing.

1
Figure 30-42-16
P-45238
Close the cab door. (If loader is so equipped.)

Place the loader Control Pattern Switch (Item 1) [Figure
30-42-13] in the ISO position.
Verify the parking brake (Item 2) [Figure 30-42-13] is
OFF. P-26476
Figure 30-42-14
Move the left joystick to the forward position and toward
the side screen [Figure 30-42-16] and hold in position.
P-26475

514 of 1030
Hydrostatic Pump Calibration (Cont'd)
Figure 30-42-17
2 38-05
3
P-26476
1 Move the left joystick to the reverse position and toward

the operator [Figure 30-42-19] and hold in position.
P-26477A
Figure 30-42-20
Press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 30-42-17].

Three audible beeps will sound and an error code (Item 38-05
2) [Figure 30-42-17] (38-05 & 38-07) will be displayed if
the operator presses the PRESS FOR CODES,
(LIGHTS) switch (Item 3) [Figure 30-42-17].
The Control Pattern ISO Switch (Item 1) [Figure 30-42-

13] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Figure 30-42-18 1
P-26477A

1 1) [Figure 30-42-20].
P-26479
The warning light (Item 1) [Figure 30-42-18] on the right

console will be ON.

515 of 1030
Figure 30-42-21 2 38-98
3
1
P-26477A

1) [Figure 30-42-23].
P-26479
Three audible beeps will sound and the error code (Item
2) [Figure 30-42-23] (38-98) will be displayed if the
The warning light (Item 1) [Figure 30-42-21] on the right operator presses the PRESS FOR CODES (LIGHTS)
console will continue to be ON.

switch (Item 3) [Figure 30-42-23].
Figure 30-42-22 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.
P-26474
Allow the left joystick to go to the neutral position [Figure

30-42-22].

516 of 1030
Figure 30-42-24
P-26482
Move and hold the left joystick to the forward position

[Figure 30-42-25] until the forward calibration is
P-34548 completed.
The pump controller will start increasing the electrical

Move the throttle (Item 1) [Figure 30-42-24] 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 must calibration is complete.
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
operator must shut the loader OFF, and start
WARNING the calibration procedure from the beginning.

W-2017-0286

517 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK Move the joystick to the reverse position [Figure 30-42-
CONTROL) (SJC) (CONT'D) 26] and check for normal reverse wheel rotation.
Hydrostatic Pump Calibration (Cont'd) Stop the engine, and remove the loader from jackstands.
Figure 30-42-26 Start the loader, press the PRESS TO OPERATE

LOADER button and return to normal loader operation.
Figure 30-42-27
P-26483
2
Move and hold the left joystick to the reverse position

[Figure 30-42-26] until the reverse calibration is

1
completed.
N-15337
The pump controller will start increasing the electrical

current to the hydrostatic pumps until it sees a pulse from Remove the hydrostatic pump/engine assembly from the
the wheel speed sensors. loader. (See Hydraulic Pump Removal on Page 30-40-8.)
The loader wheels will rotate a short distance in reverse Remove the belt shield clips (Item 1) [Figure 30-42-27]
each time it sees a pulse. and belt shield (Item 2) [Figure 30-42-27].
The four wheels will then go to Full Speed Reverse. Figure 30-42-28
Continue holding the joystick in the reverse position until
the wheels stop and there is an audible beep. Reverse
calibration is complete.
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. 2 1
There will be an audible beep and the PRESS TO 3

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.
P-37270
Allow the joystick to go to the neutral position.
The calibration procedure is completed. Loosen the stop mounting bolt (Item 1) [Figure 30-42-
28].
Press the PRESS TO OPERATE LOADER button. Move
the joystick to forward position [Figure 30-42-25] and Loosen the spring tension bolt (Item 2) [Figure 30-42-
check for normal forward wheel rotation. 28].
Remove the drive belt (Item 3) [Figure 30-42-28].

518 of 1030

2
Figure 30-42-29
1
P5658
Figure 30-42-32
N-15339
Remove the washer and nut (Item 1) [Figure 30-42-29]

from the hydrostatic pump drive shaft.

Installation: Tighten the nut to 175-200 ft.-lb. (237-271 1
N•m) torque
Figure 30-42-30
P-28072

31] and nuts (Item 1) [Figure 30-42-32].

[Figure 30-42-31] is installed.
1
N-15340
Install the nut on the end of the pump drive shaft (without
washer).


519 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK
Figure 30-42-33
P-28073

the hydraulic pump end of the pump.


520 of 1030
2 5 1
23
24 25
26
20 21 27
19 28 21
22 29 20
18
17 19
14 30 18 17
13 16 33
4 23 16 33
15 31

6 29 34 34
7
8 32
35 36
9
3
39
37
10
11 38
12 66 42 43 41 40
68 46
70 65 44 45 48
67 47 49
52
69 51
64 63 64
5
43 63 50 55
15
14 53
72 54
71 73 56
32
75 74
76 31
28
73 27
77 57
26
25 78
23 25 58
60 61 34
24
62 33
59
60
B-16054A

521 of 1030
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
14. Plug 53. Cover
15. O-ring 54. Screw
17. Valve 56. Gear Pump
18. O-ring 57. Spool
19. Washer 58. Spring
20. O-ring 59. Bracket
21. Valve 60. Screw

22. Nut 61. Screw
23. O-ring 62. Nut
24. Plug 63. Plug
25. Screw 64. Pin
26. Cover 65. Filter
27. Gasket 66. Poppet
28. Ring 67. Spring
30. Servo 69. Adjuster
31. Plug 70. Nut
32. O-ring 71. Rotating Piece
33. Plug 72. Valve Plate
34. O-ring 73. Bearing
35. Screw 74. Cam
36. Screw 75. Bearing
37. Control 76. Swash plate
38. Gasket 77. Gasket
39. Screw 78. Cover

522 of 1030
5
2
1
23
22
25
26
19 23 27
18 28 21
29 20
17 22
19
16 18 17
14 30
13 23 33
4 16
29 34 33
6 31

15 34
7 32
8
56 35 36
9
3
39 38
10
11
4140 38
12 66 42 43 46
68
70 44 45 47 48
65 49
67
69 51 52
63 64
64
43 50 55
63
15
14
72 53
54
71
73 32
7574
31
76 28
73 27
57
25 77 26
78 23 25 58
60 61 34
24 59
62
33
60
B-16055A

523 of 1030
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
10. Bearing 49. Cover
14. Plug 53. Cover
15. O-ring 54. Screw
17. Valve 56. Key
18. O-ring 57. Spool
19. Washer 58. Spring
20. O-ring 59. Bracket
21. Valve 60. Screw

22. Nut 61. Screw
23. O-ring 62. Nut
24. Plug 63. Plug
25. Screw 64. Pin
26. Cover 65. Filter
27. Gasket 66. Poppet
28. Ring 67. Spring
30. Servo 69. Adjuster
31. Plug 70. Nut
32. O-ring 71. Rotating Piece
33. Plug 72. Valve Plate
34. O-ring 73. Bearing
35. Screw 74. Cam
36. Screw 75. Bearing
37. Control 76. Swash plate
38. Gasket 77. Gasket
39. Screw 78. Cover

524 of 1030
System Check Relief Valves (High Pressure Relief, 3

Charge Check & By-Pass Valve)
Figure 30-42-34
2
1
1
1
1 P-28615
Check the valve seat plug O-rings (Item 1) [Figure 30-

42-36] and back-up ring (Item 2) [Figure 30-42-36], and
replace as needed.
P-28613
Check the valve seat surface (Item 3) [Figure 30-42-36]
for scratches and replace as needed.
There are four system check relief valves (Item 1)

[Figure 30-42-34] in the hydrostatic pump. Two are Figure 30-42-37
located on the back side of each pump half.
Figure 30-42-35
1
1
P-28616
P-28614 Remove relief valve assembly (Item 1) [Figure 30-42-37]

from the pump housing.
Remove the valve seat plug (Item 1) [Figure 30-42-35] Check the conical spring (Item 2) [Figure 30-42-37] to be
from the pump. sure it is retained on the relief valve. DO NOT REMOVE.

525 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK Charge Relief Valve
Figure 30-42-40
System Check Relief Valves (High Pressure Relief,
Charge Check & By-Pass Valve) (Cont'd)
Figure 30-42-38
1 1
P-28613
There are two charge pressure relief valves (Item 1)

P-28617 [Figure 30-42-40].
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 30-42-38]. section [Figure 30-42-40].
Figure 30-42-39 Figure 30-42-41
1
2
P-28614
P-28625
Install the valve seat plug (Item 1) [Figure 30-42-39] in Mark the plug (Item 1) [Figure 30-42-41] the lock nut
the pump, and tighten to 30-70 ft.-lb. (40-95 N•m) torque. (Item 2) [Figure 30-42-41] and the housing (Item 3)
[Figure 30-42-41] for ease of assembly.
Loosen the lock nut.
Loosen the charge pressure plug, and remove the

complete assembly from the pump housing.

526 of 1030
Charge Relief Valve (Cont'd)
Figure 30-42-42 1
2
P-28627
Install the poppet (Item 1) [Figure 30-42-44] and spring

(Item 2) [Figure 30-42-44] into the pump housing.
P-28626
Figure 30-42-45
Check and replace the O-ring (Item 1) [Figure 30-42-42].

Figure 30-42-43
2
1
2
3 1
P-28625
Install the plug (Item 1) [Figure 30-42-45] and its lock nut
P-28627 (Item 2) [Figure 30-42-45], align the marks made during
disassembly. Tighten to 34-42 ft.-lb. (47-57 N•m) torque.
Inspect the poppet (Item 1) [Figure 30-42-43] and the

mating seat in the pump housing for damage or foreign
material.
Inspect the spring (Item 2) [Figure 30-42-43] and the

adjustable charge relief valve (Item 3) [Figure 30-42-43].

527 of 1030
Pump Separation 1
Figure 30-42-46
P-28640
2 1
Replace the O-ring (Item 1) [Figure 30-42-48].
P-28638
Remove the two mount bolts (Item 1) [Figure 30-42-46].

(Front and Rear.)

Remove the lifting bracket (Item 2) [Figure 30-42-46]
from the pump.
Figure 30-42-47
P-28639

528 of 1030
Shaft Seal And Shaft Replacement 1
Figure 30-42-49
P-28643

top of the bearing.
P-28641
Figure 30-42-52
Remove the snap ring (Item 1) [Figure 30-42-49].

Figure 30-42-50 1
P-28648
Using a press, remove the old seal (Item 1) [Figure 30-

P-28642 42-52] from the seal carrier.
With the pump shaft up, remove the seal carrier

assembly (Item 1) [Figure 30-42-50] using a screwdriver.

529 of 1030
Shaft Seal And Shaft Replacement (Cont'd)
Figure 30-42-53
P-28646

the shaft.
P-28644
Figure 30-42-56
Press a new seal into the shaft bearing side of the seal
carrier (Item 1) [Figure 30-42-53].

Figure 30-42-54
P-28753
Remove the roller bearing [Figure 30-42-56] 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 30-42-54].

530 of 1030
Shaft Seal And Shaft Installation
Figure 30-42-57
P-28646
Install the bearing and snap ring on the shaft [Figure 30-
42-59].
P-28752
Figure 30-42-60
Inspect the shaft [Figure 30-42-57] for wear and replace

as needed.

Figure 30-42-58
P-28645
Install the shaft and roller bearing in the pump housing

[Figure 30-42-60].
P-28754
Inspect the snap ring [Figure 30-42-58] and replace as

needed.

531 of 1030
Shaft Seal And Shaft Installation (Cont'd)
Figure 30-42-61
P-28648
Lubricate the seal (Item 1) [Figure 30-42-63] with

petroleum jelly.
P-28643
Figure 30-42-64
Install the O-ring (Item 1) [Figure 30-42-61] on top of the

shaft bearing.

2
Figure 30-42-62
1
P-28641
Slide the seal carrier (Item 1) [Figure 30-42-64]

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 30-42-64].
30-42-62].
Lubricate the O-ring with petroleum jelly [Figure 30-42-

62].

532 of 1030
Charge Pump Removal
Figure 30-42-65
P-28669
Remove the old charge pump cover gasket (Item 1)

[Figure 30-42-67].
P-28668
Figure 30-42-68
Position the pump so the auxiliary mounting pad is facing 1

up.

Mark pump housing for proper installation [Figure 30-42-
65].
Figure 30-42-66
2
1 1 P-28670
Remove the alignment pins (Item 1) [Figure 30-42-68].

1
Remove the gerotor cover (Item 2) [Figure 30-42-68].
P-28667
Remove the six auxiliary mount pad mount bolts (Item 1)

[Figure 30-42-66].
Remove the charge pump cover.

533 of 1030
Charge Pump Removal (Cont'd)
Figure 30-42-69
P-28673
Remove the inner gerotor and drive coupler (Item 1)

[Figure 30-42-71].
P-28671
Figure 30-42-72
Remove the old gerotor cover O-rings (Item 1) [Figure

30-42-69].

1
Figure 30-42-70
P-28674
1
Remove the retainer ring from the drive coupler (Item 1)

[Figure 30-42-72].
P-28672
Remove the outer gerotor assembly from the pump

Remove the gerotor cover alignment pin from the

housing.

534 of 1030
Charge Pump Removal (Cont'd) 2
Figure 30-42-73
P-28675
1
Inspect the inner gerotor assembly (Item 1) [Figure 30-
2
42-75] 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 30-42-75] for

Remove the inner gerotor (Item 1) [Figure 30-42-73] and wear, and replace as needed.
key (Item 2) [Figure 30-42-73] from the drive couple.

Figure 30-42-76
Charge Pump Inspection
2
Figure 30-42-74 1
P-28675A
P-28757 Inspect the gerotor drive key (Item 1) [Figure 30-42-76]

and retainer ring (Item 2) [Figure 30-42-76], and replace
as needed.
Inspect the outer gerotor assembly [Figure 30-42-74] for
scratches and wear, if it must be replaced, replace both
the outer and inner gerotors as a set.

535 of 1030
Charge Pump Inspection (Cont’d)

2
Figure 30-42-77
1
P-28673
Be sure the pump surface (Item 1) [Figure 30-42-79] is

clean and free of gasket material.
P-28758
Install the drive coupler/inner gerotor in the pump
Inspect the inside of the gerotor cover (Item 1) [Figure
30-42-77] for scratches and foreign material, replace as

Figure 30-42-80
needed.
Charge Pump Installation
Figure 30-42-78 2
1
4
2 P-28672
3
Install the outer gerotor (Item 1) [Figure 30-42-80] and
1
gerotor cover alignment pin (Item 2) [Figure 30-42-80].
P-28675
Install the key (Item 1) [Figure 30-42-78] in the drive

coupler (Item 2) [Figure 30-42-78].
Install the inner gerotor (Item 3) [Figure 30-42-78] and

the retaining ring (Item 4) [Figure 30-42-78] on the drive
coupler.
Lubricate the gerotor assembly with clean oil.

536 of 1030
1
Charge Pump Installation (Cont'd)
Figure 30-42-81
1 1
P-28670
Install the charge pump cover locating pins (Item 1)

[Figure 30-42-83].
P-28671
Figure 30-42-84
Install the new O-rings (Item 1) [Figure 30-42-81] on the

gerotor cover.

Figure 30-42-82
1
2 P-28669
Install a new charge pump cover gasket (Item 1) [Figure

30-42-84]
P-28676
.
Install the gerotor cover over the gerotor assembly (Item

1) [Figure 30-42-82] and align the pin in the cover (Item
2) [Figure 30-42-82].

537 of 1030
Charge Pump Installation (Cont'd)
Figure 30-42-85
1
1
P-28678
1
Press down on the swash plate with the handle of a clean

rubber mallet (Item 1) [Figure 30-42-87] and remove the
P-28667 side cover.
Figure 30-42-88
Align the charge pump cover on the alignment pins
[Figure 30-42-85]. Install the six cover bolts (Item 1)

[Figure 30-42-85] and tighten to 26-32 ft.-lb. (36-43 N•m)
1
torque.
Disassembly
Figure 30-42-86
P-28679
1 Remove the gasket (Item 1) [Figure 30-42-88] 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 30-40-23
Remove the shaft and shaft seal. (See Shaft Seal And
Shaft Replacement on Page 30-40-19
Remove the six side cover bolts (Item 1) [Figure 30-42-

86].

538 of 1030
Figure 30-42-89 1
P-28683
2
Remove the swash plate needle bearing assembly (Item

1) [Figure 30-42-91]. It may be necessary to rotate the
P-28680 servo piston, so the bearing can be removed.
Figure 30-42-92
Lift the swash plate (Item 1) [Figure 30-42-89] and
remove cylinder block (Item 2) [Figure 30-42-89].

Figure 30-42-90
1
1
P-28684
Remove the valve plate timing pin (Item 1) [Figure 30-

P-28682 42-92].
Remove the swash plate (Item 1) [Figure 30-42-90].

539 of 1030
Figure 30-42-93
P-28687
Remove the control spool plug (Item 1) [Figure 30-42-

95].
P-28685
Figure 30-42-96
Remove the valve plate (Item 1) [Figure 30-42-93].

Figure 30-42-94
1 1
P-26469
Do Not remove the spring (Item 1) [Figure 30-42-96], 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 30-42-94].

540 of 1030
Figure 30-42-97
P-28698
Remove control spool and spring (Item 1) [Figure 30-42-

99].
P-28688
Figure 30-42-100
Move the control spool and summing link (Item 1)

[Figure 30-42-97] until the summing link disconnects

from the control spool.
Figure 30-42-98
P-28691
1 Remove the linkage pivot bolt (Item 1) [Figure 30-42-

100].
P-28689
Remove the summing link (Item 1) [Figure 30-42-98].

541 of 1030
1
Figure 30-42-101
2
1
2
1
P-28700
Remove the five servo cover mount bolts (Item 1)

[Figure 30-42-103] from the servo cover that does NOT
P-28692 have the servo piston neutral adjustment tie bolt.
Remove the cover (Item 2) [Figure 30-42-103] and

Slide the control feedback link (Item 1) [Figure 30-42- gasket.
101] toward the servo piston and disengage it from the

neutral adjustment link (Item 2) [Figure 30-42-101]. Figure 30-42-104
Remove the control feedback link.
Figure 30-42-102
P-28701
Remove the servo piston adjustment seal nut (Item 1)

P-28694 [Figure 30-42-104] 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
42-102] from the pump housing. with new, to insure a proper seal.

542 of 1030
1
Figure 30-42-105
1
1
P-28705
Remove the servo cover (Item 1) [Figure 30-42-107]

from the servo piston.
P-28703
Figure 30-42-108
Remove the five servo piston cover mount bolts (Item 1)

[Figure 30-42-105]. 1

Figure 30-42-106
1
P-28706
Remove the piston seals (Item 1) [Figure 30-42-108]

and O-rings located under the seals, from the servo
P-28704 piston.
Remove the servo cover and servo piston (Item 1)

[Figure 30-42-106] from the pump.

543 of 1030
Figure 30-42-109 1
1
1 P-28744
Remove the three hold down pins (Item 1) [Figure 30-42-

111] and retainer ring (Item 2) [Figure 30-42-111].
P-28681
Inspection: Rotating Group

Remove the piston assemblies and slipper retainer (Item
1) [Figure 30-42-109] from the cylinder block.
Figure 30-42-110
P-28743
Remove the ball guide (Item 1) [Figure 30-42-110].

544 of 1030
Inspection
2
Figure 30-42-112
1
P-28747
Check the piston slippers (Item 1) [Figure 30-42-114] for

any excess wear or damage.
P-28745
Check the pistons (Item 2) [Figure 30-42-114] for any
discoloration, due to excessive heat.
Inspect the cylinder block surface, that runs against the
valve plate (Item 1) [Figure 30-42-112] for nicks or burrs.

Figure 30-42-115
Figure 30-42-113
1 1
1
P-28750
P-28746
Check the pump housing and housing piston bore (Item
1) [Figure 30-42-115] for piston seal fragments,
Check the cylinder bores (Item 1) [Figure 30-42-113] for scratches or damage.
grooves or scratches.

545 of 1030
Inspection (Cont'd)
Figure 30-42-116
1
1
P-28755
Check the swash plate surface (Item 1) [Figure 30-42-

118] for scratches or damage.
P-28706
Check the swash plate bearing surface (Item 2) [Figure
30-42-118] for wear.
Check the surface of the servo piston (Item 1) [Figure
30-42-116] for scratches or damage.

Figure 30-42-119
Figure 30-42-117
P-28756
P-28751
Check the swash plate needle bearing (Item 1) [Figure
30-42-119] 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-
42-117]. It should be free of deep groves.

546 of 1030
Inspection (Cont'd)
1
Figure 30-42-120
P-28699
Check the control spool and spring (Item 1) [Figure 30-

42-122] for wear and replace as needed.
P-28767
Figure 30-42-123
Check the pump housing swash plate needle bearing

(Item 1) [Figure 30-42-120] 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 30-42-121
P-28690
Check the summing link (Item 1) [Figure 30-42-123] for

wear and replace as needed.
P-28679
Check the pump side cover swash plate needle bearing

(Item 1) [Figure 30-42-121] 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.

547 of 1030
Inspection (Cont'd)
Figure 30-42-124
1 1
P-28695
Check the neutral adjustment link (Item 1) [Figure 30-42-

126] for wear and replace as needed.
Figure 30-42-127
Check the linkage pivot bolt (Item 1) [Figure 30-42-124]
for wear and replace as needed.

Figure 30-42-125
P-28697
1
Check the complete linkage assembly for wear [Figure

P-28693 30-42-127].
Check the control feedback link (Item 1) [Figure 30-42-

125] for wear and replace as needed.

548 of 1030
Assembly
Figure 30-42-128
P-28787
Install a new O-ring (Item 1) [Figure 30-42-129] and new

piston ring (Item 2) [Figure 30-42-129] on the tie bolt end
P-28789 of the servo piston (Item 1) [Figure 30-42-130].
Lubricate the piston ring with a liberal amount of

Position the pump housing so the charge pump face is hydraulic oil.
pointing downward [Figure 30-42-128].

Figure 30-42-131
Figure 30-42-129
2
1
P-28786
P-28788
Install the servo piston in the corresponding housing bore

in the pump housing [Figure 30-42-131].
Install the non-tie bolt end of the servo piston into the
housing first [Figure 30-42-131].
Be sure the cavity for the servo piston/swash plate

needle bearing (Item 1) [Figure 30-42-131] faces the
center of the housing.

549 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK Install a new servo cover gasket (Item 1) [Figure 30-42-
CONTROL) (SJC) (CONT'D) 133].
Assembly (Cont'd) Figure 30-42-134
Figure 30-42-132
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 30-42-
that the other O-ring and piston seal may be installed

134].
(Item 1) [Figure 30-42-132].
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 30-42-135
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 30-42-133 1
1
1
P-28782
Install the second servo cover gasket and cover. Install

the five mount bolts (Item 1) [Figure 30-42-135] and
tighten to 11-13 ft.-lb. 15-17,5 N•m) 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 30-42-133].

550 of 1030
Assembly (Cont'd)
Figure 30-42-136
1
1
1
P-28780
1 1
Install the control spool and spring (Item 1) [Figure 30-

42-138] into the pump housing.
P-28701
Figure 30-42-139
Tighten the tie bolt end, mount bolts (Item 1) [Figure 30-
42-136] to 11-13 ft.-lb. 15-17,5 N•m) torque.

Install a new adjustment seal nut (Item 2) [Figure 30-42-
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 30-40-
48 2
Figure 30-42-137
P-28763
Install the center pin on the control feedback link (Item 1)

[Figure 30-42-139] into the bore in the neutral
adjustment link (Item 2) [Figure 30-42-139].
P-28781
Rotate the pump housing so that the control face is

accessible [Figure 30-42-137].

551 of 1030
Assembly (Cont'd)
Figure 30-42-140
1 2
1
3
P-28776
The neutral adjustment link (Item 1) [Figure 30-42-142]

should mate and engage the neutral adjustment screw
P-28778 (Item 2) [Figure 30-42-142], and both links should align
with the pivot screw hole (Item 3) [Figure 30-42-142].
Figure 30-42-141 Figure 30-42-143

1
2
P-28777
P-28775
Install the end of the feedback link containing the hole Install the linkage pivot screw (Item 1) [Figure 30-42-
(Item 1) [Figure 30-42-140] & [Figure 30-42-141] into 143] and tighten to 6-11 ft.-lb. (8-15 N•m) torque.
the servo piston slot (Item 2) [Figure 30-42-141].

552 of 1030
Assembly (Cont'd)
Figure 30-42-144
1
P-28772
Shift the control spool to the center of the housing until

the summing link pin (Item 1) [Figure 30-42-146] is
P-28774 located in the center.
Figure 30-42-147
Install the summing link (Item 1) [Figure 30-42-144] on to
the feedback link pin.

Figure 30-42-145
P-28771
Install a new gasket (Item 1) [Figure 30-42-147] on the

P-28773 pump housing controller face.
Move the control spool (Item 1) [Figure 30-42-145] until

the summing link (Item 2) [Figure 30-42-145] lines up
with the flat spot on the control spool.

553 of 1030
Assembly (Cont'd)
1
Figure 30-42-148
P-28687
Install the control spool bore plug (Item 1) [Figure 30-42-

150] and tighten to 30-70 ft.-lbs (41-94 N•m) torque.
P-28769
Figure 30-42-151
Install the control module on the pump housing.

NOTE: The pin on the summing link (Item 1) [Figure
30-42-148] must engage the bore (Item 2)
[Figure 30-42-148] on the control module for
proper control operation.
Figure 30-42-149
1
P-28768
1 Install the valve plate timing pin (Item 1) [Figure 30-42-

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

30-42-149] and tighten to 11-13 ft.-lb. (15-17.5 N•m)
torque.

554 of 1030
Assembly (Cont'd)
Figure 30-42-152
P-28766
2
Install the swash plate needle bearing (Item 1) [Figure

30-42-154] on the swash plate, so the letters on the
P-28684 bearing face the swash plate.
Figure 30-42-155
Install the pump valve plate (Item 1) and engage the
valve plate timing pin (Item 2) [Figure 30-42-152].

Lubricate the top surface of the valve plate with a coating
of hydraulic fluid. 1
Figure 30-42-153
P-28765
Install the swash plate and needle bearing into the servo
piston cavity (Item 1) [Figure 30-42-155].
P-28767
Be sure the servo piston cavity (Item 1) [Figure 30-42-

153] is facing the center of the pump.

555 of 1030
Assembly (Cont'd)
Figure 30-42-156
P-28743
Install the ball guide (Item 1) [Figure 30-42-158] on the

hold down pins.
P-28748
Figure 30-42-159
Lightly coat all parts with hydraulic oil, before installing

the cylinder block.

Place the retainer ring (Item 1) [Figure 30-42-156] in the
cylinder block, so that it sits approximately 1/8 inch
(3,175 mm) below the surface.
Figure 30-42-157
P-28681
Install the slipper retainer, containing the slippers and

1 pistons [Figure 30-42-159].
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 30-42-

157], making sure they are setting squarely in the
grooves.

556 of 1030
Assembly (Cont'd)
Figure 30-42-160
P-28764
Install a new gasket (Item 1) [Figure 30-42-162] on the

side cover.
P-28682
Figure 30-42-163
Figure 30-42-161

1
1
P-28779
P-28680
Press down on the swash plate, with a clean rubber
mallet.
Lift the end of the swash plate (Item 1) [Figure 30-42-
160] and insert the cylinder block assembly (Item 1) Install the side cover/swash plate bearing assembly (Item
[Figure 30-42-161]. 1) [Figure 30-42-163] into the pump housing.
Visually center the cylinder block assembly over the

valve plate [Figure 30-42-161].

557 of 1030
HYDROSTATIC PUMP (SELECTABLE JOYSTICK Pump Neutral Adjustment
Figure 30-42-165
Assembly (Cont'd)
Figure 30-42-164
1
P-28790
P-28677 Figure 30-42-166
Align the holes and the gasket, and install the six
mounting bolts (Item 1) [Figure 30-42-164] and tighten to

11-13 ft.-lbs (15-17,5) N•m torque.
Install the shaft assembly into the pump housing. (See

Shaft Seal And Shaft Installation on Page 30-40-21
Install the charge pump. (See Charge Pump Removal on 1

Page 30-40-23
P-28791
The pump neutral adjustment sets the position of the

servo piston and pump swash plate relative to the
controlling mechanism.
Place the loader on jackstands. (See TRANSPORTING

Raise the lift arms, and install an approved lift arm


on Page 10-30-1.)

Page 10-60-1.)
Connect a hydraulic hose between port M4 (Item 1)

[Figure 30-42-165] on the back side of the hydrostatic
pump, and port M5 (Item 1) [Figure 30-42-166] on the
front side of the hydrostatic pump, to equalize the
pressures on both ends of the servo piston.

558 of 1030
Pump Neutral Adjustment (Cont’d)
Figure 30-42-167
P-28790
1 Loosen the pump neutral adjustment lock nut (Item 1)

[Figure 30-42-169].
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 30-42-170
PSI pressure gauge.
Figure 30-42-168
P-28790
1
P-28791 Turn the adjustment screw (Item 1) [Figure 30-42-170]
clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
Remove the plug (Item 1) [Figure 30-42-168] from the screw.
M2 port on the front side of the pump, and install a 7500
PSI pressure gauge.

559 of 1030
Pump Neutral Adjustment (Cont’d)
Figure 30-42-171
P-28790
1 While holding the adjustment screw (Item 1) [Figure 30-

42-173] in position, tighten the seal lock nut (Item 2)
P-28790 [Figure 30-42-173] to 21-37 ft.-lb. (28-51 N•m) torque.
Shut loader OFF.

Turn the adjustment screw (Item 1) [Figure 30-42-171]
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 30-42-172 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 30-40-51
P-28790

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

560 of 1030
Pump Controller Neutral Adjustment
Figure 30-42-174
1
1
P-28790
Remove the M4 plug (Item 1) [Figure 30-42-175] and

install a 500 PSI pressure gauge.
P-26464
Figure 30-42-176
The pump controller neutral adjustment, aligns the pump

swash plate and the control spool so that a zero angle

control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump neutral setting is
adjusted.
Place the loader on jackstands. (See TRANSPORTING 1

Raise the lift arms, and install an approved lift arm

P-28791

on Page 10-30-1.) Remove the M5 plug (Item 1) [Figure 30-42-176] and
install a 500 PSI pressure gauge.
Page 10-60-1.)
Disconnect the pump controllers (Item 1) [Figure 30-42-

174] from the loader wiring harness.

561 of 1030
Pump Controller Neutral Adjustment (Cont’d)
Figure 30-42-177
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 30-42-180
(Item 1) [Figure 30-42-177].

Start the loader using the remote start tool and run at an
idle.
Figure 30-42-178
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.

562 of 1030
Pump Controller Neutral Adjustment (Cont'd)
Figure 30-42-181
P-28791
While holding the adjustment screw (Item 1) [Figure 30-

42-181] in position, tighten the seal lock nut (Item 2)

[Figure 30-42-181] to 10-18 ft.-lb. (14-24 N•m) 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.

563 of 1030

564 of 1030
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 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.

565 of 1030
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 Shield Removal And
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].

566 of 1030
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.

567 of 1030
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.

568 of 1030
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 (Item 1) [Figure 30-60-2] to the

1 outside of the rubber sleeve.
Slide the rubber sleeve in toward the radiator.
1 Figure 30-60-3

1
P-37017
Raise and remove the rear grill.
Drain the coolant from the radiator and remove the P-37019
radiator coolant tank.
Remove the two radiator coolant tank mount bolts (Item The connector will release from the radiator [Figure 30-
1) [Figure 30-60-1]. 60-3].
Remove the mount from the loader. 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.

569 of 1030
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.

570 of 1030
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 . . . . . . . . . . . . . . . . 40-20-8

571 of 1030

572 of 1030
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].
device. (See Installing The Lift Arm Support Device on Disconnect the crossmember from the control valve lift
Page 10-20-1.) spool (Item 1) [Figure 40-10-3].

on Page 10-30-1.)
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.

573 of 1030
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.-lb. (22-27 N•m) 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.

574 of 1030
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.

575 of 1030

576 of 1030
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

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.

577 of 1030
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
Remove the two mounting bolts (Item 1) [Figure 40-11-6]

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.

578 of 1030
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.-lb. (6,78-9,49

N•m) torque.

579 of 1030
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.-lb. (27,1 N•m) 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.-lb. (27,1 N•m) torque.

580 of 1030
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.-lb. (6,78-9,49 solenoid valve to 20 ft.-lb. (27,1 N•m) torque.
N•m) torque.
Check the O-rings [Figure 40-11-20] and replace as
needed.

581 of 1030

582 of 1030
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


Remove the tire/wheel assembly.
Installation: Tighten the wheel nuts to 105-115 ft.-lb.

(142-155 N•m) 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.-lb. (240-260
N•m) 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.

583 of 1030
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.
The tool listed will be needed to do the following

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].

584 of 1030
DRIVE COMPONENTS (CONT'D) Lift and block the loader. (See LIFTING AND BLOCKING
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
Steering Lever Boot on Page -1.)
MEL1242 - Port-a-Power
MEL1202B - Axle Bearing Service Set Remove the front cover. (See Front Chaincase Cover
Removal And Installation on Page 40-30-1.)
NOTE: The procedure shown for removal and
installation of the axle, sprocket and bearings Remove the fluid from the chaincase. (See FINAL DRIVE
is for a front axle. This procedure will be the TRANSMISSION (CHAINCASE) on Page 10-130-1.)
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 ft.-

Figure 40-20-7

2
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.-lb. (240-260

N•m) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-7]

2 across from each other.
P4810
Page 10-20-1.)

585 of 1030
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].

586 of 1030

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].

587 of 1030

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].

588 of 1030
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].

589 of 1030
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
Removal And Installation on Page 40-20- 3.)
Remove the fluid from the chaincase. (See FINAL DRIVE

TRANSMISSION (CHAINCASE) on Page 10-130-1)
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
Page 10-20-1.)


on Page 10-30-1.)
Remove the front panel/steering lever assembly. (See

Steering Lever Boot on Page -1.)
Remove the center chaincase cover. (See CHAINCASE

on Page 40-30-1.)

590 of 1030
CHAINCASE Figure 40-30-2
Front Chaincase Cover Removal And Installation
Figure 40-30-1
1
2
1
P5676
P5382 device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)
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

591 of 1030

592 of 1030
MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 50-100-3
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-100-3
CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) 50-101-1

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
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

593 of 1030
MAIN FRAME (CONT’D)
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1

Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1
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 Removal And Installation (Early Models) . . . . . . . . .50-20-1
Gas Cylinder Removal And Installation (Later Models) . . . . . . . . .50-20-3
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . .50-31-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .50-31-3
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .50-31-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-31-2
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-41-1

Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . . . . .50-41-5
Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . .50-41-3
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-1

Adjusting The Rear Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-60-1


594 of 1030
MAIN FRAME (CONT’D)
SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . 50-10-3

595 of 1030

596 of 1030
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.

597 of 1030
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.-lb. (38 N•m)
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.-lb. (5,6-7,9 N•m)
torque.

598 of 1030
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 NOTE: For procedures requiring the use of LOCTITE

5 #518 adhesive, thoroughly clean and dry
3 affected parts before the application of
6 LOCTITE #518.
2
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)
Spacer Bushing (Item 4) Bolt (Item 1)
Seat Bar (Item 5) Bushing (Item 2)
Keyed Plastic Bushing (Item 6) Spring (Item 3)
Mounting Bolt (Item 7) Bushing (Item 4)
Clevis (Item 5)
Installation: Tighten the mounting bolt (Item 7) [Figure Retaining Pin (Item 6)
50-10-9] & [Figure 50-10-10] to 50-70 in.-lb. (5,6-7,9 Bushing (Item 7)
N•m) torque. Pin (Item 8)

599 of 1030

600 of 1030
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation (Early

Models)
WARNING
1
Cylinder contains high pressure gas. Do not open.
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
from tipping forward when the gas cylinder(s) are
1 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 1
stops are removed.

P-43444
on Page 10-30-1.)
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].

601 of 1030
Gas Cylinder Removal And Installation (Early

Models) (Cont'd)
Figure 50-20-4
1 2
P-43446
1
Installation: Mount the gas cylinder to the cab pivot pin

[Figure 50-20-5]. Install the front mount bolt (Item 1)
P-43445 [Figure 50-20-6]. Use a locking pliers and turn the mount
bracket to allign the bracket with the hole (Item 2)
[Figure 50-20-6]. Install the bolt and tighten the mount
Turn the mounting bracket forward to relieve any bolts to 15-20 ft.-lb. (20,3-27,1 N•m) torque.

remaining tension on the gas cylinder [Figure 50-20-4].
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.

602 of 1030
Gas Cylinder Removal And Installation (Later

Models)
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
Figure 50-20-7 P-31546

from tipping forward when the gas cylinder(s) are
removed.
Figure 50-20-9

1
1
P-31545
Remove the operator cab stop (Item 1) [Figure 50-20-7].

(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. P-39601

on Page 10-30-1.) Remove the retaining pins (Item 1) [Figure 50-20-9] from
the cab pivot pins.

603 of 1030
OPERATOR CAB (CONT'D)
Gas Cylinder Removal And Installation (Later

Models) (Cont'd)
Figure 50-20-10
1
P-43354
Remove the retaining pins (Item 1) [Figure 50-20-10]

from the lower pivot pins.
Remove the gas cylinders (Item 2) [Figure 50-20-10]

from the operator cab.

604 of 1030
OPERATOR CAB (CONT'D) Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly Figure 50-20-13
Figure 50-20-11
2 P-31289
1
P1008
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-13] (both sides).
Remove the clevis (Item 1) [Figure 50-20-11] and
washer (Item 2) [Figure 50-20-11] from the end of the Installation: Tighten the nut to 40-50 ft.-lb. (54-68 N•m)

gas cylinder. torque.
Remove the gas cylinder from the outer housing. Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-20-12
Figure 50-20-14
P1006
P-31550
Assembly: Install a replacement cylinder inside the

cylinder housing. Disconnect the two wiring harness connectors (Item 1 &
2) [Figure 50-20-14].
Apply a small amount of LOCTITE on the threads of the
cylinder rod [Figure 50-20-12]. Remove the tie-straps (Item 3) [Figure 50-20-14] from
the wiring harness.
Reinstall the washer and clevis on the cylinder rod.

605 of 1030
Figure 50-20-15
1
P-31546
P-31551
Disconnect the electrical connector (Item 1) [Figure 50- from tipping forward when the gas cylinders are
20-15]. removed.

Figure 50-20-16 Remove both gas cylinders. (See Gas Cylinder Removal
And Installation (Early Models) on Page 50-20-1.)
P-31552
Remove the mount bolt (Item 1) [Figure 50-20-16] from

the wire harness mount bracket (Item 2) [Figure 50-20-
16] and ground strap (Item 3) [Figure 50-20-16].
Remove the tie-straps from the wiring harness.
Position the wiring harness, so that it does not get

damaged when the cab is removed.

606 of 1030
Figure 50-20-18
P-31554
Move the operator cab forward a small amount for

P-31553 clearance at the pivot mounting brackets [Figure 50-20-
20].
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 20-20] in the cab pivot (both sides).

gas cylinders are disconnected [Figure 50-20-18].
Install the sling under the pivot bolt and pivot of the
Figure 50-20-19 operator cab [Figure 50-20-20].
Figure 50-20-21
1
2
P-31545
P-31555
Remove the operator cab stop (Item 1) [Figure 50-20-
19].
Connect the slings (Items 1 & 2) [Figure 50-20-21] to a
Remove the nut (Item 2) [Figure 50-20-19] 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.-lb. 21].
Remove the pivot bolt (both sides).

607 of 1030

608 of 1030
OPERATOR SEAT Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
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.-lb. (27

N•m) 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.-lb. (73 N•m) torque. Tighten nut (Item 2) [Figure 50-
P-31288 P-31289 30-4] to 34 ft.-lb. (46 N•m) 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.

609 of 1030

610 of 1030
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) [Figure 50-31-3] 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.-lb. (27

N•m) 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.

611 of 1030
OPERATOR SEAT (SUSPENSION) (CONT'D) Figure 50-31-7
Slide Rail Removal And Installation 2

1 1
Figure 50-31-5
1
1
2 2
1
1
N-18582
1 Figure 50-31-8
N-18587

on Page 10-30-1.) 1

Remove the operator seat. (See OPERATOR SEAT on
Page 50-30-1.)
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.
N-18581
seat slide rail.
Remove the cushion (Item 2) [Figure 50-31-7] from the
Cushion Removal And Installation seat frame (Item 1) [Figure 50-31-8].
Figure 50-31-6
N-18579
Press the two buttons (Item 1) [Figure 50-31-6] &

[Figure 50-31-7] and lift the seat cushion.

612 of 1030
Cushion Removal And Installation (Cont’d)
Figure 50-31-9
1 1
N-18578
Remove the two mounting screws (Item 1) [Figure 50-

N-18580 31-11] from the seat back and remove the back.

Inspect the seat ride adjustment [Figure 50-31-9]. seat back.

seat back.
Back Removal And Installation
Figure 50-31-10
N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50-

31-10] and tilt the seat back all the way forward.

613 of 1030
Shock Removal And Installation
Figure 50-31-12 1
1
1
1
N-18586
2
NOTE: The seat block mounting studs (Item 1)

N-18584 [Figure 50-31-14] are replaceable.

Figure 50-31-13 seat shock.

1
2
N-18585

on Page 10-30-1.)
Remove the operator seat. (See OPERATOR SEAT on

Page 50-30-1.)
Remove the seat shock retaining pin (Item 1) [Figure 50-

31-12] & [Figure 50-31-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-12] &

[Figure 50-31-13].

614 of 1030
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).

615 of 1030
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.-

lb. (258 N•m) torque.

616 of 1030
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.

617 of 1030
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.

618 of 1030
POWER BOB-TACH Installation: Tighten the retainer nut to 18-20 ft.-lb. (24-
27 N•m) torque.
Figure 50-41-3
Figure 50-41-1
2 1
1 2
P-31401
P-31379
Remove the pivot pin (Item 1) [Figure 50-41-3] from the

Tilt the Bob-Tach forward, so it is parallel to the floor. Put tilt cylinder rod end (both sides).
2x4 blocks under each side of the Bob-Tach [Figure 50-

41-1]. Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Lower the Bob-Tach onto the blocks.
Figure 50-41-4
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.
Figure 50-41-2 1
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).

619 of 1030
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 lb. (258 N•m) 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.

620 of 1030
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).

torque.
Remove the cylinder from the lever pivots.

621 of 1030
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.

622 of 1030
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.

623 of 1030

624 of 1030
LIFT ARMS Installation: Tighten the retainer bolt to 18-20 ft.-lb. (24-
27 N•m) 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.

625 of 1030
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.-lb.


626 of 1030
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

627 of 1030
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].

628 of 1030
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 N•m) 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.)

629 of 1030
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).


630 of 1030
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.

631 of 1030

632 of 1030
REAR DOOR Figure 50-70-3
Figure 50-70-1
1
1
N-19676
Remove the light housing (Item 1) [Figure 50-70-3] from

N-19674 the rear door. (Both sides).
Figure 50-70-4
Open the rear door.

Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the engine harness.
Figure 50-70-2
1
1
N-19678
Install a nylon sling (Item 1) [Figure 50-70-4] through the

holes for the light housings.
N-19675 Connect a chain hoist to the nylon sling.
Remove the light bulb (Item 1) [Figure 50-70-2] from the

light housing. (Both sides).

633 of 1030
REAR DOOR (CONT'D) Adjusting The Rear Door Latch
Removal And Installation (Cont'd) Figure 50-70-6
Figure 50-70-5
2 1
3
P-16367
P-31247
The door catch (Item 1) [Figure 50-70-6] can be adjusted

side to side for alignment with the door latch.
Figure 50-70-7

1
N-19677
1
Remove the nuts from the top and bottom hinge bolts
(Item 1) [Figure 50-70-5] and remove the hinge bolts.
Installation: Tigthen the mounting bolts and nuts to 25- P-31248

28 ft.-lb. (34-38 N•m) torque. The door stop (Item 2)
[Figure 50-70-5] is installed in the top hinge bolt, above
the stop retainer (Item 3) [Figure 50-70-5]. The door latch (Item 1) [Figure 50-70-7] cannot be
adjusted.
Remove the rear door from the loader frame and lay it flat
on the floor.

634 of 1030
FUEL TANK Figure 50-80-3
Figure 50-80-1
1
1
N-19994
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
N-19995
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 30-40-2
or Removal And Installation on Page 30-41-1.)
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.
Check the drain plug and replace if necessary.

635 of 1030
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].

636 of 1030
CONTROL PEDALS

WARNING
Figure 50-90-1
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
1
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.-lb. (28-
34 N•m) 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.
Pedal Adjustment
After installing the pedal, adjust the pedal so that there is

clearance under the rear of the pedal and the valve spool
must travel full stroke without hitting the floor panel.

637 of 1030

638 of 1030
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.

Pull the pin (Item 1) [Figure 50-91-1] holding the foot N•m) 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.-lb. (47-54 N•m) lubed
Tilt the foot pedal up and remove the two nuts (Item 1) 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.
torque.
Remove the sensor assembly
NOTE: The calibration must be followed when
replacing handle sensor, foot pedal sensor,
actuator or ACS Controller. (See Calibration
Of The ACS System on Page 60-130-14.)
639 of 1030
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.

640 of 1030
CONTROL PANEL 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 on Page 70-21-1.)
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.
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
Page 10-20-1.)
to 25-28 ft.-lb. (34-38 N•m) torque.

641 of 1030
CONTROL PANEL (CONT'D) Figure 50-100-6
Figure 50-100-4 1
1
1
1
1 1
1
P-37876
1
Remove the six control panel mounting bolts (Item 1)
1
P-37875 [Figure 50-100-6] from the left side of the control panel.
Remove the side panel mount bolts.

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.-lb. (34-38 N•m) torque.
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lb. (34-38 N•m) 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.-lb. (34-38 N•m) torque.
Remove the control panel from the loader.

642 of 1030
CONTROL PANEL (CONT'D) Loosen both U-bolts (Item 1) [Figure 50-100-9] at the
steering lever (both sides).
Shock Removal And Installation
Remove the steering cross shaft mounting bolts (Item 2)
Figure 50-100-8 [Figure 50-100-9] (both sides).
Installation: Tighten the mounting bolts to 180-200 in.-lb.

Shaft Disassembly And Assembly
Figure 50-100-10
1
3
2 3
1
P-4069

from the end of the shock connected to the steering

linkage.
Remove the mounting nut (Item 2) [Figure 50-100-8] 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.
(34-38 N•m) torque. Disassemble the right and left steering shafts from the
cross shaft assembly.
Shaft Removal And Installation NOTE: Some loaders may have a sleeve (Item 1),
between the bearing (Item 2) and the bell
Figure 50-100-9 crank (Item 3) [Figure 50-100-10].
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.

643 of 1030
Shaft Disassembly And Assembly (Cont'd)
Figure 50-100-11
1
2
2
3
4
P13774
3 NOTE: Some loaders may have a spacer (Item 1),

N-17640 between the bearing (Item 2) and the bell
crank (Item 3) [Figure 50-100-13].
Check the bearings (Item 1) [Figure 50-100-11] for wear Check the fiber washer (Item 4) [Figure 50-100-13] and
and replace as needed. replace all worn parts.

Check the fiber washers (Item 2) [Figure 50-100-11] for
wear and replace as needed.
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.

644 of 1030
CONTROL PANEL (CONT'D) Lift and block the loader. (See LIFTING AND BLOCKING
Linkage Removal And Installation
on Page 10-30-1.)
WARNING Open the access covers (both sides).
Remove the nut (Item 1) from the end of the centering

spring shoulder bolt (Item 2) [Figure 50-100-14].
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.-lb. (34-38 N•m) torque.

Page 20-80-1.)
Figure 50-100-15

WARNING
W-2059-0598 P-39283
Figure 50-100-14 Slide the plate (Item 1) [Figure 50-100-15] to the right
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
2 from the guide pins.
P-39282
Page 10-20-1.)

645 of 1030
Linkage Removal and Installation (Cont'd)

1
Figure 50-100-16
1
4
2
N-17607
2
3 Check the wear on the centering blocks (Item 1) [Figure
N-17608 50-100-18].
Figure 50-100-19
The centering plate/centering spring assembly consists
of the following parts [Figure 50-100-16]: 1

ITEM DESCRIPTION
1 Centering Spring Assembly
2 Guide Bushings
3 Lock Nut
4 Centering Plate
1
Figure 50-100-17
2
1 5 N-17606
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

4
ft.-lb. (34-38 N•m) torque.
3
N-17735
The centering plate/centering spring assembly consists

of the following parts [Figure 50-100-17]:
ITEM DESCRIPTION
1 Bolt
2 Washer
3 Sleeve
4 Bushing
5 Spring

646 of 1030
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

N-17726 the pintle arm. remove the torsion bushing (Item 2)
[Figure 50-100-22] from the pintle arm.
Check the surface of the four pintle cams (Item 1) Figure 50-100-23
[Figure 50-100-20].

If worn replace the cam.

torque. 1
Figure 50-100-21 2
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.-lb. (34-38 N•m)

torque.
N-17726 Disconnect the shock absorbers from the linkage bars.
Remove the nuts (Item 2) [Figure 50-100-23] from the
Remove the linkage bar nut (Item 1) [Figure 50-100-21] linkage bar mounting bolt. The bolts are threaded into the
from the torsion bushing. linkage bars, remove the bolts.
The bolt is threaded into the linkage bar, remove the bolt Installation: Tighten the bolts to 11-13 ft.-lb. (21-25 N•m)
torque, then tighten the nuts to 21-25 ft.-lb. (28-33 N•m)
from underneath the pintle arm. torque.
Installation: Tighten the bolt to 11-13 ft.-lb. (21-25 N•m) The torsion bushings can now be removed from the
steering bell cranks.
torque, then tighten the nut (Item 1) [Figure 50-100-21]
to 21-25 ft.-lb. (28-33 N•m) torque. The linkage and the centering plate must be readjusted
for neutral after the components have been reassembled.

647 of 1030
CONTROL PANEL (CONT'D) Place the loader on jackstands. (See TRANSPORTING
Linkage Neutral Adjustment
on Page 10-30-1.)
WARNING Connect the remote start tool. (MEL 1563) (See

REMOTE START on Page 10-60-1.)
Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
Loosen the nut (Item 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

WARNING
the lift arms are secured by an approved lift arm 2
W-2059-0598
Loosen the nut (three to four turns), then loosen the bolt
Figure 50-100-24
at the linkage bar (Item 1). The bolt is threaded into the
linkage bar (Item 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
Page 10-20-1.)

648 of 1030
Linkage Neutral Adjustment (Cont'd)
Figure 50-100-26
P-45087
With an Allen wrench turn the loader drift adjustment bolt

P-45084 (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.)
control panel. (Both sides.) NOTE: This allows the steering lever to be move to

the full forward position without hitting the
Figure 50-100-27 adjustment bolt.
Figure 50-100-29
2
3
1
P-45085
N-17619
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].

649 of 1030
Figure 50-100-30
1
1
3 N-19812
2 1
Loosen the two bolts and nuts (Item 1) [Figure 50-100-

N-17620 32] on each steering linkage bar.
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.-lb. (34-38 N•m) 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.-lb. (62-68 N•m) torque.

650 of 1030
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.-lb. (34-38 N•m)

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.

651 of 1030
Figure 50-100-35
1
1
N-17621
Adjust the left side centering block first (Item 1) [Figure

N-17732 50-100-37].
Start the engine, using the remote start tool, and run the
Figure 50-100-36 loader at high RPM.

Figure 50-100-38
N-17734
N-19581
Loosen the four bolts (Item 1) [Figure 50-100-35] &
[Figure 50-100-36] holding the two centering blocks.
Move the right side centering block to the right as far as On the remote start tool, move the traction lock override
possible. switch (Item 1) [Figure 50-100-38] to the OFF position so
the traction function is unlocked. The wheels are now
NOTE: Bolt holes are slotted for pintle arm centering able to turn.
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.

652 of 1030
Figure 50-100-39
1
P-39281
Tighten the two linkage bar bolts to 221-25 ft.-lb. (28-33

N-17618 N•m) torque, then tighten the two nuts to 21-25 ft.-lb. (28-
33 N•m) torque at the pintle levers (Item 1) [Figure 50-
100-40].
Adjust the right side centering block (Item 1) [Figure 50-
100-39]. Figure 50-100-41

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
the neutral position [Figure 50-100-39]. 1
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 tires do not N-17728
come to a complete stop, repeat the adjustment
procedure again.
Tighten the two linkage bar bolts to 21-25 ft.-lb. (28-33
Stop the engine. N•m) torque, then tighten the two nuts to 21-25 ft.-lb. (28-
33 N•m) torque at the steering cross shaft (Item 1)
Remove the remote start tool from the loader. [Figure 50-100-41].
Remove the loader from the jackstands.

653 of 1030
CONTROL PANEL (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.

654 of 1030
CONTROL PANEL (SELECTABLE JOYSTICK Raise the operator cab. (See Raising The Operator Cab
CONTROL) (SJC) on Page 10-30-1.)
Removal And Installation Remove the lift arm by-pass control knob and washer
(Item 1) [Figure 50-101-1].
Figure 50-101-2
WARNING
W-2017-0286
P-31824

Remove the control panel mount bolt (Item 1) [Figure 50-
101-2].
WARNING Remove the two mount bolts (Item 2) [Figure 50-101-2]

from the engine speed control.
Remove the engine speed control linkage from the
engine speed control lever, and remove the lever from
the loader.
W-2059-0598
Figure 50-101-3
Figure 50-101-1
P-26234
P-31822 Remove the two control panel mount bolts (Item 1)

[Figure 50-101-3].
Raise the lift arms and install an approved lift arm support Installation: Tighten the control panel mounting bolts to
device. (See Installing The Lift Arm Support Device on 25-28 ft.-lb. (34-38 N•m) torque.
Page 10-20-1.)

655 of 1030
CONTROL PANEL (SELECTABLE JOYSTICK Figure 50-101-6
CONTROL) (SJC) (CONT’D)
Figure 50-101-4
P-26237
Remove the two side panel mount bolts (Item 1) [Figure

50-101-6], 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.-lb. (34-38 N•m) torque.
101-4].

Figure 50-101-7
Remove the fuse cover.
Figure 50-101-5
P-26227
P-26236 Disconnect the right joystick wire harness connector

(Item 1) [Figure 50-101-7].
Remove the control panel mount bolt (Item1) [Figure 50-

101-5] from the left side of the control panel.
Remove the two side panel mount bolts (Item 2) [Figure

50-101-5], to allow clearance for the removal of the cotrol
panel.

25-28 ft.-lb. (34-38 N•m) torque.

656 of 1030
CONTROL PANEL (SELECTABLE JOYSTICK Figure 50-101-10
Figure 50-101-8
1 1
P-26240

from the foot rests.
P-26238
Figure 50-101-11
Disconnect the left joystick wire harness connector (Item

1 1
1) [Figure 50-101-8].

Figure 50-101-9
1
1
P-26241
Remove the front four mount bolts (Item 1) [Figure 50-

101-11] from the foot rests.
P-26239
Remove the foot rests from the loader.
Remove the two control panel mount bolts (Item 1)

[Figure 50-101-9].
Remove the control panel from the loader.

657 of 1030
CONTROL PANEL (SELECTABLE JOYSTICK
Figure 50-101-12
1
1
P-26242

from the lower fill panel.

Remove the panel from the loader.

658 of 1030
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.

Revised June 04 50-110-1 Service Manual
659 of 1030

Revised June 04 50-110-2 Service Manual
660 of 1030
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].
NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60-
130-14.)
661 of 1030
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.-lb. (3,6-4,3

P-21861 N•m) 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.

662 of 1030
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
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.-lb. (3,6-4,3 N•m)
torque.
Installation: Tighten bolt to 32-38 in.-lb. (3,6-4,3 N•m)
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.

663 of 1030
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.
NOTE: The calibration procedure must be followed
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-
Calibration Of The ACS System on Page 60-
12], washer (Item 6) [Figure 50-111-12], stop strap (Item
130-14.)
Control Handle Removal And Installation
Figure 50-111-13
Figure 50-111-15
3
1
1
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.)

664 of 1030
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.-lb.

(4 N•m) 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.

665 of 1030
(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 ADVANCED CONTROL SYSTEM
(ACS) on Page 60-130-1.)

666 of 1030
CONTROL HANDLE (ADVANCED CONTROL Control Lever Boot
(CONT'D) Figure 50-111-25
Control Lever Removal And Installation
Figure 50-111-24
2
2
1 1
N-22659
To replace the rubber boot (Item 1) [Figure 50-111-25]

P13734 on the control panel, remove the control lever. (See
Control Lever Removal And Installation on Page 50-111-
6.)
The control lever (Item 1) [Figure 50-111-24] must be

replaced as a complete unit. Drill out the four rivets (Item 2) [Figure 50-111-25]
located on the flange of the rubber boot and remove the
The connector clip (Item 2) [Figure 50-111-24] can be old boot.
replaced separately from the control lever.
Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-111-
6.)

667 of 1030

668 of 1030
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)
[Figure 50-112-3] from the loader wiring harness (Item 2)
The tools listed will be needed to do the following [Figure 50-112-3].
procedure:

Install the test harness (Item 3) [Figure 50-112-3]
MEL1608-Joystick Test Harness [Figure 50-112-1] between the two connectors.
MEL1563-Remote Start Tool
Multimeter Turn the remote start key to ON position without starting
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.
1 Figure 50-112-4
1
P-28311
Page 10-20-1.)
P-28310
on Page 10-30-1.)
Repeat the procedure at the right joystick wiring harness
Connect the remote start tool to the loader. (See connector (Item 1) [Figure 50-112-4]. (If needed.)
REMOTE START on Page 10-60-1.)

669 of 1030
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

Page 10-20-1.)

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].

670 of 1030
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 support
Page 10-20-1.)
Disconnect the electrical harness (Item 1) [Figure 50-
112-9] from the joystick.

on Page 10-30-1.)
Remove the joystick from the loader.
Joystick Boot Removal (Right & Left) Remove the joystick. See Joystick Removal (Right &
Left) on Page 50-112-2
Figure 50-112-10
Remove the joystick boot. (See Joystick Boot Removal
(Right & Left) on Page 50-90-3.)
Remove the joystick wiring grommet (Item 1) [Figure 50-

112-11]
Figure 50-112-12
P-26225
1
Page 10-20-1.)
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].

671 of 1030
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.

672 of 1030
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.

673 of 1030

674 of 1030
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 support the loader.

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.

675 of 1030
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].

676 of 1030
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.

677 of 1030
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 support amount toward the center of the loader, to allow

clearance for the panel to be removed.
Page 10-20-1.)
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.

678 of 1030
ELECTRICAL SYSTEM & ANALYSIS
ADVANCED CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . .60-130-1

ACS Controller Removal And Installation . . . . . . . . . . . . . .60-130-5
Actuators Disassembly And Assembly . . . . . . . . . . . . . . .60-130-12
Calibration Of The ACS System . . . . . . . . . . . . . . . . . . . .60-130-14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-18
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . .60-130-17
Hand Controls Only Calibration Procedure . . . . . . . . . . . .60-130-16
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-6
Handle Lock Solenoid Removal And Installation . . . . . . . .60-130-13
Handle Lock Solenoid Disassembly And Assembly. . . . . .60-130-13
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . . .60-130-14
Switchable Hand/Foot Controls Calibration Procedure . . .60-130-15
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-9
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-7
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-3

ELECTRICAL
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1 SYSTEM &
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1 ANALYSIS
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-6
Alternator Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-3
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
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . .60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . .60-20-4

679 of 1030
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Inspecting The BICS™ Controller (Engine STOPPED - Key ON)60-100-1
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-100-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . .60-100-1
Inspecting The Traction Lock (Engine RUNNING). . . . . . . . . . . .60-100-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . .60-100-2
Additional Inspection For Loaders With Advanced Controls System (ACS)
or Selectable Joystick Control (SJC) . . . . . . . . . . . . . . . . . . . . . .60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-100-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-100-4
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-2

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-2
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . .60-71-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-1

DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1
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
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 (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . .60-50-2
Right Panel (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . .60-50-3
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . .60-50-5
Standard Panel Removal And Installation (Right Side) . . . . . . . . .60-50-9
Standard & Deluxe Panel Removal And Installation (Left Side). .60-50-11
680 of 1030
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
LIFT AND TILT ACTUATOR CALIBRATION (SELECTABLE JOYSTICK

CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-4
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
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-10
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

681 of 1030

682 of 1030
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
WIRING SCHEMATIC Printable Version Click Here
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
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) 6733137 REAR BASE 2380 2 2

PWM
C414
HIGH FLOW BICS HYDRAULIC LOCK
A A 4440
G
C
D
E
B
A
K
E
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 521311001 - 521313912) 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
(S/N 521411001 - 521411180) BUCKET POSITIONING FRONT ROD
C423
C418
A A
C441
TWO SPEED 7.5 ohm 4350 9.8 ohm A A 4420 4330 1 1 3.3 ohm
S300 (S/N 521511001 - 521512099) SOLENOID 12V B B 2350
12V
B B 2420 2330 2 2 PWM FRONT BASE
C419 C106
4340 1
(S/N 521611001 - 521611029)
CAB 6727178
C437
TWO SPEED 5 ohm A A 4390 2340 2
MAKE-UP 12V
(PRINTED JUNE 2004) B B 2360
DIVERTER
3600 A A
C416
SPEED
A A
V-0182 4450 7.5 ohm 3610 B B SENSOR MAIN
WORKLIGHTS
YELLOW TIE STRAP 2450 B B 12V FRAME
RED = RED
FRONT
RNG = ORANGE
2530 UNSWITCHED POWER 1000-1999 RED BLK = BLACK
GROUNDS
LBL = LIGHT BLUE
SWITCH
BRAKE
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT
2480 DBL = DARK BLUE
1930
SWITCHED POWER 1000-1999 RNG
2000
LGN = LIGHT GREEN ENGINE
GROUND 2000-2999 BLK
C104 C405 C406

2460
MONITORING 3000-3999 LBL DGN = DARK GREEN SEE J1
3210 B B COOLANT
REAR AUX RELIEF
C435
2450 t SENDER
RIGHT
7 HYDRAULIC 4000-4999 LGN YEL = YELLOW 3200 A A 2760 B B
C417
PNK = PINK 4480 A A C 500-3000 ohm
2440 2400 ATTACHMENT CONTROLS 5000-5999 YEL 9.8 ohm
LIGHTS 6000-6999 PNK WHT = WHITE
6120 A A
2480 B B 12V
2430 ACCESSORIES 7000-7999 WHT BRN = BROWN
SEAT
CAB
ENGINE 8000-8999 TAN TAN = TAN 3700 A A
C434
2340 AIR FILTER BAR 6110 A A
LEFT
COMMUNICATION 9000-9999 PUR PUR = PURPLE 12
4330
4360
4340
4410
4440
4430
4420
B SWITCH
2770
SEE J1 B 3710 B
3300
2330
2110
GRY = GRAY
3700
B
3200
B
3600
2750
4350
4460
4450
4390
4480
C476
2520 3110 B 3110 B FUEL
B B
2100 SENDER -
3100 A A 3100 A A +8 2910
30-270 ohm
2360 J1 J2 C C
2920 2900
C
2930
A
WIRES CONNECT BY LETTER SOME CONNECTOR 31 J1 J2
2420 6 18 29 26 32 12 22 1 41 3 21 10 38 48 8 18 2770
ACROSS CONNECTORS BODIES NOT SHOWN 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2410 FOR DRAWING CLARITY 3100 2760
11 A B SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
TEMP SIGNAL
PWM +8V ENG SPEED 28
LOCK SIGNAL
2380 2390 ANALOG 1 ROD GROUND Tx RIGHT SERIAL IN SUPPLY
B A 1 2 3 4 5 6 7 8 9 10
2370
4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2200 11 9110 D
2000
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
9210 E
C408
13 14 15 16 18 19 20
7 N K G L B R P S F E D C M A J H
11 12 17
2240 1200 9200 4820 3700 4310 4920 23 9400 F
+ 9110 4440
2350 A
A 42 9410 G
A FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C C
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
3210 0.5 - 7.5 V -
B 3400 A A 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
B B 4340 4430
2800 3420 E E 3420 47 BUCKET 35 3910
KEY/ENTER SEATBAR LH SKI RH SKI
POSITION OPEN OPEN GROUND OPEN UP
3610 HYDRAULIC 3410 F 3010 23
OPEN SWITCH GROUND UP
45
C102
F 3410 3920
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940 25 3900 A
2110
2600 A B
500-3000 ohm A 3300 C C 3300 C HYD LOCK STATUS
HEADLIGHT BRAKE SW HYDRAULIC
34 9350 C407
SOLENOID FLOAT SEATBAR OPEN
2300 SEE J2 SEE J2 OUT
SWITCH SIGNAL IN TEMP OPEN OPEN
2110
14 1200 SEE FUSE/RELAY CENTER
HYDRAULIC OIL 41 42 43 44 45 46 47 48 49 50 THIS PAGE
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300 24 1900
2740 GLOW PLUG TRACTION LOCK 46 4500
RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT
OPEN RELAY PULL / 963
HYDRAULIC FILTER 6717247

(AC INPUT) SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER
2730 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 44 9340
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
TWO SPEED FUEL PULL UNSWITCHED 29 4320
CAN GLOW PLUG ENG OIL MARKER FUEL PULL
SOLENOID FEEDBACK BATTERY (3) OPEN GROUND
SELECT FEEDBACK PRESS +8v 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
HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V HYD CHARGE ENG OIL RESERVED
36 4840
SPARE
POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
15 ohm B B 8820 A A 8800

J1 6 4810
FUEL
C C 2800 J2
D3
SHUTOFF
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 8 48 17 41 4
0.5 ohm A A 8120 B B 8100
J1
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
4910
STARTER
1480
4810
4820
4830
4840
4640
4300
4320
4310
4920
4930
4940
4230
2530
1490
2520
4240
M R Dealer Copy -- Not for Resale
C109
1015 B B 8250
S
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
A A 8200
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
A 1800 4200 A A HOLD
C425
BAT
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
ALTERNATOR
2015 4100 B B PULL 0.3 ohm
TAILGATE / WORKLIGHTS 6716419

F F
RIGHT + -
WORKLIGHT
2620 6200 2600 B B 2600
FLOAT
6210 6200 H H 6200 PWM
SHIFT
SKI CTRL
SIDE
C103
TWO SPD
SKI CTRL
LEFT
DETENT
A A
FLOW
2630 6210 6310 6310
WORKLIGHT
E E 6400
RIGHT
2610 6320 D D 6500
TAILLIGHT
2650 G G 6600
C404
LEFT TO OPTIONS
SEE CAB LEFT HANDLE
TAILLIGHT
2640 6330 7100 C C 7100 A CONNECTOR RIGHT HANDLE
BACKUP B (BACKUP ALARM
ALARM SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600 AIR INLET
6000
M 6500 HEATER
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 TO OPTIONS
25A (ACS CONNECTOR)
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M

7200 J J
C489
TO OPTIONS B 2720 SWITCHED MARKER REAR GLOW FUEL

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L
CONNECTOR) A 1720 1720
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 4550 K K
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
MAINFRAME HARNESS 6730292 1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040
FUSE 5 FUSE 1 FUSE 9

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
30A 15A 25A 1050

G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
FUSE 12
25A 100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR
25A 25A
1040 V-0182 (6-10-04)
Printed in U.S.A. (For S/M P/N 6901926) 1080
BATTERY
683 of 1030
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
B B 2430 2370 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
(With ACS Option) 6733137 REAR BASE 2380 2
C414
A A 4440
G
C
D
E
A
K
E
F
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
C423
C418
A A
C441
S300 (S/N 521511001 - 521512099) SOLENOID 12V B B 2350
12V
C419 C106
4340 1
(S/N 521611001 - 521611029)
CAB 6727178
C437
MAKE-UP 12V
DIVERTER
3600 A A
C416
SPEED
A A
WORKLIGHTS
RED = RED
FRONT
RNG = ORANGE
GROUNDS
LBL = LIGHT BLUE
SWITCH
BRAKE
1930
2000
2460 GROUND 2000-2999 BLK LGN = LIGHT GREEN ENGINE
C104 C405 C406

REAR AUX RELIEF 3210 B B COOLANT
C435
2450
RIGHT
7 HYDRAULIC 4000-4999 LGN YEL = YELLOW t SENDER 2760 B B
C417
PNK = PINK 4480 A A C 3200 A A
2440 2400 ATTACHMENT CONTROLS 5000-5999 YEL 9.8 ohm 500-3000 ohm
6120 A A
2480 B B 12V
SEAT
CAB
C434
LEFT
4330
4360
4340
4410
4440
4430
4420
B SWITCH
2770
SEE J1 B 3710 B
3300
2330
2110
GRY = GRAY
3700
B
3200
B
3600
2750
4350
4460
4450
4390
4480
C476
2520 3110 B 3110 B FUEL
B B
2100 SENDER -
3100 A A 3100 A A +8 2910
30-270 ohm
2360 J1 J2 C C
2920 2900
C
2930
A
2420 6 18 29 26 32 12 22 1 41 3 21 10 38 48 8 18 2770
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
COOLANT
TEMP SIGNAL
LOCK SIGNAL
B A 1 2 3 4 5 6 7 8 9 10
2370
2200 11 9110 D
2000
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
9210 E
C408
7
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 1200 9200 3700 4310 4920 23 9400 F
+ 9110 4440 4820
2350 A 42 9410 G
A A FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C C
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
3210 0.5 - 7.5 V -
B 3400 A A 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
B B 4340 4430
2800 3420 E E 3420 47 BUCKET 35 3910
3610 HYDRAULIC 3410 F 3010 23
45
C102
F 3410 3920
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940 25 3900 A
2110
2600 A B
34 9350 C407
2110
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300 24 1900

2730 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 44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
9 4300
31 32 33 34 35 36 37 38 39 40
4640
4350 8150 1130 9700 8550 3500 2100 6320 8110
36 4840
SPARE
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
15 ohm B B 8820 A A 8800

J1 6 4810
FUEL
C C 2800 J2
D3
SHUTOFF
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 8 48 17 41 4
0.5 ohm A A 8120 B B 8100
J1
4910
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
4300
4320
4310
4920
4930
4940
4230
2530
1490
1480
4810
4820
4830
4840
4640
2520
4240
STARTER

C109
1015 B B 8250
G
D
C
H
B
K
F
J
G
H
C
D
E
A
F
K
J
S
A A 8200
C410 C409
Traction Lock C409
G
D
C
H
B
K
F
J
G
H
C
D
E
K
F
J
C110
1020 B B 1020
WHT/RED
WHT/BLK
WHT/LGN
10.9 ohm
A
YEL/LGN
1015
B
A
YEL/RED
A 1800 A A
A
B
4200 HOLD
WHT
DGN
YEL
LGN
RGN
WHT
PUR
C425
RGN
DBL
BAT
C C C465 C466
2200
A
B
ALTERNATOR
A
B
2015 4100 B B PULL 0.3 ohm
TAILGATE / WORKLIGHTS 6716419 + -

F F HANDLE
HANDLE LOCK
FLOAT
SHIFT
SKI CTRL
RIGHT LOCK
SIDE
WORKLIGHT
2620 6200 2600 B B 2600 PWM
LEFT HANDLE
TWO SPD
SKI CTRL
DETENT
6210 6200 H H 6200
FLOW
C103
LEFT HORN RIGHT

2630 6210 6310 A A 6310 AHC LIFT
WORKLIGHT HALL SENSOR TURN SIGNAL
E E 6400 HANDLE
RIGHT AHC TILT
B
C
A
2610 6320 D D 6500 HALL SENSOR
TAILLIGHT
RNG/WHT
RNG/DBL
2650 G G 6600 C450
DGN
BRN
YEL
C404
LEFT SEE CAB
B
C
A
2640 6330 7100 C C 7100 A TO OPTIONS
A
C
B
TAILLIGHT CONNECTOR
BACKUP B (BACKUP ALARM C449
ALARM SWITCH) C407
C
B
D
E
B
A
B
C
A
A
2730 J J 2730
C411
B
C412
C
A
6600 P P 6600 AIR INLET C469
HEATER C472
6000
A
6500 M M 6500
C
B
C
B
A
(ACCESSORY (ACCESSORY
6400 L L 6400
CONNECTOR) CONNECTOR)
4750
1510
1610
2750
2650
4650
4730 F F 4730
hand 4 D D
4235 4235 4235
C488
6300 N N 6300 13 ohm TILT ACTUATOR LIFT ACTUATOR

5 4275 4275 C C 4275 12V
foot 6 FOOT PEDAL LOCK

4550 E E 4550 M M
1700 S S 1700
h
1140 A A 1140 1740
DGN
RED
RED
DGN
RED
RED
BLK
BLK
BLK
BLK
1700 f 1150 H H 1150
A B A B
2 4550 R R
C467 C468
1 B B
A B A B
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
G G
C428 C429
4270
2500
4280
2510
K K (ALTERNATOR
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
1800 & KITS)
FUSE 11
1530
4670
1630
4770
2670
2770
4690
4680
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M 4220

7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L 4275
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
C492
9620 D D 9620
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
MAINFRAME HARNESS 6730292 1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1
RELAY GROUNDS 2000-2060 G
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
(UNSWITCHED
POWER)
25A
(ACS)
1170
9110 F
A F
P
1740
1500
B
A
J2
D
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
15A GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A 100A
1010 1030
C426 (ATTACHMENT
A A 1520
FUSE 8 FUSE 4 FUSE 12 CONTROL)
ACS HARNESS 6733292
C471
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR LIFT C C 4660
25A 25A PEDAL
1040
V-0183 (6-10-04) B B 2660
BATTERY
684 of 1030
WIRING SCHEMATIC
OPTIONS
S250 (S/N 521311001 AND ABOVE)
S300 (S/N 521511001 AND ABOVE)
(PRINTED JUNE 2004) Printable Version Click Here TO ENGINE OR MAINFRAME
TO OPTIONS (HVAC) 2205 C C THERMOSTAT 7100 C
C639
V-0184 6 7010 B B 2650 F
AIR CONDITIONER SWITCH
5 3100 A A
C103
6600 G
C634
THERMOSTAT
4 2200 6400 E
3100 A A BLOWER MOTOR BACK-UP
C630
3 5000 3 3 YEL ALARM 6310 A
C612
OFF A 7010 B B
2 1200 2 2 RED 6500 D
LOW
C638
B 2310 2205 C C M TO ENGINE OR MAINFRAME
2100 1 1010 1 1 RNG 6200 H
MEDIUM TO OPTIONS (AC)
2210 4 4 BLK
RNG C
HIGH 2600 B
5 5
RNG/DGN F
G
C103
HERE OR TO OPTIONS 6 6
6340
2620
HEATER VALVE E
2610
6610
6320
6620
6330
2640
(HVAC JUMPER) BACK-UP
DBL A A 3200 1300 A A RED 10 TO OPTIONS
ALARM A
C613
(HVAC HARNESS)
WHT B B 7200 D D WHT 8 M BACK-UP ALARM D
C640
C614
7000 2630 6210 H
BLK C C 2110 2130 C C BLK 7 7020 A E F C A B D F E D C B A
C
1110
POTENTIOMETER B B C604 C605 REGISTRATION LEFT WORK RIGHT WORK
HARNESS - 6715659 B
C641
2320 B B AIR CONDITIONER
E E E F C A B D F E D C B A LAMP
B CLUTCH SOLENOID
1000 7020 A A
F F
L BLOWER MOTOR
5000 3 3 YEL
M
1200 2 2 RED HVAC ADAPTER HARNESSES - 6726357 DELUXE EUROPEAN
C611
M
H 1010 1 1 RNG
LEFT TAILLIGHT RIGHT TAILLIGHT
TAILLIGHT HARNESS - 6718198
2200 4 4 BLK
BLOWER SWITCH POWER RELAY
5 5 TO OPTIONS
(DELUXE ACCESSORY)
6 6 85 86
1740 2210
87 A LEFT RIGHT LEFT TAILLIGHT
C617
30 FLASHER FLASHER RIGHT TAILLIGHT
87A 1190 B
LIGHT LIGHT
HVAC HARNESS - 6725933 2740 C BACK-UP
ALARM
TO OPTIONS
2790
2795
TO ENGINE OR MAINFRAME (EXTERIOR CAB) TO ENGINE OR
TO OPTIONS (HVAC) A B C D E F LEFT WORK REGISTRATION MAINFRAME RIGHT WORK A B C D E F
C
6440 1
C669
RNG ACCESSORY STOP LIGHT
BACK-UP
C631
C612
B B 2310 2300 B 2785 2 C604 C103 C605

ALARM RNG/DGN F
A A 7030 A 6540 3 A B C D E F A B B A A B C A B C D E F G H A B C D E F
C103
G
E
4 WAY FLASHER
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
6410
6810
6640
2540
2540
2530
6240
1720
2720
1740
2730
1730
6600
2530
2520
7100
6370
6310
2500
7100
6500
6400
6200
6250
2520
2510
6240
6230
6510
6710
6610
2550
AIR CONDITIONER DIODE PNK A
CLUTCH SOLENOID
D HARNESS - 6718873
DBL/WHT H
BLK B
7020
7010
DBL/WHT
BLK
BLK
PNK
PNK
BLK
BLK
46 C C 6430 A A 6520
B A 41 B B 6730 B B 6720
C632 40 A A 2660 OPEN C C 6620

HARNESS 6713993 2630 D D 2620
B A
LEFT RIGHT
AIR CONDITIONER LEFT
TAILLIGHT
RIGHT
TAILLIGHT
WORK
LIGHT
WORK
LIGHT
40
42
A
B
A
B
2640 OPEN
6330 Dealer Copy -- Not for Resale
E
F
E
F
OPEN
6320
HARNESS - REAR LIGHT HARNESS - 6714350

HARNESS 6713994
46 C C
HARNESS 6731239
6430 A A 6430
6719630 EVAPORATOR (AC) 41 B B 6730 B B 6830
PRESSURE SWITCH 40 A A 2660 OPEN C C 6630
HARNESS 6713993 2630 D D 2630
40 A A 2640 OPEN E E OPEN
DOME LIGHT 42 B B 6330 F F 6330
FRONT WIPER TO OPTIONS SWITCH HARNESS 6713994 HARNESS 6731239
M BOTTLE AND TANK
C608
A RED
6800
2670
6700
2660
FRONT WIPER B BLK
6360
2650
1370
2640
MOTOR
2620
V DOME LIGHT 2630
M 87A 87 86 87A 87 86
2640 87A 87 86 87A 87 86
2610 2650
C622
7200 or YEL
7150 or DGN
2765 or BRN
2660
To Engine Ground 30 85 30 85
L X
2670 30 85 30 85
TO ATTACHMENT
2730
TO
6350
6340
B MAINFRAME
1370
6210
6310
C404
TO OPTIONS B
2745
1020
1320
1020
1320
1020
1320
(DELUXE ACCESSORY)
N 7100 A
C 7310
B 2735 2755 B B P
C610
C667
BACK-UP ALARM
E 7150 7160 C C M TO OLDER A B A B A B
SWITCHES
MODEL ATTACHMENTS
A 7210 A A A 7110
C506
TO To Starter "B" Terminal

F 7190 7180 D WHT S MAINFRAME
2 2 2 Left Marker Fuse 10A
C402
1720 1730 A Right Marker Fuse 10A Signal Fuse 10A
C BRN LT
C623
D 4710 1 1 4720 1 1010

E BLK TM 2720 B HARNESS 6726430
WIPER HARNESS - 6730885 F DBL CENTER BACK-UP ALARM ROAD LIGHTS
G RED GD ADDITIONAL POWER
H YEL RT
SWITCHES HARNESS - CONNECTOR
C491
B TO OPTIONS
L RNG
6718820 OR 6807152 1740 A (HVAC)
TO OPTIONS
(DELUXE ACCESSORY) ADDITIONAL POWER CONNECTOR
K RNG
C490
C636 C 2740 C
1740 A
C642
2740 B
STROBE OR
GRADER HARNESS - B 1140 B RED = RED
RNG = ORANGE
WIRES CONNECT BY
A 1740 A LETTER ACROSS
BEACON
6707303 TO MAINFRAME
BLK = BLACK
LBL = LIGHT BLUE CONNECTORS
(ACCESSORY CONNECTOR) DBL = DARK BLUE A B
ADDITIONAL POWER CONNECTOR
HVAC/ACCESSORY 1730 1720 A LGN = LIGHT GREEN B A
C490
C402
1740 A DGN = DARK GREEN
2 1
C609 POWER BOB-TACH
2740 B HARNESS - 6725390 2720 B YEL = YELLOW
PNK = PINK
SOME CONNECTOR
SOLENOID WHT = WHITE BODIES NOT SHOWN
TO TO OPTIONS FOR DRAWING CLARITY
2 1 TO MAINFRAME
ALARM BRN = BROWN
C606
STROBE/BEACON A 7000 A A HORN TO HANDLE CONNECT0R TAN = TAN

(ACCESSORY CONNECTOR)
C412
TO OPTIONS TO ATTACHMENT 2730 B PUR = PURPLE
D 2760 B B TO BATTERY FEED 1000-1999 RED, RED/WHT, RNG
C601
1730 1720 A GRY = GRAY

C489
(BOOM
6700 E C MAINFRAME 7200 A GROUND 2000-2999 BLK
C668 OR C670
2720 B CONNECTOR)
2775
MONITORING 3000-3999 LBL

A FRONT HORN HARNESS -
C607
TO OPTIONS B 7010 B B POWER BOB-TACH A 9500 A HYDRAULIC 4000-4999 LGN

(4 WAY FLASHER) C SOLENOID ATTACHMENT CONTROLS 5000-5999 YEL
E 2770 A A B 9600 B
2 2785 2780 D
ALARM
TO HANDLE CONNECT0R C 9700 C 6727498 LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
C669
HORN
C666
C426
ENGINE 8000-8999 TAN
C412
1 6440 F 2730 B D 9800 D COMMUNICATION 9000-9999 PUR

3 6540 B 7200 A 1 1710 E
EXTERIOR CAB HARNESS - POWER BOB-TACH HARNESS - FRONT HORN HARNESS - 2 1160 F
3 2710 G
6718872 6718652 or 6730770 6719151 or 6727498
BOOM HARNESS - 6718426
V-0184 (6-10-04)
(For S/M P/N 6901926)
685 of 1030
WIRING SCHEMATIC RIGHT HANDLE
OPTIONS PNK/
C432
C450
A 1 1 RED
S250 (S/N 521311001 AND ABOVE) C 3 3 PNK/DGN
TILT
CONTROL
(S/N 521411001 AND ABOVE) B 2 2 PNK/BLK
S300 (S/N 521511001 AND ABOVE)

SSL 7-PIN
(S/N 521611001 AND ABOVE) CAN CONNECTOR
B WHT
(PRINTED JUNE 2004) KEY "RUN" D 9800 YEL D D WHT/RED PWM
V-0185
UNSW POWER 2 1160 RED F
SSL 7-PIN
C426 To Mainframe C WHT/BLK
CAN SHIELD C 9700 DGN C CAN CONNECTOR Harness RIGHT
D F C E A B G
To Mainframe
C409
SW POWER 1 1710 RNG E ROCKER
Printable Version Click Here CAN LOW B 9600 LBL A
Harness F WHT/LGN UP
9800
1160
9700
1710
9500
9600
2710
CAN HIGH A 9500 WHT B
DETENT
GROUND 3 2700 BLK G E DGN
7-PIN
C666 C426 ATTACHMENT

CONNECTOR
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
K
J YEL
UNSW POWER F 1160 RED/WHT 2720 H GROUND SKI
H LGN CONTROL
CONTROL HARNESS - 6718426 CAN SHIELD
SW POWER
C
E
9710
1730
PUR
RNG
9710
1720
F
B
CAN SHIELD
SW POWER
A RNG
CAN LOW B 9620 PUR 9610 E CAN LOW

CAN HIGH A 9520 PUR 9510 D CAN HIGH D PUR FLOAT
SIGNAL
GROUND G 2730 BLK C OPEN J
7-PIN A OPEN A RNG
TO OPTIONS C666 ATTACHMENT
CONNECTOR G OPEN C WHT SKI
(POWER BOB-TACH)
C410
J B DBL CONTROL
POWER BOB-TACH 2770 E
SWITCH BOOM-MOUNTED
FLASHER N G PNK PADDLE
2760 D ACD CONNECTORS
C601
1 SW POWER K 1740 F TAN MOMENTARY
7000 A
BEACON SWITCH
6
2
C
GROUND B 2740 C703 J2 - 10-PIN BLACK K
E OUTPUT E 5100 5100 C E OUTPUT E
5 HAZARD SWITCH 7010 B
4 3 F OUTPUT F 5350 5350 H F OUTPUT H
2 1
1130 6010 6430 4
3 L 5 G OUTPUT G 5400 5400 J G OUTPUT
X 3
1180 B BRN
TO OPTIONS 1 2 H OUTPUT H 5050 5050 B H OUTPUT
C449 C412 C411

4 6 TURN
(EXTERIOR CAB) 6530 C OUTPUT C 5300 5300 G C OUTPUT D YEL
5 SIGNAL
6 2750
E 6700 TO MAINFRAME D OUTPUT D 5150 5150 D D OUTPUT A DGN
2755 ACS SWITCH
D 2780 1 A OUTPUT A 5250 5250 F A OUTPUT C
C670
4550 E
B 6540 2
3 M OUTPUT M 5200 5200 E B OUTPUT E
2745 R
F 6440 4 ID (K TO L) L 5910 5000 A J OUTPUT
A
2755 4235 D A BLK
5 ID (K TO P) P 5510 5450 K K OUTPUT
4275 C
6 B RED HORN
C K
C506 14-PIN
C488
G ATTACHMENT
CONNECTOR
C704 J3 - 10-PIN GRAY
B 5900 J ID #1
C433
A 1 1 RED/WHT
2730 J 5500 A ID #2 C 3 3 PUR/WHT
LIFT
CONTROL
1700 S B ID #3 B 2 2 BLK/WHT
6400 L C ID #4 LEFT HANDLE
6500 M D ID #0
1150 H
DELUXE ATTACHMENT E OPEN
N F OPEN ADVANCED HAND CONTROL
P CONTROL HARNESS - G OPEN
F
A
Dealer Copy -- Not for
6732730 Resale H OPEN (WITH PUSH BUTTON FLOAT) -
STANDARD ACCESSORY HARNESS - 6727468
K OPEN RIGHT STEERING LEVER - 6675742 and
LEFT STEERING LEVER 6675750
TO OPTIONS
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH
BEACON SWITCH 2770 E V
SWITCH
1 2760 D M
2745 6420
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
WIRES CONNECT BY 1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
LETTER ACROSS 2 4 7220
3 5 SWITCH
4 1
CONNECTORS 4 5 2
6530 3
A B TO OPTIONS 5 6 1730
6 2750 2 1
B A (EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
SOME CONNECTOR D 2780 6 5
4
C670
BODIES NOT SHOWN 7310

B 6540 5
FOR DRAWING CLARITY TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A
C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411
RED = RED (FRONT WIPER)
RNG = ORANGE PLUG
6000 B C
BLK = BLACK
LBL = LIGHT BLUE C F
DBL = DARK BLUE
E
C667
LGN = LIGHT GREEN 7210 A
DGN = DARK GREEN ACS SWITCH TO MAINFRAME 4710 D
YEL = YELLOW 1
PNK = PINK 1770 4550 E 1760 E
2
WHT = WHITE 3 R 2735 B
BRN = BROWN 4
TAN = TAN 2755 4235 D
5 4275
PUR = PURPLE 6 C
GRY = GRAY K
G
B
C488
2730 J
6400 L
6500 M
1150 H
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK 6300 N
MONITORING 3000-3999 LBL 6600 P
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL TO EUR0. LIGHTS 4730 F
LIGHTS 6000-6999 PNK CONNECTOR 1140 A
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN 1700 S
COMMUNICATION 9000-9999 PUR
DELUXE ACCESSORY HARNESS - 6727190

Printed in U.S.A. (For S/M P/N 6901926) V-0185 (6-10-04)
686 of 1030
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
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
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380 1
DATA B
7.7 ohm
(With SJC Option) 6733137 REAR BASE 2380 2 2

PWM
C414
A A 4440
G
C
D
E
A
K
E
F
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
C423
C418
A A
C441
S300 (S/N 521511001 - 521512099) SOLENOID 12V B B 2350
12V
C419 C106
4340 1
(S/N 521611001 - 521611029)
CAB 6727178
C437
MAKE-UP 12V
DIVERTER
3600 A A
C416
SPEED
A A
WORKLIGHTS
RED = RED
FRONT
RNG = ORANGE
GROUNDS
LBL = LIGHT BLUE
SWITCH
BRAKE
1930
2000
C104 C405 C406

2460
3210 B B COOLANT
REAR AUX RELIEF
C435
2450 t SENDER
RIGHT
C417
PNK = PINK 4480 A A C 500-3000 ohm
2440 2400 ATTACHMENT CONTROLS 5000-5999 YEL 9.8 ohm
6120 A A
2480 B B 12V
SEAT
CAB
C434
LEFT
4330
4360
4340
4410
4440
4430
4420
B SWITCH
2770
SEE J1 B 3710 B
3300
2330
2110
GRY = GRAY
3700
B
3200
B
3600
2750
4350
4460
4450
4390
4480
C476
2520 3110 B 3110 B FUEL
B B
2100 SENDER -
3100 A A 3100 A A +8 2910
30-270 ohm
2360 J1 J2 C C
2920 2900
C
2930
A
2420 6 18 29 26 32 12 22 1 41 3 21 10 38 48 8 18 2770
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
COOLANT
TEMP SIGNAL
LOCK SIGNAL
B A 1 2 3 4 5 6 7 8 9 10
2370 11 9110 D
2200 7 9210 E
2000
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
9400 F
C408
23
2240 1200 9200 3700 4920 42 9410 G
+ 9110 4440 4820 4310
2350 A
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C C
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
3210 0.5 - 7.5 V -
B 3400 A A 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
B B 4340 4430
2800 3420 E E 3420 47 BUCKET 35 3910
3610 HYDRAULIC 3410 F 3010 23
45
C102
F 3410 3920
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940 25 3900 A
2110
2600 A B
34 9350 C407
2110
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300 24 1900

2730 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 44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
9 4300
31 32 33 34 35 36 37 38 39 40
4640
4350 8150 1130 9700 8550 3500 2100 6320 8110
36 4840
SPARE
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
15 ohm B B 8820 A A 8800

J1 6 4810
FUEL
C C 2800 J2
D3
SHUTOFF
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 8 48 17 41 4
0.5 ohm A A 8120 B B 8100
J1
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
4910
STARTER
1480
4810
4820
4830
4840
4640
4300
4320
4310
4920
4930
4940
4230
2530
1490
2520
4240
C109
1015 B B 8250
S
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
A A 8200

C110
1020 B B 1020 NOT USED WITH NOT USED WITH

1015 10.9 ohm SJC OPTION SJC OPTION
A A 1800 4200 A A HOLD
C425
BAT
2200 C C
ALTERNATOR
2015 4100 B B PULL 0.3 ohm

F F
RIGHT
WORKLIGHT
2620 6200 2600 B B 2600
6210 6200 H H 6200
C103
LEFT
WORKLIGHT
2630 6210 6310 A A 6310
E E 6400
RIGHT
2610 6320 D D 6500
TAILLIGHT LEFT RIGHT RIGHT LEFT
2650 G G 6600 HANDLE HANDLE SIDE SIDE
C404
LEFT SEE CAB WHEEL WHEEL

2640 6330 7100 C C 7100 A TO OPTIONS 1 7 2 6 5 4 3 3 4 5 6 2 7 1
TAILLIGHT CONNECTOR SPEED SPEED
ALARM SWITCH) C407 AIR INLET C459 C460 HALL HALL
HEATER 1 7 2 6 5 4 3 3 4 5 6 2 7 1 EFFECTS EFFECTS
A
J 2730 SENSOR SENSOR
RED
RED
WHT
BRN
WHT
LGN
LGN
BRN
BLK
BLK
P 6600
4 3 2 1 4 3 2 1
6000
M 6500 C453 C454
TO OPTIONS 6 5 4 3 2 1 1 2 3 4 5 6 4 3 2 1 4 3 2 1
L 6400
C497 C449 C450
1530
1540
F 4730
3070
3000
3080
3020
2570
2580
A B C 6 5 4 3 2 1 1 2 3 4 5 6
D 4235
OPEN
9000
C488
4520
4530
OPEN
4540
1510
4510
2080
1520
2070
9010
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) 4220 M N 6510
E 4550
7200 J P 6410
S 1700
4275 L J 7200
A 1140 1740
6410 P F 9000 2620 1 1 BLK
OPEN
OPEN
OPEN
OPEN
OPEN
H 1150 6510 N 3050
G 9010 2 2 DGN
TILT ACTUATOR
R 1570
4550 K K 4950 3 3 RED
B
C492
9720 E E OPEN S L M E F K J N P R C D B A G H OPEN 4 4
C428
G S 1230
9620 D H 2240 1500 G J1 5 5 RED
K (ALTERNATOR G 9410 S B OPEN OPEN
A 1170 1190 H 6 6
& KITS) M
120
1800 F 9400 C OPEN
FUSE 11 R R 1180 J OPEN 7 7
25A H 2170 8 8
E 9210 G S 9420 OPEN D BLK
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 9520 C D OPEN

B 1740 R
C489
TO OPTIONS B 2720 MARKER GLOW FUEL 2240 H D 9620 B R OPEN 2630 1 1 BLK
SWITCHED REAR
(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 3060
A 1720 1720 1740 B C 9520 C F OPEN 2 2 DGN
CONNECTOR)
LIFT ACTUATOR
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
L OPEN 1580 3
(ATTACHMENT) 1170 A M 4420 2500 A 3 RED
(COMPUTER)
J3
FUSE 4
FUSE 10 M OPEN OPEN 4 4
30 85 30 85 30 85 30 85 30 85 30 85 85 30 D 9110 F L 4275 J2
C429
25A 2250 S
A 1240 5 5 RED
1730 OPEN E
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
N OPEN OPEN 6 6
(HEATER OPEN F M
) K 2250 OPEN 7
FUSE 1 FUSE 2 FUSE 5 OPEN K 7
FUSE 3 FUSE 6 8 8
25A 15A 15A 30A 30A J 2180 BLK
OPEN L
1140
OPEN M G 7100
C404
A TO
MAINFRAME HARNESS 6730292 1150 1160
OPEN N E
P
4275
4420
B OPTIONS
OPEN P J4
RELAY GROUNDS 2000-2060 1070
FUSE 9 FUSE 12 B K J G C D E H A F
ARE CONNECTED IN SERIES
(UNSWITCHED
25A
OPE
4250
2690
2680
4260
4270
2670
2660
4280
OPE
N
N
POWER) (ACS)
2070
2080
A B C D A B C D
1080
1040
2500 2570
C451 C452 2580
A B C D A B C D 2620
2630
FUSE 1 FUSE 9 13 ohm - 12V
FUSE 5
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT POWER RIGHT RIGHT LEFT LEFT
FUSE 6 FUSE 2 LIGHT FUSE 10 2240 2250
DRIVE DRIVE DRIVE DRIVE
REVERSE FORWARD 2260
REVERSE FORWARD
30A 15A 25A 1050
G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
FUSE 12
25A 100A
1010 1030
C426 (ATTACHMENT
CONTROL)
SJC HARNESS 6736028
ACD & REMOTE
COMPUTER ACS
25A 25A
1040 V-0355 (6-10-04)
Printed in U.S.A. (For S/M P/N 6901926) BATTERY 1080
687 of 1030
LOCK VALVE LOCK VALVE REAR ROD REAR BASE
BUCKET POSITIONING
C423
B A A B A B A B 4420 A A 9.8 ohm
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
12V
COMPUTER POWER F
COMPUTER POWER
2420 B B TILT SPOOL LOCK
RIGHT PANEL
C416A C417A C413A C414A
LEFT PANEL
(NOT Used With AHC or ACS)
WIRING SCHEMATIC
CLOCK/LATCH A
CLOCK/LATCH
C421
HEADLIGHTS
B A A B A B A B 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
7.7 ohm
GROUND
2370 2 2
GROUND
(NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
4430
2430
4440
2440
C422
2450
4452
4482
START J
2480
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
(Without Option) HIGH FLOW

6733137 2380 2 2
PWM
BICS HYDRAULIC LOCK
REAR AUX.
G
HARNESS
D
E
B
A
K
E
F
J
6736011
C415
C420
7.5 ohm A A 4460 A A 4460 4410 A A 9.8 ohm
S250 (S/N 521313913 AND ABOVE) 12V B B 2460 B B 2460 BLUE TIE STRAP 2410 B B 12V
4481
4451
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
(S/N 521411181 AND ABOVE) FRONT ROD
C418
A A
C441
TWO SPEED 7.5 ohm 4350 4330 1 1 3.3 ohm
S300 (S/N 521512100 AND ABOVE) SOLENOID 12V B B 2350 2330 2 2 PWM FRONT BASE
C419 C106
WHITE TIE STRAP 4340 1
CAB 6727178
C437
A A 4390 YELLOW TIE STRAP GREEN TIE STRAP BROWN TIE STRAP
TWO SPEED 5 ohm 2340 2
4440
2440
MAKE-UP 12V
4430
2430
2450
4450
4480
2480
3600 A A SPEED
V-0585 A B 3610 B B SENSOR MAIN
WORKLIGHTS
A B FRAME
RED = RED B A A B
C414
FRONT
RNG = ORANGE
2530 GROUNDS UNSWITCHED POWER 1000-1999 RED BLK = BLACK C416 C417 C413 A B
LBL = LIGHT BLUE
SWITCH
BRAKE
2480 DBL = DARK BLUE B A A B A B
1930
2000
ENGINE
4440
2440
GROUND 2000-2999 BLK LGN = LIGHT GREEN
C104 C405 C406

2460
MONITORING 3000-3999 LBL DGN = DARK GREEN 3210 B B COOLANT
4430
2430
SEE J1
C435
2450
4450
t
4480
2480
2450 SENDER
RIGHT
PNK = PINK C 500-3000 ohm
2440 2400 ATTACHMENT CONTROLS 5000-5999 YEL
WHITE TIE STRAP 6120 A A
YELLOW TIE STRAP
2430 ACCESSORIES 7000-7999 WHT BRN = BROWN GREEN TIE STRAP BROWN TIE STRAP
SEAT
CAB
C434
LEFT
4330
4360
4340
4440
4410
4430
4420
B SWITCH
2770
SEE J1 B 3710 B
3300
2330
2110
GRY = GRAY
3700
B
3200
B
3600
2750
4350
4450
4460
4390
4480
C476
2520 3110 B 3110 B FUEL
B B
2100 SENDER -
3100 A A 3100 A A +8 2910
30-270 ohm
2360 J1 J2 C C
2920 2900
C
2930
A
WIRES CONNECT BY LETTER SOME CONNECTOR 31 29 26 J1 J2
2420 6 18 22 12 32 1 41 3 21 10 38 48 8 18 2770
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
COOLANT
TEMP SIGNAL
LOCK SIGNAL
B A 1 2 3 4 5 6 7 8 9 10
2370
2200 11 9110 D
2000
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
9210 E
C408
13 14 15 16 18 19 20
7 N K G L B R P S F E D C M A J H
11 12 17
2240 1200 9200 4820 3700 4310 4920 23 9400 F
+ 9110 4440
2350 A
A 42 9410 G
A FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C C
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
3210 0.5 - 7.5 V -
B 3400 A A 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
B B 4340 4430
2800 3420 E E 3420 47 BUCKET 35 3910
3610 HYDRAULIC 3410 F 3010 23
45
C102
F 3410 3920
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940 25 3900 A
2110
2600 A B
34 9350 C407
2110
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300 24 1900

2730 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 44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
9 4300
31 32 33 34 35 36 37 38 39 40
4640
4350 8150 1130 9700 8550 3500 2100 6320 8110
36 4840
SPARE
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
15 ohm B B 8820 A A 8800

J1 6 4810
FUEL
C C 2800 J2
D3
SHUTOFF
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 8 48 17 41 4
0.5 ohm A A 8120 B B 8100
J1
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
4910
STARTER
1480
4810
4820
4830
4840
4640
4300
4320
4310
4920
4930
4940
4230
2530
1490
2520
4240
C109
1015 B B 8250
S
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
A A 8200

C110
1020 B B 1020
G
H
C
D
G
E
D
C
H
F
K
J
J
1015 A 10.9 ohm
A 1800 4200 A A HOLD
C425
BAT
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
ALTERNATOR
2015 4100 B B PULL 0.3 ohm

F F
RIGHT + -
WORKLIGHT
2620 6200 2600 B B 2600
FLOAT
6210 6200 H H 6200 PWM
SHIFT
SKI CTRL
SIDE
C103
TWO SPD
SKI CTRL
LEFT
DETENT
A A
FLOW
2630 6210 6310 6310
WORKLIGHT
E E 6400
RIGHT
2610 6320 D D 6500
TAILLIGHT
2650 G G 6600
C404
LEFT TO OPTIONS
SEE CAB LEFT HANDLE
TAILLIGHT
2640 6330 7100 C C 7100 A CONNECTOR RIGHT HANDLE
ALARM SWITCH) C407
TURN SIGNAL HORN
A
J 2730 AIR INLET
P 6600 HEATER
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 TO OPTIONS
25A (ACS CONNECTOR)
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M

7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 4550 K K
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
MAINFRAME HARNESS 6730292 1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040

FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
30A 15A 25A 1050

G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
FUSE 12
25A 100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
25A 25A
1040 V-0585 (6-10-04)
BATTERY
688 of 1030
BUCKET POSITIONING
C423
B A A B A B A B 4420 A A 9.8 ohm
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
12V
COMPUTER POWER F
COMPUTER POWER
B B TILT SPOOL LOCK
RIGHT PANEL
2420
C416A C417A C413A C414A
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C421
HEADLIGHTS
B A A B A B A B 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
GROUND
2370 2
GROUND G
BUZZER
BUZZER
4430
2430
4440
2440
C422
2450
4452
4482
START J
2480
START J
OPEN
1
DATA B
4380
DATA B
(With ACS Option) HIGH FLOW
6733137 2380 2
BICS HYDRAULIC LOCK
REAR AUX.
G
HARNESS
D
E
A
K
E
F
6736011
C415
C420
7.5 ohm A A 4460 A A 4460 4410 A A 9.8 ohm
4481
4451
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C418
A A
C441
TWO SPEED 7.5 ohm 4350 4330 1 1 3.3 ohm
C419 C106
CAB 6727178
C437
A A 4390 YELLOW TIE STRAP GREEN TIE STRAP BROWN TIE STRAP
TWO SPEED 5 ohm 2340 2
4440
2440
MAKE-UP 12V
4430
2430
2450
4450
4480
2480
3600 A A SPEED
WORKLIGHTS
A B FRAME
RED = RED B A A B
C414
FRONT
RNG = ORANGE
LBL = LIGHT BLUE
SWITCH
BRAKE
2480 DBL = DARK BLUE B A A B A B
1930
2000
4440
2440
2460 GROUND 2000-2999 BLK LGN = LIGHT GREEN ENGINE
C104 C405 C406

MONITORING 3000-3999 LBL DGN = DARK GREEN
4430
2430
SEE J1 3210 B B COOLANT
C435
2450
4450
4480
2480
2450
RIGHT
7 HYDRAULIC 4000-4999 LGN YEL = YELLOW t SENDER 2760 B B
PNK = PINK C 3200 A A
2440 2400 ATTACHMENT CONTROLS 5000-5999 YEL 500-3000 ohm
YELLOW TIE STRAP
SEAT
CAB
C434
LEFT
4330
4360
4340
4440
4410
4430
4420
B SWITCH
2770
SEE J1 B 3710 B
3300
2330
2110
GRY = GRAY
3700
B
3200
B
3600
2750
4350
4450
4460
4390
4480
C476
2520 3110 B 3110 B FUEL
B B
2100 SENDER -
3100 A A 3100 A A +8 2910
30-270 ohm
2360 J1 J2 C C
2920 2900
C
2930
A
WIRES CONNECT BY LETTER SOME CONNECTOR 31 29 26 J1 J2
2420 6 18 22 12 32 1 41 3 21 10 38 48 8 18 2770
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
COOLANT
TEMP SIGNAL
LOCK SIGNAL
B A 1 2 3 4 5 6 7 8 9 10
2370
2200 11 9110 D
2000
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
9210 E
C408
7
2240 1200 9200 3700 4310 4920 23 9400 F
+ 9110 4440 4820
2350 A 42 9410 G
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C C
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
3210 0.5 - 7.5 V -
B 3400 A A 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
B B 4340 4430
2800 3420 E E 3420 47 BUCKET 35 3910
3610 HYDRAULIC 3410 F 3010 23
45
C102
F 3410 3920
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940 25 3900 A
2110
2600 A B
34 9350 C407
2110
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300 24 1900

2730 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 44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
9 4300
31 32 33 34 35 36 37 38 39 40
4640
4350 8150 1130 9700 8550 3500 2100 6320 8110
36 4840
SPARE
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
15 ohm B B 8820 A A 8800

J1 6 4810
FUEL
C C 2800 J2
D3
SHUTOFF
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 8 48 17 41 4
0.5 ohm A A 8120 B B 8100
J1
4910
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
4300
4320
4310
4920
4930
4940
4230
2530
1490
1480
4810
4820
4830
4840
4640
2520
4240
STARTER

C109
1015 B B 8250
G
D
C
H
B
K
F
J
G
H
C
D
E
A
F
K
J
S
A A 8200
C410 C409
Traction Lock C409
G
D
C
H
B
K
F
J
G
H
C
D
E
K
F
J
C110
1020 B B 1020
WHT/RED
WHT/BLK
WHT/LGN
10.9 ohm
A
YEL/LGN
1015
B
A
YEL/RED
A 1800 A A
A
B
4200 HOLD
WHT
DGN
YEL
LGN
RGN
WHT
PUR
C425
RGN
DBL
BAT
C C C465 C466
2200
A
B
ALTERNATOR
A
B
2015 4100 B B PULL 0.3 ohm
TAILGATE / WORKLIGHTS 6716419 + -

F F HANDLE
HANDLE LOCK
FLOAT
SHIFT
SKI CTRL
RIGHT LOCK
SIDE
WORKLIGHT
2620 6200 2600 B B 2600 PWM
LEFT HANDLE
TWO SPD
SKI CTRL
DETENT
6210 6200 H H 6200
FLOW
C103
LEFT HORN RIGHT

2630 6210 6310 A A 6310 AHC LIFT
WORKLIGHT HALL SENSOR TURN SIGNAL
E E 6400 HANDLE
RIGHT AHC TILT
B
C
A
2610 6320 D D 6500 HALL SENSOR
TAILLIGHT
RNG/WHT
RNG/DBL
2650 G G 6600 C450
DGN
BRN
YEL
C404
LEFT SEE CAB
B
C
A
2640 6330 7100 C C 7100 A TO OPTIONS AIR INLET
A
C
B
TAILLIGHT CONNECTOR
BACKUP B (BACKUP ALARM HEATER C449
ALARM SWITCH) C407
C
B
D
E
B
A
B
C
A
A
2730 J J 2730
C411
B
C412
C
A
6600 P P 6600 C469
C472
6000
A
6500 M M 6500
C
B
C
B
A
(ACCESSORY (ACCESSORY
6400 L L 6400
CONNECTOR) CONNECTOR)
4750
1510
1610
2750
2650
4650
4730 F F 4730
hand 4 D D
4235 4235 4235
C488
6300 N N 6300 13 ohm TILT ACTUATOR LIFT ACTUATOR

5 4275 4275 C C 4275 12V
foot 6 FOOT PEDAL LOCK

4550 E E 4550 M M
1700 S S 1700
h
1140 A A 1140 1740
DGN
RED
RED
DGN
RED
RED
BLK
BLK
BLK
BLK
1700 f 1150 H H 1150
A B A B
2 4550 R R
C467 C468
1 B B
A B A B
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
G G
C428 C429
4270
2500
4280
2510
K K (ALTERNATOR
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
1800 & KITS)
FUSE 11
1530
4670
1630
4770
2670
2770
4690
4680
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M 4220

7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L 4275
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
C492
9620 D D 9620
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
MAINFRAME HARNESS 6730292 1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1
RELAY GROUNDS 2000-2060 G
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
(UNSWITCHED
POWER)
25A
(ACS)
1170
9110 F
A F
P
1740
1500
B
A
J2
D
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
15A GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A 100A
1010 1030
C426 (ATTACHMENT
A A 1520
FUSE 8 FUSE 4 FUSE 12 CONTROL)
ACS HARNESS 6733292
C471
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR LIFT C C 4660
25A 25A PEDAL
1040
V-0586 (6-10-04) B B 2660
BATTERY
689 of 1030
BUCKET POSITIONING
C423
A B A B A B 4420 A A 9.8 ohm
B A
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
12V
COMPUTER POWER F
COMPUTER POWER
2420 B B TILT SPOOL LOCK
RIGHT PANEL
C417A C413A C414A
LEFT PANEL
C416A (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C421
HEADLIGHTS
B A A B A B A B 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
7.7 ohm
GROUND
2370 2 2
GROUND
(NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
4430
2430
4440
2440
C422
START J
2450
4452
4482
START J
2480
OPEN
1
DATA B
4380 1
DATA B
7.7 ohm
(With SJC Option) HIGH FLOW

6733137 2380 2 2
PWM
BICS HYDRAULIC LOCK
REAR AUX.
G
C
D
E
A
K
E
HARNESS
F
6736011
C415
C420
7.5 ohm A A 4460 A A 4460 4410 A A 9.8 ohm
4481
4451
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C418
A A
C441
TWO SPEED 7.5 ohm 4350 4330 1 1 3.3 ohm
C419 C106
CAB 6727178
C437
TWO SPEED 5 ohm A A 4390 YELLOW TIE STRAP GREEN TIE STRAP BROWN TIE STRAP
2340 2
4440
2440
MAKE-UP 12V
4430
2430
2450
4450
4480
2480
3600 A A SPEED
WORKLIGHTS
FRAME
RED = RED B A A B A B
C414
FRONT
RNG = ORANGE
LBL = LIGHT BLUE
SWITCH
BRAKE
2480 DBL = DARK BLUE B A A B
1930
SWITCHED POWER 1000-1999 RNG A B
2000
4440
2440
C104 C405 C406

2460
3210 B B COOLANT
4430
2430
C435
t
2450
4450
4480
2480
2450 SENDER
RIGHT
PNK = PINK C 500-3000 ohm
2440 2400 ATTACHMENT CONTROLS 5000-5999 YEL
YELLOW TIE STRAP
SEAT
CAB
C434
LEFT
4330
4360
4340
4410
4440
4420
4430
B SWITCH
2770
SEE J1 B 3710 B
3300
2330
2110
GRY = GRAY
3700
B
3200
B
3600
2750
4350
4460
4450
4390
4480
C476
2520 3110 B 3110 B FUEL
B B
2100 SENDER -
3100 A A 3100 A A +8 2910
30-270 ohm
2360 J1 J2 C C
2920 2900
C
2930
A
2420 6 18 29 26 22 12 32 1 41 3 21 10 38 48 8 18 2770
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
COOLANT
TEMP SIGNAL
LOCK SIGNAL
B A 1 2 3 4 5 6 7 8 9 10
2370 11 9110 D
2200 7 9210 E
2000
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
9400 F
C408
23
2240 1200 9200 3700 4920 42 9410 G
+ 9110 4440 4820 4310
2350 A
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C C
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
3210 0.5 - 7.5 V -
B 3400 A A 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
B B 4340 4430
2800 3420 E E 3420 47 BUCKET 35 3910
3610 HYDRAULIC 3410 F 3010 23
45
C102
F 3410 3920
2300 31 32 33 34 35 36 37 38
38 39 40
C477
3510 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 4940 25 3900 A
2110
2600 A B
34 9350 C407
2110
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300 24 1900

2730 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 44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
9 4300
31 32 33 34 35 36 37 38 39 40
4640
4350 8150 1130 9700 8550 3500 2100 6320 8110
36 4840
SPARE
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
15 ohm B B 8820 A A 8800

J1 6 4810
FUEL
C C 2800 J2
D3
SHUTOFF
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 8 48 17 41 4
0.5 ohm A A 8120 B B 8100
J1
4910

SM-s250-s300 6901926 SM 3-06 Bobcat S250 Service Manual

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SM-s250-s300 6901926 SM 3-06 Bobcat S250 Service Manual

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SM-s250-s300 6901926 SM 3-06 Bobcat S250 Service Manual

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2 of 1030

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

B-10731a B-16261 B-16264

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

B-16271 B-16270 B-6589

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

Dealer Copy -- Not for Resale

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

Dealer Copy -- Not for Resale

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

Dealer Copy -- Not for Resale

21. Inspect for loose or broken

S250, S300 Bobcat Loader

S250, S300 Bobcat Loader

Dealer Copy -- Not for Resale

• 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

Dealer Copy -- Not for Resale

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

Dealer Copy -- Not for Resale

• 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

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

Dealer Copy -- Not for Resale

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module

2. The five digit Production Sequence Number identifies

S250, S300 Bobcat Loader

The Delivery Report must be filled out by the dealer and

Dealer Copy -- Not for Resale

S250, S300 Bobcat Loader

FRONT LIGHTS OPERATOR SEAT

BUCKET STEPS STEPS